FA 3000K FULLY AUTOMATIC SAW MODEL: S350D FERROUS SAW

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1 BROBO WALDOWN (AUST) PTY. LTD. A.C.N A.B.N Fowler Rd, Dandenong, 3175 PO BOX 4274 Dandenong Sth, 3164 Victoria, AUSTRALIA. Tel: info@brobo.com.au Fax: Website: Quality Endorsed Company ISO 9001 Lic Standards Australia Quality System PRODUCT AND MAINTENANCE MANUAL FA 3000K FULLY AUTOMATIC SAW MODEL: S350D FERROUS SAW YOUR BROBO WALDOWN DISTRIBUTOR IS: Precision Drilling Machines Tapping Machines Multi Head Drills Tool Grinders Tool Post Grinders Machine Vices Special Production Equipment Accessories Riveting Machines Pedestal Grinders Metal Cutting Saws Linishers

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3 FA 3000K PRODUCT OPERATION AND MAINTENANCE MANUAL Table of Contents Section Page 1. Technical Specification 1 2. Installation of the Machine Unpacking and Handling the Machine Minimum Requirements 4 3. Main Functions and Operation FA 3000K Calibration FA 3000K Fully Automatic Operation Semi-Automatic and Length Stop Mode Job Lists Unit Maintenance and Consumables Role of the Operator General Maintenance of Functioning Components Maintenance Requirements Layouts, Assembly and Spare Parts Safety and Accident Prevention Operation of the Machine Safety Notes Advice for the Operator Reference Standards Troubleshooting Guide General Troubleshooting 37 Appendix A Risk / Hazard Assessment 38

4 1. TECHNICAL SPECIFICATIONS Cutting Unit Specifications Cutting Unit Main Motor Power Main Motor Torque Main Motor RPM Main Drive Ratio Blade RPM (Speed) Sound Level Brobo S350D Ferrous Unit 2.2 KW (415 V, 3-phase) 7.5 Nm 2800 RPM (at 50 Hz) 1:33 (Reduction) 30 to 80 RPM (33 to 88 m/min) < 85 db(a) Blade Specification Standard Blade Size Mount HSS AISI M-Z High Speed Steel (62-64 HRC, Hollow Ground) 350 mm, 180 teeth, 2.5 mm thickness 40 mm bore, 2 8 mm holes, 55 mm PCD (Brobo mount) Blade Selection Chart (HSS Ø350 mm Blade Only) HOLLOW SECTIONS SOLID SECTIONS Material Outer Diamater (mm) Wall Thickness (mm) Recommended Number of Teeth Table 1.1 Blade Selection Chart (Ø350 mm HSS Blade) NOTE This chart is issued as a GUIDE ONLY and appropriate blade selection is wholly the responsibility of the Operator. Brobo Waldown Pty Ltd does not accept any responsibility for unsatisfactory cutting performance and/or machine or blade breakage as a result of blade selection. 20 August 2016 Technical Specifications 1

5 Vice Clamps Type Air Requirements Working Air Pressure Maximum Air Pressure Clamping Range Clamping Force Manual adjusting pneumatic clamp Dry, filtered, lubricated air supply 600 KPa (6 bar, 87 PSI) 1000 KPa (10 bar, 145 PSI) 0 to 135 mm (145 mm without wear plates) 1620 N/bar (9720 N at 6 bar working pressure) Cutting Range Profile Angle Max Cutting Capacity (mm) RHS Bar RHS Square RHS Rectangular Solid Sections Table 1.2 Saw Cutting Range NOTE: Values based on a full sized new blade. Capacity is reduced with a worn or resharpened blade. Saw Feed Specifications Feed Rate (max) Feed Stroke (max) 32 mm/s 125 mm Material Feed Specifications Feed Rate (max) Feed Stroke (max) 500 mm/s 2590 mm Overall Dimensions Dimensions Weight Table Working Height , mm 315 kg 968mm 20 August 2016 Technical Specifications 2

