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Summary of Contents for Cosen SH-510LDMM
- Page 1 COSEN SAWS SH-510LDMM Semi-Automatic Linear Guided Double Miter-Cutting Horizontal Band saw (Standard model) Instruction Manual The Pinnacle of Cutting Performance Cosen Mechatronics Co., Ltd.
- Page 3 FROM THE MANUFACTURER Thank you for your purchase of COSEN’s bandsaw machine and your trust in the COSEN brand. We are excited to have you as our valued customer and look forward as much as you do to the accelerated productivity, long-lasting endurance and superb cost-effectiveness this machine is about to bring to you.
- Page 5 Safety rules Make sure your work area is cleared of uninvited people and obstacles every time before you start operating the machine. Never step or stand on the roller table. Your foot may slip or trip on the rollers and you will fall.
- Page 6 Safety rules Never adjust the wire brush or remove chips while the saw blade is still running. It is extremely dangerous if hands or clothing are caught by the running blade. Stop the saw blade before you clean the machine. It is dangerous if hands or clothing are caught by the running blade.
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Page 7: Table Of Contents
Table of Contents Safety Information Section 1 – Safety Instructions ……………………………………………………………………………………………………… 1-1 Safeguard Devices ………………………………………………………………………………………………………. 1-3 Illustration: Safety Fence ………….……………………………………………………………………………..… Emergency Stop …………………………………………………………………………………………………………. 1-5 Illustration: Emergency Stop ……………………………………………………………………………………… Safety Labels ………………………………………………………………………………………………………………. 1-7 Illustration: Safety Labels ………………………………………………………………………………………..… Hearing Protection ……………………………………………………………………………………………………... 1-9 CE Compliance ……………………………………………………………………………………………………………. - Page 8 Table of Contents Control Buttons ……………………………………………………………………………………….…….. 4-5 Blade Descend Pressure & Speed ………..…………………………………………………….…… 4-7 HMI Touch Screen & Functions …………………………………………………………….………… 4-7 HMI Error Codes ………………………..……………………………………………………….…………. 4-17 Standard Accessories ………….………………………..……………………………………………….…………… 4-18 Optional Accessories …….…….………………………..…………………………………………….……………… 4-20 Unrolling & Installing the Blade …………………………………………………………………….……………. 4-21 Adjusting Wire Brush ………..……………………………………………………………………….……………….
- Page 9 Table of Contents Every Six Months ……………….……….………………………………………….……………………… 8-3 Storage Conditions …………………………..…………..………………………………………………………….. 8-3 Terminating the Use of Machine ……..……………..………………………………………………………….. 8-3 Oil Recommendation for Maintenance …………..………………………………………………………….. 8-4 Troubleshooting Section 9 – Introduction ……………………….…….……………………………………………………………………………….. 9-1 Precautions ………………….…………………..…………….………………………………………………………..9-2 General Troubles & Solutions ………………………..….……………………………………………………….. 9-2 Minor Troubles &...
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Page 11: Safety Information
Safety is a combination of a well-designed machine, operator’s knowledge about the machine and alertness at all times. COSEN’s band machine has incorporated many safety measures during the design process and used protective devices to prevent personal injuries and potential risks. Warning labels also serve as a reminder to the operator. - Page 12 This manual has important safety Wear proper apparel during operation information. Read through it carefully and when servicing the machine. Some before operating this machine to personal protective equipment is prevent personal injury or machine required for the safe use of the machine, damage.
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Page 13: Safeguard Devices
SAFEGUARD DEVICES The safeguard devices incorporated in this machine include the following two main parts: 1. Protection covers & guards 2. Safety-related switches Protection Covers & Guards 1. Idle wheel housing cover 2. Drive wheel housing cover 3. Gear reducer cover 4. -
Page 14: Emergency Stop
Safety Related Switches To protect the operator, the following safety related switches on the machine are actuated when the machine is in operation. Wheel motion detector This is a proximity sensor used to detect the motion of the drive wheel. Once the saw blade is broken or as soon as it starts slipping, the sensor will detect and stop the drive wheel and the machine. - Page 15 Safety Related Switches To protect the operator, the following safety related switches on the machine are actuated when the machine is in operation. Wheel motion detector This is a proximity sensor used to detect the motion of the drive wheel. Once the saw blade is broken as soon as it starts slipping, the sensor will detect and stop the drive wheel and the machine.
