AD 1050

Instruction Manual
Automatic Glazing Bead Saw
Revision : 06
AD 1050
2
Manufacturer Firm : Kaban Makine Sanayi ve Ticaret Ltd. ti.
Factory - Turkey Sales Office
Adress : Hadmky Atatrk Sanayi Blgesi merl i Mahallesi 75.Yl Caddesi
Uzunayr Sokak No:12
34555 Arnavutky - stanbul / TRKYE
Telephone : + 90 ( 212 ) 866 25 00
Fax : + 90 ( 212 ) 771 16 83
Service Telephone : + 90 ( 212 ) 866 25 20 - 24
http://www.kaban.com.tr
e-mail : kaban@kaban.com.tr
3
Right Choice for Technology, Performance and Quality
4
Dear Customer.
Your product which is produced in our factory with future technology,regardful
working and passed from precise quality control is designed for high performance and
qualified production
For that reason please read all of this manual very carefully.
It is important to hide this operating manual,because in the future maybe it will be
useful.
Because of the developments actions in our company,we have the right of changing
machine speciality without giving report.
5
Precaution and Advices........................................................................................................................ 7 Problems, Causes and Solutions........................................................................................................................ 41
Guarantee Procedure........................................................................................................................ 7 If Saw Motor Doesn't Run................................................................................................... 41
Out of Guarantee Cases........................................................................................................................ 7 Start button pressed, but pistons do not clamp and
Signs And Symbols........................................................................................................................ 8 blades do not move................................................................................................... 41
Motors go forward, but not come back........................................................................................... 41
General Information........................................................................................................................ 9 Motors come back, but pistons do not go up..................................................................................... 41
Intended Use........................................................................................................................ 9 Pistons down, but motors do not move forward..................................................................................... 42
Features........................................................................................................................ 9 Pistons clamp immediately when machine is
Optional Equipments........................................................................................................................ 9 energized.............................................................................................. 42
Machine Description Label........................................................................................................................ 10 Piston Failure............................................................................................................................................. 43
Technical Information........................................................................................................................ 11 Sensor Location Adjustment............................................................................................................................................ 43
Piston Cross Section............................................................................................................................................ 44
Safety Warnings........................................................................................................................ 13 Button Failure............................................................................................................................................ 45
Using of Machine According to Security Rules........................................................................................................................ 13 Valve Failure............................................................................................................................................ 45
Safety Components and Their Locations........................................................................................................................ 15 Switch Failure............................................................................................................................................ 45
Warning Labels........................................................................................................................ 16
Maintenance and Controls........................................................................................................................ 46
Working Conditions........................................................................................................................ 18 Daily Maintenance........................................................................................................................ 46
Weekly Maintenance........................................................................................................................ 46
Packing And Transportation Process........................................................................................................................ 19 Mountly Maintenance........................................................................................................................ 46
Packaging Process........................................................................................................................ 19 Maintenance Table........................................................................................................................ 47
Packaging Process For Transportation To
Short Distance........................................................................................................................ 19 Authorized Services And Dealers........................................................................................................................ 48
Packaging Process For Transportation To Instruction Manual Test Form........................................................................................................................ 49
Long Distance........................................................................................................................ 19
Loading Of Machine On Truck........................................................................................................................ 19
Unloading of Machine........................................................................................................................ 20
Instruction Manual Test Information........................................................................................................................ 20
Storage........................................................................................................................ 20
Installation Processes........................................................................................................................ 21
Levelling and Fixing of the Machine........................................................................................................................ 21
Installation of Electric and Pneumatic Line........................................................................................................................ 21
Effect of safety Switches on Running of Machine........................................................................................................................ 22
Adjustment of Clamping Pistons........................................................................................................................ 22
Control Of Rotation Direction Of Saw........................................................................................................................ 22
Control Of Up-Down Movement Speed Of Saw................................................................ 23
Adjustment of Forward-Backward Movement
speed of saw......................................................................................................................................... 23
Optional Accessories............................................................................................................................ 24
SS300 Cutting Oil Spray System................................................................................... 24
DS 500L. Digital Measurement System-Left........................................................................................................................ 26
DS 500R. Digital Measurement System-Right........................................................................................................................ 26
DK 100 Digital Compass........................................................................................................................ 36
Operating Processes........................................................................................................................ 40
Contents
6
Precaution and Advices
Please, read Instruction Manual carefully, and
keep for reference !
If personnel doesn't know these informations in
the Instruction Manual, they musn't work
on the machine.
Copying, transferring, or using this document
or its contents without a written permission is
prohibited.People acting in contrast will be
responsible from damages.
All rights including rights to patent approval or
registration of a new model or design are
reserved in Kaban Makina San.Tic.Ltd.ti.
Some functions might be not mentioned in this
document. Content is subject to change please
ask the latest version in that case.
Convenience of subjects described in this
document were controlled by Kaban Machine. In
spite of this, still there has been some
differences, and there is no guarantee for they
are similar with each other completely.
Subjects in this document are controlled
regularly, and required revisons are added to the
following issue.Revisions in the document and in
the machine without prior notice is possible. We
appreciate valuable suggestions for further
development.
Guarantee Procedure
Machines have 1 year guarantee from the date
of invoice.
After purchasing the machines, if the buyer
delayes the installation, to include this period to
the guarantee it is of Kaban Machine initiative.
The guarantee of the parts replaced during the
warranty period, expires when the guarantee of
the machine is finished.
Out of Guarantee Cases
For the following conditions the gurantee is not
included.
First start-up of the machine with unauthorized
person;
If modifications or repair works are done with
unauthorized person.
Consumption parts ( oil for conditional unit,
grease, blade )
Transport damage Introduction
Operators, must read the informations in the
Instruction Manual carefully, and they must have
knowledge about running, adjustment and
maintenance of the machine. Initial training is
given by Kaban Machine.
7
This symbol is used for warning against to dangers
which may cause to be injured, become physically
disabled and vital danger.
It defines the points which are required to pay attention
by the user for working of machine in ideal conditions.
