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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ. 

 

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

 

TEL: +90 (212) 544-2518  FAX: +90 (212) 577-6557  www.temelsan.com   [email protected] 

 

Summary of Contents for DK 1500 LS

Page 1: ...DK 1500 LS PLC CONTROLLED VERTICAL BANDSAW MACHINE ...

Page 2: ...MEANINGS 6 5 GENERAL DESCRIPTION OF THE MACHINE 7 5 1 Description of the Machine 7 5 2 Expansion of the Model Name 7 5 3 List of Machine Models 7 5 4 Machine type and Specifications 8 5 4 1 Machine type DK 1500 LS 8 5 4 2 Machine specifications 8 6 Sample of Machine Name Plate 9 7 GENERAL PRINCIPLE OF OPERATION 10 8 PREREQUISITS OF TRANSPORTATION 11 8 1 Transportation style 11 8 2 Precautions 11 8...

Page 3: ... 12 9 2 INSTALLATION 13 9 3 OPERATIONAL INSTRUCTIONS 15 9 3 1 Operation of the Machine 15 10 TRAINING 16 11 SPARE PART LIST 16 12 SERVICE 16 13 PLANNED MAINTENANCE CHART 17 13 1 DAILY MAINTENANCE 17 13 2 WEEKLY MAINTENANCE 17 13 3 MONTHLY MAINTENANCE 17 13 4 BI ANNUAL MAINTENANCE 17 14 TROUBLESHOOTING 17 15 GUARANTEE CERTIFICATE 22 16 DECLARATION OF CONFORMITY Hata Yer işareti tanımlanmamış CONTRO...

Page 4: ...MANUAL HYDRAULIC VALVE 54 Given Tention to the bandsaw blade 54 Loosen Tension on bandsaw blade and change the blade 55 BLADE CHANGE INSTRUCTION 55 APPENDICES 55 Appendix 1 Exploded Views and Technical Representation of Parts or Main Units 56 FREE WHEEL AND SHAFT 56 MAIN BLADE MOTOR SHAFT 57 TENTION WHEEL AND SHAFT 58 RACK GUIDE POST 59 BLADE GUIDES 60 HYDRAULIC UNIT 61 TENSION VALVE 62 BALLSCREW ...

Page 5: ... filament winding method Temelsan as being family owned company and established in 1976 started the business with the production of vertical bandsaw machines which are used for accurate and mass production cutting in the business fields such as automotive aerospace household related etc Our own products Block Plate Cutting Vertical Bandsaw Machine DK 3500 Vertical Bandsaw Machines DK 400 series DK...

Page 6: ...rements Phase Neutr 240 V 50 Hz Phase Phase 400 V 50 Hz Attent that all the doors are closed while the machine is running 3 SAFETY STIPULATIONS Never do maintenance and repair work when the machine is energized Never step over the cables and the equipments Never remove or replace the covers with the non standardized one of electrical motors fans moving parts Never come close to the machine and nev...

Page 7: ...İ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com 4 SAFETY SIGNS ON THE MACHINE AND THEIR MEANINGS ATTENTION LIVE ELECTRICITY ATTENTION DANGER ...

Page 8: ...odel of the actual model S1 CE certified Some models without S1 designation might have CE certification whereas the ones with S1 designation certainly have 5 3 List of Machine Models The machines are classified according to the throat width and the types of accessories equipped as standard and produced DK 400 ÖZEL DK 400 01 EXPORT DK 400 01 DK 400 01 S1 DK 400 02 DK 400 03 DK 400 03 S1 DK 400 04 D...

Page 9: ...00 LS 5 4 2 Machine specifications Main Motor 7 5 kW Dimension of Table 800 x 1500 mm Cutting Height Over Table 1200 mm Throat Width 800 mm Cutting Speed 2 1000 mm min Servo Travel Stroke 1500 mm Equipment Configuration Providing the Speed Adjustment Frequency Invertor PLC Length of applicable bandsaw blade 6850 mm Width and wall thickness of applicable bandsaw blade 54x1 3 54x1 6 mm Height of the...

Page 10: ...MELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com 6 Sample of Machine Name Plate ...

