DoAll C-530 M Instructions And Parts Manual

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Edition A

INSTRUCTION &

PARTS MANUAL

for

Band Saw Machine type

C-530 M

Y

EAR OF PRODUCTION

S

ERIAL NUMBER

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Dear Customer,

first of all, thank you for choosing a DoAll product.

DoAll represents an important reference in the metal cutting business worldwide, and
its production has always been recognized as synonymous of quality.

All machine components have been designed and manufactured to guarantee best
possible performances. To keep this high standard, we kindly invite you to use only
original DoAll spare parts.

DoAll band saw machines are CE marked and in the following pages the reader will
find a CE declaration which follows the European Directive 89/392 requirements.

DoAll is sure to assure with this machine the state of the art solutions for the opera­tor safety, and to be part of the general improvement of labor conditions.

DoAll

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CE DECLARATION ......................................................................................................................... 6

GENERAL INFORMATION ........................................................................................................... 7

1. GENERAL INFORMATION ....................................................................................................... 8

1.1. Goal of this manual. .....................................................................................................................8

1.2. Regulations to refer....................................................................................................................... 8

1.3. Manual description........................................................................................................................ 8

2. MACHINE IDENTIFICATION DATA ......................................................................................9

2.1 Main constructive characteristics................................................................................................. 10

2.2. Blade speed ................................................................................................................................. 10

2.5. Vises ...........................................................................................................................................10

3. HOW TO USE THE INSTRUCTION MANUAL .................................................................... 11

3.1. Where to keep this manual..........................................................................................................11

3.2. Manual update.............................................................................................................................11

3.3. How to obtain more copies .........................................................................................................11

3.4. If the machine changes owner.................................................................................................... 12

3.5. Suggestions .................................................................................................................................12

4. LIABILITY LIMITS ................................................................................................................... 13

4.1 Inappropriate use of the machine ................................................................................................. 13

5. TYPE OF USE ALLOWED........................................................................................................ 14

5.1. Machine addressee .....................................................................................................................14

5.2. Operator ......................................................................................................................................14

5.3. Regulation ...................................................................................................................................14

5.4 Typical use ...................................................................................................................................14

5.5. Limits using the saw ...................................................................................................................15

5.6. Workable materials ..................................................................................................................... 15

5.7. Work area................................................................................................................................... 15

5.8. Work place ..................................................................................................................................15

5.9. Command modes, stop, emergency stop and out of service. ....................................................16

5.9.1 Command modes....................................................................................................................... 16

5.9.1.1. Stop ....................................................................................................................................... 16

5.9.1.2. Emergency stop..................................................................................................................... 16

5.9.1.3. Out of service........................................................................................................................ 16

5.9.1.4. Safety precautions................................................................................................................. 16

6. TECHNICAL DESCRIPTION................................................................................................... 17

6.1. Machine structure .......................................................................................................................17

6.1.1. Base frame ............................................................................................................................... 17

6.1.4. Vices ........................................................................................................................................ 17

6.2. Cutting bridge .............................................................................................................................17

6.2.1 Cutting bridge frame ................................................................................................................. 17

6.2.2 Guiding columns....................................................................................................................... 18

6.2.3 Columns connection.................................................................................................................. 18

6.2.4 Lifting cylinder .........................................................................................................................18

6.2.5 Blade tension assembly............................................................................................................. 18

6.2.6 Band drive assembly ................................................................................................................. 18

6.2.7 Band brush assembly ................................................................................................................18

6.2.8 Left and right band guides. ......................................................................................................18

6.2.9 Feed pressure control ................................................................................................................ 18

6.2.10 Wheels ................................................................................................................................... 18

6.2.11 Band drive motor ...................................................................................................................18

6.3. Hydraulic power unit ..................................................................................................................18

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6.3.1 Motor-pump assembly .............................................................................................................. 19

6.3.2 Oil reservoir .............................................................................................................................. 19

6.3.3 Solenoid valves ......................................................................................................................... 19

6.4. Electrical system ........................................................................................................................ 19

