New Assembly Instruction of Smg 1

5/26/2018 New Assembly Instruction of Smg 1

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AD 1050

Instruction Manual


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Automatic Glazing Bead Saw

Revision : 06

AD 1050

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Manufacturer Firm : Kaban Makine Sanayi ve Ticaret Ltd. ti.Factory - Turkey Sales Office

Adress : Hadmky Atatrk Sanayi Blgesi merli Mahallesi 75.Yl CaddesiUzunayr Sokak No:12

34555 Arnavutky - stanbul / TRKYE

Telephone : + 90 ( 212 ) 866 25 00Fax : + 90 ( 212 ) 771 16 83Service Telephone : + 90 ( 212 ) 866 25 20 - 24

http://www.kaban.com.tre-mail : [email protected]

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Right Choice for Technology Performan ce and Quality

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Dear Customer.

Your product which is produced in our factory with future technology,regardfulworking and passed from precise quality control is designed for high performance andqualified production

For that reason please read all of this manual very carefully.

It is important to hide this operating manual,because in the future maybe it will beuseful. Because of the developments actions in our company,we have the right of changingmachine speciality without giving report.

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Precaution and Advices.................................... 7 Problems, Causes and Solutions................... ... 41Guarantee Procedure.................................................. 7 If Saw Motor Doesn't Run........................ ................... . 41

Out of Guarantee Cases............................................. 7 Start button pressed, but pistons do not clamp and

Signs And Symbols.....................................................8 blades do not m ove..................................................... 41

Motors go forward, but not come back........................ 41

General Information...........................................9 Motors come back, but pistons do not go up.............. 41Intended Use...............................................................9 Pistons down, but motors do not move forward.......... 42

Features......................................................................9 Pistons clamp immediately when machine is

Optional Equipments...................................................9 energized..................................................................... 42

Machine Description Label..........................................10 Piston Failure............................................................... 43

Technical Information..................................................11 Sensor Location Adjustment........................................ 43Piston Cross Section................................................... 44

Safety Warnings................................................ 13 Button Failure.............................................................. 45Using of Machine According to Security Rules........... 13 Valve Failure................................................................45

Safety Components and Their Locations.................... 15 Switch Failure.............................................................. 45

Warning Labels...........................................................16

Maintenance and Controls.......... .............. ......... 46Working Conditions...........................................18 Daily Maintenance....................................................... 46

Weekly Maintenance.................................................... 46

Packing And Transportation Process.............. 19 Mountly Maintenance................................................... 46Packaging Process..................................................... 19 Maintenance Table............ .......... ........... .......... ............ 47

Packaging Process For Transportation To

Short Distance............................................................ 19 Authorized Services And Dealers..................... 48Packaging Process For Transportation To Instruction Manual Test Form........................... 49Long Distance............................................................. 19

Loading Of Machine On Truck.................................... 19

Unloading of Machine................................................. 20

Instruction Manual Test Information............................ 20

Storage....................................................................... 20

Installation Processes....................................... 21Levelling and Fixing of the Machine........................... 21

Installation of Electric and Pneumatic Line.................21

Effect of safety Switches on Running of Machine.......22

Adjustment of Clamping Pistons.... ..... .... .... ..... .... .... ... 22Control Of Rotation Direction Of Saw......................... 22

Control Of Up-Down Movement Speed Of Saw.......... 23

Adjustment of Forward-Backward Movement

speed of saw.............................................................. 23

Optional Accessories........................................ 24SS300 Cutting Oil Spray System................................ 24

DS 500L. Digital Measurement System-Left............... 26

DS 500R. Digital Measurement System-Right............ 26

DK 100 Digital Compass............................................ 36

Operating Processes......................................... 40

Contents

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Precaution and Advices

Please, read Instruction Manual carefully, andkeep for reference ! If personnel doesn't know these informations inthe Instruction Manual, they musn't workon the machine. Copying, transferring, or using this documentor its contents without a written permission is

prohibited.People acting in contrast will beresponsible from damages. All rights including rights to patent approval orregistration of a new model or design arereserved in Kaban Makina San.Tic.Ltd.ti. Some functions might be not mentioned in thisdocument. Content is subject to change pleaseask the latest version in that case. Convenience of subjects described in thisdocument were controlled by Kaban Machine. Inspite of this, still there has been somedifferences, and there is no guarantee for theyare similar with each other completely. Subjects in this document are controlledregularly, and required revisons are added to thefollowing issue.Revisions in the document and inthe machine without prior notice is possible. Weappreciate valuable suggestions for furtherdevelopment.

Guarantee Procedure Machines have 1 year guarantee from the dateof invoice. After purchasing the machines, if the buyerdelayes the installation, to include this period tothe guarantee it is of Kaban Machine initiative. The guarantee of the parts replaced during thewarranty period, expires when the guarantee ofthe machine is finished.

Out of Guarantee CasesFor the following conditions the gurantee is notincluded. First start-up of the machine with unauthorizedperson; If modifications or repair works are done withunauthorized person. Consumption parts ( oil for conditional unit,grease, blade ) Transport damage Introduction Operators, must read the informations in theInstruction Manual carefully, and they must haveknowledge about running, adjustment andmaintenance of the machine. Initial training isgiven by Kaban Machine.

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This symbol is used for warning against to dangerswhich may cause to be injured, become physicallydisabled and vital danger.

It defines the points which are required to pay attentionby the user for working of machine in ideal conditions.

It defines the processes which will do on the machine.

Signs And Symbols

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Intended Use

Features

Optional Equipments

General Informations

Automatically cuts the glazing beads made ofPVC or Aluminium.Kaban Machine is not responsible from thethings that were made out of usage purpose.

