BAYKAL

USER′ MANUAL
HYDRAULIC SHEAR
MODEL HGL

Machine Types: HGL CXXXXX-Xxx

HGL SXX0XX-Xxx
No part of this User‘s Manual may be reproduced or transmitted by any without Prior permission of Baykal
Makine Sanayi ve Ticaret A. .

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 BAYKAL

MACHINE TYPE DESCRIPTION

BLADE GAP
SUPPLY BACK GAUGE BAKCSIDE HYDRAULIC
STANDARD ADJUSTMENT ACCESSORIES
VOLTAGE CONTROLLER SAFETY BLOCK
SYSTEM

HGL X X X X X X ---- XXX

C – CE 1 – 220 1 – PRG 911 0 – NO SAFETY 1 – MANUAL 1 – BOSH 1 – PNEUMATIC

S – STAND. 2 – 230 2 - ELGO 9521 1 – LE 20 2 - MOTORIZED 2 – REXTROTH A - Type
3 – 240 3 – S3 (SICK) 3 – BOSH – B – Type
4 – 400 2 - PHOTOCELL REXTROTH 2- REMOVEBALE
5 – 415 FINGER
6 – 440 PROTECTION
7 – 480
8 – 600
9 – 220/400

!
NOTE:

In order to SEE THE TYPE OF YOUR MACHINE, please

see the electric circuit diagram in APPENDIX C. It is written
in the left bottom side of the diagram.

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! ATTENTION
PUMP ROTATION MUST BE IN
ARROW DIRECTION,
OTHERWISE
THE PUMP WILL BE DAMAGED

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INFORMATION AND WARNING LABELS

DESIGNATION PLATE
Manufacturer BAYKAL Mak. San. Tic. A. .
Bursa / TÜRK YE
Machine Hydraulic Shear
Type HGL
Model
Serial No
Cutting Capacity ton
Cutting length mm
Main voltage V/Hz/Ph
Motor Power kW
System Pressure bar
Stroke per minute mm
Machine weight kg
Length mm
Width mm
Height mm

DESIGNATION PLATE

CE CONFIRMATION DANGER:
ELECTRIC SHOCK

GROUND LUBRICATION PUMP ROTATION

POINT

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C O N T E N T S:
1. GENERAL MACHINE INFORMATION
1.1. Registered trademark
1.2. Machine type
1.3. Serial number
1.4. Year of manufacturer
1.5. Address of the manufacturer
1.6. Address of the authorized dealer
2. IMPORTANT INFORMATION
2.1. Safety features of your shear
2.2. Important safety information & instructions
2.3. Noise Measurement
3. OVERALL DRAWING OF THE MACHINE
4. LIFTING & TRANSPORTATION
5. UNPACKING & INSTALLATION
6. OPERATING AND MAINTENANCE INSTRUCTIONS
6.1. Technical data
6.2. Description of shear applications
6.3. Prohibited uses of the shear
6.4. Incorrect uses of the shear
6.5. Using the shear
6.6. Maintenance and inspection
6.7. Troubleshooting
6.8. Conditions of storage, re-utilization and scrapping
7. LUBRICATION CHART
APPENDIX
A. SPARE PARTS LIST
B. HYDRAULIC CIRCUIT DIAGRAM
C. ELECTRIC CIRCUIT DIAGRAM
D. DIGITAL CONTROLLER PARAMETER
E. FREQUENCY INVERTER PARAMETERS
ADDITIONAL MANUALS
A. DIGITAL CONTROLLER MANUAL (to control backgauge)
B. DIGITAL CONTROLLER MANUAL (for motorized blade gap
adjustment) (optional)

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1. GENERAL MACHINE INFORMATION

1.1. Registered trademark : BAYKAL

1.2. Machine type : HGL

1.3. Serial number :

1.4. Year of manufacture :

1.5. Address of manufacturer:

1.6. Address of the authorized dealer:

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2. IMPORTANT INFORMATION
2.1. Safety features of your shear:

• The electrical and hydraulic circuits of your shear are designed to allow
operation with maximum safety. The following precautions are available on
the machine for enhanced safety.

• Emergency stop buttons (engaging type) are available on the electrical

cabinet, on the foot switch control unit and on the right-hand side of the
upper frame of the machine, all of which are easily accessible.

Figure 2.1

When the foot-switch is released in case of an emergency, the cutting beam

• will retract automatically by design of the shear.

To prevent operator or other persons from accidental contact with cutting

blades or holddowns, a finger protection grid is fitted in front of the machine
• alongside the blade length.

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Figure 2.2

• The rear of the shear is covered by a photocell operated fence system against
any careless access into the back-gauge area. If the light from sensor to
reflector is cut for any reason when the cutting beam is down-stroking, the
beam will stop at a standstill. If the light from sensor to reflector is cut for
any reason before operation, the machine will be inactive.

Figure 2.3

• The cylinder and piston group is located inside the frame of the machine by
design to avoid any damage to operator or other persons within vicinity of
the shear.
• The lifting springs of the top beam are covered by fixed cover plates
In case of a power supply failure during operation, the beam will stop at a
• standstill. When power supply is recovered, it is NOT possible to start the
machine without resetting.

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(b)

(a)

(b)

The plate (a) and grid (b) are used to protect the operator from accidental
contact while the cutting beam is moving upward and downward

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2.2. Important safety information & instructions:

The machine must NOT be operated before reading this User‘s Manual.
1. Operate the machine only if it is in a perfect condition and in accordance with
the work regulations of your factory and operating instructions of this manual.

TRANSPORTATION!
2. The lifting points are shown in the Lifting Diagram attached. The dimensions
and the weight of the machine are given in section 6.1.1.of this manual.

INSTALLATION!
The shear is delivered in complete assembled execution. It must be leveled and
3. firmly stationed on the floor where it is to be used, according to the Installation
Diagram attached. Indoor installation and a dry working environment without
danger of fire and explosion is necessary.

The permissible floor load, where the machine

! is to be installed, must be accounted for.
The machine must be operated only by authorized and trained personnel.
Operation by unauthorized and untrained Personnel in a way that does not
4.
comply with the instructions and regulations may lead to dangerous situations
and is strictly FORBIDDEN.

In case of any emergency, push the emergency stop buttons and follow the
5.
emergency rules of your factory.

The shear is designed that it can be operated by a single operator. Using the
6. machine with more than one operator is forbidden, except for certain
maintenance situations. (See Section 6.6.)

The following instructions must be born in mind and be adhered

7.
to for safe operation and maintenance of your shear :

This shear is designed for cutting only within the meaning

of section 6.2. of this manual regarding shear applications.
! Prohibited uses of the machine are dealt with in section
6.3. of this manual.
DO NOT remove the ″ finger protection grid″ in front of the
! machine under any circumstances while the machine is in an
operational mode.

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DO NOT operate the machine without proper blade gap adjustment
! according to sheet thickness.
(See section 6.5.5.)

! DO NOT use cutting blades which are excessively blunted.

Check the machine daily for recognizable external damages and

! defects.

Operate the machine only if all protective devices and guarding are
! mounted and effective.

Take notice of any warning labels on the machine and do not

! remove them.
In case of malfunction, immediately shut down and secure the
! machine. All troubles must be eliminated before re-starting.

Avoid any operation which may endanger other persons and

! immediately shut down the machine when a danger is noticed.
Shut off the machine completely before any repair work is carried
! out.

! DO NOT access into the backgauge area, while the machine is

working.

! DO NOT bridge the safety limit switch of the rear protective fence.

DO NOT use side squaring arm and front support arms for
! intermediate storage of workpieces.
During the shearing process, the workpiece may slide or move
! unexpectedly. Therefore, the material must be handled carefully.
All connecting bolts on the machine must be checked periodically
! and be re-tightened if necessary.

! DO NOT change the default settings of the hydraulic valves.

When changing oil the illustration in Figure 1 of this manual must

! be referred to. Make sure that dirty filters are disposed separately.

! The operating temperature range of the oil is : (10° C - 65° C )

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Any fire in the electric control system must be quenched using a

! CO² fire extinguisher.

Any burning oil must be quenched using a CO² or powder

! extinguisher.

All regulations concerning surface facilities designed for the use of

! water polluting liquids must be observed in operation and
maintenance of this shear.

All environmental regulations effective must be observed in use of

! this shear.

