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10002683-en-00

BS 820 - Using the operating instructions

1.2

Target group

The OM must be read, understood and all points complied with by all persons

who are tasked with the following work with or on the machine:

■

Operation including preparation, trouble-shooting during the working sequence,

removal of production waste, care, disposal of process materials

■

Servicing (maintenance, inspection, repair)

■

Transport

1.3

Assessing the operating manual

When drafting this OM, we carefully applied standards DIN 62079 (VDE0039)

and EN ISO 12100-2. Despite our efforts, experience tells us that an OM is not a static do-
cument – it is a living document and is experienced by others.

Please let us know of any suggestions for improvements to or comments about this OM!

Every contribution is welcome and will be reviewed by us.

Thank you in advance for your contributions.

Your technical editorial team

Содержание BS 820

Страница 1: ...10002683 en 00 Band Saw BS 820 Manual...

Страница 2: ...Meyer Burger AG Allmendstrasse 86 CH 3600 Thun Phone 41 0 33 439 05 05 Fax 41 0 33 439 05 10 sales meyerburger ch www meyerburger ch 2 10002683 en 00...

Страница 3: ...dling assembly function 13 2 1 3 Crystal Gluing Station 14 2 1 3 1 Crystal gluing station assembly function 14 3 Safety 15 3 1 Safety information 15 3 2 Intended use 16 3 3 Dangers to life and limb an...

Страница 4: ...ompressed air 29 4 4 3 Coolant supply 29 4 4 4 Coolant recirculation waste 29 4 4 5 Motor cooling system 30 4 4 6 Air exhaust 30 4 4 7 Location of the various connections 30 4 4 8 Colour coding of the...

Страница 5: ...matic mode 62 8 1 3 Aborting the cycle 62 8 2 Moving away from the limit switch 62 8 3 Engaging the safety clutch 63 9 Maintenance 65 9 1 Maintenance schedule 65 9 2 Lubricant 66 9 3 Cleaning agent 66...

Страница 6: ...4 12 4 Repair 84 12 5 Equipment lists and diagrams 84 12 5 1 Arranged according to technical area 84 12 5 2 Numbering in equipment lists and diagrams 84 12 6 Ordering spare parts 85 12 6 1 MB part num...

Страница 7: ...hine and shows you among other things how the machine can be operated and serviced safely and economically In contrast to drawings and details in this OM the company reserves the right to make technic...

Страница 8: ...ocess materials Servicing maintenance inspection repair Transport 1 3 Assessing the operating manual When drafting this OM we carefully applied standards DIN 62079 VDE0039 and EN ISO 12100 2 Despite o...

Страница 9: ...2683 en 00 9 2 2 Product description 2 1 Assemblies The BS 820 consists of the following assemblies Machine Handling Crystal Gluing Station These assemblies and their function are presented below in b...

Страница 10: ...ensioning unit with linear guide and two symmetrically arranged hydraulic cylinders Bearing unit Bearing unit with vertical axis and precision roller bearing to receive the wheels Wheel Wheel with cen...

Страница 11: ...the automatic dressing of the saw band by making incisions in the dressing stone Electrical control Siemens PLC control system Modules for drive and positioning of the cutting feed infeed and dressing...

Страница 12: ...2 2 5 is fed horizontally over two wheels Fig 2 2 3 and routed along both sides of the workpiece Fig 2 2 2 by guide jaws The band tensioning unit provides the appropriate tensioning force required by...

Страница 13: ...moval 4 Identification device 5 Operating panel 6 Wafer holding device 7 Rod and end piece holder 2 1 2 1 Handling assembly function Handling is done automatically The following work steps are carried...

Страница 14: ...station 4 Stand 5 Support 6 End piece holders 7 Adjusting unit 8 Measuring arm adjustment 2 1 3 1 Crystal gluing station assembly function The crystals to be processed are measured on the crystal glui...

