Manual Sierra Durma DCB-S 560

BANDSAW MACHINE

USER GUIDE

DCB

WARNING ! The images in this catalogue may differ according to the machine you buy.

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HYDRAULIC DOUBLE COLUMN AUTOMATIC BANDSAW

MACHINE COMPANY NAME : DCB-S

MACHINE TYPE : 560

SERIAL NUMBER : 804213143

ORDER NUMBER :

DATE : 19.12.2013

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CONTENTS PAGE - Contents 3

- Foreword 6

- About Durmazlar 7

- EC Declaration of conformity 8

PART 1 GENERAL SAFETY WARNINGS 1.1 Safety Instructions 9

1.2 Unavoidable Risks 13

PART 2 GENERAL MACHINE PRESENTATION 2.1 About the Machine 16

2.2 Machine presentation 17

2.3 Presentation and warning tags fixed onto the machine 18

2.3 Prohibited applications 26

2.4 Safety members and switches in the machine 29

2.5 Safety regions of the machine 31

2.6 Technical machine data 32

DCB-A 360 Technical specifications 32

DCB-S 360 Technical specifications 33











DCB-M 460 Technical specifications 44



DCB-DM 560 Technical specifications 47

DCB-FA 330 Technical specifications 48

2.7 Main parts of the machine 49

2.8 Standard and optional accessories in the machine 53

2.8.1 Standard accessories 54

2.8.2 Optional accessories 55

2.8.3 Particular solutions 56

2.9 Noise 56

2.9.1 Noise level measurements 56

2.10 Standards used in the saw design 57

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PART 3 INSTRUCTIONS FOR MACHINE TRANSPORTATION 3.1 Transportation of the machine 59

3.2 Removal of the package 60

PART 4 STORING CONDITIONS 61

PART 5 MACHINE INSTALLATION INSTRUCTIONS 5.1 Operating area of the machine 62

5.2 Machine installation 62

5.3 Machine placement 63

5.4 Electrical connections 63

5.4.1 Motor direction 64

5.4.2 Motor current values 64 5.5 First checks 65

5.5.1 Cooling liquid 65

5.5.2 Hydraulic Unit 65

5.5.3 Hydraulic Unit Cleaning 66

5.5.4 Hydraulic Unit pressure adjustment 67

PART 6 INSTRUCTIONS FOR COMMISSIONING THE MACHINE 6.1 Commissioning 68

6.2 Powering 69

6.3 Confirmation of the Machine 70

PART 7 USAGE INSTRUCTIONS 7.1 User region 70

7.1.1 Prior to Cutting 71

7.1.2 Cutting 71

7.1.3 Language Selection 72

7.1.4 Counter usage 72

7.1.5 Digital potentiometer 72

7.2 Operating the machine 73

7.2.1 Manual cutting 73

7.2.2 Automatic cutting 74

7.2.3 Siemens Simatic Panel 75

7.2.2 Turning off the Machine 84

7.2.3 Restarting the machine which is stopped emergently 85

7.3 Presentation of the buttons 85

7.4 Clamp usage 86

PART 8 MAINTENANCE, REPAIRING AND CLEANING INSTRUCTIONS 8.1 Saw blade adjustment 87

8.2 Maintenance information 87

8.2.1 Daily maintenance 87

8.3.2 Weekly maintenance 88

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8.4.3 Monthly maintenance 88

8.3 Changing of blades 89

8.4 Information about the lubricant used in the machine 89

PART 9 TROUBLESHOOTING DATA 9.1 Probable failures 90

9.2 Inverter failure codes and the descriptions thereof 90

PART 10 HEALTH AND SAFETY OF THE OPERATOR 10.1 Rescue of the Squeezed Personnel 95 10.2 Properties of the hydraulic lubricant used 96

10.2.1 Transportation 97

10.2.2 Storing 98

10.2.3 Definitions of the dangers 98

10.2.4 Recommended first aid 98

10.2.5 Control of usage and individual protection 99

10.2.6 Toxic data 99

10.2.7 Disposal data 99

PART 11 DECOMMISSIONING 101

PART 12 FEEDBACK FORM 102

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FOREWORD

This handbook is prepared so as to comprise the required information with the required techniques taking into

account the object of more actively and effectively usage of the machines serving you.

Our first principle is to provide you the maximum performance with our machines which are produced using

the most qualitative materials, the state-of-the-art technology and engineering services.

Our products which have the minimal operating costs will serve you for several years if you care for their

periodical maintenance and if you carry out the periodical maintenance regularly.

Press brakes which are among our products are used in bending of sheets with pluralities of thicknesses and

qualities, and the shears and saws are used in cutting of different materials (Sheet plate, Aluminum, Cu,

plastic, paper, etc.).

This handbook should be read at least once by the operating responsible and also by the stuff operating the

machines. The handbook should be in the vicinity of the machine, this is important for the troubleshooting of

the failures which may occur.

Our factory has the rights to realize the required novelties according to the improving technology

without appealing to any authority.

Our situation in the domestic market which we serve since 1956 has become higher since we are in the

international market for 30 years. Thus, the experience and the technological improvements obtained from this

market are presented to you in the best manner.

Congratulations with your machine and we wish you success in your works.

DURMAZLAR MAKINA SAN. VE TIC. A.S. Organize Sanayi Blgesi 75. Yil Caddesi BURSA

Tel : + 90 224 219 18 00 pbx. Fax : + 90 224 242 75 80 242 93 73

Internet : www.durmazlar.com.tr e-mail : [email protected]

[email protected]

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ABOUT DURMAZLAR A.S

Durmazlar Machine is one of the leading machine manufacturers in Turkey and it is the leader of the market in terms of the production numbers.

Durmazlar is one of the leading industrial institutions of Turkey, which improves the production and services thereof continuously. Durmazlar realizes production in international standards, it represents Turkey in the world and it contributes to the national income.

Today, Durmazlar Machine is a company which is older than 50 years, it has a closed production area equal to 150000 m2, it has 1000 personnel and it realizes exportation to 82 countries and Durmazlar Machine always tries to do the best.

Durmazlar Machine has the principle of production in world standards, it realizes investments in novel technologies and it presents the products thereof with suitable prices.

Durmazlar is the first country in Turkey which produces sheet processing machines; and the following products are among the products of Durmazlar: CNC Hydraulic press, full automatic press, CNC Hydraulic shear, Punch press, Plasma Cutting and Laser cutting machines, Hydraulic Cylinder, Asymmetric Cylinder, Profile Bending, Manual Cylinder, Circle Cutting, Cord and Saw Machines. These have a wide usage area in sectors like automotive, construction, textile, electronics, air transportation, marine transportation and defense industry.

The production process, which is realized with very sensitive process machines, provides our products to function with high performance after long years; and during this process, processes like automatic welding and tension elimination are realized under the light of this object.

Durmazlar Machine has sensitive processing CNC centers up to 20 meters in one piece; and it increases this production standard by means of the laser technology. Durmazlar Machine supports the customers thereof in both standard machine production and in particular machine production.

For preserving and maintaining DURMA quality, the products are tested with high technology tests in all of the production steps.

Durmazlar exists as long as it assures to the customers and since according to the vision of Durmazlar the most valuable investment is person, Durmazlar improves itself continuously and it always tries to provide better customer service.

DURMAZLAR MAKINA SAN. VE TIC. A.S. Organize Sanayi Blgesi 75. Yil Caddesi BURSA

Tel : + 90 224 219 18 00 pbx. Fax : + 90 224 242 75 80 242 93 73

Internet : www.durmazlar.com.tr e-mail : [email protected]

[email protected]

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EC DECLARATION OF CONFORMITY AT UYGUNLUK BEYANI

MANUFACTURER IMALATI

DURMAZLAR MAKINE SAN. VE TIC. AS.

ADDRESS ADRES

Organize Sanayi Blgesi 75. Yil Cd. 16159 Bursa - Trkiye

Name and address of the person authorised to compile the technical file Teknik Dosyayi derleyen yetkili kisi ve adresi

Ramadan Kelebek Organize Sanayi Blgesi 75. Yil Cd. 16159 Bursa - Trkiye

The undersigned Company certifies under its sole responsibility that the item of equipment specified below satisfies the requirements of

the Machinery Directive 2006/42/EC which is apply to it.

The item of equipment identified below has been subject to internal manufacturing checks with monitoring of the final assessment by

DURMAZLAR MAK.SAN.TIC.AS.

Asagida tanimlanmis olan ekipmanlar iin Machine Emniyeti ynetmeligi 2006 / 42 / ATnin uygulanabilen gerekliliklerinin yerine

getirildigini ve sorumlulugun alinmis olundugunu beyan ederiz.

Asagida tanimlanan ekipmanlar i retim kontrollerine bagli olarak DURMAZLAR MAK.SAN.TIC.AS. tarafindan kontrol edilmistir.