It defines the processes which will do on the machine.
Signs And Symbols
8
Intended Use
Features
Optional Equipments
General Informations
Automatically cuts the glazing beads made of
PVC or Aluminium.
Kaban Machine is not responsible from the
things that were made out of usage purpose.
SS300 Cutting Oil Spray System.
Glazing Bead Moulds.
DS 500 L Digital Measuring System Left.
DS 500 R Digital Measuring System Right.
DK100 Digital Calliper.
MS 200 L Manual Feeding System Left.
MS 200 R Manual Feeding System Right.
BS 200 L Feeding Table Left.
BS 200 R Feeding Table Right.
Precise cutting of PVC and aluminium glazing
beads at 45.
Profile feeding table on left side and profile
measuring.
Adjustable saw progress speed.
Cuts two ends at the same time.
Easy-change moulds.
Works fast thanks to single button usage.
9
Machine Description Label
General Informations
Machine introduction label located on
designated place.
10
(1) Saw dimension
( D ) Outer diameter
( d ) Inner diameter
( b ) Thickness
(1) Saw teeth number
Saw speed
(2) Saw dimension
( D ) Outer diameter
( d ) Inner diameter
( b ) Thickness
(2) Saw teeth number
(2) Saw speed
General Informations
Technical Information - AD 1050
mm
kg
rpm
adet
adet
2,01
470 - 5130
1060
Total air consumption
Air pressure
Voltage
Total power
rpm
1,5
V
kW
hp
400
l/cycle
bar 6 - 8
8
50 - 60 Hz
Motor power
2x1
2x0,75 kW
hp
Frequency
Motor speed
Dimension
H = Height 1295
2820 - 3384
148
2820
160
80
200
mm 32
1,8
2820 - 3384 rpm
mm 32
2,5
Cuttable profile dimension
W = Width
D = Depth
Weight
95
L = Minimum
mm
L = Maximum 2425
234
11
W = Width
D = Depth
Motor speed
Dimension
H = Height
mm
Technical Information - DS 500R/L
Frequency
Weight
Hz
Motor Power
1x1
1x0,75 kW
hp
rpm
Voltage
Total Power
230
bar
1
kg
General Informations
0,75
V
kW
hp
Air pressure
3065
477
104
6 - 8
50 - 60
3000
1325
12
Using of Machine According to Safety Rules
Safety Warnings
Machine must be used only by the operators
which had education training, anyone except the
operator shoul d not stand around the machine
as the machine is running.
Operator must use job gloves and job glasses.
Jewell ery, necktie, loose clothes, is not bottoned
up job clothes,normal shoes, etc. musn't be
used, If operator has long hair, he/she must fix
his/her hair.
Safety components of machine musn't
switched off.
For a safe working, saw doesn't cut before the
safety cover closes. ( Safety Covers aren't be
removed.)
While putting profile into the machine, it is
important paying attention for hand damages.
Safety labels musn't be taken apart from the
machine.
Flat surfaces of the machine musn't be used
for working area.
Anyone musn't get out on the machine, in
whatever situations.
Machine musn't be used in moist environment
(please see working conditions).
When oil or similar materials are spilled on the
machine, it must be cleaned immediatel y.
Petroleum, sol vent, or other easy burning
liquids musn't be used for cleaning of machine.
Onl y unburning and nonpoisonous commercial
sol vents can be used.
The machine should be used according to the
conditions given in the "WORKING
CONDITIONS"
In the safety related components and/or
functions are out of order, the machine should be
stopped immediately and should not be run until
the problem is solved.In the meantime sign "out
of order" should be put on the machine.
The operator should obey the safety instruction. Any technical modifications related to the
safety related component and its functions
should be done by Kaban or with the written
authorization of Kaban. Otherwise, Kaban will be
not responsible for the technical and/or legal
probl ems.Guarantee is also excluded.
During and maintenance or repair please shut
off the air supply (6bar) and electricity. Swicth off
the main switch on the el ectrical panel and take
the power cable (plug) off.
All maintenance and repair work should be
done by qual ified personnell .
During working process mask,etc..has to be
used not to smell harmful dusts
Cutter saws have to carry with gloves not to cut
any part of the body.Necessary changes and
maintenances have to make with gloves.
Do not remove security equipments and
protectors from machine,if any of them break
down request the new one from Kaban
Machine If equipment change done by machine
buyer,equipments have to change with the same
brands &codes.Otherwise do not start the
machine.
Stock and finished process profiles have tobe
closed to the working position of the operator.
Stop the machine when not using or process
finished.
If dusts get on the machine compressed air
hammer which is located on the right side of the
machine used to clean the dust
Just only operator who take tranning about
machine have to use machine,during working
process no one have to be located around the
machine.
Before starting machine,using adj ustments and
operations during working process have to make
from operator who take tranning about machine.
13
Safety Warnings
This sign explains that there is
electrical shock danger.
You can find them on the electrical
panel and inside the electrical panel .
To reduce voice just only use pvc,aluminium
and wood cutting in the machine.Apart from this;
- True Saw have to be used during Operation.
- Before starting operation maintenance of the
machine have to done,if saw become blunt it
needs to be change.
The operator who will use the machine must
use gloves,eyewear and mask.Operator did not
wear casual cl othes,tie,trappings.And also
operator have to wear normal shoes,col lect
his/her hairs and close front of the shirt during
working process.
Saw,etc.. sharp parts have to change with
gloves or with a holder device.
Saw cutter maintenance,adj ustment and
change process there is need to take information
from Kaban department and make necessary
changes within the control of the service staff.
During cutting process sharp saw cutters have
to be used.
Suitable flanges for saw have to be Kaban's
production fl anges.Need to take information from
service.
Electrical Shock
All electrical system and metal parts are earted
and insulated from live or dangerour voltage.
However, there might be still high voltage when
you switch off the main switch and open the
door.
Please take the power supply cord out, if you
want to access inside the electrical panel for
repair on maintenance purpose.
