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Series Ergonomic Ergonomic 340.278 DG Operating instructions Before transporting and using the machine, please read the instructions thoroughly! Seriové číslo / Serien Nummer / Serial Number ___________________...
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Type : Ergonomic 340.275 DG Serial number: Manufacturer BOMAR, spol. s r.o., Těžební 1236/1, 627 00 Brno Product data Determination: for cross dividing and cutting of rolled and towed bars and profiles made of steel, stainless steel, non-ferrous metals and plastics...
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If the equipment is installed without safety equipment offered by BOMAR, spol. s ro or its agents and used by the customer (or buyer) then EC declaration loses validity. EC Declaration of conformity is valid only if customer (buyer) installed the BOMAR safety equipment with the machine or with some other with equivalent safety device in accordance with current applicable regulations and standards.
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Manual version: 1.03/ May 2016 Manual rev.:...
Content BEZPEČNOSTNÍ POKYNY / SAFETY NOTES / SICHERHEITSHINWEISE ..............11 1.1. Machine determination........................13 1.2. Protective clothing and personal safety ..................13 1.3. Safety notes for machine operator ....................15 1.4. Safety notes for the servicing and repairs .................. 17 1.4.1.
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3.3.6. Speed adjustment of the arm lowering ..............56 3.3.7. Setting the type of cooling .................... 58 3.4. Material insertion ..........................59 3.4.1. Selecting means of manipulation ................. 59 3.4.2. Insertion ..........................59 3.4.3. Bundle material cutting ....................59 ÚDRŽBA STROJE / MACHINE MAINTENANCE / WARTUNG .. 60 4.1.
The operating instructions must be read by any person, who gets in touch with the machine during transportation, installation, using, servicing, reparation, stocking or removal! Attention! The operating instructions must be available at the machine position! Keep the operating instructions in a good condition! The operating instructions include relevant information.
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Always wear ear protection! Most of the machines emit up to 80 dB and may damage your hearing. Do not wear jewellery and always tie back long hair! Moving machine parts can catch jewellery or loose hair and may cause serious injuries. Manual version: 1.03/ May 2016 Manual rev.:...
Operate the machine only when you are fit enough to work. Illnesses or injuries diminish concentration. Avoid machine work, which may compromise the safety of you and your colleagues! Attention! Mind the safety signs on the machine. Do not remove or damage them! Attention! Machine can be operated by person older than 18 years!
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Do not use compressed air for the machine cleaning or for the chip removal! Use the protective instruments for chip removal! Manual version: 1.03/ May 2016 Manual rev.:...
Do not remove lock the limit switches or safety equipment! Any use of the saw, accessories or machine parts other than that intended by the BOMAR, spol. s r.o. company is not permitted. The guarantee on this product will be lost afterward and BOMAR, spol.
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Wash with water and eventually treat with crème any points of contact with the skin. Flush your eyes with water and seek out a doctor. If swallowed, drink a lot of water and induce vomiting. Look for medical help Manual version: 1.03/ May 2016 Manual rev.:...
1.6. Safety machine accessories The machine is equipped with safety accessories. They protect the operator from injuries and the machine from damage. The safety accessories are blocking accessories, emergency switches and covers. Check the function of the safety accessories once a week. If the safety accessories are not fulfilling their function, stop your work and repair or change the safety accessories.
If the cover is opened during operation, the limit switch is opened and the band saw is stopped. The machine cannot be run with the arm open even in the service mode. Make sure the arm cover is closed before starting the machine! 1.6.3.
from the jaw of the vice to the arm (both sides) Never turn the band drive on, if these covers are not mounted 1.6.4. Saw band stretching and rupture inspection This device checks the saw band stretching and causes an immediate machine shut –...
1.7. Umístění štítku stroje / Maschinenschild position / Position of the machine label Štítek stroje/ Maschineschild Machine label Manual version: 1.03/ May 2016 Manual rev.:...
2.1. Technická data / Technische Daten / Technical data Hmotnost stroje / Maschinengewicht / Machine weight: Hmotnost / Gewicht / Weight 372 kg Rozměry stroje / Maschinengröße / Machine size : Délka / Länge / Lenght 1960 mm ...
2.4. Transportation and stocking 2.4.1. Conditions for transportation and stocking Follow the recommendations of the manufacturer for transportation and stocking! If the recommendations are not kept, damage may occur to the machine. Don’t use a forklift truck for handling the machine, if you do not have ...
2.5. Activation 2.5.1. Machine working conditions Keep the conditions of the manufacturer for machine operation! If the recommendations are not kept, damage can occur to the machine. The manufacturer warrants the correct function of the machine for these conditions: At air temperature from 10°C to 40°C; the temperature average during 24 ...
