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8. Finding and repairing malfunctions

8. Finding and repairing malfunctions

8.1 Reparing mechanical malfunctions

Danger!

Running saw band may cause serious severance injury!

Before repairing a malfunction, press the

Emergency-Off-Button

so the

motors are not accidentally turned on.

The malfunctions may only be repaired by one person at a time.

For the most part saw-band malfunctions occur while sawing.Go through the table from top to
bottom when searching for the cause of the malfunction.

Malfunction

Cause

Corrective action

Saw band "displaced" or
pushed up by the work-
piece that is being sawed

Saw band jumps off
diversion-wheels

Saw band torn

Saw-band tension not properly
adjusted

Set proper saw-band tension (see
Chap. 9.2 on p. 55)

Saw feed rate too high

Reduce saw feed rate (see Chap.
7.6 on p. 35)

Saw band dull

Exchange saw band (see Chap.
7.6 on p. 35)

Saw band installed in wrong
direction

Properly installing a saw band
(see Chap. 9.4 on p. 60)

Saw band does not have nec-
essary properties.

Use original saw-band from the
manufacturer (see Chap. 3.4 on p.
16)

Workpiece has unsuitable mate-
rial type (see Chap. 3.5 on p. 17)

Consultation with the man-
ufacturer (see Chap. 11. on p. 71)

Saw-band speed not correct

Check saw-band motor (see
Chap. 8.3 on p. 47)

Saw band jammed in
workpiece

Used wrong saw-band type

Consultation with the man-
ufacturer (see Chap. 11. on p. 71)

Frame under workpiece no
longer flat

The workpiece is not
completely cut off, while
the lower stop is
reached.

Lower limit switch is displaced.

Set lower limit switch of the saw
bow (see Chap. 8.4 on p. 48)

Quick clamping device
can not open or close,
though you have pressed
the

lower foot switch

No air pressure

Check air pressure

Air pressure in the pneumatic
system is too low

Provide sufficient air pressure in
the pneumatic system (see Chap.
3.7 on p. 18)

The clamping arms of
the quick clamping

Lower foot switch

is not locked

Press the lower foot switch up to
the stop, so that it locks into place

BSM 631 / BSM 800 / BSM 1000

Содержание BSM 1000

Страница 1: ...Translation of the original operating manual Operating manual Band saw machine for plastic pipes Type BSM 631 BSM 800 BSM 1000...

Страница 2: ...Status April 2016 Eugen Riexinger GmbH Co KG...

Страница 3: ...requirements 10 2 6 Informal safety measures 12 2 7 Properly functioning of protective devices 12 2 8 Organizational measures 12 2 9 Other hazards 12 2 9 1 Fire hazard 13 2 9 2 Electrical hazards 13 2...

Страница 4: ...5 Connect to electrical power supply 30 6 6 Establish pneumatic connection optional 30 6 7 Connect to suctioning optional 31 6 8 Initial operation 31 7 Operation 33 7 1 Before start up 33 7 2 Protect...

Страница 5: ...quipment 64 9 7 BSM 631 BSM 800 BSM 1000 maintenance 66 10 Dismantling and disposal 69 10 1 Deactivation 69 10 2 Final shutdown 69 10 3 Disposal 69 11 Annex 71 11 1 Contact form 71 11 2 EC Conformity...

Страница 6: ...4 BSM 631 BSM 800 BSM 1000...

Страница 7: ...way The company Eugen Riexinger GmbH Co KG is not liable for damages resulting from non or partial compliance with the operating manual 1 3 Safety symbols This operating manual uses the following desi...

Страница 8: ...s to perform specific functions always begin with a number or a letter Activities or notifications which the machine uses as a response to executed instructions are marked with a preceding full stop e...

Страница 9: ...c information 7 1 6 Location of objects in the room The spatial information about locations of objects in the room in relation to the BSM 631 BSM 800 BSM 1000 always refer to the image below BSM 631 B...

Страница 10: ...of laser beams Switchboard cabinet Control panel Electrical components Warning of dangerous electrical voltage when opening the door of the switchboard cabinet or the control panel casing or touch in...

Страница 11: ...on p 33 3 Call for an authorised person who can discover the reason for the emergency and fix the prob lem 2 2 Follow the operating manual l Carefully read this operating manual before using the mach...

Страница 12: ...fied or changed l operated in an explosive atmosphere l operated in a dusty environment without appropriate ventilation l be operated outdoors but only in inside rooms Furthermore it is also not permi...