In the operation of the shear no special personal safety equipment is necessary.

8.
It is however recommended to use working gloves when handling the work-
pieces.

General maintenance of the shear can be carried out by universal tools and
9.
equipment while the machine is at a standstill.

The manufacturer is free of any responsibility in case of any unapproved

10. modifications made on the machine and/or any replacement of the original
safety and protective devices by unoriginal ones.

The machine is to be serviced and/or be repaired only by the authorized

11.
personnel of Baykal or its appointed representatives.

2.3. Noise measurement:

The sound pressure level of the shear at operator ′s working position is under 70
dB(A).

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3. OVERALL DRAWING

Mak. Tip A A1 B B1 B2 B3 C
HGL 2600X6 2760 3190 1260 1200 1740 2940 1560
HGL 3100X6 3260 3740 1320 1200 1800 3000 1576
HGL 3100X8 3305 3735 1450 1200 1930 3130 1650
HGL 3700X6 3965 4395 1450 1200 1930 3130 1650
HGL 4100X6 4305 4735 1560 1200 1990 3190 1750
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4. LIFTING & TRANSPORTATION

The following points should be taken into account:

The lifting points are illustrated in the Lifting Diagram attached. The
•
dimensions and the weight of the machine are given in section 6.1.1.of this
manual.

Make sure that the lifting rope or chain has sufficient capacity for the lifting
•
operation.

The machine must be handled with extreme caution when lifting and
! installing to prevent it from inclining forward, or even falling down.

! Make sure that the machine is not subjected to impact during

loading or unloading.

! The crane to lift the machine must be controlled by a single

operator.

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Figure 4.1

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5. UNPACKING & INSTALLATION

•
The shear is packed inside a nylon cover, and is bolted on wooden crates.

Prior to installation, dispose nylon and wooden crate separately and safely in
! accordance with environmental regulations.

After unpacking, check the machine visually against any damage during
•
transport.

Install the machine in an indoor area which is free from humidity and excessive
•
dust.

Make sure that the machine is installed in accordance with the work and
maintenance space indicated in the enclosed Installation Diagram to enable the
! operator to visualize the work area without obstruction. Therefore, the hazardous
situations regarding the operator, other
persons, or materials due to incorrect installation will be reduced.

To facilitate collection of the sheared material from the rear of the machine,
• sufficient space must be provided at the rear and by at least one side of the shear
during installation phase.

• Floor conditions for installation: Flat and concrete surface (BS 25).

Station the machine on the floor by anchorage bolts or steel expansion inserts as
•
illustrated in the Installation Diagram.

• Level the machine by using a water level.

Mount the side squaring arm and the front support arms as illustrated in the
•
Installation Diagram.

As the top and bottom blades are already fitted, the machine is now ready to
•
connect to an electricity supply.

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INSTALLATION DIAGRAM

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6. OPERATING AND MAINTENANCE INSTRUCTIONS

6.1. Technical Data

6.1.1. Specification:

1. Shearing length mm
2. Shearing capacity (≤ 450 ν /mm) mm
3. Rake angle °
4. Length mm
5. Width mm
6. Height mm
7. Weight kg
8. System pressure kg/cm²
9. Number of holddowns pcs
10. Strokes per minute cuts/min
11. Pump flow rate cm³/rev.
12. Oil tank volume lt.
13. Back-gauge range mm
14. Main motor, 3 phase 220V 60Hz kW
15. Back-gauge, 3 phase 220V 60Hz kW

6.1.2. Standard Equipment:

• Electric motor: 220V 60Hz 3phase

• Top and bottom blades
• Back-gauge position controller
• Finger protection grid
• Side squaring arm
• Front support arms
• 750 mm. power back-gauge
• Oil tank level indicator
• Rear fence guarding (If the machine has CE confirmation)
• Footswitch

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6.1.3. List of parts subject to rapid wear:

No. Part name Size specification Qty.

1. Bottom Blade - 1
2. Top Blade - 1
3. Piston Seal 2
4. Rod guide ring 2
5 Rod guide ring 4

6. Holddown Seal 17
7. O-Ring (Holddowns) 17
8. O-Ring (Pump-Suction) 1
9. O-Ring (Pump-Pressure) 1
*10. Holddown Bumper 17
Warning:*Out of warranty
6.1.4. List of bearings and special parts:

No Parta Name Part no / description Qty. Location on machine

1. Self-aligning roller bearing GE 60 ES 2 Top Beam
2. Bearing 16006 4 Blade Gap

3. Bearing 6002 2 Back-Gauge

4. Bearing 3304 2 Back-Gauge

5. Bearing 6204 ZZ 2 Back-Gauge

6. Small pulley / belt 1400 H 100 1 Back-Gauge

7. Pulley / belt Z = 14, t = 1/2″ 2 Back-Gauge

8. Large pulley / belt Z = 60, t = 1/5″ 1 Back-Gauge

9. Small pulley / belt Z =30, t = 1/5″ 1 Back-Gauge

10. Small pulley / belt 220 XL 0.62 1 Back-Gauge

11. Digital readout - 1 Back-Gauge

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6.2. Description of shear applications:

Your shear is designed and constructed for cutting of flat metal material up
to 3060 mm in length and of maximum 6 mm thickness in case of (≤ 450 ν
/mm)steel-plate.

The HGL shear features a box-type construction meaning that there are
no throat gaps on the sides of the machine. The cutting beam movement is
one of ″swinging″ type as opposed to ″guillotine″ type. The cutting beam is
actuated by two hydraulic cylinders, and retracts by a spring system.

A set of top and bottom blades, which are made of specially hardened steel
material, execute the shearing process. The gap between blades varies
according to workpiece thickness and this procedure is further explained in
section 6.5.5. of this manual. Blade gap adjustment is a very important part
of the shearing process as it directly affects the quality of the cut, and the
correct use of your machine.

The HGL shear is designed for feeding material from the front of the
machine. A front squaring-arm is available to assist in guiding and squaring
the material to the blade.
The back-gauge system provides the means to position material under the
cutting blade at a predetermined distance.

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6.3. Prohibited uses of the shear

The shear should not be used in the following circumstances:

! If there is ANYTHING OTHER THAN THE WORKPIECE, inserted,

extended, put or placed in the working area between top and bottom blades.

! When any of the protective devices or guarding of the machine are NOT
mounted or NOT functioning.

! For shearing operations involving non-flat metals (at origin) e.g. rods, bars,
tubes, pipes.

! For shearing hardened materials.

! For cutting ceramic or glass-originated materials.

The manufacturer does not accept responsibility for personal

! safety and for damage to the machine if the machine is used in
prohibited ways.

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6.4. Incorrect uses of the shear

During normal operation of the shear, the following incorrect uses must be
avoided. The likely consequences of such incorrect uses also explained below:

1. Incorrect use: Cutting material without blade gap adjustment according

to sheet thickness

Consequence: a) Blade gap is smaller than necessary:

• Blades get blunted and may break due to overlapping

• Bad material surface

b) Blade gap is greater than necessary:

• Blades get blunted and may break

• The sheared material may get jammed between blades

• The sheared material edge is burred

2. Incorrect use: Cutting over-capacity material

Consequence: • No cutting possible

3. Incorrect use: Cutting material having a width which is less than (sheet
thickness x 15)

Consequence: • The sheared material is twisted

4. Incorrect use: Shearing flame-cut material.

Consequence: • Blades get blunted and may break

5. Incorrect use: Cutting sheet-plates in layers of two or more

Consequence: • Normal cutting not possible

• Blades get blunted and may break

• One of the sheet-plates may get jammed between

blades

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! Non-recommended use: Cutting high-silica and high-carbon material

Consequence: Blades get blunted

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6.5. Using the shear:

6.5.1. Requirements for the initial test and examination

• Check the machine visually against any transport damage.

• Clean the oil tank and the suction filter.

• Fill the oil tank up the level indicator with one of the oil types recommended in
the Lubrication Diagram.

• Check that the rear guard is functioning mechanically in proper.

• Check that the blades are rigidly fixed in their places.

• Make sure that the cables are not damaged.

• Check the components and terminal ends inside the electrical cabinet against
any loosening.

• Make sure that switches and buttons are not damaged.

• Carry out the electrical connections according to section 6.5.2 and then proceed
with initial testing and start-up according to instructions in section 6.5.4.

