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WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0

W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40

Internet: www.widos.de email: [email protected]

Headquarters: D-71254 Ditzingen-Heimerdingen country court Stuttgart HRB 200973 managing directors: Dieter Dommer, Jürgen Dommer

Working Instructions

Translation

Saw RSC 2400

Keep for further use!


Product identification

26.07.11 Working instructions WIDOS RSC 2400 of 63

Type: Saw RSC 2400

Serial number / year of construction: see type label

Customer entries

Inventory No.:

Location:

Order of spare parts and after sales service

Address of manufacturer WIDOS

W. Dommer Söhne GmbH Einsteinstr. 5

D -71254 Ditzingen-Heimerdingen

Phone: ++49 7152 / 99 39 - 0

Fax: ++49 7152 / 99 39 - 40

[email protected]

Internet : www.widos.de

Address of the subsidiary companies:

WIDOS

WIDOS GmbH W. Dommer Söhne AG

An der Wiesenmühle 15 St. Gallerstr. 93

D-09224 Grüna / Sachsen CH– 9201 Gossau

Phone: ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 388 89 79

Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73


Introduction


Purpose of the document

These working instructions give you information about all important questions which refer to the construction and the safe working of your machine.

Just as we are, you are obliged to engage in these working instructions, as well.

Not only to run your machine economically but also to avoid damages and injuries.

Should questions arise, contact our service team in the factory or in our subsidiary companies.

We will help you with pleasure.

According to our interest to continuously improve our products and working instructions, we kindly ask you to inform us about problems and defects which occur in exercise.

Thank you.

Structure of the working instructions

This manual is arranged in chapters which belong to the different using phases of the machine.

Due to this structure, the searched information can be easily found.

7/26/2011 WIDOS

W. Dommer Söhne GmbH

Einsteinstraße 5

D-71254 Ditzingen-Heimerdingen

All rights reserved.

Reprinting only allowed with permission of the corporation.

Any changes are subject to technical innovations.


Contents


1. DESCRIPTION OF THE PRODUCT .................................................................................... 6

1.1. Usage and purpose-oriented use ...................................................................................6

1.2. Safety measures ..............................................................................................................6

1.3. Conformity........................................................................................................................6

1.4. Designation of the product..............................................................................................7

1.4.1. Technical data ...........................................................................................................7

1.4.2. Electrical data............................................................................................................7

1.4.3. Electrical data vacuums .............................................................................................8

1.4.4. Technical data laser...................................................................................................8

1.5. Equipment and accessories............................................................................................8

1.6. Wear parts list ..................................................................................................................8

2. SAFETY RULES..................................................................................................................... 9

2.1. Explanation of the symbols and indications ..................................................................9

2.2. Obligations of the owner................................................................................................10

2.3. Obligations of the operator ...........................................................................................10

2.4. Measures of organization..............................................................................................10

2.5. Information about safety precautions ..........................................................................10

2.6. Instructions for the staff................................................................................................10

2.7. Dangers while handling the machine............................................................................11

2.8. General safety indications.............................................................................................11

2.9. Specific dangers ............................................................................................................12

2.9.1. Danger of cutting or catching clothes .......................................................................12

2.9.2. Danger of stumbling over pneumatic and electric wires ............................................12

2.9.3. Danger of laser beams.............................................................................................12

2.9.4. Danger of getting injured by chips / oddments / noise...............................................12

2.10. Maintenance and inspection, repair..............................................................................12

2.11. Remaining risks .............................................................................................................12

2.12. Structural modifications on the machine .....................................................................13

2.13. Warranty and liability .....................................................................................................13

3. FUNCTIONAL DESCRIPTION............................................................................................ 14

4. OPERATING AND INDICATING ELEMENTS .................................................................. 15

4.1. Operator console ...........................................................................................................16

4.1.1. Operator panel.........................................................................................................16

4.1.2. Emergency stop switch............................................................................................17

4.1.3. Main switch..............................................................................................................17

4.1.4. Elements in switch cabinet .......................................................................................18

4.2. Laser...............................................................................................................................19

4.3. Pipe supports, prisms and pipe lifters (option)............................................................19


Contents


4.4. How to clamp pipes........................................................................................................20

4.5. How to adjust angles......................................................................................................22

4.6. Pneumatic.......................................................................................................................23

4.6.1. Service unit..............................................................................................................23

4.6.1.1. How to adjust the regulator: .................................................................................23

4.6.2. How to adjust the pressure regulator: .......................................................................23

4.7. Vacuum...........................................................................................................................24

5. STARTING AND OPERATING........................................................................................... 25

5.1. Starting ...........................................................................................................................25

5.2. How to switch on the saw..............................................................................................26

5.2.1. How to calibrate angles............................................................................................27

5.2.2. How to set the time, date and language....................................................................27

5.3. How to make vertical cuts .............................................................................................28

5.4. How to cut angles...........................................................................................................29

6. MAINTENANCE / STORAGE / TRANSPORT.................................................................. 31

6.1. In general........................................................................................................................31

6.2. Storage ...........................................................................................................................31

6.3. How to align the saw......................................................................................................32

6.4. How to maintain and replace the cutting chain............................................................32

6.5. How to clean / replace the chip bag..............................................................................33

6.6. Service unit ....................................................................................................................34

6.7. How to protect the machine parts against corrosion ..................................................34

6.8. Disposal..........................................................................................................................34

7. ELECTRIC AND PNEUMATIC DIAGRAMS ..................................................................... 35

8. DECLARATION OF CONFORMITY .................................................................................. 63






1. Description of the product

This chapter gives important basic information about the product and its prescribed use.

