Mega Machine BS-250HAS

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Summary

SPECIFICATIONS

Specifications

Details the technical specifications of the BS-250HAS model, including dimensions and capacities.

OPERATION

Operating Preparation

Outlines the steps required to prepare the machine before operation.

OPERATION (Type 2)

Control Panel

Describes the control panel and its functions for Type 2 operation.

Maintenance

Hydraulic Circuit

Diagrams and explanation of the machine's hydraulic system.

This document describes the MEGA BS-250HAS Automatic Bandsaw, an industrial machine designed for cutting various materials.

Function Description

The MEGA BS-250HAS is an automatic bandsaw primarily used for cutting workpieces. It features a saw frame that descends to cut material and then ascends, with an automatic feeding system for continuous operation. The machine is designed for fast and accurate cutting, suitable for heavy-duty use.

Key functions include:

Cutting Piece Counter: Presets the number of cuts for automatic operation. The machine stops automatically once the preset number is reached. A "Clear" key is available to reset the counter.
Multiple Stroke Feed Counter: Allows for multiplying index cycles, useful for cutting off-cut pieces longer than 500mm, with a maximum setting of 9 strokes.
Blade Speed LED-Display: Shows the saw blade's running speed in meters per minute.
Digital Cut Length Counter: Calculates the required cut length based on the formula: S = (L (length req.) + K (blade thickness)) / N (multiple feed times) - K.
Hydraulic System: Controls the saw frame's movement, blade tension, and vise clamping.
Coolant System: Injects cutting fluid during operation to remove saw chips and cool the blade.
Chip Conveyor: Automatically removes chips from the cutting area.

Important Technical Specifications

Model: BS-250HAS

Cutting Capacity:

(Mm): Ø 260, 300W180H, 280W250H
(In): Ø 10, 127, 1110

Bundle Cutting:

(Mm): 200W*140H
(In): 8"*5 1/2"

Blade Size:

(Mm): 341.13660
(In): 1 1/40.042144

Blade Speed:

(M/Min): 25, 32, 42, 55, 70, 80 (Fixed Speeds)
(M/Min): Variable Speed 20-80 (Optional)
(F/Min): 82, 105, 138, 180, 230, 260 (Fixed Speeds)
(F/Min): Variable Speed 65-260 (Optional)

Motor Output:

Blade Motor: 2.25 KW (3 HP)
Hydraulic Motor: 0.75 KW (1 HP)
Coolant Motor: 0.1 KW (1/8 HP)

Shipping Volume:

(Mm): 204020121500
(Ft): 6.7L6.6w5.0H

Weight Net/Gross:

1380 KG / 1610 lb.
3036 KG / 3542 lb. (Likely for a different configuration or model, as the manual lists two sets of weights)

Standard Accessories:

Tools with tool box (1 set)
7 ft.(2M) long roller table (1 set)
Band-cleaning wire brush (1 piece)
Band saw blade (1 piece)
Vertical guide rollers (1 set)
Instruction manual (1 copy)

Hydraulic Pressure (for 250HAS/300HAS models):

8 KG/SQ.CM

Usage Features

The bandsaw offers both manual and automatic operation modes, with a comprehensive control panel for precise adjustments.

Installation:

The machine can be moved and lifted using a crane or forklift.
Requires a level and flat reinforced concrete foundation.
Anchor bolts are used to secure the machine.
Proper leveling is crucial for accuracy, with specific fore-and-aft (10mm higher at rear) and left-and-right (3mm higher at left) adjustments for fluid return and car feeding.
Thorough cleaning and oiling are required before initial operation, removing rust preventive coating and applying machine oil.
Power source connection requires a 3HP main motor, 1HP hydraulic motor, and 1/8HP coolant motor. Earth connection is mandatory.
A starting procedure checks the hydraulic pump motor rotation direction; if incorrect, phase connections must be interchanged.