SS300 Cutting Oil Spray System.Glazing Bead Moulds.DS 500 L Digital Measuring System Left.DS 500 R Digital Measuring System Right.DK100 Digital Calliper.

MS 200 L Manual Feeding System Left.MS 200 R Manual Feeding System Right.BS 200 L Feeding Table Left.BS 200 R Feeding Table Right.

Precise cutting of PVC and aluminium glazingbeads at 45. Profile feeding table on left side and profilemeasuring. Adjustable saw progress speed. Cuts two ends at the same time. Easy-change moulds. Works fast thanks to single button usage.

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Machine Description Label


Machine introduction label located ondesignated place.

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(1) Saw dimension

( D ) Outer diameter( d ) Inner diameter ( b ) Thickness

(1) Saw teeth number Saw speed

(2) Saw dimension

( D ) Outer diameter( d ) Inner diameter ( b ) Thickness

(2) Saw teeth number

(2) Saw speed


Technical Information - AD 1050

mm

kg

rpm

adet

adet

2,01

470 - 51301060

Total air consumption

Air pressure

Voltage

Total power

rpm

1,5

V

kWhp

400

l/cycle

bar6 - 8

850 - 60 Hz

Motor power2x1

2x0,75 kWhp

Frequency

Motor speed

Dimension

H = Height 1295

2820 - 3384

148

2820

160

80

200mm32

1,8

2820 - 3384 rpm

mm322,5

Cuttable profile dimension

W = WidthD = Depth

Weight

95

L = Minimummm

L = Maximum 2425234

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W = WidthD = Depth

Motor speed

Dimension

H = Height

mm

Technical Information - DS 500R/L

Frequency

Weight

Hz

Motor Power1x1

1x0,75 kWhp

rpm

Voltage

Total Power

230

bar

1

kg


0,75

V

kWhp

Air pressure

3065477

104

6 - 8

50 - 60

3000

1325

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Using of Machine According to Safety Rules

Safety Warnings

Machine must be used only by the operatorswhich had education training, anyone except theoperator should not stand around the machineas the machine is running. Operator must use job gloves and job glasses.

Jewellery, necktie, loose clothes, is not bottonedup job clothes,normal shoes, etc. musn't beused, If operator has long hair, he/she must fixhis/her hair. Safety components of machine musn'tswitched off. For a safe working, saw doesn't cut before thesafety cover closes. ( Safety Covers aren't beremoved.) While putting profile into the machine, it isimportant paying attention for hand damages. Safety labels musn't be taken apart from the

machine. Flat surfaces of the machine musn't be usedfor working area. Anyone musn't get out on the machine, inwhatever situations. Machine musn't be used in moist environment(please see working conditions). When oil or similar materials are spilled on themachine, it must be cleaned immediately. Petroleum, solvent, or other easy burningliquids musn't be used for cleaning of machine.Only unburning and nonpoisonous commercial

solvents can be used. The machine should be used according to theconditions given in the "WORKINGCONDITIONS" In the safety related components and/orfunctions are out of order, the machine should bestopped immediately and should not be run untilthe problem is solved.In the meantime sign "outof order" should be put on the machine.

The operator should obey the safety instruction. Any technical m odifications related to thesafety related component and its functionsshould be done by Kaban or with the writtenauthorization of Kaban. Otherwise, Kaban will benot responsible for the technical and/or legalproblems.Guarantee is also excluded. During and maintenance or repair please shutoff the air supply (6bar) and electricity. Swicth off

the main switch on the electrical panel and takethe power cable (plug) off. All maintenance and repair work should bedone by qualified personnell. During working process mask,etc..has to beused not to smell harmful dusts Cutter saws have to carry with gloves not to cutany part of the body.Necessary changes andmaintenances have to make with gloves. Do not remove security equipments andprotectors from machine,if any of them breakdown request the new one from Kaban

Machine If equipment change done by machinebuyer,equipments have to change with the samebrands &codes.Otherwise do not start themachine. Stock and finished process profiles have tobeclosed to the working position of the operator. Stop the machine when not using or processfinished. If dusts get on the machine compressed airhammer which is located on the right side of themachine used to clean the dust Just only operator who take tranning about

machine have to use machine,during workingprocess no one have to be located around themachine. Before starting machine,using adjustments andoperations during working process have to makefrom operator who take tranning about machine.

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Safety Warnings

This sign explains that there iselectrical shock danger.You can find them on the electricalpanel and inside the electrical panel.

To reduce voice just only use pvc,aluminiumand wood cutting in the machine.Apart from this;- True Saw have to be used during Operation.- Before starting operation maintenance of themachine have to done,if saw become blunt itneeds to be change. The operator who will use the machine mustuse gloves,eyewear and mask.Operator did not

wear casual clothes,tie,trappings.And alsooperator have to wear normal shoes,collecthis/her hairs and close front of the shirt duringworking process. Saw,etc.. sharp parts have to change withgloves or with a holder device. Saw cutter maintenance,adjustment andchange process there is need to take informationfrom Kaban department and make necessarychanges within the control of the service staff. During cutting process sharp saw cutters haveto be used.

Suitable flanges for saw have to be Kaban'sproduction flanges.Need to take information fromservice.

Electrical Shock

All electrical system and metal parts are eartedand insulated from live or dangerour voltage.However, there might be still high voltage whenyou switch off the main switch and open thedoor.Please take the power supply cord out, if youwant to access inside the electrical panel forrepair on maintenance purpose.

Information: If you see someone catched byelectricity, please check out first whether thepower supply is switched off as explainedabove.After that,help and touch the injured man.

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Safety Components and Their Locations

1-2-Saw Safety Cover Sensor

Safety Warnings

Located on machine top plate. Shutsdown the electricity when the safety cover isopened.