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Page 16: Illustration: Emergency Stop
Illustration: Emergency Stop Emergency Stop Button... -
Page 17: Safety Labels
SAFETY LABELS Please read through and understand these safety labels before operating the machine. Refer to Illustration: Safety Labels. Label Meaning Label Meaning Impact Hazard Read Operator’s Manual WEAR SAFETY SHOES. Do This manual has important safety not approach dropping area information. -
Page 18: Illustration: Safety Labels
Illustration: Safety Labels... -
Page 19: Hearing Protection
If maintenance does not seem to solve the problem, follow the troubleshooting procedures under Section 9. CE COMPLIANCE Cosen’s CE model is designed to satisfy regulations of the Council Directive on the approximation of the laws of the Member States relating to machinery (2006/42/EC) - Annex I Essential health and safety requirements relating to the design and construction of machinery. -
Page 21: General Information
INFORMATION SPECIFICATION MACHINE PARTS IDENTIFICATION FLOOR PLAN This band saw machine is designed by Cosen’s R&D engineers to provide you the following features and advantages: Safety This machine is designed to fully protect the operator from its moving parts during cutting operation. - Page 22 SPECIFICATION SH-510LDMM Model Semi-Automatic Linear Guided Double Miter-Cutting Horizontal Band saw 0° ±45° ±60° Miter Angle 320 mm 320 mm 200 mm Round (12.5”) (12.5”) (7.8”) Capacity 330 x 510 mm 330 x 320 mm 330 x 200 mm Rectangular (H x W) (12.9”...
- Page 23 MACHINE PARTS IDENTIFICATION Control panel Motor Saw bow Idle wheel Vise Vise hydraulic Drive wheel cylinder Chip conveyor (optional)
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Page 24: Floor Plan
FLOOR PLAN Machine top view... - Page 25 Machine front view...
- Page 26 Machine side view...
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Page 27: Moving & Installation
Section 3 MOVING & INSTALLATION LOCATION & ENVIRONMENT UNPACKING & INSPECTING LIFTING REMOVING SHIPPING BRACKET CLEANING INSTALLING RELOCATING LOCATION & ENVIRONMENT For your safety, please read all information regarding installation before proceeding. Install your machine in a place satisfying all of the following conditions: Space: ... -
Page 28: Unpacking & Inspecting
UNPACKING & INSPECTING Unpack your machine carefully to avoid damage to machine parts or surfaces. Upon arrival of your new band saw, please confirm that your machine is the correct model and it comes in the same specification you ordered by checking the model plate on the machine base. ... -
Page 29: Lifting
LIFTING When moving the machine, we strongly suggest you choose any one of the methods described below to move your machine. Use a crane (Only applies to the machine with the design of the hanging point.) Move the machine to its location by using a crane and a wire rope sling that can fully withstand the weight of the machine (refer to machine specification under Section 2 General Information). - Page 30 When you work together with more than two people, it is best to keep constant verbal communication with each other. Use a forklift (Only applies to the machine with the design of the lifting point.) Make sure that the lifting rod can fully withstand the weight of the machine. (Refer to Section 2 – General Information for Specifications.) Machine lifting with a forklift should be done strictly according to the lifting points designated by the original manufacturer.