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Move the length stop up to the saw band. Set the measuring unit to zero value. Fix the guiding pole of the length stop in place with a screw, which is put into the opening on the top side of the vice.
2.6.2. Attachment of the cooling liquid tub Put the tub for the dripping off of the coolant on the pedestal from the back side of the saw Attach the hose for the coolant removal to the outlet of the tub and put its other and immerse its other end into the coolant tank.
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Remove the nut from the handle of the hand wheel, place it into the hex opening on the back side of the wheel and fasten the handle.
2.6.4. Machine installing and leveling Check the floor supporting capacity before installing the machine. If the floor capacity does not meet the requirements, you must ready the necessary base for the machine. Minimal requirement: machine weight – Ergonomic 340.278 DG – 372 kg + weight of the accessories + maximum weight of material The machine must be leveled in a horizontal position.
2.7. Electrical connection Attention! Only a qualified professional must carry out the servicing and repairs of the electric equipment! Take special care during work with the electrical equipment. High voltage accident can have fatal consequences! Always follow instructions for work safety. Electrical parameters of the machine: Service voltage: ~ 3×400 V, 50 Hz, TN-C-S...
2.7.2. Inspection of the connection to the electrical network Attention! When you connect the machine to the electrical network insure correct connection of all phases! THE HYDRAULIC AGGREGATE ENGINE MUST NOT BE OPERATED IN REVERSED MODE FOR MORE THEN 10 SECONDS!!! 2.8.
The important factor for selection of the tooth system is the length of the cutting canal with respect to the size of the product. BOMAR recommends variable tooth system for its band saws. Constant tooth system – the saw band has a constant tooth pitch all over its length.
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When cutting small pieces run the band until approximately 300 cm of material has been cut. When cutting large pieces run the band for approximately 15 minutes. When the band has been run, increase the lowering speed of the arm to normal. The running in of the saw band avoids micro chips on the cutting edges of a new saw band ensuing from first excessive stress.
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2.11. Table for teeth selection SHAPED MATERIAL (D , S = mm) Note: Table shows tooth system selection for cutting one piece of the profile. For cutting of more pieces of the profiles (bundle), you must think of the size of the wall as double size of the wall of one profile (that means, size „S“...
3.1. Starting the band saw and switching on the safety circuits Turn the main switch into position 1 –ON The main switch is located on the side of the control panel.. Switch on the Safety circuit of the saw. The safety circuit will run a check on all safety switches.
3.2. Control elements Manual version: 1.03/ May 2016 Manual rev.:...
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TOTAL – STOP button Immediately stops the machine in a case of emergency. Safety circuit Press button to turn on the safety circuit START Starts the drive of the saw band.. STOP Stops the drive of the saw band Ergonomic 340.278 DG without a frequency converter Cutting speed switch Serves to switch the speed of the saw band during cutting (40 or 80 m.
3.3. Machine control 3.3.1. Cutting Open the main vice of the band saw. Set the length stop to the desired length of the material. Set the desired cutting angle. Insert the material and push it to the length stop. Move the vice jaw to about 5 mm from the material For a longer distance movement of the vice jaw use the rapid shift option: a) loosen the arresting lever of the moveable jaw of the main vice b) move the jaw to the required distance...
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For shifting the jaw for a shorter distance use the hand wheel. Tighten the material by the clamping lever. Set the left guiding cube of the saw band as close as possible to the material. Note: It is possible to stop the saw band drive by pressing the STOP button or in a case emergency with the TOTAL STOP anytime during the cutting Set the saw band speed.
3.3.2. Setting of the material length Loosen the clamping screw of the length stop Shift the length stop to the required length and tighten the clamping screw. Warning! The length stop enables a gap between the length stop slat line and the material to avoid clenching the saw band in the cut during cutting.
3.3.3. Setting of the cutting angle The band saw Ergonomic 340.278 DG allows cutting under angles from -45° to 60°. For an easier setup of common angles, there are latches on the turning console at every 15° angle increment. Locking in the latches can be felt when turning the saw frame by hand.
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Picture Procedure 16. Loosen the clamping lever of the vice. Manual version: 1.03/ May 2016 Manual rev.:...
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Picture Procedure angle < 0° 17. Shift the vice according to the set angle of the cut. For negative angles move the vice to the right, for positive and angle ≥ 0° zero angles to the left.
3.3.4. Setting of the optimal span of the guiding cubes For reaching a smooth and accurate cut it is necessary to move the left guiding cube as close to the cut material as possible. Loosen the lever of the left guiding lath and move the left part of the saw band guide so that the edge of the left guiding cube will be as close to the material as possible.