PRODUCT

RN

Double Column Bandsaw

ift Stunlu Serit Testere MODEL / TYPE

SERIAL NO

DCB -S 560

804213143

DIRECTIVES / YNETMELIKLER

MACHINERY DIRECTIVE 2006/42/EC MAKINE EMNIYETI YNETMELIGI 2006/42/AT LOW VOLTAGE DIRECTIVE 2006/95/EC BELIRLI GERILIM SINIRLARI DHILINDE ALISMAK ZERE TASARLANMIS ELEKTRIKLI TECHIZAT YNETMELIGI 2006/95/AT ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2004/108/EC ELEKTROMANYETIK UYUMLULUK YNETMELIGI 2004/108/AT Regulations Applied acc. to HARMONIZE STANDARDS

UYGULANAN UYUMLASTIRILMIS STANDARTLAR

EN12622:2001 ;EN ISO 4414:2010 ;EN ISO 4413:2010 ;EN 999:1998 ; EN ISO 13849-1:2009 ;EN 13857:2008 ;EN 60204-

1:2011 ;EN ISO 12100:2010

Place and date of issue

Yer ve Tarih

: Bursa, 19.12.2013

Name and position of authorized person

Yetkili kisinin adi ve grevi

: Ramadan KELEBEK

Researching-Development Dep. Manager / Ar-Ge Mdr

Singanature of authorized person

Yetkili kisinin imzasi

:

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PART 1 GENERAL SAFETY WARNINGS

1.1 Safety Instructions

In cases where operator intervention is required on the machine, READ the user manual prior to

intervention. Before using the machine, check the required fixtures (material table, chip conveyor, etc.) and

operate the machine so as to be compliant with the values given in the presentation tag. While the machine is operating, be sure to be in the control panel region mentioned in Figure 1.2.

Otherwise, accidents may take place. NEVER! approach the saw blade or the other moving parts without wearing gloves, protective

clothes and eye-glasses. (Figure-1.1)

When the user desires to work on the open region of the blade, or when the blade is required to be changed, fix the blade protector in order for the teeth not to give damage to you or in order for the teeth not to be damaged. (Figure-1.3).

Wear gloves when the blade is to be changed.

Attention Before operating the machine, read the users manual. If you have a question about the machine, please contact with the manufacturer company.

Figure 1.1 - Wrong Figure 1.2.-Correct

Do not approach the Open Region of the Blade without taking precautions

Do not forget to fix the Blade Protector while changing the

band

Figure 1.3.

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There is emergency stop button on the control panel of the machine (Figure-1.4). The emergency stop stops all of the dangerous movements.

Do not approach the machine while the machine is being operated. If there is a very important

case, turn off the machine and activate the emergency stop.

Prior to maintenance, ALWAYS be sure that the machine is in STOPPED position.

The service process should be carried out by the authorized personnel only.

Do not wear wide and long clothes and do not wear tie in order to prevent being caught by the movable parts.

For safety, the dangerous regions are covered by guards. During the operation of the machine or after maintenance, these covers should always be in closed position.

Be far away from the cutting region against the throwing danger of the work piece.

While the machine is being operated, do not try to open the electrical panel. Prior to opening the electrical panel, de-energize the machine and pull the plug.

The machine should not be operated over the capacity thereof.

The machine is designed so as to be operated with one (1) operator.

Prior to using the machine, check if the safety mechanisms function well.

Keep third party away from the machine.

The operator should wear shoes with steel end parts in the front in order to protect against

being crushed as a result of the falling of the work piece.

The operator should work using gloves.

The operator should wear protective eye-glasses while working.

Figure -1.4

Emergency Stop Button

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Keep the operating area tidy. Untidiness in the operating region leads to fault and danger. It limits your actions.

Prior to powering the machine, the grounding should be checked. Realize the grounding of the

machine using copper grounding cable in the region in Figure 1.5.

Be compliant with the Maintenance Instructions.

Be careful that at least three sides of the region, where the machine is to be placed, are open. If possible, prefer closed regions.

Do not remove and de-activate or do not change the places of the Safety Members and Protective members.

Do not operate the machine without putting cooling liquid and hydraulic lubricant. For lubricant

selection, please look at the Lubrication Schemas table.

In cases where the machine will not be operated for one week or for longer durations, loosen

the blade for increasing the blades life.

Change the reducer lubricant at the end of the first 2000 hours.

There has to be material between the clamps in order for the cutting process to be realized.

There are two stops in the cutting motor for safety purposes. Emergency stop mushroom

button stops cutting in saw in time duration shorter than 1 second, the stop button stops

cutting in 2-3 seconds. However, usage of the emergency stop button continuously shortens

the motor and inverter life.

In the cutting of pieces which are longer than 300 mm, since the falling of the piece from the

machine leads to accidents, material table is recommended to be used.

Figure -1.5

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When the machine is not in use, do not leave material under the blade. The guided body may

move downwardly as a result of the gravitational force, and may lead to the breakage of the

blade. When the blade will not be used for a long time, loosen the blade.

Bring the Rectification Arm to the closest position to the material/materials to be cut, and

realize the cutting process. Otherwise, the material vibrates, the blade teeth may be broken

and the chips or broken teeth may be thrown and this may lead to injuries.

Carry the machine by holding the machine from the tagged regions. If you carry the machine

from different points, you may be hurt and your machine may be damaged.

Position of the Rectification Arm

Figure 1.9 -Correct Figure 1.8 -Wrong

The position of the material when the machine will not be operated.

Figure 1.6 - Wrong- Figure 1.7 - Correct

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1. 2 UNAVOIDABLE RISKS

Since the cutting bandsaw can not be closed by any casing, while cutting and/or while operating in the idle mode, there will be accidents in case the workers approach their hands or fingers.

While the guided body moves upwardly-downwardly, if the worker approaches the body, there may become accidents. Keep far away from the movable members.

Figure 1.11

Figure -1.10

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Look at the weight of the removable pieces from the piece list, do not lift and do not try to lift

pieces heavier than 15 kg without using auxiliary equipment (hoist, crane, etc.).

The intermediate distance between the rotating helix and the conveyor groove sheet is 10 mm

(Figure 1-13). In order to prevent accidents while the chip conveyor is functioning, be careful with

the rotating helix region.

Figure 1.12

ATTENTION! Lifting heavy loads gives permanent damages to your body.

Figure -1.13

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The machine with the rotating table can rotate 60 in clockwise direction. As can be seen in

Figure 1-14 and Figure 1-15, while rotating the machine with the rotating table, be sure that

the machine is not in the safety distances below. Otherwise, there may be accidents.

Figure -1.14 Figure -1.15

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PART 2 GENERAL MACHINE PRESENTATION

2.1 About the machine

Today, among the benches whose usage is simple, the best and most rapid metal cutting is realized by bandsaw machines.

In the flat or angled cutting of iron, copper alloys, aluminum alloys, production

steels, carbon steels, hot-cold work tool steels, case hardened steels, mould steels, nickel chrome alloyed steels, bearing steels, stainless steels, titanium alloys, castings, construction steels and non-iron metals, metal bandsaw machines are used. The cutting process can be realized one by one, the multiple cutting of materials in binding form can be realized in a comfortable manner.

In iron steel factories, in plane industry, ship industry, automotive industry,

production industry, in construction sector, in aluminum industry; it is mostly used since it has a low cost and since it is rapid.

Thanks to the reinforced body structure, the bending and vibrations formed

during cutting are minimized. These rigid bodies are connected to the reinforced chassis by means of columns which are covered by chrome, and a strong frame is formed.

All of the tensions of the body, chassis and other accessories are eliminated by

means of the tension eliminating device after the welding and casting process. In 5 axis CNC processing centers, all of the processes are realized in one binding. Thanks to this, the parallelism of all of the axes and surfaces is provided. These processes provide sensitivity and strength to the DURMA HB and DCB series bandsaw machines for long years.

The usage and publication rights of the information given in this document belong only to DURMAZLAR MAK.SAN.TIC A.S. Without the permission of the company, it can not be copied, published and used in any manner. Said company can change the specifications and pieces existing in said guide without informing beforehand. The figures and schemas existing in the guide can be different from the product.

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2.2 Machine presentation DCB series Bandsaw Machines are benches which are used for cutting partially cold or cold (iron or non-iron) metals by means of the saw blade.

Our machines, which are designed and manufactured as pivot type and column type in the TS EN 13898, meet the customer needs in the highest level.

Figure 2.1

ATTENTION! Do not use the machine for wrong purposes. The manufacturer is not responsible if the machine is used for wrong purposes.

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PRESENTATION AND WARNING TAGS FIXED ONTO THE MACHINE

Tag 8 : Electrical warning tag

Attention Do not operate the machine without filling the Hydraulic Lubricant and cooling liquid!

Tag 9: This is the tag which illustrates the safety instruction which the user should obey. Tag 10: Tightening Pressure Tag Tag 11: Saw Blade Lowering Speed Adjustment Tag Tag 12: Grounding tag Tag 13: Motor rotation direction tag

Tag : 9

Tag : 12

Tag : 13

Tag : 1 Tag : 2 Tag : 3 Tag : 4 Tag : 5 Tag : 6 Tag : 7 Tag 1: The person using the machine should read the user manual. Tag 2: Protective Eye-Glass should be used. Tag 3: Turn off when not in use. Tag 4: Cutting Tool Warning. Tag 5: Throwing Danger Warning. Tag 6: The user should wear shoes with steel end parts. Tag 7: The user should wear gloves.