Information: If you see someone catched by
electricity, please check out first whether the
power supply is switched off as explained
above.After that,hel p and touch the injured man.
14
Safety Components and Their Locations
1-2-Saw Safety Cover Sensor
Safety Warnings
Located on machine top plate. Shuts
down the electricity when the safety cover is
opened.
15
Warning Labels
4 8
7 3
5
6
Safety Warnings
1
2
Electrical
Current
Don't Insert
Your Hand
Oil Warning
Label
Earthing
Double Saw
Rotation
Direction Label
Air Pressure
Headset Must
Be Used
Caution Label
Do not operate
the machine
without reading
the manual
16
Warning Labels
AD 1050
Safety Warnings
9
15
13
12
14 10
11
Urgent Stop
Button
CE
Declerations
Compatibility
Label
Should be used
only in case of
emergency
Producer
Label
Direction Label Machine Code
Label
Main Switch
Label
17
Illumination
Lighted sufficiently ( at about 500 lux )
Humidity
Approximate relative humidity 50 - 60 %
Altitude
Maximum 1000 mbar
Working Conditions
1
0
0
0
3000
3
0
0
0
3000
DIAGRAM - 1
Acceptable voltage change is %10 of the
rated voltage on the label.( 400V )
PE Protective Earth line must be installed to
machine conveniently.
Supply line to the machine should be feeded
with power fuse capacity.
Voltage regulator should install to the
electricity line to be connected
Pneumatic supply line of the machine should
be at 6 bar, it should be purified from humidity (
To purifying the pneumatic line from humidity, a
drier should be put on the outlet of compressor )
To make air connection to the machine,
required air hose should be ready.
Required equipments for working environment
of machine, and necessary gap values to leave
around the machine are shown on Diagram - 1 in
milimeter.
The floor should have the capacity which can
carry weight of machine. ( 1 square metre must
carry 1 tone.)
Please try to maintain ambient working
conditions as follows :
Compressor
Air Dryer
Electrical
Panel
18
Packaging Process
Before starting to packaging process Loading Of Machine On Truck
Packaging Process For Transportation To
Short Distance
Packing And Transportation Process
If electric and pneumatic connections were
done, they are removed from machine.
The machine is purified from dust with
pressured air and with a cotton material.
Galvanized plates, saws, main axles which
are on the machine are oiled with protection oil
against rustings which could be occur during
waiting in stock and transportation. ( Shell
ENSIS SX )
The machine which will be package must
passed from the Warping Process ( covered by
clingfilm )
Machine does not need cleaning and
protection oil during packaging process,if it has
passed from the warping process.Machine could
be clean and protect oiling if it is waited on stock
for a long time.
( 1 ) Machine has to be lifted from it's balance
points and putted on the pallet for shipment.
Machine putted down to it's chassis frame by
forklift
( 2 ) For the sucssesful shipment there is
need to put support pieces under the machine
frame and both of them screwed to the pallet.
( 3 ) During the packaging machine covered
by carton box.Front,rear and all sides covered by
carton box.Carton box have to be prepared to
the size of the machine.
( 4 )Dimensions of the pallet is adjusted
according to the weight of the machine.
While machine is being lifted and brought
down, it is required to act convenient to job
safety regulations,and below instructions
must be obeyed.
Machine is lifted up, carefully, by using
balance points, with a forklift or crane which has
convenient capacity.
If crane is used for lifting process, it is holded
from points which are shown on Diagram - 2.
If forklift is used for lifting process, it is holded
from points which are shown on Diagram - 3.
During lifting up machine, for better sight
and for less danger, machine musn't be lifted
to very high position.
When machine is lifted up and brought
down, somebody must be not stand under
and around the machine.
While machine is being loaded on truck,
informations on the machine must be taken
into account :
Weightness information of machine for not
changing its balance during settlement on truck.
Direction label information which defines bottom
and up direction for setlement of machine on
right direction.After packaging process machine
lifted from it's balance points and putted on the
truck.And during the transportation do not put
anything on the machine.
19
Unloading of Machine Instruction Manual Test Information
Storage
Installation Of Machine
Packing And Transportation Process
While machine is being lifted and brought
down,it is required to act convenient to job
safety regulations,and instructions written
below must be obeyed.
Machine is lifted up, by using balance points,
carefully, with a forklift or crane which has
convenient capacity.
If crane is used for lifting process, it is holded
from points which are shown on Diagram - 2.
If forklift is used for lifting process, it is holded
from points which are shown on Diagram - 3
While machine is being lifted and brought
down, someone shouldn't be under or near
the machine.
The legs which are removed for preventing
from damages during transportation are put on
their places, carefully.
Machine must be taken down by using
identified balance points, carefully.
Necessary precautions must be taken for
preventing body and other parts from any
damage during unloading of machine.
When user takes machine on, he should fill in
test form and give it back to Kaban Machine or
to an authorized person from Kaban Machine.
The storage must be done according the
machine storage rules which has been declared
on "working conditions" part, if the machine
needs to wait for some time after delivery.
DIAGRAM - 2
DIAGRAM - 3
The machine is located to the ground which is
prepared according to Diagram - 1 on "working
condition" part, after the guide test form
approved
Before start up the machine, the protection
oil which were layed on the machine for
preventing machine from rusting which can
occur during storage and tranportation must
be cleaned. Cleaning can be done with alkali
or chemistry solvents (white spirit, kerosene,
etc..).
20
Levelling and Fixing Of The Machine
Installation of Electric and Pneumatic Line
Installation Processes
Natural rubber plate is put on the bottom of
the machine in order to prevent the vibration.
( 1 ) Levelling adjusment is made with
adjustment bolts on the chassis shoes.
( 2 ) Levelling is checked with water level.
( 3 ) The machine is fixed to the surface with
the fixation bolts as shown in the Picture.
Before connection of air hose, air system
must be worked freely. By this way dirty particles
can be thrown from the system, and after
cleaning of the system, air hose can be
connected.