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Page 31: Illustration: Lifting Points
You must use rolling cylinders made in material of proper compressive strength. 4. Other ways to move If the machine does not have stickers, please contact your local agent immediately. Illustration: Lifting Points Minimum weight capacity for each wire rope: 3 ton Total number of wire ropes required: 4... -
Page 32: Removing Shipping Bracket
Do not remove the rust-preventive grease with a metal scraper and do not wipe the painted surfaces with solvent as doing so would damage surface paint. INSTALLING Cosen’s bandsaw machine is relatively easy to install. Follow these six easy steps to install your machine. Connect Leveling &... -
Page 33: Supplying Coolant
Supplying coolant Fill the coolant tank to the middle level of the sight gauge by pouring the coolant from above the chip conveyor. Use the sight gauge to check the coolant level remaining in the tank. Always check the coolant supply before starting the machine. -
Page 34: Connecting Electric Power
Have a qualified electrician make the electrical connections. If the power supply voltage is different from the transformer and motor connection voltage shown on the label attached to the electrical compartment of the machine, contact COSEN or your agent immediately. -
Page 35: Installing Roller Table (Optional)
Leveling Place spirit level on the vise slide plates and the work feed table. Level the machine in both directions i.e. along and across the machine. Adjust the level of the machine by turning the leveling bolts. Make sure all leveling bolts evenly support the machine weight. -
Page 36: Installing Fire Control Device
Installing Fire Control Device Install a fire extinguisher or any other fire control device in the shop in case a fire breaks out. RELOCATING We recommend you follow these procedures when relocating or shipping your machine to other place: 1. Descend the saw frame to its lowest position then turn off the power. 2. -
Page 37: Operating Instructions
Section 4 OPERATING INSTRUCTION SAFETY PRECAUTIONS BEFORE OPERATING CONTROL PANEL STANDARD ACCESSORIES OPTIONAL ACCESSORIES UNROLLING & INSTALLING THE BLADE ADJUSTING WIRE BRUSH PLACING WORKPIECE ONTO WORKBED POSITIONING WORKPIECE ADJUSTING BLADE SPEED ADJUSTING COOLANT FLOW BREAKING-IN THE BLADE TEST-RUNNING THE MACHINE CUTTING OPERATION USING TOP CLAMP FOR BUNDLE CUTTING TERMINATING A CUTTING OPERATION... -
Page 38: Safety Precautions
SAFETY PRECAUTIONS For your safety, please read and understand the instruction manual before you operate the machine. The operator should always follow these safety guidelines: The machine should only be used for its designated purpose. Do not wear gloves, neckties, jewelry or loose clothing/hair while operating the machine. ... -
Page 39: Before Operating
BEFORE OPERATING Choosing an appropriate saw blade and using the right cutting method is essential to your cutting efficiency and safety. Select a suitable saw blade and cutting method based on your work material and job requirements e.g. cutting accuracy, cutting speed, economic concern, and safety control. Wet cutting If you choose dry cutting or low-speed cutting, the chips may accumulate in machine parts and may cause operation failure or insulation malfunction. -
Page 40: Control Panel
CONTROL PANEL The control panel is located on the top of the electrical box. It includes the following function: power system, hydraulic system, cooling system and the human-machine–interface (HMI). The operator must fully understand the function of each switch and button before operating the machine. Control Blade speed display Blade speed control knob... -
Page 41: Control Buttons
Control Buttons 1. Blade speed display Displays current blade speed. 2. Blade speed control knob Blade speed is controlled by the inverter located under the workbed. Turning the knob clockwise increases the blade speed. 3. Power indicator lamp When the lamp is on, it indicates the power to the machine is turned on. 4. - Page 42 5. Projection lamp ON/OFF ON : When the mode is selected, projection lamp will OFF / OFF. Hydraulic ON/OFF button O ( Red) : Press this button to turn off the hydraulic motor immediately. I (Green): Press this button to turn on the hydraulic motor immediately. 7.
