Cosen C-325NC Page 2 Instruction Manual Download

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Printed in Taiwan

NOTICE:

Please read this instruction manual carefully to familiarize

yourself with the installation, operation and maintenance. Please keep in

mind the following: Correctly operate the machine as described in the

manual to prevent accidents. We suggest you always keep manual handy

and refer to it whenever you are unsure of how to perform any procedure

for C-325NC.

TECHNICAL ADVICE/ SPARE PARTS

Please contact the COSEN-representative in your local area in case you need any

technical advice or if you want to order spare parts.

Instruction Manual:

C-325NC Cosen Programmable Automatic Mass Production Horizontal Bandsaw

Ver. 1 Date: 03/12/2012

2012 by COSEN CO., LTD./ R&D DIVISION.

110 Ching-Fu Street Hsin-Chu 300, Taiwan, R.O.C.

Tel: 886-3-5332143~5 Fax: 886-3-5348324

No part of this publication may be photocopied or otherwise reproduced without the prior written

permission of COSEN CO., LTD.

Summary of Contents for C-325NC

Page 1: ...dsaw Specialist Bandsaw Specialist Bandsaw Specialist Bandsaw Specialist Instruction Manual Model C 325NC Programmable Automatic Mass Production Horizontal Bandsaw Manual COSEN MACHINERY INDUSTRIAL CO LTD ...

Page 2: ...rform any procedure for C 325NC TECHNICAL ADVICE SPARE PARTS Please contact the COSEN representative in your local area in case you need any technical advice or if you want to order spare parts Instruction Manual C 325NC Cosen Programmable Automatic Mass Production Horizontal Bandsaw Ver 1 Date 03 12 2012 2012 by COSEN CO LTD R D DIVISION 110 Ching Fu Street Hsin Chu 300 Taiwan R O C Tel 886 3 533...

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Page 4: ...3 MOVING AND INSTALLATION 3 1 INTRODUCTION 3 1 3 2 MOVING THE MACHINE 3 1 3 3 3 INSTALLATION OF THE MACHINE 3 3 3 3 1 Safety Precautions 3 4 3 3 2 Initial Inspection 3 4 3 3 3 Space Required 3 4 3 3 4 Unpacking 3 6 3 3 5 Equipment Furnished 3 7 3 3 6 Installation Procedure 3 7 Fixing the Machine to the Floor 3 7 Machine Leveling 3 8 Installation of Feed Roller 3 8 Cutting Fluid Supply 3 8 Hydrauli...

Page 5: ... 28 29 4 8 TEST RUN THE MACHINE 4 30 4 9 CUTTING OPERATION 4 30 31 4 10 TERMINATING A CUTTING OPERATION 4 31 5 ELECTRICAL SYSTEM 5 1 INTRODUCTION 5 1 5 2 ELECTRICAL CIRCUIT DIAGRAMS 5 1 5 6 HYDRAULIC SYSTEM 6 1 INTRODUCTION 6 1 2 7 BAND SAW CUTTING A PRACTICAL GUIDE 7 1 INTRODUCTION 7 1 7 2 BAND SAW BLADE SELECTION 7 1 3 7 3 Some Sawing Practices 7 4 7 3 1 Selection of Saw Pitch 7 4 7 3 2 Material...

Page 6: ...9 1 9 2 PRECAUTION 9 1 9 3 GENERAL TROUBLES AND SOLUTIONS 9 2 9 4 MINOR TROUBLE SHOOTING 9 3 9 5 BLADE TROUBLES AND SOLUTIONS 9 4 9 6 SAWING PROBLEMS AND SOLUTIONS 9 5 9 7 MINOR TROUBLE SHOOTING 9 6 9 8 THE ADJUSTMENT OF THE FEEDING TABLE 9 6 7 10 PART LIST 10 1 12 ...

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Page 17: ...ance information etc It is divided into 10 sections Each section covers a specific aspect of the machine This section contains a general description of the machine and other available documentation We are going to introduce this smart machine now 2 2 EQUIPMENT DESCRIPTION This automatic band saw machine is designed based on the guidelines of low cost and high performance It is designed to cut vari...

Page 18: ... 0 04 TENSION Hydraulic controlled GUIDE Tungsten Carbide Blade Guide SAW BLADE CLEANING Wire Brush SAW BLADE 5HP 2 2 kW HYDRAULIC 1HP 0 75kW MOTOR OUTPUT COOLANT 1 8 HP 0 1 kW HYDRAULIC OIL 35 L TANK CAPACITY COOLANT 75 L Mode HYDRAULIC Automatic NC controller FEEDING Length Single Stroke 403 mm 15 9 Multiple 9999mm VISE CONTROL Hydraulic NET WEIGHT 1800 kg GROSS WEIGHT 2000 kg Design and specifi...

