Table of contents Safety Glossary of symbols ............................5 Rating plate..............................5 Hazards Classification ........................... 6 1.3.1 Other pictograms..........................6 Intended use ..............................7 Reasonably foreseeable misuses........................8 1.5.1 Avoiding misuse ..........................8 Possible dangers caused by the metal band saw..................9 Qualification of personnel ..........................
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Control and indicating elements ........................30 4.2.1 Control panel ..........................31 4.2.2 Inserting the workpiece and clamping it firmly ................32 Switching the machine on ..........................33 Switching off the machine ..........................33 Resetting an emergency stop situation ......................34 Power failure, Restoring readiness for operation ..................34 Turn the saw bow ............................34 Adjusting the saw band guide ........................35 Coolant equipment ............................35...
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Dear customer, Thank you very much for purchasing a product made by OPTIMUM. OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions and convince by an outstanding price performance ratio. Continuous enhancements and pro- duct innovations guarantee state-of-the-art products and safety at any time.
Always keep this documentation close to the metal band saw. INFORMATION If you are unable to rectify an issue using these operating instructions, please contact us for advice: Optimum Maschinen Germany GmbH Dr. Robert-Pfleger-Str. 26 D- 96103 Hallstadt, Germany Email: info@optimum-maschinen.de...
Hazards Classification We classify the safety warnings into different categories. The table below gives an overview of the classification of symbols (ideogram) and the warning signs for each specific danger and its (possible) consequences. Symbol Alarm expression Definition / consequence DANGER! Impending danger that will cause serious injury or death to people.
Operations not in accordance with tion of Optimum Maschinen Germany GmbH, then the metal belt saw is being used improperly. intended use! We will not be held liable for any damages resulting from any operation which is not in accor- dance with the intended use.
INFORMATION The metal band saw with frequency converter is built according to the standard EN61800 class WARNING! Class C2 (machine tools) is not intended for use in residential or mixed areas where the power supply is provided by a low-voltage public power supply system. In these areas it may possibly be difficult to guarantee electromagnetic compatibility due to lead bound as well as emitted interferences.
Clamp the workpiece firmly and as vibration-free as possible. Long workpieces must be supported. Use a suitable support. Possible dangers caused by the metal band saw. The construction and design of the metal band saw are state-of-the-art. Nevertheless, there is a residual risk as the metal belt saw operates with ...
may only be performed by an operator if they are described in these instructions and if the ope- rator has been specifically trained to perform them by the operating company. Qualified electrician With professional training, knowledge and experience as well as knowledge of respective stan- dards and regulations, qualified electricians are able to perform work on the electrical system and recognise and avoid any possible dangers.
Before starting work on electrical parts or operating agents, following measures are to be performed in the following order: - disconnect all poles - secure against restarting - check that there is no voltage User positions The operator must stand beside or in front of the metal band saw. Safety devices Use the metal belt saw only with properly functioning safety devices.
1.9.2 Emergency stop switch CAUTION! Only press the emergency-stop button in a genuine emergency. The emergency stop switch is not suitable for shutting down the machine operationally. The emergency stop switch switches off the drives of the metal band saw. INFORMATION Turn the emergency stop button clockwise after pressing it to switch on the metal band saw again.
General check Equipment Check Guards Mounted, firmly bolted and not damaged Signs, Installed and legible Markers Date: Checked by (signature): Functional check Equipment Check Emergency stop switch After pressing the emergency stop button, the metal band saw must switch off. Positions switch The metal belt saw may only switches on when the protective Protective cover saw...
1.12 Safety during operation WARNING! Danger to life from electromagnetic fields. Electromagnetic fields (EMF) are generated by the operation of electrical power equipment such as transformers, converters or motors. People with pacemakers or implants are at a special risk in the immediate vicinity of these devices/systems.
Check that they are working properly! 1.14 Accident report Inform your supervisors and Optimum Maschinen Germany GmbH immediately in the event of accidents, possible sources of danger and any actions which almost led to an accident (near misses). There are many possible causes for "near misses".
The inspection prior to initial commissioning is not required if the operator receives confirma- tion from the manufacturer or installer that the electrical systems and operating equipment com- ply with the accident prevention regulations, see conformity declaration. Permanently installed electrical systems and operating equipment are considered constantly monitored if they are continually serviced by qualified electricians and inspected by means of measurements in the scope of operation (e.g.
Technical specification The following information represents the dimensions and indications of weight and the manu- facturer‘s approved machine data. Electrical connection Drive motor of saw 400V ~50Hz (60Hz) ; 2,2 kW 400V ~50Hz (60Hz) ; 3 kW from construction year end 2020 Hydraulic pump 400V ~50Hz (60Hz) ;...
