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Страница 1: ...COSEN SAWS SH 1000F Semi Automatic Double Column Canted Frame Straight Cutting Bandsaw Non CE Model Instruction Manual The Pinnacle of Cutting Performance Cosen Mechatronics Co Ltd ...

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Страница 3: ...04 943 1031 web www cosensaws com For China email service cosensaws cn phone 86 152 50127815 web www cosensaws cn Instruction Manual SH 1000F Semi Automatic Double Column Canted Frame Straight Cutting Bandsaw Non CE Model Ver 7 2017 12 26 2013 by COSEN MECHATRONICS CO LTD No part of this publication may be photocopied or otherwise reproduced without the prior written permission of COSEN Printed in...

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Страница 5: ...our hands clothing or gloves are caught by the running blade Make sure any use of fire is prohibited in the shop and install a fire extinguisher or other fire control device near the machine when cutting titanium magnesium or any other material that produces flammable chips Never leave the machine unattended when cutting flammable materials Use a water soluble cutting fluid on this machine Oil bas...

Страница 6: ...ce has been clamped firmly If the workpiece is not securely clamped it will be forced out of the vise during cutting Take preventive measures when cutting thin or short pieces from the work to keep them from falling It is dangerous if the cut pieces fall Use roller tables at the front and rear sides of the machine when cutting long work It is dangerous if the work piece falls off the machine Turn ...

Страница 7: ...ification 2 3 Floor Plan 2 4 Section 3 Moving Installation 3 1 Location Environment 3 1 Unpacking Inspecting 3 2 Lifting 3 3 Illustration Lifting Points 3 4 Removing Shipping Bracket 3 6 Cleaning 3 6 Installing 3 6 Supplying Hydraulic Oil 3 6 Supplying Coolant 3 7 Connecting Electric Power 3 7 Leveling 3 8 Anchoring the Machine 3 9 Installing Roller Table Optional 3 9 Installing Fire Control Devic...

Страница 8: ...rminating a Cutting Operation 4 17 Section 5 Electrical System 5 1 Electrical Circuit Diagrams 5 1 Section 6 Hydraulic System 6 1 Hydraulic Diagrams 6 1 Section 7 Bandsaw Cutting A Practical Guide 7 1 Introduction 7 1 Saw Blade Selection 7 2 VISE LOADING 7 3 BladeBreak In 7 3 Section 8 Maintenance Service 8 1 Introduction 8 1 Basic Maintenance 8 1 Maintenance Schedule 8 1 Before Beginning a Day s ...

Страница 9: ...neral Troubles Solutions 9 2 Minor Troubles Solutions 9 3 Motor Troubles Solutions 9 3 Blade Troubles Solutions 9 4 Sawing Problems Solutions 9 5 Re Adjusting the Roller Table 9 12 Section 10 Parts 10 1 Spare Parts Recommendations 10 1 Part List 10 2 Section 11 Warranty 11 1 Warranty 11 1 ...

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Страница 11: ...he machine or part of its functions These important safety instructions do not cover all possible situations that might occur It is your responsibility to take caution and follow procedures stated in this manual when installing maintaining and operating your machine Cosen will not be liable for damages resulting from improper use SAFETY INSTRUCTIONS What the icons and signs in this user manual mea...

Страница 12: ...rate while under the influence of drugs alcohol or medication All users must read it before performing any activity on the machine such as replacing the saw band or doing regular maintenance Some personal protective equipment is required for the safe use of the machine e g protection goggles Keep blade protection cover and wheel covers in place and in working order Use recommended accessories Impr...

Страница 13: ... safeguard devices under any circumstances except when servicing the machine Even skilled service technicians should still take cautions when performing repairs or service on the machine with any of these protectors removed It is the responsibility of the user to make sure all these elements are not lost and damaged Take note of the following main moving parts on the machine prior to and during ma...

Страница 14: ...o assure that the machine will stop whenever the wheel covers are open This device is to protect users from being cut by the running saw blades Among all these safety switches some of them are used to protect the users and some of them are used to prevent damage to saw blades the workpiece and the machine itself etc We have taken every precaution to prevent injury or damage and to provide safe and...