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Warning Labels

4 8

73

5

6

Safety Warnings

1

2

ElectricalCurrent

Don't InsertYour Hand

Oil WarningLabel

Earthing

Double SawRotationDirection Label

Air Pressure

Headset MustBe UsedCaution Label

Do not operatethe machinewithout readingthe manual

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Warning Labels

AD 1050

Safety Warnings

9

15

13

12

1410

11

Urgent StopButton

CEDeclerationsCompatibility

Label

Should be usedonly in case ofemergency

ProducerLabel

Direction Label Machine CodeLabel

Main SwitchLabel

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Illumination

Lighted sufficiently ( at about 500 lux )HumidityApproximate relative humidity 50 - 60 %AltitudeMaximum 1000 mbar

Working Conditions

1000

3000

300

0

3000

DIAGRAM - 1

Acceptable voltage change is %10 of therated voltage on the label.( 400V ) PE Protective Earth line must be installed tomachine conveniently. Supply line to the machine should be feeded

with power fuse capacity. Voltage regulator should install to theelectricity line to be connected Pneumatic supply line of the machine shouldbe at 6 bar, it should be purified from humidity (To purifying the pneumatic line from humidity, adrier should be put on the outlet of compressor ) To make air connection to the machine,required air hose should be ready.

Required equipments for working environmentof machine, and necessary gap values to leavearound the machine are shown on Diagram - 1 inmilimeter. The floor should have the capacity which can

carry weight of machine. ( 1 square metre mustcarry 1 tone.) Please try to maintain ambient workingconditions as follows :

Compressor

Air DryerElectricalPanel

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Packaging Process

Before starting to packaging process Loading Of Machine On Truck

Packaging Process For Transportation ToShort Distance

Packing And Transportation Process

If electric and pneumatic connections weredone, they are removed from machine. The machine is purified from dust withpressured air and with a cotton material. Galvanized plates, saws, main axles which

are on the machine are oiled with protection oilagainst rustings which could be occur duringwaiting in stock and transportation. ( ShellENSIS SX )

The machine which will be package mustpassed from the Warping Process ( covered byclingfilm ) Machine does not need cleaning andprotection oil during packaging process,if it has

passed from the warping process.Machine couldbe clean and protect oiling if it is waited on stockfor a long time. ( 1 ) Machine has to be lifted from it's balancepoints and putted on the pallet for shipment. Machine putted down to it's chassis frame byforklift ( 2 ) For the sucssesful shipment there isneed to put support pieces under the machineframe and both of them screwed to the pallet. ( 3 ) During the packaging machine coveredby carton box.Front,rear and all sides covered by

carton box.Carton box have to be prepared tothe size of the machine. ( 4 )Dimensions of the pallet is adjustedaccording to the weight of the machine.

While machine is being lifted and broughtdown, it is required to act convenient to jobsafety regulations,and below instructionsmust be obeyed. Machine is lifted up, carefully, by usingbalance points, with a forklift or crane which hasconvenient capacity.If crane is used for lifting process, it is holdedfrom points which are shown on Diagram - 2.If forklift is used for lifting process, it is holdedfrom points which are shown on Diagram - 3. During lifting up machine, for better sightand for less danger, machine musn't be liftedto very high position. When machine is lifted up and broughtdown, somebody must be not stand under

and around the machine. While machine is being loaded on truck,informations on the machine must be takeninto account : Weightness information of machine for notchanging its balance during settlement on truck.Direction label information which defines bottomand up direction for setlement of machine onright direction.After packaging process machinelifted from it's balance points and putted on thetruck.And during the transportation do not putanything on the machine.

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Unloading of Machine Instruction Manual Test Information

Storage

Installation Of Machine

Packing And Transportation Process

While machine is being lifted and broughtdown,it is required to act convenient to jobsafety regulations,and instructions writtenbelow must be obeyed. Machine is lifted up, by using balance points,carefully, with a forklift or crane which hasconvenient capacity.If crane is used for lifting process, it is holdedfrom points which are shown on Diagram - 2.If forklift is used for lifting process, it is holdedfrom points which are shown on Diagram - 3 While machine is being lifted and brought

down, someone shouldn't be under or nearthe machine. The legs which are removed for preventingfrom damages during transportation are put ontheir places, carefully. Machine must be taken down by usingidentified balance points, carefully. Necessary precautions must be taken forpreventing body and other parts from anydamage during unloading of machine.

When user takes machine on, he should fill intest form and give it back to Kaban Machine orto an authorized erson from Kaban Machine.

The storage must be done according themachine storage rules which has been declaredon "working conditions" part, if the machineneeds to wait for some time after delivery.

DIAGRAM - 2 DIAGRAM - 3

The machine is located to the ground which isprepared according to Diagram - 1 on "workingcondition" part, after the guide test formapprovedBefore start up the machine, the protectionoil which were layed on the machine forpreventing machine from rusting which canoccur during storage and tranportation mustbe cleaned. Cleaning can be done with alkalior chemistry solvents (white spirit, kerosene,etc..).

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Levelling and Fixing Of The Machine

Installation of Electric and Pneumatic Line

Installation Processes

Natural rubber plate is put on the bottom ofthe machine in order to prevent the vibration. ( 1 ) Levelling adjusment is made withadjustment bolts on the chassis shoes. ( 2 ) Levelling is checked with water level. ( 3 ) The machine is fixed to the surface withthe fixation bolts as shown in the Picture.

Before connection of air hose, air systemmust be worked freely. By this way dirty particlescan be thrown from the system, and aftercleaning of the system, air hose can beconnected. When air is given to the machine, manometerdial show 6 bar on the conditioner.

Electricity for the machine connection has to

be 400V/3 phase,before connection electric to machine and control table. There is need to check electric problems onmachine after giving electric to the machine(Could be check by unpainted parts of themachine by the help of voltage tester.

