SAFAN HT Book 3, Transportation, installation and starting up

BOOK 3
Transportation, delivery, installation, starting up,
dismantling and technical data

Contents page
3.1 Transportation .........................................................................................2
3.1.1 Vertical transportation: Lifting..................................................................2
3.1.2 Horizontal transportation: Sliding ............................................................2
3.2 Delivery....................................................................................................3
3.3 Technical data .........................................................................................4
3.3.1 Specifications: .........................................................................................4
3.3.2 Floor plan of working and maintenance space........................................6
3.3.3 Specifications ..........................................................................................7
3.3.4 Noise nuisance/safety .............................................................................8
3.4 Setting up.................................................................................................9
3.4.1 Preparing the floor, anchoring systems...................................................9
3.4.2 Mechanical assembly, part 1.................................................................11
Electrical assembly, part 2...............................................................................11
Assembly, part 3 ..............................................................................................13
3.5 Start-up ..................................................................................................14
3.5.1 Start-up report .......................................................................................14

List of illustrations:

Figure 51 Lifting angle a < 90°...........................................................................2

Figure 52. Main dimensions and foundation sizes ............................................4
Figure 53. Dimensions for working and maintenance space in mm..................6
Figure 54: "Airloc" levelling shoes .....................................................................9
Figure 55 Chemical anchor with “Airloc” damping plate..................................10
Figure 56. Chemical anchor with steel foundation plate..................................10
Figure 57: Inside of control cabinet .................................................................11
Figure 58. Components of rear protection system ..........................................12

See page IV of Book 1, User Instruction Manual, and the rating plate on the control cabinet
for the exact model.

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Book 3, Transportation, installation and starting up SAFAN HT

3.1 Transportation
NB:
- Never lift and transport the machine with a fork-lift truck.
- Handle the machine with extreme care on inclines; the transportation method
described is for flat, horizontal floors only.

3.1.1 Vertical transportation: Lifting

Method:
1. There are crane hooks in the front crossbar (see figures 1 and 2, and table of main
dimensions).
Lift the machine with these.
2. Attach a cable or chain of a length such that the angle (a) between the two parts of the
chain or cable is less than 90° during lifting.
This will avoid deformation caused by horizontal reactive forces on the frame.
- See section 3.3.1 for the distance between the crane hooks and the machine weight.

Figure 51 Lifting angle a < 90°

3.1.2 Horizontal transportation: Sliding

Note the following rules for horizontal transportation:
1. Place the side frames of the machine on steel beams.
2. Place rollers (steel pipes etc.) under the steel beams. Instead of steel beams with
rollers, heavy-duty transportation rollers (transportation tanks) can be used.
3. Make sure the floor is flat and horizontal. If it is not, anchor the machine with winch
cables.
4. Move the machine with the rollers under the steel beams.
See section 3.3.1 for machine dimensions and weights.

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SAFAN HT Book 3, Transportation, installation and starting up

3.2 Delivery
Delivery report

Check the machine on arrival for:

1. damage and faults
Ask the forwarder to compile a transport damage report on delivery if necessary.
2. full supply of all parts and accessories ordered.

Always contact SAFAN B.V. directly in case of damage or faults.

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3.3 Technical data

3.3.1 Specifications:
Main dimensions, foundation data and weights
NB: See the front page of this manual and the rating plate on the control cabinet
for the exact model.

1705 N
G
S

Electrical wire entry point

Pneumatic pipe entry point

T

F
Jmin
T

C
Q

E
K
P

950 H Z
L
B

Type of foundation, anchoring system, see par 3.4

Figure 52. Main dimensions and foundation sizes

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SAFAN HT Book 3, Transportation, installation and starting up

Model Transport Foundation

Number total transport min crane total width front to depth incl. side protection device rear stop min. free floor beam free floor weight
Machine wxdxh depth. hooks depth edge front edge width x depth depth width space space
B x (E+F@) x H E Z C L P Q# NxS F@ G$ J min K kg
HT 255-13 3650 x 2520 x 2500 1685 1500 3330 2860 100 1590 2880 x 3245 835 2700 615 nihil 10.500
HT 310-13 4200 x 2520 x 2500 1685 1500 3330 3410 100 1590 3430 x 3245 835 3250 615 nihil 12.500
HT 430-13 5400 x 2520 x 2500 1740 2800 3330 4610 100 1590 4630 x 3245 780 4450 615 nihil 18.500

HT 255-16 3650 x 2520 x 2500 1685 1500 3330 2860 100 1590 2880 x 3245 835 2700 615 nihil 10.500
HT 310-16 4200 x 2520 x 2500 1685 1500 3330 3410 100 1590 3430 x 3245 835 3250 615 nihil 12.500
HT 430-16 5400 x 2520 x 2500 1740 2800 3330 4610 100 1590 4630 x 3245 780 4450 615 nihil 21.500

Q#: Distance from foundation to front edge of cutting table; all dimensions Q and S measured from front edge of cutting table.
F@ : With an extended rear stop of 1,250 or 1,500 mm, F@ becomes 905 or 1155 mm.
G$: Free space between posts of rear protection system.
J min: Minimum clearance between floor and rear stop beam.
K: Minimum clearance between floor and lower beam.
T: Foundation holes in rear protection system; these must be marked and drilled during installation.