Страница 15: ...ng designations or symbols are for especially important information DANGER For a directly threatening hazard that can cause severe personal injuries or death WARNING For a hazard that may be directly...

Страница 16: ...rent from or exceeding this is not regarded as intended use The manufacturer supplier is not responsible for any damage arising from this The user alone is responsible The intended use of the machine...

Страница 17: ...3 5 2 Safety and danger notes on the machine Follow all safety and danger notes on the machine Keep all safety and danger notes at on the machine complete and in a legible condition 3 5 3 Changes to t...

Страница 18: ...h Note Only the maintenance personnel has access to the main switch padlock 3 5 7 Decommissioning Decommissioning of machines can only be done by personnel authorised and fully trained by MB or by an...

Страница 19: ...ble with cover open Movement of the saw band Hand injury possible Work carefully with the cover open Wear protective goggles Keep third parties at a distance DANGER Risk of electric shock Maintenance...

Страница 20: ...ty switches Fig 3 1 2 and Fig 3 13 monitor the position of the cover The automatic mode cannot be started until the cover is closed and locked Fig 3 1 Cover safety switch Legend 1 Cover 2 Drive side s...

Страница 21: ...gon socket head screws Fig 3 2 1 2 Open the lock and slide the door open Fig 3 2 Locking the sliding door Legend 1 Hexagon screws CAUTION The door must not be opened during automatic operation Locking...

Страница 22: ...ig 3 3 2 regulates the supply of fresh water Coolant supply optional Legend 1 Level switch supply 2 Supply valve 3 Water flushing Fig 3 3 Coolant return Legend 1 Level switch return 3 8 4 Band drive s...

Страница 23: ...tch in accordance with Chap 13 4 3 8 7 Band break monitoring If a band breaks an EMERGENCY SWITCH OFF is initiated 3 8 8 Emergency stop After the emergency stop button has been pressed the control sys...

Страница 24: ...displayed in the coolant screens and automatic mode displays The limits can be set in screen 610 If the set coolant flow is exceeded or not met the automatic mode is discontinued 3 8 10 Motor cooling...

Страница 25: ...data 4 1 Features Workpiece Length max incl top tail 800 2 900 mm Length cylindric part 2 420 mm Length of top tail 300 und 200 mm Diameter 305 320 mm Cutted block length 80 500 mm Thickness of test w...

Страница 26: ...mm Width 50 mm Number 2 Distance between axes 2390 mm Material Aluminium Roller coating Polyurethan Coating hardness 97 Shore Speed 0 160 RPM Required power 13 kW Total travel 800 mm Travel path prog...

Страница 27: ...ly 125 l Coolant tank waste 125 l Coolant pump supply 25 l min 6 bar Coolant pump waste 100 l min 2 bar Type SIMATIC Operator panel Viscontrol Touch SCD 1297 Length 6 503 mm Width 6 356 mm Height 3 78...

Страница 28: ...28 10002683 en 00 BS 820 Product data 4 3 Layout Fig 4 1 Layout 6503 6356 3755 max 3782...

Страница 29: ...rical connection has to be externally fused for all three phases Protection required 50 A inert integrated power protection operating class Voltage see machine sign Frequency see machine sign Connecti...

Страница 30: ...rious connections Fig 4 2 Connections interfaces Legend 1 Elektrical connections 2 Compressed air 3 Vacuum 4 Air exhaust 5 Coolant supply 6 Coolant waste Quantity ca 5 7 l min Pressure max 2 bar Speci...

Страница 31: ...chine must be placed on a solid flat and vibration free base The machine must not be installed at places directly exposed to heat sources such as solar radiation The machine is not suitable for use in...

Страница 32: ...0 Product data 4 6 Emissions 4 6 1 Noise levels Noise level measured during cutting process 78 dB A 4 6 2 Used water Depending on the coolant used it must be disposed according to the regulations of t...