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If the regulation valve is fully closed, the arm is fixed in a vertical position. To allow the arm to move downwards (into cut) it is necessary to release the valve.
3.3.7. Setting the type of cooling The required type of cooling can be chosen using knob no. 3 o the control panel. Cooling with liquid: The cooling pump runs, even if the pump is turned off (washing) The saw band runs without cooling. The cooling is turned on together with the saw band drive Cooling with oil vapor- Microniser (optional equipment) Saw band runs without cooling.
If you are cutting long pieces (for example rods, tubes), you must use a roller conveyor for shifting the material to the band saw. Contact Bomar for more information about roller conveyors. Make sure the conveyor is long enough and the material cannot drop off the conveyor.
4.1. Saw band dismantling Lift the arm to its uppermost position and lock the arm in position with the regulation valve. Remove the yellow safety covers of the band. The covers are tightened with screws. Open the back cover of the arm. It is mounted with two plastic head screws. Loosen the holder of the brush and turn it away from the band so it does not hinder the dismantling of the band.
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By turning the tightening star to the left loosen the stretching of the band. Pull the saw band from the wheels. After that pull out the band carefully from the guiding cubes.
4.2. Saw band installation Prior to installation, clean the track wheels, guiding cubes and inner side of the arm thoroughly of all traces of chips and dirt. Keep in mind the teeth direction when installing the saw band. Insert a new saw band in the guide cubes. Make sure the saw band runs between both guiding rollers and that it is pushed all the way to the top.
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Adjust the brush to the saw band and tighten the holder screws. Close the back cover and secure it with two plastic head screws.
Mount the yellow safety covers of the band. Arrow on the cover must agree with the direction of the teeth. If it does not, you have to flip the saw band. 4.3. Saw band stretching and inspection Correct saw band stretching is one of the most important factors, which influences accuracy and saw band lifespan.
4.3.1. Saw band stretching After installation of the saw band stretch it gently, so it does not fall of the wheels. Mount the Tenzomat on the saw band and secure it with screws. Stretch the saw band until it is stretched to the recommended value. For a quick control of the tension of the band there is an indicator near the tightening star.
If the distance between backside of the saw band and the wheel rim is 1 mm, the setting is right. If the distance is bigger than 1 mm, or the saw band runs on the rim of the wheel, adjust the saw band.
Tighten the screw on the side of guide cube so that the band is loosened Loosen the screw slowly and let the hard metal plate touch the band. You must be able to turn the screw by hand. Set the hard metal guiding on the right cube in the same way.
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Release the tightening screw of the brush so that it is possible to move the brush. Manual version: 1.03/ May 2016 Manual rev.:...
Adjust the brush to the saw band. Its ends must not reach the saw band teeth bottoms. Tighten the screw again and turn on the band driver. If the chip removing brush is correctly fastened the brush turns smoothly with the saw band. Do not tighten the screw with brute force! Attention! Do not tighten the screw with brute force!
4.4.6. Saw frame lower position stop adjustment The lower stop limits the lowest position of the saw frame. This stop has to be checked at least once a month. If the lower stop is adjusted incorrectly, the loading surface of the table can be cut too deeply or the material will not be cut completely Raise the saw frame to the upper position Release the nut of the adjusting screw and adjust the stop Fasten the adjusting screw with the nut again...
Release the nut of the stop screw and screw down the stop screw Lower the arm to the lower stop and turn on the band driver Screw out the stop screw until the band driver stops Secure the screw with nut again and check the limit switch setting once more 4.5.
4.5.2. Cooling liquid preparation Prepare a mixture of water and cooling liquid. Conform the notes of the manufacturer and keep the manufacturer’s-approved concentration All instructions are stated on the tank of the cooling liquid or in documentation of the cooling liquid. For cooling liquid usage and disposal heed the instructions of the manufacturer.
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Place the container into the care of a disposal company equipped for the disposal of chips contaminated with cooling liquid. In case the machine is equipped with micronisation device, the chips must also be handed over to a disposal company.
In gearboxes, oil is used for the whole lifetime of the gearbox. We recommend replacing of the filling oil in case of repair. Attention: When replacing the oil, use oils recommended by BOMAR or oils from other manufacturers, which have comparable parameters.
4.6.2. Lubrication greases For lubrication we recommend using lithium based class NGLI-2 saponified grease. Different greases are mixable, if their oil bases and density classes are identical. Comparative table of the lubricant greases: Manufacturer Type of the lubricant grease Energrease LS - EP Paragon EP1 FETT EGL 3144 Esso...