6 2. INSTALLATION OF THE MACHINE 2.1 Unpacking and Handling the Machine FA 3000K consists of the following major components (Figure 2.1): Brobo S350D cold saw with automatic actuation F3000 automatic material feeder Electrical control box with 10 inch HMI touch screen Main Saw Guard Feeder Guard 10 inch Touch Screen Tablet Material Feeder Unit FA Cold Saw Unit Electrical Box Steel Roller Table Figure 2.1 FA 3000K Major Components FA 3000K will arrive at your workshop in three packages: FA Cold saw unit with electrical box. Material feeder unit. Spare table with the control tablet. Cold saw unit is the heaviest of the components, hence needs to be placed in position first with the rest of the machine to be built around it. When selecting suitable space keep in mind the space requirements of the feeder unit which is 3+ m long. When happy with unit position, unpack the material feeder and proceed first to attach the feeder legs to the main body (using four M8 bolts), and then to attach the material feeder itself to the cold saw unit (two M10 bolts). Refer to Section 5 for machine assembly drawings. Place the electrical box as illustrated in Figure 2.1, leaving the Operator in optimum position, accessible to controls and the main cutting area, but out of the way of the machine cutting and feeding zone. When determining location for the machine, ensure that floor is as level as possible and that the requirements from Section 2 (below) and safety precautions in Section 6 are adequately met. Additionally for best performance ensure that the feeder working table is leveled, adjusting the two standing feet if necessary. When sourcing the power supply cable, check that they are within the acceptable standards (Section 6). Install the power cable as per electrical schematics in Figures 5.5 and 5.6 (Section 5). The installation of the Earthing system must comply with the IEC Standards Part 195: Earthing and Protection Against Electric Shocks Insufficient lighting during the unit operation would constitute a safety hazard according to the ISO Lighting of Indoor Workplaces. For this reason, the user must provide adequate lighting in the working area (500 LUX), while also preventing dazzling illumination sources. 20 August 2016 Installation of the Machine 3

7 2.2 Minimum Requirements For the machine to operate correctly, the place where the saw is to be positioned must be in the vicinity of and satisfy the following conditions: 1) 5-wire 415 VAC 3-phase with neutral wire and ground 2) Lighting more than 500 LUX Note that neutral wire MUST be connected to the system. Without neutral wire, sensitive electronic equipment can be damaged. 20 August 2016 Installation of the Machine 4

8 3. MAIN FUNCTIONS AND OPERATION Upon placing the machine in position, connect the power cable as per Section 5 electrical schematics and plug it into the power socket (note the machine can only run on 5-wire 440V 3-phase power, not on 4-wire). Connect the machine to the air-compressor system at the main air supply connections (Figure 3.1). Machine is now ready to be turned on. 3-PHASE POWER SUPPLY CABLE COMPRESSED AIR SUPPLY Figure 3.1 Main Air-Supply Connections Figure 3.2 illustrates FA 3000K control panel and the external control buttons. Machine operation is controlled two-fold by external push buttons shown in the Figure 3.2 (Emergency Stop, Start button, Reset button and the Main Power switch), and the touch-screen buttons which are displayed electronically on the Control Panel. Machine Status Panel and Re- Calibrate Button Initial Cut Length (Not Applicable) Start Auto Cutting Parts Cut List: Part Name, Length, Qty Requested Pause Auto Cutting (Feeder Operation Only) Stop Auto Cutting (Feeder and Saw) Figure 3.2 Main Control Screen Calculated Total Stock Length Required for the Cut List Entered Cuts Counter Go To Job List Screen Go To Length Stop Screen 20 August 2016 Main Functions and Operation 5

9 Spindle RPM Saw Feed Rate Dual Start (Semi-Auto Mode Only) Dual Start (Semi-Auto Mode Only) Set Stroke Home/Reset End Cut Detect On/Off Switch with Power Light Emergency Figure 3.2 FA 3000K Touch Panel and Control Buttons To switch the machine on, turn the on / off power switch to the ON position. You also may need to turn on the switch on the feeder box, and turn on the tablet by scrolling the tablet on / off button. This will light up the control panel screen as well as all on / off buttons if machine is powered. Once the Control Panel powers up, the machine is ready for operation. There are two ways to stop the machine: Emergency stop executed by pressing any mushroom button. Controlled stop by pressing Home / Reset button on the control box, Stop button on the control panel, opening of the guard, or loss of air pressure. Pressing ANY emergency stop on the machine will turn off all operating machine units in an emergency. A machine calibration is required after an emergency stop. Activating controlled stop will immediately stop the operation, release clamps, stop saw motor and retract to home position. No calibration is required after a controlled stop. Pressing emergency stop will turn off the power lights which indicate the machine is not powered. Always refer to power lights for the correct power status of the machine. 20 August 2016 Main Functions and Operation 6

