Hyd-Mech S20DSP Use And Maintenance Manual Download Page 12

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Use and maintenance manual

S20DSP

Cutting head

The oerating head is the element that performs the cut and is made up of a bow

made from a fusion of cast iron onto which the band, the band guide elements,

the band tensioning unit and the mechanical speed variator are mounted. The

operating head is restricted in its movements by the articulated joint on the

rotatng platform.

Motor

Blade guide heads

Belt tensioning wheel

Transmission box

Drive pulley

Idle pulley

Rear flywheel

Speed variator

Cutting head beam

Front flywheel

Blade casing

Summary of Contents for S20DSP

Page 1: ...YEAR OF MANUFACTURE ______________ USE AND MAINTENANCE MANUAL S20DSP EN ...

Page 2: ......

Page 3: ...asurement 3 8 Noise level values 3 8 Vibration emission 3 9 Electromagnetic compatibility 3 9 Machine installation 4 1 Packaging and storage 4 1 Anchoring the machine 4 4 Minimum requirements 4 4 Check list 4 5 Connection to the power supply 4 6 Description of machine operation 5 1 Control panel description 5 1 Basic instructions for carrying out a cutting operation cycle 5 3 Manoeuvring the cutti...

Page 4: ...settings 7 3 Blade speed proximity settings 7 3 Minimal lubrication system settings 7 3 FCTI FCTA digital output enabling setting 7 3 Blade stop setting 7 3 Cutting vice opening setting 7 4 Cutting vice opening closing time setting 7 4 Machine maximum power input setting 7 4 Measurement unit setting 7 4 Setting minimum blade tensioning 7 5 Display backlighting time setting 7 5 Cutting head stroke ...

Page 5: ...oolant fluid 9 4 Blade structure 9 4 Blade types 9 5 Conventional rake 9 5 Positive rake 9 5 Variable pitch 9 5 Variable pitch blades with 0 cutting angle 9 6 Variable pitch with positive rake from 9 to 10 degrees 9 6 Set 9 6 Standard or splayed set 9 6 Undulated set 9 7 Alternating grouped sets 9 7 Alternating set 9 7 Blade selection table relating to cutting speed and downstroke speed 9 8 Classi...

Page 6: ......

Page 7: ...cutting needs of machine shops turneries structural steel shops and engineering workshops We congratulate our clients on having chosen this product which will give effective and faithful service for many years especially if the instructions contained in this use and maintenance manual are carefully followed This band saw has been exclusively designed to cut metals Machine presentation Functioning ...

Page 8: ...ed mt min 15 100 BAND SAW Rated size mm 4500 x 27 x 0 9 Max min blade length mm 4500 40 Blade height mm 27 Blade width mm 0 9 Band saw tension Kg 1250 When choosing the cutting tool if its dimensions do not correspond to those included in the Rated size section check that the dimensions at least fall within the admissible max min specifications RATED ELECTRICAL POWER Head spindle motor KW 1 5 Elec...

Page 9: ...sprayed from all directions with shaft oil seal Conforming to CEI norms publication IEC 34 of 01 07 1985 Example of class F insulation in air cooled machines at an ambient tempera ture of 40 C according to CEI 2 3 and IEC 85 the allowable overtempera ture is 100 C where 100ٛC represents the allowable DT ELECTROPUMP MOTOR Single phase Frequency 50 Hz Voltage Volts Absorption Amps Power Kw rpm Deliv...

Page 10: ...l S20DSP Dimensions MACHINE INSTALLED Work table height mm 880 Weight Kg 1110 1200 1300 800 2260 1200 310 230 880 2580 1200 3300 1300 800 1200 780 600 650 PACKED WEIGHT Wooden cage and pallet Kg 130 Wooden pallet Kg 70 2900 1800 1800 ...

Page 11: ...n order for the user to move towards a full understanding of how the machine works which is described in detail in the chapter 5 this chapter deals with the main units and their locations CUTTING HEAD CONTROL PANEL VICE TURNTABLE BASE 2 ...

Page 12: ...which the band the band guide elements the band tensioning unit and the mechanical speed variator are mounted The operating head is restricted in its movements by the articulated joint on the rotatng platform Motor Blade guide heads Belt tensioning wheel Transmission box Drive pulley Idle pulley Rear flywheel Speed variator Cutting head beam Front flywheel Blade casing ...

Page 13: ...eres The vice is manually neared to the material to be cut using a hand wheel and blocking is performed using a hydraulic cylinder in the AV version Slideway Handwheel Vice support lead nut Control Panel The control panel has a protection rating of IP 54 and contains the electronic equipment Access to the control panel is protected by a safety panel mounted on hinges and fastened with screws speci...

Page 14: ... platform It is made up of two parts upper and lower which close the rotating and platform and support the cutting surface in interchangeable steel The lower part is the resting base of the rotating platform cutting surface and vice It is free to run transversely on linear guides and slides with re circulation of pre loaded spheres It is integral to the base and the rear part has the reference str...

Page 15: ...tor reducer unit Rotation of the band is performed by a system made up of a motor connected to a variator and a mechanical speed reducer This unit allows rotation of the band in a continuous adjustment range that goes from 20 to 100m min ...

Page 16: ... surface which conveys the coolant to the rear tank via the tank cover and a swarf collection drawer An electric pump is housed inside the tank which draws the clean fluid from the filter system Lubricant coolant tank Electric pump housing Swarf collection drawer Hydraulic single box housing ...

