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• Page 1
  BANDSAWING MACHINE VM1200/2500 OPERATOR’S MANUAL This product comes standard with: Circuit Diagrams Operator’s Manual VM1200&2500 US- -201008…
• Page 2
  Operator’s Manual: VM Series Bandsawing Machine © 2010 by AMADA CO., LTD. No part of this publication may be photocopied or otherwise reproduced with- out the prior written permission of AMADA CO., LTD. Aug. 2010 Printed in Japan…

• Page 3: Table Of Contents

  CONTENTS Safety Rules ………………..vii Safety rules ……………..vii Cutting precautions …………..xiv EMERGENCY STOP button location……… xix Part I Description…………….I-1 Names and functions of main parts ……….. I-3 Specifications …………….I-4 Dimensions of main parts …………I-4 Machine ………………I-7 Standard accessories…………..

• Page 4
  PROGRAM display ……………III-14 CNC INPUT display …………..III-15 MANUAL INPUT display …………III-16 DIMENT display …………..III-18 DEVIATION display……………III-18 MONITOR I/O display …………III-19 COUNTER display …………..III-20 HIST. ERR display…………..III-21 MAINTENANCE display…………III-22 Part IV Operation …………….IV-1 Preparing for operation …………. IV-3 Turning on power …………..IV-3 Zero-returning upper saw blade guide ……..
• Page 5
  Troubleshooting …………… IV-27 Troubles during cutting…………IV-27 Error list………………IV-29 Part V Maintenance…………….V-1 Cleaning………………V-2 Checking before start of day’s work………..V-3 Hydraulic oil level…………..V-3 Cutting fluid level …………..V-3 Saw blade …………….V-3 Wire brush …………….V-4 Periodic maintenance …………..V-5 Saw blade guides …………..V-5 Spiral of chip conveyor (option)……….V-5 Changing fluid and oil …………..V-6 Cutting fluid …………….V-6…

• Page 7: Safety Rules

  SAFETY RULES Observe these safety rules to prevent injuries and accidents. (The illustrations may be partly different from the actual machine in detail.) a) Never wear gloves and loose clothing when operating the machine. It is dangerous if they are caught in the running machine.

• Page 8
  The machine needs special measures for cutting explosive materials (for details, consult AMADA). e) Confirm that the area around the machine is cleared of people and obstacles every time before starting the machine or operation.
• Page 9
  Set the MODE keyswitch at “ ” when installing or removing the saw blade, or lubricating the saw blade tension slides and driven wheel bearing. g) Never look directly into the source of the laser beam. You may lose your eyesight. h) Never start the saw blade unless it has been confirmed that the work is firmly…
• Page 10
  Never operate the machine with the wheel covers and other covers removed or opened. It is dangerous if your hands or clothing are caught in the running machine. k) Never take your eyes off the machine or lean on the machine during operation.
• Page 11
  n) Stop the saw blade whenever STOP cleaning the machine. It is dangerous if your hands or clothing are caught in the running saw blade. o) Turn off the shop circuit breaker switch before servicing the machine. Then SERVICING post a sign to inform people that the machine is under maintenance.
• Page 12
  Warning plates Keep the warning plates well noticeable and never remove them. View at A…
• Page 13
  Warning signs and messages Read the operator’s manual. Do not operate the machine unattended. Oil-based cutting fluids may catch fire. Do not use them. Some chips can violently burn. Do not cut titanium, magnesium, and especially carbon. You may lose your eyesight. Do not look directly into the source of the laser beam.

• Page 14: Cutting Precautions

  An appropriate saw blade also varies with the requirements of your job (such as cutting accuracy, cutting speed, and economy) even when the same work is to be cut. Consult AMADA about the selection of saw blades for specific jobs.

