THE VERTICAL BAND SAW MODEL VS-400

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1 THE VERTICAL BAND SAW MODEL VS-400 Assembly & Operating Instruction

2 1. INTRODUCTION This operation instruction manual conforms to the requirements of the 98/37/EEC Machine Directives and subsequent amendments. In the light of this,special attention has been given to safety aspects and accident prevention in the work-place for each stage in the machine s life. Information which could be of particular assistance to the operator has been highlighted. The Operating instructions are an integral part of the machine and should be consulted before, during and after the start up of the machine and whenever else required. The content of these instructions should always be carefully observed. The observance of the above is the only way to achieve the two fundamental aims of this manual: Optimization of machine performance Prevent damage to the machine and injury to the operator The index of the chapters and the index of the drawings, diagrams and tables are contained in chapter 3 and can be used to help the location of specific information. CAUTION: BEFORE INSTALLING THE MACHINE, READ THE OPERATING INSTRUCTIONS CAREFULLY 2. INFORMATION ABOUT MAINTENANCE ASSISTANCE 2.1 GUARANTEE The products are guaranteed against material and manufacturing defects for a period of 12 months from the date of delivery or, if the machine is installed by our employees,from the date of machine start up. The buyer is only entitled to the replacement of parts which are acknowledged as faulty: carriage and packing are at the buyer s. In the event of the above, the following information should be supplied: 1. Date and number of purchasing document 2. Machine model 3. Serial number

3 4. Code of any relevant drawings Requests for compensation for the inactivity of the machine will not be accepted. The guarantee does not cover uses which are not in line with these operating instructions which are an integral part of the machine. Nor is maintenance covered if the instructions supplied are not observed. The guarantee will not cover machines which have undergone unauthorized modifications. Modification or tampering with the safety devices is strictly forbidden. 3. INDEX 3.1 INDEX OF CHAPTERS Chap. 1 Introduction Chap. 2 Information about maintenance assistance Chap. 3 Index of chapters, drawings, diagrams and tables Chap. 4 Description of the machine Safety standards complied with during the design and construction of the machine Description of the machine and its components Chap. 5 Main technical data Chap. 6 Handling and transportation Chap. 7 Installation Chap. 8 Start up and operation Devices and their location Tools supplied Operation Special safety checks General safety rules Measures to prevent residual risks Chap. 9 Maintenance and repairs General safety measures Routine checks and maintenance

4 Description of routine maintenance Chap. 10 Information regarding environmental noise Chap. 11 List of spare parts Chap. 12 Laying off-demolition 3.2 INDEX OF DRAWINGS,DIAGRAMS AND TABLES ENCL.TYPE DESCRIPTION ENCL NO. CHAP Table Cutting capacity-selection of 1 blade-cutting speeds-installation plan Drawings Handling and transportation 2 Drawings Blade guides-blade guide bearings 2 Drawings Vice block-rotation block 3 Drawings Motor- Tensioning 4 Diagram Electric system 5 Drawings Box exploded view-machine 5 exploded view Diagram Wiring diagram-hydraulic diagram 6 4. DESCRIPTION OF THE MACHINE 4.1 SAFETY STANDARDS COMPLIED WITH DURING THE DESIGN AND CONSTRUSTION OF THE MACHINE The machine produced by us is in compliance with: 98/37/EEC Machinery Directive (ex 89/392/EEC, as amended by the 91/368/EEC, 93/94/ECC and 93/68/EEC Directives). The following Standards apply: - EN Safety of machinery- Basic concepts and general principles for design. Basic terminology and methods. - EN Safety of machinery. Basic concepts and general principles for design. Specifications and technical principles. - EN Safety of machinery. Emergency stop devices, functional