Страница 13: ...e knowledge of state of the art technology for the tasks to be executed and recognise hazards he must also maintain this state of expertise Warning Electrocution hazard Only professional electricians...

Страница 14: ...e g locking the main switch 2 8 Organizational measures The proprietor of the BSM 631 BSM 800 BSM 1000 is obligated to provide the required per sonal protective equipment The personal protective equi...

Страница 15: ...a fire source 2 9 2 Electrical hazards Warning Directly or indirectly touching live parts may result in electrocution l Turn off the main switch before opening the door of the switchboard cab inet l...

Страница 16: ...rp machine parts It is not permissible to climb onto the machine when performing maintenance or any other kind of work Use suitable climbing aids e g stepladders or multi pur pose ladders but no leani...

Страница 17: ...ustable feed rate of saw bow for various materials and wall thicknesses Operation l Tensioning of workpieces with clamping belts l optional Pneumatical pipe clamping for fast and secure clamping of wo...

Страница 18: ...mm 3700 mm Width at angle cut 2300 mm 2400 mm 2800 mm Maximum Height completely raised saw bow 2800 mm 3250 mm 3700 mm Weight ca 450 kg 650 kg 980 kg Transport dimensions BSM 631 BSM 800 BSM 1000 Leng...

Страница 19: ...min diameter in mm 200 200 315 max diameter in mm 630 800 1000 min length The workpiece must be tensioned sure Attention The BSM 631 BSM 800 BSM 1000 may only be used to saw glass fibre rein forced pl...

Страница 20: ...ssure 8 bar Connection 1 4 plug fitting 3 8 Suction of saw shavings Shavings produced during cutting of plastic pipes can be removed by suction For this machine must be connected to an suction system...

Страница 21: ...r ing the sawing mode at an emission sound level from 80 dB A EMC The BSM 631 BSM 800 BSM 1000 complies with protection requirements in regard to inter ference immunity according to EN 61000 6 2 2005...

Страница 22: ......

Страница 23: ...itional components Pos Description 1 Saw frame 2 Saw bow 3 Switchboard cabinet 4 Tensioning device for saw band 5 Adjustment device for sawing angle 6 Screw foot 7 Control paneel 8 Machine frame 9 Qui...

Страница 24: ...d rate The workpiece is sawed off l The clamps on the workpiece are released and the workpiece is removed from the machine 4 3 Safety concept 4 3 1 Emergency off circuit The emergency off circuit is a...

Страница 25: ...rloading by too high braking frequency the device protects itself by an integrated control For commissioning or for a adjusting 5 braking operations are admitted directly in suc cession If an exceedan...

Страница 26: ......

Страница 27: ...ntents of the BSM 631 BSM 800 BSM 1000 are complete see Chap 3 2 on p 16 5 2 Environmental conditions for storage and transport Temperature 10 to 40 degrees C Relative humidity 15 55 non condensing At...

Страница 28: ...he in company transport of the machine 2 Lift the machine frame centrally with the forklift 3 Remove the underlying wooden blocks 4 Transport the machine to the desired storage or setup location 5 Lay...

Страница 29: ...to the setup location The floor of the setup room for the BSM 631 BSM 800 BSM 1000 must have the following characteristics l Hard level without slope l Sufficient load bearing capacity l No disruptiv...

Страница 30: ...rietor is obligated to setup a properly dimensioned ventilation sys tem at the setup site for sawing of glass fibre reinforced plastics GFP or similar dusty work materials in case of non compliance re...

Страница 31: ...ally followed l Also ensure that no persons are in the transportation path or in the setup area and wear safety shoes with toe protection caps 1 Transport the BSM 631 BSM 800 BSM 1000 to the setup loc...

Страница 32: ...ceiling can be used Attention Faulty connection values may cause material damage to machine Therefore observe the machine s connection values see Chap 3 6 on p 17 1 Ensure that the cables that connect...

Страница 33: ...o an appropriate extraction system Attention An incorrectly routet suction hose can be damaged Therefore take into account when routing the suction hose the vertical move ments of the saw frame 1 Ensu...

Страница 34: ...se serious severance injury l The machine may only be operated by one person l Before running the saw band the operator must ensure that no persons are behind the workpiece or in the danger area 13 Te...

Страница 35: ...and fastened with screws see Chap 9 3 on p 58 l Door of switchboard cabinet closed and locked l Sheet metal cladding of saw bow guides fastened with 6 screws see Chap 9 5 on p 62 7 3 Turning the BSM...