• During test run check that:

a) All switches and buttons are fulfilling their functions.(in particular, emergency
buttons, safety and limit switches )

b) There is no oil leakage in cylinders, valves, pipes and hoses.

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6.5.2. Electrical connections

! All electrical connections, however simple, must be carried out by

qualified electricians.
Machine must be placed as close as possible to an electricity supply point. In
cases where this is not possible, it is recommended to bring an auxiliary supply
duct alongside the machine. Electricity should be connected by supply cable
with correct diameter.

! EARTHING connection is strictly necessary.

Voltage and power requirements are labeled on the machine. First class
components are used in the electrical cabinet, all electric wires are numbered
according to electric circuit diagram and all components confirm the established
standards. Cartridge fuses are used in the control circuit.

As the footswitch connection is already made in the factory, your shear is ready
for initial start-up.

A. Foot switch connections:

(b)

(a)

Figure 6.5.2.1

Figure Label Description

(Electrical
Diagram)
(a) 4S2 Foot switch
(b) 2S1 Emergency stop button

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B. Light barrier connections and main switch:

(a)

(b) (c) (d)

Figure 6.5.2.2

Figure Label (Electrical Description

Diagram)
(a) - Light guard connector
(b) 2S5 Reset button
(c) - Light guard connector
(d) 1Q1 Main switch

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C. Back-gauge connections and the top-bottom limit switches:

(a)

(c)

(b)

(d)

(e)

Figure 6.5.2.3

Figure Label (Electrical Description

Diagram)
(a) 1M5 Back-gauge motor connection
(b) 3S8 Back-gauge +limit switch
(c) 3S7 Back-gauge –limit switch
(d) 4S6 / 4S5 Beam maximum/minimum switch
(e) 3B1 Encoder

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D. Blade Gap Adjustment Motor and connections:

Blade gap adjustment motor is on the right side of the machine, if the machine
has Motorized blade gap adjustment system.

(a)
(a)

(b)

Figure 6.5.2.4 Figure 6.5.2.5

Figure Label (Electrical Description

Diagram)
(a) 1M7 Blade gap adjustment motor and its power connection

(b) 1K5 Potentiometer of the blade gap adjustment system and

its connection.

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Blade gap limit switches is present on the rear of the electrical cabinet on the
left side of the machine, if the machine has Motorized blade gap adjustment
system.

(b)

(a)

Figure 6.5.2.6

Figure Label (Electrical Description

Diagram)
(a) 7S8 Blade gap minimum limit switch

(b) 7S7 Blade gap maximum limit switch

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D. Hydraulic Valve connections:

Figure 6.5.2.7

No Name Description
1 Directional Valve It controls downward movement of the beam

2 Directional Valve It controls upward movement of the beam

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6.5.3. Electrical Cabinet and Control Units

6.5.3.1. Control Units

1. Control Unit with PRG 911 digital controller:

Labels: Labels:

Digital Controller Hourcounter

Back-gauge forward Back-gauge

button backward button

Stroke adjustment Inside illumination

timer switch
Beam-down button

Cutting Control Switch

Beam-up button

Pump-start button

Control on Pump-stop button

Front Emergency stop Reset lamp

button

Reset button (Beam-

up) and lamp

Figure 6.5.3.1

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Label
(Electrical Designation Function (Figure 6.5.3.1)
Diagram)
It controls back-gauge distance from the table.
7A2 Digital Controller
This distance decides the cutting width.
2H3 Hourcounter It shows total working time
Back-gauge backward When this button is pressed, the backgauge
3S9
button moves backward
Back-gauge forward When this button is pressed, the backgauge
3S10
button moves forward
Stroke adjustment It set the cutting length
4K1
timer

Position 1. Series or repetitive cutting

4S1
Cutting Control Switch Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

4S4 Beam-up button It is used for raising the beam

4S5 Beam-down button It is used for lowering the beam

3S4 Pump-stop button When pressing, the main pump stops

3S5 Pump-start button When pressing, the main pump starts up.

Front Emergency stop In case of emergency, when pressing, all

2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Because of any reason (power failure etc.) If
Reset button (Beam- the beam standstills at anywhere, this button
4H1
up) and lamp must be pressed in order to operate the
2S5
machine again. When this button is pressed the
beam goes to its upper point.
3S11 Inside illumination When turning on, lamp inside the machine will
switch lit up.

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2. Control Unit with PRG 911 digital controller and Pneumatic Sheet Holder:

Digital Controller Hourcounter

Back-gauge forward Back-gauge

button backward button

Stroke adjustment
timer Inside illumination
switch
Beam-down button
Cutting Control Beam-up button
Switch
Pump-start button

Control on Pump-stop button

Front Emergency
stop button Reset lamp

Reset button (Beam-

Pneumatic support up) and lamp
switch

Figure 6.5.3.2

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Label
(Electrical Designation Function (Figure 6.5.3.2)
Diagram)
It controls back-gauge distance from the table.
7A2 Digital Controller
This distance decides the cutting width.
2H3 Hourcounter It shows total working time
Back-gauge backward When this button is pressed, the backgauge
3S9
button moves backward
Back-gauge forward When this button is pressed, the backgauge
3S10
button moves forward
Stroke adjustment It set the cutting length
4K1
timer

Position 1. Series or repetitive cutting

4S1 Cutting Control Switch
Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

4S4 Beam-up button It is used for raising the beam

4S5 Beam-down button It is used for lowering the beam

3S4 Pump-stop button When pressing, the main pump stops

3S5 Pump-start button When pressing, the main pump starts up.

Front Emergency stop In case of emergency, when pressing, all

2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Because of any reason (power failure etc.) If
Reset button (Beam- the beam standstills at anywhere, this button
4H1 must be pressed in order to operate the
2S5 up) and lamp
machine again. When this button is pressed the
beam goes to its upper point.
Inside illumination When turning on, lamp inside the machine will
3S11
switch lit up.
Pneumatic support It switches on/off pneumatic support system
5S1 switch

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3. Control Unit with PRG 911 and P400 digital controller:

Digital Controller Digital Controller

P400

Back-gauge forward Back-gauge

button backward button

Stroke adjustment Inside illumination

timer switch
Beam-down button

Cutting Control Switch Beam-up button

Pump-start button

Control on Pump-stop button

Front Emergency stop Reset lamp

button

Reset button (Beam-

up) and lamp

Figure 6.5.3.3

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Label
(Electrical Designation Function (Figure 6.5.3.3)
Diagram)
It controls back-gauge distance from the table.
7A2 Digital Controller
This distance decides the cutting width.
Digital Controller It adjust blade gap for determining cutting
10A2
P400 thickness
Back-gauge backward When this button is pressed, the backgauge
3S9
button moves backward

Back-gauge forward When this button is pressed, the backgauge

3S10
button moves forward
Stroke adjustment It set the cutting length
4K1
timer

Position 1. Series or repetitive cutting

4S1 Cutting Control Switch
Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

4S4 Beam-up button It is used for raising the beam

4S5 Beam-down button It is used for lowering the beam

3S4 Pump-stop button When pressing, the main pump stops

3S5 Pump-start button When pressing, the main pump starts up.

Front Emergency stop In case of emergency, when pressing, all

2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Because of any reason (power failure etc.) If
Reset button (Beam- the beam standstills at anywhere, this button
4H1
up) and lamp must be pressed in order to operate the
2S5
machine again. When this button is pressed the
beam goes to its upper point.
3S11 Inside illumination When turning on, lamp inside the machine will
switch lit up.