GETK.8032.007

0

CUTTING PRESSURE

Tag : 10 Tag : 11

Tag : 8

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Tag 14: The tag illustrating the rotation direction of the saw blade. Tag 15: The tag illustrating the rotation direction of the saw blade. Tag 16 : Lubrication Tag Tag 17 : Illumination Tag

Tag 18 : Clamp Tightening Tag

Tag 19 : Blade Tensioning Tag

Attention If the machine will not be used for one week or for a longer time, in order to lengthen the blade life time, loosen the blade.

Tag : 16

Tag : 14 Tag : 15

Tag : 19

Tag : 18

Tag : 17

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Tag 20 Type Tag (Machine type, Manufacturing Year, Serial Number, Capacity, Outer Dimensions and Weight) Tag 21 Electrical Values Tag (Motor Power, Phase, Frequency, Operating Voltage, Control Voltage, Current, Intermediate Fuse Current, Electrical Circuit Number).

Tag 22 Danger of Hydraulic High Pressure Tag 23 Danger of Blade Pressure

Attention Change the reducer lubricant at the end of the first 2000 hours.

Tag : 20 Tag : 21

Tag : 22 Tag : 23

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WARNING In order for the cutting process to be realized, there has to be material between the clamps.

Tag 24 Cutting Information Tag According to the Chips Obtained from the Cut Product

Tag 25 Blade Selection Tag According to the Material to be Cut

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WARNING As a safety precaution, there are two stops in the cutting motor. Emergency stop mushroom button stops the cutting in the saw in a time shorter than 1 second and the stop button stops cutting in 2-3 seconds. However, if the emergency stop button is used frequently, the motor and

inverter life is shortened.

Tag 26 Cutting Values Tag According to the Material to be Cut

Tag 29 Warning Tag

Tag 30 Do not open machine guards unless machine is turned off.

Tag 27 The tag illustrating the presence of the chip conveyor

Tag 28 Upper Press Downward-Upward Tag

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Tag 31 Rulers (It illustrates the length and angle value of the material to be cut)

Tag 32 Yag Basilacak Grasrlkleri gsterir

Tag 32 It illustrates the lubricators where lubricant is to be applied

Tag 33 It illustrates the lubricators where lubricant is to be applied

Blue ground Yellow ground Red ground

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Tag 34 Warning and Precaution Tag (It illustrates the risks which can be encountered and the precautions to be taken)

Tag 35 Manufacturers Symbol

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Tag

27

Mat

eria

l Tag

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2. 3 Prohibited Applications

Since the cutting bandsaw can not be closed by any casing, while cutting and/or while operating in the idle mode, there will be accidents in case the workers approach their hands or fingers.

While the guided body moves downwardly-upwardly, if the worker approaches the guided body, accidents may occur. Keep far away from the movable members.

Figure 2.2

Figure 2.3

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Look at the piece list for the weight of the removable pieces. Do not lift and do not try to lift

pieces heavier than 15 kg without using auxiliary equipment (hoist, crane, etc.).

The intermediate distance between the rotating helix and the conveyor groove sheet is 10 mm.

In order to prevent accidents while the chip conveyor is functioning, be careful with the rotating

helix region.

ATTENTION! Lifting heavy loads gives permanent damages to your body.

Figure -2.4

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The machine with the rotating table can rotate 60 in clockwise direction. While rotating the

machine with the rotating table, be sure that the machine is not inside the safety distances below.

If a worker exists inside the machine rotation region illustrated in Figure 2-6, accidents can take

place.

ATTENTION! The body is rotated by hand. After the body is brought to the desired angle, do not lock the body!


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2.4 Safety members and switches in the machine

LOWER LEVEL SWITCH (LIMIT SWITCH) It lifts the saw head upwardly when the saw head reaches the lowest level.

COVER SWITCHES (LIMIT SWITCH)

It prevents the operation of the machine while the cover is open.

MATERIAL FINISH SWITCH (MATERIAL SWITCH)

The switch which contacts with the automatically driven material does not contact with the material and the material is finished and it stops the driving process.

EMERGENCY STOP BUTTON (EMERGENCY STOP)

When pressed in an emergent case, it electrically stops the machine. There are two stops in the cutting motor as a safety precaution. Emergency stop mushroom button stops the cutting process in the saw in a time shorter than 1 second and it stops the button in a time longer than 2 seconds. However, if the emergency stop button is pressed frequently, the motor and inverter life is shortened.

Acil Stop

Right Cover Switch

Upper Level Switch

Figure -2.7

Lower Level Switch

Material Finish Switch

Emergency Stop Button

Left Cover Switch

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BLADE TENSIONING SWITCH (VICE SWITCH)

COVER SWITCHES

TENSION SWITCH: When the blade is broken or when the blade loses the tension, it stops the machine.

Keep Cover Switches in Closed Position.

Tension switch

Do not leave Cover Switches open.

ATTENTION! While the protective covers are open, thanks to the switches with XCS- A701 CE, the machine is prevented from being operated. When the cover is open, the machine does not function! Cover switches can be positioned on the cover or next to the cover. This does not change the abovementioned warnings.

Figure -2.8


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2.5 Safety regions of the machine

For the correct placement of the machine, the placement dimensions and the space distances to be left in the periphery thereof are mentioned below:

Placement Dimensions

A: 2060 mm. B: 1000 mm. Space Distances A1: 1200mm. A2: 800 mm. B1: 3000 mm. B2: 3000 mm.

Figure -2.11

THE CUT MATERIAL + 500

THE MATERIAL TO BE

CUT

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2.6 Technical machine data

DCB-A 360 TECHNICAL SPECIFICATIONS

DURMA

LW300

HA

DCB-A 360 Double Column Bandsaw Automatic Round mm 360 Square mm 360 90 Rectangle mm 360x380 Round mm - Square mm - 60 Rectangle mm - Round mm - Square mm - 45 Rectangle mm - Round mm - Square mm -

Cu

ttin

g C

apac

ity

30 Rectangle mm -

Main Motor kW 2,2 Hydraulic Pump Motor kW 0,55 Material Driving Motor kW 0,25

Mo

tors

Cooling Motor kW 0.09 Length (L) mm 2480 Width (W) mm 1100

Dim

ensi

on

Height (H) mm 1615 Cutting Speed m/min 20 ~ 80 Inverter Blade Dimensions mm 34x1,1x4570 Working Height (A) mm 540 Oil Tank Capasity Lt. 8 Weight Kg 1650

Figure -2.112

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DCB-S 360 TECHNICAL SPECIFICATIONS

DURMA

AH

W320 L

HORIZONTAL BANDSAW HALF AUTOMATIC DCB-S 360

Standard Rotating Table

Round mm 360 360 Square mm 360 360 90 Rectangle mm 500x360 360x380 Round mm 280 280 Square mm 280 280 60 Rectangle mm 280x360 280x360 Round mm 160 160 Square mm 160 160 45 Rectangle mm 160x360 160x360 Round mm - - Square mm - -

Cu

ttin

g C

apac

ity

30 Rectangle mm - -

Main Motor kW 2,2 Hydraulic Pump Motor kW 0,55 Blade Rotation Motor kW - M

oto

rs

Cooling Motor kW 0.09 Length (L) mm 2480 2480 Width (W) mm 1100 1250

Mac

hin

e D

imen

sio

ns

Height (H) mm 1615 1715 Cutting Speed m/min 20 ~ 80 Non-gradual Electronics Blade Dimensions mm 34x1,1x4570 Working height (A) mm 540 640 Oil Tank Capasity Lt. 8 Weight Kg 1500 1750

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DURMA

AH

W480 L


Cu

ttin

g C

apac

ity

30 Rectangle mm -

Main motor kW 3 Hydraulic pump motor kW 1,1 Material Driving Motor kW 0,75 M

oto

rs


Dim

en

sio

n

Height (H) mm 1820 Cutting Speed m/min 20 ~ 90 Inverter Blade dimensions mm 41x1,3x5800 Working Height (A) mm 580 Oil Tank Capasity Lt. 18 Weight Kg 2300

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DURMA

AH

W320 L

HORIZONTAL BANDSAW HALF AUTOMATIC DCB-S 460

Standard Rotating Table

Round mm 460 460 Square mm 460 460 90 Rectangle mm 460x620 460x620 Round mm 460 460 Square mm 460 460 60 Rectangle mm 460x500 460x440 Round mm 310 290 Square mm 310 290 45 Rectangle mm 460x310 460x290 Round mm - 120 Square mm - 120

Cu

ttin

g C

apac

itie

s

30 Rectangle mm - 460x120

Main motor kW 3 Hydraulic pump motor kW 1,1 Blade Rotation Motor kW - M

oto

rs


Mac

hin

e D

imen

si

on

s

Height (H) mm 1900 2000 Cutting Speed m/min 20 ~ 90 Inverter Blade Dimension mm 41x1,3x5800 Working height (A) mm 580 680 Oil Tank Capasity Lt. 18 Weight Kg 2090 2470