Страница 36: ...ning handle 7 4 Control panel Fig similar Pos Description Purpose 1 Emergency off button Stop the machine in an emergency 2 Button Lift up Lifts up saw bow 3 Button Lift down Lifts down saw bow 4 Adju...

Страница 37: ...Setting the saw feed rate Warning A torn saw band or a saw band that jumped off the wheel poses an injury risk l If the saw feed rate is set too high the saw band may jump off or tear l Always turn th...

Страница 38: ...te in small steps beginning with 1 while checking the quality of the cut You can record the determined information in the table below to quickly find the optimal result in case you come across the sam...

Страница 39: ...The operator must ensure that saw band is above the workpiece Mitre cuts The BSM 631 BSM 800 BSM 1000 has a mitre range of 45 degrees on both sides This allows the operator to e g saw pipe segments wi...

Страница 40: ...the workpiece can not bee safely clamped with minimum two tension belts rotate the work piece by 180 degrees in order to clamp it securely to the longer side or take a longer workpiece 7 When the wor...

Страница 41: ...k 1 Tension arm left Clamping workpiece 2 Thumb screw tension arm Adjust tension arm 3 Tension arm middle Clamping workpiece 4 Tension arm right adjustable Clamping workpiece as close as possible to t...

Страница 42: ...pening the tension arms with foot pedal make sure that your hands or your assistant s keep hands away from moving area of clamping device Attention Heavy workpieces may cause lifting injury Use liftin...

Страница 43: ...nd up about 100 mm higher than the upper work piece edge 2 Press the emergency off button so no one turns on the machine motor 3 For the processing of pipes with max 200 mm mount the V Support optiona...

Страница 44: ...see Chap 7 9 on p 42 14 Support protruding ends of long workpieces that tip down when clamped in 15 Unlock the emergency off button Remove workpiece from the machine 1 If the saw band remains below t...

Страница 45: ...alling offcut workpieces may injure the operator l Secure workpiece offcuts that are not clamped in e g with suitable lifting gear so that these pieces do not fall from the table after sawing l It is...

Страница 46: ...w band has been raised above the upper workpiece edge 9 Remove the workpiece and offcut piece from the machine or position it anew if you wish to perform another cut on the same workpiece see Chap 7 8...

Страница 47: ...irection Properly installing a saw band see Chap 9 4 on p 60 Saw band does not have nec essary properties Use original saw band from the manufacturer see Chap 3 4 on p 16 Workpiece has unsuitable mate...

Страница 48: ...on at a time Go through the table from top to bottom when searching for the cause of the malfunction Malfunction Cause Corrective action Lamp STEUERUNG EIN AUS don t lighten but tons are not functioni...

Страница 49: ...7 8 on p 38 2 Place the saw bow in the lowest position 3 Turn the machine off at the main switch and secure it against re activation 4 Remove the lower back saw band cover 5 Check the tension of the...

Страница 50: ...n see Chap 7 8 on p 38 2 With Button Lift down place the saw bow in the lowest position 3 Press Emergency Off Button so the motor is not accidentally turned on 4 Loosen both fixing screws of the lower...

Страница 51: ...e clear Danger Climbing onto the machine poses a fall and injury risk due to sharp machine parts It is not permissible to climb onto the machine when performing maintenance work Use suitable climbing...

Страница 52: ...s a guarantee for a 12 month term after the purchasing date according to legal and country specific regulations This means that damages to the machine that have resulted from material or manufacturer...

Страница 53: ...laint for machine type Serial number on type label Please briefly describe the problem Please briefly describe the setup location of the machine Please describe the environmental parameters in the tab...

Страница 54: ......

Страница 55: ...chine Daily or after usage see Chap 9 1 on p 54 Check saw band tension Weekly see Chap 9 2 on p 55 Check safety equipment Weekly see Chap 9 6 on p 64 Check steel ropes of saw bow lift if there are bro...

Страница 56: ...med activities except cleaning in the maintenance protocol see Chap 9 7 on p 66 9 1 Cleaning the machine Attention Do not used compressed air to clean the machine Compressed air blows shavings and dus...

Страница 57: ...brush or vacuum cleaner 3 Use a brush to remove the shavings in the guide rolls at the saw band guide 4 Clean up the shavings and plastic waste on the ground with a broom or vacuum cleaner 9 2 Tension...

Страница 58: ...off valve maintains the tape under tension for the case that the compressed air is failed Information l Since the length of the saw band varies due to manufacturing tolerances and temperature fluctuat...