Страница 15: ...1 5 Illustration Emergency Stop Emergency Stop Button ...

Страница 16: ...jury The arrow indicates direction of the blade WARNING Labels An orange and black WARNING label marks hazards or unsafe practices that can result in severe personal injury or damage to the machine Label Meaning Label Meaning Cutting Hazard KEEP COVER CLOSED while the blade is running Turn power off before opening cover Failure to follow the warning can result in severe injury Cutting Hazard KEEP ...

Страница 17: ...ades or adjusting wire brush NOTICE Labels Blue and white NOTICE labels mean unsafe practices that could result in damage to products or property Label Meaning Replace the hydraulic oil every six months or every 1 200 hours of operation Oil specification Shell TELLUS 27 or Mobil DTE OIL LIGHT HYDRAULIC 28 To extend blade life always adjust the location of wire brush so that it is properly touching...

Страница 18: ...wear gloves neckties jewelry or loose clothing while operating the machine 3 Always wear eye protection goggles 4 Check blade tension and adjust blade guide before starting to cut 5 Always clamp stock firmly in place before cutting 6 Do not remove jammed or cut off pieces until blade has stopped 7 Keep fingers out of path of blade 8 Blade guards should be in place and used at all times 9 Disconnec...

Страница 19: ...1 9 Illustration Safety Labels ...

Страница 20: ... interface problem that may make people feel uncomfortable Our products pass noise testing less than 78 dBA If your machine produces an undesirable noise while it is running you should 1 Make sure all maintenance tasks have been performed following the prescribed maintenance schedule Refer to Section 8 2 If maintenance does not seem to solve the problem follow the troubleshooting procedures under ...

Страница 21: ...tically when the saw blade is broken protecting both the operator and the machine Convenience High Performance The machine is designed in the way that the operation and adjustment can be easily performed The machine will stop automatically when out of stock Dual valve system is designed to achieve optimal cutting performance with the simple setting of feed rate and perspective cutting pressure for...

Страница 22: ... in Tension Hydraulic with automatic blade breakage detection Guide Interchangeable tungsten carbide Cleaning Steel wire brush Motor Output Saw Blade 10 HP 7 5 kW Hydraulic 2 HP 1 5 kW Coolant Pump 1 4 HP 0 18 kW Tank Capacity Hydraulic 75 L 18 8 gal Coolant 120 L 30 gal Workbed Height 650 mm 25 6 in Weight Net 5 200 kg 11 440 lb Gross 5 600 kg 12 320 lb Floor Space L x W x H 1 380 x 3 800 x 2 600...

Страница 23: ...ARTS IDENTIFICATION Machine front view Double Column Front Vise Cylinder Electrical Compartment Front Vise Blade Guide Arm Wire Brush Assembly Drive Wheel Cross Link Control Panel with Dual Control Valves Idle Wheel ...

Страница 24: ...2 4 FLOOR PLAN Machine top view Machine front view ...

Страница 25: ... to Section 2 General Information for machine dimensions and floor space Environment Well lighted 500 lumen at minimum Floor kept dry at all times in order to prevent operators from slipping Away from direct exposure to the sunlight Room temperature between 5 C to 40 C Humidity level kept at 30 95 without condensation to avoid dew on electric installation and machine Away from vibration of other m...

Страница 26: ...attention to machine surface equipments furnished and the electrical and hydraulic systems for damaged cords hoses and fluid leaks In the event of damage caused during shipping please contact your dealer and consult about filing a damage claim with the carrier Your machine comes in with a set of tools for you to maintain the machine The accessories furnished are as follows 1 Tool box 1 pc 2 Grease...

Страница 27: ...o perform the job You must use tools and equipment with the proper tensile strength and use proper method when moving your machine Apply the wire rope sling to the lifting hooks on the four ends of the machine Refer to Illustration Lifting Points for exact locations Slowly lift the machine Be sure to protect the machine from impact or shock during this procedure Also watch out your own fingers and...

Страница 28: ...3 4 Illustration Lifting Points Machine top view Minimum weight capacity for each wire rope 6 ton Total number of wire ropes required 6 ...

