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Safety rules Make sure your work area is cleared of uninvited people and obstacles every time before you start operating the machine. Never step or stand on the roller table. Your foot may slip or trip on the rollers and you will fall.
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Safety rules Never adjust the wire brush or remove chips while the saw blade is still running. It is extremely dangerous if hands or clothing are caught by the running blade. Stop the saw blade before you clean the machine. It is dangerous if hands or clothing are caught by the running blade.
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Table of Contents Control Buttons ……………………………………………………………………………………….…….. 4-5 Blade Descend Pressure & Speed ………..…………………………………………………….…… 4-7 HMI Touch Screen & Functions …………………………………………………………….………… 4-7 Standard Accessories ………….………………………..……………………………………………….…………… 4-17 Optional Accessories …….…….………………………..…………………………………………….……………… 4-18 Unrolling & Installing the Blade …………………………………………………………………….……………. 4-20 Adjusting Wire Brush ………..……………………………………………………………………….………………. 4-22 Adjusting Saw Arm ………..……………………………………………………………………….…………………..
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Table of Contents Every Month ………………………………………………………………………….………………………. 8-3 Every 600 hours/every 1200 hours ………………..…………..………….………………………. 8-3 Every Six Months ……………….………………………………………………….………………………. 8-3 Storage Conditions …………………………..………..…………………………………………………………….. 8-3 Terminating the Use of Machine ……..…………..…………………………………………………………….. 8-3 Oil Recommendation for Maintenance ………………………………………………………………………. 8-4 Troubleshooting Section 9 – Introduction ……………………….…….…………………..…………………………………………………………….
Section 1 SAFETY INFORMATION SAFETY INSTRUCTIONS SAFEGUARD DEVICES EMERGENCY STOP SAFETY LABELS HEARING PROTECTION CE COMPLIANCE RISK ASSESSMENT Safety is a combination of a well-designed machine, operator’s knowledge about the machine and alertness at all times. This band machine has incorporated many safety measures during the design process and used protective devices to prevent personal injuries and potential risks.
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When a workpiece is too long or heavy, Use a sharp saw blade and keep the make sure it is supported with a roller machine in its best and safest table (recommended).
Safety Related Switches To protect the operator, the following safety related switches on the machine are actuated when the machine is in operation. Wheel motion detector This is a proximity sensor used to detect the motion of the drive wheel. Once the saw blade is broken as soon as it starts slipping, the sensor will detect and stop the drive wheel and the machine.
SAFETY LABELS Safety-related labels mounted on the machine are categorized into the following four categories. Please read through and understand them before operating the machine. Refer to Illustration: Safety Labels. DANGER Labels A red and white DANGER labels marks s hazards or unsafe practices that will result in severe personal injury or death.
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CAUTION Labels Yellow and black CAUTION labels mark hazards or unsafe practices that can result in considerable personal injury. Label Meaning Keep hands out of the machine while the blade is running. Power to machine must be turned off when changing blades or adjusting wire brush.
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SAFETY INSTRUCTION Labels Green and white SAFETY INSTRUCTIONS are important reminders that should be read before operating the machine. Label Meaning 1. Read and understand the instruction manual and warning signs before operating machine. Failure to follow these instructions and warnings can result in serious injury or death.
HEARING PROTECTION Always use ear protection! When your machine is running, noise generated by the machine may come from the following: Saw blade during cutting or material feed mechanism Wire brush unit Chip conveyor unit Speed reducer ...
Section 2 GENERAL INFORMATION SPECIFICATION MACHINE PARTS IDENTIFICATION FLOOR PLAN This band saw machine is designed by our R&D engineers to provide you the following features and advantages: Safety This machine is designed to fully protect the operator from its moving parts during cutting operation.
Section 3 MOVING & INSTALLATION LOCATION & ENVIRONMENT UNPACKING & INSPECTING LIFTING REMOVING SHIPPING BRACKET CLEANING INSTALLING RELOCATING LOCATION & ENVIRONMENT For your safety, please read all information regarding installation before proceeding. Install your machine in a place satisfying all of the following conditions: Space: ...
UNPACKING & INSPECTING Unpack your machine carefully to avoid damage to machine parts or surfaces. Upon arrival of your new band saw, please confirm that your machine is the correct model and it comes in the same specification you ordered by checking the model plate on the machine base. ...
LIFTING When moving the machine, we strongly suggest you choose any one of the methods described below to move your machine. 1. Use a crane Move the machine to its location by using a crane and a wire rope sling that can fully withstand the weight of the machine (refer to machine specification under Section 2 General Information).
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2. Use a forklift Most users choose this method to move their machine because it is easy to set up. Make sure that the lifting rod can fully withstand the weight of the machine. (Refer to Section 2 – General Information for Specifications.) ...
REMOVING SHIPPING BRACKET After the machine has been properly positioned, remove the shipping bracket that is used to lock the saw frame and the saw bed. Retain this bracket so that it can be used again in the event that your machine must be relocated.