Emissions The noise emission of the metal band saw is 76 to 80 dB(A). If several machines are operated at the location of the metal band saw, the noise exposure (immission) to the operator of the metal band saw at the workplace may exceed 80 dB(A). INFORMATION This numerical value was measured on a new machine under the operating conditions specified by the manufacturer.
Delivery, interdepartmental transport, assembly and commissioning Notes on transport, installation, commissioning Improper transport, installation and commissioning is liable to accidents and can cause damage or malfunctions to the machine for which we do not assume any liability or guarantee. Transport the scope of delivery secured against shifting or tilting with a sufficiently dimen- sioned industrial truck or a crane to the installation site.
3.1.2 Load suspension point Fasten the load end material on the assigned load end positions on the machine sub- structure. Use an adequate conveyor equipment, for instance a crane. Make sure that you distribute the loads evenly so that the metal belt saw cannot turn over while lifting.
Avoid places close to machines which cause chips or dust. The installation site must be vibration-free, i.e. located away from presses, planing machi- nes, etc. The substructure must be suitable for metal band saws. Pay attention also to the load-bea- ring capacity and evenness of the floor.
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Fasten the machine stand to the ground. Abb.3-3: Example ground fastening Mount the intermediate plate with the hydraulic unit in the machine stand. Lift the metal band saw with an appropriate lifting equipment onto the machine stand. „3.1.2 Load suspension point“...
Hexagon screws Machine stand Abb.3-4: 3.2.5 Roller support assembly Mount the roller support to the machine substructure with the fixing material included in the delivery. Adjust the roller support. Make sure that the wor- king table and the roller Fixing screws support are of the same height.
3.2.6 Material stop Insert the guide rod into the location hole. Clamp the motion rod with Clamping screw the front clamp screw. front Mount the material stop on the limit stop fixture Material stop and clamp it using the Clamping screw clamping screw.
3.2.9 Fill with coolant ATTENTION! Destruction of the pump due dry running. The pump is lubricated by the coolant. Do not operate the pump without coolant. The capacity of the tank is approx. 36 litres of coolant. 3.2.10 Checks Perform the following checks. ATTENTION! Danger of cutting, perform the works described hereunder with care.
Lateral pilot bearings of the saw band Check if the saw band is positioned between the lateral pilot bearings. Guide bearing right Saw blade brush Fig.3-10: Saw band guidance on the right Saw band tension Check the tension of the saw band. Adjusting the Saw band tension on page 45 First commissioning WARNING!
3.4.1 Direct current on the PE conductor WARNING! This product can cause a direct current on the PE conductor. If the wrong type of protection device is used, then the expected protection by such a device could fail to provide the expected protection. If a residual current device (RCD) is used to provide protection in case of direct or indirect con- tact, only a type B RCD may be used on the power supply side of this product.
3.4.2 Regulated drives in connection with residual current devices Speed-controlled drives are one of the standard equipment in machine and plant construction and perform various tasks. Compared to a simple motor, the electronic rectifiers or converters require some special features for the necessary safety measures for electrical safety. Depend- ing on the application, the use of a fault current protection device, differential current monitor- ing or insulation monitoring can make more sense.
To avoid an operating fault, you need an AC/DC-sensitive ELCB. Be absolutely sure which leakage current security is necessary for dangerous body currents, as regulated in DIN VDE 0100 part 410, at your mains connection. 3.4.5 When the ELCB triggers ...
Operation Safety Use the metal belt saw only under the following conditions: The metal belt saw is in proper working order. The metal belt saw is used as prescribed. The operating instructions are followed. All safety devices are installed and activated. Rectify faults or have them rectified immediately.
Rotary knob lowering speed The rotary switch acts on the hydraulic lowering valve, which influences the feed speed. The adjustment range is from 0 to 15 (minimum to maximum load due to the weight of the saw bow). Positioning the saw bow The pushbutton "Position saw bow"...
Lift the saw bow with the push button (15) in manual mode on the control panel. Turn the lowering speed completely to zero. Release the clamping lever (28) to move the vice sideways depending on the angle to be sawed.
Resetting an emergency stop situation Lift the saw bow and close the lowering valve. Unlock the emergency stop button again. Switch on the control with the rotary switch (13). Power failure, Restoring readiness for operation Lift the saw bow and close the lowering valve. ...
Adjusting the saw band guide ATTENTION! An unnecessarily wide space between the work piece and the saw band guide, in combi- nation with a high feed rate very quickly causes the saw band to wear down. Change the position of the saw band guide (4) depending on the size of the parts to be sawn. ...
4.10 General information concerning saw bands In order to achieve an optimum service life with a new saw band, it is necessary to run-in the saw band carefully. The excessively sharp cutting edges of the saw teeth of a new saw blade are sensitive against small splinters coming off.