Страница 29: ...lified forklift operator to perform the job You must apply proper forklift technique to avoid damage to the machine Make sure the forks are able to reach in at least 2 3 of the machine depth You must keep the machine balanced at all times Make sure the forks are centered before use Illustration only Please follow user guide of your forklift 3 Use rolling cylinders You can use rolling cylinders to ...

Страница 30: ... to machine surfaces that are prone to rust Do not remove the rust preventive grease with a metal scraper and do not wipe the painted surfaces with solvent as doing so would damage surface paint INSTALLING Cosen s bandsaw machine is relatively easy to install Follow these six easy steps to install your machine Supplying hydraulic oil Open the filler cap and fill the hydraulic oil tank to above 2 3...

Страница 31: ...ve a qualified electrician make the electrical connections If the power supply voltage is different from the transformer and motor connection voltage shown on the label attached to the electrical compartment of the machine contact COSEN or your agent immediately Connect to power supply independently and directly Avoid using the same power supply with electric spark machines such as electric welder...

Страница 32: ...g area is clear of any objects Start the blade and check the blade rotation If the electrical connections are made correctly the blade should run in a counterclockwise direction If not shut the hydraulics off turn off the machine as well as the shop circuit breaker Then swap the power the power cable conductors connected to R and T terminals 10 Repeat step 6 to 9 to ensure the electrical connectio...

Страница 33: ...ling bolts Installing Fire Control Device Install a fire extinguisher or any other fire control device in the shop in case a fire breaks out RELOCATING We recommend you follow these procedures when relocating or shipping your machine to other place 1 Descend the saw frame to its lowest position then turn off the power 2 Fix the saw frame using the shipping bracket that originally came with the mac...

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Страница 35: ...ORIES OPTIONAL ACCESSORIES UNROLLING INSTALLING THE BLADE ADJUSTING WIRE BRUSH ADJUSTING COOLANT FLOW ADJUSTING SAW ARM ADJUSTING BLADE SPEED TEST RUNNING THE MACHINE BREAKING IN THE BLADE PLACING WORKPIECE ONTO WORKBED POSITIONING WORKPIECE FOR CUTTING CUTTING OPERATION TERMINATING A CUTTING OPERATION ...

Страница 36: ...material in place before cutting long workpieces Always make sure the material is clamped firmly in place before starting to cut Do not remove jammed or cut off pieces until the blade has come to a full stop Keep fingers away from the path of the blade Protection devices should be in place at all times For your own safety never remove these devices Disconnect machine from the power source before m...

Страница 37: ...he material is flammable Never take your eyes off the machine while in operation Cutting fluid For cooling and lubrication purpose we recommend you use water soluble cutting fluids The following table lists out its pros and cons for your reference Pro Con Have a high cooling effect Not flammable Economical Does not require cleaning of the cut products Remove machine paint Lose its rust protection ...

Страница 38: ...utton 2 Hydraulic start button with built in lamp 12 Guide arm left right switch 3 Blade start button with built in lamp 13 Lift rollers up down switch 4 Emergency stop button 14 Vise open clamp switch 5 Blade speed indicator 15 Carbide inserts clamp unclamp switch 6 Blade speed control knob 16 Lift rollers feed backward button 7 Saw bow up button 17 Lift rollers feed forward button 8 Saw bow down...

Страница 39: ...escend pressure and speed control panel The blade motor will not start when the the saw bow is at the lower limit position The vise open clamp switch must be turned to the right to clamp position and held for 2 seconds before the blade can start running While pressing the saw bow up button can stop the running blade please still use the emergency stop button in an emergency 4 Emergency stop button...

Страница 40: ...as to be triggered for the blade to start Flip the switch to the left to turn off this function This function is not available for material with width less than 400mm Before cutting the material with width less than 400mm please turn off guide arm and vise sync function and manually adjust the guide arm position according to the scale on top of the sliding board Be sure that the guide arm will not...

Страница 41: ...old the switch for 2 seconds and let it go the vise will automatically close until it is fully clamped Turn the switch to the left to unclamp the vise For the blade to start running this switch must be turned to the right and held for 2 seconds as to ensure the vise is fully clamped When the saw bow is below the middle limit position vise can only move in the jog mode to prevent the vise from hitt...