10 3.1 FA 3000K Calibration Upon powering up, the first screen displayed is the calibration shown in Figure 3.3: Calibrate Button Figure 3.3 Startup Screen On power up and after every emergency stop, the machine requires calibration. Before pressing calibrate button ALWAYS ensure that: The feeder travelling zone is clear of obstacles. The saw travelling zone is clear of obstacles. There is no material present in the saw vice area. Press CALIBRATE button to commence calibration. No obstacles to be present in the feeder travel zone and in the saw vice during calibration Figure 3.4 Ensure Machine Working Area is Clear BEFORE Calibration Feeder will travel towards the saw until it hits a hard stop. Saw will travel back, and then forward until it detects both reverse and forward limits to the travel. For best operation it is recommended that saw homes forward against its base and that it is not limited by a screw travel limiter. On both feeder and saw homing machine is ready for operation and the control screen will go to the main machine control screen (Figure3.2). In case of emergency stop machine will instruct you to release the emergency stop button when safe, and to rehome you need to press the status panel on the home screen as instructed by the machine. 20 August 2016 Main Functions and Operation 7

11 3.2 FA 3000K Fully Automatic Operation 1. Enter cut list information 1. Press Cut Length panel. 2. Using Num Pad enter Cut Length required. 3. Repeat for up to 6 different cut lengths. 1. Press Qty Panel. 2. Using Num Pad enter desired qty of cuts. 3. Repeat for up to 6 different cut lengths. Num Pad for Entering Data Figure 3.5 Cut List Information Entering 2. Ensure that material stock you are putting to cut is long enough by comparing its length to the calculated cut list length shown in Figure 3.6. Figure 3.6 Calculated Cut List Length 20 August 2016 Main Functions and Operation 8

12 3. Slide the stock material through the feeder clamp, through the saw clamp and at least 75 mm past the blade. 4. Press AUTO CUT. Figure 3.7 Auto Cut Button On pressing AUTO CUT the saw will start coming down and detect where the stock material is present and on detection, set up this position as the cut start point so it strokes from this point only. After this procedure it will commence cutting. During cutting, when machine has sawn through the piece, press SET to set the cut end point i.e. the end of the stroke. Once set saw will only travel the minimum distance between start and end point required to make a full cut. These start and end cut settings will reset automatically for the next bar. Use the following to fine tune the cutting operation: Spindle RPM dial to change blade speed RPM Saw Feed Rate dial to change saw stroking max speed. Dual Start (disabled during auto cutting) Dual Start (disabled during auto cutting) Set Stroke to set the cut end point Home/Reset to stop auto cutting End Cut Detect to enable automatic detection of the end of the cut. On/Off Switch with Power Light Emergency Stop Figure 3.8 Fully Automatic Operation Control Buttons 20 August 2016 Main Functions and Operation 9

13 Notes: If your cut list has less than six parts you should enter Qty=0 in the field after the last part entered. The machine will ignore all data in the cut list after this point during operation. As you cut more bar stock the counter will count total cuts during the session. Therefore cuts counter will be higher than the quantity entered and count up as high as you keep cutting. To reset the cuts counter press on the cuts panel. This will reset all counters to zero. The machine cuts the six-part pattern entered for each bar stock input providing the pattern fits on the bar stock length. If the cut list is too long for the bar stock length, the machine will detect it can not complete the full list and instead complete as much as it is possible for it to cut, then ending the process as normal. Counter will reflect actual bars cut, i.e. incomplete cutting. The machine can be tasked to cut and count a very large qty of cuts (i.e. not per bar jobbing but absolute number of cuts required). To do this, set Part 2 to Qty=0 and then set Part 1 to the length required and any number of qty of cuts. The machine will keep cutting and counting with each bar stock up until all cuts are completed. 3.3 Semi-Automatic and Length Stop Mode You can use the machine in semi-automatic mode and feeder as a length stop if you need to use it as a manual saw. The guard will need to be down for the saw to run in the semi-automatic mode. 1. Press LENGTH STOP panel on the Main Screen to go to Length Stop screen. This will take you to the length stop screen (Figure 3.9). Figure 3.9 Length Stop Screen 2. You will need to setup initially the stop minimum length. To do this, command the stop to go to position 0. Cut one length using this setting and measure it. Enter this value as the stop minimum length. Once this value is set, it remains set ongoing. 3. Enter the cut length you want and press GO. Feeder head will move to this position and you can slide stock through and cut using semi-auto cutting on the saw as detailed in Figure August 2016 Main Functions and Operation 10