Toothing pitch when using HSS Bi metal bands Standard toothing Combined tooth Material Number of teeth per Material Number of teeth per Inch Inch Cross section Cross section [mm] (tooth shape) (tooth shape) [ mm ] [teeth per Inch] [teeth per Inch] <...
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Set of saw teeth right/left To saw soft materials (non-ferrous metals, plastics, wood) Group of set of saw teeth A development to almost oscillation-free sawing of thin material cross sections, i.e. tubes and profiles. Due to the inclined teeth in a series of set of saw teeth, smooth cut surfaces for increa- sed cutting speeds are being achieved.
Thin chips which look like powder. Increase the feed or reduce the speed of the saw band. Burnt, heavy chips. Reduce the feed and/or the speed of the saw band. Gathered, silver and warm chips. Optimum feed and Speed of saw band...
Maintenance In this chapter you will find important information about Inspection Maintenance Repair of the metal band saw. ATTENTION! Properly performed regular maintenance is an essential prerequisite for operational safety, failure-free operation, long service life of the metal band saw and ...
WARNING! Before starting the metal band saw you must be sure that no dangers generated for persons, the metal band saw is not damaged. Inspection and maintenance The type and level of wear depends to a large extent on the individual usage and operating conditions.
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Wher Interval / When What? How? Adjust the cam of the end position switch (12) so that the mechanical end stop (13) of the saw bow corre- sponds to the position of the switch. Do not set the mechanical end stop too low. If the metal band saw and the coo- lant pump...
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Wher Interval / When What? How? The saw band is to be tensed during the readjustment. Adjust the carbide guide (14). The sides of the band saw band should rest slightly against the guide bearings (15). If necessary, read- just the guide bearings (15) by turning.
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Wher Interval / When What? How? The saw band is being tensed with the handwheel. Turn the handwheel clockwise to increase the ten- sion in the saw band. The correct saw blade tension is reached when the pointer is in the green range. Set screw Saw band roller Adjusting the...
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Proceed a trial run. Assemble all the removed protective covers. ATTENTION! In order to achieve an optimum service life with a new saw band, it is necessary to run-in the saw band carefully. General information concerning saw...
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Wher Interval / When What? How? Fill new hydraulic oil into the tank of the hydraulic unit via the filling opening. Pay attention to the filling quantity using the scale on the container. Note the minimum and maximum values of the scale. ...
Wher Interval / When What? How? The saw bow joint is factory set and should not need to be changed. If inclined sections occur which cannot be eliminated by adjusting the saw blade guide as descri- bed under Saw band guides Readjust on page 44, the joint can be readjusted to the required angle.
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If the repairs are carried out by qualified technical personnel, they must follow the indications given in these operating instructions. Optimum Maschinen Germany GmbH accepts no liability nor does it guarantee against damage and operating malfunctions resulting from failure to observe these operating instructions.
Hydraulic system 5.6.1 Inspection and exchange of hydraulic hoses Hydraulic hoses are used in almost any machine or system with hydraulically controlled compo- nents, especially where rigid pipes cannot be used for the energy transfer. Hydraulic hoses pose a particular danger due to faulty insertion, ageing, wear and tear, dam- age and other reasons.
Cooling lubricants and tanks CAUTION! The cooling lubricant can cause diseases. Avoid direct contact with cooling lubricant or parts covered in cooling lubricant. Cooling lubricant circuits and tanks for water-cooling lubricant mixtures must be completely emptied, cleaned and disinfected as needed, but at least once per year or every time the coo- ling lubricant is replaced.
5.7.1 Inspection plan for water-mixed cooling lubricants Company: No.: Date: used cooling lubricant size to be checked Inspection methods Inspection Procedure and comment intervals noticeable Appearance, odour daily Find and rectify causes, changes e.g. skim off oil, check filter, ventilate cooling lubricant system pH value Laboratory techniques...
Ersatzteile - Spare parts Ersatzteilbestellung - Ordering spare parts Bitte geben Sie folgendes an - Please indicate the following : Seriennummer - Serial No. Maschinenbezeichnung - Machines name Herstellungsdatum - Date of manufacture Artikelnummer - Article no. Die Artikelnummer befindet sich in der Ersatzteilliste.
Ersatzteilzeichnung Maschinenunterbau - Spare parts drawing machine stand Abb.6-3: DE | EN SD500AV Originalbetriebsanleitung Version 1.0.4 - 2020-10-13...
Ersatzteilzeichnung Getriebe - Gearbox spare parts drawing Den Unterschied zu einem 3 kW Getriebe kann man am Getriebedeckel erkennen. The difference to a 3 kW gearbox can be seen on the gearbox cover. La différence par rapport à une boîte de vitesses de 3 kW est visible sur le couvercle de la boîte de vitesses.