During hoisting the machine needs 250 mm more space at each side than the dimensions in the table

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3.3.2 Floor plan of working and maintenance space

The working space for the machine operator and for maintenance is given in fig. 3.

1000

F
C
E
P P

R
Q

500
500

Figure 53. Dimensions for working and maintenance space in mm.

Measurement line Mode (sizes in mm)

P Space next to cylinder caps 750 750

Q On left in front of cutting table Maximum sheet length or length of right-angle
guide
R On right in front of cutting table Maximum sheet length or length of support arms

The shaded area indicates the working space around the machine.

NB:
- If sheet material with a larger size than the machine’s maximum cutting length is cut,
working space dimensions Q and R must be adjusted.

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SAFAN HT Book 3, Transportation, installation and starting up

3.3.3 Specifications
Cutting capacity, cutting angle, main motor, oil tank, rear stop area, oil pump, filter, setting
and working pressure, model of linear guide, connecting cables.

Model Capacity sheet FE360 Cutting Main motor Oil tank Rear stop
Length x thickness angle connection capacity, range length
mm x mm min-max° rating kW litres * mm
HT 310– 3100 x 13 0.5 – 3.0 30 250 1250
13
HT 310– 3100 x 16 0.5 – 3.0 30 250 1250
16
* Optional: 1250 and 1500 mm lengths available.

General information:
Maximum working pressure: 300 bar
Main motor: 30KW: max. speed: 1420 r/min
Oil pump:(30KW) Voith, type IPV 5-40 (double pump)
Filter: MANN W962
Cutters, no. of cutting edges: 4
Linear guide: TLH 450 (13 and 16mm)

Cable diameters and fuses:

Supply voltage Rating of main motor Motor current Cable diameter † Fuse ‡
Volt (+/- 5%) KW pk A qmm Max. A,
inert
3x 440 30 40 58 16 80

† Cable diameter is given per core for maximum main motor current with multi-core insulated copper
wiring (3 phase + N + earth), valid for a maximum length of 20 metres. Consult Safan if longer
lengths required.
‡ The fuse given is the maximum for the cable specification given.

This technical data is for information purposes only; it should therefore not be regarded as
binding.

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3.3.4 Noise nuisance/safety

MEASUREMENT REPORT
Compilation and reference model
Measurements were taken on the standard version of the machine, model HT 310-6.
Foundation: concrete floor.
Surround: plexiglass wall 1.7m high 1 metre behind the machine

Cutting cycle: unloaded state (cutting movement without sheet): 74.4 dBa
Cutting cycle: maximum load (cutting movement with 1 mm steel sheet): 84.5 dBa

Ear protection is essential for personnel present at the machine.

When the sheet has been cut it falls to the floor. This causes a loud noise depending on the
dimensions of the sheet and the kind of floor.

Advice:
Wood, plastic or rubber strips on the floor behind the machine will dampen the volume of
noise produced by falling sheet cut-offs.

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SAFAN HT Book 3, Transportation, installation and starting up

3.4 Setting up
3.4.1 Preparing the floor, anchoring systems
Place the machine on a good foundation and anchor with four anchors.
It is not permitted to use the machine if it is not permanently anchored.

Requirements for floor and foundation:

1 Floor must be made of one single slab.
2 Floor must be flat and free from obstacles.
3 Floor load: maximum pressure reached per foundation is 1/3 machine weight.
4 Horizontal. If it is not horizontal, compensate with filler strips in the foundation. The
machine must be installed level in order for the cutters to be properly adjusted.

Pay attention to:

1 the weight of the machine for the floor load: see specifications, section 3.3.1.
2 propagation of vibrations; see section 3.4.1.1 for choice of anchoring system.
3 generation of noise; see section 3.3.4 for countermeasures.