6.4.1 Control console ......................................................................................................................... 19

6.4.2 Control enclosure ...................................................................................................................... 19

7. MACHINE PROTECTIONS...................................................................................................... 20

8. HOW TO MOVE THE MACHINE........................................................................................... 20

9. HOW TO INSTALL THE MACHINE...................................................................................... 20

10. WHAT TO DO TO PREPARE THE MACHINE TO OPERATE ...................................... 21

11. SAFETY DEVICES ................................................................................................................... 22

11.1 Limit switches and signal devices.............................................................................................. 22

11.1.1. Limit switches........................................................................................................................ 22

11.1.2. Speed reducer......................................................................................................................... 22

11.1.3. Mechanical extra stroke ......................................................................................................... 22

11.1.4. Signals.................................................................................................................................... 22

11.1.5. Led, indicators and signals to avoid danger situations .........................................................22

11.1.6. Protection devices .................................................................................................................. 22

11.2. Fix protections........................................................................................................................... 22

11.3. Movable protections.................................................................................................................. 22

11.4. Safety features set-up ................................................................................................................22

12. USE OF THE MACHINE ......................................................................................................... 23

12.1. Operate the machine.................................................................................................................. 23

12.1.1 Control panel........................................................................................................................... 23

12.1.2 To start the machine................................................................................................................24

12.2. Head feeding control................................................................................................................. 24

13. CALIBRATION AND TUNE-UP............................................................................................. 25

13.1. Calibration................................................................................................................................. 25

13.2. Machine tuning-up ....................................................................................................................25

13.3. Blade motor inverter .................................................................................................................25

13.3.1 Control panel........................................................................................................................... 25

13.3.2 Display ................................................................................................................................... 26

13.3.3 Help - function and language - selection ................................................................................26

13.3.4 Inverter status ......................................................................................................................... 26

13.3.5 Warnings ................................................................................................................................. 26

13.3.6 Operating error messages........................................................................................................ 27

13.3.7 Hardware error messages........................................................................................................ 28

13.3.8 Programming structure............................................................................................................ 29

14. DISMANTLING OF THE MACHINE.................................................................................... 31

15. ORDINARY PROBLEMS ........................................................................................................ 31

15.1. Base .......................................................................................................................................... 31

15.2. Cutting bridge ..........................................................................................................................31

15.2.1 Columns .................................................................................................................................. 31

15.2.2 Connection bar ........................................................................................................................ 31

15.2.3 Lifting cylinder .......................................................................................................................31

15.2.4 Blade tension assembly .......................................................................................................... 31

15.2.5 Band drive assembly ............................................................................................................... 32

15.2.6 Guide arms .............................................................................................................................. 32

15.2.7 Band brush assembly ..............................................................................................................32

15.2.8 Wheels..................................................................................................................................... 32

15.2.9 Servo-cutting device ...............................................................................................................32

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15.4 Hydraulic power unit .................................................................................................................32

15.5 Electric control panel ................................................................................................................. 32

16. MAINTENANCE ....................................................................................................................... 33

16.1 Lubrication ................................................................................................................................33

16.2. Problems.................................................................................................................................... 34

16.3. Blade replacement....................................................................................................................34

17. REMAINING DANGERS........................................................................................................ 35

18. PERSONNEL TRAINING....................................................................................................... 35

19. MACHINE DISMANTLE........................................................................................................ 35

EXHIBIT A – PROOF OF TEST................................................................................................... 36

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CE DECLARATION

We declare that the product “Band saw machine type C-530 M”:

Serial number Year of production

referred to in this declaration is in compliance with:

• CEI EN 60204-1

• UNI EN 12100-1

• UNI EN 12100-2

and:

1. EEC Machine Directive 89/332 dated June 14, 1989 and amendments ;

1. EEC Low Voltage Directive 73/23 and amendments ;

1. EEC Directive 89/336 and amendments.

This product uses only tested and certified components, which meet the CE requirements, unless
otherwise specified.