• Page 15
  Dry cutting The machine needs special measures for performing dry cutting. Consult AMADA. If dry cutting is performed without taking special measures, chips may accumulate in machine parts and may cause the operation or insulation failure of the machine.
• Page 16
  Materials to be cut wet or dry AISI SUM11–43 9S20–9SMn36 S250Pb–45MF6.3 220M07–226M44 1110–1144 St33–St52-3 1C22–1C55 40A–50F 30–70 S20C–S55C CK22–CK55 (C22–C55) 55C3–50CV4 070M20–070M55 1020–1055 SUP3–13 55Cr3–50CrV4 20MC5–45C4 250A53–735A50 1075–6150 SCr415–445 34Cr4–41Cr4 18CD4–42CD4 530A30–530A40 5120–5147 SCM415–822 34CrMo4–42CrMo4 30NC11 708M20–708A47 4130–4145 SNC415–815 X10CrNiS189–X20Cr13 20NCD2 655M13 8615–4340…
• Page 17
  Cutting flammable materials Chips of titanium or magnesium violently burn when they catch fire. Once these chips burn, the resultant fire may explosively propagate through surrounding chips. When an oil-based cutting fluid is used on the machine, it may also be ignited and spread the fire. When cutting such flammable materials, be sure to clean the machine of accumulated chips at the start and end of every operation.
• Page 18
  Appendix 3: Cutting fluids suited for specific materials This table shows the general machinability of materials with different cutting fluids. SUM11–43 S40C–S55C SCr415–445 Aluminum Nickel base alloy FC10–35 SCM415–822 SUP3–13 Aluminum alloy Monel S20C–S30C SNCM220–815 SNC415–815 Magnesium Inconel FCMB SKS2, 4, 5 SK1–7 Copper SKS3, 7–…

• Page 19: Emergency Stop Button Location

  EMERGENCY STOP BUTTON LOCATION When one of the EMERGENCY STOP buttons is pressed, the machine comes to a total stop immediately. The button locks when pressed and must be pulled out to unlock it. EMERGENCY STOP BUTTON EMERGENCY STOP BUTTON…

• Page 21
  Part Description Names and functions of main parts ……….I-3 Specifications ……………….I-4 Dimensions of main parts ………….I-4 Machine ………………I-7 Standard accessories …………..I-9 Optional accessories …………..I-9…

• Page 23: Names And Functions Of Main Parts

  NAMES AND FUNCTIONS OF MAIN PARTS Laser beam unit (option) Driven wheel Projects the shadow of the saw blade by Control panel A wheel to tension the saw blade. a red laser beam onto the work surface. Pushbuttons, keyswitches, and other When changing the saw blade, shift the The work must be positioned by aligning machine controls are arranged here.

• Page 24: Specifications

  SPECIFICATIONS Dimensions of main parts VM1200 Unit: mm {in.} 3200 {125.98} 1407 {55.39} (SUB-TABLE) SAW BLADE RUNNING LINE SIGNAL TOWER (OPTION) 1219 {48.00} (MAXIMUM WORK LENGTH) 1640 {64.57} (MAIN TABLE) 66 {2.60} SAW BLADE BACK POSITION 3263 {128.46} 1684 {66.30} 1579 {62.17} LASER BEAM UNIT (OPTION)

• Page 25
  VM2500 Unit: mm {in.} 2707 {106.57} (SUB-TABLE) SAW BLADE RUNNING LINE SIGNAL TOWER (OPTION) 70 {2.76} 2515 {99.00} (MAXIMUM WORK LENGTH) 3095 {121.85} (MAIN TABLE) 5800 {228.35} SAW BLADE BACK POSITION 5863 {230.83} 2984 {117.48} 2879 {113.35} LASER BEAM UNIT(OPTION) RUNOUT DETECTOR (OPTION)

• Page 27: Machine

  Machine VM1200 VM2500 Throat (width), 508 {20.0} mm {in.} Cutting Height, 508 {20.0} capacity mm {in.} Length, 1219 {48.0} 2515 {99.0} mm {in.} Width, 41 {1.61} mm {in.} Thickness, 1.3 {0.051} mm {in.} Saw blade Length, 4670 {183.8} mm {in.} Running speed, 10 to 90 {32.8 to 295.3} m/min {fpm}…

• Page 28
  VM1200 VM2500 Tank capacity, 105 {27.7} L {US gal} Cutting fluid Pump Centrifugal immersion type Tank capacity, 10 {2.6} L {US gal} Hydraulic Pump unit 11 L/min {2.9 US gal/min} at 50 Hz capacity Set pressure 3.5 MPa {508 psi} Saw blade 5.5 kW {7.38 HP}, 4P, 200 V, 50/60 Hz motor…

