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‐

SAFETY

LABELS

Please

read

through

and

understand

these

safety

labels

before

operating

the

machine.

Refer

Illustration:

Safety

Labels.

Label

Meaning

Label

Meaning

Impact

Hazard

WEAR

SAFETY

SHOES.

not

approach

dropping

area

during

operation.

Read

Operator’s

Manual

This

manual

has

important

safety

information.

Read

through

carefully

before

operating

this

machine

prevent

personal

injury

machine

damage.

Keep

Unauthorized

Personnel

Away

not

step.

not

stand

the

machine

the

accessories!

DANGER:

Running

Blade

runs

through

this

area.

Keep

your

hands

away

from

running

blade

avoid

severe

injury.

The

arrow

indicates

direction

the

blade.

Cutting

Hazard

KEEP

COVER

CLOSED

KEEP

HAND

OFF

while

the

blade

running.

Turn

power

off

before

opening

cover.

Failure

the

warning

can

result

severe

injury.

Hazardous

Voltage

TURN

POWER

OFF

before

servicing.

Failure

following

the

warning

can

result

severe

injury.

Burn

Hazard/Hot

Surface

Hand

Crush/Force

from

Above

Crush

hazard

vise

Loose

Hand

Hazard

KEEP

HAND

OFF.

not

touch

chip

conveyor.

Failure

the

warning

can

result

severe

injury.

Pinch

Point/Hand

Entanglement

Содержание SH-5542

Страница 1: ...COSEN SAWS SH 5542 Semi Automatic Horizontal Bandsaw CE Non CE Models Instruction Manual The Pinnacle of Cutting Performance Cosen Mechatronics Co Ltd ...

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Страница 3: ...7 7600280 fax 31 77 7600288 For China email service cosensaws cn phone 86 152 50127815 Instruction Manual SH 5542 Semi Automatic Horizontal Bandsaw CE Non CE models Ver 4 2016 8 16 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 Taiwan FROM THE MANUFACTURER Thank you for your purchase ...

Страница 4: ...ials Never adjust the wire brush or remove chips while the saw blade is still running It is extremely dangerous if hands or clothing are caught by the running blade Never touch the running saw blade with gloves or not It is dangerous if your hands clothing or gloves are caught by the running blade Stop the saw blade before you clean the machine It is dangerous if hands or clothing are caught by th...

Страница 5: ...ation 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 5 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 Anchoring 3 8 Installing Roller Table Optional 3 9 Installing Fire Control Device 3 9 Relocating 3 9...

Страница 6: ...al 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 1 Some Sawing Practices 7 4 Saw Pitch Selection 7 4 Material Size and Saw Pitch 7 4 Section 8 Maintenance Service 8 1 Introduction 8 1 Basic Maintenance 8 1 Maintenance Schedule 8 2 Before Beginning a Day s Work 8 2 After Ending a Day ...

Страница 7: ...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 6 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 9: ...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 10: ...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 11: ... 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 12: ...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 13: ...1 5 Illustration Emergency Stop Emergency Stop ...

Страница 14: ...hine or on the accessories DANGER Running Blade Blade runs through this area Keep your hands away from a running blade to avoid severe injury The arrow indicates direction of the blade Cutting Hazard KEEP COVER CLOSED KEEP HAND OFF while the blade is running Turn power off before opening cover Failure to follow the warning can result in severe injury Hazardous Voltage TURN POWER OFF before servici...

Страница 15: ...1 7 Illustration Safety Labels ...

Страница 16: ...he prescribed maintenance schedule Refer to Section 8 2 If maintenance does not seem to solve the problem follow the troubleshooting procedures under Section 9 CE COMPLIANCE Cosen s CE model is designed to satisfy regulations of the Council Directive on the approximation of the laws of the Member States relating to machinery 2006 42 EC Annex I Essential health and safety requirements relating to t...

Страница 17: ...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 18: ... Interchangeable tungsten carbide Cleaning Steel wire brush with flexible drive shaft driven by main motor Motor Output Saw Blade 7 5 HP 5 5 kW Hydraulic 2 HP 1 5 kW Coolant Pump 1 8 HP 0 1 kW Tank Capacity Hydraulic 40L 10 gal Coolant 85 L 21 25 gal Vise Control Method Hydraulic with full stroke cylinder Min Clamping Capacity 38mm 1 5 Workbed Height 700 mm 27 5 Weight Net 1 900 kg 4 188 lb Gross ...

Страница 19: ...2 3 MACHINE PARTS IDENTIFICATION Double Column Idle Wheel Drive Wheel Chip Conveyor optional Blade Guide Arm Control Panel with dual control valve Electrical Compartment Cross Link ...

Страница 20: ...2 4 FLOOR PLAN Machine top view Machine front view ...