14 Spindle RPM dial to change blade speed RPM Saw Feed Rate dial to change saw stroking max speed. Dual Start Cut to commence a cut Set Stroke to set the cut end point Home/Reset to stop cutting Dual Start Cut to commence a cut End Cut Detect to enable automatic detection of the end of the cut. On/Off Switch with Power Light Emergency Stop Figure 3.10 Semi Automatic Operation Control Buttons 3.4 Job Lists Cut lists you enter you are able to save for future use. If you have entered a cut list to save: 1. Press JOB LIST on the main screen to go to the job list screen. 2. Press SAVE CURRENT. This will save the job list you entered into the next available job line. Figure 3.11 Job List Screen To retrieve a previously saved cut list: 1. Press JOB LIST on the main screen to go to the job list screen. 2. Select the job list you want to retrieve by pressing on the table. The job list will become highlighted. 3. Press LOAD SELECTED and return to HOME screen. Your save job will be loaded and ready for operation. 20 August 2016 Main Functions and Operation 11

15 4. UNIT MAINTENANCE AND CONSUMABLES 4.1 Role of the Operator Responsibility must be taken by the Operator on the general maintenance and up-keeping of the unit as specified in this chapter. The person operating and maintaining the FA 3000K saw must familiarise themselves with these instructions to ensure twofold; a long economic life of the machine, and a safe working environment around it. On everyday, operational basis, the Operator must: 1) Ensure that all Operators of the machine are aware of and comply with the relevant safety instructions and standards as specified in Section 6 - Safety and Accident Prevention. 2) Check that the safety devices are operational and in place and that the personal safety instructions are complied with. 3) Regularly check that the working cycle is efficient and guarantees maximum productivity, with respect to: Function of the main components of the machine The machine operational parameters measured or perceived (e.g. the measured cutting feed and rotation rates, rate of effort, etc.) 4.2 General Maintenance of Functioning Components General maintenance operations that should be carried out regularly are as follows: 1) Keep the main cutting area and the overall machine free of any excess swarf using compressed air or thread-free cloth. Keep the machine clean and all unpainted surfaces lightly oiled to protect from corrosion. 2) Regularly check blade sharpness. Watch for warning signs such as, difficulty cutting, machine laboring during the cut, or rough edges. 3) Regularly check the condition of the saw actuator unit. Observe for side-to-side play or response delay in actuator which indicate worn internals. Ensure that the actuator unit is aligned to the saw well during the stroke. 20 August 2016 Unit Maintenance and Consumables 12

16 Actuator Bracket Actuator Actuator motor Figure 4.1 Saw Actuator Drive 4) Regularly check condition of the feeder belt and ensure it is clear of swarf. Belt is factory tightened and does not need adjustment. Correct belt tightness is taught and not tight. If belt not able to hold tension replace the belt. Figure 4.2 Material Feeder Clamp 5) Regularly check the condition of the feeder radial bearings. The bearings are fully-sealed non-adjustable units. If there is any play replace bearings. 6) Clean and lubricate all moving joints or sliding surfaces with good quality oil / grease, including the actuator pivot points. 7) During any cutting, generously lubricate the blade with coolant using the saw unit pump. 20 August 2016 Unit Maintenance and Consumables 13