Page 11: ...only The operatör places the metal workpiece on the table of the machine and fixes it with the vise s Turns the machine ON from the main switch By pressing the GREEN button initializes the rotation of bandsaw blade Adjusts the speed of rotation noticing the type and the hardness of the workpiece If the machine is equipped with a hydraulic table then the speed of the hydraulic table must also be ad...

Page 12: ... machine on the transporting vehicle firmly and tightened with ropes to eliminate possible bending and vibration during the journey b The height of the tunnels and the bridges along the travelling route must be taken into account It is very important especially for DK 3500 and above 8 4 Storing Conditions a Roof of the storing area must be closed b There must not be any contact with moisture water...

Page 13: ...544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com 9 INSTALLATION AND OPERATIONAL INSTRUCTIONS 9 1 UNLOADING Machine should be carried as below drawing Customer is fully responsible to provide necessary ropes Please check the rope hanging at below drawing Please remove both upper covers before you carry machine ...

Page 14: ...ed to the electrical panel of the machine To provide the cables to the electrical cabinet and to provide electricity are under customer s responsibility Electrical connections must be done by qualified electricians only The manufacturer will not be responsible if unauthorized and unexperienced electrical technician intervenes the machine The customer has the right to claim an authorized personnel ...

Page 15: ...g the bandsaw blade open the 3 of those covers in front side of the machine and loosen the bandsaw blade tightening shaft By pulling the loosened bandsaw blade towards yourself let it free from the wheels and the guides To install a new bandsaw blade follow the procedure in reverse direction and apply tightening pressure ATTENTION Before replacement of the bandsaw blade turn the machine off from t...

Page 16: ...ufacturer will support the customer Check the Appendix 1 to know about the control panel of the machine Steps of the operation 1 Depending of the height of workpiece adjust the inserts to the closest location to the workpiece 2 Choose the right teeth form for the bandsaw blade which will be used to cut the workpiece 3 Adjust the rotational speed and the speed of the Servo controlled table accordin...

Page 17: ...TYPE Q TY 1 MAIN MOTOR ELECTRICAL 1 2 HYDRAULIC MOTOR ELECTRICAL 1 3 BANDSAW INSERTS STEEL 2 4 FREE WHEEL CAST IRON 1 5 UPPER WHEEL CAST IRON 1 6 WHEEL OF GEAR CAST IRON 1 7 SERVO MOTOR ELECTRICAL 1 8 SERVO GEARBOX MECHANIC 1 9 HYDRAULIC TENTION UNIT MECHANIC 1 10 CONTROL MONITOR ELECTRONIC 1 12 SERVICE The necessary parts will be distributed by the manufacturer once the buyer claims during repair...

Page 18: ...ary 13 3 MONTHLY MAINTENANCE a Check the level of lubricant of hydraulic system If the level is not full then add the lubricant b Check the valves If oil is leaking replace them c Lubricate the bandsaw blade tensioning unit d Rack shaft should be lubricated 13 4 BI ANNUAL MAINTENANCE The initial oil of gear should be replaced after 300 hours of operation Then replace the oil of the gear bi annuall...

Page 19: ...sure block Replace if worn Adjust wheel alignment Allow 1 2 clearance before starting cut See Machine Operator s Manual Blade teeth inverted backwards Improper break in period Hard spots in material like scale Material work hardened check for hardness and adjust feed Improper cutting fluid or mixture Speed and feed too high Install blade correctly Reduce feeds and speeds during break in period in ...

Page 20: ... Reduce speed or pressure Check your cutting chart Check your coolant Incorrect feed and or speed Incorrect blade wrong pitch Saw guides not adjusted properly Check your cutting chart Check your cutting chart Adjust or replace saw guides Indexing out of sequence Material loose in vise Check for correct indexing sequence head rise Check hydraulic pressure Feed pressure too high Tooth lodged in cut ...

Page 21: ...ce feed pressure See your cutting chart Free pressure block and realign if worn replace never regrind Move arms close to work as possible Adjust wheel alignment Dull or damaged blade Incorrect feed and or speed Lack of band support Insufficient band tension Incorrect pitch blade Replace with proper blade Check your cutting chart Adjust until noise disappears Set guide arm properly close to work as...