Page 19: ...GENERAL INFORMATION Section 2 2 3 2 2 2 Indentification of Main Parts Terminology FIG 2 1 THE SIDE VIEW OF THE MACHINE FIG 2 2 TOP VIEW DRAWING TOP VIEW DRAWING TOP VIEW DRAWING TOP VIEW DRAWING ...

Page 20: ...t you must pull it Its appearance has red color and rubber material for safe operation We hope you do not press this button inadvertently or otherwise 2 2 4 Noise Level Noise has a major effect on the quality of the environment at the work site We refer you to testing data and information as follows Excessive exposure to high levels of noise may cause impairment to hearing but the vulnerability to...

Page 21: ...d Guards This manual show safety related components illustration as following Safety moving element All the major moving elements on the machine include 1 Saw head assembly 2 Saw wheels 3 Saw blade guide arm 4 Saw blade guide roller 5 Quick approcah mechanism 6 Wire brush 7 Chip conveyor 8 Workpiece clamping vises 9 Material feed mechanism 10 Multi vises 11 Belt transmissions variable speed motors...

Page 22: ...ine Guard mountings The locations of all safety guards on the machine are indicated above All of these protectors should always be mounted on the machine whenever the machine is running Users are not allowed to move any of these elements under any circumstances except when servicing the machine However even skilled service technicians still have to be very careful when performing repairs or servic...

Page 23: ...re adopted We then put protective devices at those places Other than the safety hardware mentioned above we have also put warning labels on the machine as a reminder to the user and listed all these risks in the manual We separate all these items into four categories Please detail reading manual Section 1 SAFELY RULES before operated machine We also provide some risk analysis and procedures The sp...

Page 24: ...efore entering DANGER Do not use the machine to cut explosive material or high pressure vessels Since it will generate high heat during the sawing process that will ignite an explosion Read all WARNINGS to prevent personal injury Orange and black WARNING labels mean hazards or unsafe practices can result in severe personal injury or death WARNING This manual has important safety information All us...

Page 25: ...s 2 6 RISK ASSESSMENT Risk assessment generally takes account of intended use and foreseeable misuse including process control and maintenance requirements We made every effort to avoid any personal injury or equipment damage during the machine design stage However the operator or other people still needs to take precautions when handling any part of the machine that is unfamiliar and anywhere on ...

Page 26: ...Section 3 MOVING AND STALLATION ...

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Page 38: ...g 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 ...

Page 39: ...d 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 Not flammable Economical Does not require cleaning of the cut products Remove machine paint Lose its rust protection effect if deteriorated Tend to create foam Subject to decay Decline in performance depending on the quality of the water used for dilution Not...

Page 40: ... laser projecting system The operator must fully understand the function of each switch and button before operating the machine Fig 4 1 Control Panel Illustration 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 spe...

Page 41: ... up 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 Note 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 This button only works when the machine is switched to manual mode Note If the saw bow is not above the...

Page 42: ...rns 10 Feed backward 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 fron...

Page 43: ...e descend speed 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 valve 4 3 4 Human machine interface HMI touch screen This HMI touch screen displays operation messages so that the operator is able to understand the system condition It...

Page 44: ...rust Startup Screen After the power is turned on Cosen s logo will appear as the startup screen followed by the main operation menu 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 ...

Page 45: ... motor immediately Note When the blade is running the Hydraulic Stop button is temporarily disabled You need to press the saw blade stop or the emergency stop button to stop the blade first 3 Saw 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 4 Saw blade stop Press this button to stop the blade 5...

Page 46: ...itching to Manual mode while cutting is in action the machine will stop after the individual cut is finished Switching to manual mode at any time other than cutting the machine will proceed with the next cut until it is finished 7 Material retract 2mm ON OFF When this function is turned on the machine will retract the material for 2mm after completing each cut before the blade rises from its lowes...

Page 47: ... can be set Blade deviation detector optional can be also configured in this setup page Refer to Cutting Display Setup in the following page 13 Cutting program setting Press this button to directly enter the cutting job program setup page A total of 100 cutting programs can be set 14 Material cutting reference This 2 page reference chart lists out the required blade speed and cutting rate for each...

Page 48: ...lays current feeding length while the material is being fed 23 Blade speed display Displays current blade speed 24 yellow highlight Error display Displays error messages in the order of occurrences press the message for three seconds to clear the messages 25 Trim cut ON OFF This selection button works with the automatic cutting mode When under AUTO mode and before proceeding with your automatic cu...