When air is given to the machine, manometer
dial show 6 bar on the conditioner.
Electricity for the machine connection has to
be 400V/3 phase,before connection electric
to machine and control table.
There is need to check electric problems on
machine after giving electric to the machine
(Could be check by unpainted parts of the
machine by the help of voltage tester.
Accident Danger
During giving electric to the machine get far
away from the machine(extraordinary
movements) not to be damaged.Otherwise there
will be injuries caused from the machine moving
parts.
There is need to make provision for bonding
mistakes.
There is need to make provision for high and
low voltage mistakes.
21

Effect of Safety Switches on Running of Adjustment of Clamping Pistons
Machine
Control Of Rotation Direction Of Saw
Installation Processes
Accident Danger
If the machine works while some or all of the lids
open, it must be stopped and musn't be worked
until solving the problem.
As seen on the left picture, there is one safety
switch on the machine.
As seen on the left picture :
( 1 ) Switch
( 2 ) Claw which press to the switch
Safety switch is functionning with relation to the
top protection cover, in case the protection cover
is open machine does not operate. Claws on the
protection cover should press 4mm on the safety
switch pin.
Clamping piston should be such fixed that
when closed, it should stand on the upper
surface of the die.
1
2
4

m
m
( 1 ) Main switch is turned on
( 2 ) Motor is started by pushing once on the
run button.
( 3 ) Motor is stopped by pushing on the stop
button. Turning direction of saws is checked
(looking from front of machine, turning direction
of saws should be similar to the down picture.
If the rotation direction is wrong, turning of
right direction is provided, by changing place of
phases. Process of phase changement should
be made by using one of the below points;
From the control panel which supply energy to
machine
From the plug of machine
From the energy inlet of electric cabinet
From the connection box on the motor.
1 2 3
22

Control Of Up-Down Movement Speed Of Saw Adjustment of Forward-Backward Movement
Speed of Saw
Forward movement with
no-load on saw : 3 sn
Backward movement with
no-load on saw : 2 sn
Installation Processes
In order to move the saw forward and
backward
( 1 ) Main switch is turned on
( 2 ) Motor is started by pushing once on the
run button.
( 3 ) Either one of the bar clamping buttons is
pressed
Saw is moved by pressing simultaneously on
both of the buttons (no 3) buttons are released
when the cutting process is finished (saw returns
to original position as the buttons are
released)
( 4 ) After the saw returns to its original
position, motor can be stopped by pushing on
the partial stop button.
Movement speed of saw can be checked and
validated with the figures below
If the movement speed of saw is not suitable to
the declared figures, it can be adjusted by
following steps
( 1 ) Forward movement speed of saw can be
adjusted by the reduction screw on the piston (
Speed increases when the reduction screw is
turned clockwise, decreases when turned
anti-clockwise)
( 2 ) Backward movement speed of saw can
be adjusted by the reduction screw "selenoid one-
coil valve" which is included in the valve group
of the machine
( 3 ) If the motor hits hard on return,
cushioning screw on the piston can be used for
adjustment
Forward movement time of saw must be
increased 25% for cutting aluminium bars.
1
2
3
1 2 3
23
SS300 Cutting Oil Spray System 3) 1/2 Supplementary Lubricator
1) Assembly of Cutting Oil Power on-off
Switch
2) Popet valve Supplement
Optional Accessories
Take out "22 blind switch" which is used to
close the place of power switch and fasten "0-1 1
NA Black Metal Latch Switch"
Take out the blind plug on existing popet
valve.
Attach the supplementary popet valve on
existing popet valve by putting an o-ring
between them.
Connect popet valves and fasteners with
cables.
Fasten the hose numbered 5, which is getting
out from the supplementary popet valve to the
inlet of "1/2 Lubricator"
Wrap teflon to the reducers which will be
fastened on the lubricators While wrapping the
teflon to the reduction gear notchs,start wrapping
by leaving 1-2 notchs vacant from the starting
point of notchs.
Assembly lubricator connection parts to their
places on chassis by two bolts.
Fasten lubricator to connection part with
reducers.
Fasten elbow (T) couplings to the lubricator.
24
4) Cutting Oil Spray System Parts
Optional Accessories
Use "Automatic Triple T Coupling" in order to
distribute cutting oil hose to both spray parts.
Fasten 6" to 4" converter to both sides of
automatic T couplings.
Insert the hose numbered 6, which is getting
out from lubricators outlet, to automatic triple T
coupling.
Drill M5 hole on motor group holding plate for
spray parts.
Fasten cutting oil spray parts to these holes.
( cutting oil should arrive to saw surface with a
45 angle)
Fasten M5 elbow coupling to spray parts.
Fasten 4" hose to the converter on Automatic
T coupling
While the cooling system is used for the first
time, run the machine free till the lubrication
hose fills with oil.
On cooling system, Petrol Ofisi Basel - C or
Shell Macrou Series are used as "aluminium
cutting oil"
25
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
REFERENCE
Operating Processes
Main switch opens,Machine is in operational,
and Ad page ( side ) appears.
The ad page on the screen disappears within a
few seconds.Then, it automatically pops up
"language selection screen".
The same time, PLC and screen programs
version numbers author on the ''Language
selection screen "
if you did not select any language on the
"Language selection screen" Within 2-3 second
,"REFERENCE" screen pops up from
automatically the last used language
On the side "REFERENCE" page, "OK" button is
pressed,the robot, until you press on reference
switch medium speed moves to the left.
When robot push the referance switch, move to
right direction until dispose of referance switch
slowly.When dispose of from switch stops and
that point determine as referance position.
Robot push the referance switch, it move to the
right until rescue from referance switch. When
rescue from switch it stops and the stopped point
is determined as referance position.
26
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
SETTINGS
Setup Menu 1. Level Display Field
Descriptions
Operating Processes
When the process "making to reference "
completed "MAIN MENU" screen appears.
For Parameter settings of the machine to make
"MAIN MENU" screen, "SETTINGS" button pres,
Then, the password enter. '' level 1 Settings ''
page opens.