• Page 29: Standard Accessories

  Standard accessories Name Specification or type Quantity Hydraulic oil Amada A32 (ISO VG 32 equivalent) 18 L Cutting fluid Amada SD, 4L can 3 cans VM1200: 7 Leveling plate 1453832 VM2500: 11 Wire brush WH1503 Amada SGLB 2/3P, 4670 mm Saw blade {1.61…

• Page 30
  I-10…

• Page 31: Installation

  Part Installation Location ………………II-2 Foundation ………………II-2 Carrying ………………II-5 Cleaning………………II-7 Leveling………………. II-7 Removing shipping brackets…………II-9 Supplying hydraulic oil …………..II-9 Supplying cutting fluid …………..II-10 Supplying electric power …………..II-11 Installing fire control devices…………II-13 II-1…

• Page 32: Location

  LOCATION Select such a location that ample space can be provided around the machine for loading workpieces, unloading cut pieces, and performing maintenance on the machine. NOTICE Select a location where the machine will not be exposed to rain and wind. If another machine located nearby produces vibration or dust, take necessary measures against the vibration or dust.

• Page 33
  Foundation drawing for VM1200 Unit: mm : ANCHOR BOLT POSITIONS : LEVELING BOLT POSITIONS 1023 SAW BLADE RUNNING LINE SAW BLADE BACK POSITION II-3…
• Page 34
  Foundation drawing for VM2500 Unit: mm : ANCHOR BOLT POSITIONS : LEVELING BOLT POSITIONS 1023 SAW BLADE RUNNING LINE SAW BLADE BACK POSITION II-4…

• Page 35: Carrying

  This machine calls for advanced techniques to carry and install it. Be sure to ask a specialized contractor or AMADA to do the work. Use a forklift truck or crane to carry the machine to its location.

• Page 36
  Carrying with crane Four JIS No. 4, 6 24 wire ropes, 22.4 mm WARNING in diameter and 4129 mm or more in length, are required to lift the machine. Take care so that the wire ropes do not touch the table. The mass of the machine is as follows: VM1200: 3300 kg {7277 lb} VM2500: 5500 kg {12128 lb}…

• Page 37: Cleaning

  LEVELING When the machine is delivered direct from AMADA, the AMADA service engineer will level the machine. NOTICE The machine must be leveled accurately according to a prescribed procedure.

• Page 38
  Securely tighten the lock nuts of the anchor bolts to complete the leveling procedure. Positions of leveling bolts (marked ) VM1200 VM2500 II-8…

• Page 39: Removing Shipping Brackets

  The hydraulic pump may be damaged if its motor is started without the tank filled to the specified level. The oil discharge rate of the hydraulic pump is adjusted at the time of factory shipment. Do not tamper with it. If you have a problem, contact AMADA. II-9…

• Page 40: Supplying Cutting Fluid

  SUPPLYING CUTTING FLUID Use a water-soluble cutting fluid on this WARNING machine. Oil-based cutting fluids may emit smoke or catch fire, depending on the condition of their use. Never use oil-based cutting fluids on this machine. Pour the cutting fluid from above its pan to a little above the middle of the SIGHT GAUGE…

• Page 41: Supplying Electric Power

  SUPPLYING ELECTRIC POWER Have a qualified electrician make the WARNING necessary electrical connections. Before opening the door of the electrical enclosure, be sure to turn off the shop circuit breaker switch. Ground the machine independently of other equipment. NOTICE Supply the machine with 3-phase, AC 200V, 50/60 Hz electric power with Prepare a transformer that suits voltage variations of 10% or less.

• Page 42
  Checking electrical connections When the necessary electrical connections are completed, check that they are correctly made as described below. For the description of the switches, buttons and lights, refer to Part III, Controls. Close and screw the door of the electrical enclosure. Turn on the shop circuit breaker switch, and turn the POWER switch on the electrical enclosure to ON to illuminate the POWER ON light on the control panel.