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DURMA

AH

W480 L


Cu

ttin

g C

apac

ity

30 Rectangle mm -

Main Motor kW 4 Hydraulic pump motor kW 1,1 Material Driving Motor kW 1,1 M

oto

rs


Dim

en

sio

n

Height (H) mm 2040 Cutting Speed m/min 20 ~ 90 Inverter Blade dimensions mm 41x1,3x7000 Working Height (A) mm 580 Oil Tank Capasity Lt. 18 Weight Kg 2600

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DURMA

AH

W320 L HORIZONTAL BANDSAW HALF

AUTOMATIC DCB-S 560 Standard Rotating table

Round mm 560 560 Square mm 560 560 90 Rectangle mm 560x750 560x750 Round mm 560 560 Square mm 560 560 60 Rectangle mm 560x600 560x560 Round mm 430 380 Square mm 430 380 45 Rectangle mm 560x430 560x380 Round mm - 160 Square mm - 160

Cu

ttin

g C

apac

itie

s

30 Rectangle mm - 560x160

Main motor kW 4 Hydraulic pump motor kW 1,1 Blade Rotation Motor kW - M

oto

rs


Mac

hin

e d

imen

si

on

s

Height (H) mm 2040 2140 Cutting Speed m/min 20 ~ 90 Inverter Blade dimensions mm 41x1,3x7000 Working Height (A) mm 580 680 Oil Tank Capasity Lt. 18 Weight Kg 2450 2850

ORIGINAL GUIDE

383838101 38

DCB-A 800 TECHNICAL DATA

L

AH

W

BC

DURMA

DCB-A 800 Hydraulic Double Column Automatic Bandsaw Machine Round mm 800 Square mm 800 90 Rectangle mm 800x920 Round mm - Square mm - 60 Rectangle mm - Round mm - Square mm - 45 Rectangle mm - Round mm - Square mm -

Cu

ttin

g C

apac

itie

s

30 Rectangle mm -

Cutting motor kW 7,5 Hydraulic motor kW 1,5 Material driving motor kW Hydraulic M

oto

r P

ow

ers

Cooling motor kW 0,37 Length (L) mm 3970 Width (W) mm 2000 Height (H) mm 2660 Clamp height (B) mm 470

Dim

ensi

on

s

Hydraulic Upper Press Height (C) mm 500 Cutting speed m/min 20 ~ 90 Non-gradual Electronics Blade dimensions mm 54x1,6x8600 Working height (A) mm 660 Weight Kg 4500 Oil Tank Capasity Lt. 45 Blade Twisting Angle 60

ORIGINAL GUIDE

393939101 39


W

AH

L

DURMA

DCB-S 800 HORIZONTAL BANDSAW HALF AUTOMATIC Round mm 800 Square mm 800 90 Rectangle mm 800x90 Round mm 700 Square mm 720 60 Rectangle mm 800x700 Round mm 530 Square mm 530 45 Rectangle mm 800x530 Round mm - Square mm -

CU

TT

ING

CA

PA

CIT

IES

30 Rectangle mm -

Main motor kW 7,5 Hydraulic pump motor kW 1,5 Blade rotation motor kW - M

oto

rs

Cooling motor kW 0,37 Length (L) mm 3970 Width (W) mm 1380

Mac

hin

e D

imen

si

on

s

Height (H) mm 2660 Cutting speed m/min 20 ~ 90 Inverter Blade dimensions mm 54x1,6x8600 Working height (A) mm 660 Oil Tank Capasity Lt. 45 Weight Kg 3400

ORIGINAL GUIDE

404040101 40


L

AH

W

BC

DURMA

DCB-A 1100 Hydraulic Double Column Automatic Bandsaw Machine Round mm 1100 Square mm 1100 90 Rectangle mm 1100x1300 Round mm - Square mm - 60 Rectangle mm - Round mm - Square mm - 45 Rectangle mm - Round mm - Square mm -

Cu

ttin

g C

apac

itie

s

30 Rectangle mm -

Cutting motor kW 11 Hydraulic motor kW 3 Material driving motor kW Hydraulic M

oto

r P

ow

ers

Cooling motor kW 0,37 Length (L) mm 5500 Width (W) mm 2400 Height (H) mm 3400 Clamp height (B) mm 650

Dim

ensi

on

s

Hydraulic Upper Press Height (C) mm

680

Cutting speed m/min 20 ~ 90 Non-gradual Electronics Blade dimensions mm 67x1,6x12000 Working height (A) mm 680 Weight Kg 9400 Oil Tank Capasity Lt. 45 Blade twisting angle 65

ORIGINAL GUIDE

414141101 41


W

AH

L

DURMA

DCB-S 1100 HORIZONTAL BANDSAW HALF AUTOMATIC Round mm 1100 Square mm 1100 90 Rectangle mm 1100x1300 Round mm 840 Square mm 840 60 Rectangle mm 1100x840 Round mm 640 Square mm 640 45 Rectangle mm 1100x640 Round mm - Square mm -

CU

TT

ING

CA

PA

CIT

IES

30 Rectangle mm -

Main motor kW 11 Hydraulic pump motor kW 2,2 Blade rotation motor kW - M

oto

rs


Mac

hin

e D

imen

si

on

s


ORIGINAL GUIDE

424242101 42


W

A

H

L

W

B

DURMA

DCB-A 1600 Double Column Half Automatic

Bandsaw Machine

Round mm 1600 Square mm 1600 90 Rectangle mm 1600x2050 Round mm - Square mm - 60 Rectangle mm - Round mm - Square mm - 45 Rectangle mm - Round mm - Square mm -

Cu

ttin

g C

apac

itie

s

30 Rectangle mm -

Cutting motor kW - Hydraulic motor kW - Material driving motor kW - M

oto

r P

ow

ers

Cooling motor kW 0,55 Length (L) mm ~7500 Width (W) mm ~3600 Height (H) mm ~5200

Dim

ensi

on

s

Clamp height (B) mm ~1000 Cutting speed m/min 20 ~ 100 Non-gradual Electronics Blade dimensions mm 80x1,6x16000 Working height (A) mm ~800 Weight Kg ~22000 Oil Tank Capasity Lt. ? Blade twisting angle 90

ORIGINAL GUIDE

434343101 43

DCB-S 1600 TECHNICAL DATA

W

A

H

L

W

B

DURMA

DCB-S 1600 Double Column Half Automatic Bandsaw Machine Round mm 1600 Square mm 1600 90 Rectangle mm 1600x1600 Round mm 1200 Square mm 1200 60 Rectangle mm 1600x1200 Round mm 900 Square mm 900 45 Rectangle mm 1600x900 Round mm - Square mm -

Cu

ttin

g C

apac

itie

s

30 Rectangle mm -

Cutting motor kW 18,5 Hydraulic motor kW 4 Material driving motor kW - M

oto

r P

ow

ers

Cooling motor kW 0,55 Length (L) mm ~6100 Width (W) mm ~2200 Height (H) mm ~4350 Minimum Saw Body Height (W) mm ~3000

Dim

ensi

on

s

Clamp height (B) mm 1000 Cutting speed m/min 20 ~ 100 Non-gradual Electronics Blade dimensions mm 80x1,6x16000 Working height (A) mm 680 Weight Kg ~12500 Oil Tank Capasity Lt. ? Blade twisting angle 90

ORIGINAL GUIDE

444444101 44

DCB-M 460 TECHNICAL DATA

DCB-M 460 Hydraulic Double Column One-

Directional Angled Cutting Bandsaw Machine

Round mm 460 Square mm 460 90 Rectangle mm 460x620 Round mm 460 Square mm 460 60 Rectangle mm 460x440 Round mm 290 Square mm 290 45 Rectangle mm 460x290 Round mm 120 Square mm 120

Cu

ttin

g C

apac

itie

s

30 Rectangle mm 460X120

Cutting motor kW 3 Hydraulic motor kW 1,1 Material driving motor kW - M

oto

r P

ow

ers

Cooling motor kW 0.09 Length (L) mm 3000 Width (W) mm 1250 Height (H) mm 2000

Dim

ensi

ons

Clamp height (B) mm 280 Cutting speed m/min 20 ~ 90 Non-gradual Electronics Blade dimensions mm 41x1,3x5800 Working height (A) mm 680 Weight Kg 2140 Oil Tank Capasity Lt. 18 Blade twisting angle 60

ORIGINAL GUIDE

454545101 45

DCB-M 560 TECHNICAL SPECIFICATIONS

DCB-M 560 HORIZONTAL BANDSAW HALF

AUTOMATIC Standard Rotating table


Cu

ttin

g C

apac

itie

s

30 Rectangle mm 560x470

Main motor kW 7,5 Hydraulic pump motor kW 1,5 Blade rotation motor kW - M

oto

rs


Mac

hin

e D

imen

si

on

s


ORIGINAL GUIDE

464646101 46

DCB-M 800 TECHNICAL DATA

DCB-M 800 Hydraulic Double Column One-



Cu

ttin

g C

apac

itie

s


Cutting motor kW 7,5 Hydraulic motor kW 1,5 Material driving motor kW - M

oto

r P

ow

ers

Cooling motor kW 0,37 Length (L) mm 3970 Width (W) mm 1720 Height (H) mm 2890 D

imen

si

on

s

Clamp height (B) mm 470 Cutting speed m/min 20 ~ 90 Non-gradual Electronics Blade dimensions mm 54x1,6x8600 Working height (A) mm 885 Weight Kg 5860 Oil Tank Capasity Lt. 45 Blade twisting angle 60