17 4.3 Maintenance Requirements 1) All maintenance must be carried out with the power switched off at the plug isolator, isolated compressed air supply, and the machine in emergency stop condition. 2) On completion of maintenance works, ensure that the replaced parts or tools used have been removed from the machine tables / working surfaces before starting up. 3) Any use not in accordance with the design instructions for the machine specified in this manual may create hazards and/or safety risks for the operator.! WARNING UNAUTHORISED MODIFICATIONS/REPLACEMENTS/USE The manufacturer declines any responsibility whatsoever, either civil or criminal, in the case of unauthorised interference or replacement of one or more parts or assemblies on the machine, or if accessories, tools and consumable materials are used that are different from those recommended by the manufacturer, or if the machine is inserted in a plant system and its proper function is altered. 20 August 2016 Unit Maintenance and Consumables 14

18 5. LAYOUTS ASSEMBLIES AND SPARE PARTS Main Saw Guard Feeder Guard 10 inch Touch Screen Tablet Steel Roller Table Material Feeder Unit FA Cold Saw Unit Electrical Box Steel Roller Table Figure 5.1 FA 3000K Saw, General View 20 August 2016 Layouts Assemblies and Spare Parts 15

19 SAFETY NOTE Access past red line to the danger zone MUST be blocked by placement of the machine against the wall and / or erecting appropriate barriers or otherwise. 20 August 2016 Layouts Assemblies and Spare Parts 16

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35 6. SAFETY AND ACCIDENT PREVENTION FA 3000K saw has been designed and manufactured in adherence to the applicable Australian Standards. The instructions and warnings contained in this chapter MUST be carefully followed for safe and efficient use of the machine. 6.1 Operation of the Machine FA 3000K is designed to cut through steel components and the FA saw unit and the blade specifically selected to this end. Saw can cut through hollow and solid profiles alike, however feed rate and blade RPM appropriate to the material, size and type of the profile to cut must always be selected before cutting. The machine additionally comes equipped with an automatically retractable blade safety guard. This guard should NEVER be removed from the saw, unless changing a blade, which should be done with the machine switched off and isolated at the mains power and compressed air disconnected. Machine is additionally equipped with a saw guard with a stop switch which will stop the machine on opening. DO NOT place hands inside the saw guard for any purpose at any point. Lift the guard to gain access as required. Cutting small length bars in lengths shorter than 100 mm carries risk of cuts falling in the block openings and subsequently jamming the feeder with danger to the Operator. To cut such bars in lengths shorter than 100 mm Operator must make special considerations to ensure clearance of the cut pieces from the cutting area (Figure 6.1). This Vice Opening Must be Blocked for Short Length Cuts Figure 6.1 FA 3000K Block Openings Steel profiles to be cut often contain many dimensional imperfections and long flat profiles can often be distorted across length significantly, which increases the possibility of a mechanical jam. Operator must be aware that in case of a jam, the machine is constantly pushing the bar even though this is not moving. Hence, if the Operator attempts to release the jam without stopping the cycle, feeder may IMMEDIATELY SPRING INTO MOVEMENT, without any warning possibly putting Operator in DANGER. In case of a jam always press EMERGENCY STOP first. To the right of the cutting area is the cuts collection chute where the machine drops off short cuts, as well as to the left of the cutting area where the machine drops unusable material lengths. Machine will drop cuts and unusable material in this area, therefore place bins for collection, as appropriate, and make sure no part of person is directly under during operation (Figure 6.2). 20 August 2016 Safety and Accident Prevention 30

36 As the feeder moves the material the bar will progressively emerge from the saw guard posing a risk to anything in the way (Figure 6.2). This area should be kept completely clear during operation. Material drop zone. Place collection bins here. Material feeding zone. Keep this area clear during operation. Figure 6.2 Offcut and Short Cut Drop Openings Figure 6.3 illustrates the restricted access zone on the FA 3000K. The area behind the machine is a restricted access zone. The end user is required to setup the machine with a restricted access to this area by placement of the machine against the wall and / or by erecting appropriate barriers. Figure 6.3 Restricted Access Zone 6.2 Safety Notes FA 3000K is a high-powered cutting unit. Caution is required when operating the machine. The machine operator must be fully aware of all the functions and controls in this manual. The Employer is responsible for adequately instructing the Operator on the machine operation, risks, safety devices and noise emissions, in addition to being aware of, and implementing, the accident prevention regulations provided for by the National and International laws governing the use of the machine. All those concerned must strictly adhere to all instructions, warnings and accident prevention standards in this manual. 20 August 2016 Safety and Accident Prevention 31