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Control Unit with PRG 911 - P400 digital controllers and Pneumatic Sheet
4. Holder (CE):

Digital Controller
P400 Digital Controller

Back-gauge forward Back-gauge

button backward button

Stroke adjustment
timer Beam-down
button
Cutting Control Switch
Beam-up button

Pump-start button
Control on
Pump-stop button

Front Emergency stop

button Reset lamp

Pneumatic support Reset button

switch (Beam-up) and
lamp

Hourcounter

Figure 6.5.3.4

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Label
(Electrical Designation Function(Figure 6.5.3.4)
Diagram)
Digital Controller It controls back-gauge distance from the table.
7A2
PRG911 This distance decides the cutting width.
10A2 Digital Controller It adjust blade gap for determining cutting
P400 thickness
Hourcounter It shows total working time
2H3
Back-gauge backward When this button is pressed, the backgauge moves
3S9 backward
button
Back-gauge forward When this button is pressed, the backgauge moves
3S10 forward
button
Stroke adjustment It set the cutting length
4K1 timer

Position 1. Series or repetitive cutting

4S1 Cutting Control Switch
Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

Beam-up button It is used for raising the beam
4S4
Beam-down button It is used for lowering the beam
4S5
Pump-stop button When pressing, the main pump stops
3S4
Pump-start button When pressing, the main pump starts up.
3S5
Front Emergency stop In case of emergency, when pressing, all
2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Reset button (Beam- Because of any reason (power failure etc.) If
up) and lamp the beam standstills at anywhere, this button
4H1
must be pressed in order to operate the
2S5
machine again. When this button is pressed the
beam goes to its upper point.
Pneumatic support It switches on/off pneumatic support system
5S1 switch

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 BAYKAL

5. Control Unit with Elgo P9521 digital controller:

Hourcounter Digital controller

Back-gauge forward Back-gauge backward

button button

Stroke adjustment Inside illumination

timer switch
Beam-down button

Cutting Control Switch Beam-up button

Pump-start button

Control on Pump-stop button

Front Emergency stop Reset lamp

button

Reset button (Beam-

up) and lamp

Figure 6.5.3.5

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Label
(Electrical Designation Function (Figure 6.5.3.5)
Diagram)
It controls back-gauge distance from the table.
7A2 Digital Controller
This distance decides the cutting width.
2H3 Hourcounter It shows total working time
Back-gauge backward When this button is pressed, the backgauge moves
3S9 backward
button
Back-gauge forward When this button is pressed, the backgauge moves
3S10 forward
button
Stroke adjustment It set the cutting length
4K1
timer

Position 1. Series or repetitive cutting

4S1 Cutting Control Switch
Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

4S4 Beam-up button It is used for raising the beam

4S5 Beam-down button It is used for lowering the beam

3S4 Pump-stop button When pressing, the main pump stops

3S5 Pump-start button When pressing, the main pump starts up.
Front Emergency stop In case of emergency, when pressing, all
2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Because of any reason (power failure etc.) If
Reset button (Beam- the beam standstills at anywhere, this button
4H1
up) and lamp must be pressed in order to operate the
2S5
machine again. When this button is pressed the
beam goes to its upper point.
3S11 Inside illumination When turning on, lamp inside the machine will
switch lit up.

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6. Control Unit with Elgo P9521 and P400 digital

controllers:

Digital Controller Digital controller

P9521 P400

Back-gauge forward Back-gauge backward

button button

Stroke adjustment Inside illumination

timer switch
Beam-down button

Cutting Control Switch Beam-up button

Pump-start button
Control on Pump-stop button

Reset lamp
Front Emergency stop
button

Reset button (Beam-

up) and lamp

Figure 6.5.3.6

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Label
(Electrical Designation Function (Figure 6.5.3.6)
Diagram)
Digital Controller It controls back-gauge distance from the table.
7A2
P9521 This distance decides the cutting width.
10A2 Digital Controller It adjust blade gap for determining cutting
P400 thickness
Back-gauge backward When this button is pressed, the backgauge moves
3S9 backward
button
Back-gauge forward When this button is pressed, the backgauge moves
3S10 forward
button
Stroke adjustment It set the cutting length
4K1
timer

Position 1. Series or repetitive cutting

4S1 Cutting Control Switch
Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

4S4 Beam-up button It is used for raising the beam

4S5 Beam-down button It is used for lowering the beam

3S4 Pump-stop button When pressing, the main pump stops

3S5 Pump-start button When pressing, the main pump starts up.
Front Emergency stop In case of emergency, when pressing, all
2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Because of any reason (power failure etc.) If
Reset button (Beam- the beam standstills at anywhere, this button
4H1
up) and lamp must be pressed in order to operate the
2S5
machine again. When this button is pressed the
beam goes to its upper point.
3S11 Inside illumination When turning on, lamp inside the machine will
switch lit up.

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Control Unit with Elgo P9521 digital controller and Pneumatic Sheet
7. Holder:

Hourcounter Digital controller

Back-gauge
Back-gauge forward
backward button
button

Stroke adjustment
Inside illumination
timer
switch

Beam-down button
Cutting Control
Switch Beam-up button
Pump-start button

Control on Pump-stop button

Front Emergency Reset lamp

stop button

figure 6.5.3.7
Pneumatic support Reset button (Beam-
switch up) and lamp

(Figure 6.5.3.7)

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Label
(Electrical Designation Function (Figure 6.5.3.7)
Diagram)
It controls back-gauge distance from the table.
7A2 Digital Controller
This distance decides the cutting width.
2H3 Hourcounter It shows total working time
Back-gauge backward When this button is pressed, the backgauge moves
3S9 backward
button
Back-gauge forward When this button is pressed, the backgauge moves
3S10 forward
button
Stroke adjustment It set the cutting length
4K1
timer

Position 1. Series or repetitive cutting

4S1 Cutting Control Switch
Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

4S4 Beam-up button It is used for raising the beam

4S5 Beam-down button It is used for lowering the beam

3S4 Pump-stop button When pressing, the main pump stops

3S5 Pump-start button When pressing, the main pump starts up.

Front Emergency stop In case of emergency, when pressing, all

2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on button order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Because of any reason (power failure etc.) If
Reset button (Beam- the beam standstills at anywhere, this button
4H1
up) and lamp must be pressed in order to operate the
2S5
machine again. When this button is pressed the
beam goes to its upper point.
3S11 Inside illumination When turning on, lamp inside the machine will
switch lit up.
Pneumatic support It switches on/off pneumatic support system
5S1 switch

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Control Unit with Elgo P9521 and P400 digital controllers and Pneumatic Sheet
8. Holder:

Digital Controller Digital controller

P9521 P400

Back-gauge
backward button
Back-gauge forward
button
Inside illumination
Stroke adjustment
switch
timer
Beam-down button
Beam-up button
Cutting Control
Switch
Pump-start button
Pump-stop button
Control on

Front Emergency Reset lamp

stop button
Figure 6.5.3.8
Reset button (Beam-
Pneumatic support up) and lamp
switch

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Label
(Electrical Designation Function (Figure 6.5.3.8)
Diagram)
It controls back-gauge distance from the table.
7A2 Digital Controller
This distance decides the cutting width.
Digital Controller It adjust blade gap for determining cutting
10A2
P400 thickness
Back-gauge backward When this button is pressed, the backgauge moves
3S9 backward
button
Back-gauge forward When this button is pressed, the backgauge moves
3S10 forward
button
Stroke adjustment It set the cutting length
4K1
timer

Position 1. Series or repetitive cutting

4S1 Cutting Control Switch
Position 2. One-off cut (single)

Position 3. Manual cutting (Inching)

4S4 Beam-up button It is used for raising the beam

4S5 Beam-down button It is used for lowering the beam

3S4 Pump-stop button When pressing, the main pump stops

3S5 Pump-start button When pressing, the main pump starts up.

Front Emergency stop In case of emergency, when pressing, all

2S2 button machine functions and controls will be
inactive and the main pump will stop.
After emergency stop button is pressed, in
2S3 Control on button order to operate the machine, the button must
2H1 be pressed. The button initializes the
emergency stop module.
Reset lamp (Safety It indicates that the rear light guard should be
2H2 switch) reset. When it illuminates, press the reset
button on the light guard transmitter branch.
Because of any reason (power failure etc.) If
Reset button (Beam- the beam standstills at anywhere, this button
4H1
up) and lamp must be pressed in order to operate the
2S5
machine again. When this button is pressed the
beam goes to its upper point.
Inside illumination When turning on, lamp inside the machine will
5S1 switch lit up.
Pneumatic support It switches on/off pneumatic support system
switch

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6.5.3.2. Electrical Cabinets:

Main Switch

Left Side Front cover

Figure 6.5.3.9

Label (Elect. Name Description

Diag.)
1Q1 Main Switch It switches on/off the machine

2. Main switch on the cover of Electrical Cabinet:

Main Switch

Left Side Front cover

Figure 6.5.3.10

Label (Elect. Name Description

Diag.)
1Q1 Main Switch It switches on/off the machine

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6.5.4. Operating the machine

6.5.4.1. First start-up and getting ready to work:

Figure 6.5.4.1 Figure 6.5.4.2 Figure 6.5.4.3

! The machine must be first started-up and be put into service by

authorized and qualified personnel.