ORIGINAL GUIDE

474747101 47

DCB-DM 560 TECHNICAL DATA

B

DURMAHA

W W

DCB-DM 560 Hydraulic Double Column One-



Cu

ttin

g C

apac

itie

s


Cutting motor kW 7,5 Hydraulic motor kW 3 Material driving motor kW - M

oto

r P

ow

ers

Cooling motor kW 0,37 Length (L) mm 4100 Width (W) mm 2080 Height (H) mm 2620 D

imen

si

on

s

Clamp height (B) mm 450 Cutting speed m/min 20 ~ 100 Kademesiz Elektronik Blade dimensions mm 54x1,6x8200 Working height (A) mm 780 Weight Kg 5300 Blade twisting angle 60

ORIGINAL GUIDE

484848101 48

DCB-FA 330 TECHNICAL DATA

A

H

W L

B

DURMA

DCB-FA 330 Hydraulic Dual Column Fully Automatic Band Saw Machine Round mm 330 Square mm 330 90 Rectangle mm 330x370 Round mm 310 Square mm 310 60 Rectangle mm 330x310 Round mm 220 Square mm 220 45 Rectangle mm 330x220 Round mm 120 Square mm 120

Cu

ttin

g C

apac

itie

s


Cutting motor kW 1,5 Hydraulic motor kW 0,55 Material driving motor kW 1,1 M

oto

r P

ow

ers

Cooling motor kW 0.09 Length (L) mm 1950 Width (W) mm 2150 Height (H) mm 1710 D

imen

si

on

s

Clamp height (B) mm 200 Cutting speed m/min 20 ~ 100 Kademesiz Elektronik Blade dimensions mm 27 x 0,9 x 3900 Working height (A) mm 700 Weight Kg 1200 Blade twisting angle 90

ORIGINAL GUIDE

494949101 49

2.7 The main pieces of the machine The frontal view of the machine

Piece number PIECE NAME and STANDARD NUMBER Figure / Code Number

Weight KG

COMPANY / CERTIFICATE

1 BODY B8042010100 220 DURMA

2 LOWER COLUMN BEARING B8042020001 17 DURMA

3 CUTTING TABLE B8042020100 260 DURMA

4 RIGHT FRONT COVER B8042032900 -- DURMA

5 DRIVE ROLLER B8042030802 52 DURMA

6 LEFT RECTIFICATION ARM B8042031501 34 DURMA

7 LEFT FLAP B8042030201 140 DURMA

8 IDLE ROLLER B8042030801 49 DURMA

9 LEFT FRONT COVER B8042032900 -- DURMA

10 TELESCOPIC BLADE PROTECTION B8042031100 -- DURMA

11 ELECTRICAL PANEL 336709000514 48 EKINPANO/CE

12 BLADE 2010901410 -- LENOX / CE

13 MOVABLE CLAMP B8042020700 130 DURMA

14 LENGTH ADJUSTMENT MECHANISM B8032180001 -- DURMA

15 LOOPHOLE B8032061004 20 DURMA

16 CHIP BOX B8046180700 -- DURMA

17 FIXED CLAMP B8042020600 180 DURMA

18 BRUSH GUARD B8042300001 -- DURMA

19 BRUSH MECHANISM ASSEMBLY B8032032700 -- DURMA

20 MATERIAL TABLE ASSEMBLY B8033190000 105 DURMA

Figure -2.13

ORIGINAL GUIDE

505050101 50

The rear view of the machine

Piece number PIECE NAME and STANDARD NUMBER Figure / Code Number Weight KG COMPANY /

CERTIFICATE

21 MAIN MOTOR 9170001460 80 YILMAZ REDKTR/CE

22 DRIVING MOTOR 3300102631 25 YILMAZ REDKTR/CE 23 FIXED CLAMP GUARD B8043020900 -- DURMA

24 MATERIAL DRIVING REDUCER GUARD B8043021500 -- DURMA

25 DIRECTION CHANGING BOX ASSEMBLY B8043020400 -- DURMA

26 MANUAL MULTIPLE CUTTING APPARATUS B8043021600 -- DURMA

27 LIFTING CYLINDER ASSEMBLY (DCB 560) B8042070000 DURMA

28 HYDRAULIC UNIT 1,1 KW 3,2CC 12LT TANK 3605100073 16 HYDRO PACK/CE

29 CENTRIFUGE PUMP BP12 3434000398 -- DEGISIM MOTOR 30 ROLLER TENSIONING GUIDE B8032031202 -- DURMA

Figure -2.14

ORIGINAL GUIDE

515151101 51

THE DETAILS OF THE LENGTH AND HEIGHT ADJUSTMENT APPARATUS

Piece number PIECE NAME and STANDARD NUMBER Figure / Code Number Weight

KG COMPANY /

CERTIFICATE

31 ROLLER TENSIONING CYLINDER B8042030102 -- DURMA

32 CLAMP TIGHTENING CYLINDER B8042020200 -- DURMA

33 ROLLER TENSIONING ROTATION WHEEL B8042032606 -- DURMA

34 CABLE CHANNEL CPS50.75.BO 3770002145 -- CPS / CE 35 GUIDED BODY INTERMEDIATE COVER B8042030008 -- DURMA

36 UPPER BRIDGE B8042050000 -- DURMA

37 CHAIN TENSIONING GEAR 2 B8043020108 -- DURMA

38 CHAIN DOUBLE SEQUENCED 1/2 0803000042 -- ZIMAS/CE

39 CHAIN TENSIONING GEAR 1 B8043020106 -- DURMA

40 CAM SHAFT B8043020105 --

41 ROLLER TENSIONING CYLINDER GUARD B8042030007 --

Piece number PIECE NAME and STANDARD NUMBER Figure / Code Number Weight

KG COMPANY

1 LENGTH ADJUSTMENT SWITCH PIN B8004100004 -- DURMA

2 LENGTH ADJUSTMENT SWITCH SHELL B8004100005 -- DURMA

3 LENGTH ADJUSTMENT SWITCH CONNECTION PIECE B8004100003 -- DURMA

4 SWITCH CONNECTION PIECE B1010010013 -- DURMA

5 LENGTH MEASUREMENT RULER TAG ETK:8002-015 3903013075 -- SAHELLER/CE

Figure -2.15

ORIGINAL GUIDE

525252101 52

CONTROL PANEL

FIXED CLAMP MAIN PIECES

Piece number PIECE NAME and STANDARD NUMBER

Figure / Code Number

Weight KG


1 START BUTTON 3300700470 -- SIEMENS / CE

2 STOP BUTTON 3300700490 -- SIEMENS / CE

3 ALARM LAMP 3301400102 -- SIEMENS / CE

4 WATER PUMP SWITCH 3300700355 -- HIDROPAR/CE

5 SAW UPWARD BUTTON 3300700450 -- SIEMENS / CE

6 SAW DOWNWARD BUTTON 3300700450 -- SIEMENS / CE

7 BACK DRIVING BUTTON 3300700450 -- SIEMENS / CE 8 FORWARD DRIVING BUTTON 3300700450 -- SIEMENS / CE

9 MANUAL / AUTO SELECTIVE BUTTON 3300700450 -- SIEMENS / CE

10 CLAMP RELEASING BUTTON 3300700450 -- SIEMENS / CE

11 CLAMP TIGHTENING BUTTON 3300700450 -- SIEMENS / CE

12 EMERGENCY STOP BUTTON 3300700040 -- SIEMENS / CE

13 COUNTER 3303910170 -- EMKO / CE

14 DIGITAL EPM 3790 3303910171 -- EMKO / CE

15 HYDRAULIC SPEED ADJUSTMENT VALVE 3427050195 -- HIDROPAR/CE

P

NC

3

1

START

2

STOP

2 8

4

3

15

56

7

10

9

E

12

OS T

MER EG

5

6

GETK.8042.001

Y

4

9

7 8

set

10 11

13 14

Figure -2.16

ORIGINAL GUIDE

535353101 53

MAIN PIECES OF THE MOVABLE CLAMP

MAIN PIECES OF THE CHIP CONVEYOR

Piece number PIECE NAME and STANDARD NUMBER Figure / Code Number


1 WELDED ASSEMBLY OF THE CONVEYOR 8052.07.01.00 DURMA

2 CONVEYOR MOTOR REDUCER 3300102626 YILMAZ RED./CE 3 HELIX ASSEMBLY 8052.07.01.20 DURMA 4 KONVEYOR REDUCER FLANGE 8052.07.00.07 DURMA 5 6206 -BEARING 3603600022 ORS / CE 6 GRAPHITE BUSH PAP 3545 P10 3603510314 BUSHING/CE 7 M8 x 20 DIN 912 DURMA

Figure -2.17

ORIGINAL GUIDE

545454101 54

2.8 Standard and optional accessories in the machine 2.8.1 Standard accessories

Hydraulic Material Tightening: The fixation of the materials, which are to be cut, between the

clamps is one of the most important factors for the cutting process. The material, which is tightened

by the hydraulic cylinder driven clamps, is fixed during the cutting process without being loosened.