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GENERAL INFORMATION

This machine has been designed and built adopting the state of the art technologies, and with respect of the European
Laws for machine tools.

Notwithstanding what above, it is implicit that working underestimating or forgetting the dangers related to this kind of
machine can generate, the operator could cause serious injuries to him/herself.

Therefore, the operator should carefully read the entire instruction manual, and respect strictly what prescribed in it.

This symbol indicates that the paragraph contains important information concerning
safety and injuries preventions

In particular, please pay attention to the following suggestions :

1. Keep always your working area clean.

1. Avoid to keep in your working area pieces of material, chips, cans, or other things which could reduce the possibil­ity of movement to the operator or even generate risks of injury.

1. Be always cautious using the machine, because, even if it is protected in every dangerous spot, it can be a danger­ous equipment, and thus it has to be use being particularly careful and aware.

1. Give immediately notice to your supervisor if the machine needs to be maintained or serviced, even if the problem
is caused by inexperience. An incorrect use of the machine can be dangerous and can cause injuries.

1. Do not try to repair the problem if you are not sure of what caused it.

1. Never service or maintain the machine when it is running. Always turn it off.

1. Never leave the machine working without respecting the safety rules or removing the safety devices.

1. Remove electrical power when the machine is not working.

1. Always wear protective cloths, especially when replacing the blade.

1. Never do anything imprudent.

1. Never touch the unprotected part of the blade.

1. Never cut any piece shorter than the shortest possible length.

1. Never start cutting if the material is not firmly clamped by the vises.

1. Move the material only if the cutting bridge is completely up.

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1. GENERAL INFORMATION

1.1.

This manual wants to explain instructions about how to operate safely, using texts, drawings,
pictures and diagrams used by themselves or combined to instruct the operator to use the ma­chine.

GOAL OF THIS MANUAL.

1.2.

This manual was written to comply to the European Machine Directive UNI-EN 89/392 and following modifications,
and based on UNI-EN 292/1 e 292/2 concerning a safe use of the machine.

REGULATIONS TO REFER.

1.3. MANUAL DESCRIPTION

This document contains information needed to :

9 install and make the machine work
9 normal use of the saw
9 how to maintain the machine
9 how to service the machine
9 how to dismantle the machine

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2. MACHINE IDENTIFICATION DATA

TAB 2.1

Identification data

Description

Band Saw machine

Type C-530 M
Serial number
Year 2005
Voltage and frequency 400 V 3ph+N+GND ±10% 50 Hz ±1%
Approximate weight 3.000 Kg.
Total power installed 10,50 Kw
Total required current 30 Amp
Control circuit 24Vdc
Dangerous area Area around the machine (1.5meters)
Working place Machine control panel
Type of tool Band saw blade

TAB 2.2

Denomination or value plate name

Technical Characteristics

Description C-530 M
Round cutting capacity mm 530
Square cutting capacity mm 530x600
Band drive motor kW 7,5
Blade dimension mm 6.700x54x1.6
Blade speed m/1’ 20-100
Hydraulic pump motor kW 2,2
Coolant pump motor kW 0.3
Hydraulic pump capacity l/1’ 14
Voltage of motors Vac 400
Control circuit voltage Vdc 24
Cutting kerf mm 2,5
Hydraulic reservoir l 55
Coolant reservoir l 65
Working height mm 750
Color DoALL hammered blue
Moving components color RAL Beige 1001

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2.1 MAIN CONSTRUCTIVE CHARACTERISTICS.

The machine uses :

• Band speed readout

• Constant feed pressure control.

• Band wheel drive with AC inverter and worm gear.

• Automatic guide arm.

• Carbide faced saw guides with large diameter lead in rollers on both guide arms.

• Hardened, ground, anti-wear steel plates on all work clamping surfaces.

• Ground, hardened and hard-chrome plated guide columns.

• Power driven band cleaning brush.

• Hydraulic band tension.

• Recirculating, coolant system, pump 400/50/3, applied through nozzle.

• Band wheel door interlocks.

• Blade guards.

• C26 gray iron castings

The saw is built to work in semi-automatic.