Страница 59: ...ned when the reference mark is located between the values 45 and 55on the scala l The band tensioning device automatically balances out the warmth induced expansion during sawing 1 If you have not alr...

Страница 60: ...behind 7 Adjustable saw band guide behind 8 Adjustable saw band guide in front 9 Fasten screw for saw band guide in front 10 Short saw band cover in front 11 Lower saw band cover in front Danger Runn...

Страница 61: ...ant for assistance with the next steps The assisting person can e g execute the same movements at the back of the machine as the operator in the front 5 Operator and assisting person are required to w...

Страница 62: ...Danger Climbing onto the machine poses a fall and injury risk due to sharp machine parts It is not permissible to climb onto the machine when performing maintenance or any other kind of work Use suit...

Страница 63: ...he band 7 Use the climbing aids and insert the saw bow into the upper channel so that the saw band teeth point in the cutting direction at the bottom 8 Insert the saw band around the both saw band div...

Страница 64: ...climbing aids e g stepladders or multi purpose ladders but no leaning ladders How to prepare the machine for greasing 1 Keep appropriate climbing aids on hand 2 If you have not already done so execut...

Страница 65: ...9 Maintenance 63 Pos Description 1 Rear rope cover below 2 Rope cover on the gearbox 3 6 saw bow 4 Rear rope cover above 5 Front rope cover above 7 Front rope cover below BSM 631 BSM 800 BSM 1000...

Страница 66: ...trician How to check the safety button If a workpiece is still in the machine remove it see Chapter 1 1 on p 1 1 Turn on the machine with the main switch see Chapter 1 1 on p 1 2 Press and hold both b...

Страница 67: ...n 7 If the drives can be started while the emergency off is activated or if the drives do not stop immediately turn off the machine with the main switch and contact the manufacturer s customer service...

Страница 68: ...Serial number of BSM 631 BSM 800 BSM 1000 Please record the maintenance activities in the table according to the sample entry Date Activity Next maintenance Name 07 05 2012 Machine greased according...

Страница 69: ...9 Maintenance 67 Date Activity Next maintenance Name BSM 631 BSM 800 BSM 1000...

Страница 70: ......

Страница 71: ...ly by pulling off the plug in coupling from the machine s plug in fitting see Chap 6 6 on p 30 6 If the machine is transported to a different location set the saw bow to 45 degrees see Chap ter 1 1 on...

Страница 72: ...ions machine parts may not be discarded with unsorted household garbage During disposal separate the individual types of materials and dispose of them in accordance with country specific regulations I...

Страница 73: ...xperience with the BSM 631 BSM 800 BSM 1000 or make some sug gestions for improving either the BSM 631 BSM 800 BSM 1000 or this operating manual Copy fill out and send us this contact form We want to...

Страница 74: ...72 11 Annex BSM 631 BSM 800 BSM 1000...

Страница 75: ...t relevant guidelines l Guideline 2014 30 EU EMC guideline l Guideline 2011 65 EG RoHS guideline l The safety objectives of European Directive 2014 35 EU low voltage guideline comply with machine guid...

Страница 76: ...74 11 Annex BSM 631 BSM 800 BSM 1000...

Страница 77: ...11 Annex 75 11 3 Dimenson sheets 11 3 1 Dimension sheet BSM 631 BSM 631 BSM 800 BSM 1000...

Страница 78: ...76 11 Annex BSM 631 BSM 800 BSM 1000...

Страница 79: ...11 Annex 77 11 3 2 Dimension sheet BSM 800 BSM 631 BSM 800 BSM 1000...

Страница 80: ...78 11 Annex BSM 631 BSM 800 BSM 1000...

Страница 81: ...11 Annex 79 11 3 3 Dimension sheet BSM 1000 BSM 631 BSM 800 BSM 1000...

Страница 82: ...80 11 Annex BSM 631 BSM 800 BSM 1000...

Страница 83: ...11 Annex 81 11 4 Circuit diagram The following pages contain the electrical circuit diagrams for the BSM 631 BSM 800 BSM 1000 BSM 631 BSM 800 BSM 1000...

Страница 84: ...82 11 Annex 11 5 Pneumatic diagram optional BSM 631 BSM 800 BSM 1000...

Страница 85: ...ormations 83 12 Other informations The following pages contain the lubricating instructions for linear guideways and ballscrews of HIWIN Lineartechnologie for the BSM 631 BSM 800 BSM 1000 BSM 631 BSM...

Страница 86: ......

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