Cutting Speed which can be Adjusted in a non-gradual manner: For obtaining ideal cuttings, the

cutting speed should be adjusted to a suitable value. When the cutting speed is low or high, the

cutting results are bad and the blade life is decreased. The cutting speed can be easily adjusted to

the desired speed through the digital display on the control panel in a non-gradual manner.

Motorized 90 Rolled Driven Clamp: This is the simplest and most rapid material driving system

among the automatic models. All of the rolls are driven by a chain from the motor outlet. It provides

great advantages in all of the general purpose cuttings.

Bimetal Bandsaw: As a standard, in all of the bandsaw machines, one bimetal bandsaw is given so

as to be compliant with the general usage. When desired, different models or the blades in tooth step

can be provided as extra.

Cooling System: Thanks to the strong centrifuge pump, in watery sections, water-based borate oil is

adjusted with the desired flow rate and sent to the cutting region and to the blade bearings. The

machine is delivered so as not to have borate oil.

Cutting Height Adjustment: The positioning of the blade at a substantial height according to the

height of the materials to be cut, provides great time saving by decreasing the waiting time in the

cycle particularly in serial cuttings.

Bearing and Carbide Type Blade Bedding: When a suitable saw blade is used, the perpendicularity

and the glibness of the cutting mostly depend on the blade bearings. Thanks to the carbide metals

which contact with the lateral surfaces of the blade so as to have a suitable space and parallelism and

thanks to the bearings on the back surface, cuttings with ideal perpendicularity and glibness are

realized. Thanks to this, the blade and material costs and the after-cutting labor are minimized.

Chip Brush: During the cutting process, the cleaning of the chips existing between the teeth of the

blade is very important for the life of the blade. These chips are substantially cleaned by the chip

brush rotating by means of the blade effect. The chip accumulation around the saw body is

prevented.

Hydro-mechanical Blade Tensioning: During the manual tensioning of the blade, it provides the

ideal tension to be seen on the manometer. It stops the system in case the blade is broken.

Mechanical Upper Press: In the multiple cutting of the materials in binding form, the packet is

prevented from being distributed since the roll, which has bearing and which is adjusted by hand,

applies pressure from above.

ORIGINAL GUIDE

555555101 55

Electrical Length Adjustment: In automatic models, the length adjustment of the material to be cut

is realized by fixing, by hand, of the mechanic stop in the desired dimension up to 600 mm. In serial

cuttings, rolled driven clamp drives the material up to the stop and when it contacts with the stop, the

desired length dimension is obtained, and the driving process ends and the cutting process begins.

When the cutting is finished, the piece falls and the cycle is repeated.

Piece counter: In automatic models, the number of the material to be cut is entered and serial

cuttings are provided to be realized. Besides, it also illustrates the alarm and cutting data regarding

the machine.

1200mm Material Table: By means of the bearing type rolled material table existing in the inlet or

outlet of the machine, the material to be cut can be easily driven. One table is provided together with

the related machine as a standard. Since the additional tables can be added one after the other,

longer materials can also be supported.

2.8.2 Optional accessories

Hydraulic Blade Tensioning: It provides the blade tensioning process to be realized through the

control panel without human force. When ideal tension is provided, the tensioning process is ended. It

stops the system in case the blade is broken.

Motorized Chip Brush: The chips remaining between the teeth of the blade during cutting should be

cleaned for the lifetime of the blade to be longer. By means of motorized chip brush, these chips are

substantially cleaned. Chip accumulation around the blade body is prevented.

NC Control System: In automatic models, operation of all of the functions becomes easier with the

programming of the length, cutting number and other parameters through the touch-screen. The

measuring of the material, which is pressed between the roller driven clamps, by the encoder, and

cutting of said material in the desired length are provided without the need for the switch type

automatic length stop system.

Chip Conveyor: Particularly during the cutting of full materials, the output chip amount is excessive

and it has to be cleaned frequently. By means of the motorized chip conveyor, the accumulated chips

are discharged from the machine.

Laser Marking System: It facilitates the length adjustment of the material to be cut. From the laser

line reflected onto the material surface, without the need for the front surface of the bandsaw, the

length dimension and the point where the material will be cut can be easily seen. By positioning the

saw blade upwardly from the material, during the advancing of the material, it is prevented from being

damaged. This facilitates operation in half automatic models and particular cutting processes.

Automatic Cutting Pressure Control: In order to provide ideal cuttings, the adjustment of the

suitable lowering speed is very important. If the lowering speed is low or excessive, the cuttings are

deteriorated and the blade lifetime is shortened. By means of automatic cutting pressure control, the

blade is provided to function with ideal load during the cutting process, the blade lifetime is

ORIGINAL GUIDE

565656101 56

engthened.

Micro-spray Cooling System: Particularly during the cutting of walled materials (Pipe, Profile, U, I,

H, L), it is used instead of the borate oil which is used for cooling the heated blade. By spraying air

and micronized particular cutting lubricant mixture to the tooth ends of the saw, the chips on the teeth

can be removed in an easier manner, the heating formed on the teeth is decreased and the blade

lifetime is increased. It is ecologic, besides, it minimizes the borate oil costs.

2.8.3 Particular solutions

For cutting long materials easily, order Material Tables with particular dimensions.

Contact with the manufacturer company for Different Clamp Height Solutions.

ORIGINAL GUIDE

575757101 57

2.9 Noise

2.9.1 Noise measurement levels

NOTE: The measurements are realized according to the EN ISO 11202 noise measurement standard in the direction of the standard EN 12100.

The noise limit is designed to be at the minimum level. The design is prepared in the direction of the below-mentioned factors:

In the rollers where the blade is bedded, bearings and guides, which function without noise, are used. The flexible hoses are insulated from the pump and manifold assembled to the machine. In case the valves function during pressure, hydraulic circuit designs are selected which prevent the noise which may be formed as a result of the hydraulic.

Couplings are used between the motor and the pump which prevent vibration.

When the machine is idle......55......dB

When the machine is operating with load......58.....dB

Water pump......52......dB

Figure -2.19

Operator position measurement point (5)

ORIGINAL GUIDE

585858101 58

2.10 Standards used in saw design

In the design of DCB series columned type machines, the TS EN 13898 standard is used. During the assembly steps, by using certificated safety members compliant with the standards, operating conditions with 0 accident with high safety are desired to be obtained.

EN 13898 Machine Safety Simple designs, design for the general principles

Item 1 : Simple terminology, methodology.

EN 292-2

EN 292-1

Machine Safety - Simple designs, design for the general principles

Item 2 : Technical principles and properties.

EN 418 Machine Safety Emergency stop fixtures and functional pieces.

EN 953 Machine Safety - Traceability (fixed, movable).

EN 982 Machine Safety Safety rules for the fluid systems and pieces Hydraulic.

EN 60204-1 Machine Safety Electrical equipment of the industrial machines.

Item 1: General rules.

Figure 2.20

ORIGINAL GUIDE

595959101 59

PART 3 - INSTRUCTIONS FOR MACHINE TRANSPORTATION

3.1 Transportation of the machine

There are four carrying hooks on the machine. This is illustrated as A, B, C and D in Figure 3-1.

Before starting the carrying process, fix the movable members (clamp, rotating table, electrical panel, etc.). Take the guided body to the bottom position. Fix the members which can be rotated.

Do not carry machine members like material table, which are used externally, together with the

machine. Carry these members after the machine is carried and placed.

Connect the hoist hook and carrying hooks by means of a firm rope, and afterwards, place the machine to a suitable place inside the plant.

During the carrying of the machine, be sure that the machine is positioned so as not to give damage to the machine and to the environment.

While positioning the machine, taking into consideration that the piece to be cut is to be driven, be sure that the machine is positioned so as not to give damage to the personnel, to the machine and to the environment.

Q : 2450 kg.

A

B

C

D

Attention!

Attention! During hoist movement and during carrying, there should not be any person under the carried material and comply with the general carrying rules.

Figure 3.1

ORIGINAL GUIDE

606060101 60

During transportation and storing, in order for our machines not to be affected from the environmental conditions, our machines are wrapped by nylon folio.

When the machine arrives at the place where it is to be operated or stored, tools like crane, hoist, lifter, etc. should be ready and the region where the machine will be placed should be completed and the environmental conditions of the region where the machine will be placed should be suitable. On the concrete where the machine will be installed, there should not be cracks and spaces. Before bringing the machine to its final position, check the anchorage bolts, be sure these bolts are in the correct place. Balancing bolts should be lubricated and they should be placed on the ground with the whole length.

TASIMA SEKLI WEIGHT : 2600 Kg.