Page 17: ...ll the machine s controls The instructions warnings and accident prevention standards in this manual must be respected without question by all those concerned The following definitions are those provided for by EEC MACHINES DIRECTIVE 98 37 CE H Danger zone any zone in and or around a machine in which the presence of a person constitutes a risk for the safety and health of that person H Person expo...

Page 18: ...o avoiding any blinding light concentrations Reference standard ISO 8995 89 Lighting in work environments CONNECTIONS Check that the power supply cables and pneumatic feed systems comply with the maximum machine absorption values listed in the Machine Specification tables replace if necessary EARTHING The installation of the earthing system must comply with the requirements set out in IEC STANDARD...

Page 19: ...st be tied back and bunched Always disconnect the power supply to the machine before carrying out any maintenance work whatsoever including in the case of abnormal operation of the machine Before starting cutting operations support the material at both ends of the machine using the support arm standard or OPTIONAL acces sories such as the feed and discharge roller tables shown in the diagram below...

Page 20: ... zone always keep the working area as clean as possible Before starting any cutting operations ensure that the workpiece is securely held in the vice and the machine has been set correctly A number of examples of how to clamp different profiles correctly in our machines are shown below Do not use the machine to cut pieces that exceed the capacity of the machine as listed in the machine specificati...

Page 21: ...t a standstill Machine safety devices This use and maintenance manual is not intended as purely a guide for the use of the machine in a strictly productive environment it is instead an instrument providing information on how to use the machine correctly and safely The following standards are those specified by the EEC Committee in the directives regarding safety of machinery health and safety at w...

Page 22: ...dance with Presidential Decree no 547 55 art 108 4 hinged protective cover over blade fitted with removable closing devices 5 blade guide plates completely covering the blade teeth 6 the cutting vice is operated by hydraulic devices with a max stroke of 8 mm the jaws locking the piece must be moved at a distance of 2P3 mm from the piece to be machined 7 programming and control panel mounted on an ...

Page 23: ...non return mushroom head pushbutton colour red on yellow background is located on the control panel of the machine To release the pushbutton the actuator must be rotated 45 After the emergency situ ation has been resolved the machine must be reset 2 Automatic thermal magnetic cutout switch with thermal magnetic relay The machine s automatic switch positioned on the left hand side of the base has t...

Page 24: ...ed in dBA as that actually fluctuating over the same period of time This calculation is made automatically by the integrator noise meter The measurements are taken every 60 seconds in order to obtain a stabilised value The reading stays on the display for a sufficient time to enable a reading to be taken by the operator Measurements are taken by holding the instrument at approximately 1 metre from...

Page 25: ...EI EN 55011 1999 Industrial scientific and medical radio frequency appliances ISM Characteristics of radio frequency disturbance Limits and methods of measurement H CEI EN 50370 2 2004 Electromagnetic Compatibility EMC Product family for machine tools Part 2 Immunity Basic standards H EN 61000 4 2 A1 A2 1996 1999 2001 Electromagnetic Compatibility EMC Part 4 Test and measurement techniques Section...

Page 26: ...V B Complies IMMUNITY TO VOLTAGE BURSTS Gate Test levels Evaluation criterion Result A C power supply in put 2 kV B Complies IMMUNITY TO HIGH VOLTAGE PULSES Surge Gate Test levels Evaluation criterion Result A C power supply in put 1 kV Phase phase 2 kV Phase earth B Complies IMMUNITY TO DIPS AND SHORT VOLTAGE INTERRUPTIONS PQT Gate Test levels Evaluation criterion Result A C power supply in 70 pe...

Page 27: ... following ways 1 on a pallet with straps and heat shrink plastic 2 on a pallet with straps heat shrink plastic and a wooden crate In both cases for correct balancing the machine must be handled using a fork lift truck inserting the tines at the points indicated by the arrows using the reference marks on the crate itself Before carrying out lifting operations make sure that the weight of the ma ch...

Page 28: ... wrapped must not be stacked two high and machines pallettized and crated must not be stacked three high To install the machine first remove the packing paying particular attention not to cut any electric wires or hydraulic hoses if necessary use pliers a hammer and a cutter Open crate in the illustrated order Attention Attention ...

Page 29: ...shrink covering 4 remove the straps 5 remove nails from pallet securing planks and remove planks 6 remove the front panel and insert fork tines 3 4 5 6 To locate the machine in the workplace the machine dimensions and necessary operator working space including the spaces laid down in safety standards must be taken into account ...

Page 30: ...g the machine BASE 1138 1296 Minimum requirements For the machine to function correctly the room in which it is to be installed must satisfy the following requirements H power supply voltage frequency refer to the values on the rating plate H pneumatic operating pressure not less than 6 Bar and not more than 8 Bar H temperature of machine location from 10 to 50ٛC H relative humidity not more than ...

Page 31: ... right and 45 60 left angles n Electronic transducer of the stretching of the band with display on the con sole n Blade cleaning device with rotating brushes with movement transmitted from the pulley engine n Designed for transpallet handling systems n Mobile console to operate while maintaining visual control n Manual vice with screws with rapid nearing and transfer on the linear guides and slide...

Page 32: ...hich matches the socket to be used EN 60204 1 par 5 3 2 CONNECTION FOR 5 CORE WIRE SYSTEMS WITH NEUTRAL R L1 S L2 T L3 PE GND N NEUTRAL CONNECTION FOR 4 CORE WIRE SYSTEMS WITH NEUTRAL S L2 T L3 PE GND R L1 When using systems with a neutral wire special care must be taken when con necting the blue neutral wire in that if it is connected to a phase wire it will dis charge the phase voltage to the eq...