Accident Danger

During giving electric to the machine get faraway from the machine(extraordinarymovements) not to be damaged.Otherwise therewill be injuries caused from the machine movingparts. There is need to make provision for bondingmistakes. There is need to make provision for high andlow voltage mistakes.

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Effect of Safety Switches on Running of Adjustment of Clamping PistonsMachine

Control Of Rotation Direction Of Saw


Accident Danger

If the machine works while some or all of the lidsopen, it must be stopped and musn't be workeduntil solving the problem.

As seen on the left picture, there is one safetyswitch on the machine.As seen on the left picture : ( 1 ) Switch ( 2 ) Claw which press to the switch

Safety switch is functionning with relation to thetop protection cover, in case the protection coveris open machine does not operate. Claws on theprotection cover should press 4mm on the safetyswitch pin.

Clamping piston should be such fixed thatwhen closed, it should stand on the uppersurface of the die.

1

24mm

( 1 ) Main switch is turned on ( 2 ) Motor is started by pushing once on therun button. ( 3 ) Motor is stopped by pushing on the stopbutton. Turning direction of saws is checked(looking from front of machine, turning directionof saws should be similar to the down picture. If the rotation direction is wrong, turning ofright direction is provided, by changing place ofphases. Process of phase changement shouldbe made by using one of the below points; From the control panel which supply energy tomachine From the plug of machine From the energy inlet of electric cabinet From the connection box on the motor.

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Control Of Up-Down Movement Speed Of Saw Adjustment of Forward-Backward MovementSpeed of Saw

Forward movement withno-load on saw : 3 sn

Backward movement withno-load on saw : 2 sn


In order to move the saw forward andbackward ( 1 ) Main switch is turned on ( 2 ) Motor is started by pushing once on therun button. ( 3 ) Either one of the bar clamping buttons is

pressed Saw is moved by pressing simultaneously onboth of the buttons (no 3) buttons are releasedwhen the cutting process is finished (saw returnsto original position as the buttons arereleased) ( 4 ) After the saw returns to its originalposition, motor can be stopped by pushing onthe partial stop button. Movement speed of saw can be checked andvalidated with the figures below

If the movement speed of saw is not suitable tothe declared figures, it can be adjusted byfollowing steps ( 1 ) Forward movement speed of saw can beadjusted by the reduction screw on the piston (

Speed increases when the reduction screw isturned clockwise, decreases when turnedanti-clockwise) ( 2 ) Backward movement speed of saw canbe adjusted by the reduction screw "selenoid onecoil valve" which is included in the valve groupof the machine ( 3 ) If the motor hits hard on return,cushioning screw on the piston can be used foradjustment Forward movement time of saw must beincreased 25% for cutting aluminium bars.

1

2

3

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SS300 Cutting Oil Spray System 3) 1/2 Supplementary Lubricator

1) Assembly of Cutting Oil Power on-offSwitch

2) Popet valve Supplement

Optional Accessories

Take out "22 blind switch" which is used toclose the place of power switch and fasten "0-1 1NA Black Metal Latch Switch"

Take out the blind plug on existing popetvalve. Attach the supplementary popet valve onexisting popet valve by putting an o-ringbetween them. Connect popet valves and fasteners withcables. Fasten the hose numbered 5, which is gettingout from the supplementary popet valve to theinlet of "1/2 Lubricator"

Wrap teflon to the reducers which will befastened on the lubricators While wrapping theteflon to the reduction gear notchs,start wrappingby leaving 1-2 notchs vacant from the startingpoint of notchs. Assembly lubricator connection parts to theirplaces on chassis by two bolts. Fasten lubricator to connection part withreducers. Fasten elbow (T) couplings to the lubricator.

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4) Cutting Oil Spray System Parts


Use "Automatic Triple T Coupling" in order todistribute cutting oil hose to both spray parts. Fasten 6" to 4" converter to both sides ofautomatic T couplings. Insert the hose numbered 6, which is gettingout from lubricators outlet, to automatic triple T

coupling. Drill M5 hole on motor group holding plate forspray parts. Fasten cutting oil spray parts to these holes.( cutting oil should arrive to saw surface with a45 angle) Fasten M5 elbow coupling to spray parts. Fasten 4" hose to the converter on AutomaticT coupling

While the cooling system is used for the firsttime, run the machine free till the lubricationhose fills with oil.

On cooling system, Petrol Ofisi Basel - C orShell Macrou Series are used as "aluminiumcutting oil"

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DS 500L. Digital Measurement System-LeftDS 500R. Digital Measurement System-Right

REFERENCE

Operating Processes

Main switch opens,Machine is in operational,and Ad page ( side ) appears.

The ad page on the screen disappears within afew seconds.Then, it automatically pops up"language selection screen".

The same time, PLC and screen programsversion numbers author on the ''Language

selection screen "

if you did not select any language on the"Language selection screen" Within 2-3 second,"REFERENCE" screen pops up fromautomatically the last used language

On the side "REFERENCE" page, "OK" button ispressed,the robot, until you press on referenceswitch medium speed moves to the left.When robot push the referance switch, move to

right direction until dispose of referance switchslowly.When dispose of from switch stops andthat point determine as referance position.Robot push the referance switch, it move to theright until rescue from referance switch. Whenrescue from switch it stops and the stopped pointis determined as referance position.

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SETTINGS

Setup Menu 1. Level Display FieldDescriptions

Operating Processes

When the process "making to reference "completed "MAIN MENU" screen appears.

For Parameter settings of the machine to make"MAIN MENU" screen, "SETTINGS" button pres,Then, the password enter. '' level 1 Settings ''page opens.