• Page 43: Installing Fire Control Devices

  INSTALLING FIRE CONTROL DEVICES Install a fire extinguisher or other fire control device in the shop to provide against fires. II-13…

• Page 44
  II-14…

• Page 45: Controls

  Part Controls Control panel……………….III-2 Machine base rear …………….III-8 Cutting fluid supply system ………….III-9 Protective devices…………….III-10 Wheel cover open limit switches ……….III-10 Saw blade slip detector (Motion detector)……..III-10 Displays ………………III-11 Schematic diagram of displays………..III-11 MENU display…………….III-13 BLADE display …………….III-13 PROGRAM display…………..III-14 CNC INPUT display…………..III-15 MANUAL INPUT display………….III-16 DIMENT display…………….III-18…

• Page 46: Control Panel

  CONTROL PANEL [19] [18] [22] [20] [21] [11] [10] [12] [14] [16] [13] [15] [17] [1] POWER switch [2] POWER ON light [3] EMERGENCY STOP button [4] HYDRAULIC ON button (with white light) [5] HYDRAULIC OFF button [6] BLADE START button (with white light) [7] BLADE STOP button [8] TABLE CUTTING FEED button (with white light) [9] TABLE FORWARD button…

• Page 47
  [1] POWER switch (Machine circuit breaker switch) Turned to ON to power on the machine, to OFF to power off the machine, and to RESET (OPEN) to open the electrical enclosure. Lock the switch with the accessory padlock to prevent unauthorized operation.
• Page 48
  [5] HYDRAULIC OFF button Pressed to stop the hydraulic pump motor and extinguish the HYDRAULIC ON button. [6] BLADE START button (with white light) Pressed to start the saw blade motor and run the [11] saw blade, and wire brush. At the same time, the [10] cutting fluid pump starts,…
• Page 49
  [11] TABLE SPEED CHANGE button (with white light) Used to change the table forward and backward speed to high or low. Pressed and illuminated to change the table forward and backward speed to low. Pressed again and extinguished to change the table forward and backward speed to high.
• Page 50
  [13] LASER BEAM ON button (option) (with white light) Pressed and illuminated to turn on the laser beam (option) for guiding the work. After 5 min, the laser beam automatically turns off, and the button extinguishes. Never look directly into the source of the WARNING laser beam.
• Page 51
  [15] BLADE INSERT OPEN/CLOSE button (with white light) Pressed to close and open the upper and lower saw blade inserts. [15] The button illuminates when the upper and lower saw blade inserts are closed. NOTE When the saw blade starts, the saw blade inserts automatically close. When the upper saw blade guide moves, the saw blade inserts automatically opens.

• Page 52: Machine Base Rear

  [20] BLADE TENSION keyswitch Used when changing the saw blade. Turned to the “ ” position to tension the saw blade and to the [20] “ ” position to slacken the saw blade. NOTE The BLADE TENSION keyswitch is disabled when the saw blade is running. [21] ZERO-RETURN button (with white light) Used to zero-return the upper saw blade guide and backgauge (option).

• Page 53: Cutting Fluid Supply System

  CUTTING FLUID SUPPLY SYSTEM The cutting fluid delivered from its pump is discharged through the upper saw blade guide nozzle A, lower saw blade guide nozzle B, and cleaning hose nozzle C. Adjust the flow rate through the nozzles with the three cock levers near the stairway of the bed.

• Page 54: Protective Devices

  PROTECTIVE DEVICES The machine is fitted with the following protective devices in addition to the EMERGENCY STOP buttons. Wheel cover open limit switches When either the drive or driven wheel cover is opened during cutting, its open limit switch operates to display an error and stop the saw blade. When the BLADE START button on the control panel is pressed with either or both of the covers opened, the saw blade does not start either, resulting in an error condition.

• Page 55: Displays

  DISPLAYS Schematic diagram of displays Monitor I/O display Touch screen goes to MENU display BLADE display when zero-return of upper saw blade PROGRAM guide, table, and backgauge (option) display BACKGAUGE display has been completed. (Zero-return of table: Execute zero-return of table on ADJUST DEVIATION display display.) MAINTENANCE display…

• Page 56
  III-12…

• Page 57: Menu Display

  MENU display Appears when the zero-return of the upper saw blade guide, table, and backgauge (option) has been completed. BLADE display Press the BLADE button on the MENU display to go to the BLADE display. Select the saw blade type and the tooth pitch of the saw blade. The lights at the left of the selected saw blade type and tooth pitch illuminate.

• Page 58: Program Display

  PROGRAM display Press the PROGRAM button on the MENU display to go to the PROGRAM display. When automatically setting the cutting conditions, press the AUTO CUT CONDIT button to open the CNC INPUT display. When manually setting the cutting conditions, press the MANUAL CUT CONDIT button to open the MANUAL INPUT display.