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Page 43: Blade Descend Pressure & Speed
Blade descend pressure and speed The part of control panel is where cutting pressure and saw bow descend speed can be adjusted. 1. Cutting pressure control knob This pressure control knob is used to adjust the cutting pressure of the blade. ... -
Page 44: Standard Accessories
STANDARD ACCESSORIES Split front vises The spilt vises are a clever design to make sure your workpiece is tightly clamped by the two vises from both sides of the blade, maximizing stability and cutting precision. Blade tension device This blade tension device equipped with hydraulic cylinder provides appropriate tension to the saw blade. - Page 45 Gear reducer The specially designed gear reducer can work toward your preset blade speed and torque. Gear reducer Please refer to Chapter 8 for information on maintenance. Coolant Pump The coolant pump supplies coolant to cool off cutting temperatures during cutting. Also, it can be used to wash off chips.
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Page 46: Optional Accessories
OPTIONAL ACCESSORIES Vise Pressure Regulator This adjustment valve is used to control vise pressure. Adjust vise pressure based on the material of your workpiece. When cutting pipes or soft materials, reduce vise pressure to prevent exerted pressure from damaging the workpiece shape or exterior. - Page 47 How to Check & Adjust 1. Start the hydraulic motor. Turn on the deviation function. Start the saw blade and let it run for 1~2 minutes.. 2. Stop the saw blade. Observe the deviation value while the saw blade is completely still. 3.
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Page 48: Unrolling & Installing The Blade
Projection Light Activate the switch to project a beam of light on the work piece. The operator can use the light as reference to adjust the cutting dimension of the work piece. UNROLLING & INSTALLING THE BLADE Always wear leather gloves and protection glasses when handling a blade. Unrolling the blade Please follow the procedures illustrated below. -
Page 49: Adjusting Wire Brush
Installing a new blade Step 1 - Select the most suitable saw blade for your workpiece considering the size, shape and material. Step 2 - Turn on the machine power by switching to ON and turn on the hydraulic system. Step 3 - Press the saw bow up button and elevate the saw bow to an appropriate height. -
Page 50: Placing Workpiece Onto Workbed
Proper Improper Lock lever PLACING WORKPIECE ONTO WORKBED Step 1 – Press the saw bow up button and elevate the saw bow until it reaches to its highest point. Step 2 – Turn the vise open/clamp switch to the left to open vise. Step 3 –... -
Page 51: Adjusting Coolant Flow
ADJUSTING COOLANT FLOW Step 1 – Press the saw blade start button to start the saw blade drive motor. Step 2 – Press the saw bow down button to lower the saw bow. Step 3 – Use the flow control valve (shown below) to adjust the amount of fluid flowing to the cutting area. -
Page 52: Test-Running The Machine
TEST-RUNNING THE MACHINE Test-running this machine can ensure good machine performance in the future. We suggest you run the following tests on the machine before first use: Testing machine performance: Turn on the power and run a basic performance test after you finish installing the machine. Follow these steps to test machine performance: Step 1 –... -
Page 53: Cutting Operation
CUTTING OPERATION Step 1 – Check before you cut Power: Check the voltage and frequency of your power source. Coolant: Check if you have sufficient coolant in the tank. Hydraulic: Check if you have sufficient (at least two-thirds or higher) hydraulic oil. ... -
Page 54: Using Top Clamp For Bundle Cutting
USING TOP CLAMP FOR BUNDLE CUTTING Step 1 – Open the adjustment valve of top clamp. Step 2 – Position the workpiece for bundle cutting. Note the allowable clamping width and height. (Refer to Section 2 – General Information, Specifications) Proper and improper stacking of workpieces Proper Improper... -
Page 55: Electrical System
Section 5 ELECTRICAL SYSTEM ELECTRICAL CIRCUIT DIAGRAMS... -
Page 61: Hydraulic System
Section 6 HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS... -
Page 63: Bandsaw Cutting: A Practical Guide
Section 7 BANDSAW CUTTING: A PRACTICAL GUIDE INTRODUCTION SAW BLADE SELECTION VISE LOADING BladeBreak -In SOLUTIONS TO SAWING PROBLEMS... - Page 64 INTRODUCTION TPI: The number of teeth per inch as measured from gullet to gullet. 2. Tooth Rake Angle: The angle of the tooth face measured with respect to a line perpendicular to the cutting direction of the saw. 3.Tooth Pitch: Tooth pitch refers to the number of teeth per inch (tpi). 1 inch equates to 25.4 mm. A distinction is made between constant tooth pitches with a uniform tooth distance, 2 tpi for example, and variable tooth pitches with different tooth distances within one toothing interval.