Page 22: ...o tight Work not held firmly Incorrect or lack of cutting fluid Check table and Operator s manual for correct blade width Check for correct blade tension Check your cutting chart Check your coolant Incorrect blade Incorrect feed or speed Improper or lack of cutting fluid Check your cutting chart Check your cutting chart Check your coolant Material loose in vise Incorrect blade wrong pitch Check hy...

Page 23: ...e warranty period if the problem originates from the production of the machine itself 2 If the machine gets broken or malfunctions due to the mis shipment loading unloading the warranty voids immediately 3 If the machine gets broken or malfunctions due to the natural disaster the warranty voids immediately 4 If the machine gets broken or malfunctions due to operator s own fault the warranty voids ...

Page 24: ...P a g e 23 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com ...

Page 25: ...tical saw machine Interface was designed do not be using accept permitted users By this before you start to work with machine you have to enter your user name and password This is important to do other case machine will not be activated On begining you have to select your language to start to work In two seconds if you not select your language the page automaticly will pass to the user login page ...

Page 26: ...AX 90 212 577 6557 www temelsan com temelsan temelsan com USER LOGIN AND LOGOUT The operators should enter the user name and passwords Machine is comes with some user name and settings Please check the passwords and user names below User Name Password Description 1 OP1 1 Operator 2 OP2 2 Operator 3 OP3 3 Operator 4 SERVIS 1234 Maintenance ...

Page 27: ... page 2 Main Page Button If you need to change the language you can pass on first page 3 Login Button After you text your user name OP1 OP2 OP3 or SERVIS and passwords you have to click on login button to be able using the machine 4 Wrong Login Tracking Button The every users can use this to see who get use the wrong id or password to get in to system 5 Report Button Maintenance users after the si...

Page 28: ...art to work with machine User should click the home button to choise the operation 7 Logout Button After user finish the duty to keep machine ready for next user has to click the logout button Also this is needed to be used always to have a proper working hour tracking 8 Take Report Button This button can be used just in case of maintenance or more authorized user IMPORTANT NOTE When operator is f...

Page 29: ...tton open manual usage page of the machine 12 Operator Tracking Button The button open the user tracking page On this page you can feed the operators real name By the reports operator real names will not appear but on using the machine that will appear on name tag Also you can see the working hours life of machine on same page 13 Working Page Button This button open the automatic working page of D...

Page 30: ... on Authorized user Its generally motor settings of the machine can be changed In case users change the motor they are able to change spesification of motors 17 Passport Configuration Button This button has different function on different users The button will appear on each user but the maintenance user will be able to use it only 18 I O Tracking Button This button will open the input and output ...

Page 31: ... motor 22 Table Front Move Button This button can move manually tablet by your speed adjustment 23 Blade Motor Speed Set Button This button allow you to set the speed of the bandsaw blade motor 24 Table Speed Set button This button allow you the set the speed of table on manual move 25 Table Back Move Button This button can move manually tablet by your speed adjustment 26 Motor Stop Button This bu...

Page 32: ...indicator show the Blade motor current usage 30 Digital Indicator of Table Servo Speed This indicator show the Servo motor speed of table 31 Digital Indicator of Table Speed This indicator show the table speed 32 Table Speed This indicator show the table speed 33 Service and Blade Change Button While machine is on 0 mode at the control panel user should click this button 3 second to turn on the hy...

Page 33: ...on switch on the chips cleanning motor 36 Working Area Light Button While the light off the button will stay on off position and when user will turn it on by touch its will move to on 37 Hydraulic Motor Stop Button This button switch off the hydraulic motor to lose tention on the bandsaw blade 38 Chips Motor Stop Button This button switch of the chips cleanning motor 39 Cutting Line Laser Light Bu...

Page 34: ...users to change the users passwords and delete the user this user is autohized to change the name of operators or to take reports from the machine about users usage The indication of users usage times for the machine will stay until taken report to USB stick When maintenance user get the reports all working times of operators will be cleared The maintenance user should signed in to system with the...