Removing Upper Limit: This limit use for
determine upper limit of move back support plat
can go during work.
Removing Distance: Support please move
back as this limit during work.
Note: Support Plate do not move back over
2000 mm.
Proces Waiting Time: This time value give us
the time to take cutted part from machine until
plate go to the possition for next process.
Extra RF Scale: If there is any extra scale,
lenght of scale value enters here.
27
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
Settings Menu 2. Level Display Field
Explanation
Operating Processes
Barcod Lenght Start: 4 digit lenght value on
the barcod's which is readed to machine, first
digit's which character enters here.
Main Menu: When you press this button
returned to "Main Menu"
If "Servis password" used when enter to
"Settings" menu when you press to button on
down you enter " 2 . Level setting page" If you
used " Users password" when you press to
button on down password input page open and
by entering servis password pass to the 2. level
setting page.
Reference Value: While support plate on the
regular point,measured value between support
plate and machine's process center ( this is
cutting point for this machine) which is
connected to option and the differance between
the value which is appaered on operations pages
and the referance value which exist on this field
is written to this field. In other words calibration
process, the part, which is handled on the
machine is measured and differance
between entered value and measured ( lenght
error value on the part ) is doing change to "
Referance Value" .
28
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
Operating Processes
Support Plate Depth: If for the reason of get
close to machine's support plate to process
center, this additional part's dept ( the measure
of support's plate was got closed to process
center) entered this field. When to the this field
entered "0" value it means there is no additional
part.If to this field entered to bigger value than
"0", the value lowest limit is reduced equal to
entered value.To this field can not enter a value
which is bigger that referance value.
Note: If the length value is less than the
reference value or the difference between these
values is smaller than the value entered in this
field or during the operation the additional part of
the gauge is not installed, when the "START"
button is pressed, the following warning screen
will appear. Additional part should be mounted
and "OK" and then again the "START" button
must be pressed.
Measurement Tolereance: Depend to
the process is taken on the machine the
tolerance value we needs enter here.
Because of the positing of the machine is
getting easy when the value in this field
get bigger, we can input higher work
speed with change inverter paramaters.
Push the following button return the
screen to " 1. Level Settings"
Main Menu: Push the this button return you to
main menu screen.
If " product password" was used to enter to
menu "2. Level" on " Settings" , when is presed
to following button " you across to " 3. Level
Settings" page.If not used to password to entery,
when push to this button on password inquiry
screen opens and using servis password across
to " 3. Level settings" page.
29
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
Settings Menu 3. Level Screen Field
Explanation
Main Menu: Pushing this button returns you to
Main menu page.
RF Work
Rf work screen field explanation
Operating Processes
Encoder Factor: 4 times bigger than rotary
encoders's pulse count on one cycle is entered
here.
Encoder Dividing: 10 times biggier than the
machine support table's the moving distance for
egine's one cycle is entered here by mm.
Note: Encoder Factor and Encoder Dividing
values can be entered as minimized same
rate.For example on the machine instead of
"4000" and "2900" values "40" and " 29" values
can be entered.
Support Plate Distance: During process
support plate's moving capacity is entered here.
Push to following button returns you to " 2. Level
setting"
No: Hereby you see memory index of "RF Work"
which was send to machine.
Lenght: Hereby you see cutting memory's lenth
value
Piece: Hereby you see process count at this
lenght.
OFSET: If The lenght is sending from RF scale is
wanted to cut specific offset value entered here. If
is wanted to do precess bigger than measured
value to this field is entered " -".
Piece X: To this field is entered how many piece
is wanted of lenth value sent from RF scale.and
for each lenght value, that value is assigned as
piece.
30
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
Operating Processes
SUPPORT PLATE ON / OFF: In order to cut
smaller lengths, an additional part can be
inserted to support plate part. The length of this
additional part is inserted to "SUPPORT PLATE
DEPTH" field. This button is taken to "ON"
position while the part is inserted.
Cut: Herebyyou see was did process count.
Start: Support plate go to entered lenght value
when pushing this button.
Edge Amendment: Pushing this button is used
to activeted to machine for once for the material
as edge amendment which is not required long
process. Button is automaticly become passive
when machine go back to start position.
Stop: Push that button stops the machine
Delete: Pushing that button and confirm the
warning message selected memory field is
deleted and cutting contune from next line.
Delete All: Pushing that button and confirm the
warning message all RF work memory fielf is
deleted.
Manuel: Pushing this button all process become
automatic and button indicator chace
automaticly.
MANUAL/OTO: When this button is pressed,
processes becomes automatic and button
indicator turns to "AUTO". When the button is
pressed again, it returns to manual mode.
Main Menu: Pushing that button opens " Man
Menu"
Note:Middle of the screen exist memory index
field and by using up and down bottons we are
able to move in memory, moreover by pusing
the index number between arrows wanted
value is entered this field and goes direcly that
memory digit.
Cutting list sending process by using RF
Tools;
1) On Screen "RF WORK" to " Piece X" field is
use for enter how many cutting wants.
2) Rf scale device is send cutting lenght to
machine
3) Sended lengh values are entered to RF work
memory on the machine by line, as "Piece X "
value is be cutting piece.
Note: From scale, Can not be entered bigger
lenght value than support plate moving limits
RF Work List;
1) For clean glazing bead pushing to " Edge
Amendment" button and during the edge
amendment there will be no conversion on
memory value.
2) If there is memory lenght value pushing to "
Start" button.
3) Support Plate goes length value in the
memory
4) Engines are started. After engines are started
once dont need to starts engines again.
5) Pushing the Piston button and works pistons
group move forward.
6) After cutting process over and engine come
back sensor was appaered, pistons opens and
support plate is go back as parametric
lenght.For longer lenght value than 2000 support
plate do not go back.
7) Support Plate waits, as long as the value was
entered to parametric settings of cutting waiting
time and after it goes nezt lenght measure.