Supplying hydraulic oil Open the filler cap and fill the hydraulic oil tank to above 2/3 or full level. Check the sight gauge to make sure the oil level in the tank. Refer to specification chart under Section 2 for tank capacity. Oil tank should be full already if it is a new machine that operates for the first time.
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Supply voltage: 90 - 110 of nominal supply voltage. Source frequency: 99 - 101 of nominal frequency. Refer to the specification chart under Section 2 for total electric power consumption of the motors and make sure your shop circuit breaker is capable of this consumption amount. Also use a power supply cable of proper size to suit the power supply voltage.
Leveling Place spirit level on the vise slide plates and the work feed table. Level the machine in both directions i.e. along and across the machine. Adjust the level of the machine by turning the leveling bolts. Make sure all leveling bolts evenly support the machine weight.
Installing fire control device Install a fire extinguisher or any other fire control device in the shop in case a fire breaks out. RELOCATING We recommend you follow these procedures when relocating or shipping your machine to other place: 1. Descend the saw frame to its lowest position then turn off the power. 2.
Section 4 OPERATING INSTRUCTION SAFETY PRECAUTIONS BEFORE OPERATING CONTROL PANEL STANDARD ACCESSORIES OPTIONAL ACCESSORIES UNROLLING & INSTALLING THE BLADE ADJUSTING WIRE BRUSH ADJUSTING SAW ARM ADJUSTING COOLANT FLOW ADJUSTING BLADE SPEED BREAKING‐IN THE BLADE PLACING WORKPIECE ONTO WORKBED POSITIONING WORKPIECE FOR CUTTING TEST‐RUNNING THE MACHINE CUTTING OPERATION STARTING AN AUTOMATIC OPERATION USING TOP CLAMP FOR BUNDLE CUTTING TERMINATING A CUTTING OPERATION 4‐1 ...
SAFETY PRECAUTIONS For your safety, please read and understand the instruction manual before you operate the machine. The operator should always follow these safety guidelines: The machine should only be used for its designated purpose. Do not wear gloves, neckties, jewelry or loose clothing/hair while operating the machine. For eye protection, always wear protective safety glasses. Check the blade tension and adjust blade guides before starting the machine. Use auxiliary clamping or supporting devices to fix material in place before cutting long workpieces. Always make sure the material is clamped firmly in place before starting to cut. Do not remove jammed or cut‐off pieces until the blade has come to a full stop. Keep fingers away from the path of the blade. Protection devices should be in place at all times. For your own safety, never remove these devices. Disconnect machine from the power source before making repairs or adjustments. Wear protection gloves only when changing the blade. Do not operate the machine while under the influence of drugs, alcohol or medication. Do not take your eyes off the machine while in operation. Do place warning signs to mark out machine work zone and restrict entry to be staff‐only. 4‐2 ...
BEFORE OPERATING Choosing an appropriate saw blade and using the right cutting method is essential to your cutting efficiency and safety. Select a suitable saw blade and cutting method based on your work material and job requirements e.g. cutting accuracy, cutting speed, economic concern, and safety control. Wet cutting If you choose dry cutting or low‐speed cutting, the chips may accumulate in machine parts and may cause operation failure or insulation malfunction. We suggest you choose wet cutting to avoid machine damage. Cutting unknown materials Before cutting an unknown material, consult the material supplier, burn a small amount of chips from the material in a safe place, or follow any other procedure to check if the material is flammable. Never take your eyes off the machine while in operation. Cutting fluid For cooling and lubrication purpose, we recommend you use water‐soluble cutting fluids. The following table lists out its pros and cons for your reference. Pro Con Have a high cooling effect Remove machine paint Not flammable Lose its rust protection effect if Economical deteriorated Does not require cleaning of the cut Tend to create foam Subject to decay products ...
CONTROL PANEL The control panel is located on the top of the electrical box. It includes the following function: power system, hydraulic system, cooling system and the human‐machine–interface (HMI). The operator must fully understand the function of each switch and button before operating the machine. No. Name No. Name 1 Emergency stop button 7 Rear vise open button 2 Power indicator lamp 8 Rear vise clamp button 3 Saw bow down button 9 Feed forward button 4 Saw bow up button 10 Feed backward button 5 Front vise open button 11 Blade speed control knob 6 Front vise clamp button 12 HMI touch screen 4‐4 ...
Control Buttons 1. Emergency stop button Press this button to stop the machine in an emergency. When the button is pressed, it brings the machine to a full stop. The button locks when pressed. In order to unlock it, please turn the button clockwise. 2. Power indicator lamp When the lamp is on, it indicates the power to the machine is turned on. 3. Saw bow down button When this button is pressed, the saw bow descends. Before lowering the saw bow, the guide arm must be positioned outside the vise in order to avoid hitting the vise and causing damages. 4. Saw bow up button When this button is pressed, the saw bow rises until the operator lets go of the button or until the saw bow touches the upper limit switch. While pressing the saw bow up button can stop the running blade, please still make use of the emergency stop button in an emergency. 5. Front vise open button This button only works when the machine is switched to manual mode “ ”. If the saw bow is not above the middle limit switch, the front vise can only be opened in small increments, so as to prevent the vise from hitting the guide arm. 6. Front vise clamp button This button only works when the machine is switched to manual mode “ ”. 7. Rear vise open button This button only works when the machine is switched to manual mode “ ”. ...