All technical details of the machine are put together as a general arrangement.

1.1. Usage and purpose-oriented use

The WIDOS Saw RSC 2400 is special machinery for the straight cutting plastic pipes up to Ø 2400 mm, and an angle of max. 45° on both sides resp. 67,5° on one side, in the way described as follows.

All use going beyond is not purpose-oriented.

The purpose-oriented use includes also that a sufficiently dimensioned, operational suction plant is connected to the machine. The described plastic band saw may only be operated, maintained and repaired by persons who are trained and informed about the dangers.

The machine is a workshop machine and not suitable for operation in hazardous locations.

It is forbidden to cut wood and sheets made out of wood (e.g. pressboard).

The manufacturer is not responsible for any damages caused by inexpert handling or operation.

For personal injuries, material and immaterial damages resulting herefrom, only the user is responsible!

Also part of the purpose-oriented use is

• respecting all the indications of the working instructions and

• performing the inspection and maintenance work.

1.2. Safety measures

In case of wrong use, wrong operation or wrong maintenance, the machine itself or products standing nearby can be damaged or destroyed.

Persons being in the endangered area may be injured.

Therefore these working instructions have to be thoroughly read and the corresponding safety regulations must be necessarily adhered to.

1.3. Conformity

The machine corresponds in its construction to the valid recommendations of the European Community as well as to the according European standard specifications.

The development, manufacturing and mounting of the machine were made very carefully.


Description of the product Chapter 1


1.4. Designation of the product

The product is designated by a type label at the basic mounting.

It contains the type, the serial number and the year of construction of the machine.

1.4.1. Technical data

Total height: appr. 4600 mm

Total depth: appr. 7000 mm

Total width: appr. 7600 mm

Length pipe supports (Prisms): 2400 mm

Max. diameter of pipes: 2400 mm

Length cutting chain: 6825,2 mm / 302 chain links

1.4.2. Electrical data

Feeding: 14 kW

Voltage: 400V AC

Plug: CEE-32 A

Frequency: 50 Hz

Motor-pipe clamping left / right

Voltage: 400V AC

Power each motor: 4,0 kW

Current each motor: 9,1 A

Cutting chain

Voltage: 400V AC

Power: 5,06 kW

Current maximum: 95,6 A

Speed of chainsaw motor: 0 – 3000 rpm

Cutting speed of saw drive: 0 – 400 m/min

Travel chainsaw

Voltage: 400 V

Power chainsaw travel: 1,4 kW

Current maximum: 12,0 A

Rotational speed of travel motor: 0 – 5000 rpm


Description of the product Chapter 1


1.4.3. Electrical data vacuums

Voltage saw motor: 400V

Frequency: 50 Hz

Power saw motor: 3 kW

Current: 5 A

Speed of saw motor/travel motor 200 rpm

1.4.4. Technical data laser

Range: 2-3 m

Power: 5 mW

1.5. Equipment and accessories

Pieces Name

1 Key for switch cupboard; hand out the key to authorized persons only

1 each Key for key switch of manual mode, travel brake and toothed chain brake

1 Cutting chain 6825,2 (302 chain links)

1 Working instruction for vacuum AF22 (Felder)

1 Working instruction laser Z5-24

1.6. Wear parts list

Pieces/

Mach.

Name Article-No.

1 Cutting chain 6825,2 mm (302 chain links on request

1 Laser Z5-24 on request

1 (2) each Filter bag, chip bag, filter … see working instruction AF 22






2. Safety rules

The base for the safe handling and the fault-free operation of this machine is the knowledge of the basic safety indications and rules.

• These working instructions contain the most important indications to run the machine safely.

• The safety indications are to be followed by all persons working with the machine.

2.1. Explanation of the symbols and indications

In the working instructions, following denominations and signs are used for dangers:

This symbol means a possible danger for the life and the health of persons.

• The disrespect of these indications may have heavy consequences for the health.

This symbol means a possible dangerous situation.

• The disrespect of these indications may cause light injuries or damages on goods.

This symbol means a possible dangerous situation by moving parts of the machine

• The disrespect of these indications may cause heavy crushing of parts of the body resp. damages of parts of the machine.

This symbol gives important indications for the proper use of the laser.

• The disrespect of these indications may cause light injuries or damages on goods.

This symbol gives important indications for the proper use of the machine.