31
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
Manuel Work
Manuel
Automatic
Operating Processes
1) For clean glazing bead pushing to " Edge
Amendment" button and during the edge
amendment there will be no conversion on
memory value.
2) Pushs the "Start" Button.
3) Support Plate goes length value in the
memory.
4) Engines are started. After engines are started
once dont need to starts engines again.
5) After Process overs and machine go back to
start position,support plate go backs as
parameter value and even the all list is not over
for each time have to push the " Start" button.
6) Made proces number is appeared " cut" field.
7) If all list is over support plate is go back and
for move next cutting value need to push start
button.
8) "Delete All" Pushing that button and confirm
the warning message all RF work memory fielf is
deleted.
Note: For safety support plate goes to left slowly
after specific value
1) For clean glazing bead pushing to " Edge
Amendment" button and during the edge
amendment there will be no conversion on
memory value.
2) Pushs the "Start" Button
3) Support Plate goes length value in the
memory
4) Engines are started. After engines are started
once dont need to starts engines again.
5) After Process overs and machine go back to
start position, support plate go backs as
parameter value.If all list was over. After await
32
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
CF CARD WORK
CONVEYE CF CARD VALUES
Operating Processes
as long as wait period as was entered parameter
page and go back ex position.
6) Made proces number is appeared "cut" field
7) If all list is over support plate is go back and
for move next cutting value need to push start
button.
After Reading process is over " CF CARD
WORK" work list is conveyed. Other process like
"Manuel Work" page.
Before CF card cutting list over if you send new
dates with CF card this message appears.
When press to "CF CARD READ" the dates in
CF card is started to read and following message
appears on screen.
33
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
Barcode work
Last 10 Cutting
Operating Processes
When "BARCODE WORK" menu is actived,
from the readed barcode 4 digit lenght value is
taken after the barcode lenght start number
which was entered to parameter number.And if
this value is in the limit of support plate can go
this measurement is written to first free
memory." Piece X" field is automaticly is written
to this field.
Other process continue as " RF WORK"
Hereby you can see last 10 cutting process
34
DS 500L. Digital Measurement System-Left
DS 500R. Digital Measurement System-Right
1- If the machine start position information is not 7- If Size or pieces is zero;
appearing;
2- If there is fault at the inverter; 8- When "DELETE ALL" button is pressed;
3- If have a problem with CF card access; 9- When "DELETE" button is pressed;
4- While there is a measurement out of limit, 10- The Encoder, "supporter movement" does
the "START" button is pressed; not command
5- If is exceeded Limit (-) direction; 11- If measurement is received outside of the
limit movement from the Barcode or RF device;
6- If is exceeded Limit (+) direction;
Operating Processes
35
DK 100 Digital Compass
Digital compass parameter settings
Explication P01 0 11 Counter direction ( 10
'' + '' direction, 11 " -"
direction)
P02 0 0 mm/inch selection
(mm)
Parameter Entry P03 2 1 Screen decimal places
number ( After comma
one digit)
P04 1 1 Automatic turn off du -
ration (1 min)
P05 0 0 Button active/passive
chose ( all active)
P08 1 0,1 Counter coefficient
(multiplied by 0,1 mm)
P09 0 105 Referance Value
P10 0 0 Offset1
P11 0 0 Offset2
P12 0 0 Offset3
P13 3 2 Offset configuration
( 1 and 2 active)
P20 106 106 RF Channel
P21 xxx ??? Measurement device
network-id ( entered by
read from device)
P22 xxx ??? Measurement device
address ( entered by
read from device)
P23 1 ??? RF receiver network
id ( entered by read
from device)
P24 0 ??? RF receiver address
( entered by read from
device)
P90 0 1 Function active/passive
P99 xxx 1 Device producter version
PARAMETER
EXPLCATON
Optional Accessories
PARAM
NO:
FACTORY
VALUE
SETTING
VALUE
The document of RF parameter setting of of
Elgo trade mark which code is IZ16E
Parameter Screen open with pushing "F"
button for 3 seconds when machine was
energy position.If you push this button for 3
seconds when parameter screen
open you get out from parameter page.
Pressing " F" button show us concerned
parameter's value. Pressing the button gaing
shows next paremeter's value.
By pressing " Set " button you move the curser
right until which character is wanted to
chance.When curser arrive the character
which is wanted to chance;
By pressing " Inc / Abs" chosed character's
value increase until wanted value.
36
DK 100 Digital Compass
Referans Settings
Back to Default Settings
Optional Accessories
During power on, slide to measurement head to
referans point, at the same time press to "F" ad
"Set" buttons, TO device measurent
value "P09" parameter referans value is entered.
Take off to device battery. When device is
turned off.
Pushing "IncAbs" button and put back battery
same time makes load the default settings to
device ad encodes page is opened.Repeat take
off hte battery, go back to normal work page.
37
Operating Processes
Running Of The Machine
Optional Accessories
( 1 ) For each measureament which is sent to
machine how many process ll be made to enter
to " Piece X " field.
( 2 ) Device move forward on the digital
compass to wanted measurement.
( 3 ) when digital compass on demanded
measurement value press " Set " button to send
measurement to device.When pushing that
button on the scree seems figure which
shows us measurement value is recived by
machine.
38
Problems,Causes and Solutions
Optional Accessories
There is no display on device Attached no device battery or
battery low
Attached new battery
When pressing to " Set" button
for send the measuremet to
machine,screen view lost,
Low Battery Endustrial purpuse use high flow
capacity battery attached to
device
There is a differance between
displayed on device and
material's real measurement.
Reference of device was made
incorrectly
Reference process is make
again as made on users manuel
When device is moved on
digital
compass the value on scree
P1 parameter of device is
entered incorrectly
Fix this parameter
Even device is moved on digital
compass measuremetn value
on the sceen do not change or
change irregular
The distance between encoder
on the device and band on
digital compass could be so
much.
Distance is adjusted.