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Page 65: Vise Loading
4. Tooth pitch The main factor here is the contact length of the blade in the workpiece. If it is 4P, 25.4 ÷ 4 P = 6.35 mm, that is, one tooth is 6.35 mm. If it is 3P, 25.4 ÷ 3 P = 8.46 mm If the number is small, it means that the tooth is large. What is written as 3/4 is that it is a variable pitch of large (3) / small (4). -
Page 66: Bladebreak -In
The following diagrams suggest some costeffective ways of loading and fixturing. Be sure, regardless of the arrangement selected, that the work can be firmly secured to avoid damage to the machine or injury to the operator. BladeBreak -In Completing a proper break-in on a new band saw blade will dramatically increase its life. 1. -
Page 67: Maintenance & Service
Section 8 MAINTENANCE & SERVICE INTRODUCTION BASIC MAINTENANCE MAINTENANCE SCHEDULE BEFORE BEGINNING A DAY’S WORK AFTER ENDING A DAY’S WORK EVERY MONTH EVERY THREE MONTHS EVERY SIX MONTHS STORAGE CONDITIONS TERMINATING THE USE OF MACHINE OIL RECOMMENDATION FOR MAINTENANCE INTRODUCTION For the best performance and longer life of the band saw machine, a maintenance schedule is necessary. -
Page 68: Every 2 Weeks
MAINTENANCE SCHEDULE We suggest you do the maintenance on schedule. Before beginning a day’s work 1. Please check the hydraulic oil level. If oil level volume is below 1/2, please add oil as necessary.(Filling up to 2/3 level is better for system operation.) 2. -
Page 69: Every Six Months
Every six months 1.Clean the filter of the cutting fluid. 2.Replace the transmission oil for every half of a year(or 1200 hours). Check the sight gauge to ascertain the transmission level. Recommended TRANSMISSION OIL Omala oil HD220 Mobil comp 632 600W Cylinder oil 3.Replace the hydraulic oil. -
Page 70: Oil Recommendation For Maintenance
OIL RECOMMENDATION FOR MAINTENANCE Item Method Revolution Suggest oil Dovetail guide Keep grease covered. Antirust. Daily Shell R2 Roller bearing Sweep clean and oil with lubricant. Daily SEA #10 Bed roller / surface Sweep clean and oil with lubricant. Daily SEA #10 Nipples of bearing Use grease gun, but not excess. -
Page 71: Troubleshooting
Section 9 TROUBLESHOOTING INTRODUCTION PRECAUTIONS GENERAL TROUBLES & SOLUTIONS MINOR TROUBLES & SOLUTIONS MOTOR TROUBLES & SOLUTIONS BLADE TROUBLES & SOLUTIONS SAWING PROBLEMS & SOLUTIONS RE-ADJUSTING THE ROLLER TABLE INTRODUCTION All the machines manufactured by us pass a 48 hours continuously running test before shipping out and we are responsible for the after sales service problems during the warranty period if the machines are used normally. - Page 72 PRECAUTIONS When an abnormality occurs in the machine during operation, you can do it yourself safely. If you have to stop machine motion immediately for parts exchanging, you should do so according to the following procedures: Press HYDRAULIC MOTOR OFF button or EMERGENCY STOP button. ...