PROCEDURE:

Before putting the machine into service, perform following items

sequentially.

a) Switch on the main switch in the way shown in the Figure 6.5.4.1.
The reset lamp shown in Figure 6.5.4.3 will lit. (If not, there is either a
bulb failure or a disconnection in the electrical circuitry).

b) Check the rear side of the machine and make sure that the safety switch of
the rear fence is engaged. Push the rear reset button shown in Figure
6.5.4.2; the reset lamp will be off. (If it remains lighted, check the back
gauge area against anything that prevents the transmitter and the receiver
from contact.)

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Figure 6.5.4.4 Figure 6.5.4.5 Figure 6.5.4.6

c) Push the front reset button shown in Figure 6.5.4.4. The button lamp will
be on. If the lamp does not lit (except for reasons of bulb failure), it
indicates that one of the three or all of the emergency stop buttons are left
depressed. Disengage the emergency stop button (s), and push the reset
button again.

d) Check the motor rotation by pushing motor start button shown in Figure
6.5.4.5, and immediately after, motor stop button shown in Figure 6.5.4.6

! on the control panel. The motor must be rotating in the direction of ″arrow″″
marked. If it is rotating in the reverse direction, change any two phases in
the electricity supply point. After pushing motor start button, the lamp of
the reset button shown in Figure 6.5.4.3 will lit for a short while and will
be off after, indicating the beam is ready for up-down movement.

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Figure 6.5.4.7 Figure 6.5.4.8 Figure 6.5.4.9

e) Turn the cutting control switch to the position 1 (Manual cutting or inching)
shown in Figure 6.5.4.7. Check whether the beam goes up and down by using
Beam up button and Beam down button (shown in Figure 6.5.4.8 and Figure
6.5.4.9) respectively or not. If they work properly, your machine is now ready
for selecting a working position. Follow the instructions in section 6.5.4.2.

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6.5.4.2. Cutting Control Modes of the Shear:

Your shear is capacity-tested prior to dispatch, and blade gap adjustment is made.

The operation of the machine depends on two different positions of the cutting beam;
namely (A) the beam is at the top-most point of its stroke shown in Figure 6.5.4.10.b
there is contact with the top limit switch shown in Figure 6.5.2.3.d (upper one), or (B)
the beam is in a lower position than top-most stroke shown in Figure 6.5.4.10.a (no
contact with switch 4S6).

(a) (b)
Figure 6.5.4.10

A. The beam is at the topmost point of its stroke:

a) Single and Continuous cutting mode: Select a cutting mode by turning the
cutting control switch shown in Figure 6.5.4.7 in CCW. You can select single
cutting or continuous cutting mode.

Initial settings…..

1. Press Control on button (shown in Figure 6.5.4.4). The lamp of the reset
button (shown in Figure 6.5.4.3) will lit for a short while, and will be off
after. This button sets emergency stop module and energies (or activate)
machine control.

2. Adjust the blade gap according to the instruction in section 6.5.5

3. Select the value 9 on the stroke timer by pushing on the small button on it

4. Set back-gauge range on the digital controller according to the instruction in

section 6.5.6

After completing the procedure above, your machine is ready for cutting.

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Feeding…..

5. Put the plate on the work-table and feed it until touching the back-gauge
arms (see Figure 6.5.4.11). For correct cutting, the plate must touch the
back-gauge arm at least minimum two points.

! Do not push the plate excessively. In some thickness, plate can be bent
resulting unwilling or incorrect cutting width.

Figure 6.5.4.11

Pressing pedal …

6. After being sure of putting the plate on its place, press the footswitch (see
Figure 6.5.4.12). Keep it pressed until the beam finishes its down-up
movement cycle. If you release footswitch at any moment of this cycle,
the beam suddenly will retract (or rise) from its position to the top
standstill point.

In continuous cutting mode, if you keep the footswitch pressed the beam
repeats down-up cycle for the pre-determined value on the digital controller.
How much time the beam will wait at the top standstill point is determined
by the time relay inside the electrical cabinet.

In single cutting mode, keep the footswitch pressed until the beam finishes
its down movement (stroke). After finishing down movement you can
release the footswitch.

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At the topmost stroke, the beam goes down until it touches the bottom
! limit switch shown in Figure 6.5.2.3.d

Figure 6.5.4.12

During cutting….

After pressing the foot switch, the beam starts the down movement and the
hold down cylinders compress the plate on the work table (see Figure
6.5.4.13).
! The cutting process occurs from the left to the right side of the plate

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Figure 6.5.4.13

After cutting….
After the beam (blade) completes its stroke (down movement), the sheared
part of the plate falls down from the backside of the machine.

Always switch off the main switch 1Q1 to ″0″″ when inside the
WARNING! danger zone (backgauge area) of the shear for any reason.

b) Manual (inching) mode: Select manual (inching) mode by turning the

cutting control switch in CW (see Figure 6.5.4.7 )

1. Push Control on button (shown in Figure 6.5.4.4). The lamp of the

reset button (shown in Figure 6.5.4.3) will lit for a short while, and
will be off after.

2. The beam can be made to travel down or up manually by pushing the

Beam down button or Beam up button respectively. The beam
travel will stop if the button is released. Pushing the button again, the
beam will continue to travel as long as the button is pushed on.

Inching operation is NOT the fundamental working mode of the machine,

and should be used only for making the beam travel up or down for blade
gap adjustment and fine adjustment of top blade.

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B. The beam is in lower position than top-most stroke:

All settings and cutting procedure are as in section A. Only difference is

the stroke adjustment.

Stroke adjustment: Select a value between 0 and 8 (including 0 and 8) in

the stroke timer by pushing on the small button on it.

This timer controls down movement of the beam and stops the movement
before the beam wouldn’t reach to the bottom limit switch shown in
Figure 6.5.2.3.d
! The stroke timer is used for selecting the plate length to be sheared.

For inching and cutting operation, repeat the procedure explained in

section A.

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6.5.5. Blade Gap Adjustment
A. Manual Blade Gap Adjustment

Blade gap adjustment on the shear is necessary to obtain a perfect cutting quality.

Blade gap is adjusted by means of the steering handle shown in Figure 6.5.5.1 located
on the left hand side of the machine:

Figure 6.5.5.1 Figure 6.5.5.2

1 Pull up the fixing spindle shown in Figure 6.5.5.2 so that the steering handle is
free for adjustment.

2 Set the handle shown in Figure 6.5.5.1 to required material thickness utilizing the
pointer (the black arrow directed downward) and the thickness scale (the scale on
the steering handle center indicating numbers from 1 to 4).

3 Retighten the fixing spindle shown in Figure 6.5.5.2.

4 To set the correct gap between blades, refer to the blade gap chart labeled on the
machine.

B. Motorized Blade Gap adjustment

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Blade gap adjustment on the shear is necessary to obtain a perfect cutting quality.

Blade gap is adjusted by means of the digital controller on the control panel as shown
in Figure 6.5.5.3 below

(a) (b) (c)

Figure 6.5.5.3

1 Enter required material thickness by using Up/Down keys on the digital

controller (See in Figure 6.5.5.3.a and Figure 6.5.5.3.b)

2 Then, press RUN key to set correct gap between blades (See in Figure 6.5.5.3.c).

If the motorized blade gap adjustment fails for any reason, the
NOTE: manually blade gap adjustment can be used temporarily.

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6.5.6. Adjustment of back-gauge range (Adjustment of cutting width)

Your shear is equipped with a power back-gauge system. Its range can be set by
entering the desired amount to the digital control unit on the electrical panel. It is also
possible to set the range manually using the pushbuttons Backgauge forward button
and Backgauge backward button on the control panel. In HGL machines three type
digital controllers, namely PRG 911, Elgo 9521 and S3 are used. These controllers
are explained below

PRG 911

Position and repetition

Display Cycle Display Program Display

Figure 6.5.6.1

Keys and Functions:

KEY NAME DESCRIPTION

Jog + Fast forward jogging key

Jog – Fast reverse jogging key

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Jog + Slow forward jogging key

Jog – Slow reverse jogging key

Start Start key to start the movement

Stop Stop key to stop the movement

Enter and Enter and Semi-automatic mode

Semi-automatic mode selection key
selection

Automatic mode Automatic mode selection key

selection

Programming mode selection key

Programming

Inch-metric Inch-metric selection key

selection

Deviation
Deviation

Manual Mode:

When machine is switched on, PRG 911I is ready for manual mode. In this mode,
only position display is active. The back-gauge movement can be controlled by means
of four jog keys (Jog + fast, Jog – fast, Jog + slow, Jog – slow). This mode is not an
operating mode. You should use jog keys for service operations such as observing
back-gauge movement, checking limit switch activity and measuring positioning
correctness.

