Temelsan KN-40 S-MN Manual de usuario

KN-40 S-MN BUTT WELDING

MACHINE USER MANUAL

Congratulation to your new TEMELSAN Butt Welding Machine KN-40 S-MN

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.  
Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE 
TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected] 
INDEX 
BASIC INFORMATIONS........................................................................................................................3 
APPROPRIATE USE........................................................................................................................3
 
WARRANTY AND LIABILITY...........................................................................................................4
 
SAFETY.............................................................................................................................................4
 
QUALIFIELD PERSONNEL .............................................................................................................4
 
PLANNING ANG SET-UP................................................................................................................4
 
OPERATIONS...................................................................................................................................4
 
SAFETY DEVICES ...........................................................................................................................4
 
AREAS OF USAGE..........................................................................................................................5
 
MAINTENANCE................................................................................................................................5
 
ISSUES..............................................................................................................................................5
 
SAFETY MEASURED RELATED WITH THE MACHINE...............................................................6
 
TRANSPORTATION - STORAGE - PACKAGING .....................................................................7
 
STANDART ACCESSORIES...........................................................................................................9
 
OPTIONAL ACCESSORIES ............................................................................................................9
 
REQUIREMENTS OF WORKING PLACE......................................................................................9
 
FIRST CONNECTIONS........................................................................................................................11 
POWER SUPPLY (WIRING DRAW SEE AT FOLLOWING PAGE)............................................11
 
PRESS-AIR REQUIREMENTS......................................................................................................13
 
FIRST INSTALLATION AND ADJUSTMENTS.....................................................................................13 
FIRST CLEANING ..........................................................................................................................13
 
OPERATOR PANEL AND BUTTONS...........................................................................................14
 
GENELRAL USE OF BUTTONS ON KEYBOARD.......................................................................14
 
START-UP THE MACHINE............................................................................................................15
 
CALIBRATION OF JAW SPACE ...................................................................................................16
 
BASIC SETTING OF STOPPERS AND SUPPORT PLATE LEVEL ...........................................16
 
SERVICING THE JAWS ( PLEASE SERVICE THE JAWS FREQUENTLY )............................18
 
CLAMPİNG JAW GRİNDİNGİNSTRUCTİONS
.........................................................................19 
INSTALLATİON OF CLAMPİNG JAWS .......................................................................................19 
CLAMPİNG DEVİCE
...................................................................................................................19 
UPSET PRESSURE .......................................................................................................................20
 
USING THE ADJUSTMENT HANDLE .................................................................................................21 
JAW LEVEL CALIBRATION (CLAMPING JAW ANNEALING PRESSUREPOINT)..................22
 
CLAMPING JAW CALIBRATION BY CARBON PAPER..............................................................27
 
SUMMARY OF FUNCTIONALITY TYPES.........................................................................................29 
WELDING STOP POINT
....................................................................................................................30 

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

QUICK MANUAL CHART.....................................................................................................................31

MACHINE SERVICE............................................................................................................................32

CLAMPING JAW SERVICING / GRINDING INSTRUCTIONS.............................................................32

SYSTEM DRAWINGS..........................................................................................................................33

SPARE PART DRAWINGS..................................................................................................................42

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

BASIC INFORMATIONS

This manual user guide is prepared to be useful in order to get familiar with the machine and

the functions of the machine. By the help of this manual guide, the operator becomes a

capable to use the machine in an optimal way in order to operationalize safely, ergonomically

and properly.

This manual user guide allows the operators not to take risk, minimize the idle and repair time.

It also helps to increase lifetime of the machine.

This manual user guide should be kept in a proper place and be accessible easily when

needed. The local regulations included safety and environmental requirements must be

followed in addition to the statements based on this manual user guide.

In case of an issue, complaint, request, demand on spare parts etc. please note the following

information along with the below message

Concerning following Object:

Machine Model:

TEMELSAN KN-40 S-MN

Mfg. year: 2018

Serial Number:

APPROPRIATE USE

The machine is designed to weld the steel and band saw blades min. 6x0.65mm and max.

41x1.10mm.

In the event of using the machine rather than described in which case the machine would be out

of warranty situation of Temelsan.

Upset welding

/resistance butt welding is a welding technique that produces coalescence

simultaneously over the entire area of abutting surfaces or progressively along a joint, by the

heat obtained from resistance to electric current through the area where those surfaces are in

contact. Pressure is applied before heating is started and is maintained throughout the heating

period. The equipment used for upset welding is very similar to that used for flash welding.

Flash welding

is a type of resistance welding that does not use any filler metals. The pieces of

metal to be welded are set apart at a predetermined distance based on material thickness,

material composition, and desired properties of the finished weld. Current is applied to the

metal, and the gap between the two pieces creates resistance and produces the arc required

to melt the metal. Once the pieces of metal reach the proper temperature, they are pressed

together, effectively forging them together. You will be faced with technical words like Upset

Pressure, Weld-Space, Welding-Ready Position. This will be explained later in this Manual.

(Some Text here is copied from Wikipedia, which explains very well the Butt Welding procedure, many

thanks to the writer)

P a g e | 4

TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

WARRANTY AND LIABILITY

In the event of involving a personal injury or physical damages are not covered by the warranty if the

following events occur as below.

Using the machine for a purpose rather than intended

Technically, improper installation, start-up operation or maintenance of the machine

In the act of using the machine while any of safety equipment is a broken or

protective device inappropriately running.

Making constructional changes on running parameters.

Insufficient control of abrasion parts

Inappropriate repairs

The catastrophic failures due to the action of foreign objects / Bodies and excessive force applied

SAFETY

Below safety requirements must be applied without skipping anything and priority case to carry

out.