If the hydraulic system is equipped with filter (2SF 56/48-0,063), replace the filter too. Note: When replacing the oil, use oils recommended by BOMAR or oils, from other manufacturers which have comparable parameters. Do not forget, that mineral and synthetic oils...
4.8. Worn pieces replacement 4.8.1. Hard metal guides replacement If the hard metal guides cannot be adjusted, they have to be replaced. Remove the cooling agent hosepipe and dismantle the saw band and saw band guiding cube. Fasten the guiding cube in a vice. Loosen the mounting screws using a hex key Unscrew the frontal screws, which hold the hard metal guides.
4.8.2. Saw band guiding rollers replacement If the saw band is not sufficiently guided by guiding rollers and/or if the rollers are visibly worn, they should be replaced. Attention! Guiding rollers must be replaced together on both guide cubes! Remove the cooling agent hosepipe and dismantle the saw band and guiding cube.
Now insert a test piece of saw band (cca 15 - 20 cm) into the guide cube. Adjust both eccentrics so that the band runs in the middle of the milled groove. This groove is located between both eccentrics. Guide rollers may not Optimal distance between the band and guiding roller is 0,05 mm.
4.8.4. Stretching wheel replacement Dismantle the saw band. Screw off the stretching wheel screw and remove the washer. Screw the auxiliary screw onto the shaft of the stretching wheel. Put on the three-leg puller on the stretching wheel and pull off it from the shaft.
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Insert a bearing into the hole in the wheel and push it to the retaining ring. Clean the shaft and oil it. Install the new stretching wheel on the shaft. Install the distance ring on the shaft and push it to the lower bearing. 10.
4.8.5. Driving wheel replacement Dismantle the saw band. Screw of the fastening screw of the driving wheel and pull off the washer. Screw on the auxiliary screw to the driving shaft. Install the three-leg puller on the driving wheel and pull off it from the shaft. Check, if the spring and the driving shaft are not damaged.
Install the washer and screw on the driving wheel. Install the saw band. 4.8.6. Cooling pump replacement Warning! Only a qualified technician can perform the installation! Electrical accidents can be fatal! Disconnect the machine from electrical network. Pull out the tank from the pedestal as far as possible. Pull out the cooling pump from the tank and disconnect the hose for the coolant distribution from the pump.
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Disconnect the supply cable of the pump from the connector. Complete the replacement by following these steps in reversed order.
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Manual version: 1.03/ May 2016 Manual rev.:...
5.1. Mechanical problems Problem Possible causes Repair Wrongly adjusted hard metal guides. Set according to the chapter „Servicing and adjustment“ Worn hard metal guides. Replace according to the chapter „Worn pieces replacement“ Wrongly adjusted cubes of the saw Set according to the chapter „Servicing and band guiding.
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Problem Possible causes Repair Over stretched saw band Lower the stretching of the saw band and set the limit switch of the saw band stretching according to chapter „Servicing and adjustment“ Wrongly adjusted hard metal guides. Check the adjustment of the hard metal guides and carry out adjustment as described in chapter „Servicing and adjustment“...
Problem Possible causes Repair Looseness in the lifting cylinder mounting. Bearings of guiding cubes are worn Bearings of guiding cubes must be replaced. out (rolling elements are damaged or Bearings must be adjusted according to outside ring of bearing has conical operating instructions.
Problem Possible causes Repair voltage between the contactor and thermal protection Sensor of speed is not adjusted. Sensor of speed must be adjusted. The speed indicator of the saw band is Defective display The display must be replaced. not functional. Defective sensor –...
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• The hydro generator gasket is Call service damaged • Damaged clutch of the drive Call service Increased • Damaged or destroyed motor bearings Call service mechanical noise • Air intake Check for leaks. • Failure on the safety valve Wrong settings.
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Note: Frequency converter Connect the machine to electrical networks with corresponding technical parameters only. We recommend protecting the machine with RCD protection with U characteristics, which is able to compensate changes of current escaping from the filter of the frequency converter, so that additional equipments will not be required.
Výkresy sestav pro objednání náhradních dílů / Zeichnungen für Bestellung der Ersatzteile / Drawing assemblies for spare parts order Při objednávání náhradních dílů vždy uvádějte: typ stroje (např. practix Ergonomic 340.278 DG) , výrobní číslo (např. 125) a rok výroby (např. 1999). In die Bestellung der Ersatzteile führen Sie immer an: Maschinentyp (z.
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For spare parts order, you must always to allege: type of machine (for example Ergonomic 340.278 DG), serial number (for example 125, see cover page) and year of construction (for example 1999).