• The disrespect of these indications may conduct to malfunctions and damages on the machine or on goods in the surrounding.

This symbol means a possible risk of injury by sawdust.

• It is obligatory to wear safety glasses.

This symbol means a possible risk of injury by noises exceeding 80 dB (A).

• Ear protection is obligatory.

Under this symbol you get user tips and particularly useful information.

• It is a help for using all the functions on your machine in an optimal way and helps you to make the job easier.

The regu l a t i on s for t h e preven t i on o f acc i den ts a re va l i d (UVV) .


Safety rules Chapter 2


2.2. Obligations of the owner

The owner is obliged only to let persons work at the machine who

• know about basic safety and accident prevention rules and are instructed in the handling of the machine, as well as who

• have read and understood the safety chapter of this manual and certify this by their signature.

The safety-conscious working of the staff has to be checked in regular intervals.

2.3. Obligations of the operator

All persons who are to work at the machine are obliged before working:

• to follow the basic safety and accident protection rules.

• to have read and understood the safety chapter and the warnings in this manual and to confirm by their signature that they have well understood them.

• to inform themselves about the functions of the machine before using it.

2.4. Measures of organization

• All equipment required for personal safety is to be provided by the owner.

• All available safety equipment is to be inspected regularly.

2.5. Information about safety precautions

• The working instructions have to be permanently kept at the place of use of the saw. They are to be at the operator's disposal at any time and without much effort.

• In addition to the manual, the common valid and the local accident protection rules and regulations for the environmental protection must be available and followed.

• All safety and danger indications on the machine have to be in a clear readable condition.

• Every time the machine changes hands or is being rent to third persons, the working instructions are to be sent along with and their importance is to be emphasized.

2.6. Instructions for the staff

• Only skilled and trained persons are allowed to work at the saw.

• It must be clearly defined who is responsible for transport, mounting and dismounting, starting the operation, setting and tooling, operation, maintenance and inspection, repair and dismounting.

• A person who is being trained may only work at the machine under supervision of an experienced person.




2.7. Dangers while handling the machine

The band saw WIDOS RSC 2400 is constructed according to the latest technical standard and the acknowledged technical safety rules.

However, dangers for the operator or other persons standing nearby may occur. Also material damages are possible.

The machine may only be operated:

• according to the purpose-oriented usage

• in safety technical impeccable status

Disturbances which may affect the safety of the machine must be cleared immediately.

2.8. General safety indications

• A working area without obstacles around the machine and a non-slip and plane floor are of basic importance for a safe operation.

• The working area must be well lightened and free of waste (cuttings, residues).

• Check before starting with the work whether the tooth chain is tensioned correctly.

• During the operation, wear tight clothes only.

• Keep the handles dry and free from oil and grease.

• Wear safety glasses and ear protection during the cutting operation.

• Do not wear rings, bracelets etc.

• Protect long hair by means of a sufficient headgear.

• During work, the pipe must be clamped firmly.

• Do never remove reminders as long as the saw is working.

• In case of irregular running behavior of the saw blade, switch off the saw immediately and check the saw blade for correct course, correct tension and possible fractures.

• Replace dull or badly set saw blades by orderly installed saw blades.

• Before elimination of any disturbances, and before any repair or maintenance work, switch

off the saw and disconnect in any case the mains plug.

• Protect the machine from wetness and humidity.

Only skilled persons are allowed to work at electrical appliances.

• The electrical equipment of the machine has to be checked regularly. Loose connections and damaged cables have to be replaced or repaired immediately.

System parts and pressure hoses should be depressurized before beginning of any repair work.

• There is a danger of injuring the eyes by compressed air coming out suddenly.

• Replace damaged pneumatic hoses immediately.

• Make a visual inspection of the pneumatic hoses before each work beginning.




2.9. Specific dangers

2.9.1. Danger of cutting or catching clothes

You can cut yourself during sawing or when exchanging the cutting chain!

• Before starting the cutting operation, take care that no person is standing in the operating or cutting area.

• Always wear safety gloves when exchanging the cutting chain.

2.9.2. Danger of stumbling over pneumatic and electric wires

Make sure that no person has to step over the wires.

• Lay the wires in such a way that the danger is kept to a minimum.

• Do not squeeze, buckle etc. the wires.

2.9.3. Danger of laser beams

Only turn-on the laser for the sawing function. Pay attention that nobody has to watch the reflected or direct laser beam for too long time, or the person has to wear eye-protection glasses. Do not straighten laser on people.

2.9.4. Danger of getting injured by chips / oddments / noise

• Wear safety glasses during cutting!

• Never remove oddments as long as the saw is running.

• Wear ear protection during cutting!

2.10. Maintenance and inspection, repair

All maintenance and repair work have to be basically performed with the machine

in off position.

During this, the machine has to be secured against unauthorized switching on.

2.11. Remaining risks

Even at purpose-oriented use and even if following all the relevant safety instructions, the following risks are remaining due to the construction conditional on the purpose of operation of the machine:

• Injuries caused by parts of the work pieces which are squirting away.