Removing Upper Limit:This limit use fordetermine upper limit of move back support platcan go during work.Removing Distance:Support please moveback as this limit during work.Note: Support Plate do not move back over2000 mm.Proces Waiting Time:This time value give us

the time to take cutted part from machine untilplate go to the possition for next process.Extra RF Scale:If there is any extra scale,lenght of scale value enters here.

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Settings Menu 2. Level Display FieldExplanation

Operating Processes

Barcod Lenght Start:4 digit lenght value onthe barcod's which is readed to machine, firstdigit's which character enters here.

Main Menu:When you press this buttonreturned to "Main Menu"If "Servis password" used when enter to"Settings" menu when you press to button ondown you enter " 2 . Level setting page" If youused " Users password" when you press tobutton on down password input page open andby entering servis password pass to the 2. levelsetting page.

Reference Value:While support plate on theregular point,measured value between supportplate and machine's process center ( this iscutting point for this machine) which isconnected to option and the differance between

the value which is appaered on operations pagesand the referance value which exist on this fieldis written to this field. In other words calibrationprocess, the part, which is handled on themachine is measured and differancebetween entered value and measured ( lenghterror value on the part ) is doing change to "Referance Value" .

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Operating Processes

Support Plate Depth:If for the reason of getclose to machine's support plate to processcenter, this additional part's dept ( the measureof support's plate was got closed to processcenter) entered this field. When to the this field

entered "0" value it means there is no additionalpart.If to this field entered to bigger value than"0", the value lowest limit is reduced equal toentered value.To this field can not enter a valuewhich is bigger that referance value.

Note:If the length value is less than thereference value or the difference between thesevalues is smaller than the value entered in thisfield or during the operation the additional part ofthe gauge is not installed, when the "START"button is pressed, the following warning screen

will appear. Additional part should be mountedand "OK" and then again the "START" buttonmust be pressed.

Measurement Tolereance:Depend tothe process is taken on the machine thetolerance value we needs enter here.Because of the positing of the machine isgetting easy when the value in this fieldget bigger, we can input higher workspeed with change inverter paramaters.

Push the following button return thescreen to " 1. Level Settings"

Main Menu: Push the this button return you tomain menu screen.If " product password" was used to enter tomenu "2. Level" on " Settings" , when is presedto following button " you across to " 3. Level

Settings" page.If not used to password to entery,when push to this button on password inquiryscreen opens and using servis password acrossto " 3. Level settings" page.

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Settings Menu 3. Level Screen FieldExplanation

Main Menu: Pushing this button returns you toMain menu page.

RF Work

Rf work screen field explanation

Operating Processes

Encoder Factor:4 times bigger than rotaryencoders's pulse count on one cycle is entered

here.Encoder Dividing:10 times biggier than themachine support table's the moving distance foregine's one cycle is entered here by mm.Note:Encoder Factor and Encoder Dividingvalues can be entered as minimized samerate.For example on the machine instead of"4000" and "2900" values "40" and " 29" valuescan be entered.Support Plate Distance:During processsupport plate's moving capacity is entered here.Push to following button returns you to " 2. Level

setting"

No:Hereby you see memory index of "RF Work"which was send to machine.Lenght:Hereby you see cutting memory's lenth

valuePiece:Hereby you see process count at thislenght.OFSET:If The lenght is sending from RF scale iswanted to cut specific offset value entered here. Ifis wanted to do precess bigger than measuredvalue to this field is entered " -".Piece X: To this field is entered how many pieceis wanted of lenth value sent from RF scale.andfor each lenght value, that value is assigned asiece.

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Operating Processes

SUPPORT PLATE ON / OFF:In order to cutsmaller lengths, an additional part can beinserted to support plate part. The length of thisadditional part is inserted to "SUPPORT PLATEDEPTH" field. This button is taken to "ON"position while the part is inserted.Cut:Herebyyou see was did process count.Start:Support plate go to entered lenght valuewhen pushing this button.Edge Amendment:Pushing this button is usedto activeted to machine for once for the materialas edge amendment which is not required longprocess. Button is automaticly become passivewhen machine go back to start position.Stop:Push that button stops the machineDelete:Pushing that button and confirm thewarning message selected memory field isdeleted and cutting contune from next line.Delete All:Pushing that button and confirm thewarning message all RF work memory fielf isdeleted.Manuel:Pushing this button all process becomeautomatic and button indicator chaceautomaticly.MANUAL/OTO:When this button is pressed,processes becomes automatic and buttonindicator turns to "AUTO". When the button ispressed again, it returns to manual mode.

Main Menu:Pushing that button opens " ManMenu"Note:Middle of the screen exist memory indexfield and by using up and down bottons we areable to move in memory, moreover by pusingthe index number between arrows wantedvalue is entered this field and goes direcly thatmemory digit.

Cutting list sending process by using RFTools;1)On Screen "RF WORK" to " Piece X" field isuse for enter how many cutting wants.2)Rf scale device is send cutting lenght tomachine3)Sended lengh values are entered to RF workmemory on the machine by line, as "Piece X "value is be cutting piece.Note:From scale, Can not be entered biggerlenght value than support plate moving limitsRF Work List;1) For clean glazing bead pushing to " EdgeAmendment" button and during the edgeamendment there will be no conversion onmemory value.2)If there is memory lenght value pushing to "Start" button.3)Support Plate goes length value in thememory4)Engines are started. After engines are startedonce dont need to starts engines again.5)Pushing the Piston button and works pistonsgroup move forward.6)After cutting process over and engine comeback sensor was appaered, pistons opens andsupport plate is go back as parametriclenght.For longer lenght value than 2000 support

plate do not go back.7)Support Plate waits, as long as the value wasentered to parametric settings of cutting waitingtime and after it goes nezt lenght measure.