Page 33: ...this check the following operations must be carried out set the blade tension to 1200 BAR make sure the cover is properly closed at the back of the cutting head there is a bayonet limiter for correct cover closure make sure that the machine is not in an emergency condition red mush room head pushbutton released after having applied voltage to the machine set the selector for permission of motor st...

Page 34: ...de motor will start up and the blade will start rotating Ensure that the blade moves in the correct direction as shown in the above figure If it does not simply reverse two of the phase wires on the machine power supply input The sawing machine is now ready to start the work for which it was designed Chapter 5 provides a detailed description of the various functions of the machine and its operatin...

Page 35: ...tions We begin with a description of the pushbuttons and other components on the control panel Control panel description The figure below shows the control panel of the S20DSP Key of control console keyboard Initialisation key enables machine oper ation Zeroing key for cuts made 5 ...

Page 36: ... Semi automatic cycle key FCTA Head Downstroke Limit mem ory key for Head Positioning System Head up key Diagnostics key Head down key Programmed cycle start key Machine parameters input edit key Key for displaying the machine para meters for performing a machining cycle TL blade tension PT head position VL blade speed T cutting time PZ cut piece number I motor absorption Electronic speed control ...

Page 37: ...ads Basic instructions for carrying out a cutting operation cycle Manoeuvring the cutting head The cutting head may be operated by the head up and down buttons of the Head Positioning System previously illustrated in the key for the control console keyboard which are enabled in SEMI AUTOMATIC mode Head down key Head up key During any processing cycle it is possible to control the machine operating...

Page 38: ...both sides of the machine move the vice to within 2 3 mm of the workpiece using the handwheel 2 3 mm Turn the selector for the closure of the vice make sure the workpiece is securely clamped in the vice by trying to move it manually Rapid vice positioning By means of a simple device the vice can be slid back and forth to accelerate vice opening and closing operations ...

Page 39: ... in the figure below and rotate in a clockwise direc tion the vice is now free to slide back and forth to the required position Once positioned release the lever to lock the vice in place Finally position the vice to within 2 3 mm of the workpiece using the han dwheel ...

Page 40: ...ire blade stroke leaving exposed only the part of the blade required to make the cut itself as specified by current standards The width of the cut is determined by the longitudinal section of the workpiece so that only the part of the blade required to make the cut is actually exposed Position the workpiece on the work table in proximity to the blade down stroke trajectory and clamp it in the vice...

Page 41: ... be begun that the speed selected is right for the kind of piece to be cut that all protections are in place and correctly locked the level of lubricant coolant and that the electropump is activated That the blade descent speed is correct Semi automatic operating cycle Semi automatic cutting sequence power up the machine by turning the main switch position the workpiece in the vice During this pro...

Page 42: ...cocks on the blade guide heads It is also possible to set the lubricant coolant delivery mode OPTIONAL Position the cutting head about 10 mm from the workpiece using the up Y and down Y arrow keys Press the FCTI Head Upstroke Limit memory button to save the head start position at the beginning of the cycle Lower the head to the end of cut position by pressing the down Y arrow key Press the FCTA He...

Page 43: ...essing the cycle start key After you have given the START command the blade starts to rotate the vice clamps the workpiece and the coolant spray is activated The cutting head will remain in the start position until the head descent regulator located on the front right of the base is opened Adjust the head downstroke speed in accordance with the type of material being cut the blade rotation speed a...

Page 44: ...nted out that the bar support rollerway located on the loading side of the machine to the left of the cutting table has two pre set positions one for straight cuts or cuts with an inclination of up to 30 left or right the other for cuts with an inclination of 60 right Loading side rollerway position For 0 or 30 left right cuts check that the rollerway is positioned as shown in the drawing below Fo...

Page 45: ...lot slacken the turntable lock release lever The 0 45 and reference stops for cuts to the right and the 45 reference stop for cuts to the left facilitate rapid head positioning during turntable rotation However the eccentric pin is only correctly positioned if the initial rotation of the turntable when released is corrected Warning ...

Page 46: ...ition to avoid blade collision with the moving jaw on the clamp Relock the turntable lock release lever Perform the cut keeping in mind the preliminary safety instructions noted in this chapter Angled cuts 60 to the left Ensure that the vice is positioned on the left of the cutting slit at 05 see the previous paragraph Release the the block unblock head rotating surface lever remove the pre set st...

Page 47: ...is displayed on the graduation noted on the rotating surface Always rotate the head when it is in the upper position to avoid blade collision with the moving jaw on the clamp Tighten the block unblock rotating surface lever Perform the cut keeping in mind the preliminary safety instructions noted in this chapter Attention ...

Page 48: ...ce to the left or right make sure the moving jaw is be yond the 0 cutting slot to avoid any risk of collision with the blade downstroke slacken the turntable lock release lever remove the 0 stop swing the head from left to right until it is positioned at the required angle as indicated by the graduated scale on the turntable relock the turntable lock release lever Perform the cut keeping in mind t...

Page 49: ...e vice to the right of the cutting slit Remove the pre set stroke to 45 right When positioning the vice on the left or on the right pay attention that the mo bile jaw does not exceed the cutting slit at 05 In this way it will not interfere with the band during descent Attention ...

Page 50: ...lease lever swing the head from left to right until it is positioned at the required angle as indicated by the graduated scale on the turntable relock the turntable lock release lever Perform the cut keeping in mind the preliminary safety instructions noted in this chapter ...

Page 51: ...d maintenance operations This chapter will also enable the user to order replacement parts with no risk of misunderstanding as all parts are given codes Hydraulic components legend M1 CPT Mono control unit CMT Cutting clamp cylinder RDTM Motorised flow adjuster cutting head descent speed M2 CMT Mono control unit RDT Flow adjuster cutting head descent speed RPP Cutting head pressure ad juster RPM V...