Operating Preparation:

Saw Blade Selection: Choose the appropriate blade based on workpiece size, shape, and material type, referring to the reference chart in chapter 7.
Saw Blade Unpacking and Installation: Unpack the blade carefully, ensuring teeth point to the right. Install the blade onto the drive and driven wheels, ensuring it touches the back-up roller of each guide and the flange of the wheels. Tension the blade using the hydraulic tension handle and tighten the insert adjusting screw.
Workpiece Clamping: Raise the saw frame, open the vise, place the workpiece on the roller table, gently push it into the roller-feed vise, and then clamp it.
Blade Guide Arm Adjustment: Position the blade guide arms according to the workpiece diameter/width, then tighten the lock lever and insert adjusting screw.
Wire Brush Position Adjustment: Move the wire brush case to just contact the cutting edge of the saw blade, then tighten the lock lever.
Feed Rate Adjustment: Select a suitable feed rate based on workpiece material (harder materials, wider workpieces, structural sections, and tubing require slower rates). High-speed steel blades allow for faster rates than carbon steel, and bi-metal alloy is faster than high-speed steel.
Cutting Length Preset: Use the precise cutting piece counter to set the desired length, then tighten the lock screw.
Saw Blade Speed Selection: Choose from 6 fixed speeds (25, 32, 42, 55, 70, 80 M/min) or an optional variable speed drive (20-80 M/min).

Manual Operation:

Lift the saw frame to clear the workpiece (1/2 to 3/4 inch).
Set the AUTO-MANUAL selector to "manual."
Clamp the workpiece.
Adjust blade guide arms spacing.
Preset the cutting length.
Depress "BAR FEED FORWARD" until the workpiece touches the bar stop feeler.
Adjust the feed rate.
Depress "BLADE DRIVE" to start the blade motor, coolant pump, and begin saw frame descent.
Saw blade stops at the lower limit after the cut.
Depress "RAISE" to cut the next piece.

Pre-cut inspection checklist includes workpiece clamping, blade suitability, feed rate, blade speed, tightened screws and levers, blade tension, wire brush position, and sufficient cutting fluid.

Automatic Operation:

Set the AUTO-MANUAL selector to "auto."
Depress "QUICK APPROACH" to quickly descend the saw frame to the lower limit, then it rises to the freight preset.
Adjust "HEIGHT SELECTOR" if needed to ensure blade clearance (1/2 to 3/4 inch).
Depress "BAR FEED FORWARD" until the workpiece touches the bar stop feeler.
Preset the number of cuts.
Depress "BLADE DRIVE" to start the blade motor, coolant pump, and begin saw frame descent.
Machine stops automatically after the required cuts or when the workpiece is too short to feed.

Special Operation:

If the saw blade jams, immediately depress the "FRAME RAISE" button.
Blade jamming can be caused by insufficient blade tension, worn drive belt, broken/blunt blade teeth, incorrect tooth spacing, or excessive feed rate.

Break-In Operation (for new blades):

Reduce blade speed to half of its normal setting.
Increase cutting time to 2-3 times normal.
Continue until unusual noises or metallic sounds are eliminated (e.g., five complete cuts of a 200mm (8 ins) diameter workpiece).
Return blade speed and feed rate to normal settings after break-in.

Control Panel (Type 1 & Type 2):