5 aspects-design principles. - EN Safety requirements related to systems and components for hydraulic and pneumatic transmissions. - EN Safety of machinery. Isolation and energy dissipation. Prevention of unexpected start-up. - EN Safety of machinery- Interlocking devices with and without guard- locking. General principles and provisions for design. - EN Safety of machinery. Electrical equipment of machines. Part 1: General requirements Sa. - EN Electrical equipment of industrial machines. Part 2: Item designation and examples of Drawings, diagrams, tables and instructions. 89/336/EEC Directive on electromagnetic compatibility,as amended by the 92/31/EEC,96/68/EEC,93/97/EEC and 93/68/EEC The following Standards apply: -EN General Standard for emission levels -EN General Standard for immunity 73/23/EEC Low Voltage Directive,as amended by the 93/68/EEC Directive 4.2 DESCRIPTION OF THE MACHINE AND ITS COMPONENTS The band sawing machine produced by us has a sturdy frame made from welded and painted sheet-steel. The upper surface is designed to allow the complete draining away of the cutting fluid. The band holding bow is made of cast-iron and has generous dimensions,providing the cutting unit with the necessary strength and precision. The vice unit is made of cast-iron and clamps the material to be cut securely. The bar-stop device allows the length required to be preset and a constant level of performance for repeated cuts. The blade-holding bow is firmly attached to a reduction unit built onto the motor and to the base by means of a joint which allows 60 rotation to the right. This joint also allows the cutting movement to advance manually or by falling. The coolant pump is fitted to the machine base. The main switch is located on the front panel. The choice of one of the two motor rotation speeds and therefore cutting speed is carried out by the main switch. The front panel is also fitted with an emergency stop

6 button and a START button. The control lever,fitted with an ergonomic hand-grip and activation button with safety release action, reduces fatigue during operation to a minimum. The blade is protected by a guard with interlock which covers the upper area and the hand wheels and by two adjustable lower guards which protect the operator from ejected shavings and coolant. The machine is supplied with a set of service spanners. INSTRUCTION MANUAL PS. Please turn the Regulator to the lowest speed position before turning on the machine. 1. The mechanical construction of this machine is illustrated as shown on the Parts List. 2. The adjusting screws, above and under the Band Guides, can be adjusted as long as. 3. The worktable can be titled 15 degrees at left side,45 degrees at right side This manual has been prepared for the operator who operates, and the maintenance of the 16 Vertical Saw. The purpose is to promote safety through the use of accepted operation procedure. The following instructions in operations and maintenance shall be observed in order to obtain the maximum efficiency of the unit. The procedure is shown as follows: A. Power B. Sawing material selection C. Blade selection D. Blade cutting device

7 E. Welder F. Grinder G. Blade installation H. Guide rob adjustment I. Inverter speed selection J. Air pump K. Angle cutting L. Safety and maintenance M. Inverter parameters ACTION TAKEN A. Power 1. First, before operating the machine, be sure to check the voltage which is in accordance with the power supply system. B. Sawing Material Selection: Before sawing, the operator must fully understand the quality of the sawing material. Example: With super high stencil steel, the machine should be run at a slower speed. Otherwise, the blade will overheat, be worn or broken easily. With thin material, it is recommended to use a wider blade pitch at high speeds; otherwise, the teeth will be ruined easily. C. Blade Selection: 1. Generally, there are three different types of blade. These are used for metal materials such as steel, brass, iron and aluminum or non-metal such as wood, plastic, rubber and paper materials.. Selection of the blade pitch is essential. As a general rule, the thicker the material the less teeth per in pitch, and a wider blade should be used.

8 3. When cutting Radius the smaller the Radius the narrower the blade. 4. Refer to the Speed & Pitch Selector guide on the machine for proper radius and pitch. D. Blade cutting Device: Use the Blade cutter only for cutting blades if you want to maintain the cutter for a long period of time. Do not use it as a general purpose cutter. E. Welder: Reference to the Welder Operating Instructions (pg.4) F. Grinder: The grinder is used for grinding off both ends of the cut blade on the surface so that the blade can be welded together easily. Note: Do not exceed in running the grinder for more than 30 minutes at a time. G. Blade Installation: First turn off power and open the safety covers; then take off the old blade by turning the blade tension hand wheel and removing the guide bar from the table. Replace the blade with the teeth in the downward position. Be sure the safety covers have been closed. H. Guide Rod Adjustment: Adjustment to the guide rod is very essential. There are two rods: Top and Bottom. Only the top one can be adjusted about 1mm above the sawing working piece. Note: If the adjustment is made higher, the blade will be bent, so the support block of the supporting blade should also be adjusted in line with the blade width and thickness. When making adjustments, the power shall be shut off, and the support block shall be right in the middle position of the rear of the blade teeth (neither loose nor tight). I. Inverter Speed Selection and Operating: J. See the Speed & Pitch selector on the front of your machine. Operation method: Switch on; then turn motor starter switch on, and then adjust to desirable speed by speed adjusting knob.