Page 52: ...A CPT CILINDRO PORTA TESTA CMT CILINDRO MORSA DI TAGLIO RDT REG DISCESA TESTA EV BY PASS ACCOSTAMENTO RAPIDO EV RIG ELETTROVALVOLA RIGENERATRICE POMPA 2 2 cmq giro PRESSIONE DI ESERCIZIO 30 Bar MAX MOTORE 71 B14 0 37KW 1400RPM 230 400 50HZ 240 480 60HZ CMT CENTRALINA IDRAULICA 0 R D T CPT EVB BY PASS EVB RIG EVM EVT ...

Page 53: ...way in which they have been drawn up Each sheet of the project contains a box which gives the following information The numbers indicate the columns into which the entire drawing is divided Indications of the date production started Identification of the designer Identification of the Reference Standard Indications of the model of machine Indication of the page number MARIO ROSSI ...

Page 54: ...r the dot identifies the column on that page example 11 8 indicates that the wire continues on page no 11 in column 8 This symbol identifies the wire with its relative number and co lour The pages following the wiring diagrams contain the following lists 1 components list list of all components and terminals list list of all the ter minals with the following information n in house article code n i...

Page 55: ...d EN 60204 1 D2 Letter codes used to designate the type of component LETTER TYPE OF COMPONENT EXAMPLES IDENTIFICATION OF THE APPLIANCE A Complex units Laser Maser Regulator A B Transducers converting a non electrical signal to an electrical signal and vice versa Transistor amplifier IC amplifier Magnetic amplifier Valve amplifier Printed circuit board Drawer Rack AD AJ AM AV AP AT AR C Capacitors ...

Page 56: ...l or nothing timed relays timers KA KL KM KP KR KT L Inductors reactors Inductor Stop coil Reactor L M Motors M N Analogue intgrated circuits Operational amplifiers Hybrid analog digital ap pliances N P Measurement equipment test de vices Indicator recorder and inte grator measurement devices Signal generators P Q Power circuit switching appliances Automatic switch Engine saver switch Knife switch...

Page 57: ... pipes semiconductors Electronic pipe Gas discharge pipe Diode Transistor Thyristor V W Transmission lines wave guides antennas Conductor Cable Bar Wave guide Wave guide directional coupler Dipole Parabolic antenna W X Terminals sockets plugs Connector bar Test plug Plug Socket Terminal connector band XB XJ XP XS XT Y Electrically operated mechanical appliances Electromagnet Electromagnetic brake ...

Page 58: ...6 8 52 Use and maintenance manual S20DSP Standardised Wiring Diagrams S20DSP CENELEC Standard S20DSP ...

Page 59: ...6 9 53 Diagrams exploded views and replace S20DSP ...

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Page 61: ...6 11 55 Diagrams exploded views and replace S20DSP ...

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Page 63: ...6 13 57 Diagrams exploded views and replace S20DSP ...

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Page 65: ...6 15 59 Diagrams exploded views and replace S20DSP ...

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Page 69: ...6 19 63 Diagrams exploded views and replace S20DSP ...

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Page 71: ...Head position Proximity M R HS V N R M 031 032 033 034 NC 036 037 038 041 042 043 044 045 046 047 048 049 050 NC M B V G Z R R R R S Blade tension NC Wire colour coding A light blue M brown B white N black C orange R red G yellowe S pink H grey V green L blue Z purple 114 027 052 025 024 023 022 021 G S R B G H R R L R 051 052 0 Vdc 24 Vdc L R 60 561 0 Vdc 24 Vdc NC Emergency 01 02 R R 01 02 R R R...

Page 72: ...22 66 Use and maintenance manual S20DSP Exploded views This part of the manual contains detailed exploded views of the machine which can help to gain a deeper knowledge of how it is made Motor unit S20DSP ...

Page 73: ...HER NR 4 000 010 7605 0 10 WASHER NR 4 000 010 7645 M8 SPRING WASHER NR 4 000 010 7891 TCEI 8 X 16 SCREW NR 4 000 010 7893 TCEI 8 X 20 SCREW NR 4 000 010 7895 TCEI 8 X 30 SCREW NR 9 000 010 7963 TE 8 X 25 SCREW NR 4 000 010 7976 TE 10 X 30 SCREW NR 4 000 019 3621 NR 1 000 022 0212 RAPID JOINT SEM PG 16 NR 1 000 025 0121 REDUCER MVF 63 FCO 1A38 90 B14 NR 1 000 025 0625 MOTOR GASKET SH 310 320 330 N...

Page 74: ...6 24 68 Use and maintenance manual S20DSP Driving pulley unit S20DSP ...

Page 75: ... 7470 6 X 35 FLAT POINT VCE GRUB SCR NR 1 000 010 7831 5 X 12 BUTON SCREW NR 5 000 010 7859 TCEI 5 X 12 SCREW NR 3 000 010 7873 TCEI 6 X 30 SCREW NR 2 000 010 7890 TCEI 8 X 12 SCREW NR 2 000 010 7893 TCEI 8 X 20 SCREW NR 4 000 010 7899 TCEI 8 X 60 SCREW NR 4 000 010 7911 TCEI 10 X 20 SCREW NR 1 000 010 7925 TCEI 10 X 40 SCREW NR 4 000 010 7926 TCEI 10 X 45 SCREW NR 2 000 010 7927 TCEI 10 X 60 SCRE...

Page 76: ...6 26 70 Use and maintenance manual S20DSP Front flywheel assembly S20DSP ...