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Semi-automatic mode:
When you select the semi-automatic mode in the digital controller, you can
operate the machine in single and continuous cutting mode.

1. In order to work with this mode;

Press the semi-automatic selection button (enter button at the same

time) shown in Figure 6.5.6.2. The small led on the upper left corner of the
key will lit up. The position display starts flashing and shows 0000.0 which
means it is ready to read any numerical value among limit conditions from
keyboard. That is you can write the plate width to be sheared.

Figure 6.5.6.2

2. After writing back-gauge position value (it means plate width) shown in
Figure 6.5.6.3, you can enter repetition value. Repetition means how many
plates you will cut. To do so;

a. Press the key again. Position (or repetition) display shows

the value 01. You can write any value between 01 and 99 which
means you can cut as many parts as up to 99.

! If you select continuous cutting mode by working mode selector

switch, you cut all plate parts by pressing the pedal continuously (without
releasing the pedal).

If you select single cutting mode by working mode selector switch, you
cut all plate parts by pressing the pedal sequentially (one after another).

b. If you want a single cut, write 01 for repetition value.

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Figure 6.5.6.3
Writing position value

Figure 6.5.6.4
After writing position value, press the key and enter repetition value.

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3. After entering position and repetition values, press start key (see
Figure 6.5.6.5). As soon as pressing the start key, the back-gauge will begin
to move to the entered position and at this moment the position display will
begin to show changing values. Furthermore the small led on the upper left
corner of the start key will lit up. Finally the back-gauge will arrive at the
position and stop. After that moment, you can press the footswitch and cut the
material.

Figure 6.5.6.5
After entering position and repetition values, starting the back-gauge movement.

!
If positioning DOES NOT occur within the limits of tolerance entered in
parameters, PRG 911I will try and try again at most three times to
perform it. After the last attempt if it does not achieve to perform
positioning, the led on the start key will begin to flash which means a
problem exists.

Automatic mode:

In automatic mode, it is possible to execute the programs previously

stored. You can also operate the machine in single and continuous cutting
mode when you select the automatic mode in digital controller. Before
explaining automatic mode, you should understand programming
principles of the controller completely.

Programming of the digital controller:

1. Press the programming key . The led on the key will lit up and the
program display will show the first empty program number. Press enter
key. You will see 0000 in position display and 01 in the cycle display.

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Figure 6.5.6.6

2. If you want to change the program number, write new program number by using
numerical buttons and press the enter key (see Figure 6.5.6.7).

If entered program number shows a empty program (programmable section), the

! led on the programming key will begin to flash.

Thus while the position display will indicate 0000.0, cycle display will indicate
01 (see Figure 6.5.6.7).

Figure 6.5.6.7

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3. Write the position using numerical keys and press enter key.

! If you make any mistake when writing the position, press zero key
sequentially (toggle) and so set all digits to 0. Write the position again and
press the start key.

Figure 6.5.6.8

4. Now the position display indicates repetition value 01. Write a repetition value
using numerical keys and press the enter key.

! You can write any number between 01 and 9999 for repetition value. But it
does not exceed 9999.

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Figure 6.5.6.9

Figure 6.5.6.10

5. After writing the repetition and confirming with the enter key, you will see 02
in cycle display which means you are in second cycle of the programming
procedure. If you want to continue programming, repeat the items 1,2,3,4 and
so on.

! You can write 20 cycles at most.

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Figure 6.5.6.11

Write the position value of the second cycle. Press enter.

Figure 6.5.6.12

Write the repetition value of the second cycle. Press enter.

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Figure 6.5.6.13

You will see the third cycle of your program. You can continue up to the
20th cycle.

Figure 6.5.6.14

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OR !

Figure 6.5.6.15

6. If you want to finish programming, press the programming key. Thus the
led on the key will stop flashing and the position display will indicate the first
position you have written in the cycle 01.
Now you are in the program reading phase.

By pressing enter key, you can see all positions, repetitions and cycles
you have written.

If you want to change any position;

! a. Using the enter key, select the position or repetition in any cycle.
b. Press the programming key . The display will begin to flash
c. Write the new value.
d. Press enter key.

If you want to cancel the program;

a. Using enter key, select the repetition in the first cycle.
! b. Press the programming key
c. Write 00 for repetition
d. Press enter key.

If you want to cancel one or more cycles, in that cycle, press the
! programming key and write 00 for repetition value. Press enter key

7. Congratulations!!! You have finished writing program.

Press stop key. You will see the next empty program (programmable

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section no or program no). If you want to exit programming, press stop
key again. Thus PRG 911I will be back to the manual mode.

8.
Warning!!!
In order to delete all program memory (all of the programs), in
programming mode, press the programming key for 5 sec. PRG 911I will
start deleting all the programs.

Operating the machine in automatic mode:

1. Press the automatic mode key in manual mode. Now the digital
controller is in the automatic mode. The led on the automatic mode key will lit
up and the program display indicate the last executed program.

Figure 6.5.6.16

2. Write the desired program number by using numerical keys and press enter
key. The controller is ready to execute the program you have written before.
You will see the position of the first cycle of the program in the position
display.

! If you press enter again, you will see the second cycle. If you go on
pressing enter key , you will see the next cycle and so on.

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Figure 6.5.6.17

3. Press start key. Positioning will start.

While you are visualizing the cycles as in the item 2 above, if you press start
! key in any cycle of the program, the positioning will start from that cycle
(current visualized cycle).

Figure 6.5.6.18

4. If you press the automatic mode key before pressing start key or during
positioning, the led on the automatic key will start flashing. It means that your
program will start again automatically after execution. That is an infinite
execution loop will exist. In order to exit of this endless loop, press the
automatic key again. Thus you will see that the led on the key will stop flashing
and after execution the controller will finish the program.

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Figure 6.5.6.19

Figure 6.5.6.20

5. Cutting…
After positioning is completed, you can start cutting procedure explained in
section .

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Elgo P9521

LED 1 Actual Position Display

LED 2
Demand Position
Display

LED 3,4,5 Quantity Display

Absolute/Incremental
Display
Adress Display

Figure 6.5.6.21

Key Description

Pressing this button, will sequentially select Single, Manual or

Programme mode. Depressing this button for 3 sec will switch the
controller from Operation to Parameter setting mode.
The Cursor Button will :-
In Prog mode selects: Address
Absolute/Incremental
Quantity
Functions
In Parameter setting mode selects alternately and sequentially
Parameter Number
Parameter Value
For Jog operations Slow backwards

Clears selected function or parameter value.

Also clears Demand Value in Single and Programme modes

Start positioning action. Start is inactive in Parameter setting mode and

manual mode.

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Stop positioning action. In programming mode, sets end-of-

programme.

Fast backwards (For Jog operations)

Fast forwards (For Jog operations )

Slow forwards (For Jog operations)

Displays:

1. Actual Position Shows the actual position of the axis

2. Demand Position Shows the required position you can enter

Shows how many pieces are left to be cut or how
3. Quantity many incremental moves yet to be completed

4. Adress Number Shows which adress is operating

Indicates condition of Demand position
If ;
5. Absolute/Incremental 0 = Absolute value
1 = Incremental +ve value
2 = Incremental –ve value
Negative sign symbol and also illuminates when
6. LED 1 Parameter entry mode selected
Illuminates when Demanded position or Parameter
7. LED 2 input can be entered
Illuminates to indicate function Single/Manual/Prog
8. LED 3,4,5 as selected by Button F

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Using the controller

Manual mode:

1. Press the key sequentially and select manual mode (see Figure
6.5.6.22). When LED 4 lit up, you will be in manual mode.