2.12. Structural modifications on the machine

• No modifications, extensions or reconstructions may be made on the machine without permission of the manufacturer. In case of disrespect the warranty or liability will expire.

• Machine parts which are not in a perfect condition are to be immediately replaced.

• Only use original WIDOS spare and wear parts.

• In case of purchase orders please always indicate the machine number!

2.13. Warranty and liability

Fundamentally our "General Sales and Delivery Conditions" are valid.

They are at the owner's disposal latest when signing the contract.

Guarantee and liability demands referring to personal injuries or damages on objects are excluded if they are caused by one or several of the following reasons:

• Not using the machine according to the prescriptions;

• Inexpert transport, mounting, starting, operating, and maintenance of the machine;

• Running the machine with defective or not orderly mounted safety appliances;

• Ignoring the information given in this manual;

• Structural modifications on the machine without permission;

• Unsatisfactory checking of parts of the machine which are worn out;

• Repairs performed in an inexpert way;

• In case of catastrophes and force majeure.






3. Functional description

Bas ic a lly , the inte r na t iona l and na t iona l pr oces s guide lines a r e to be f o llowed. After its activation, the saw drives into reference position (chapter: 5.2).

Adjust the saw to the requested angle and secure it by clamping / latching.

Shift the pipe onto the pipe supports and clamp tightly (check distance to the cutting chain!).

Switch on the line laser.

Switch on the vacuum device.

Having finished all adjusting work, start the travel motor and drive the cutting chain towards the pipe stopping shortly in front of it.

Afterwards start the cutting chain and cut the pipe through.

Having finished the cutting, drive the cutting chain behind the pipe and shut it off.

The line laser switches off.

The vacuum switches off.

Now remove the remaining chips, unclamp the pipe and remove it.

The cutting is completed.






4. Operating and indicating elements

No. Denomination / Function

1 Bridge, may be swiveled

2 Guiding rail with cutting chain

3 Machine table, revolves with bridge

4 Pipe lifter (option), 2 pieces / side

5 Prism, 4 pieces

6 Swing rail with centering plates

7 Spring balancer with triangle, to keep the belts not being tensioned at the top

8 Clamping belt, to clamp the pipes, 2 pieces

9 Line laser, to show the cutting edge of the pipe

10 Vacuum

11 Operator console, mobile

12 Leveling foot, to adjust the saw

1

2

5

6

8

7

9

10

11

4

12

3


Operating and indicating elements Chapter 4


4.1. Operator console

4.1.1. Operator panel

No. Name / Function

20 Key holder to tension the brake of the cutting tooth chain: to switch on the brake <0> / to release brake <I>, when the brake is released you may change the cutting chain. The key may be withdrawn in position <0>*.

21 Key switch - brake of the cutting chain travel: switches the brake on <0> / brake released <I>, when the brake has been released, you may shift the cutting chain manually. The key may be withdrawn in position <0>*.

22 Control lamp of cutting chain tension: glows in red if the cutting chain is not tensioned

resp. when it is broken ⇒ the cutting is stopped resp. may not be started

23 Emergency-stop: stops travel motor, cutting motor and vacuum

24 Start button: to drive the cutting tooth chain into initial position after its activation in order to adjust

25 Display shows the current parameters, several values can be shown at the same time.

Operator panel

Switch cabinet with fuses

Main switch

Front trolleys (adjustable) Rear trolleys

21

20

22

23

25

24

26

27

28

29

30 31

33

32

34

35

36

37

39

38

40

41




No. Name / Function

26 Buttons <+> / <-> (only for diagnosis)

27 Button <Enter> (only for diagnosis)

28 Button <C>: to cancel the reference drive

29 Button <Planer>: to adjust the current angle to 0° / to cancel the reference drive

30 Button: to switch on / shut off the vacuum

31 Button laser: to switch on / shut off the laser

32 Joystick pipe clamping 1: upwards: to release the clamping / downwards: to clamp

pipe

33 Joystick pipe clamping 2: upwards: to release the clamping / downwards: to clamp

pipe

34 Button pipe lifter 1 (option), to lift / to lower

35 Button pipe lifter 2 (option), to lift / to lower

36 Switch angle 67,5-45, left side: to clamp all angles / right side: clamping released

37 Switch angle 67,5/45/0/45: to clamp the angles in the preset positions

38 Rotational speed of the cutting chain travel: to adjust the travel speed

39 Control lever of the cutting chain travel: to drive the cutting chain to the right � / to

the left �

40 Rotational speed regulator of the travel: to adjust the travel speed

41 Rotational speed regulator of the cutting chain, to adjust the chain speed

42 Control lever of the cutting chain button, you may only start the cutting chain by

keeping the button pressed

*Important! Hand over key only to authorized personnel.

4.1.2. Emergency stop switch

The emergency-stop is located on the operator panel. In case of danger for man, workpiece or machine, press the emergency-stop.

The button snaps into place if activated. The saw motor and the travel motor stand still.