Страница 42: ...el is where cutting pressure and saw blade descend speed can be adjusted Cutting pressure and speed control panel 1 Cutting pressure control knob This pressure control knob is used to adjust the cutting pressure of the blade Turning the knob clockwise increases the cutting pressure To obtain a good cutting result choose the right cutting pressure by turning the knob until it points to your materia...

Страница 43: ...eventing 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 electrical compartment It is used to control and stabilize the saw blade speed during cutting To adjust blade speed use the blade speed control knob on the control panel Note 1 Make sure the...

Страница 44: ... both sides of the blade maximizing stability and cutting precision Gear reducer The specially designed gear reducer can work toward your preset blade speed and torque Please refer to Section 8 for information on maintenance Coolant pump When the hydraulic system is turned on the coolant pump can be operated individually from the control panel Coolant can be used to wash off chips as well as provi...

Страница 45: ...ar maintenance remove the chip conveyor and clean all chip deposits inside Hydraulic top clamp The top clamp device is installed on top of the cross link before executing bundle cutting To use the top clamp open the flow control valve so that top clamp can move in synchronization with the vise Note the allowable clamping width and height Refer to Section 2 General Information Specifications 2M rol...

Страница 46: ...Select the most suitable saw blade for your workpiece considering the size shape and material Step 2 Turn on the machine power by switching to ON and turn on the hydraulic system Step 3 Press the saw bow up button and elevate the saw bow until it reaches to its highest point Step 4 Turn the tension controller handle from to position to release tension The idle wheel will then move slightly toward ...

Страница 47: ...drive wheel Step 12 Make sure the back of the blade is also pressed against the flange of the idle wheel Step 13 Turn the tension controller handle to position to obtain blade tension Step 14 Make sure the sides of the blade are in close contact with the carbide inserts and then tighten the left and right carbide inserts by flipping the carbide inserts switch up Step 15 Gently close the idle and d...

Страница 48: ...Proper Improper ADJUSTING COOLANT FLOW Step 1 Press the saw blade start button to start the saw blade drive motor Step 2 Press the saw bow down button to lower the saw bow Step 3 Use the flow control valve shown below to adjust the amount of fluid flowing to the cutting area Adjust the flow amount if you observe the following changes to the chips generated from cutting If the chips are sharp and c...

Страница 49: ...ntrol knob to adjust the blade speed The blade speed should be adjusted based on the size and the material of the workpiece TEST RUNNING THE MACHINE Test running this machine can ensure good machine performance in the future We suggest you run the following tests on the machine before first use Testing machine performance Turn on the power and run a basic performance test after you finish installi...

Страница 50: ...orkpiece Step Action lift the rollers up 1 Turn and hold the lift rollers up down switch to the right to lift up the rollers turn on the projection light 2 Press the projection light on button A beam of light will be projected on the workpiece for alignment rough position 3 Press the lift rollers feed forward button until the cutoff point on the workpiece almost aligns with the blade line confirm ...

Страница 51: ...cutting pressure according to the material Step 6 Adjust blade descend speed control knob to obtain a suitable blade descend speed for your material Step 7 Start running the blade Before you start cutting check again that there is no other object in the cutting area Step 8 While the blade descends adjust the blade speed if necessary You can do so by turning the blade speed control knob clockwise t...

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Страница 53: ... SYSTEM ELECTRICAL CIRCUIT DIAGRAMS The following are electrical circuit diagrams of the system Non CE model Fig 5 1 Control Panel Layout Fig 5 2 Circuit Board Layout Fig 5 3 Power Supply Layout Fig 5 4 PLC Input Output Layout ...

Страница 54: ...5 2 Fig 5 1 Control Panel Layout ...

Страница 55: ...5 3 Fig 5 2 Circuit Board Layout ...

Страница 56: ...5 4 Fig 5 3 Power Supply Layout ...

Страница 57: ...5 5 Fig 5 4 PLC Input Output Layout ...

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Страница 59: ...6 1 Section 6 HYDRAULIC SYSTEM HYDRAULIC CIRCUIT DIAGRAM ...