Anchoring systems
(See also Chapter 3.3.1)
U: "Airloc" levelling shoes

Figure 54: "Airloc" levelling shoes

Pos. Description Version

1 Insulation ring
2 Machine footplate
3 Airloc levelling shoe type 213-VR/O

4 Anchoring rod
Dimensions mm M16 x 300
Capsule Safan no.: 210.651.087
5 Cup springs

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V: Chemical anchor with “Airloc” damping plate

Figure 55 Chemical anchor with “Airloc” damping plate

Pos. Description Version

1 Adjustment bolt on machine
2 Machine footplate
3 Steel foundation plate Safan no.: 663.000.170
... dimensions mm 150 x 130 x 10
4 Anchor rod Safan no.: 210.650.178
.... dimensions mm M16 x 250
Capsule Safan no.: 210.651.087
5 Airloc damping plate* Safan no.: 663.000.675
Type 4.17.4; 130 x 150 x 16
dimensions mm

W: Chemical anchor with steel foundation plate

Figure 56. Chemical anchor with steel foundation plate

Pos. Description Version

1 Adjustment bolt on
machine
2 Machine footplate
3 Steel foundation plate Safan no.: 663.000.170
... dimensions mm 150 x 130 x 10
4 Anchor rod Safan no.: 210.650.178
.... dimensions mm M16 x 250
Capsule Safan no.: 210.651.087

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SAFAN HT Book 3, Transportation, installation and starting up

3.4.2 Mechanical assembly, part 1

1 Determine where the machine is to be set up. See section 3.3.1, “Main dimensions
and foundation sizes” and section 3.3.2, “Floor plan of working and maintenance
space” for specifications and size of the space required and exact dimensions.
2 Mark out the foundation holes on the floor. See section 3.4.1.1 “Anchoring systems”
for information on the foundation to be used. Make sure the holes are at right-angles!
3 Before placing the machine on the floor, drill the foundation holes in the floor.
4 Place the foundation plates over the drilled holes in accordance with the instructions in
section 3.4.1.1.
5 Remove the cladding (cylinder and table caps).
6 Place the machine in the right position so that it does not have to be moved again.
7 Insert the anchors in the foundation holes. Do not tighten the anchors yet.
8 Level the machine with the adjustment bolts in the foot plates or the levelling shoes.
- Place the spirit level on the levelling surface on the top beam (see Book 2, section
2.1.1) on the left and right-hand sides of the machine.
- Place the spirit level in the middle of the machine on the table for horizontal levelling.
- Check that all four foundation points are resting properly on the foundation
plates.

NB: If the machine is not level, the frame may twist, causing damage to the cutters when a
small clearance is set.
9 Tighten the anchors.
10 Check that the machine is level and adjust if necessary.
11 Replace the cladding on the machine.
12 Detach the control cabinet from the transportation strips and place on the floor.
13 Fit the vibration absorbers between the control cabinet and the transportation strips.
14 Determine where the side protection system is to be installed; see section 3.3.1, “Main
dimensions and foundation sizes”.
15 Mark out the foundation holes on the floor.
16 Drill the foundation holes.
17 Level the side protection supports with the adjustment bolts.
18 Check the oil level in the tank: max. 7 cm below the rim. For transportreasons a
paperwad is fitted in the tankcap. Please remove.

Electrical assembly, part 2

NB: The electrical connection must be carried out by a qualified company. Damage
caused by improper connection is not covered by the guarantee.
19 Before connecting the machine, check the input voltage on the transformer against the
mains voltage; connect the transformer to the right terminals if necessary.
20 Connect the control cabinet:
The bushing for the mains cable is in < Connections on main switch
the top of the control cabinet (see fig.
T1, T2, T3
52).
See section 3.3.3 for
cable and fuse specifications.
The connection points are:
- T1, T2, T3: at the top Transformer v
1
- Earth: connect to the earth connection
(PE) marked on the base plate of the
cabinet.
- neutral (if necessary depending on
options): connection block next to main
switch.
NB: The supply voltage on the machine Figure 57: Inside of control
cabinet, may differ from the nominal main switch 1
voltage by no more than 5%.

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21 Fit the remote control with connector on the control cabinet (21); see adjacent
photograph.
22 Connect the connectors for the rear
protection system to the connectors on the
left-hand side of the control cabinet (see Receiver
Book 1, section 3.1.2), no’s (27) and (28); transmitter
see adjacent photograph.