The pipe clamping remains active, the display shows:

Display: 2nd line:

** emergency stop **

After having cleared the dangerous situation, the Emergency Stop must be unlocked by turning / pulling.

Afterwards, you must restart the saw by main switch.

4.1.3. Main switch

You activate and shut down the machine with the main switch.

Shut down the machine and secure switch against unintentional activation when working within the machine.




4.1.4. Elements in switch cabinet

No. Denomination / Function

F1 Circuit breaker, 3 pieces, B32A, fuse motor drive

F2 Circuit breaker, K8A; fuse control

F10 Motor protector, 4,5-6,3A, travel chain saw

F40 Motor protector, 20-25A, chain saw

F50 Motor protector, 9-12A clamping pipe left

F60 Motor protector, 9-12A clamping pipe right

F80 Motor protector, 4,5-6,3A, vacuum

M10 Servo control travel chain saw

M40 Servo control chain saw

Q2 Contactor emergency stop

Q51 Contactor pipe release left

Q52 Contactor pipe clamp left

Q61 Contactor pipe release right

Q62 Contactor pipe clamp right

Q80 Contactor vacuum

T3 24V – switching power supply

F1 / F2 / F10 / F40 / F50 / Q2 / Q52 / Q62 / T3

M40 / M10

F60 / F80 / Q51 / Q61 / Q80




4.2. Laser

The line laser Z5 is mounted inwards to the bridge column 1.

The laser beam shows the cutting course on the clamped pipe.

The light beam is adjusted in a way that it corresponds to the cutting chain vertically. In case it is misaligned, you will have to readjust it vertically.

• Switch on and shut off the laser by on the operator console.

• Please gather the exact adjustment of the laser from the attached working instructions of the manufacturer.

4.3. Pipe supports, prisms and pipe lifters (option)

On both sides, you will find mounted pipe supports with prisms and (optional) pipe lifters. The pipe supports feature different drill holes; for this reason you may align the prisms to the pipe size and to the angle (arrows). In each prism there are sic drill holes.

• Fix the prisms on the pipe support by the fixing bolts.

Each pipe support features two (optional) pipe lifters; they are driven up and down pneumatically.

• In order to transport a pipe on the pipe support into the correct cutting position, drive the (optional) pipe lifter upwards.

• Now you may shift the pipe on the bearings of the (optional) pipe lifter into the requested position.

Pipe lifter (option)

Pipe lifter (option)

Prism

Prism

Holder for outside tensioning belt

Holder for inside tensioning belt

Fixing bolt

Laser




4.4. How to clamp pipes

Clamp the pipe by two clamping belts.

The clamping belts are hanging in the belt holders on the inside or outside; the spring balancers are guided by the triangles and are then tensioned by the belt winders electrically. The clamping belt is to be suspended from the inside or outside belt holders according to the pipe size. Please observe upon selecting the belt holder that the pipe is clamped optimally.

• In order to replace the suspension disassemble the respective bolt and suspend the belt from another bolt.

Spring balancer

Tensioning belt

Belt winder

Holder for inside tensioning belt


Triangle

Holder for inside tensioning belt (below the table)


Clamping belt noose

Bolt




• Insert the loose clamping belt end into the belt winder.

• Pull the clamping belt manually thus far that the belt encloses the pipe loosely.

• Make sure that you still may tension the belt by at least one turn but also observe that the belt protrudes from the belt winder below by at least 0,5 m.

• Now clamp the pipe by .

Attention! Do not deform thin-walled pipes.

• After the cutting release the pipe clamping by .

Belt winder




4.5. How to adjust angles

The swing rail features four index plates in order to adjust the angles 67,5°; 45°; 0° and 45° to the other side. Additionally, you may adjust each angle continuously from 67,5° to 45° by the clamping cylinder.

Having activated the saw and before adjusting of an angle, please calibrate the

angle to „0°“.

• In case the saw is not located in perpendicular position to the pipe support, release the

respective button of the resting or clamping cylinder and shift the saw manually in perpendicular position to the pipe support.

• Now press the resting cylinder and if necessary shift the saw until the cylinder snaps in.

• Now press <Planer> in order to have the angle calibrated. Thus, you may read on the display:

How to adjust a fix angle (67,5° / 45° / 0° / 45°):

• Release the resting or clamping cylinder and shift the saw manually to the requested angle position until the angle is displayed.

• Now press the resting cylinder and let the saw snap in.

How to adjust any angle (67,5-45°):

• Release the resting or clamping cylinder and shift the saw manually to the requested angle position until the angle is displayed.

• Now press the clamping cylinder and fix the saw in this position.

67,5°

45°

45°

angle 0°

22,5°

15°

7,5°

0°

7,5°

15°

22,5°

Clamping cylinders for all angles from 67,5°-45°

Resting cylinder for angles 67,5°/45°/0°/45°

11,25°

11,25°




4.6. Pneumatic

The service unit, the pressure regulating valve and the magnetic valves are mounted below the machine table.