Magnetic bad or encodes could
be broken or faulty
Broken or faulty part is changed
When pressing to " set" button
to send measurement value to
machine Signal do not
appear
Distance between device and
machine is very much, or there
is a reason to corruption the RF
signal
There is be a problem on
wireless receiving set's cable
connection
Control the conneciton cable
One of all of the parameters of
device P21 ,P22, P23 or P24
could be entered incorrect.
Fix the parameters
When device is moved on
digital
compass the value on screen
P8 parameter of device is
entered incorrectly
Fix this parameter
Device get closer to machine
and take a try
39
Operating Processes
( 1 ) Main power switch is turned on.
( 2 ) The bar to be cut is installed between the
upper and lower dies
( 3 ) The saws are started by pressinng the
run button
( 4 ) Bar clamping pistons clamp by pressing
one of the butons no 4
By pressing both of the buttons no 4, the saws
move, the buttons should be pressed till the end
of cutting process. When cutting process is
finished saws return and bar clamping pistons go
up. Cutting process is continued by taking out
the cut bar and inserting a new one.
( 5 ) If a new cutting process is not required,
saws are stopped by pressing on the partial stop
button and the main switch is turned off.
All steps above are repeated for a new cutting
process
Emergency Stop Button is used for stopping the
machine in case of any emergency.
After all the precautions are taken, the button
may be released by turning it and the process
may be restarted by inserting a new bar
40
If Saw Motor Doesn't Run
Start button pressed, but
pistons do not clamp and
blades do not move
Motors go forward, but not
come back
Motors come back, but
pistons do not go up
Problems,Causes and Solutions
One of the cables of motor
connection might be loose.
Tighten the cables.
One of the cables of main
switch connection might be
loose.
Tighten the cables.
Replace the deformed cables.
Thermic switch might be off. Bring it to "on" position.
Door security switches might
not be contacting.
See "Problems and Solutions"
part for the sensor adjustment.
Emergency stop might be off
Neutral not in line due to
valve, plug, switch or
connection in valve socket.
See "Problems and
Solutions" part for the sensor
adjustment.
Main phase not in line due to
valve, plug, switch or
connection in valve socket.
Motor might be not pressing
forward switch, or switch might
be not in position.
Valve migh be not working.
Motor might be not pressing
backward switch, or switch
might be not in position, or not
working.
One of the cables in the plug
might be loose or main cable
might be deformed.
Tighten the cables.
41
Pistons down, but motors do
not move forward
Pistons clamp immediately
when machine is energized
Problems,Causes and Solutions
Valve might be not working.
Piston might be not working
Motor might be not pressing
backward switch, or switch
might be not in position, or not
working
See "Problems and
Solutions" part for the sensor
adjustment.
42
Piston Failure
Problems, Causes and Solutions
1
2
3
4 5
6
In case there is not enough push and pull
power of the piston,when air is given from input
no (4), if the air goes out from input no (5),
piston felt is failed. This situation is also valid for
the opposite.
There maybe air leakage from piston neck(6).
If the piston does not stand
on the bottom or shuts
quickly,choking adjustment
may be changed.
SENSOR
LIGHT 1
2
Sensors may be loosened and dislocated.
Magnet inside the magnetic piston may be
defected.Magnet may be broken while replacing
felt, axle, neck felt due to a problem on the
piston.
Due to cushioning bolt is fastened too much,
piston stroke cannot open till the end. So sensor
may not interefere.
Sensor Location Adjustment
If the piston moves
slowly or quickly,
speed adjustment may
be changed.
It is adjusted by
turning the choking
screws (1 and 2) to
right and left
Piston speed is adjusted
by turning the speed
adjustment valve (3) to the
right and left.
Piston felt should be replaced.
Neck felt is replaced.
Sensor is placed on its slide on the piston and
moved to the indicated arrow direction until its light
is illuminating. From the point that the light is
illuminating,it is moved 5mm more to the same
direction and fixed by fastening its screw. ( it is
indicated on the picture beside that the piston is in
relation with which sensor on open and closed
positions.)
Replaced with a new one.
Cushioning bolt is released until proper
cushioning is obtained.
There may be problem on
cable connections of the
sensor.Cable may release
from connector or PLC input.
Cable place is
fixed and fastened.
Sensor may be defected
or its cable is cut.
Sensor is replaced
with a new one
43
Piston Cross Section
8 )
9 )
10 )
11 )
12 )
13 )
14 )
15 )
16 )
17 )
4 )
5 )
6 )
7 )
1 )
2 )
3 )
Problems, Causes and Solutions
1 6 2 3 7 9 9 10 14 6 15
8 8 11 13 17 17 16
Piston Neck
Bushing
Neck Felt
Hole Segment
Nutring
Oring
Piston Axle
Piston Felt Bearing
Nutring
Magnet
Oring
Piston Felt Bearing
Imbus Bolt
Piston Pipe
Piston Bottom
Nut
Choking Bearing
44
Button Failure
Valve Failure
Switch Failure
Problems, Causes and Solutions
Dust may enter inside their
contact.
After certain period of
operation, switch press
nokens may not press on
the switch properly.In this
case, switch can not
function well, so noken
should be placed to
proper location.
Switch press noken should be
adjusted to press the switch 4mm
and just from the middle.
If the switch is not functioning
even the noken presses properly,
check the switch cables are
l oosened or detached.
Switch Switch
Press
Noken
Cable ends may be loosened.
It may stick because of the arc.
Valve bobbin may be
disconnected.
Bobbin cables may be loosened
or burnt.
There may not be oil inside the
valve.
Core spindle o-rings may be failed.
There may be dirt inside the chokes.
The hose may be broken.
Try to repair the valve according to the causes of the problem mentioned above.If the problem can
not be solved, replace the valve.
If the switch is not functioning even all the checkes are performed, it is replaced with a new one.
It is cleaned with compressed
air.
Ends are fastened.
Buttons are replaced.
Valve bobbin may be
disconnected.
Bobbin cables may be
loosened or burnt.
There may not be oil inside the
valve.
O-rings are replaced.
Chokes are cl eaned
The hose is checked.