9 K. Air pump: Voltage: 220V/60HZ Current: 0.5mA Flow rate:10-12(l/min) Pressure: 0.20Kg/cm2 Type of fluid: Air L. Angles Cutting: 1. Declination sawing: Loose table nuts; adjust the table into the desirable position, and retighten the nuts. 2. R shape sawing: Turn slowly because the sawing edge must remain flat, straight and smooth. 3. Smaller working piece sawing: Be careful to push or pull the work piece by using a wood block (not by hand); otherwise, the operator may get hurt. 4. Internal contour: First, drill a hole through the work piece large enough to fit the blade through. Weld the blade ends together (grinding smooth). Reinstall blade on wheels and make normal blade adjustment. Begin to perform contour sawing. 5. Working Speed: When sawing, the speed shall remain the same (neither fast nor slow); otherwise, blade breaking may occur. M. Safety and Maintenance: 1. Be sure that the safety cover and the wheel doors are always closed before turning on the machine. 2. The band saw shall be installed in a dry place in order to avoid electrical shock. 3. Make sure the machine is grounded properly (green wire to ground). 4. After installing a new saw blade, start the motor and keep the blade turning without load about 1 minute; then proceed to cutting the work piece 5. Upon sawing, if any unusual noise, smell or blade breakage occurs, operator should immediately switch off the power. 6. Maintenance: After operating, switch the machine off. After clearing the machine,

10 take away the chips, and slightly lubricate the surface of the machine and all joints to keep them from rusting. N. INVERTER PARAMETER: (1) Consumers are not allowed to adjust the parameters without authorization.(in case that machine failure is caused by any consumer who alters any parameter without authorization, the consumer should be responsible for the failure.) (2) Inverter parameters are only provided for the qualified technician. MAINTENANCE AND CAUTIONS Remarks: 1. This welding device isn t recommended to weld saw blades made of high speed steel. Continuous welding should be avoided. After being used several times, turn the welder off for 15 minutes rest so that the transformer will not suffer from overheat. In case that transformer becomes overheated, the temperature controller will actuate the breaker. Reuse will not be allowed until the transformer cools down. WELDING INSTRUCTION(SAW BLADE WELDING METHODS) 1. First cut the two ends of saw blade to be straight and square. 2. Align and joint the saw blade ends tightly, and then fix them at the center between the two electrodes. Turn the pressure regulator clockwise to proper position. 3. Operating method: Turn pressure regulator to position (1) in case that the saw blade width is no more than 6mm. Turn pressure regulator to position (2) or (3) in case that the saw blade width is 10mm.

11 . 4. Push the welding button (green) so as to start welding operation. Notes: During welding process, wear goggles and keep away from flammable material because spark may be caused during the operation. 5. Loosen the handle for clamping saw blade, and then turn the pressure regulator counterclockwise to position Re-tighten the clamp handle to fix the saw blade again; push the anneal button to increase the temperature of saw blade which will become brown-red at that time and then release the button. Repeat this step 4-5 times to let the saw blade temperature lower down gradually. Notes: Just lightly push the anneal button(red). 7. Remove the saw blade upon completion of annealing process. Grind the welded area with a grinding wheel so as to get rid of burs, and then repeat the annealing process2-3 times. Notes: Never have the saw blade become brown-red during this stage. 8. Upon completing the grinding process, be sure to switch off the grinding wheel. V THE SPARE PARTS LISTS Item Fig.No Description Qty Item Fig.No Description Qty 1 V Low door 1 41 V Wood brush 1 2 GB/T70.1 Bolt M6X GB/T70.1 Bolt M5X GB/T6170 Nut M GB/T96 Big washer BS180G-4003 Pin 4 44 V Block 4 5 GB/T70.1 Bolt M5X V Blade block material seat 6 GB/T95 Washer V Blade stay bar 2 7 V Left seat board 1 47 V Blade back bar 2 8 V Right seat board 1 48 GB/T70.1 Bolt M8X GB/T5783 Bolt M6X V Blade down guard 10 V Blade down cover 1 50 GB/T70.1 Bolt M10X GB/T818 Bolt M5X V Down seat 1 12 V Panel 1 52 GB/T95 Washer