* As soon as you have activated the compressed air by the manual switch-on valve, the cutting chain is tensioned.

4.6.1. Service unit

The service unit (LFR-3/8-D-MIDI-KC) adjusts the incoming compressed air to the set working pressure and compensates fluctuations in pressure. It frees the compressed air of dirt and

condensed water. The use with any other fluid (liquid or gas) is a misapplication.

4.6.1.1. How to adjust the regulator:

• Slowly ventilate complete system.

• Pull the pressure setting button upwards (away from the housing).

• Turn the pressure setting button until the desired pressure is shown on the pressure gauge. The input pressure must be at least 1 bar higher than the output pressure.

• Press the pressure setting button downwards (towards the housing) to secure it against unintentional turning.

4.6.2. How to adjust the pressure regulator:

• Pull the pressure setting button upwards (away from the housing).

• Turn the pressure setting button until the desired pressure is shown on the manometer. The input pressure must be at least 1 bar higher than the output pressure.

• Press the pressure setting button downwards (towards the housing) to secure it against unintentional turning.

Pressure regulator with pressure gauge, working pressure

Manual discharge for condensed water

Activating valve manual

M83, angle free / unlock

M81, angle fixed / unlock

M45, chain release

M74, to lift pipe 2 (option)

M72, to lift pipe 1 (option)

Pressure regulator with pressure gauge, tension chain

M71 cutting chain cleaning (option)




4.7. Vacuum

(Image showing the vacuum without chip bag)

• Make sure that the vacuum is connected to the power socket at the machine and that the vacuum switch is activated.

• Switch the vacuum in the manual mode via the buttons on the operator panel: .

• Do not start the vacuum without installed chip bag.

• Select by the knob which of the two chip bags you intend to fill.

Please consult the separately enclosed working instruction of the vacuum AF22 for its

operation, maintenance, repair etc.

Brackets for the chip bag

Filter bag

Connection for vacuum hose

Socket for vacuum

Switch for vacuum

Knob






5. Starting and operating

The instructions of this chapter are supposed to initiate in the operation of the machine and lead during the appropriate starting of the machine. This includes:

• the safe operation of the machine

• economic operation of the machine.

5.1. Starting

In order to put the saw RSC 2400 into operation, you must align it by the bolts in the leveling feet in a way that the table, the pipe support and the guiding of the cutting chain are horizontal / vertical.

• Connect the mains plug to the local power supply CEE 32 A / 400 V / 14 kW / 50 Hz (right rotary field).

• Connect a pneumatic hose to the local compressed air supply (6 -8 bar) and to the service unit.

In case of danger for man and machine, immediately use the <emergency-stop> in order to stop the entire system, the saw, the pipe supply and the extruder.

• Only cut firmly clamped pipes!

• Make sure that no unauthorized person has access to the chain saw.

• Protect the chain saw against moisture and humidity!

Regularly clean the saw, especially the cutting chain, gear rods and threaded spindles, in shut-off condition! (see also chapter: 6.1 + 6.4).


Starting and operating Chapter 5


5.2. How to switch on the saw

Switch on the main switch and wait until the display is illuminated (the PC is being initialized).

Display: 2

nd line:

WIDOS GmbH Germany

after a few seconds, the display changes

Display: 2

nd line:

WIDOS GmbH Loader V11.20


Display: 2

nd line:

version 4.02.02 serial no. 1110002

Number of the software version Serial number of the machine


Display: 2

nd line:

WIDOS RSC 24 Welcome XXXX


Display: 2

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Tables REFERENCING

Keep <Start> pressed (chapter: 4.1.1) until you hear the signal; the saw drives into initial position

Display: 2

nd line:

693 rpm 690 rpm -2894.4mm 0.00

Display: Rotary speed saw motor / rotary speed saw travel Distance travel from pipe center / angle




5.2.1. How to calibrate angles

Display: 2

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0 rpm 0 rpm -2894.4mm 0.00

Display: Rotational speed of saw motor / rotational speed of saw travel Distance to pipe center / angle

In case the saw is not in 0° position, release the resting cylinder or

clamping cylinder by which the saw is locked.

Manually swivel the saw to the 0° position; press the button for the clamping

cylinder and let the saw snap in.

Display: 2

nd line:

angle 0°

Display of angle: 0°

Press <Planer> in order to have the angle calibrated.

Attention! In case you press <Planer> while the saw is not in 0° position,

the angle is also adjusted to 0 on the display!

5.2.2. How to set the time, date and language

Display: 2

nd line:

693 rpm 690 rpm -2894.4mm 0.00

Basic menu Current date and time

next menu by pressing button <Enter>

Display: 2

nd line:

diag clk WICON param _ 10:10

next menu by pressing button <Start>

Display: 2

nd line:

diag clk WICON param 10:10

Setting the time

with buttons <+> and <->: change the time. confirm with button <Enter>: press button <Start>

Display: 2

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diag clk WICON param 22.11.2000

Setting the date




with buttons <+> and <->: change the date. confirm with button <Enter>: press button <Start>

Display: 2

nd line:

language german? _

several languages are entered

buttons <+> and <->: change the language button <Enter>: confirm

press several times button <Start> or after a short while appears automatically:

Display: 2

nd line:

693 rpm 690 rpm -2894.4mm 0.00

Basic menu

5.3. How to make vertical cuts

Switch on the saw, drive the distance of the saw blade to reference position (chapter: 5.2) and calibrate the saw angle (chapter: 5.2.1).