Page 77: ...SH NR 2 000 010 1517 PROXIMITY FIXING BRACKET SH 40 NR 1 000 010 4021 GIB SLIDE ADJUSTMENT PLATE SH NR 2 000 010 7203 M6 SCREW NUT NR 7 000 010 7461 6 X 25 FLAT POINT VCE GRUB SCR NR 6 000 010 7604 0 8 WASHER NR 4 000 010 7831 5 X 12 BUTON SCREW NR 4 000 010 7878 TCEI 6 X 70 SCREW NR 1 000 010 7893 TCEI 8 X 20 SCREW NR 4 000 010 7894 TCEI 8 X 25 SCREW NR 8 000 016 0117 FRONT BOW HEAD COVER SH 452 ...

Page 78: ...6 28 72 Use and maintenance manual S20DSP Fixed worktable S20DSP ...

Page 79: ...1687 ROTATING TABLE LOCKING SCREW S NR 1 000 010 2023 UPPER VICE SLIDE GUIDE SH 420 NR 2 000 010 3164 HEAD HEAD STROKE STOP NR 1 000 010 7221 M16 LOW SCREW NUT NR 1 000 010 7488 10 X 45 FLAT POINT VCE GRUB SC NR 4 000 010 7602 0 5 WASHER NR 2 000 010 7603 0 6 WASHER NR 2 000 010 7605 0 10 WASHER NR 4 000 010 7641 GROOVER WASHER M12 NR 10 000 010 7645 M8 SPRING WASHER NR 2 000 010 7703 CYLINDRICAL ...

Page 80: ...6 30 74 Use and maintenance manual S20DSP Cutting head cover S20DSP ...

Page 81: ...B NR 1 000 010 7467 6 X 12 FLAT POINT VCE GRUB SCR NR 5 000 010 7470 6 X 35 FLAT POINT VCE GRUB SCR NR 1 000 010 7480 8 X 30 FLAT POINT VCE GRUB SCR NR 2 000 010 7603 0 6 WASHER NR 1 000 010 7606 0 12 WASHER NR 10 000 010 7831 5 X 12 BUTON SCREW NR 8 000 010 7870 TCEI 6 X 16 SCREW NR 10 000 010 7890 TCEI 8 X 12 SCREW NR 2 000 010 7893 TCEI 8 X 20 SCREW NR 2 000 016 0119 NR 1 000 016 0191 BOW WATER...

Page 82: ...6 32 76 Use and maintenance manual S20DSP Cylinders S20DSP ...

Page 83: ... 000 022 0238 CABLE PRESSER PG 7 BS01 NR 1 000 022 2702 NUT PG 7 BL01 NR 1 000 025 0876 JOINT WA 6 6 M M 28 FOR CYLIND NR 1 000 043 0250 M F ELBOW 1 4 CL 2020 NR 2 000 043 0340 13X19X1 5 1 4 COPPER WASHER NR 2 000 043 5671 GUARD F CYLINDER POTENTIOMETER NR 1 000 043 5681 CYLINDER POTENTIOMETER SUPPORT NR 1 000 044 0501 NP 1 4 HYDRAULIC NIPPLE NR 2 000 044 1005 HYDRAULIC CYLINDER SH 280 320 NR 1 00...

Page 84: ...6 34 78 Use and maintenance manual S20DSP Base assembly S20DSP ...

Page 85: ...T 1 262 160 NR 2 000 022 0324 FAIRLEADS 24 INC M M 2 5 NR 2 000 028 0010 COOLANT PISTOL SH TI 8966 NR 1 000 028 0121 JOINT 3 8 17 CL 2601 NR 2 000 028 0231 ELECTROPUMP60 150 220 230 240 NR 1 000 028 0391 LOOC LINE HOSE SPD ART 69540 3 MT 1 000 028 0396 NOZZLE 0 20 SPD FP50 11B50 NR 1 000 028 0401 FITTING 3 4 SPD FP50 17A20 NR 1 000 034 0901 1 2 GAS OIL LEVEL CAP NR 1 000 034 0905 TAO 3 1 2 BLACK O...

Page 86: ...6 36 80 Use and maintenance manual S20DSP Control panel S20DSP ...

Page 87: ... 48 NR 1 000 010 7870 TCEI 6 X 16 SCREW NR 4 000 010 7954 TE 6 X 30 SCREW NR 2 000 016 0236 CONSOLLE MOVING ROD NR 1 000 016 0307 CONTROL PANEL NR 1 000 016 1484 CONSOLLE FIX BRACKET SH 420 S NR 1 000 022 0209 RAPID JOINT SEM 29 NR 1 000 022 0247 POLYAMIDE HUMMEL NUT 1 262 290 NR 1 000 025 0073 BEARING 63001 2RS NR 2 000 031 3235 KEYPAD SH 452 CCS NR 1 000 034 1169 SINGLE TURN ADJUSTMENT KNOB NR 1...

Page 88: ...6 38 82 Use and maintenance manual S20DSP Vice assembly S20DSP ...

Page 89: ...CE GRUB SCRE NR 1 000 010 7491 10 X 60 FLAT POINT VCE GRUB SC NR 1 000 010 7830 5 X 10 BUTON SCREW NR 2 000 010 7832 BUTON SCREW 6 X 12 NR 3 000 010 7859 TCEI 5 X 12 SCREW NR 4 000 010 7870 TCEI 6 X 16 SCREW NR 8 000 010 7872 TCEI 6 X 25 SCREW NR 28 000 010 7893 TCEI 8 X 20 SCREW NR 1 000 010 7894 TCEI 8 X 25 SCREW NR 7 000 010 7924 TCEI 10 X 30 SCREW NR 2 000 010 8001 TCIC M3 X 16 SCREW NR 2 000 ...