Schaltplan - Wiring diagram DE | EN SD500AV Originalbetriebsanleitung Version 1.0.4 - 2020-10-13...
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SD500AV DE | EN Version 1.0.4 - 2020-10-13 Originalbetriebsanleitung...
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SD500AV electrical parts Elektrik Electric Menge Grösse Artikelnummer Bezeichnung Designation Qty. Size Item no. Cams Hauptschalter Main switch 03292385Cams AB INV Frequenzumrichter Frequency converter Siemens 2.2 kW 03292385ABINV AB INV Frequenzumrichter Frequency converter Siemens 3 kW 03292385ABINV3kW Antriebsmotor Drive Motor 2.2 kW 03292385116 Antriebsmotor...
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oil-compare-list.fm Viskosität Schmierstoffe Viskosity Kennzeich- Lubricant nung nach Viscosité ISO VG DIN 51502 Lubrifiant DIN 51519 mm²/s (cSt) Aral Degol BG BP Energol SPARTAN Klüberoil Mobilgear Shell Omala VG 680 CLP 680 Meropa 680 GR-XP 680 EP 680 GEM 1-680 Aral Degol BG BP Energol SPARTAN...
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Techno Service GmbH ; Detmolder Strasse 515 ; D-33605 Bielefeld ; (++49) 0521- 924440 ; www.metaflux-ts.de haute vitesse Schneidöl Aquacut C1, 10 L Gebinde, Artikel Nr. 3530030 Kühlschmiermittel EG Sicherheitsdatenblatt Cooling lubricants Chevron Aral Emusol BP Sevora Esso Kutwell Mobilcut Shell Adrana http://www.optimum-daten.de/ Soluble Oil B Lubrifiants de refroidisse- data-sheets/Optimum-Aqua- ment cut_C1-EC-datas- heet_3530030_DE.pdf oil-compare-list.fm...
Malfunctions Cause/ Malfunction Solution possible effects New metal band saw does • Frequency converter detects over- • Run in a new metal band saw. not start up. load. Running-in process on page Machine does not turn on • Engine protective switch released •...
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Cause/ Malfunction Solution possible effects Oblique saw cut (Saw band • Distance between guide and work- • Bring the guide as close to the runs incorrectly) piece too high workpiece as possible • Saw band blunt • Replace • Too low saw blade tension •...
Malfunctions on the frequency converter - Sinamics G110M 7.1.1 Sinamics G110M, Operating Instructions, 06/2016, FW V4.7.6, A5E31298649B AG Malfunctions SD500AV Version 1.0.4 - 2020-10-13 Translation of original instruction...
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SD500AV Malfunctions Translation of original instruction Version 1.0.4 - 2020-10-13...
Appendix Copyright This document is protected by copyright. All derived rights are reserved, especially those of translation, re-printing, use of figures, broadcast, reproduction by photo-mechanical or similar means and recording in data processing systems, either partial or total. Subject to technical changes without notice. Terminology/Glossary Term Explanation...
Example: not stackable - do not stack further pac- king case on top of the first one. Consult Optimum Maschinen Germany GmbH if the machine and accessories are stored for more than three months or are stored under different environmental conditions than those spe- cified here.
Non reproducible software errors Any services, which OPTIMUM GmbH or one of its agents performs in order to fulfil any additional warranty are neither an acceptance of the defects nor an acceptance of its obli- gation to compensate. These services neither delay nor interrupt the warranty period.
8.6.1 Decommissioning CAUTION! Used devices need to be decommissioned in a professional way in order to avoid later misuses and endangerment of the environment or persons. Unplug the power cord. Cut the connection cable. Remove all operating materials from the used device which are harmful to the env- ironment.
Modified settings Any experiences with the metal band saw which might be important for other users Recurring failures Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D-96103 Hallstadt, Germany Fax +49 (0) 951 - 96 555 - 888 email: info@optimum-maschinen.de...
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EC - declaration of conformity according to Machinery directive 2006/42/EC, Annex II 1.A The manufacturer / distributor Optimum Maschinen Germany GmbH Dr.-Robert-Pfleger-Str. 26 D96103 Hallstadt hereby declares that the following product Product designation: Metal band saw Type designation: SD500AV fulfills all the relevant provisions of the directive specified above and the additionally applied directives (in the following) - including the changes which applied at the time of the declaration.
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Index Specialist dealer ........... 48 Speed of saw band ..........17 Accident report ............15 Storage and packaging ........20 Assembly engine ...........23 Technical data Cleaning and lubricating ........24 electrical connection ........17 Copyright ...............73 Emissions ............18 Customer service ..........48 General ............17 Customer service technician .........48 operating material ..........
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SD500AV Translation of original instruction Version 1.0.4 - 2020-10-13...
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