In case the saw is not in „0°“ position, then shift the saw manually to this position; press and lock the saw by having the cylinder snap in.

• Place the pipe onto the pipe supports.

• Switch on the laser by and drive the pipe by the control lever until the laser indicates the requested cutting position on the pipe.

• First preclamp the pipe by the clamping belts and afterwards tighten it by both pipe clamping

buttons (chapter: 4.4).

• Necessarily put on safety glasses and ear protectors now!

• Switch on the vacuum by .

• Drive the saw blade by the control lever and with moderate speed shortly in front of the pipe; the display indicates the distance to the pipe center resp. the rotational speed of the travel.

Display: 2

nd line:

0U/min 0U/min -2894.4mm 0.0

Rotational speed of saw motor / rotational speed of saw travel Distance to pipe center / angle

• Reduce the travel as soon as the saw blade is shortly behind the pipe; it is necessary that the distance is larger than ½ the pipe diameter.

• Now press the button on the control lever and cut the pipe through by control lever ; adapt the rotational speed of the saw motor and the travel to the pipe.




• Having cut the pipe through, release the button on the control lever ; the travel stops.

• Press the control lever to the opposite side and drive the saw blade completely to the rear. As soon as the saw blade is located behind the cut pipe, you may release the control

lever ; the cutting chain stops.

• Shut off the laser by .

• Shut off the vacuum by .

• Release the pipe clamping by both pipe clamping buttons and in addition release the clamping belts manually.

• Remove the pipe pieces and the remaining chips e.g. by vacuum.

Cutting is completed.

5.4. How to cut angles

Switch on the saw, drive the distance of the saw blade to reference position (chapter: 5.2) and calibrate the saw angle (chapter: 5.2.1). It is possible to cut 45° angles on both sides, 67,5° angles only possible on one side.

• Release the resting or clamping cylinder and shift the saw manually until the requested angle is indicated on the display.

• Now press the resting cylinder depending on the angle and let the cylinder snap in,

• or press the clamping cylinder in order to have the angle locked.

• Place the pipe onto the pipe supports.

• Switch on the laser by and drive the pipe by the control lever until the laser indicates the requested cutting position on the pipe.

• Preclamp the pipe first by the clamping belts and afterwards tighten it by both pipe clamping

buttons (chapter: 4.4).

• Necessarily put on safety glasses and ear protectors now!!

• Switch on the vacuum by .

• Drive the saw blade by the control lever and with moderate speed shortly behind the pipe; the display indicates the current distance to the pipe center resp. the rotational speed of the travel.

The distance to the pipe during the angle cutting must be larger than:

½ pipe diameter * sin α




Display: 2

nd line:

0U/min 0U/min -2894.4mm 15.0

Rotational speed of saw motor / rotational speed of saw travel Distance to pipe center / angle

• Reduce the travel when the cutting chain is shortly behind the pipe.

• Now press the button on the control lever additionally and cut the pipe through by control

lever ; adapt the rotational speed of the saw motor and the travel to the pipe.

• Having cut the pipe through, release the button on the control lever ; the travel stops.

• Press the control lever to the opposite side and drive the saw blade completely to the rear. As soon as the saw blade is located behind the cut pipe, you may release the control

lever ; the cutting chain stops.

• Shut off the laser by .

• Shut off the vacuum by .

• Release the pipe clamping by both pipe clamping buttons and in addition release the clamping belts manually.

• Remove the pipe pieces and the remaining chips e.g. by vacuum.

Cutting is completed.

In case of pipes with angles >45° to 67,5°, you must first cut the stub angle → 32,5° to < 45°, afterwards swivel the saw to the opposite direction and cut the acute angle.






6. Maintenance / Storage / Transport

Goal of the chapter is:

• Keeping the nominal state and the operation capacity of the machine.

• Efficient planning of the maintenance work and the maintenance tools.

• Increasing the efficiency by avoiding non-planned outage.

6.1. In general

All maintenance and repair work have to be basically performed with the machine in off position.

During this, the machine has to be secured against unauthorized switching on.

Prescribed maintenance and inspection work should be performed in time. We recommend inspection work after 1 year.

For machines with a specially high usage percentage the testing cycle should be shortened.

The work should be performed at the WIDOS GmbH company or by an authorized partner.

The linear guides must be cleaned every week, e.g. with a brush.

Check the linear guide carriages every 12 months and grease them over the lubricating nipple if necessary. Dirty guides may cramp and run heavily.

• Check the tightness of all screwed connections every three months.