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Manuel Work

Manuel

Automatic

Operating Processes

1)For clean glazing bead pushing to " EdgeAmendment" button and during the edge

amendment there will be no conversion onmemory value.2)Pushs the "Start" Button.3)Support Plate goes length value in thememory.4)Engines are started. After engines are startedonce dont need to starts engines again.5)After Process overs and machine go back tostart position,support plate go backs asparameter value and even the all list is not overfor each time have to push the " Start" button.6)Made proces number is appeared " cut" field.

7)If all list is over support plate is go back andfor move next cutting value need to push startbutton.8)"Delete All" Pushing that button and confirmthe warning message all RF work memory fielf isdeleted.Note:For safety support plate goes to left slowlyafter specific value

1) For clean glazing bead pushing to " EdgeAmendment" button and during the edge

amendment there will be no conversion onmemory value.2) Pushs the "Start" Button3) Support Plate goes length value in thememory4) Engines are started. After engines are startedonce dont need to starts engines again.5) After Process overs and machine go back tostart position, support plate go backs asparameter value.If all list was over. After await

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CF CARD WORK

CONVEYE CF CARD VALUES

Operating Processes

as long as wait period as was entered parameterpage and go back ex position.6) Made proces number is appeared "cut" field7) If all list is over support plate is go back andfor move next cutting value need to push start

button.

After Reading process is over " CF CARDWORK" work list is conveyed. Other process like"Manuel Work" page.

Before CF card cutting list over if you send newdates with CF card this message appears.

When press to "CF CARD READ" the dates inCF card is started to read and following messageappears on screen.

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Barcode work

Last 10 Cutting

Operating Processes

When "BARCODE WORK" menu is actived,from the readed barcode 4 digit lenght value istaken after the barcode lenght start numberwhich was entered to parameter number.And if

this value is in the limit of support plate can gothis measurement is written to first freememory." Piece X" field is automaticly is writtento this field.Other process continue as " RF WORK"

Hereby you can see last 10 cutting process

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1- If the machine start position information is not 7-If Size or pieces is zero;appearing;

2- If there is fault at the inverter; 8-When "DELETE ALL" button is pressed;

3- If have a problem with CF card access; 9-When "DELETE" button is pressed;

4- While there is a measurement out of limit, 10-The Encoder, "supporter movement" doesthe "START" button is pressed; not command

5-If is exceeded Limit (-) direction; 11-If measurement is received outside of thelimit movement from the Barcode or RF device;

6-If is exceeded Limit (+) direction;

Operating Processes

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DK 100 Digital Compass

Digital compass parameter settings

Explication P01 0 11 Counter direction ( 10'' + '' direction, 11 " -"

direction)

P02 0 0 mm/inch selection

(mm)

Parameter Entry P03 2 1 Screen decimal placesnumber ( After comma

one digit)

P04 1 1 Automatic turn off du -

ration (1 min)

P05 0 0 Button active/passive

chose ( all active)

P08 1 0,1 Counter coefficient

(multiplied by 0,1 mm)

P09 0 105 Referance Value

P10 0 0 Offset1P11 0 0 Offset2

P12 0 0 Offset3

P13 3 2 Offset configuration

( 1 and 2 active)

P20 106 106 RF Channel

P21 xxx ??? Measurement device

network-id ( entered by

read from device)

P22 xxx ??? Measurement device

address ( entered by

read from device)

P23 1 ??? RF receiver network

id ( entered by read

from device)

P24 0 ??? RF receiver address

( entered by read from

device)

P90 0 1 Function active/passive

P99 xxx 1 Device producter version

PARAMETER

EXPLCATON


PARAM

NO:

FACTORY

VALUE

SETTING

VALUE

The document of RF parameter setting of ofElgo trade mark which code is IZ16E

Parameter Screen open with pushing "F"button for 3 seconds when machine wasenergy position.If you push this button for 3seconds when parameter screenopen you get out from parameter page.

Pressing " F" button show us concernedparameter's value. Pressing the button gaingshows next paremeter's value.

By pressing " Set " button you move the curserright until which character is wanted tochance.When curser arrive the characterwhich is wanted to chance;

By pressing " Inc / Abs" chosed character'svalue increase until wanted value.

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DK 100 Digital Compass

Referans Settings

Back to Default Settings


During power on, slide to measurement head toreferans point, at the same time press to "F" ad"Set" buttons, TO device measurentvalue "P09" parameter referans value is entered.

Take off to device battery. When device isturned off.

Pushing "IncAbs" button and put back batterysame time makes load the default settings todevice ad encodes page is opened.Repeat takeoff hte battery, go back to normal work page.

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Operating Processes

Running Of The Machine


( 1 ) For each measureament which is sent tomachine how many process ll be made to enterto " Piece X " field. ( 2 ) Device move forward on the digitalcompass to wanted measurement. ( 3 ) when digital compass on demandedmeasurement value press " Set " button to sendmeasurement to device.When pushing thatbutton on the scree seems figure whichshows us measurement value is recived bymachine.

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Problems,Causes and Solutions


There is no display on device Attached no device battery orbattery low

Attached new battery

When pressing to " Set" buttonfor send the measuremet to

machine,screen view lost,

Low Battery Endustrial purpuse use high flowcapacity battery attached to

deviceThere is a differance betweendisplayed on device andmaterial's real measurement.

Reference of device was madeincorrectly

Reference process is makeagain as made on users manuel

When device is moved ondigitalcompass the value on scree

P1 parameter of device isentered incorrectly

Fix this parameter

Even device is moved on digital

compass measuremetn valueon the sceen do not change orchange irregular

The distance between encoder

on the device and band ondigital compass could be somuch.

Distance is adjusted.