45
Daily Maintenance
Conditional Unit Water Level Control
Maintenance and Controls
Repairs must be done by authorized person.
Don't use materials which include petrol
solvent based, during cleaning of machine.
Accident Danger
Stop the machine, close electric and air
connections, during all repairs and
maintenances.
.
Dusts on and around the machine are
cleaned with pressured air.
Oil and other wastes are cleaned with a
clean cotton cloth.
Control of saw
If the saw become blunt should be replace
It musn't have water in the glass tube on left side
of conditional unit. If water accumulates in it,it
must be discharged. For that, according to
conditioner type used in machine, it is enough to
press on the cap which is under the tube to
upward way or to turn ( E ).
Conditional Unit Oil Level Check
Weekly Maintenance
Oil level must be maximum B, minimum D and
ideally C levels.
When oil level decrease, Shell TELLUS C
number 10 or equivalent oil is added.
Conditional Unit Oil Flow Control
Conditioner oil flow adjustment is made from (
A ) adjustment screw on the conditional unit as 1
dropper 7 works. Thin end screwdriver must be
used for adj ustment.
A
B
C
D
E
Mountly Maintenance
Controls of Weekly Maintenance
Maintenance of axles on which the moving
parts work.
Axles are first cleaned with a cloth and oiled
with grease.
Lubrication is performed by applying thin film line
oil with brush.
46
Maintenance Table
Dusts on and around the machine are cleaned
with pressurized air.
Control of bl ade
Conditioner Oil Level Control
Conditioner Oil Flow Control
Conditioner Water Level Control
Maintenance of axles on which the moving
parts work
Montly
Maintenance
Daily
Maintenance
Weekly
Maintenance
Maintenance and Controls

47
Telephone Fax E-mail Web Site
www.kabanir.com
+ 7 701 378 34 69 +7 701 378 33 96 kabankz@kaban.com.tr
+ 9821 22911335-6 + 98 21 222 53 218 palizadeh@kabanir.com
etwindows@bigpond.com www.eurotechwindows.com.au
-
India BMT Machines PVT LTD + 91 960 400 37 48 - sales@bmt-india.com www.bmt-india.com
+ 36 24 442 345
Country Company
+ 61 395 553 000 + 61 395 553 362 Euro Tech Windows pty Ltd. Austuralia
contact@wintec.com.ro
Portugal KAF TARRACO S.L. + 34 937 213 630 + 34 937 213 907
Romania S.C.Wintec S.R.L. +40 21 778 12 46 +40 21 778 12 47
www.kaban.com.tr
a.acosta@emmegi.com
Poland Kaban Polska + 48 22 751 89 34 + 48 22 751 90 34 kaban@kaban.com.pl
-
Libya Abdulfattah Ferjani
g.m.t@wanadoo.fr
naga186@yahoo.com -
+ 21 891 883 56 78 + 21 821 462 83 57 klibya@kaban.com.tr
palcobt@invitel.hu
www.kaban.by
Canada JRC MACHINERY INC. + 1 450 477 12 86 + 1 450 477 79 12 jonathan@jrcmachinery.com
+ 375 17 242 70 44 kaban@kaban.by Belarus FLTD "Vorne Bela" + 375 17 242 70 40
+ 2 011 0444 162
+ 36 24 442 345
Kazakistan Home Office
Palco BT.
KABAN IRANIAN
Egyptian Group TATWEER Egypt
Iran
Kazakhstan
G.M.T. - SUNBAC France
Hungary
+ 7 495 517 93 96 + 7 495 542 40 12
www.jrcmachinery.com
-
www.kaban.com.pl
www.wintec.com.ro
-
- + 33 233 667 774 + 33 233 658 965
+ 38 0482 47 34 66 + 38 0482 45 22 07
fest-98@fest-98.ru
Slovakia FOR-GLASS s.r.o. + 421 35 7731 728 + 421 35 7731 728 forglass@forglass.sk
Russia OOO "Fest-98" www.fest-98.ru
-
www.concord.com.ua
www.forglass.sk
www.evrofasad.com.ua Ukraine Evrofasad + 38 044 247 67 52 + 38 044 247 67 74
Ukraine concord@paco.net
Authorized Services And Dealers
evrofasad@evrofasad.com.ua
Spain KAF TARRACO S.L + 34 937 213 630 + 34 937 213 907 a.acosta@emmegi.com
Concord
info@orp-s.ru www.orp-service.ru Russia ORP Service + 7 800 333-1181 + 7 495 545-4582
48
Name of Machine :
Code :
Serial Number :
User Name Date Signatur

Name Of Buyer : Client Notes :
Buyer Stamp :
Name Of Authorized Person :
Signature Of Authorized Person :
Instruction Manual Test Form
Machine Is Del ivered Convenient To Del ivery
Documents And At Ideal Tranporting Conditions.
" User Training " Is Given To User Operator For
Working Safe and Convenient To Standards by An
Authorized Person From Kaban Machine.
Al l Mechanic Parts Are Handed Over Completely,
And in Working Condition.
Al l El ectric, Electronic, and Pneumatic Parts Are
Handed Over Completel y, And in Working Condition.
Al l Standard And Optional Accessories Which Are
Given With Machine Are Handed Over Compl etely.
Our Machine is Handed Over As All Security
Precautions Are Taken, And As Able To Work
Actively With Responsibilty Of Having " CE "
Machine Is Handed Over As All Of Its Maintainance
And Control s Operations Had Done And n Working
Contidion.
User Were Informed About Security Cautions And
Equipments With Showing Their Locations And
Functions On The Machine.
User Were Informed About Appl ication And
Materials Of Adjustment, Maintainance, Oiling, And
Cleaning of Machine.
User Were Informed About Codes Which Are Used
In All Documents.
User Were Informed About He/She Musn't Be Interfere
To Safety Equipments, And He/She Must Be Work As
Obeying To All Safety Precautions Which Had Been
Please, fill in the blanks on the list, and relay to the Kaban Machine's authorized person, or send to
Kaban Machine.
49