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9. Feed forward button When this button is pressed, the feeding workbed will move forward. Press and hold the button to feed forward. As soon as the button is released, the feeding workbed will stop moving forward. This button only works when the machine is switched to manual mode “ ”. This button is only in function when the quick approach bar is touching the upper limit switch AND when either of the front and rear vises are unclamped. After the blade motor starts running, this function is disabled due to safety concerns. 10. Feed backward button When this button is pressed, the feeding workbed will move backward. Press and hold the button to feed backward. As soon as the button is released, the feeding workbed will stop moving backward. This button only works when the machine is switched to manual mode “ ”. This button is only in function when the quick approach bar is touching the upper limit switch AND when either of the front and rear vises are unclamped. After the blade motor starts running, this function is disabled due to safety concerns. 11. Blade speed control knob Blade speed is controlled by the inverter located under the workbed. Turning the knob clockwise increases the blade speed. 12. HMI touch screen Please refer to later section for detailed introduction. ...
Blade Descend Pressure and Speed The part of control panel is where cutting pressure and saw bow descend speed can be adjusted. 1. Cutting pressure control knob This pressure control knob is used to adjust the cutting pressure of the blade. Turning the knob clockwise increases the cutting pressure. To obtain a good cutting result, choose the right cutting pressure by turning the knob until it points to your material on the color chart. 1 2. Blade descend speed control knob This knob is used to adjust the descend speed of the saw blade. Turning the knob clockwise increases the blade descend speed. 2 Blade descend speed is a determining factor to a good cutting time and quality cutoff surface. Set the blade descend speed in accordance with the cutting pressure control knob. Also commonly known as the flow control Cutting pressure and speed control panel valve ...
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Item Range Ambient temperature 5℃ ~ 50℃ Temperature for safe ‐10℃ ~ 60℃ operation Ambient humidity 30%~85% RH (No condensation) Connection RS422 MMI port Environment No condensation and rust Main control menu The main control menu includes some operating button that were used on the control panel of the earlier machines. Some convenient functions are added to the page for the operator to better understand the features of the machine. Setting the parameters shown on the screen requires a gentle touch of the finger. You can also look up the parameters or make changes while in the middle of a cut. Refer to the table below for descriptions of each function. No Item Function Description When the power is turned on, press this button to start the Hydraulic start hydraulic motor. A solid yellow icon indicates the hydraulic system has been turned on. 4‐8 ...
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No Item Function Description Hydraulic stop Press this button to turn off the hydraulic motor immediately. When the blade is running, the hydraulic stop button is temporarily disabled. You need to press the saw blade stop or the saw bow up button to stop the blade first. Blade start When the work piece is clamped properly, press this button to start cutting. A solid yellow blade icon indicates the blade has been started. Blade stop Press this button to stop the blade. Work light ON/OFF Press this button to turn on the work light. The light bulb showing a solid yellow icon indicates the worklight has been turned on. AUTO / Manual mode Use this button to switch between automatic and manual mode. AUTO mode ( ): used to automatically perform continuous cutting jobs. When switched to this mode, the machine will automatically operate according to ...
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No Item Function Description has been turned on. Single/Bundle cutting This button is used to switch between single or bundle cutting mode. mode Switch to single cutting model ( ) to cut a single work piece. Switch to bundle cutting mode ( ) to cut a stack of work pieces. When under bundle cutting mode, the feeding vise must be touching the front limit switch for the blade to be able to start. Coolant ON/OFF Press this button to turn on the coolant pump. A solid yellow faucet icon indicates the coolant pump has been turned on. Press again to turn off the coolant pump. Used only when under Manual mode. Slow material feeding mode When the slow material feeding mode is turned on, the material feeding speed will dramatically reduce to help you position the work piece precisely. Trim cut ON/OFF This selection button works with the AUTO mode. When under AUTO mode and before proceeding with your ...
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No Item Function Description cutting programs can be set.) Blade deviation detector (optional) can be also configured in this setup page. Refer to Cutting Display & Setup in the following page. Press this button to directly enter the cutting job program Cutting program setting setup page. A total of 100 cutting programs can be set. Material cutting This reference chart lists out the required blade speed and cutting rate for each different material. reference Shows current PLC signals. PLC monitor Lists a historical report of the errors and the time of Error report occurrence as well as provides troubleshooting support. 6 pages in total. Indicates that the quick approach bar is contacting the Quick approach function upper limit switch. indicator When quick approach function is activated, the saw blade icon will turn solid white. Saw blade down Indicates that a cut is completed and the saw blade is at its ...