Figure 6.5.6.22

2. Use the keys , , , for jog operation (see Figure

6.5.6.23)

Figure 6.5.6.23

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Single mode:

1. Press the key sequentially and select single mode (see Figure 6.5.6.24).
When LED 3 and LED 2 lit up, you will be in single mode.

Figure 6.5.6.24

2. Using the numerical keys, enter the position (plate width) into Demand
Display (see Figure 6.5.6.25)

Figure 6.5.6.25
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3. Press the start key so that positioning can take place. (see Figure
6.5.6.26)

Figure 6.5.6.26

Programming mode:

1. Press the key sequentially. When the LED 5 lit up (see Figure
6.5.6.27), you will be in programming mode.

Figure 6.5.6.27

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2. Write 0 to the address display (All programs always start at 0) (see Figure
6.5.6.28). You have 10 addresses at most in your programs. The biggest
program starts from address 0 and ends at address 9. You don’t have to
program all addresses. At first, start from address 0 and end at any address. It
depends on your needs.

Figure 6.5.6.28

! If you need to delete some data in any display, use the cancel button .

3. Press the cursor button . A/I (Absolute/Incremental) display will flash

(see Figure 6.5.6.29). Using numerical keys write (see Figure 6.5.6.30);
0 = Absolute
1 = Incremental +ve
2 = Incremental –ve

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Figure 6.5.6.29 Figure 6.5.6.30

4. Press the cursor key to select the quantity display (see Figure 6.5.6.31).
When the quantity display flashes, write the plate quantity to be cut.

! If you need to delete some data in any display, use the cancel button .

Figure 6.5.6.31 Figure 6.5.6.32

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5. Press the cursor key to select the Demand position display (see Figure
6.5.6.33). When the Demand display flashes, write the position (plate width).

! If you need to delete some data in any display, use the cancel button .

Figure 6.5.6.33 Figure 6.5.6.34

6. Press the cursor key to select the address display (see Figure 6.5.6.34).
When the address display flashes, write the new address (the second address is
1).

7. Continue programming procedure explained in items 2,3,4,5 above.

8. At the end of your program, press stop key to end the program at that
address.

9. After programming procedure ends, press start key. Your program will
begin to be executed from the address 0. Thus you can apply cutting methods
explained in section.

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NOTE:
Programming of the digital controller ELGO-9521 is executed in position II (PROG.)
of the switch which is located inside the electrical panel. Position (I) also enables
programming with the additional facilities for fixing and storing the program. For the
reference or ″zero-setting″ procedure the (REF.) button on the right hand side of the
(PROG.) button is used.

Figure 6.5.6.35

S3 Position Controller

Position and Quantity

Display

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Figure 6.5.6.36

Key Description

Set key display shows

Quantity counter set key

Calibration Key

Clear key

Start and Enter key

Stop and Cancel key

How to position the back-gauge

1. Press set key. The display will show 00000.

2. Write desired position to the display by using numerical keys.

3. Press start key. The back-gauge will move the desired position.

How to enter quantity

1. Press set key. The display will show 00000.

2. Write desired position to the display by using numerical keys.

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3. Press count key. Display shows 000.

4. Write desired quantity to the display by using numerical keys.

5. Press start key. The back-gauge will move the desired position.

6.5.7. Adjustment of cutting length

(a) (b)
Figure 6.5.7.1

Use the stroke timer on the control panel to adjust the cutting length.(Between
0-9, while 9 is the full length).

In order to increase cutting length, press the upper small button on the timer
1.
(see Figure 6.5.7.1.a)

To decrease cutting length, press the lower small button on the timer (see
2.
Figure 6.5.7.1.b)

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6.5.8. Illumination facility

Figure 6.5.8.1

For shadowing the cutting line, you can make use of the illumination switch on the
control panel which activates the florescent light inside the machine frame.

.5.9. Cutting speed adjustment

Figure 6.5.9.1

The timer inside the electrical cabinet actually sets the waiting time of the beam at top
position. If you decrease the waiting time at the top, the beam will make more up-down
movement in a minute. Thus you will increase the cutting speed.

TIM-2: Timer for waiting time of holddowns in top position could be adjusted with this
button.

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6.6. Maintenance & Inspection:

General maintenance and cleaning of the shear requires careful

! attention. Therefore the machine must be shut-off before starting
any maintenance work.

6.6.1. Type and frequency of inspections

Inspection Period Responsibility

Lubrication See: Lubrication Diagram

Operator

Lubrication of blades
Daily Operator

Guards against any physical

damage Daily Operator

Blade fixing bolts against

loosening Weekly Operator

Oil leakage in cylinders

Weekly Operator

Oil leakage in pipes, hoses and

hydraulic elements Weekly Operator

Hydraulic fluid level

Weekly Operator

Cylinder connections bolts

against loosening Weekly Operator

Safety & limit switches

against loosening, damage Weekly Operator

Terminal connections of the

electrical installation Annually Electrician

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6.6.2. Hydraulic System

All precautions must be taken to keep the hydraulic system clean at all circumstances.

6.6.3. Changing oil

OIL LEVEL INDICATOR COVER

Figure 6.6.3.1

1. Remove the oil tank cover after pulling out the screws.

2. Using an appropriate pump, drain out the old oil completely. Be sure nothing is
left

3. Using a pump or proper equipment, fill in new oil from the same place.
Oil level must be seen in the middle of the oil indicator. Observe the oil level
from this indicator. Always keep the oil in same level.

When changing oil, keep the oil thank clean.

!

! Oil must be changed after first 200 working hours of use, and then every 1000
working hours. (See: Lubrication Diagram).

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6.6.4. Changing the filter

COVER
Figure 6.6.4.1

1. Remove the cover on the oil tank after loosing and pulling out the screws.

2. Remove the old filter from its place inside oil tank by turning in CW.

3. Fix the new filter into its place by turning in CCW.

! The suction filter element must be changed after first 200 hours of use, and
then every 1000 working hours.

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6.6.5. Re-adjustment of back-gauge (See spare parts list)

Back--gauge stop must be parallel to the table, and this is provided in the factory. If
for some reason (e.g. transport), the parallelism is lost, set it again as follows (see
spare parts list no.26 for back-gauge):

LEFT RIGHT

Adjustment bolt ( part number 26-31)

Set screw (part number 26-32)

Figure 6.6.5.1

In case of existing a difference on one of the sides (left or right), loosen the set screw
and adjust the parallelism by turning the back-gauge bolt (see Figure 6.6.5.1).
Tighten the set screw.

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6.6.6. Changing the blades (see spare parts list)

!
To change the blades in a safe manner, at least TWO operators are
required.

The procedure for changing the blades is potentially dangerous as operators

fingers or hands can be cut. Therefore, leather-working gloves must be worn.
!

!
DO NOT touch the pre-adjusted limiting nuts and bolts
(11-23 and 11-24). Otherwise the blades may overlap.

!
DO NOT touch the fine adjustment nuts and bolts
(11-29 and 11-30) for any adjustment.

6.6.6.1. Changing the top blade:

• Lift the cutting beam to uppermost position.

• Set the backgauge to maximum distance.

• Turn off the main switch and lock it up.

• Remove the finger protection grid and shadowing wire.

• The operator and co-operator should be at the rear side of the shear.

Take out all blade fixing bolts (11-25 in spare part list and see in Figure
6.6.6.1 below), EXCEPT one bolt on each of the edges. Slightly loosen these
•
bolts on the edges.

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Top blade fixing bolts

Adjustment Bottom Blade

nuts
Figure 6.6.6.1

! DO NOT loosen the edge bolts excessively, as otherwise the blade may fall
down causing injury.

The operator and co-operator should hold the blade with one hand, while
• taking out the edge bolts completely with the other hand. The blade can now be
taken away.

NOTE: In re-fitting the top blade, the above procedure is applied in reverse
order.

6.6.6.2. Changing the bottom blade:

• Lift the cutting beam to uppermost position.

• Set the backgauge to maximum distance.

• Turn off the main switch and lock it up.

• Remove the finger protection grid and shadowing wire.

• Take out all blade fixing bolts (see in Figure 6.6.6.2) under the table in front of
the machine, EXCEPT one bolt in the middle.

• One of the operators, at the rear of the machine, should hold the blade in its
place.

• The other operator, in the front of the machine, should take

out the center bolt and go to the rear of the machine.

• The operators should hold the blade by the edges, and take it away.