Страница 21: ...2 5 Machine side view ...

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Страница 23: ...ce and inspection Refer to Section 2 Specification 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 vib...

Страница 24: ...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 25: ...rm 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 feet t...

Страница 26: ...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 27: ...3 5 Illustration Lifting Points Before lifting please remove splash shields first Minimum weight capacity for each wire rope 2 ton Total number of wire ropes required 4 ...

Страница 28: ...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 or full level Check the sight...

Страница 29: ... 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 Unstable electric tension may affect your machine s electric installation fro...

Страница 30: ... Pull to unlock the Emergency Stop button and press the hydraulic ON button to start the hydraulic motor 9 Make sure the sawing 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 swa...

Страница 31: ...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 33: ...ING CONTROL PANEL STANDARD ACCESSORIES OPTIONAL ACCESSORIES UNROLLING INSTALLING THE BLADE ADJUSTING WIRE BRUSH ADJUSTING SAW ARM ADJUSTING BLADE SPEED ADJUSTING COOLANT FLOW BREAKING IN THE BLADE TEST RUNNING THE MACHINE CUTTING OPERATION TERMINATING A CUTTING OPERATION ...

Страница 34: ...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 35: ...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 36: ...t stop buttons with built in lamp CE model Hydraulic start button with built in lamp non CE model 3 Saw blade start stop buttons with built in lamp CE model Saw blade start button with built in lamp non CE model 4 Emergency stop button 5 Blade speed indicator 6 Blade speed control knob 7 Saw bow up button 8 Saw bow down button 9 Lift rollers up down switch 10 Vise open clamp switch 11 Coolant on o...

Страница 37: ...n and the blade motor starts to operate When the red button is pressed the blade motor stops Non CE model When this button is pressed the built in lamp will come on and the blade motor starts to operate Press saw bow up button to stop the blade motor 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 4 Emergency stop b...

Страница 38: ...ated only when the vise is unclamped AND the blade is not running If clamping the vise or starting the blade while the lift rollers are still at upper position the lift rollers will automatically descend slowly as a safety design to help ensure the squareness of the cut 10 Vise open clamp switch Turn the switch to the right to clamp the vise Turn and hold the switch for 2 seconds and let it go the...

Страница 39: ...ing the knob clockwise increases the blade descend speed Blade descend speed is a determining factor to a good cutting time and quality cutoff surface Set the blade descend speed in accordance with the cutting pressure control knob Also commonly known as the flow control valve STANDARD ACCESSORIES Blade tension device This blade tension device equipped with hydraulic cylinder provides appropriate ...

Страница 40: ... 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 terminal points are connected 2 Make sure the ambient temperature is within acceptable range and keep the surroundings well ventilated 3 Keep the inverter away from dust 4 For repair or maintenance please contact your local agent Split vises The spilt vises...

Страница 41: ... be assembled to the left saw arm This optional accessory is extremely useful in reducing the high frequency noise produced when cutting large sized material Chip conveyor Chip conveyor is a spiral device to bring chips out during cutting As a regular maintenance remove the chip conveyor and clean all chip deposits inside Hydraulic top clamp The top clamp device is installed on the cross beam Befo...

Страница 42: ...aterial is fed in smoothly Refer to Section 9 for further information on adjusting the roller table UNROLLING INSTALLING THE BLADE Always wear leather gloves and protection glasses when handling a blade Unrolling the blade Please follow the procedures illustrated below Unroll and roll the blade ...

Страница 43: ...andle from to position to release tension The idle wheel will then move slightly toward the direction of the drive wheel Step 5 Open the idle and drive wheel covers Step 6 Press the Blade Clip device to hold onto the blade This device makes blade changing easy and feasible even with only one operator available Step 7 Loosen the left and right carbide inserts by unlocking the lock bars shown below ...

Страница 44: ... to obtain blade tension Step 15 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 locking the lock bars Step 16 Gently close the idle and drive wheel covers Step 17 Press the saw blade start button to start the blade Allow the blade to run for a few rotations then press the saw bow up button to elevate the saw bow...

Страница 45: ...serts back by locking the lock bar 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 ch...

Страница 46: ... 4 After the break in operation is completed set all parameters back to normal settings 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 installing the machine Follow these steps to...

Страница 47: ...to adjust blade 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 ...

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Страница 49: ...t diagrams of the non CE model 5 2 Control Panel Layout 5 3 Circuit Board Layout 5 4 Power Supply Layout 5 5 PLC Input Output Layout The following are electrical circuit diagrams of the CE model 5 6 Control Panel Layout 5 7 Circuit Board Layout 5 8 Power Supply Layout 5 9 PLC Input Output Layout ...

Страница 50: ...5 2 ...