Страница 33: ...3 en 00 33 5 5 Display and operating controls 5 1 Operating panel Fig 5 1 Operating panel Legend 1 Two hand control unit close cover 2 Screen Touch Screen 3 Joystick 4 Hardware buttons 5 Key pad 1 4 2...

Страница 34: ...ator action is necessary 2 Blue lamp blinks slowly when two sharpening cycles are possible blinks fast when one sharpening cycle is possible illuminated when sharpening cycle is not possible 3 Red lam...

Страница 35: ...back 6 Help key 7 One level forwards 5 3 1 S keys Fig 5 4 S keys Legend 1 System login Input user name and password 2 Input user defined passwords 3 Ready for automatic mode 4 Switching options on an...

Страница 36: ...ndexing 6 Sharpening and dressing 7 Vacuum water air 8 Block unloading handling 9 Wafer unloading handling 10 Statistics cutting protocols maintenance 11 Cutting program automatics 12 Alarm screen 5 3...

Страница 37: ...safety LowSafety low safety joystick confirmation key pressed HighSafety full safety cover closed 4 Messages events Dark no event present Flashing yellow at least 1 event present Green events confirm...

Страница 38: ...itching on off not possible Displaying measured values Measured values are displayed against a grey background Fig 5 8 Displaying measured values Editable values Fig 5 9 Editable values Legend 1 Blue...

Страница 39: ...osition can be held for max 20 minutes the corresponding movement can be executed Stop As soon as the confirmation key Fig 5 10 3 is released or pressed right in all movements are stopped in a control...

Страница 40: ...tic on off 2 Band drive on 3 Feed slow up 4 Rapide feed up 5 Close cover 6 Clamping cylinder open 7 Lock doors machine side 8 Operation active 9 Automatic stop 10 Band drive off 11 Rapide feed down 12...

Страница 41: ...is reached Lamp blinks Band drive up and brake run 4 Vorschub Eilgang auf The machine table approaches the saw blade fast 5 Close cover The cover closes Two hand control unit The cover can only be cl...

Страница 42: ...ged 4 Emergency stop 12 Open cover Opens the cover Lamp illuminated Cover is closed and the command CLOSE COVER is not active Lamp blinks The command CLOSE COVER is active 13 Lock doors The doors are...

Страница 43: ...and password Four password levels have been set Different rights have been set for each password level Note The entries are accepted with the Enter key Fig 5 13 7 Fig 5 13 Login Legend 1 User name 2 P...

Страница 44: ...ation menu Fig 5 4 5 Fig 5 14 Configuration menu Legend 5 1 3 4 2 1 Changing language German English 2 Drive download is shown only at password level 4 3 Lamp test 4 Storing loading and deleting data...

Страница 45: ...listed below Reference data Key combinations Configuration s_070 Fig 5 4 5 Storing loading and deleting data Fig 5 14 4 All reference values are stored read or deleted in the Reference directory Cond...

Страница 46: ...input window 2 Data name selection window 3 Action keys Storing on the hard disk Loading from the hard disk Deleting from the hard disk Storing on memory stick network drive Loading from memory stick...

Страница 47: ...oading process can be seen on the progress bar Fig 5 15 5 If the following reporting window appears the user has selected a wrong data profile Fig 5 17 Data profile window Note If this message appears...

Страница 48: ...BS 820 Display and operating controls Note To start the Delete process the Enter key Fig 5 18 must be pressed The following reporting window must also be confirmed with the Enter key Fig 5 18 Delete...

Страница 49: ...stem is brought up to speed The TOP screen with the login window appears 2 Enter the password and confirm the entry with OK 3 Choose Setup mode 4 Close and lock all the machine s hoods and doors 5 Fix...

Страница 50: ...ff 6 2 Switching off the machine and control system When the main switch is switched off the following happens 1 the PC is powered down correctly 2 The machine control system is switched off 3 The mac...

Страница 51: ...10002683 en 00 51 7 7 Setup...