PILOT LAMP (2): Indicates power supply is on.
EMERGENCY STOP (3): Stops all machine operations when pressed. Turn clockwise to power on.
HYDRAULIC "ON" BUTTON (4/6): Operates the hydraulic pump motor.
POWER SWITCH OFF (5): Turns off power.
FRONT INCHING OPEN SWITCH (6/9): Inches open the front vise jaw.
AUTO - MANUAL SELECTOR (7/11): Selects continuous (AUTO) or individual function (MANUAL) operation.
FRONT VISE SWITCH (8): Controls front vise jaws (open/clamp) in manual mode.
BLADE DRIVE BUTTON (9/7): Starts saw blade motor, coolant pump, and saw head descent.
REAR VISE SWITCH (10): Controls rear vise jaws (open/clamp) in manual mode.
MANUAL FEED FORWARD BUTTON (11/12): Moves workpiece forward.
MANUAL FEED BACKWARD BUTTON (12/13): Moves workpiece backward.
QUICK APPROACH BUTTON (13/14): Causes saw head to descend quickly until it contacts the workpiece.
SAW FRAME RAISE BUTTON (14/15): Stops blade motor and raises saw head.
WORK BEAM LIGHT SWITCH (15/16): Illuminates the work area.
AUTO CHIP CONVEYOR & COOLANT SWITCH (16/17): Operates coolant pump and chip conveyor without blade running, for chip removal.
INVERTER CONTROL KNOB (17): Adjusts blade speed (left for slow, right for fast).
FEED RATE CONTROL KNOB (18/19): Adjusts cutting feed rate (clockwise increases, counter-clockwise decreases).
CUTTING PRESSURE CONTROL KNOB (19/18): Adjusts cutting pressure (clockwise increases, counter-clockwise decreases).

Maintenance Features

Regular maintenance, including proper oiling and lubrication, is essential for the machine's longevity and optimal performance.

Hydraulic Circuit:

The hydraulic circuit diagram (F:\DWG\H550A\PNC-10.DWG.1) illustrates the components like lifting cylinder, vertical vise, rear/front vises, feed, and blade tension.
Amplifying Valve Setup: The hydraulic pressure in line
should remain constant during the lifting cylinder's stroke. Springs inside the lifting cylinder compensate for pressure changes. A dry run is recommended to check pressure readings, ensuring they remain consistent.
Re-zeroing Knobs "a" & "b" on Amplifying Valve:
- Knob "a" (zero feed-rate) is zeroed by checking if its mark points to "0" position. If not, loosen the set screw and adjust.
- Knob "b" (cutting pressure) is zeroed by dry running the machine, turning knob "b" while reading pressure ~~. If pressure is read, turn knob "a". After zeroing "a", set "a" to "5" and adjust "b" until pressure ~~reaches 5.5 to 6 kg/sq.cm, then set "b" to "5".~~~~
- Knob "a" sets maximum feed-rate; knob "b" sets cutting pressure.
- Limitation: The sum of numbers set on knob "a" and "b" cannot exceed 10.

Oiling and Lubrication Chart:

NO.	Lubricating Point	Lubricant	Quantity	Oiling Frequency
1	Blade Tension Device	DAPHNE FLUID 32T	few	Twice a year
2	Driving Wheel Bearing	Grease	few	Thrice a year
3	Guide Slides	DAPHNE FLUID 32T	few	Oil daily
4	Transmission Gear Box	DAPHNE GEAR LUBE 320	3 Litres	Twice a year
5	Pivot Shaft	Grease	few	Twice a year
6	Adjusting Slide	DAPHNE FLUID 32T	few	Oil daily
7	Hydraulic Oil Tank	DAPHNE FLUID 32T	40 Litres	Twice a year
8	Vise Slides	DAPHNE FLUID 32T	few	Oil daily
9	Cutting Fluid Tank	Cutting Oil Mixture	30 Litres	Daily

Belt Size:

NO.	Belt Name	Belt Size	Qty.
10	Motor Belt	50HZ use 3V475 & 60HZ use 3V450, Inverter use 3V450	1
11	Wire Brush Belt	M43	1

General Maintenance:

Check the sight gauge for cutting fluid level daily.
Top up transmission gear box, bar feed gear box, and hydraulic oil tank monthly.
Regularly observe oil levels for proper operation and long machine life.
The ratio of cutting fluid to water should be 1:30 - 1:50.

The manual also includes a "Trouble Shooting Guide" and "Reference Charts" (not detailed here) to assist with problem resolution and optimal cutting conditions.