Страница 51: ...5 3 ...

Страница 52: ...5 4 ...

Страница 53: ...5 5 ...

Страница 54: ...5 6 張鴻昌 1030821 ...

Страница 55: ...5 7 1030823 張鴻昌 ...

Страница 56: ...5 8 1030823 張鴻昌 ...

Страница 57: ...5 9 1030823 張鴻昌 ...

Страница 58: ......

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

Страница 60: ...6 2 ...

Страница 61: ...s Your machine has all these features to provide a better service for you The saw blade is guided through the cutting area by roller guides to keep it straight as it comes off the driving wheels The precision carbide inserted guides then hold the blade securely and accurately throughout the sawing process The tension of the saw blade is adjusted through the tensioning device on the strong saw bow ...

Страница 62: ...g is determined by the hardness of the material and its thickness in cross section Tooth set prevents the 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 m...

Страница 63: ...recognize for example that rollers are considered as a pivotal contact Whereas carbide faces could be considered as anchored supports A more complete deviation including band tension and guide design is included in Roark s handbook Formula for stress and strain Blade selection There are different types of blades available Please contact a bandsaw blade manufacturer for advice Blade speed and feed ...

Страница 64: ...have at least three teeth in contact with the material being cut Material Size and Saw Pitch Anytime during the cutting operation at least three teeth must be in contact with the material being cut Figure 7 4 shows some sawing practices SAWING PRACTICES CORRECT INCORRECT several teeth contact work teeth strike sharp edge Coarse teeth clear chips freely Teeth too fine for large solids Three or more...

Страница 65: ... 1 4 100 250mm 4 10 8 10 TPI Teeth per inch 6 8 TPI 3 4 TPI Structurals STYLE up to 10 mm 3 8 10 20mm 3 8 3 4 above 20mm 3 4 10 8 TPI 8 10 TPI 6 8 TPI Solid Bundle STYLE up to 20 mm 3 4 20 80mm 3 4 3 1 4 above 80mm 3 1 4 8 10 TPI 2 8 TPI 4 6 TPI ...

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Страница 67: ...nce schedule is necessary Some of the daily 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 bas...

Страница 68: ...nd 3 Please check the saw blade to ensure that it is properly positioned on both the drive and idle wheels 4 Please make sure that the saw blade is properly clamped by the left and right inserts 5 Please check the wire brush for proper contact with the saw blade Replace the wire brush if it is worn out After ending a day s work Please remove saw chips and clean the machine when work has been compl...

Страница 69: ... STORAGE CONDITIONS Generally this machine will be stored on the following conditions in future 1 Turn off the power 2 Ambient temperature 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 A...

Страница 70: ... then refill new oil Do so hereafter every 1200 hours of operation Regularly Shell Omala oil R220 Mobil gear 630 Hydraulic system if there is an oil tank After 600 hours of initial operation drain away the oil and clean the internals of the machine then refill new oil Do so hereafter every 1200 hours of operation Regularly Shell Tellus 32 Mobil DTE Oil Light Hydraulic 24 Bearing Inserts Oil with l...

Страница 71: ...ble 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 COSEN has accumulated enough exp...

Страница 72: ...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 73: ... 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 74: ...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 75: ...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 76: ...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 the machine frame are not positioned under the horizontal balance the loaded material may be going up...

Страница 77: ...IONS PART LIST The following table lists common spare parts we suggest you purchase in advance Part Name Part Name Saw blade Filter Wire brush Steel plates Carbide inserts Pump Bearings Belt Chain Duster seal Asbestos Idle wheel Washer Drive wheel ...

Страница 78: ...10 2 ...

Страница 79: ...10 3 ...

Страница 80: ...10 4 ...

Страница 81: ...內六角螺絲 12 8 SGG 1003W front fixed vise jaw 前固定虎鉗二 1 9 bolt 內六角螺絲 4 10 SGG 1004W front fixed vise jaw 前固定虎鉗一 1 11 12 13 14 SGG 1005W frront movable vise jaw 前活動虎鉗 1 15 16 17 SGG 10090 auxiliary plate 虎鉗輔助板 1 18 bolt 內六角螺絲 2 19 S5542 23000 vise cylinder 虎鉗油缸組 1 20 bolt 內六角螺絲 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 AHK 1005 WRK BED ASSEMBLY 10 5 PBA 16 35 ...

Страница 82: ...10 6 ...

Страница 83: ...10 7 ...

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Страница 85: ...10 9 ...

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Страница 97: ...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 100: ... Vertical Plate Saws Horizontal Billet Saws NC CNC Band Saws Structural Miter Cutting Saws Automatic Band Saws Industry 4 0 Cosen Predictive Computing Visit our website at www cosen com COSEN MECHATRONICS CO LTD ...

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