37 The following definitions are those provided for by the EEC DIRECTIVE ON MACHINERY No. 98/37/CE: 1) Danger Zone Any zone in and/or around a machine in which the presence of a person constitutes a risk for the safety and health of that person. FA 3000K Danger Zones are identified identified in Figures 6.3. Cutting Vice Clamping Zone Actuator Travel Zone Main Cutting Zone Feeder Travel Zone Feeder Clamp Zone Figure 6.3 FA 3000K Danger Zones 2) Person Exposed Any person finding him or herself, either completely or partly in the Danger Zone. 3) Operator Person, or persons, given the responsibility for installing, operating, adjusting, maintaining, cleaning, repairing and transporting the machine. 20 August 2016 Safety and Accident Prevention 32

38 6.2.1 Noise Level The noise level of an idling unit has been measured below 85 dba. This complies with the Australian Occupational Health and Safety (Noise) Regulations Please note, saw noise levels when cutting are higher than idling. The noise level will vary according to the sharpness of the blade. Management should make available to the Operator(s) appropriate hearing protection as prescribed under the State Act, if necessary Power Supply The machine uses 415 V (3-phase) power. Any unauthorised interference and / or inadequate maintenance could put the Operator or Person Exposed at risk. A qualified electrician should be assigned to maintain and repair the system. Check that the power supply cables comply with, and are operating within the acceptable range of the saw capabilities. Faulty, damaged or worn components must be replaced immediately. Installation of the earthing system must comply with the requirements stated in the IEC Standards Part 195: Earthing and Protection Against Electric Shocks Lighting Insufficient lighting during cutting would constitute a safety hazard for the Operator and Person Exposed. For this reason, the user of the machine must have access to adequate lighting in the working area, while also preventing dazzling illumination sources (Reference standard ISO Lighting of Indoor Workplaces ). 20 August 2016 Safety and Accident Prevention 33

39 6.3 Advice for the Operator Protective eyewear or goggles must be worn at all times while attending and operating the saw. Steel capped boots must be worn at all times while operating the saw Do not attempt to operate the machine unless blade safety guard is in place. Do not place hands in the saw guard area during operation. Lift the guard to access the cutting zone. Ensure that hands and arms are kept well clear of the guarded cutting zone when the machine is operating. Always disconnect the power and compressed air supply to the machine before carrying out any maintenance work or adjustments. This includes the cases of abnormal operations of the machine. Any maintenance work performed on the pneumatic or coolant systems must be carried out only after the pressure in the system has been released. The Operator must not conduct any risky operations or those not required in the course of normal cutting (e.g. remove swarf from the machine while cutting). Always keep the machine working area clean. Always check that there are no tools or material left on the feeder and saw operation zones. Ensure that the material being cut is gripped securely by the vice clamps as well as supported by the saw back fence. Do not use cutting blades of different sizes to those recommended to the machine s specifications. Always follow safe practices and inspection procedures when installing blades. When cutting very short lengths ensure that cuts can not fall into table openings or get jammed during feeding in other ways. 20 August 2016 Safety and Accident Prevention 34

40 If the blade becomes jammed, stop the saw immediately. Use Calibrate function to jog backward to release the bar. 6.4 Reference Standards The following general standards, applicable to the FA 3000K saw, are those specified by the EEC Committee that governs the safety of machinery, health and safety at work, personal protection and safeguarding of the work environment. In addition, the FA 3000K also complies with the Australian Standards regarding safeguarding and general requirements for electrical equipment: 1) EEC Directive No. 98/37/CE - Machines Directive 2) EEC Directive No. 91/368-94/68 - Amends sections of EEC Directive No. 98/37/CE relating to machine safety 3) EEC Directive No. 73/23 - Low Voltage Directive 4) AS Safeguarding of Machinery The following applicable standards relate to Health and Safety at work: 1) AS General Requirements for Electrical Equipment 2) Operational Health and Safety (OHS) / Compliance References 3) EEC Directive No. 80/1107; 83/477; 86/188; 88/188; 88/642 - Protection of Workers against risks caused by exposure to physical, chemical and biological agents in workplace 4) EEC Directive No. 73/23 and Special EEC Directives No. 89/654; 89/655 - Improvements in health and safety at work 20 August 2016 Safety and Accident Prevention 35