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No Item Function Description Feeding length display Displays current feeding length while the material is being fed. Blade speed display Displays current blade speed. Displays error messages in the order of occurrences; press Error display the message for one second to clear the messages. (yellow highlight) The message must be cleared for the machine to continue to operate normally. Cutting status display & setup When cutting is in operation, press to enter cutting status display and setup page. Page 1 – cutting status display This page shows the following information (from top to bottom): Feeding length (current feeding vise position) Blade speed Current in ampere (optional) ...
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Page 2 – cutting status setup Cut Piece Reset ‐ Reset all Cuts Finished data by pressing this button for three seconds. If you start a new set of program without clearing cutoff data from previous job, the first cut (trim cut) will be skipped as the second program is deemed as the succeeding part of the previous program. All Reset ‐ Reset all preset cutting data within Starts JOB and Ends JOB by pressing this button for three seconds. Blade Life Reset ‐ Reset the blade life to zero after installing the new blade. Current blade life in hours Error message (bottom of page) Press Home to return to the main control menu. Press PGUP to go back to the previous setup page. Press Next to go to the next setup page. Page 3 – cutting program setup In this page you can set your desired cutting length and quantity and see the number of finished cuts (Cut Finished). A total of 100 cutting jobs can be set and performed under the automatic mode. ...
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Press Home to return to the main control menu. Press PGUP to go back to the previous setup page. Press Next to go to the next cutting program setup page. Press P01, P05, P10, P15 to quickly jump between cutting programs (Step 00 ~ 99) Cutting program setup When cutting is in operation, press to quickly access the cutting program setup page (the same as page 3 of the cutting status display and setup page) This setup page is the same as page 3 of the cutting status display and setup page. Material cutting reference This reference chart lists out the required blade speed and cutting rate for each different material. 4‐14 ...
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PLC Monitor Shows all signals of the PLC system. Error report Page 1 – error report Lists a historical report of the errors and the time of occurrence. Press Home to return to the main control menu. Press Next to go to the troubleshooting support page. Page 2 – troubleshooting Provides suggestions on troubleshooting. 6 pages in total. Also refer to the below table for error codes, descriptions and solutions. Press Home to return to the main control menu. Press Next to go to the troubleshooting support page. 4‐15 ...
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Error Error Description Solution Code M300 Front vises not clamping Check if the queen valve works M301 Rear vises not clamping Check if the queen valve works M303 Lower limit switch error Check if the lower limit switch works M304 Hydraulic motor not starting Check if the hydraulic motor works M306 Broken blade detected 1. Check if the speed switch works 2. Check if the blade is broken M308 Left safety door abnormal 1. Check if the left safety door is shut properly 2. Check if the left safety door limit switch works M309 Right safety door abnormal 1. Check if the right safety door is hut properly 2. Check if the right safety door limit switch works M312 Quick approach bar abnormal Check if the quick approach limit switch works M313 OL1 abnormal Check if the blade motor overload relay has tripped M314 OL2 abnormal Check if the hydraulic motor overload relay has tripped M315 OL3 abnormal Check if the coolant pump motor overload relay has tripped M316 ...
STANDARD ACCESSORIES Blade tension device This blade tension device equipped with hydraulic cylinder provides appropriate tension to the saw blade. To tighten the saw blade, turn the selector to . Upon saw blade breakage, the safety device will activate and automatically stop all machine operation. The limit switch of the safety device can be reset by turning the blade tension selector to To change the blade, turn the handle to to release saw blade tension. Blade speed/motion detector Besides detecting the blade speed, the speed/motion detector also functions as a safety device. The speed/motion detector protects operators and the machine by preventing blade overloads and consequent damages if a saw blade breaks or skids. Once blade breakage or slippage is detected, the drive wheel will stop in 10 seconds. Inverter This inverter is installed under the workbed. It is used to control and stabilize the saw blade speed during cutting. To adjust blade speed, use the blade speed control knob on the ...
Quick approach device This device allows the blade to quickly descend to just right above the material to save you operation time. Split front vises The spilt vises are a clever design to make sure your workpiece is tightly clamped by the two vises from both sides of the blade, maximizing stability and cutting precision. Gear reducer The specially designed gear reducer can work toward your preset blade speed and torque. Please refer to Section 8 for information on maintenance. OPTIONAL ACCESSORIES Vise pressure regulator This adjustment valve is used to control vise pressure. Adjust vise pressure based on the material of your workpiece. When cutting pipes or soft materials, reduce vise pressure to prevent exerted pressure from damaging the workpiece shape or Pressure exterior. Pressure adjusting gauge valve Do not adjust vise pressure at any time during cutting. ...
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Vibration damper The vibration damper can be assembled to the left saw arm. This optional accessory is extremely useful in reducing the high‐ frequency noise produced when cutting large‐sized material. Chip conveyor Chip conveyor is a spiral device to bring chips out during cutting. As a regular maintenance, remove the chip conveyor and clean all chip deposits inside. Hydraulic top clamps The top clamp device composed of two clamps is installed on top of the front and rear vises before executing bundle cutting. Refer to Using Top Clamp for Bundle Cutting for operating procedure on bundle cutting. 2M roller table The optional 2M roller table supports the work material and ensures the material be fed in smoothly. Refer to Section 9 for further information on adjusting the roller table. 4‐19 ...