Magnetic bad or encodes couldbe broken or faulty

Broken or faulty part is changed

When pressing to " set" buttonto send measurement value tomachine Signal do notappear

Distance between device andmachine is very much, or thereis a reason to corruption the RFsignal

There is be a problem onwireless receiving set's cable

connection

Control the conneciton cable

One of all of the parameters ofdevice P21 ,P22, P23 or P24could be entered incorrect.

Fix the parameters

When device is moved ondigitalcompass the value on screen

P8 parameter of device isentered incorrectly

Fix this parameter

Device get closer to machineand take a try

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Operating Processes

( 1 ) Main power switch is turned on. ( 2 ) The bar to be cut is installed between theupper and lower dies ( 3 ) The saws are started by pressinng therun button ( 4 ) Bar clamping pistons clamp by pressingone of the butons no 4 By pressing both of the buttons no 4, the sawsmove, the buttons should be pressed till the endof cutting process. When cutting process isfinished saws return and bar clamping pistons goup. Cutting process is continued by taking outthe cut bar and inserting a new one.

( 5 ) If a new cutting process is not required,saws are stopped by pressing on the partial stopbutton and the main switch is turned off.All steps above are repeated for a new cuttingprocessEmergency Stop Button is used for stopping themachine in case of any emergency.After all the precautions are taken, the buttonmay be released by turning it and the processmay be restarted by inserting a new bar

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If Saw Motor Doesn't Run

Start button pressed, butpistons do not clamp andblades do not move

Motors go forward, but notcome back

Motors come back, butpistons do not go up


One of the cables of motorconnection might be loose.

Tighten the cables.

One of the cables of mainswitch connection might beloose.

Tighten the cables.

Replace the deformed cables.

Thermic switch might be off. Bring it to "on" position.

Door security switches mightnot be contacting.

See "Problems and Solutions"part for the sensor adjustment.

Emergency stop might be off

Neutral not in line due tovalve, plug, switch orconnection in valve socket.

See "Problems andSolutions" part for the sensoradjustment.

Main phase not in line due to

valve, plug, switch orconnection in valve socket.

Motor might be not pressingforward switch, or switch mightbe not in position.

Valve migh be not working.

Motor might be not pressingbackward switch, or switchmight be not in position, or notworking.

One of the cables in the plugmight be loose or main cable

might be deformed.

Tighten the cables.

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Pistons down, but motors donot move forward

Pistons clamp immediatelywhen machine is energized


Valve might be not working.

Piston might be not working

Motor might be not pressingbackward switch, or switchmight be not in position, or notworking

See "Problems andSolutions" part for the sensoradjustment.

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Piston Failure

Problems, Causes and Solutions

1

2

3

4 5

6

In case there is not enough push and pullpower of the piston,when air is given from inputno (4), if the air goes out from input no (5),piston felt is failed. This situation is also valid forthe opposite.

There maybe air leakage from piston neck(6).

If the piston does not standon the bottom or shutsquickly,choking adjustmentmay be changed.

SENSORLIGHT 1

2

Sensors may be loosened and dislocated.

Magnet inside the magnetic piston may bedefected.Magnet may be broken while replacingfelt, axle, neck felt due to a problem on thepiston.

Due to cushioning bolt is fastened too much,piston stroke cannot open till the end. So sensormay not interefere.

Sensor Location Adjustment

If the piston movesslowly or quickly,speed adjustment maybe changed.

It is adjusted byturning the chokingscrews (1 and 2) toright and left

Piston speed is adjustedby turning the speedadjustment valve (3) to theright and left.

Piston felt should be replaced.

Neck felt is replaced.

Sensor is placed on its slide on the piston andmoved to the indicated arrow direction until its lightis illuminating. From the point that the light isilluminating,it is moved 5mm more to the samedirection and fixed by fastening its screw. ( it is

indicated on the picture beside that the piston is inrelation with which sensor on open and closedpositions.)

Replaced with a new one.

Cushioning bolt is released until propercushioning is obtained.

There may be problem oncable connections of thesensor.Cable may releasefrom connector or PLC input.

Cable place isfixed and fastened.

Sensor may be defectedor its cable is cut.

Sensor is replacedwith a new one

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Piston Cross Section

8 )

9 )

10 )

11 )

12 )

13 )

14 )15 )

16 )

17 )

4 )

5 )6 )

7 )

1 )

2 )

3 )


1 623 7 9 910 14 6 15

8 811 13 171716

Piston Neck

Bushing

Neck Felt

Hole Segment

NutringOring

Piston Axle

Piston Felt Bearing

Nutring

Magnet

Oring

Piston Felt Bearing

Imbus Bolt

Piston PipePiston Bottom

Nut

Choking Bearing

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Button Failure

Valve Failure

Switch Failure


Dust may enter inside theircontact.

After certain period ofoperation, switch pressnokens may not press onthe switch properly.In this

case, switch can notfunction well, so nokenshould be placed toproper location.

Switch press noken should beadjusted to press the switch 4mmand just from the middle. If the switch is not functioning

even the noken presses properly,check the switch cables areloosened or detached.

Switch SwitchPress

Noken

Cable ends may be loosened.

It may stick because of the arc.

Valve bobbin may bedisconnected.

Bobbin cables may be loosenedor burnt.

There may not be oil inside thevalve.

Core spindle o-rings may be failed.

There may be dirt inside the chokes. The hose may be broken.

Try to repair the valve according to the causes of the problem mentioned above.If the problem cannot be solved, replace the valve.

If the switch is not functioning even all the checkes are performed, it is replaced with a new one.

It is cleaned with compressedair.

Ends are fastened.

Buttons are replaced.

Valve bobbin may bedisconnected.

Bobbin cables may beloosened or burnt.