• Page 59: Cnc Input Display

  CNC INPUT display Press the AUTO CUT CONDIT button on the PROGRAM display to go to the CNC INPUT display. On the CNC INPUT display, the cutting conditions are automatically set when the material type of the work is selected from the registered standards and the length and height of the work are entered.

• Page 60: Manual Input Display

  When the work length (L) and height (H) and the work material type are set, the cutting rate (cm /min or in /min) and the saw blade running speed (m/min or ft/min) are automatically set and shown in the R and V fields respectively.

• Page 61
  MANUAL INPUT display (2) (table feed speed “mm/min” input) Enter the desired table feed speed and saw blade running speed. DIMENT button: Pressed to go to the DIMENT display to enter the work length (L) and height (H). VT field: Enters the desired table feed speed (mm/min or in./min). V field: Enters the desired saw blade running speed (m/min or ft/min).

• Page 62: Diment Display

  DIMENT display Press the DIMENT button to go to the DIMENT display. Enter the work length (L) and height (H). 1000 DEVIATION display Press the DEVIATION button to go to the DEVIATION display. Select whether to enable or disable the runout detector (option) and set the runout tolerance of the saw blade.

• Page 63: Monitor I/O Display

  MONITOR I/O display Press the Monitor I/O button on the MENU display to go to the Monitor I/O display. The Monitor I/O display is used to monitor the sequencer inputs and outputs. NOTE The Monitor I/O display is provided for maintenance and requires no data entry for cutting the work.

• Page 64: Counter Display

  COUNTER display Press the COUNTER button on the MENU display to go to the COUNTER display. The COUNTER display shows the total cut area and total running time of the saw blade up to the current time. CUT SURF field: Shows the total cut area up to the current time. BLADE RUNNING field: Shows the total running time of the saw blade up to the current time.

• Page 65: Hist. Err Display

  HIST. ERR display Press the HIST. ERR button on the MENU display to go to the HIST. ERR display. The HIST. ERR display lists the history of errors that has occurred. The newest error is listed first. The display can be scrolled. III-21…

• Page 66: Maintenance Display

  MAINTENANCE display Press the MAINTE button to go to the PASSWORD display, and enter the password “1200” to go to the MAINTENANCE display. The parameters can be set on the MAINTENANCE display. III-22…

• Page 67
  INITIALIZE button: Resets the setting values to their default values. Press the YES button for confirmation with utmost care. III-23…
• Page 68
  III-24…

• Page 69: Part Iv Operation

  Part Operation Preparing for operation …………..IV-3 Turning on power……………..IV-3 Zero-returning upper saw blade guide ……..IV-3 Selecting saw blade …………..IV-3 Unfolding saw blade …………..IV-4 Installing saw blade …………..IV-5 Registering saw blade …………..IV-8 Adjusting flow rate of cutting fluid……….IV-9 Loading work …………….IV-9 Setting work dimensions …………

• Page 70
  Ending cutting…………….IV-21 Automatic stop …………….IV-21 Returning table ……………IV-21 Stopping machine……………IV-22 Emergency stop…………..IV-22 Turning off power ……………IV-23 List of cutting operations…………..IV-24 Troubleshooting …………….IV-27 Troubles during cutting……………IV-27 Error list………………IV-29 IV-2…

• Page 71: Preparing For Operation

  The MENU display appears on the touch screen. Selecting saw blade Select an appropriate saw blade to suit the material type, shape, and size of work to be cut. Dedicated saw blades are available for difficult-to-cut workpieces and irregular-shaped workpieces. Contact AMADA. IV-3…

• Page 72: Unfolding Saw Blade

  If its teeth are oriented lower left, the saw blade cannot be used. Contact AMADA. Remove the band Open the first Grasp the Turn back the left…

• Page 73: Installing Saw Blade

  Installing saw blade Install the saw blade as described below. Turn the POWER switch to ON to power on the machine, press and illuminate the HYDRAULIC ON button to start the hydraulic pump motor, and zero-return the upper saw blade guide. (Refer to “Turning on power”…

• Page 74
  Press the BLADE INSERT OPEN/CLOSE button to open the upper and lower saw blade inserts. Loosen the lock NUT at the forward end of the table. JOINT PLATE LOCK NUT Hold the HANDLE of the joint plate, and turn the joint plate to leave an opening for the saw blade.
• Page 75
  Check that the saw blade does not ride on the flanges of the FLANGE drive and driven wheels. Push the handle of the wire brush to return the wire brush to the original position. Close the drive wheel cover. HANDLE Close the driven wheel cover.