21

41 42

44 43
Figure 58. Components of rear protection system
on/off
What you will need: a piece of white cardboard, approx. 10 x
10 cm, sticky tape

23 Attach the alignment piece (45) in front of the transmitter (41).

NB: The alignment piece is an optional extra.
24 Put a piece of white cardboard in front of the angled mirror (42).
25 This will enable you to see the light beam better.
26 Switch the alignment piece (45) on.
27 Align the transmitter (41) so that the light beam comes out of the alignment piece (45) in
the middle of the angled mirror (42).
28 Fix the transmitter (41) in position.
29 Remove the cardboard from mirror no. (42) and apply it to mirror no. (43).
30 Align mirror no. (42) so that the light beam comes out in the middle of angled mirror no. (43).
31 Fix the mirror (42) in position.
32 Remove the cardboard from the mirror (43) and apply it to the front of the receiver (44).
33 Align the mirror (43) so that the light beam comes out in the middle of the lens on the
receiver (44).
34 Fix the mirror (43) in position.
35 Put the cardboard back up in front of mirror no. (43).
36 Attach the alignment piece (45) in front of the receiver (44).
37 Align the receiver (44) so that the light beam comes out of the alignment piece (45) in the
middle of the mirror (43).
38 Fix the receiver (44) in position.
39 Switch off the alignment piece (45) and remove it from the receiver (44).
40 Start the machine; see Book 1, chapter 4 “Operation”.
41 Check that the photo-electric rear protection system is working properly; see Book 1,
section 5.4.

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Assembly, part 3
42 NB: Check the direction in which the clearance motors are rotating!

Instructions for checking the direction in which the clearance motors are
rotating:
- After starting up the machine in point 40, the controls may display the error message:
“SNIJSPLEET ERROR” (Clearance error).
- If this message is not displayed, the clearance motors are turning in the right direction
and nothing more needs to be done.
- If it is displayed, the clearance motors are turning in the wrong direction.

- Disconnect the supply current to the control cabinet.

- Change connectors T1 and T2.
- Check on the controls to see if the clearance setting is now working properly by
starting up the machine and then pressing Start.

NB:
You may still see the error message “SNIJSPLEET ERROR” (Clearance error)
after you have pressed Start for the first time. This is because the clearance
motor is only given a few seconds to reach its position. Because the clearance
motor was turning the wrong way when you first checked it, it now has to travel
right back to its original position.
You should therefore press Start again and make sure the error message has
now disappeared.

43 Fit the accessories, if any. See Book 1, chapter 8.

Checkpoints for definitive start-up:

44 Check the clearance on the left and right. See book 2, section 2.1.1, “Setting or re-
adjusting the clearance”. Re-adjust if necessary.
45 Check the rear stop by cutting test sheets. See Book 1, chapter 4.8.
46 Check that the accessories are working properly.
47 Make sure the cutting table is well lit, including the area at the back of the machine.
48 If cut material falls on the floor, provide noise-absorbing strips of wood, plastic or rubber.
49 If the machine is preserved with preservation agents, remove these by wiping with a soft
cloth soaked in petrol.
50 For transportreasons a paperwad is fitted in the tankcap. Please remove.
51 Carefully remove the plastic film.
52 Complete the start-up report. See section 3.5.1.

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Book 3, Transportation, installation and starting up SAFAN HT

3.5 Start-up
The SAFAN start-up engineer will compile a start-up report.
This report will be signed by the customer and the start-up engineer when it is handed over
to the customer.
SAFAN B.V. archives the original.
The copy is intended for the customer.
The customer hereby declares that the machine has been properly installed and that they
understand the operation, safety and maintenance instructions.

3.5.1 Start-up report

STANDARD VERSION
Description initials
All components present and in good order (see packlist/order list) ……..
Machine levelled ……..
Oil level ……..
All bolts and nuts tight ……..
Check electrical connections:
- direction of clearance motors ……..
- emergency stop ……..
- fuses ……..
- cable thicknesses ……..
- right connection voltage ……..
- right voltage frequency ……..
Side and rear protection systems set up and operational ……..
Check stops:
- rear stop ……..
- right-angle stops ……..
- shadow line ……..
- stop cams ……..
Check operation of controls ……..
Go through manual with client/operator ……..
Demonstrate machine:
- safety instructions ……..
- lubrication ……..
- maintenance ……..
- operation ……..
Complete Book 1, page IV of this manual (model, number, year of construction, accessories)
……..

SPECIAL ACCESSORIES
Description initials
All components present ……..
Fit, adjust and demonstrate right-angle guide, extended, hardened strip, stop cams ……..
Fit, adjust and demonstrate support arms, extended ……..
Fit, adjust and demonstrate angle guide ……..
Fit, adjust and demonstrate special table cladding, ball rings, extra t-slots ……..
Fit and demonstrate Adiprene slip-on caps ……..
Fit, adjust and demonstrate rear stop, extended, contact stop, support pins ……..
Fit, adjust and demonstrate sheet support device, pneumatic, scrap flap ……..
Fit, adjust and demonstrate discharge belt on sheet support device, scrap flap, counter-
roller ……..
Fit, adjust and demonstrate stacker, rollers, drive. ……..

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