UNROLLING & INSTALLING THE BLADE Always wear leather gloves and protection glasses when handling a blade. Unrolling the blade Please follow the procedures illustrated below. Unroll and roll the blade Installing a new blade Step 1 ‐ Select the most suitable saw blade for your workpiece considering the size, shape and material. Step 2 ‐ Turn on the machine power by switching to ON and turn on the hydraulic system. Step 3 ‐ Switch to manual ( ) mode. Step 4 ‐ Press the saw bow up button and elevate the saw bow until the right insert holder is clear of the front fixed vise. 4‐20 ...
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Step 5 ‐ Turn the tension controller handle from “ ” to “ ” position to release tension. The idle wheel will then move slightly toward the direction of the drive wheel. Step 6 ‐ Open the idle and drive wheel covers. Step 7 ‐ Press the Blade Clip device to hold onto the blade. This device makes blade changing easy and feasible even with only one operator available. Easy Blade Replacement Device Step 8 ‐ Loosen the left and right carbide inserts by loosening the “lock nut” shown below. Step 9 ‐ Open the wire brush cover. Loosen the lock lever and lower the wire brush. Wire Brush Cover Lock Lever Step 10 ‐ Take out the blade. If necessary, clean the carbide inserts before installing a new saw blade. Step 11 ‐ Place the new blade around the idle wheel and the drive wheel. Step 12 ‐ Insert the blade into the left and right tungsten carbide inserts. The back and the sides of the blade need to be touching the inserts as well as the adjacent rollers. Step 13 ‐ Place the blade to the drive wheel and press the back of the blade against the flange of the drive wheel. Use the Blade Clip device to tightly hold the blade from falling out of the drive wheel. 4‐21 ...
When saw blade begins to rotate, the blade holder will automatically release the blade and fall back to its original position. Step 14 ‐ Make sure the back of the blade is also pressed against the flange of the idle wheel. Step 15 ‐ Turn the tension controller handle to [ ] position to obtain blade tension. Step 16 ‐ Make sure the sides of the blade are in close contact with the carbide inserts and then tighten the left and right carbide inserts by tightening the “lock nut.” Step 17 ‐ Gently close the idle and drive wheel covers. Step 18 ‐ Press the saw blade start button to start the blade. Allow the blade to run for a few rotations then press the saw bow up button to elevate the saw bow. Open the wheel covers and make sure the blade has not fallen off the drive and idle wheels. If the blade has shifted, follow the same procedure to reinstall the blade again. Step 19 ‐ Adjust wire brush to a proper position. Refer to Adjusting Wire Brush in this section. ADJUSTING WIRE BRUSH Follow these steps to adjust wire brush to appropriate position: Step 1 ‐ Open the drive wheel cover. Step 2 ‐ Loosen the lock lever and the wire brush cover. Step 3 ‐ Make brush move up / down until it makes proper contact with the saw blade (see below illustration). Step 4 ‐ Reinstall the wire brush cover and tighten the lock lever. Step 5 ‐ Close the drive wheel cover. Proper Improper Wire Brush Cover Lock Lever ...
ADJUSTING SAW ARM Adjust the blade guide (guide arm) position based on the size of your workpiece: Step 1 – Loosen the inserts by unlocking the lock nut. Step 2 – Loosen the blade guide locking lever. Then adjust the guide arm to a position suitable for your workpiece size. Step 3 – After adjustment is made, tighten the blade guide locking lever. Step 4 – Clamp the inserts back by tightening the lock nut. Locking Lever Inserts Lock Nut ADJUSTING COOLANT FLOW Step 1 – Press the saw blade start button to start the saw blade drive motor. Step 2 – Press the saw bow down button to lower the saw bow. Step 3 – Use the flow control valve (shown below) to adjust the amount of fluid flowing to the cutting area. Adjust the flow amount if you observe the following changes to the chips generated from cutting. If the chips are sharp and curved, increase the coolant flow amount. If the chips are granulated, decrease the coolant flow amount. 4‐23 ...
ADJUSTING BLADE SPEED Step 1 – Set the flow control to “0” position. Step 2 – Press the saw blade start button to start the blade. Step 3 – Turn the blade speed control knob to adjust the blade speed. The blade speed should be adjusted based on the size and the material of the workpiece. BREAKING‐IN THE BLADE When a new saw blade is used, be sure to first break in the blade before using it for actual, extended operation. Failure to break in the blade will result in less than optimum efficiency. To perform this break‐in operation, the following instructions should be followed: Step 1 ‐ Reduce the blade speed to one‐half of its normal setting. Step 2 ‐ Lengthen the cutting time to 2‐3 times of what is normally required. 2 Step 3 ‐ The complete break‐in operation requires cutting on a 645 mm (25.4 square inches) section for 5 times. Step 4‐ After the break‐in operation is completed, set all parameters back to normal settings. PLACING WORKPIECE ONTO WORKBED Step 1 – Press the saw bow up button and elevate the saw bow until it reaches to its highest point. Step 2 – Press the front vise open and rear vise open buttons to open vises. Step 3 – Loosen the vertical roller lock handles and fully open the vertical rollers. Step 4 – Carefully place the workpiece onto the work feed table to where it extends approximately 30mm (1.2”) beyond the rear vise toward the front vise. Vertical Roller 4‐24 ...