Page 90: ......

Page 91: ...stom ise your machine to suit the type of cut required thereby optimising cutting times Displaying and editing the set up parameters The machine set up parameters may be programmed directly from the control console Power up the machine at the main switch located on the left hand side Press simultaneously and in sequence the keys MACHINE PARAMETERS and MACHINE START 7 ...

Page 92: ...o quit the SETUP parameters press in sequence and simultaneously the MACHINE PARAMETERS and MACHINE START keys Set language parameter Press Y to change the display messages presentation language ENGLISH LANGUAGE Set parameter for machine type Press to display the parameter for the machine type Press the Y key to change machine type each press of the key corresponds to a different ma chine configur...

Page 93: ...onal choosing YES or NO NO BLADE SPEED PROXY Minimal lubrication system settings Press to display the min lubrication system parameter then press Y to set the presence or the absence of this optional choosing YES or NO NO MIN LUBR FCTI FCTA digital output enabling setting Press the key to display the parameter enabling or disabling the outputs of the positions FCTI backward head limit switch and F...

Page 94: ...ening closing time setting Press the key to display the parameter indicating the time between the vice closing and the cut start and between the cut end and the vice re opening Press Y to change this value ranging between 0 0 and 9 9 seconds TIME 0 0 VICE OPENING CLOSING Machine maximum power input setting Press the key to display the parameter and then increase or reduce the value with the Y key ...

Page 95: ...be set Check that the bow really and not virtually crosses the amplitude of the cut between the structural limits of cutting head backward end run and cutting head forward end run The scope of adjust ment is to set the value of the real cutting head position both at FCTI backward limit 275 300 and at FCTA forward limit 008 012 Two adjustments are performed to obtain this result one on the cutting ...

Page 96: ...anging between 008 and 012 otherwise operate as follows Remove the fixing screws from the black box on the cylinder using a hex wrench Remove the box protecting the potentiometer taking care not to tug at the connection cables Using an Allen key slacken the grub screws fixing the rod and free the poten tiometer body Manually rotate the potentiometer body until the display readout is between 008 01...

Page 97: ...A keys in sequence and simultaneously Set the FCTI point taking the head completely backwards pressing in se quence and simultaneously the key and the key for the head lifting Y Open the control board removing the frame and pull the keyboard out of the console Identify the board IUD IUV of the controller M30 to adjust the potentio meter indicated by the arrow in the following image ...

Page 98: ...e installed software version and the total working time of the machine TT 0000 00 M30 v01 01 00 05 Adjusting the display brightness If external factors like changing ambient lighting conditions in the machine installation site affect visibility adjust the brightness of the control and program ming console display This is very important since the operator must be able to clearly read the display me...

Page 99: ... vices have a maximum travel of 8 mm This means that after positioning the workpiece on the work table and before start ing the cycle the moving jaw must be positioned to within 2 3 mm of the workpiece as previously described in Chapter 5 The operating pressures shearing vice and cutting head can be adjusted by the max pressure adjusting valve Open the door of the machine base remove the fastening...

Page 100: ...lide as follows open the cutting head cover un tension the band with the relevant hand wheel remove the blade from the flywheels remove the plug connecting the slideway to the cylinder rod move the slide back and forwards to locate any friction or excessive play slacken the nuts using a tubular nut driver to hold the grub screws firm finally tighten the grub screws to take up any play or otherwise...

Page 101: ...he blade steady buttons prevent upward blade flexure caused by the vertical action of the cutting force These buttons are fitted on both the front and rear heads and need no adjustment Blade guide plates The plate contact points feature widia inserts which guide the blade longitudinal ly A small amount of play must exist between the plates and blade to ensure that the blade runs smoothly and perpe...

Page 102: ... it as illus trated in the figure below wear protective gloves when making this adjustment make sure there is a small amount of play between the blade and guide plate inserts if the amount of play is not sufficient for the blade to run smoothly adjust the locking torque of the two grub screws with an Allen key ...

Page 103: ...djustments replace any worn plates by removing the plate fixing screw repeat the above sequence of steps on the rear blade guide head refit the front blade guard tension the blade and power up the machine again ...

Page 104: ... as follows In case of machine in emergency or simply to lower the cutting head without starting up belt rotation close the cutting head descent regulator completely and press the START button then gradually open the cutting head descent regulator If the machine has version HH perform the same operations by pressing the mushroom shaped EMERGENCY button and the START button at the same time disconn...

Page 105: ...ade into the front blade guide head make sure the back of the blade is facing the flywheel stop and that the teeth along the lower part of the blade are inclined towards the head pivot Make sure there is a small amount of play between the blade and guide plate inserts repeat the above sequence of steps on the rear blade guide head fit the blade on the flywheels and remount the front and rear blade...

Page 106: ...cutting vice position the square on the cleaned work surface and rest it against the blade close to the right hand vice jaw at a point where the blade teeth do not pre vent contact Slacken the head fixing screw A and adjust the two grub screws B if the blade touches the square at the bottom If the contact point is instead located at the top of the square slacken screw A and tighten grubs screws B ...

Page 107: ...uare Operation sequence place the head in the lowest position Position the goniometer or square against the fixed vice jaw adjacent to the blade If an error in orthogonality is found realign the blade guide heads as follows loosen the TCEI head locking screws A A and uniformly adjust grub screws B B until blade orthogonality in relation to workpiece rest shoulder is obtained After adjusting check ...