• Page 76: Registering Saw Blade

  Turn the MODE keyswitch to “ ” to unlock the table. Press the BLADE STEP 22 START button to start the saw blade. Check that the saw blade runs smoothly. Press the BLADE STOP button to stop the saw blade. STEP 23 NOTICE When using a new saw blade, be sure to break it in as described in “Breaking…

• Page 77: Adjusting Flow Rate Of Cutting Fluid

  Adjusting flow rate of cutting fluid When the BLADE START button or CUTTING FLUID button is pressed, the cutting fluid pump starts, and the cutting fluid discharges through each nozzle. Adjust the flow rate of the cutting fluid to suit the material type and size of work to be cut and the cutting rate.

• Page 78: Setting Work Dimensions

  Setting work dimensions Set the work length and height as described below. Press the PROGRAM button on the MENU display to go to the PROGRAM display. Press the AUTO CUT CONDIT button or MANUAL CUT CONDIT button to go to the CNC INPUT display or MANUAL INPUT display.

• Page 79: Setting Cutting Rate

  MANUAL INPUT display Press the V field to open the numeric keypad. Enter the desired value with the 0 to 9 and • keys to set the saw blade running speed (m/min or ft/min). Press the ENT key. Setting cutting rate CNC INPUT display On the CNC INPUT display, the proper cutting…

• Page 80
  NOTE The cutting rate is given by Cutting area Cutting rate (cm /min) = Cutting time (min) Cutting rate (cm /min) for rectangle = Cutting time (min) Cutting area (in. Cutting rate (in. /min) = Cutting time (min) Cutting rate (in. /min) for rectangle = Cutting time…

• Page 81: Adjusting Position Of Upper Saw Blade Guide

  Adjusting position of upper saw blade guide The upper saw blade guide is automatically positioned about 30 mm {1.2 in.} plus the work height at the start of the saw blade running, if the work length (L) and height (H) are entered in the L and H fields.

• Page 82: Setting Cutting Length

  Setting cutting length Set the cutting length to DEPTH OF CUT suit the work length or WORK TO depth of cut as described BE CUT below. When the table moves over the set length, the machine automatically stops. When the table moves over its stroke length, the machine stops.

• Page 83: Setting Runout Detector (Option

  Setting runout detector (option) When using the optional runout detector, set the runout tolerance before starting the cutting operation of the machine. NOTICE Just after the start of the machine, the runout detector is turned off, and OFF is shown in the ON/OFF field at the right of the DEVIATION button on the CNC INPUT or MANUAL INPUT display.

• Page 84: Operation

  OPERATION Starting cutting After setting the work and cutting conditions, start cutting the work as described below. Press and hold the TABLE BLADE START TABLE TABLE FORWARD SPEED FORWARD button to bring the CHANGE work close to the saw blade. NOTICE Take care not to bring the work into contact…

• Page 85: Operation During Cutting

  Operation during cutting ADJUSTING CUTTING RATE CNC INPUT display Press the OVERRIDE button to go to the OVERRIDE display. Press the CUT RATE button to adjust the cutting rate. Each time the button is pressed, the cutting rate increases or decreases by 1 %. The settable range of the override rate (%) is 50 to 150%.

• Page 86
  MANUAL INPUT display (table feed speed “mm/min” input) Press the OVERRIDE button to go to the OVERRIDE display. Press the CUT RATE button to adjust the table feed speed. IV-18…

• Page 87: Adjusting Running Speed Of Saw Blade

  ADJUSTING RUNNING SPEED OF SAW BLADE CNC INPUT display Press the OVERRIDE button to go to the OVERRIDE display. Press the BLADE SPEED button to adjust the running speed of the saw blade. Each time the button is pressed, the cutting rate increases or decreases by 1 %.

• Page 88: Upper Saw Blade Guide Position

  MANUAL INPUT display (table feed speed “mm/min” input) Press the OVERRIDE button to go to the OVERRIDE display. Press the BLADE SPEED button to adjust the saw blade running speed. UPPER SAW BLADE GUIDE POSITION Cannot be changed during cutting. RESETTING RUNOUT TOLERANCE (OPTION) The runout tolerance can be changed during cutting.