Страница 60: ...6 2 ...

Страница 61: ...7 1 Section 7 BANDSAW CUTTING A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION VISE LOADING BladeBreak In SOLUTIONS TO SAWING PROBLEMS ...

Страница 62: ...nds for the minimum tooth distance in the toothing interval Constant Variable Min Max 4 Set The bending of teeth to right or left to allow clearance of the back of the blade through the cut 5 Width The nominal dimension of a saw blade as measured from the tip of the tooth to the back of the band 6 Thickness The dimension from side to side on the blade 7 Gullet The curved area at the base of the to...

Страница 63: ...blade from binding in the cut It may be either a regular set also called a raker set or a wavy set The regular or raker set is most common and consists of a pattern of one tooth to the left one tooth to the right and one which is straight or unset This type of set is generally used where the material to be cut is uniform in size and for contour cutting Wavy set has groups of teeth set alternately ...

Страница 64: ...band speed for the material to be cut 2 Reduce the feed force rate to achieve a cutting rate 20 to 50 of normal soft materials require a larger feed rate reduction than harder materials 3 Begin the first cut at the reduced rate Make sure the teeth are forming a chip Small adjustments to the band speed may be made in the event of excessive noise vibration During the first cut increase feed rate for...

Страница 65: ...aily maintenance usually takes just a little time but will give remarkable results for the efficient and proper operation of cutting BASIC MAINTENANCE It is always easy and takes just a little effort to do the basic maintenance But it always turns out to be a very essential process to assure the long life and efficient operation of the machine Most of the basic maintenance requires the operator to...

Страница 66: ...e wire brush if it is worn out After ending a day s work Please remove saw chips and clean the machine with discharging the cutting fluid when work has been completed Do not discharge cutting fluid while the saw blade is operating because it will cause severe injury on operator s hand Be sure the saw blade is fully stop it will be performed after working inspection Every month Please apply grease ...

Страница 67: ...emperature 5 40 3 Relative humidity 30 95 without condensation 4 Atmosphere use a plastic canvas to cover machine to avoid excessive dust acid fume corrosive gases and salt 5 Avoid exposing to direct sunlight or heat rays which can change the environmental temperature 6 Avoid exposing to abnormal vibration 7 Must be connected to earth TERMINATING THE USE OF THE MACHINE Waste disposal When your mac...

Страница 68: ... of using Change it every year Regularly Omala oil HD220 Mobil Gear 630 Hydraulic system Inspect half a year Change oil every year Regularly Shell Tellus 32 Mobil DTE oil Light Hydraulic 24 Bearing Inserts Oil with lubricant but not excess Daily Shell R2 Band wheel Oil with lubricant but not excess Weekly Cylinder Oil with lubricant but not excess 6 Monthly Wire brush Oil with lubricant but not ex...

Страница 69: ... disable the machine from operating Generally speaking the system troubles in this machine model can be classified into three types namely GENERAL TROUBLES MOTOR TROUBLES and BLADE TROUBLES Although you may have other troubles which can not be recognized in advance such as malfunctions due to the limited life span of mechanical electric or hydraulic parts of the machine We have accumulated enough ...

Страница 70: ...er to Operating Instructions Adjusting Feed Excessive blade speed Refer to Operating Instructions Speed Selection Improper blade selection Refer to Operating Instructions Blade Selection Cannot make square cut Dull blade Replace blade Guide rollers not adjusted properly Refer to Adjustments Rear vise jaw not adjusted properly Set fixed vise jaw 90 to blade Excessive head pressure Reduce head press...

Страница 71: ... Install correct fuses or circuit breakers Motor fail to develop full power Power output of motor decreases rapidly with decrease in voltage at motor terminals Power line overloaded with lights appliances and other motors Reduce the load on the power line Undersize wires or circuit too long Increase wire sizes or reduce length of wiring General overloading of power company s facilities Request a v...

Страница 72: ...n drive wheel while cutting Wheels out of line Adjust wheels Blade line Run out or Run in Guides out of line For a straight and true cut realign guides check bearings for wear Excessive pressure Conservative pressure assures long blade life and clean straight cuts Support of blade insufficient Move saw guides as close to work as possible Material not properly secured in vise Clamp material in vise...