QUALIFIELD PERSONNEL

Certain tasks must be carried out on the machine by a professional qualified personnel. Not

third parties neither the children should be near the machine working area.

PLANNING ANG SET-UP

Planning, transportation, installation, programming, start-up, maintenance, repairs and other

works must be done by qualified personnel. Authorized technician must check it also.

The following matters must be noted:

Technical data and details concerning the permissible use of the machine and its

accessories.

General and specific local preparation and safety measures.

Personal usage and the use of general safety equipment must be related the norms.

Especially listed on this manual guide but specifically not listed in the operating instructions

that has been explicitly forbidden. Such as a handicapped to use the machine is such

cases it is necessary to contact the manufacturing company.

OPERATIONS

Dangers hidden in disregards of safety regulations.

SAFETY DEVICES

The machine is equipped with the safety devices corresponding to current state of the art. In the

matter of safety equipment, the machine may not be disabled, removed, dismantled, damaged.

It applies in particular to:

Safety switches (Emergency Stop Button)

Electrical and electronic fuses

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

AREAS OF USAGE

The butt-welding machine Temelsan KN40S-MN is used for low-alloyed and high-alloyed steel

bands and band saw blades or bi-metal or carbide tipped band saw blades.

The welding capacity for Band Saw Blades is from minimum 6x0.65mm up to a maximum 41

x1.10mm. The machine is capable to weld all kinds of band saw blades which are called

carbon, wood, bi-metal, CT Work on the electrical power supply is only to be done by

professional electrician.

The machine is a single piece and no need to be assembled.

The machine can be set-up by the customer’s own staff if officially approved by Temelsan.

Please read the following sections thoroughly and carefully before the initial start-up and ensure

that you clearly understand it.

MAINTENANCE

In order to insure a safe operation on the machine and prevent accidents, the job listed in the

section “Servicing” must be carried out regularly. If the owner of machine is not in a position to

do that also must be arranged by an authorized service agent.

ISSUES

The machine must be switched off at once in case of any problem occurs during the operation

and then locked for not being restarted accidently by an unauthorized person.

The machine must be switched off in this case.

Unusual sounds, vibrations, smells

Unusual operations on the monitoring device

Increased temperatures or power consumption

Unusual reaction during the manual or automatic operation

Strange behavior and error messages displayed

WARNING!

Only suitably qualified personnel must service the machine!

EMERGENCY

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TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

ATTENTION!

Note the following at emergent cases (fire, water, explosions, breakage):

•

Cut the machine off from the mains power supply at an external main switch or external

fuses

•

Switch off the compressed air supply

•

Use the fire extinguishers of a suitable type to deal with the fire

SAFETY MEASURED RELATED WITH THE MACHINE

WEAR PROTECTIVE GLASSES!

Welding beads produced during welding work could damage your eyes.

WEAR GLOVES!

The sharp edges of the blades can cause hand injuries.

DANGER OF FIRE!

Easily inflammable materials could be set alight if they come in to contact with

welding sparks

SWITCH OFF THE MACHINE!

Cut off machine from the main supply before carrying out setting-up maintenance

and servicing work on the machine. Kind of inflammable materials should keep far

away from welding area constantly during the operation!

DANGEL OF BEING CRUSHED!

There is a degree of danger if being crushed when in the proximity of the

clamping jaws during inserting parts. There is a degree of danger being crushed

between the clamping jaws during the setting-up operations.

ATTENTION!

It’s dangerous when contacting parts of the power supply, control and transformer.

IN CASE OF EMERGENCY;

Push the emergency stop button.

The emergency stop button is to use by emergency issues only!

P a g e | 7

TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

TRANSPORTATION - STORAGE - PACKAGING

The machine may not be handled with special care in transport so as to prevent damage from

impacts to careless loading and unloading. The measures listed below are essential. The

following measures that must be taken only cover the transport within the company. Road, rail,

airline transport and sea transport require additional measures to be taken.

Transport in assembled state (see figure below)

•

Use only the lifting eyelets for transport by crane (Picture below)

P a g e | 8

TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

•The use by forklift (pictured blow)

Attention:RISK OF TIPPING OVER

The higher center of gravity requires a special view for transportation even the

Machine should be fixed by screws to the pallet.

CENTER OF GRAVITY

P a g e | 9

TEMELSAN MAKİNA SAN. VE TİC. LTD. ŞTİ.

Akçaburgaz Mah. Muhsin Yazıcıoğlu Cad. No:55/1 Esenyurt / İstanbul / TÜRKİYE

TEL: +90 (212) 544-2518 FAX: +90 (212) 577-6557 www.temelsan.com teme[email protected]

STANDART ACCESSORIES

6-41mm Width Bi-Metal and CT-Band welding capacity

10-50mm Width Wood-Band welding capacity

One type jaws Both side usable and turn able for small widths

Adjustable Manuel stoppers for cambered band saw blades

3 Program Memories For 3 fully range of band saw blade dimensions

Air Pistol For manual cleaning

Support Tools Pre-Adjustment tools

OPTIONAL ACCESSORIES

1 Set Spare Upper and Lower Jaws (2 pcs of upper + 2 pcs of lower jaws)

Please check the Packing when arrived before unloading the machine from truck.

Do not accept the delivery if packaging is damaged or broken by transportation.

In case of broken or damaged packing of machine, it’s possible with agreement of Transportation

Company to unpack and check the machine condition before down loading

As soon you unload the machine, you accept the condition of machine, you take any responsibility for

damages and eventually repairs.

REQUIREMENTS OF WORKING PLACE

-Flat and smooth desk

-Required big enough area around the machine

-Environmental conditions

-The running of the machine is not permitted if flammable liquids and objects are near to welding

machine

-Enough air circulation is required

-The client is obliged to local electrical distributor notified technical requirements

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