Figure 3.2

Attention! Before beginning the carrying process, fix the movable members. Take the guided body to the lowest position. Fix the rotatable members.

ORIGINAL GUIDE

616161101 61

3.2 REMOVING THE PACKAGE

After placing the machine to its place, take it from the package thereof carefully. During the removal of the package, do not give damage to the machine. PART 4 - STORING CONDITIONS If the machine will not be used for a long time:

Remove the saw blade and preserve it. Empty the hydraulic lubricant.

Empty the cooling liquid.

Clean the dust and chips on the machine.

Lubricate with protective lubricant.

Protect the machine from excessive sunlight.

Storing in open area (in rainy environment) should be avoided. The valve sockets may be damaged or the electrical system may be damaged.

Package the machine so that dust does not enter.

Attention! If the machine will not be used for a long time, keep it in packaged form in a dry environment.

ORIGINAL GUIDE

626262101 62

PART 5 - MACHINE INSTALLATION INSTRUCTIONS

5.1 The working area of the machine For machine installation, prepare the region illustrated by dashed lines in Figure 5-1. The area, which

you determine the general borders, will be the safe operating area of your machine. While operating on the machine, there should be no person inside these areas. The length of the material you cut can be long. Determine the operating area by giving attention that the area, the material will be loaded to the machine, is at least equal to L + 500. If possible, leave the feeding area open.

The balance bolts of the machine should be supported by suitable metal pieces. As can be seen in Figure 5-2, the machine should be fixed to the ground by anchorage bolts. Prior to fixation, the concrete should be made compliant to the machine. Moreover, using bolts with the required sizes and quality, this process can be realized. The machine should be checked by means of sensitive balance apparatus (water balance or digital balance). The recommended balance planes are the surfaces on which the clamp functions. The rear material table is balanced by balancing the material table onto the lower surface whereon the clamps function.

The balance of the machine is adjusted by the tightening and loosening of the bolts which are placed separately in each leg.

THE BODY OF THE MACHINE SHOULD NOT BE SUBJECTED TO BE TWISTED IN ANY CASE. 5.2 Machine installation

Attention! The length of the material to be cut should not be greater than the length of

the material table.

Figure 5.1

THE MATERIAL TO BE

CUT

THE CUT MATERIAL + 500

ORIGINAL GUIDE

636363101 63

5.3 Machine placement

A

NUT M12 DIN 934

WASHER

A DETAIL

CONCRETE

ANCHORAGEBOLT

SHEET PLATE

BOLT M12x30DIN 933

Attention! The machine should be installed by trained personnel.

Figure 5.2

ORIGINAL GUIDE

646464101 64

5.4 Electrical connections

Connect the machine to the main supply by means of standard electrical cables. The machine is arranged with respect to 3 phase main voltage. The cable input is through under the electrical panel, the cable ends should be connected to the terminals illustrated in the electrical schema.

The electrical connections of the machine should be realized by qualified personnel. 1. In order to realize a correct electrical connection, first of all be sure that the main switch of the machine is closed. Afterwards, realize 3 phased cable and grounding connection. 2. Connect the L1, L2, L3 and N and PE end of the cables to the terminal inside the electrical panel.

3. After you connect the cable ends, apply power to the panel. If the connection is correct, bring the main switch on the electrical panel from 0 to 1 position (it is on the control panel).

4. Bring the switch numbered 1 on the machine control panel (Figure 5-3) from 0 to 1 position. The light of the screens should turn on. If the screens do not turn on, this shows that there is problem in the electrical connection. By changing the places of the cable ends, the machine should be COMPLETELY INSULATED and the phase of the machine should be interrupted and the connections should be checked.

5. After the screen is turned on, press the button numbered 2. The hydraulic pump operates. Now the machine is ready for functioning. After you observe that the blade functions after pressing the button numbered 3, stop the blade by pressing the button numbered 4.

6. Panel feeding voltage is 24 volt; Solenoid coil feeding voltage is equal to 24 DC. Each solenoid coil adjustment is connected to the circuit by means of separate relays. Local (coming to the machine) voltage should be checked by assessing the transformer and the main motor voltage. Connect the suitable supply cable to the machine and apply power after checking.

1 2 3 4

Figure 5.3

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5.4.1 Motor direction

Cutting motor will be seen when observed from the rear of the machine. The rotation direction of the

cutting motor, which rotates the cutting blade, should not be changed. In order for the teeth on the blade to

realize cutting, the teeth should face the motor side and they have to rotate towards the motor. Material

feeding motor is adjusted so as to be able to rotate in both directions. For feeding the material, the clamps

should be tightened. In order to be able to realize cutting in the desired size, the newly designed driving group

facilitates the cutting process for the user.

Check the rotation direction of the machine motors.

Machinenin

5.4.2 Motor current values

kW

A AHP mm

q

AAA mm

q

mmAAA mm

q

A Amm

q q

Figure 5.4

CUTTING MOTOR DIRECTION

DRIVING MOTOR DIRECTION

BLADE DIRECTION

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5.5 First checks

All of the sensitive adjustments of the machine are realized by qualified personnel in our company in the final control step.

The electrical powering connections are described in the previous title. Though, check the below-mentioned items. 5.5.1 Cooling liquid

Take borate oil, which is equal to 10 % of the depot capacity, and take water, and mix the borate oil and water inside a vessel substantially.

Exemplary Application: For a depot of 60 liters, mix 6 liters of borate oil and 54 liters of water. Pour the prepared mixture to the grid holes on the chip box carefully. While filling the cutting liquid, be careful not to pour the liquid outwardly.

Carefully pour the 60 liters of cutting liquid, which was prepared outside beforehand, to the machine pool. Afterwards, take the cooling pump switch, which is illustrated by number 3 in Figure 5-3, to the right position. Be sure that the cooling water is pressed by the related pump. Afterwards, take the cooling pump switch to the left position and interrupt water flow.

After checking that the cooling water pump functions in a correct manner, bring the saw to the upper border position in the plant adjustment by pressing the saw upward button which is mentioned in the previous title.

5.5.2 Hydraulic Unit

The hydraulic unit comprises hydraulic depot and valves (Figure 5-5). The hydraulic unit, which does not occupy much space in the machine, provides high efficiency and it provides the hydraulic of the machine.

Attention! Check the grounding connection of the hydraulic power unit. Check the lubricant level. If it is missing, fill it.

Hydraulic Depot capacity is 12 liters.

Figure 5.5

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The power unit comprises three units:

1. Electrical motor 2. Solenoid valves 3. Tank (Hydraulic Depot) The electrical motor has 3 synchronized types or single-step normally operating B14 type or continuous

unshielded version (model). DC, functioning with 12 and 24 volt, serves the valve block for the front shield of the motors.

The solenoid members are cartridge type. Their coils can function with 12, 24 V DC voltages. And 110, 220 V Rac, Binders are under DIN 43650. 5.5.3 Hydraulic Unit Cleaning

The cleaning of hydraulic unit is realized by cloth fabric. Other members can not be used. The fabric should not be dispersed onto the surface. Once a year, the lubricant in the tank should be cleaned and moreover, the tank should be cleaned. The lubricant change should be realized in the following manner. The pressure in the system is discharged. The electrical connection of the hydraulic unit is interrupted. The pipe (tube) is removed. The hydraulic unit screws are removed by means of a screwdriver. The unit is placed vertically on the tank. The repairing screw is removed and the tank elbows are placed again. The electrical motor is placed together with the center block. The old lubricant is discharged. The tank inner surface is cleaned. In addition to this, the suctioning filter is also cleaned.

The electrical motor with center block is cleaned and afterwards it is placed inside the tank. The repairing screw and the elbow are screwed. The assembled unit is put into operating position. The mentioned amount of hydraulic lubricant is carefully put into the tank through the opening illustrated in Figure 5-6. The air hole should be tightly closed. The pipe (tube) is assembled. And the hydraulic unit is joined with the electrical motor.

Realize the pressure adjustment from here.

Realize the hydraulic level check and the filling process from here.

Attention! Operation using dirty oil decreases the lifetime of the machine.

Figure 5.6

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5.5.4 Hydraulic Unit pressure adjustment

The pressure adjustment in the hydraulic unit is realized by the RV08-2A valve. The pressure adjustment should be realized through the place illustrated in Figure 5-6.

A pressure adjustment is assembled to part P. The adjustment screw is removed. The adjustment screw should be removed completely.

The hydraulic unit is operated and the adjustment screw is made active until the desired pressure level is reached. Afterwards, the adjustment screw is locked.

PART 6 INSTRUCTIONS FOR COMMISSIONING THE MACHINE

6.1 Commissioning

For testing the hydraulic system, be sure that the saw is in the top position and be sure that there is no material between the clamp and the saw.

Turn the machine turning-on button, which is illustrated by number 1, towards right and take it to the final position.

Press the operate pump button illustrated by number 2. Check if the hydraulic system operates. Press the operate cutting motor button illustrated by number 3, and be sure that the bandsaw

turns in the correct direction towards right when viewed from the front side. For stopping, press once to the stop button illustrated by number 4.