Page 35: ...rking page while operator is active 45 Save Button Maintenance user is able to use this button Before click this button be sure that USB stick is plugged on control panel 46 User Usage Indication Area Maintenance user can control the users current usage of the machine by this screen 47 Status Indication This place will be turned the orange while reports are passing to USB stick While its complated...

Page 36: ...o new datas inside will change from gray to green that means there is new datas are in memory 49 Export CSV Button This button do transaction of memories to the USB stick which is plugged to the control panel USB socket While transaction is on the Status area NUMBER 47 will keep on orange color While the transaction is completed color will change to green In case there is a red color appear there ...

Page 37: ...ser which will be updated Maintenance user is just available to do changes on users which has Access level less then 50 51 Add User Button Maintenance user can add the user with this button We as a producer company we not advise to remove some user from the list In needs to add a new user please following instuction Select Group Click the user name tag to feed new name Write password for this user...

Page 38: ... the password once again Click the Password update button 53 Delete User Button The maintenance user is able to delete the users from the list which is exist We as a producer company we not advise to remove some user from the list In case needed to be deleted please follow the instruction to delete the user Select Group Select User Write the existing password for the user will be deleted Write the...

Page 39: ... I O tracking in DK 1500 LS machine has two pages Page 1 Input Controls I O input tracking system has function control of following inputs Emergency stop button Blade motor start button Blue reset button Blade motor stop button Manual Hydraulic pump start button Manual hydraulic pump stop button Table manual front move button Table manual back move button Manual table selection button Auto table s...

Page 40: ...AX 90 212 577 6557 www temelsan com temelsan temelsan com Rack up button Rack down button Door switch 1 Door switch 2 Door switch 3 Door switch 4 Door switch 5 Door switch 6 Rack up limit switch Rack down limit switch Table front limit switch Table back limit switch Blade breake switch Hydraulic motor thermic error Rack motor termic error ...

Page 41: ...melsan temelsan com Page 2 Output and safety controls I O output tracking system has function control of following outputs Green light on traffic lights Yellow light on traffic lights Red light on traffic lights Chips cleaning motor has started Hydraulic motor has started Rack moving down Rack moving up Laser light is active Lighting is active Blue reset button is not pressed ...

Page 42: ...hsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com Also tracking system is given some more safety controls as its below Output OK Channel 1 Channel 2 Start K1 K2 S1 S2 S4 ENABLE RESET ...

Page 43: ...users can change their name by theirself 57 Working Time Indicator This indicator show total working time of the machine 58 Users Usage Times This indicator shown users how long they use the machin 59 Cleaning Buttons Cleaning buttons are getting visiable just on maintenance user login Also maintenance user is able to use button 8 Take Report Button to download or clean the histories on this page ...

Page 44: ...ble Speed Manual table speed can be adjusted to move the table with manual rapid speed speed using buttons 22 and 25 62 Automatic Table speed Automatic table speed also can be adjusted and this value is also named as a cutting speed too 63 Actual Position Indicator This indicator shows the actual position of table 64 Actual Blade Speed Indicator This indicator shows the actual speed of main motor ...

Page 45: ... button has few functions to get on while its clicked By clicking button machine first start the hydraulic pump to make a tention on blade before starting to cut starting the chips cleaning motor then the bandsaw blade motor is starting to turn By this cutting is starting by users adjustment of cutting length on the button 60 69 Stop Cutting Button By clicking this button can pause or stop the cut...

Page 46: ... 90 212 577 6557 www temelsan com temelsan temelsan com 73 Alarm Warning Log Sheet Users can check this page in case of alarm The alarm list also will be reported to the authorized user such a maintenance and Temelsan users 74 Reset Button Error Indicator In case the red light is blink means the reset button should be pressed 74 75 76 73 77 ...

Page 47: ...user to reset the alarm Button usage instruction is below Read the alarm Look at the page To see how to solve the problem Solve the problem Click Alarm Reset button Click the Home button to back on operation 76 Door Switch Indicator Button While user see any of door switch alarm on log can click this button to see exactly which door is opened As its shows on below Picture the opened door red light...