Страница 52: ...lock the cover and front window 4 Open the cover and front window 5 Loosen the clamping of both band guides Fig 7 1 2 SW8 ring spanner 6 Move both band guides with the crank Fig 7 1 1 right up to the...

Страница 53: ...k that the saw band is resting on all band supports 4 Tension the saw band up to a maximum of 2000 N and press the confirmation button Fig 5 10 3 5 Retract the band supports and press the confirmation...

Страница 54: ...ide 3 Switch on the water for the band guide 4 Change to the fall adjustment screen 5 Set the band drive override factor to 10 6 Switch on the band drive 7 Check the band concentric running using the...

Страница 55: ...w 5 Clamping of guide jaw 6 Clamping of sliding block 7 Inhibiting air cover 8 Clamping of height adjustment 9 Sliding block 10 Guide jaws pair Procedure 1 Remove the inhibiting air cover Fig 7 2 7 2...

Страница 56: ...e screws Fig 7 3 1 7 Undo clamps Fig 7 2 4 5 and 6 8 Adjust the rear guide jaw with Fig 7 2 2 until the guide jaw is touching the saw band 9 Tighten clamps Fig 7 2 4 5 and 6 to 5 Nm 10 Fit the front g...

Страница 57: ...ing nozzles 4 Band flushing Position of cooling nozzles for saw band and sliding block Saw band nozzles The clearance between the saw band Fig 7 4 2 and cooling nozzles Fig 7 4 3 is 1 mm Sliding block...

Страница 58: ...8 L min Fig 7 5 Adjusting coolant flow Setting for Legend 1 Band cooling centre 2 Band guide left 3 Band guide right 4 Band cooling rear 5 Band cooling front 6 Band reverse cooling right 7 Band revers...

Страница 59: ...stone 3 Clamping of dressing stone 4 Move to loading position to replace the dressing stone 5 Unlock cover door 0 lock cover door 1 6 Confirming dressing stone replaced 7 Emergency Stop 8 Cover for ma...

Страница 60: ...60 10002683 en 00 BS 820 Setup...

Страница 61: ...Close the cover two hand operation 2 Select the TOP screen 3 Choose Automatic mode 4 Change to the Automatic screen 5 Enter the cutting parameters with calculation program if necessary see online hel...

Страница 62: ...ains rejected 8 2 Moving away from the limit switch Note If a limit switch has been engaged this brings the system to an EMERGENCY stop Procedure 1 Cancel automatic mode 1 Abort the cycle 1 Choose the...

Страница 63: ...imit switch and safety limit switch 1 Move the X1 axis manually by the toothed belt until the clutch engages Designation X1 Axis index axis Drive mode toothed belt Drive module A 641 2 Acknowledge the...

Страница 64: ...64 10002683 en 00 BS 820 Cutting...

Страница 65: ...ice life of the machine with good production quality In the event of faults or after repairs checks and maintenance work need to be done to fix the fault or do the repair Fault free operation and safe...

Страница 66: ...l adjustment Replace Hydraulic oil Hydraulic filter 9 4 2 9 4 3 9 4 3 Annually Clean Cooling fins of the electric motors wheel drive servo drive of X and U axis fall adjustment drive hydraulic pump co...

Страница 67: ...r is monitored by the control system and displayed on screen Note Interval and duration of the lubrication can be changed in the Water Vacuum Air F16 menu Fig 9 1 Automatic central lubrication lubrica...

Страница 68: ...ubricant MOLYKOTE P40 Fig 9 2 Fall adjustment Legend 1 Threaded spindle 9 4 3 Hydraulic aggregate Interval Every 6 months or every 2500 hours Work Replace the hydraulic oil and hydraulic filter Lubric...

Страница 69: ...ve the filter housing Fig 9 3 3 2 Replace the filter 3 Fit the filter housing Fig 9 3 3 4 Connect the compressed air 5 Check the air pressure with the pressure gauge Fig 9 3 2 6 bar 6 Set the pressure...