Page 108: ...e shaft in or out restore the machine and turn the blade Check the distance between the blade and and edge of the wheels if necessary repeat the above operation until a gap od 1 mm is obtained be tween the back of the blade and the edge of the wheels Rear flywheel Rear flywheel alignment is closely linked to adjustment of the front wheel Adjustment is aimed at maintaining a distance of 1mm from th...

Page 109: ... safety as well as for the safety of other personnel and in the interests of machine productivity H check that his own work and that of the other operators of the machine always complies with the relevant safety standards Therefore check that the safety de vices are in position and work perfectly and that personal safety requirements are complied with H Ensure that the working cycle is efficient a...

Page 110: ... instructions for use and maintenance of the ma chine and those on the product itself General maintenance Daily The daily maintenance operations to carry out on the machine are as follows remove all swarf from the machine preferably with a non fibrous cloth empty the swarf drawer this is located on the right side of the base top up the lubricant coolant level check state of blade wear and replace ...

Page 111: ...f necessary see Chapter 7 thoroughly clean the bottom of the water tank and the electropump filter Maintenance of working parts Maintenance personnel working on the S20DSP must pay particular attention to operating components such as the blade tensioning cylinder already dealt with in Chapter 7 loading the air treatment unit and the pneumatic vice No mainte nance is required for the worm screw red...

Page 112: ...ese types of oils Hyd Mech considers that the above product has the best price quality rapport The following oils can also be said to have similar characteristics and are therefore compatible AGIP NB 200 SHELL Lutem TT IP Utens Fluid F Finally a lubricant coolant guaranteed and distributed by a band saw manufactu rer LENOX is BAND ADE SAWING FLUID LENOX tank capacity Lt 80 oil concentration 5 6 ...

Page 113: ... m min Inverter technical specifications Protection rating IP 31 Vibration and shock resistance EN50178 0 6 gn from 10 to 50 Hz 2 gn from 50 to 150 Hz Max relative humidity 93 without condensation or drop forming Acceptable Temperature Range EN 50178 For warehouse storing from 25 C to 65 C For operating purposes from 10 C to 40 C Max altitude 1000mt with no derating single phase 200V 15 to 240V 10...

Page 114: ...oys soft bronze etc also require a coarse tooth pitch Saw tooth pitch The choice of teeth per inch therefore depends on various factors H the size of the section H the hardness of the material H workpiece wall breadth Very large dimensions require coarse teeth while small dimensions require finer teeth Whatever the case ensure that there are always at least six teeth engaged in the cut with refere...

Page 115: ...ls Types of swarf H Very fine or fragmented swarf indicates that the downstroke speed and or cutting pressure is too low H Thick and or blue swarf indicates that the blade is overloaded H Long coils of swarf indicate ideal cutting conditions ...

Page 116: ...ed with a silicon steel body and having a high fatigue strength and super high speed steel teeth the two parts are welded by electronic or laser welding Standardised teeth types are termed M2 and M42 the difference being that M42 teeth are harder due to the addition of cobalt to the steel used to make the teeth Key Mo Molyb denum Ni Nickel Si Silicon V Vanadium W Tungsten Al Aluminium C Carbon Co ...

Page 117: ...lled materials for straight or angled cuts Positive rake Positive cutting angle 9 10 constant pitch Can be used for cutting all types of materials and is particularly suited to low carbon and non ferrous steels Used for cutting very large sections and diameters Variable pitch These blades have groups of teeth having different pitches and as a consequence have various tooth dimensions and differing...

Page 118: ...ing type is the most suitable for cutting large dimension pipes and profiles including large sections as well as for cutting solid sections up to the machine capacity limit Pitches available 3 4 4 6 Set The term set refers to the section of material removed by the blade during the cutting operation i e relating to width of cut and the offset position of the teeth with respect to the blade back Sta...

Page 119: ...f set is used with very fine teeth for cutting thin pipe walls and small section profiles from 1 to 3 mm Alternating grouped sets These are groups of teeth angled to the right one straight tooth then a further group angled to the left This set is used for very fine teeth for cutting very thin sections less than 1 mm Alternating set This set is one tooth to the right followed by one to the left Thi...

Page 120: ...4 6 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 60 70 50 60 15 20 15 20 75 90 80 90 25 40 70 80 80 90 S 10 10 S 30 30 S 50 50 S 80 80 S 120 120 S 230 Dimensions of the cutting section S mm Cutting speed mt min Cutting material Blade pitch Number of teeth per inch Lubrication sq mt min cut Structural steel Casehardened steel Steel for turning Mild steel High duty cast iron Rolled steel ...

Page 121: ... 845 En 58 E En 56 A En 58 G A 1 A 2 En 36 4360 50 A 3706 1 2 3 En 20 A En 31 1022 1035 1040 1010 1015 1060 1065 5135 5145 4135 3135 4315 8645 W 1 L 6 T 1 1310 316 304 410 309 S D 3 M 13 3310 3315 ASTMA 36 68 52100 Brinell HB HRB Kg mmq 160 170 160 180 150 175 160 180 160 180 180 205 180 200 200 230 190 230 200 225 190 220 150 190 190 230 217 248 217 248 160 200 130 170 150 200 215 240 200 230 160...