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NOTE: In re-fitting the bottom blade, the above procedure is applied in
reverse order.

Bottom Blade
Fixing Bolts
Figure 6.6.6.2

TO REMEMBER:

! It is recommended that top blade is not removed before bottom

blade is removed.

! It is recommended that bottom blade is not re-fitted before top

blade is re-fitted.

! Before re-fitted the blades, the blade housings and surfaces

should be cleaned thoroughly.

If the blades are to be re-fitted after sharpening, the position of blade

NOTES: a) gap adjustment scale must be rearranged by means of adjusting bolts
and nuts (11-23 and 11-24 in spare part list). This position is
determined by blade gap adjustment procedure with the shear working
in ″inching″ mode.

b) If the blades are excessively sharpened, the above rearrangement will

not be possible. In this case, take out the bolts (11-05) and remove the
geared plates on both sides. Rotate the both eccentric pivot pin (11-01)
by a rod as much as necessary to adjust the blade gap using a ″filler
gauge″. Align the geared plate (11-04) on the suitable holes of the
eccentric pivot pin (11-01) and fix it by means of the bolts (11-05).
Then correct the scale position.

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6.6.7. Fine adjustment of top blade (see spare parts list)

Prior to dispatch from the factory, top blade of your shear has been fine-
adjusted by means of the nuts and bolts (11-29 and 11-30 in spare part list or
see in Figure 6.6.7.1).

Unless necessary, these nuts and bolts (11-29 and 11-30) should be
! left untouched.

If the pre-adjusted positions of the (11-29 and 11-30) nuts and bolts have been
changed for some reason, or in cases where it is not possible to obtain burr-free
cuts in the center of the machine (tough on the edges the cut quality can be
burr-free), a fine adjustment of the top blade is necessary.

The procedure below must be followed:

Fine adjustment of top blade is a hazardous procedure, which

! necessitates two qualified operators, and utmost care and attention.
Otherwise, the operator may cut his hand.

One of the operators should be at the rear side of the shear by informing
the other operator.

During this procedure the operator behind the machine must be in

! charge for giving all the instructions to operate the machine.

Switch on the machine, and lift up the cutting beam to uppermost position in
a) ″inching″ mode.

b) Set the blade gap lever to 1 mm on the thickness scale, which should
correspond to a gap of 0.1mm between top and bottom blades.

c) Move down the cutting beam such that top and bottom blades are edge to edge
on the left-hand side of the machine. Check the blade gap again by a filler
gauge and make sure that the gap is 0.1 mm by means of the blade gap
adjustment lever.

d) Repeat the procedure in (c) on the right hand side of the machine.
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e) Lift up the beam.

f) Move down the cutting beam such that top and bottom blades are edge to edge
on the left side where the first adjusting bolts are. Check the blade gap by a
filler gauge. If the gap is greater than 0.1 mm, loosen up the blade fixing bolts
(11-25).Push-in the fine adjusting bolts (11-29) to obtain a blade gap of 0.1
mm and tighten the nuts (11-30). Re-tighten the bolts
(11-25). If the gap is smaller than 0.1 mm, loosen up the nuts (11-30) and the
bolts (11-29). Screw up the blade fixing bolts (11-25) to obtain a blade gap of
0.1 mm. Tighten the bolts (11-29) and the nuts (11-30).

Top blade fixing bolts

Adjustment nuts

Figure 6.6.7.1

g) Repeat the procedure in (f) for all fine adjusting bolts alongside the blade
length from left to right.

h) Test the cut quality by shearing a 1 mm thickness material. Where the cut is not
burr-free alongside the blade length, repeat the procedure in (f) to attain a fine
shearing quality.

Make sure that the blades do not overlap, when fine-adjusting the
top blade.

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6.6.8. Lifting Cylinders (see spare parts list)

This is shown in the spare parts list as number (15A).

Lifting cylinders must be checked periodically against any gas leakage.

Pressure must be checked regularly to be at 35bar.

To refill the lifting cylinders SEE (Sec.7 Page 11/15). Before refilling gas in
the cylinders, fill in 50gr hydraulic fluid to prevent seal from damaging.
Both lifting cylinders must have the same pressure at 35 bar.

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6.7. TROUBLESHOOTING

PROBLEM POSSIBLE CAUSES CORRECTION

• Blade gap is misadjusted • Re-adjusted blade gap

a) Sheared material is burred
• Blade edges are blunt • Sharpen blades

b) Beam does not descent • Pressure relief valve is • Clean valve

(Very little or no pressure in blocked
• Change valve
cylinder) • Failure is pressure relief
• Clean valve
valve
• Directional valve is • Change spool
blocked
• Change valve
• Spool of directional valve
is burnt • Clean filter

• Failure in directional valve • Check pump, replace if

• Suction filter is blocked necessary
• Failure in pump • Find out where leakage is
• Leakage in pipes or and repair
cylinder

c) Beam does not ascend • Low pressure in lifting • Refill gas (See spare part list)
cylinders
• Replace rod seal and refill gas
• Leakage lifting cylinders

d) Oil leakage under cylinder • Piston seal is torn out • Change seal

e) Oil leakage in fittings • Fittings are loose • Tighten fittings

f) Oil leakage in holddowns. • Holddown seals are torn • Change seal or seals
out
• Change o-ring
• O-ring is damaged

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6.8. Conditions of storage, re-utilization and scrapping:

6.8.1. Storage

In cases where the machine is not be used for a long period of time, the
following precautions must be taken:

• Disconnect electrical supply to the machine, and write so on the electric panel
as a reminder for future use.

• The storage place of the shear must be indoor with protection against humidity,
dust, and danger of fire.
• Lubricate top and bottom blades by an anti-rust lubricant.
• Empty the oil the tank.
• Lubricate pistons and all metal surfaces by an anti-rust lubricant
• Lubricate plastic hoses against cracking.

• Cover the machine by a nylon cover for protection against dust.

6.8.2. Re-utilization after storage

Take the following steps if the shear is to be re-utilized after a long period of
storage:

• To use the old machine oil, make sure that the physical and chemical properties
of the liquid is intact. This should be verified by an expert body. Otherwise, fill
the tank with new oil.

• All electrical components must be checked by a qualified electrician to make

sure that all of them are properly functional. Replace the faulty components.

• The machine body and mechanical parts must be checked through by

authorized and qualified personnel, and the machine must be prepared for
operation according to the operating instructions.

6.8.3. Scrapping

If the shear has completed its normal operating life, prior to scrapping all the oil
in the tank and cylinders should be drained off, and the machine should be
dismantled.

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7. LUBRICATION DIAGRAM

3 2
3
2

1 1

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3) LUBRICATION OF THE PISTON

ARM HOUSINGS:

3.1- Make sure that the beam is at the top position.

3.2- Take the bolts (M) and the cover (N).
3.3- Move the beam downward manually until the
lubricator on the piston arm is seen by the
operator.
3.4- Switch off the main switch. 3
3.5- Grease the areas between piston - piston arm
and piston arm - top beam from the lubricator
(3) on the piston arm by using grease gun. (If
the lubricator is not in the correct direction, turn N
the piston arm by using a wrench.)
M

NUMBER OF OIL TYPE

PLACE OF NO LUBRICATION PREFILLED IN EQUIVALENT LUBRICATION
LUBRICATION SPOTS FACTORY OIL TYPES PERIOD

BACK-GAUGE 1 2 DIN 52 825 / K2K BP ENER GREASE C2 2-7 Days

NUT
ECCENTRIC 2 2 GREASE No.2 BP ENER GREASE C2 60 Days
HUB
PISTON ARMS 3 2 GREASE No.2 BP ENER GREASE C2 90 Days
t<10 ˚C – HLP 32 RANDO OIL 32
MUST BE CHANGED
OIL TANK 4 1 TELLUS 32
AFTER FIRST 200
WORKING HOURS,
t>10 ˚C – HLP 46 RANDO OIL 46 NEXT CHANGE :
TELLUS 46 AFTER 1000
WORKING HOURS.
t>30˚ C – HLP 60 RANDO OIL 68
TELLUS 68

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APPENDIX
A. SPARE PART LIST

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B. HYDRAULIC CIRCUIT DIAGRAM

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C. ELECTRIC CIRCUIT DIAGRAM

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ADDITIONAL MANUALS

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