• Page 89: Ending Cutting

  Ending cutting AUTOMATIC STOP Relative coordinate system When cutting proceeds and the value shown in the field at the right of the PB field reaches the value shown in the PB field, the cutting feed stops. After 30 sec, the machine totally stops. Absolute coordinate system The cutting feed stops when the table move distance reaches the work length (L) shown in the L field.

• Page 90: Stopping Machine

  Stopping machine EMERGENCY STOP As soon as an abnormal condition occurs to interrupt the continuous operation of the machine, press an EMERGENCY STOP button. The machine stops totally and immediately, resulting in an emergency stop error. Remove the cause of the emergency stop, pull out the EMERGENCY STOP button.

• Page 91: Turning Off Power

  Turning off power NOTE Before turning off the power of the machine at the end of the day’s work, press and illuminate the CUTTING FLUID button to discharge the cutting fluid and clean the machine. Press the HYDRAULIC OFF button to stop the hydraulic pump motor and extinguish the HYDRAULIC ON button.

• Page 92: List Of Cutting Operations

  LIST OF CUTTING OPERATIONS General flow of cutting operations Turn POWER switch to ······· Turn POWER switch to ON to illuminate POWER ON light. When error occurs, error ······· Remove cause of error. message is shown on touch Refer to “Error list” later in this Part. screen Press HYDRAULIC ON ·······…

• Page 93
  Set work data, saw blade ······· CNC INPUT display running speed, and Press DIMENT button to enter work length (L) and cutting rate height (H) in L and H fields. Press QUAL. MAT button to show standards by countries, and select standard and material type of work to be cut.
• Page 94
  Adjust saw blade running ······· CNC INPUT display speed and cutting rate Press OVERRIDE button to go to OVERRIDE display. Adjust saw blade running speed with BLADE SPEED buttons. Adjust cutting rate with CUT RATE buttons. MANUAL INPUT display Press V field to open numeric keypad, and enter desired value to adjust speed of saw blade.

• Page 95: Troubleshooting

  TROUBLESHOOTING Troubles during cutting The saw blade is consumable and is certain to reach the end of its service life after cutting a sufficient amount of work. If it prematurely comes to the end of its service life, one of the causes described below may be responsible.

• Page 96
  Vibration Poor cutting Premature saw blade life Unstraight cut Saw blade breakage Cause Remedy Backup tips worn or cracked. Change backup tips. Saw blade running in Adjust saw blade to proper improper position. running position. Saw blade in contact with Adjust clearance to proper flange of wheel.

• Page 97: Error List

  E002 BLADE SLIPPED Saw blade slipped on Check saw blade and drive wheel. cutting conditions. E003 INVERTER ERROR Saw blade inverter is in Contact AMADA. abnormal condition. E004 COVER OPEN Wheel cover is open. Close wheel covers. Saw blade stops.

• Page 98
  IV-30…

• Page 99: Part V Maintenance

  Part Maintenance Cleaning………………V-2 Checking before start of day’s work……….V-3 Hydraulic oil level…………..V-3 Cutting fluid level …………..V-3 Saw blade …………….V-3 Wire brush…………….V-4 Periodic maintenance …………..V-5 Saw blade guides ……………. V-5 Spiral of chip conveyor (option)……….. V-5 Changing fluid and oil …………..V-6 Cutting fluid ……………..V-6 Hydraulic oil ……………..V-6 Saw blade speed reducer oil …………V-7…

• Page 100: Cleaning

  Maintenance is particularly important in ensuring the safety of the operator and the performance of the machine. Be sure to perform maintenance on the machine as described below. CLEANING Before cleaning the machine, be sure to WARNING stop the saw blade. When cleaning the machine by discharging the cutting fluid from the cleaning hose nozzle, wear protective…

• Page 101: Checking Before Start Of Day’swork

  CHECKING BEFORE START OF DAY’S WORK Before starting the machine every day, check it for the following items: HYDRAULIC OIL LEVEL Check the hydraulic oil level with the sight gauge. If it is low, add the same hydraulic oil. For the recommended hydraulic oils and other details, refer to page V-6.