41 7. TROUBLESHOOTING GUIDE 7.1 General Troubleshooting Table 7.1 illustrates a list of some of the most common problems associated with FA 3000K saw and the recommended troubleshooting procedures. If the solutions provided do not resolve the problems, or the problem identified differs from those listed, contact Brobo Waldown Engineering Department. Always disconnect the machine at the Main Power switch before attempting any fix. PROBLEM IDENTIFIED No Power Calibrate won t start after powering up. DIAGNOSIS Electrical Power Supply not Connected. Main Switch not on. Factory or machine circuit breaker has tripped. Emergency Stop pressed and on / off switch power light is off. SOLUTIONS Ensure that the main power cable is plugged in and switched on. Check the phases, cables, plugs and sockets for loose connection. Check the factory and machine circuit breaker. Check that there is no emergency stop buttons activated and on / off switch power light is on. Excessive heat, sparks or smoke during cutting Blade RPM or feed rate set too high or worn blade. Set saw rotational speed appropriate for the cut, between 40 to 90 RPM or change the blade. Machine not cutting lengths accurately. Incorrect blade thickness setting. Check the blade thickness using a Vernier and enter the correct blade thickness into the machine settings. Overload monitoring actively controlling the feed. Normal Operation Main motor struggles or stops (feed or blade) Main Motor torque limit exceeded. Mechanical Jam. Dull Blades. Restart the machine and check if there is worn blade or another reason for overload. Check that there is no mechanical jam and the movement of saw head is free. Re-sharpen or replace blades on the unit. Table 7.1 General Troubleshooting Guide 31 January 2009 Troubleshooting Guide 37

42 BROBO WALDOWN (AUST) PTY. LTD. A.C.N A.B.N Fowler Rd, Dandenong, 3175 PO BOX 4274 Dandenong Sth, 3164 Victoria, AUSTRALIA. Tel: info@brobo.com.au Fax: Website: Quality Endorsed Company ISO 9001 Lic Standards Australia Quality System APPENDIX A RISK / HAZARD ASSESSMENT Hazard Type Hazard Identification Hazard Assessment Hazard Management Strategies (Recommended for the Purchasing / Buyer / User) Mechanical Cutting Entanglement Puncturing Low Low Low Electrical Electrocution Low Thermal Burn Low Noise - Low Hazardous Events Failure of Control System Low Do not place hands inside the guard at all times. Lift open the guard for access. Ensure you and others around the saw are clear of the table working area when starting the machine. Do not place hands inside the guard at all times. Lift open the guard for access. Do not touch feeder head at any times. No operational reason to ever touch the feeder clamp. Ensure you and others around the saw are clear of the table working area when starting the machine. Do not place hands inside the guard at all times. Lift open the guard for access. Do not touch feeder head at any times. No operational reason to ever touch the feeder clamp. Ensure you and others around the saw are clear of the table working area when starting the machine. Disconnect the power supply when any maintenance and/or repairs are to be undertaken. Power source is to be isolated prior to opening electrical enclosures. Under normal working conditions the profile and the saw blade may become hot during cutting. Always wear gloves when handling the profiles after the cut. No-load measured noise level is below 85db(A). If the noise level becomes unusually high, stop and inspect for problem. Ensure that factory or machine circuit breakers are not tripped. Turn off the machine upon any unusual control operation and contact a qualified repairer. Additional Hazards Operator Error Impact Low Low Ensure the Operator is well aware and knowledgeable of the machine operation from this manual and experience. Wear safety glasses and steel capped boots t all times during operation. MACHINE TYPE: FA 3000K RECEVING COMPANY: (SAFETY OFFICIER) 31 January 2009 Appendices 38