POSITIONING WORKPIECE FOR CUTTING Follow these steps to position your workpiece: Step Action Press the rear vise clamp button until the workpiece is securely rear vises clamp material clamped. Move the vertical alignment rollers toward workpiece until it align vertical rollers stands against the workpiece. Lock the vertical alignment rollers by tightening the lock handles Press the feed forward button until the rear vise touches the feed material forward front limit switch. Press the front vise clamp button until the workpiece is front vises clamp material securely clamped. Press the rear vise open button. rear vises retract to clamp material again Press the feed backward button until the rear vises reach back limit switch. Press the rear vise clamp button until the workpiece is securely clamped again. Simultaneously press the front vise open button and the rear ...
TEST‐RUNNING THE MACHINE Test‐running this machine can ensure good machine performance in the future. We suggest you run the following tests on the machine before first use: Testing machine performance: Turn on the power and run a basic performance test after you finish installing the machine. Follow these steps to test machine performance: Step 1 – Disassemble shipping brackets and bolts. Step 2 – Install roller table (optional). Step 3 – Turn on the relay switch in the control box. Step 4 – Elevate the saw bow. (If your coolant pump is in reverse and the machine cannot run, please change the electrical phase.) Step 5 – After the saw bow ascends, extend the quick approach device. Step 6 – Remove the rust‐prevention grease with cleaning oil or kerosene. Step 7 – Start the coolant pump. Step 8 – Test these functions under manual mode: vise clamping/unclamping saw bow ascending/descending feeding forward and backward ...
CUTTING OPERATION Step 1 – Check before you cut Power: Check the voltage and frequency of your power source. Coolant: Check if you have sufficient coolant in the tank. Hydraulic: Check if you have sufficient (at least two‐thirds or higher) hydraulic oil. Workbed: Check if there is any object on the feeding bed that may cause interference. Blade: Check the blade teeth and make sure there is no worn out teeth along the blade. Light: Check the work lamp or laser light (optional) and make sure there is sufficient lighting. Roller: Check all the rollers on the front and rear workbed can roll smoothly. Saw bow: Check the saw bow to see if it can be elevated and lowered smoothly. Step 2 ‐ Place your workpiece onto the workbed manually or by using a lifting tool e.g. a crane. Before loading, make sure the vises are opened to at least wider than the width of the workpiece. Step 3 – Position your workpiece. Step 4 – Clamp the workpiece. Step 5 – Turn the cutting pressure control knob to adjust cutting pressure according to the material. Step 6 – Adjust blade descend speed control knob to obtain a suitable blade descend speed for your material. Step 7 – Start running the blade. Before you start cutting, check again that there is no other object in the cutting area. Step 8 – While the blade descends, adjust the blade speed if necessary. You can do so by turning the blade speed control knob, clockwise to speed up and counterclockwise to slow down. The blade speed is displayed in the HMI touch screen. Step 9 – Select the proper cutting condition according to different material. Step 10 – After the entire cutting job is completed, elevate the saw bow to the top and open the vises to remove the workpiece. Step 11 – Clean the workbed by removing chips and cutting fluids. Step 12 – Lower the saw bow to a proper position then turn off the power. ...
STARTING AN AUTOMATIC OPERATION Step 1 – Use manual mode and cut the edge of the workpiece by using the same procedures as those described under manual operation. Step 2 – After the trim cut is completed and the saw blade has stopped at the lower limit position, press the saw blade up button to raise the saw bow until the quick approach bar is approximately 10mm (0.4inch) above the workpiece. Step 3 – Turn the Auto / manual switch to manual. Step 4 – Set your desired cutting length and quantity via the HMI touch screen. A total of 100 sets of cutting data can be programmed. Step 5 – Turn the Auto / manual switch to Auto. Step 6 – Press the saw blade start button and press the saw bow down button to start automatic cutting. ...