There may not be oil inside thevalve.

O-rings are replaced.

Chokes are cleaned The hose is checked.

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Daily Maintenance

Conditional Unit Water Level Control

Maintenance and Controls

Repairs must be done by authorized person. Don't use materials which include petrolsolvent based, during cleaning of machine.

Accident Danger

Stop the machine, close electric and airconnections, during all repairs andmaintenances.

Dusts on and around the machine are

cleaned with pressured air.

Oil and other wastes are cleaned with a

clean cotton cloth. Control of saw

If the saw become blunt should be replace

It musn't have water in the glass tube on left sideof conditional unit. If water accumulates in it,itmust be discharged. For that, according toconditioner type used in machine, it is enough topress on the cap which is under the tube toupward way or to turn ( E ).

Conditional Unit Oil Level Check

Weekly Maintenance

Oil level must be maximum B, minimum D andideally C levels. When oil level decrease, Shell TELLUS Cnumber 10 or equivalent oil is added.

Conditional Unit Oil Flow Control Conditioner oil flow adjustment is made from (A ) adjustment screw on the conditional unit as 1dropper 7 works. Thin end screwdriver must beused for adjustment.

A

BC

D

E

Mountly Maintenance

Controls of Weekly MaintenanceMaintenance of axles on which the moving

parts work.

Axles are first cleaned with a cloth and oiledwith grease.

Lubrication is performed by applying thin film lineoil with brush.

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Maintenance Table

Dusts on and around the machine are cleanedwith pressurized air.

Control of blade

Conditioner Oil Level Control

Conditioner Oil Flow Control

Conditioner Water Level Control

Maintenance of axles on which the movingparts work

Montly

Maintenance

Daily

Maintenance

Weekly

Maintenance

Maintenance and Controls

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Telephone Fax E-mail Web Site

www.kabanir.com

+ 7 701 378 34 69 +7 701 378 33 96 [email protected]

+ 9821 22911335-6 + 98 21 222 53 218 [email protected]

[email protected] www.eurotechwindows.com.au

-

India BMT Machines PVT LTD + 91 960 400 37 48 - [email protected] www.bmt-india.com

+ 36 24 442 345

Country Company

+ 61 395 553 000 + 61 395 553 362Euro Tech Windows pty Ltd.Austura lia

[email protected]

Portugal KAF TARRACO S.L. + 34 937 213 630 + 34 937 213 907

Romania S.C.Wintec S.R.L. +40 21 778 12 46 +40 21 778 12 47

www.kaban.com.tr

[email protected]

Poland Kaban Polska + 48 22 751 89 34 + 48 22 751 90 34 [email protected]

-

Libya Abdulfattah Ferjani

[email protected]

[email protected]

+ 21 891 883 56 78 + 21 821 462 83 57 [email protected]

[email protected]

www.kaban.by

Canada JRC MACHINERY INC. + 1 450 477 12 86 + 1 450 477 79 12 [email protected]

+ 375 17 242 70 44 [email protected] FLTD "Vorne Bela" + 375 17 242 70 40

+ 2 011 0444 162

+ 36 24 442 345

Kazakistan Home Office

Palco BT.

KABAN IRANIAN

Egyptian Group TATWEEREgypt

Iran

Kazakhstan

G.M.T. - SUNBACFrance

Hungary

+ 7 495 517 93 96 + 7 495 542 40 12

www.jrcmachinery.com

-

www.kaban.com.pl

www.wintec.com.ro

-

-+ 33 233 667 774 + 33 233 658 965

+ 38 0482 47 34 66 + 38 0482 45 22 07

[email protected]

Slovakia FOR-GLASS s.r.o. + 421 35 7731 728 + 421 35 7731 728 [email protected]

Russia OOO "Fest-98" www.fest-98.ru

-

www.concord.com.ua

www.forglass.sk

www.evrofasad.com.uaUkraine Evrofasad + 38 044 247 67 52 + 38 044 247 67 74

Ukraine [email protected]

Authorized Services And Dealers

[email protected]

Spain KAF TARRACO S.L + 34 937 213 630 + 34 937 213 907 [email protected]

Concord

[email protected] www.orp-service.ruRussia ORP Service + 7 800 333-1181 + 7 495 545-4582

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Name of Machine :Code :Serial Number :

User Name Date Signatur

Name Of Buyer : Client Notes :

Buyer Stamp :

Name Of Authorized Person :

Signature Of Authorized Person :

Instruction Manual Test Form

Machine Is Delivered Convenient To DeliveryDocuments And At Ideal Tranporting Conditions.

" User Training " Is Given To User Operator ForWorking Safe and Convenient To Standards by An

Authorized Person From Kaban Machine.

All Mechanic Parts Are Handed Over Completely,And in Working Condition.

All Electric, Electronic, and Pneumatic Parts AreHanded Over Completely, And in Working Condition.

All Standard And Optional Accessories Which AreGiven With Machine Are Handed Over Completely.

Our Machine is Handed Over As All SecurityPrecautions Are Taken, And As Able To WorkActively With Responsibilty Of Having " CE "

Machine Is Handed Over As All Of Its MaintainanceAnd Controls Operations Had Done And n WorkingContidion.

User Were Informed About Security Cautions AndEquipments With Showing Their Locations AndFunctions On The Machine.

User Were Informed About Application And

Materials Of Adjustment, Maintainance, Oiling, AndCleaning of Machine.

User Were Informed About Codes Which Are UsedIn All Documents.

User Were Informed About He/She Musn't Be InterfereTo Safety Equipments, And He/She Must Be Work AsObeying To All Safety Precautions Which Had Been

Please, fill in the blanks on the list, and relay to the Kaban Machine's authorized person, or send toKaban Machine.