Attention! For the failures checked, look at the Probable Failures, Reasons and the Repairing Routes part.

1 2 3 4

Attention! While realizing pressure adjustment, look at the pressure tag. Never exceed the pressure mentioned on the machine.

Figure 6.1

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6.2 Powering

Connect the R, S, T phases of the supply to the L1, L2, and L3 connectors inside the electrical panel by means of 5x2.5 mm2 cable.

During the connections, be sure that the supply switch is closed. Be sure that you connect the protective grounding of the plant to the yellow green grounding

connector of the bench. After taking the required safety precautions, bring the supply switch to the open position. Afterwards, bring the main switch on the electrical panel cover of the machine to 1 position. If the power connections are realized in a correct manner, the lights on the control panel will turn on.

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6.3 Confirmation of the machine

The numbers, which exist on the speed control device and on the counter illustrated by 12 and 13, appear on the screen. Turn the button numbered 9 towards left, and take it to the manual position, and press the saw upward button illustrated by number 5.

When this button is pressed, if the saw is lifted upwardly, the connections are correct. Otherwise, the

phases are connected in an inverse manner. Interrupt the power supply and change the cable ends in the L1 and L2 connectors.

When the machine is lifted upwardly, it will stop at the upper limit when it contacts with the switch

which is illustrated in Figure 6-3 and which exists on the guided body in the upper reference point. This process shows that the machine is operating in a correct manner and that the safety switch operates well.

Figure 6.2

Figure 6.3

Button numbered 9

Button numbered 5

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PART 7 USAGE INSTRUCTIONS

7.1 Users region

The machine is designed so as to be operated with one (1) operator. Do not approach the movable points while the machine is in operation. Comply with the values

mentioned in the safety distance dimension (Figure 5-1). While the machine is in operation, the region where the operator has to exist is given in Figure 7-1. If

the user exists in these regions, accidents may occur. Since the cutting table, which moves downwardly and upwardly, is close to the electrical panel, if the

user approaches his hands towards the rear of the panel, accidents may occur. Therefore, do not approach hands to the rear of the electrical panel.

Attention ! The electrical panel can be on the right or on the left depending on the machine model. This does not change the dangers and warnings above.

Attention! IN CASE OF AN INJURY, A DOCTOR SHOULD BE CALLED OR THE INJURED PERSON SHOULD BE BROUGHT TO A HEALTH CENTER EMERGENTLY.

Figure 7.1

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7.1.1 Prior to cutting

In the cutting table on the electrical panel, the suitable cutting conditions for the material to be cut are described. In this table; the most suitable cutting speed, the blade type to be used, tooth number, and if watery cutting can be realized or not can be seen.

Prior to cutting, the blade bearings should be adjusted according to the material to be cut. Take the blade bearing to the desired position by turning the turning wheel existing on the arm and tighten the fixation screw. Be sure that the blade bearing does not hit the clamps. Do not forget that if the bearing is close to the material, the cutting will be realized in a steeper and smoother manner. 7.1.2 Cutting

1. By turning the button 1 switch in Figure 7-2, turn on the machine and operate the pump using button 2. 2. By taking the blade to the upper position by means of Button 3, carefully place the material to be cut

between the clamps. 3. Tighten the clamp (Button 4) without deforming the material to be cut; and using the driving buttons,

adjust (Button 5-6) the length of the material to be cut. 4. By pressing the start button illustrated by 7, operate the cutting motor. Observe the movement of the

blade. 5. According to the type of the material to be cut, turn the water motor functioning switch, which is

illustrated by 8, to the right, and thereby provide the flowing of the cooling water. Adjust the water flow through the valves on the blade bearings and on the clamp.

6. By pressing the button illustrated by 9, check the lowering of the saw head by means of the saw speed adjustment valve illustrated by 10.

7. Adjust the rotation speed of the bandsaw by means of the potentiometer on the saw speed adjustment device illustrated by 11.

8. Realize the material cutting using the adjusted cutting speed and the lowering speed. 9. In case of any failure, press the stop button illustrated by 12, in case of an emergency, press the

emergency stop button illustrated by 13.

9 6

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3

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7

8

10 11 12 13

Figure 7.2

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7.1.3 Language Selection For selecting the screen language as English or Turkish; use the + button in manual mode. When pressed

once, the other language will be selected. 7.1.4 Counter usage

The hydraulic clamps can be tightened and loosened only when there is no cutting process. If there is no material between the clamps, the following warning message appears on the screen.

7.1.5 Digital potentiometer 1. Press the Set button once for a short time. The

revolution (as revolution/minute) on the screen will start flashing.

2. Using the ? and s buttons, adjust the revolution speed.

3. In case the ? and s buttons are pressed, firstly the 0.1s, afterwards the 1s, afterwards the 10s digit will increase or decrease.

4. Confirm this value by pressing the set button again. 5. If the set button is not pressed for confirmation, it will turn to the prior revolution value 10 seconds later.

M K I

G

N L J H

1. There are six buttons in the counter for entering the target number. These are illustrated by G,H,I,J,K,L. G is used for changing the number in the units digit, H is used for changing the number in the 10s digit, I is used for changing the number in the hundreds digit, J is used for thousands digit, K for 10.000s digit, and L is used for changing the number in the 100.000s digit.

2. When these buttons are pressed, the number always increments by 1. If it is 0, it becomes 1, if it is 1, it becomes 2. When pressed if the number is 9, it returns to 0 again.

3. The reset button illustrated by M in the counter is used for resetting the number of cuts. The LOCK button, which is illustrated by N in the figure, cancels the resetting button. When the LOCK button is pressed again, the resetting button can be used.

Attention!

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7.2 Operating the machine 7.2.1 Manual cutting

1. Take the machine to the manual cutting mode by turning the button 3 to the left.

2. In manual operation, if there is material between the

clamps and if there is no alarm, the following screen will appear:

3. In case of a failure, in both manual and automatic mode, the following screen will appear.

As can also be seen from above, the alarm cases are the following: a. The emergency stop button is pressed, b. Inverter warning, c. The thermal protection of the cooling and driving motors (overloading) and d. The blade is loosened.

4. In case where the blade is loosened, tighten the blade by turning the blade tightening unit and observing

the blade pressure if the blade is mechanic; and if the blade is hydraulic, tighten the blade by means of the button numbered 11.

5. In hydraulic blade tightening, pressure switch with hysteresis is used. If you tighten the blade with 120 bars, the alarm message on the screen will disappear. On the other hand, when the pressure is 70 bars, the blade will loosen and it will give alarm. Hydraulic blade tightening can only be realized in the manual mode and when the cutting motor is not functioning.

6. By pressing the blade upward button illustrated by 9, lift the blade head upwardly. 7. By pressing the downward button illustrated by 10, lower the head in a hydraulically controlled manner.

When the blade head is above the material, it will move downwardly in a rapid manner. When the contact arm (blade) contacts with the material, the valve, illustrated by 12, will be activated and it will move downwardly in the adjusted low speed (both during the cutting process and when there is no cutting).

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8. Press the forward button (illustrated by 8), and feed

the material forward on the clamp. Press the button which is illustrated by 7, and take the material back.

9. If watery cutting is to be realized, turn the water motor

button (illustrated by 4) to the right and thereby the cooling water flows. Adjust the water flow through the valves on the flexible hose and the rectification arm.

10. For starting the cutting process, press the start cutting motor button illustrated by 1. The cutting process will begin only when there is no contact between the material contact arm (blade) and the material.

11. In case of a failure, press the stop button illustrated by 2, when there is a more emergent case, press

the emergency stop button illustrated by 13.

12. Adjust the hydraulic lowering speed of the head by means of the valve illustrated by 12.

13. Adjust the rotation speed of the bandsaw by means of the digital potentiometer illustrated by 15.

7.2.1 Automatic cutting 1. Take the machine to the automatic cutting mode by turning button 3 to the right. 2. During automatic operation, if there is material between the clamps, and if there is no alarm condition, the

following screen will appear.

3. Adjust the length adjustment apparatus (illustrated in the figure) according to the size of the material to be

cut. For this reason, use the ruler illustrated by D.

Attention! The cooling liquid will only flow while the cutting motor is functioning during the cutting process. Take precautions for preventing the sloshing of the cooling liquid.

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4. After adjusting the length to be cut, enter the number, you desire to cut, through the smart relay. In the

adjustment of the numbers to be cut: a. + button is used for increasing the number to be cut, b. - button is used for decreasing the number to be cut, c. OK button is used for resetting the number being cut and the number to be cut, d. A button is used for passing from the units digit to the 10s digit and to the hundreds digit, in the

numbers to be cut, e. The B button is used for realizing the inverse of the function of the A button. f. When the ESC button is pressed for a short time, the screen is illuminated.

5. If watery cutting is to be realized, turn the water motor activate button (illustrated by 6) to the right and the cooling water flows. Adjust the water flow through the valves on the flexible hose and the rectification arm.

6. For starting the cutting process, press the cutting motor activate button (illustrated by 1). If the head is not in the upper position, it will automa

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Manual Sierra Durma DCB-S 560