USING TOP CLAMP FOR BUNDLE CUTTING Installing top clamp To perform bundle cutting, use the top clamps and take the following installation procedures. Step 1 – Install stud bolts on the front and rear vises and position the top clamp. Step 2 – Connect the top clamp hoses to the pressure joints on the vise hydraulic cylinders. Step 3 – Position the workpiece for bundle cutting. Note the allowable clamping width and height. (Refer to Section 2 – General Information, Specifications) Proper and improper stacking of workpieces Proper Improper Step 4 – Align the top clamp cylinders with the center of the workpiece and tighten the lock nuts. Step 5 – Turn the top clamp handles so that the clearance between the top clamp jaw and the top of the bundled workpiece is within 5 to 10 mm ( 0.2 ~ 0.4 inch). Step 6 – Install the bundle‐cutting fence to the work tray. The fence is designed to prevent cut pieces 4‐29 ...
from scattering across the work tray. Adjust the width of the fence to be slightly larger than the width of the bundle. Step 7 – Press . Single/Bundle cutting mode button and switch to bundle cutting mode Step 8 – For subsequent cutting procedures, refer to the instructions under manual operation and automatic operation. Uninstalling top clamp Follow these steps to uninstall top clamp for cutting single material: Step 1 – Disconnect the top clamp hoses. Step 2 – Loosen the lock nuts and remove the top clamp. Step 3 – Remove the stud bolts. STOP TERMINATING A CUTTING OPERATION To terminate a cutting operation, press either the saw bow up button or the emergency stop button. The saw blade will stop running when the saw bow up button is pressed. Both the saw blade and hydraulic pump motors will stop running when the emergency stop button is pressed. The machine will stop automatically when an error occurs. The error message will be shown on the screen. 4‐30 ...
Section 5 ELECTRICAL SYSTEM ELECTRICAL CIRCUIT DIAGRAMS The following are electrical circuit diagrams of the system: Fig.5-1 Control panel layout Fig.5-2 Circuit board layout Fig.5-3 Power supply layout Fig.5-4 PLC input/output layout...
Section 7 BANDSAW CUTTING: A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION VISE LOADING BladeBreak -In SOLUTIONS TO SAWING PROBLEMS INTRODUCTION TPI: The number of teeth per inch as measured from gullet to gullet. 2. Tooth Rake Angle: The angle of the tooth face measured with respect to a line perpendicular to the cutting direction of the saw.
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SAW BLADE SELECTION 1. Band length The dimensions of the band will depend on the band saw machine that has been installed. Please refer to Section 2 – General Information 2. Band width Band width: the wider the band saw blade, the more stability it will have. 3.
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VISE LOADING The position in which material is placed in the vise can have a significant impact on the cost per cut. Often, loading smaller bundles can mean greater sawing efficiency. When it comes to cutting odd-shaped material, such as angles, I-beams, channel, and tubing, the main point is to arrange the materials in such a way that the blade cuts through as uniform a width as possible throughout the entire distance of cut.
Section 8 MAINTENANCE & SERVICE INTRODUCTION BASIC MAINTENANCE MAINTENANCE SCHEDULE STORAGE CONDITIONS TERMINATING THE USE OF MACHINE OIL RECOMMENDATION FOR MAINTENANCE INTRODUCTION For the best performance and longer life of the band saw machine, a maintenance schedule is necessary. Some of the daily maintenance usually takes just a little time but will give remarkable results for the efficient and proper operation of cutting. BASIC MAINTENANCE It is always easy and takes just a little effort to do the basic maintenance. But it always turns out to be a very essential process to assure the long life and efficient operation of the machine. Most of the basic maintenance requires the operator to perform it regularly. 8‐1...
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MAINTENANCE SCHEDULE We suggest you do the maintenance on schedule. Before beginning a day’s work 1. Please check the hydraulic oil level. If oil level volume is below 1/2, please add oil as necessary. (Filling up to 2/3 level is better for system operation.) 2. Please check the cutting fluid level, adding fluid as necessary. If the fluid appears contaminated or deteriorated, drain and replace it. Do not discharge cutting fluid while the saw blade is operating because it will cause severe injury on operator’s hand. 3. Please check the saw blade to ensure that it is properly positioned on both the drive and idle wheels. 4. Please make sure that the saw blade is properly clamped by the left and right inserts. 5. Please check the wire brush for proper contact with the saw blade. Replace the wire brush if it is worn out. After ending a day’s work Please remove saw chips and clean the machine when work has been completed. Be sure the saw blade is fully stop. Every week Clean and lubricate the following: 1. feed cylinder surfaces 2. vise slideway. Recommended lubricant: Ordinary lubricant Every 2 weeks Please apply grease to the following: 1. Idle wheel 2. Drive wheel Recommended Grease: Shell Alvania EP Grease 2 Mobil Mobilplex 48 ...
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Every month 1. Clean the filter of the oil tank. 2. Please apply grease to the blade tension device. Recommended Grease: • Shell Alvania EP Grease 2 • Mobil Mobilplex 48 Every 600 hours / every 1200 hours After 600 hours of initial operation, drain away the oil and clean the internals of the machine, then refill new oil. Do so hereafter every 1200 hours of operation. Recommended gear oil: Shell Omala oil R220 Mobil gear 630 Recommended hydraulic oil: Shell Tellus 32 Mobil DTE Oil Light Hydraulic 24 Every six months Clean or change hydraulic circuits and inner filter if there is an oil tank. STORAGE CONDITIONS Generally, this machine will be stored on the following conditions in future: 1. Turn off the power. 2. Ambient temperature: 5℃ ~ 40℃ 3. Relative humidity: 30%~95% (without condensation) 4. Atmosphere: use a plastic canvas to cover machine to avoid excessive dust, acid fume, corrosive gases and salt. 5. Avoid exposing to direct sunlight or heat rays which can change the environmental ...