You must clean the gear rods and the threaded spindles weekly by suction or cloth in order to remove the sawing chips.

• The operating staff has to be informed before the starting of the maintenance work.

• Replace damaged parts immediately. Be particularly careful with electric parts → dust and humidity are very much current leading.

• Only use original WIDOS spare parts for repair work.

• Store dry.

• Protect the machine from heavy shocks.

• Handle the machine carefully.

• We basically recommend removing regularly any remaining cuttings (switch off the machine!). For that purpose, detach the cover.

6.2. Storage

If any storage becomes necessary, make sure that the storage room is dry and that the temperature is between +5° C and +35° C.


Maintenance / Storage / Transport Chapter 6


6.3. How to align the saw

Supporting holders are mounted at the swing arm in order to be guided on the swing rail. The supporting holders each have four bearing rollers / curved rollers between which the swing rail is guided.

Align the swing arm by the leveling feet in the base frame and in the swing rail.

You may carry out the fine adjustment by the set and fit screws in vertical and horizontal direction.

• In order to align detach the fit screws.

• Then slightly detach or tighten the fixing screws.

• Check the position of the table and the swing arm by a water level; in case both the swing arm and the table are vertical as well as horizontal, then tighten the fit screws again.

• Afterwards, swivel the swing arm manually in order to check a correct running of the rollers.

6.4. How to maintain and replace the cutting chain

• Spray the cutting chain once per day using a multifunctional PTFE spray (e.g.

Interflon fine super / Caramba / Weicon).

• Regularly remove the planing chips from the chain, do not blow the chips away by compressed air.

Risk of injury! The saw teeth are very sharp, necessarily wear safety gloves!

We recommend that you consult a second person in order to replace the cutting chains.

Swing arm

Supporting holder

Swing rail

Set screw

Fit screw




• In order to replace the cutting chain, shut off the main switch and necessarily the

manual switch-on valve at the service unit.

• In case the upper pinion has not lowered downwards, pull it downwards in order that the chain is not tensioned.

• Remove the chain first from the upper pinion of the guiding and then from the lower pinion.

• Put the new chain onto the upper pinion and laterally on the guiding; make sure that cutting chain is located correctly on the guiding and then put the chain onto the lower pinion.

• Shift the vacuum cap back and fix it by the fixing screws.

• Switch on the manual switch-on valve at the service unit in order to have the clamping cylinder tension the cutting chain again.

We recommend to check if the chain is both located and running correctly.

• Adjust the pressure regulator for the cutting chain (below the table) onto 1 bar.

• Activate the main switch.

• Put the key switch to „1“; the control lamp is lighting up.

• Now shift the cutting chain manually on the guiding and check if it has been mounted correctly.

• If everything is ok, put the switch back to „0“ and pull off the key; the control lamp extinguishes.

• Adjust the pressure relief valve back to the requested pressure (e.g. 4-6 bars).

6.5. How to clean / replace the chip bag

Clean / replace the chip bag if the chip contents reach 150 mm below the fixing frame.

Guiding

Cutting chain 302 links

(6825,2 mm)

Upper pinion

Lower pinion




6.6. Service unit

When the level of the condensate is about 10 mm under the filter element: Open the bleeder screw by turning it in anticlockwise direction (seen from below) to let off the condensed water.

With less flow despite same pressure setting:

• Replace the filter element

Exhaust the system and the unit Unscrew the filter bowl in an anti-clockwise direction Grasp the new filter element only at the lower end Refit the parts in the reverse order from dismantling Recommission as described in chapter “settings" (see chapter: 4.6.1)

6.7. How to protect the machine parts against corrosion

In case of air humidity of > 85 % and / or high temperatures you must treat the untreated steel parts of the machine with anti-corrosive protecting agent (e.g. AVILUB NCI 9840).

6.8. Disposal

At the end of their lifetime, the machine and the wear parts have to be disposed of properly and environment-friendly, in accordance with the national laws regulating waste disposal.






7. Electric and pneumatic diagrams


Electric and pneumatic diagrams Chapter 7







8. Declaration of conformity

In the sense of the EC guideline EG-MRL 2006/42/EG

Corporation

WIDOS GmbH

Einsteinstr. 5

D-71254 Ditzingen-Heimerdingen

declare under own responsibility that the product

Band Saw

WIDOS RSC 2400

to which this declaration refers corresponds to the following norms and normative documents:

1. DIN EN ISO 12100 – 1 and 2 (replacement for DIN EN 292 parts 1 and 2)

Safety of machines, basic terminology, general guidelines for design

2. DIN EN 60204.1

Electric equipment of industrial machines

3. EN 60555, EN 50082, EN 55014

Electro-magnetic resistance

4. DIN EN 4414

Safety regulations for fluid-technical devices and components (pneumatic)

5. DIN EN 60950

Safety of equipments of the information technology

The technical documentation is completely available.

Ditzingen-Heimerdingen, the 26.07.11

Dieter Dommer (Director)

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