Страница 73: ...lamped workpiece Check and correct Excessively hard material surface Soften material surface Excessive cutting rate Reduce cutting rate Non annealed workpiece Replace with suitable workpiece Insufficient or lean cutting fluid Add fluid or replace Vibration near machine Relocate machine Non water soluble cutting fluid used Replace Air in cylinder Bleed air Broken back up roller Replace Use of non s...

Страница 74: ...h Material 18 Used Band Is Long On The Tooth Edge 9 Discolored Tips Of Teeth Due To Excessive Frictional Heat 19 Used Band Is Short On The Tooth Edge 10 Heavy Wear On Both Sides Of Band 20 Broken Band Shows A Twist In Band Length 1 Heavy Even Wear On Tips and Corners Of Teeth Probable Cause A Improper break in procedure B Excessive band speed for the type of material being cut This generates a hig...

Страница 75: ...eless wheel B Loose or improperly positioned side guides C Blade not perpendicular to cut D Blade rubbing against cut surface on return stroke of machine head E The teeth rubbing against a part of machine such as chip brush assembly guards etc 4 Chipped Or Broken Teeth Probable Cause A Improper break in procedure B Improper blade selection for application C Handling damage due to improper opening ...

Страница 76: ...y positioned chip brush C Excessive feeding rate or feed pressure D Movement or vibration of material being cut E Improper tooth pitch for cross sectional size of material being cut F Improper positioning of material being cut G Insufficient sawing fluid due to inadequate supply improper ratio and or improper application H Hard spots in material being cut I Band speed too slow for grade of materia...

Страница 77: ...y improper ratio and or improper application B Excessive band speed C Improper feeding rate D Band installed backwards 10 Heavy Wear On Both Sides Of Band Probable Cause A Chipped or broken side guides B Side guide adjustment may be too tight C Insufficient flow of sawing fluid through the side guides D Insufficient sawing fluid due to inadequate supply improper ratio and or improper application 1...

Страница 78: ...tt weld breaks See Observations 5 15 and 16 14 Heavy Wear In Only The Smallest Gullets Probable Cause A Excessive feeding rate B Too slow of band speed C Using too fine of a tooth pitch for the size of material being cut 15 Body Breaking Fracture Traveling In An Angular Direction Probable Cause A An excessive twist type of stress existed B Guide arms spread to capacity causing excessive twist from...

Страница 79: ... or short 19 on tooth edge C Cutting a tight radius 18 Used Band Is Long On The Tooth Edge Probable Cause A Side guides are too tight rubbing near gullets B Excessive preload band riding heavily against back up guides C Worn band wheels causing uneven tension D Excessive feeding rate E Guide arms are spread to maximum capacity F Improper band tracking back edge rubbing heavy on wheel flange 19 Use...

Страница 80: ...adjust TOOL measuring Measurement Horizontal balance Procedure 1 Screw or loosen the adjusting bolt to attain the horizontal balance leveling between the roller table and the machine frame 2 Ensure that the machine frame is not struck by the loaded material on the feeding table 3 Check the leveling by the measuring tool 4 After finished the adjusting fix the roller table If the feeding table and t...

Страница 81: ...lowing table lists the common spare parts we suggest you purchase in advance Part Name Part Name Saw blade Coolant tank filter Wire brush Steel plates Carbide inserts Rollers Bearings Belt Hydraulic tank leak proof gasket Duster seal Rubber washer Oil seal O ring Snap ring Drive wheel Idle wheel ...

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Страница 101: ...d normally acceptable practices This warranty does not apply if the machine has been altered or modified without our prior written consent In the case of components or units purchased by Seller including work holding devices tool holders motors and controls the warranty shall not exceed that received by Seller from the supplier of such components or units Seller will not assume responsibility for ...

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Страница 104: ...Vertical Plate Saws Horizontal Billet Saws NC CNC Band Saws Structural Miter Cutting Saws Automatic Band Saws Visit our website at www cosen com COSEN MECHATRONICS CO LTD ...

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