12 13 V Up door 1 53 GB/T6170 Nut M Blade weld 1 54 GB/T96 Big washer GB/T818 Bolt M5X GB/T6170 Nut M GB/T70.1 Bolt M8X GB/T77 Bolt M8X Blade cutter 1 56 GB/T5783 Bolt M8X GB/T818 Bolt M5X GB/T818 Bolt M5X V Transducer display Transducer small fixed board 1 58 V Finger V Scale 1 21 V Machine stand 1 60 GB/T70.1 Bolt M8X Transducer 1 61 V Up seat 1 23 V Transducer seat board 1 62 V Up bolt 1 24 GB/T818 Bolt M5X V Working table 1 25 GB/T95 Washer V Gauge 1 26 V Elec. box 1 65 GB/T95 Washer GB/T96 Big washer GB/T5783 Bolt M6X GB/T70.1 Bolt M6X V Pin shaft 1 29 Working light 1 68 V Press sheet 1 30 V Working light seat 1 69 V Pin shaft 1 31 GB/T70.1 Bolt M6X V Eccentric handle 1 32 V Block 1 71 V Seat 1 33 Coolant nebulizer 1 72 GB/T95 Washer GB/T70.1 Bolt M4X GB/T70.1 Bolt M6X V Back cover 1 74 V Bar 1 36 GB/T70.1 Bolt M6X GB/T70.1 Bolt M8X GB/T96 Big washer V Gear sheet 1 38 WBS Door bar 2 77 V Blade protect cover 39 GB/T70.1 Bolt M6X GB/T95 Washer V Water box 1 79 GB/T70.1 Bolt M6X12 4 Item Fig.No Description Qty Item Fig.No Description Qty 80 V Handle wheel V Flange 1 81 GB/T80 Bolt M6X GB/T276 Bearing Z 2 82 GB/T879 Elasticity pin 2X GB/T893.1 Block V Gear seat V Handle 1 84 GB/T70.1 Bolt M6X GB/T301 Bearing GB/T96 Big washer V Bolt washer 2 86 V Worm GB/T879 Elasticity pin 2 1

13 3X24 87 V Washer V 丝杆 1 88 V Bolt washer GB/T5783 Bolt M8X V Slanting gear GB/T95 Washer V Shaft bolt V Shaft seat 1 91 Handle φ80xφ V Up wheel seat 1 92 V Screw V Right wash board 1 93 V Washer V Up wheel seat 1 94 V Up guard seat GB/T879 Elasticity pin 3X24 95 V Press board V Left washer board 1 96 GB/T879 Elasticity pin 4X GB/T93 Elasticity washer 8 97 GB/T80 Bolt M10X GB/T5783 Bolt M8X V Big saw wheel V Up wheel 1 99 V Small saw wheel V Up wheel shaft GB/T80 Bolt M10X GB/T276 Bearing Z V Motor seat board GB/T93 Elasticity washer GB/T5783 Bolt M8X GB/T6170 Nut M GB/T95 Washer Blade V Adjust seat GB/T6170 Nut M GB/T5783 Bolt M8X GB/T70.1 Bolt M8X Motor seat board Strap A V Big saw wheel GB/T5783 Bolt M8X GB/T1096 Key 8X GB/T70.1 Bolt M12X GB/T894.1 Shaft washer V Down wheel shaft V Block cover GB/T5783 Bolt M10X V Adjust bolt 4 VI THE EXPLODE DRAWING 1 4 1

14 (4) 25(4) 17 16(2) 18(4) 26 27(4) 28(4) (6) (4) (2) 35 37(10) 36(10) 10 9(2) 11(4) 12 6(4) 5(4) (2) 4(4) 2(2) 1 38(2) 39(2) 40

15 (2) (2) 85(2) 84(2) 83 82(2) (4) 74 72(4) 77 79(4) 78(4) (2) 65(2) (2) 46(2) 44(4) 45(2) 43(4) 42(4) 49 48(2) 61 60(4) 59 56(4) 55(4) (2) (8) 54.1(4)

16 (4) 134(4) (2) (2) (2) (2) 123(2) 122(2) (2) (2) 120(2) 117(4) 116(4) (3) 110(4) 111(2) (2) 97(3) (2) (2) (4) 102(4) (2) 105(2)

17 VII THE ELECTRICAL DRAWING FOR VS-400 PE L1 L2 L3 SA1 L11 L21 L31 F U4 1A L7 FU5 1A L8 TC 1 AC 24V m m FU6 5 A FU7 2A 3 TA SQ1 4 5 SQ2 6 KM1 KM2 SB1-1 SB2 7 8 SB m m 2 FU1 10A FU2 FU3 10A 1 0A 41 0 EL1 EL2 FU810A 42 KM1 EL3 KM2 EL4 4 3 F U910A 4 4 2m m 2 L12 L22 L32 AC 2 20V KM2 14 REV PE R S T 0.75mm KM 1 COM +10 V VCI GND U V W SA2 SB3 33 SQ3 SB4 U V W U2 W KVA M1 M

METAL CUTTING BAND SAW MODEL BS-280G

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