• Page 102: Wire Brush

  WIRE BRUSH Check that the wire brush properly touches the gullets of the saw blade. If the wire brush is worn or the error message E019 is shown on the touch screen, change it. When the wing nut securing the wire brush is turned clockwise and loosened, the wire brush can be…

• Page 103: Periodic Maintenance

  PERIODIC MAINTENANCE Check the following parts of the machine every month. If any part is worn or damaged, it must be changed. Contact AMADA. Saw blade guides Press the BLADE INSERT OPEN/CLOSE button to check that the saw blade inserts properly open and close.

• Page 104: Changing Fluid And Oil

  CHANGING FLUID AND OIL Cutting fluid The cutting fluid will be discolored by the contaminants and rust of the workpieces and will be degraded and subject to bacterial growth when used for a long period of time. At least once per year, especially before the summer vacation, change the entire cutting fluid.

• Page 105: Saw Blade Speed Reducer Oil

  Saw blade speed reducer oil Change the entire oil every two years or 10000 hours of operation thereafter. Drain the old oil from the speed reducer by removing the plug of the drain hose. Recommended oil: Shell Omala Oil 220 (ISO VG220 equivalent) Required amount of oil: 5.1 L {172 fl.oz.} NOTE…

• Page 106: Grease Lubrication

  GREASE LUBRICATION Before lubricating the machine, be sure to WARNING set the MODE keyswitch at “ ” to lock the table. When stepping onto the table for performing maintenance, wear a helmet and safety shoes, and take care not to slip.

• Page 107: Appendix A Options

  Appendix Options Runout detector …………….A-2 Setting runout tolerance …………..A-2 Operation at start of cutting and during cutting ……A-4 Automatic stop at detection of excessive saw blade runout..A-4 Resetting after automatic stop………….A-4 Signal tower ………………A-5 Clamping kits ……………… A-5 Chip conveyor ……………..A-6 Backgauge ………………

• Page 108: Runout Detector

  RUNOUT DETECTOR The runout detector senses the runout of the saw blade during cutting and automatically stops the machine when the actual runout of the saw blade exceeds the preset runout tolerance. A roller that detects the runout of the saw blade is installed in the upper saw blade guide.

• Page 109
  Press the RUNOUT DETECTOR ON/OFF button to show ON on the button. (The ON/OFF field at the right of the DEVIATION button on the CNC INPUT or MANUAL INPUT display shows ON.) Press the TOLERANCE field to open the numeric keypad.

• Page 110: Operation At Start Of Cutting And During Cutting

  Operation at start of cutting and during cutting Press the RUNOUT DETECTOR ON/OFF button on the DEVIATION display to show ON on the button and turn on the runout detector. (The ON/OFF field at the right of the DEVIATION button on the CNC INPUT or MANUAL INPUT display shows ON.) If the machine is started with OFF shown on the RUNOUT DETECTOR ON/OFF button by pressing again the button, it does not stop even…

• Page 111: Signal Tower

  SIGNAL TOWER The signal tower illuminates to indicate that the machine enters the conditions described below. Even when working apart from the machine, the operator can know from the lights to see if the machine is operating or not. Red light: Illuminated to indicate that the machine has stopped at the occurrence of an error.

• Page 112: Chip Conveyor

  CHIP CONVEYOR Automatically discharges the chips from the machine. The chip conveyor automatically starts when the saw blade starts running. CHIP CONVEYOR The chip conveyor is very dangerous. WARNING Never reach into the running chip conveyor. NOTICE When a trimming or solid material other than chips enters the chip conveyor, it may eat into and damage the spiral.

• Page 113: Backgauge

  BACKGAUGE The backgauge is used when positioning the work to the cutting position. Operating procedure Press the BACKGAUGE button on the MENU display to go to the BACKGAUGE display. Press the TARG. POSITION field to open the numeric keypad. Press the 0 to 9 and • keys to enter the target position.

• Page 114
  Gently push the work against the backgauge by using a crane or forklift. Keep away from the table while the WARNING backgauge is moving. You may get injured. Depending on the position and shape of the work, you may get your hands pinched and injured between the work and upper frame or between the work and backgauge.

• Page 115: Appendix B Material Safety Data Sheets

  Appendix Material Safety Data Sheets Shell Alvania Grease 2…………..B-2 Shell Omala Oil 220 …………… B-10 Shell Tellus Oil 32 …………….B-17…

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  200, Ishida, Isehara, Kanagawa, JAPAN Printed on recycled paper.