Page 49: ...meters have been set up by the manufacturer Do not make any random change to these parameters as doing so will affect cutting precision and machine life Setting language Press Lang to enter the language selection page Select Chinese Metric English Metric or English Inch to complete language setting The screen will automatically return to the main control page ...

Page 50: ...atus of the HMI touch screen Warranty is one year and starts counting after 70 hours of operation after the machine is shipped Warranty status light turning to red indicates the HMI touch screen has expired Display without optional blade deviation detector included Page 2 cutting status display 2 This page comes in two versions depending on if the optional blade deviation detector is installed on ...

Page 51: ...ished A total of 100 cutting jobs can be set and performed under the automatic mode In start step and the end step field fill in the number of the cutting job you wish to start and end with The machine will automatically perform cutting jobs within this range In Length column set each respective cutting length in mm or inch In Quantity column set each respective cutting quantity Press cut reset bu...

Page 52: ... 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 2 page reference chart lists out the required blade speed and cutting rate for each different material ...

Page 53: ...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 Table 4 1 for error codes descriptions and solutions Press Home to return to the main control menu Press NEXT to go to the troubleshooting support page ...

Page 54: ...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 Saw bow upper limit abnormal Check the upper limit switch works M352 Front vise clamping error 1 Place new material 2 Check if the vise queen valve works 3...

Page 55: ...ions 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 inside the machine base It is used to control and stabilize the saw blade speed during cutting To adjust blade ...

Page 56: ...on Gear reducer The specially designed gear reducer can work toward your preset blade speed and torque Note Please refer to Chapter 8 for information on maintenance 4 5 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 e...

Page 57: ...during cutting Note 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 Chapter 4 7 for operating procedure on bundle cutting 2M roller table The optional 2M roller table supports the work material and ensures the...

Page 58: ...21 4 6 MANUAL MODE 4 6 1 UNROLLING INSTALLING THE BLADE Caution Always wear leather gloves and protection glasses when handling a blade Unrolling the blade Please follow the procedures illustrated below Fig 4 3 Unroll and roll the blade ...

Page 59: ...bow up button and elevate the saw bow until the right insert holder is clear of the front fixed vise see below picture 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 cover Step 7 Press the Blade Clip device to hold onto the blade This device makes blade...

Page 60: ...lade 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 Note When saw blade begins to rotate the blad...

Page 61: ...e 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 20 Adjust wire brush to a proper position Refer to Adjust wire brush in this section 4 6 2 Adjusting wire brush Follow these steps to adjust wire brush to appropriate position Step ...

Page 62: ...ntly shake the lower end of the blade guide so that the dovetail fixed block behind is properly aligned Step 4 Clamp the inserts back by tightening the lock nut 4 6 4 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 roll...

Page 63: ...ach back limit switch rear vises retract to clamp material again 7 Press the rear vise clamp button until the workpiece is securely clamped again front vises open prepare for precision position 8 Press the front vise open button and the rear vise clamp button again to make sure the two vises are clamping the material simultaneously confirm cutoff point 9 Press the saw bow down button to lower the ...

Page 64: ...saw bow Step 3 Use the flow control valve shown below to adjust the amount of fluid flowing to the cutting area Note 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 6 8 Breaking in the blade BREAKING IN THE BLADE When a ne...

Page 65: ...s 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 man...

Page 66: ... 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 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 bun...

Page 67: ...hese functions under manual mode vise clamping unclamping saw bow ascending descending feeding forward and backward 4 9 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 objec...

Page 68: ...peed 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 4 10 TERMINATING A CUTTIN...

Page 69: ...Section 5 ELECTRICAL SYSTEM ...

Page 70: ...tric system diagram in easy understand way 5 2 ELECTRICAL CIRCUIT DIAGRAMS As mentioned earlier at the beginning of the section The electric circuit diagrams shown here are The electric circuit diagram 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 I O layout ...

Page 71: ...ELECTRICAL SYSTEM Section 5 5 2 Fig 5 1 control panel layout ...

Page 72: ...ELECTRICAL SYSTEM Section 5 5 3 Fig 5 2 circuit board layout ...

Page 73: ...ELECTRICAL SYSTEM Section 5 5 4 Fig 5 3 power supply layout ...

Page 74: ...ELECTRICAL SYSTEM Section 5 5 5 Fig 5 4 1 PLC I O layout ...

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Page 76: ...e tention as saw blade required The hydraulic cylinder provides pressure to clamp material CAUTION During installation or handling of higer pressure hydraulic hoses do not bend hose to smaller than specified minimum bend radius Installed higer pressure hoses removed for other maintenance assessibility should be reinstalled in same location These hoses develop a permanent set and straightening acti...

Page 77: ...HYDRAULIC SYSTEM Section 6 6 2 Fig 6 1 HYDRAULIC CIRCULIC ...

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