Страница 70: ...the battery 4 Fit the cover Fig 9 4 1 9 5 3 Ground clearance Interval Annually Work The machine s ground clearance is to be checked annually When carrying out this check ensure that the machine stand...

Страница 71: ...must be at least 3 mm thick Procedure 1 Take load off the brake switch on the compressed air 2 Undo the nut Fig 9 5 2 3 Turn the screw Fig 9 5 3 anti clockwise until contact with the bolt Fig 9 5 4 is...

Страница 72: ...ance between the contact disk Fig 9 5 1 and nut Fig 9 5 2 clearance 2 5 mm 7 Move the switch Fig 9 5 6 if necessary 8 Turn the contact disk Fig 9 5 1 against the nut Fig 9 5 2 and tighten the contact...

Страница 73: ...aring unit Fitting 1 Fit the lifting equipment Fig 9 6 1 to the wheel 2 Lift the wheel carefully with a crane or forklift 3 Align the wheel with the bearing unit i e align the positioning screw Fig 9...

Страница 74: ...BS 820 Maintenance 6 Ensure that the wheel is supported correctly 7 Fasten the wheel in place with the 6 screws shown in Fig 9 6 5 Tightening torque 150 Nm 8 Fit the cover in Fig 9 6 3 watch out for O...

Страница 75: ...and transport 10 1 Packing Take account of the following specific criteria when choosing packing Use only the original packing material Use a packing class in accordance with the valid regulations Pa...

Страница 76: ...ctric cabinet with a crane Note The user must make sure that ropes hooks lifting equipment etc comply with the necessary safety regulations or meet them NOTICE Damage possible The fall adjustment secu...

Страница 77: ...steerable rollers 10 2 3 Transport fixtures Parts that could move during transport are to be secured with fixtures to ensure they do not move 2 3 1 CAUTION Injury to people and material damage possibl...

Страница 78: ...78 10002683 en 00 BS 820 Packing and transport...

Страница 79: ...t conditions High accuracy of the BS 820 can only be expected if a suitable installation site is chosen and the following conditions met 11 1 1 Temperature 11 1 2 Humidity Room temperature 15 C 25 C F...

Страница 80: ...moved with a crane or forklift truck The individual assemblies of the dismantled machine must be lifted from the transport floor by a crane at the designated points 11 3 Transport fixtures Remove the...

Страница 81: ...hoe Legend 1 Machine base 2 Adjusting bolt 3 Counter nut 4 Machine shoe Procedure 1 Set a water level on top of the running wheel and align the machine horizontally with the adjusting bolts Fig 11 1 2...

Страница 82: ...rong swap two phases of the connecting cable at the mains connecting terminals 11 5 2 Requirements on personnel doing the work The initial operation of the machine may only be carried out by personnel...

Страница 83: ...during repair work and when replacing original parts in this context Only maintenance personnel has access to the key for the main switch padlock 12 2 Resources and material 12 2 1 Special tools measu...

Страница 84: ...manner Diagrams and equipment lists are required for repairs and maintenance work The replacement of parts may only be carried out by qualified personnel in accordance with the requested documents dr...

Страница 85: ...ber Mechanical components MB part numbers and designation can be identified in the assembly drawings and parts list Note Use original spare parts only 12 7 Fault reporting procedure Note The fault rep...

Страница 86: ...86 10002683 en 00 BS 820 Repair Service...

Страница 87: ...the power supply 13 1 2 Cleaning The machine must be thoroughly cleaned before being stored The slurry pipes must be flushed out NOTICE Bearing points can be destroyed during cleaning For this reason...

Страница 88: ...ed 13 1 5 Packing The packing must protect the machine against external influences humidity heat hail etc 13 2 Storage conditions 13 2 1 Space required For details of dimensions and weights please see...

Страница 89: ...rap the spindles completely in needle wrapping paper or equivalent material 3 Slide a synthetic tube over the wrapped spindles and enclose a desiccant bag 4 Weld the synthetic tube shut at both ends N...

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