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OIL RECOMMENDATION FOR MAINTENANCE Item Method Revolution Suggest oil Dovetail guide Keep grease covered. Antirust. Daily Shell R2 Roller bearing Sweep clean and oil with lubricant. Daily SEA #10 Bed roller / surface Sweep clean and oil with lubricant. Daily SEA #10 Nipples of bearing Use grease gun, but not excess. Monthly Shell R2 Shell Alvania EP Grease 2 Blade tension device Use grease gun, but not excess. Monthly Mobil Mobilphex 48 After 600 hours of initial operation, drain away the oil and clean the Shell Omala oil R220 internals of the machine, then refill Gear reducer Regularly Mobil gear 630 new oil. Do so hereafter every 1200 hours of operation. After 600 hours of initial operation, drain away the oil and clean the Shell Tellus 32, Hydraulic system internals of the machine, then refill ...
Section 9 TROUBLESHOOTING INTRODUCTION PRECAUTIONS GENERAL TROUBLES & SOLUTIONS MINOR TROUBLES & SOLUTIONS MOTOR TROUBLES & SOLUTIONS BLADE TROUBLES & SOLUTIONS SAWING PROBLEMS & SOLUTIONS RE-ADJUSTING THE ROLLER TABLE INTRODUCTION All the machines manufactured by us pass a 48 hours continuously running test before shipping out and we are responsible for the after sales service problems during the warranty period if the machines are used normally.
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PRECAUTIONS When an abnormality occurs in the machine during operation, you can do it yourself safely. If you have to stop machine motion immediately for parts exchanging, you should do so according to the following procedures: Press HYDRAULIC MOTOR OFF button or EMERGENCY STOP button. ...
MINOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Saw blade motor does not run Overload relay activated Reset even though blade drive button Saw blade is not at forward Press SAW FRAME is pressed. limit position. FORWARD button MOTOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY...
BLADE TROUBLES AND SOLUTIONS DISCONNECT POWER CORD TO MOTOR BEFORE ATTEMPTING ANY REPAIR OR INSPECTION. TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Too few teeth per inch Use finer tooth blade Loading of gullets Use coarse tooth blade or cutting lubricant. Teeth strippage Excessive feed Decrease feed...
SAWING PROBLEMS AND SOLUTIONS Other than this manual, the manufacturer also provides some related technical documents listed as follows: Sawing Problems and Solutions Vibration during cutting Failure to cut Short life of saw blade Curved cutting Broken blade ...
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SOLUTIONS TO SAWING PROBLEMS Table Of Contents #1. Heavy Even Wear On Tips and Corners Of Teeth #11. Uneven Wear Or Scoring On The Sides Of Band #2. Wear On Both Sides Of Teeth #12. Heavy Wear And/Or Swagging On Back Edge #3.
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#2. Wear On Both Sides Of Teeth Probable Cause : A. Broken, worn or missing back-up guides allowing teeth to contact side guides. B. Improper side guides for band width. C. Backing the band out of an incomplete cut. #3. Wear On One Side Of Teeth Probable Cause : A.
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#5. Body Breakage Or Cracks From Back Edge Probable Cause : A. Excessive back-up guide "preload" will cause back edge to work harden which results in cracking. B. Excessive feed rate. C. Improper band tracking – back edge rubbing heavy on wheel flange.
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#8. Gullets Loading Up With Material Probable Cause : A. Too fine of a tooth pitch – insufficient gullet capacity. B. Excessive feeding rate producing too large of a chip. C. Worn, missing or improperly positioned chip brush. D. Insufficient sawing fluid due to inadequate supply, improper ratio and/or improper application.
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#12. Heavy Wear And/Or Swagging On Back Edge Probable Cause : A. Excessive feed rate. B. Excessive back-up guide "preload". C. Improper band tracking – back edge rubbing heavy on wheel flange. D. Worn or defective back-up guides. #13. Butt Weld Breakage Probable Cause : A.
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#16. Body Breakage Or Cracks From Gullets Probable Cause : A. Excessive back-up guide "preload". B. Improper band tension. C. Guide arms spread to maximum capacity. D. Improper beam bar alignment. E. Side guide adjustment is too tight. F. Excessively worn teeth. #17.
#20. Broken Band Shows A Twist In Band Length Probable Cause : A. Excessive band tension B. Any of the band conditions which cause the band to be long (#18) or short (#19) on tooth edge. C. Cutting a tight radius. RE-ADJUSTING THE ROLLER TABLE If the feeding table suffers the huge stroke and the alignment is effected, follow the below procedure to adjust.
Section 10 PARTS SPARE PARTS RECOMMENDATIONS PART LIST SPARE PARTS RECOMMENDATIONS The following table lists the common spare parts we suggest you purchase in advance: Part Name Part Name Saw blade Coolant tank filter Wire brush Steel plates Carbide inserts Rollers Bearings Belt...