Page 48: ...t 10 second to open it again HYDRAULIC MOTOR THERMIC ERROR Hydraulic pump motor has too high temperature on please check the wiring and be sure that the motor wires connected and tithed well HYDRAULIC LOW PRESSURE PRESSURE SW Look at the I O tracking if hydraulic pump motor is working If not work please contact the producer company to replace the motor In case motor work well please check the pump...

Page 49: ...e producer company to solve your problem online If no then replace the switch with the new one DOOR SWITCH 4 OPENED Click on door switch indicator button to see which door is opened Close the door In case door is closed please check the switch on the door is it in function or no If yes then contact the producer company to solve your problem online If no then replace the switch with the new one DOO...

Page 50: ...motor wires connected and tithed well RACK UPPER LIMIT REACHED Maximum Guide heigh which is connected to the rack is 1230m from table In case the guide reach this point user should turn the switch on control panel to manual usage of machine then to move the rack down from control panel or from manual usage page on screen TABLE BACK LIMIT REACHED DRIVE FRONT MANUAL Maximum table move is 1600mm In c...

Page 51: ...under warrant to replace the necessary parts directly BLADE IS BROKEN PLEASE CHANGE THE BLADE In case this alarm is active there can be two issues on First issue is blade is broken so the free Wheel cant turn Second issue is hydraulic pump is not in function INVERTER ERROR Please switch off the machine from main switch keep waiting 5 minute then turn it on again In case problem is exist please con...

Page 52: ...an temelsan com HYDRAULIC OIL TEMPERATURE LOW ALARM Hydraulic oil temperature can give this alarm in case oil level is too less Please feed the Nr 46 hydraulic oil on tank then continue to work HYDRAULIC OIL TEMPERATURE HIGH ALARM Hydraulic oil temperature switch can give this alarm in case of oil temperature is reach the maximum setting as its setted on DK 1500 LS at 100 degree ...

Page 53: ... 34 on screen 79 Bandsaw Blade Motor Manual Start Button This button has same fucntion as button 21 on screen 80 Bandsaw Blade Motor Manual Stop Button This button has same fucntion as button 26 on screen 81 Hydraulic Motor Manual Stop Button This button has same function as button 37 on screen 82 Table Manual Front Move Button This button has same function as button 22 on screen 83 Table Manual B...

Page 54: ... using the machine on automatic mode just to turn this switch on service mode the machine will stop work In case machine is on cutting cycle this kind of moves can damage blade on the machine Also its possible to take the PLC on protection positon 85 Rack Manual Down Button This button has same function as button 41 on screen 86 Emergency Stop Button 87 Blue Restart Button While user switch on the...

Page 55: ...under the door of free wheel The valve can be used for two operation Given Tention to the bandsaw blade Before machine is start to work the valve should be on most lover position to open the pressure line for tention piston Other case screen will show the alarms about it Before running the machine be sure that the tention valve is on right position as its shows below picture When hydraulic pump st...

Page 56: ...nual buttons until end of back limit swich in case there is a material on the table do not move the material from table keep moving the table material on Turn Mode switch to 0 Zero from control panel Open the necessaty doors of the machine Press hydraulic motor start button 3 second keep pressed on manual usage page Move the tention valve on clockwise till end and left it there Remove the blade Re...

Page 57: ...Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com Appendix 1 Exploded Views and Technical Representation of Parts or Main Units FREE WHEEL AND SHAFT ...

Page 58: ...57 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com MAIN BLADE MOTOR SHAFT ...

Page 59: ...8 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com TENTION WHEEL AND SHAFT ...

Page 60: ... e 59 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com RACK GUIDE POST ...

Page 61: ... g e 60 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com BLADE GUIDES ...

Page 62: ...g e 61 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com HYDRAULIC UNIT ...

Page 63: ...g e 62 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com TENSION VALVE ...

Page 64: ... TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com BALLSCREW AND SERVO MOTOR ...

Page 65: ...P a g e 64 TEMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com ...

Page 66: ...EMELSAN MAKİNA SAN VE TİC LTD ŞTİ Akçaburgaz Mah Muhsin Yazıcıoğlu Cad No 55 1 Esenyurt İstanbul TÜRKİYE TEL 90 212 544 2518 FAX 90 212 577 6557 www temelsan com temelsan temelsan com Appendix 2 Electrical Diagrams ...

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