Page 122: ... 19 150 M 28 060 A 40 060 A 96 070 M 55 080 A 40 080 A 62 1717 CDS 110 708 A 37 708 M 40 735 A 50 534 A 99 817 M 40 311 tipo 6 e 7 BD 2 BD 3 BS 1 304 S 15 304 C 12 316 S 16 317 S 16 XC 18 XC 38 H 1 20 M 5 XC 60 XC 75 40 M 5 XC 42 H 1 25 CD 4 35 NCD 6 50 CV 4 100 C 6 Z 160 CVD 12 Z 200 C 12 55 NCVD 7 Z 2 CN 18 10 Z 6 CN 18 09 Z 3 CN 19 10 Z 12 CNS 25 20 Z 6 CND 17 12 304 S 12 C 15 C 35 C 22 Mn C 28...

Page 123: ...able you to follow a methodical procedure for solving any problem Troubleshooting blade and cutting problems PROBLEM PROBABLE CAUSE SOLUTION Blade scored or scratched Widia inserts chipped or worn Replace Widia inserts loose or tight Adjust Widia inserts dirty Clean and re adjust correctly Cutting surfaces scored Blade teeth worn Replace blade Head downstroke speed too fast Reduce downstroke speed...

Page 124: ... stroke speeds or clean sur face Cutting speed too high The teeth slide on the ma terial without cutting reduce cutting speed Head downstroke speed too slow The band saw runs over the material without removing it increase downstroke speed Insufficient coolant Check coolant level and clean pipes and jets Incorrect fluid concentration Check and use the correct concentration New blade inserted into a...

Page 125: ... 45 right and left by means of the appropriate screws Perpendicularity of the blade to the work surface Check and realign the blade guide heads then adjust the blade using the appropriate screws so that it is perpen dicular to the work surface Blade tension incorrect Bring pressure up to 60 Bar Blade worn Replace blade Tooth pitch unsuitable Probably a blade with too many teeth per inch is being u...

Page 126: ...e al tered surface areas such as oxides or sand or subcooled inclusions in the section These areas are much harder than the blade and will cause the teeth to break scrap or clean these ma terials Workpiece not clamped The blade may break if the workpiece moves during cut ting check the vice jaws and clamping pressure The blade stops in the cut Cutting pressure too high check and restore to rated p...

Page 127: ...hem downwards so as to bring the blade steady buttons up against the back of the blade Sections with large thickness variations The cutting speed and down stroke speed must be chosen to suit the most critical part of the cut Teeth angled in the wrong direction Fit blade so that teeth point in the right direction Blade run in wrongly When using a new blade the cutting and downstroke speeds must be ...

Page 128: ... ting check the vice jaws and clamping pressure Widia inserts positioned in correctly Adjust inserts position es pecially the width since blade thickness can exceed the manufacturer s declared tolerance ratings Widia blade steady buttons Can have a milling action on the back of the blade if worn or chipped causing cracks from the back towards the teeth Position of blade on fly wheels incorrect The...

Page 129: ...ant Check coolant fluid level clean pipes and jets Incorrect fluid concentration Check and use the correct concentration The blade stops in the cut Cutting pressure too high check pressure and reset to rated pressure Head downstroke speed too fast reduce Head downstroke speed too slow increase The blade slips on the fly wheels incorrect or low blade tension readjust or in crease Troubleshooting Th...

Page 130: ...isplayed For further information about the machine s outputs refer to the electrical and electronic diagrams illustrated in Chapter 6 of this manual Testing the control console keyboard Each console key has an identification number which is displayed on the diagnos tics screen after the letter K when the key is pressed For example when pressing the key for the manual cycle HAND key the figure 12 i...

Page 131: ...from the video page of the digital inputs press the key arrow up once to display the list of the analogic inputs of the board IUD IUV IML 000 Blade tensioner Analogic input no 4 not used Head position potentiometer 010 000 PT TL ia4 048 Blade motor current List of IUD IUV card OUTPUTS Starting from the video page of the digital inputs press the key arrow up once to display the list of the outputs ...

Page 132: ...situations if there s absence of air a pressure switch inhibits all machine functions safeguarding safety of operator from residual risks If the visualised vale is 0 OFF it means that there s no pressure or that compressed air is discon nected ANALOGIC INPUT NO 4 ANALOGIC INPUT NO 4 Available for connecting optional instruments Machine alarms and emergencies The machine s M30 controller notifies t...

Page 133: ...ses and supply voltage of the blade motor Check the connections EMERGENCY BLADE STOPPED Displayed when the blade is jammed while cutting Press RESET EMERGENCY AIR PRESSURE It is displayed when the air pressure from the net work fails Press RESET EMERGENCY BLADE MOT I OVERC It is displayed when there is an overcurrent at the blade motor Press RESET EMERGENCY BLADE TENSION This message indicates a m...

Page 134: ... NOT DEFINED EMERGENCY ERROR CODE 07 SERIAL 485 FAILURE EMERGENCY ERROR CODE 07 SERIAL 422 FAILURE EMERGENCY ERROR CODE 08 UNSTABLE DIGITAL INPUTS EMERGENCY ERROR CODE 09 UNSTABLE BLADE ch0 MOT ABSORB ANAL INPUT EMERGENCY ERROR CODE 10 UNSTABLE HEAD ch1 POSIT P ANAL INPUT EMERGENCY ERROR CODE 11 UNSTABLE BLADE ch2 TENS ANALOGIC INPUT EMERGENCY ERROR CODE 12 UNSTABLE SPARE ch3 ANALOGIC INPUT EMERGE...

Page 135: ...t overloading abuse accident inadequate maintenance or unauthorized altering LiabilityorobligationonthepartofHyd Mech fordamages whethergeneral specialor fornegligence andexpressly including any incidental and consequential damages is hereby disclaimed Hyd Mech s obligation to repair or repla ce shall be the limit of its liability under this warranty and the sole and exclusive right and remedy of ...

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