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Page 73: Motor Troubles & Solutions
MINOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Saw blade motor does not run Overload relay activated Reset even though blade drive button Saw blade is not at forward Press SAW FRAME is pressed. limit position. FORWARD button MOTOR TROUBLES & SOLUTIONS TROUBLE PROBABLE CAUSE SUGGESTED REMEDY... -
Page 74: Blade Troubles & Solutions
BLADE TROUBLES AND SOLUTIONS DISCONNECT POWER CORD TO MOTOR BEFORE ATTEMPTING ANY REPAIR OR INSPECTION. TROUBLE PROBABLE CAUSE SUGGESTED REMEDY Too few teeth per inch Use finer tooth blade Loading of gullets Use coarse tooth blade or cutting lubricant. Teeth strippage Excessive feed Decrease feed... -
Page 75: Sawing Problems & Solutions
SAWING PROBLEMS AND SOLUTIONS Other than this manual, the manufacturer also provides some related technical documents listed as follows: Sawing Problems and Solutions Vibration during cutting Failure to cut Short life of saw blade Curved cutting Broken blade ... - Page 76 SOLUTIONS TO SAWING PROBLEMS Table Of Contents #1. Heavy Even Wear On Tips and Corners Of Teeth #11. Uneven Wear Or Scoring On The Sides Of Band #2. Wear On Both Sides Of Teeth #12. Heavy Wear And/Or Swagging On Back Edge #3.
- Page 77 #2. Wear On Both Sides Of Teeth Probable Cause : A. Broken, worn or missing back-up guides allowing teeth to contact side guides. B. Improper side guides for band width. C. Backing the band out of an incomplete cut. #3. Wear On One Side Of Teeth Probable Cause : A.
- Page 78 #5. Body Breakage Or Cracks From Back Edge Probable Cause : A. Excessive back-up guide "preload" will cause back edge to work harden which results in cracking. B. Excessive feed rate. C. Improper band tracking – back edge rubbing heavy on wheel flange.
- Page 79 #8. Gullets Loading Up With Material Probable Cause : A. Too fine of a tooth pitch – insufficient gullet capacity. B. Excessive feeding rate producing too large of a chip. C. Worn, missing or improperly positioned chip brush. D. Insufficient sawing fluid due to inadequate supply, improper ratio and/or improper application.
- Page 80 #12. Heavy Wear And/Or Swagging On Back Edge Probable Cause : A. Excessive feed rate. B. Excessive back-up guide "preload". C. Improper band tracking – back edge rubbing heavy on wheel flange. D. Worn or defective back-up guides. #13. Butt Weld Breakage Probable Cause : A.
- Page 81 #16. Body Breakage Or Cracks From Gullets Probable Cause : A. Excessive back-up guide "preload". B. Improper band tension. C. Guide arms spread to maximum capacity. D. Improper beam bar alignment. E. Side guide adjustment is too tight. F. Excessively worn teeth. #17.
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Page 82: Re-Adjusting The Roller Table
#20. Broken Band Shows A Twist In Band Length Probable Cause : A. Excessive band tension B. Any of the band conditions which cause the band to be long (#18) or short (#19) on tooth edge. C. Cutting a tight radius. RE-ADJUSTING THE ROLLER TABLE If the feeding table suffers the huge stroke and the alignment is effected, follow the below procedure to adjust. -
Page 83: Parts
Section 10 PARTS SPARE PARTS RECOMMENDATIONS PART LIST SPARE PARTS RECOMMENDATIONS The following table lists the common spare parts we suggest you purchase in advance: Part Name Part Name Saw blade Coolant tank filter Wire brush Steel plates Carbide inserts Rollers Bearings Belt... -
Page 85: Warranty
Section 11 Warranty Warranty New machines are warranted to be free from defects in workmanship and material for a period of one (1) year from the date of shipment by Seller. The warranty period is based on normal usage of two thousand eighty hours (2080) per year and is reduced proportionately for any excess usage. - Page 88 Vertical Plate Saws Horizontal Billet Saws NC/CNC Band Saws Structural Miter-Cutting Saws Automatic Band Saws Visit our website at www.cosen.com COSEN MECHATRONICS CO., LTD.
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