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2.2. BLADE SPEED

The blade speed is controlled by an AC motor and a variable frequency drive, which allow to regulate the blade speed
within a range of 0- 100 m/1’. In this way the machine can cut both hard steels and aluminum. A digital reader constantly
shows the blade speed .

2.5. VISES

Vises are hydraulic. The jaws are hardened

TAB 2.3

Cutting tolerances

Machine

Description C-530 M

On the perpendicularity mm

±0,2 mm /100 mm

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3. HOW TO USE THE INSTRUCTION MANUAL

3.1. Who should read the instruction manual?
TAB 3.1 Who should read the manual

Description Operator Internal service
Mechanical Electrical
Instruction Manual Yes Yes No
Electrical Schematic No No Yes

The electrical schematic is included in this manual and cannot be supplied separately.

3.1.

This manual, that is provided along the machine in one copy, should be kept where the machine is located, in a safe and
protected place, to be consulted if necessary.

WHERE TO KEEP THIS MANUAL

3.3. Strength of this manual

1. This manual reflects the state of the art at the time the machine was built, and cannot be considered replaceable by a

newer version.

1. This manual has full force for all the life of the machine it goes along.

1. The customer is not allowed to copy totally or partially this manual to reach goals different than the one of the original

manual, and to avoid that a partial documentation replaces the original one.

3.2.

The manufacturer does not have to update this manual if improvements are adopted on newer machines of the same kind
of the one this manual make reference to.

This manual will be updated by the manufacturer only if :

Marginal errors or missing elements, if considered important for the correct work of the machine and its safe use will be
immediately notified through an “Errata Corrige”.

To modify this manual the manufacturer will bring all the copy of the same edition back and then new copies will be sent
to the customer.

The latest version is marked with higher letter (A, B....). The first edition is called “Edition A”.

MANUAL UPDATE

• this manual contains mistakes, errors, or something is missing;

• the original machine is modified by the manufacturer.

3.3. HOW TO OBTAIN MORE COPIES

If necessary, the customer can obtain new copies of this manual simply making a written request and mentioning on it the
machine serial number.
If copies are requested, the manufacturer has the right to be paid to issue them.

3.4.

IF THE MACHINE CHANGES OWNER

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If the original customer sales the machine, he/she should notify the manufacturer that the machine changed ownership, so
to allow the manufacturer to inform the new user on the dangers and limits of liability.

3.5. SUGGESTIONS

The customer should notify the manufacturer if improvements are necessary and where they are to increase an easy un­derstanding of this manual/

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4. LIABILITY LIMITS

The manufacturer cannot be responsible if the machine if used in one following ways , which are classified as inappropri­ate :

4.1 INAPPROPRIATE USE OF THE MACHINE

It has to be considered inappropriate the use of the machine if :

• the safety rules are partially are completely unattended ;

• what the manufacturer prescribed is not done ;

• the a danger or injury is due to an incorrect installation or assembly of the machine, and it was not done by the customer or

under his surveillance ;

• wrong installation of protective equipment after maintenance or service ;

• hydraulic or electrical problems due to the producer of the component and not to the producer of the machine ;

• big deficiency in maintenance ;

• modifications or maintenance on the machine without authorization of the manufacturer ;

• use of atypical tools, other than the ones suggested by the manufacturer ;

• use of non-original spare parts, other than the one suggested by the manufacturer ;

• Partial or complete non-observance of the instructions ;

• machine used by uninstructed operators without control of an expert operator ;

• movement or machining of non-typical materials, or oversize and overweight materials compared to the ones indicated ;

• natural calamities, including earthquakes, floods or others which could provoke danger or faults to the machine or its struc-

tures easy to be identified ;

• if electrical , pneumatic or mechanical safety features were partially or completely removed ;

• maintenance while the machine is working;

• when parts of the machine are tensioned using temporary connections, without protection or using faulty materials ;

• a person without experience is within the danger area while the machine is running ;

• a person with experience is within the danger area while the machine is running with the automatic cycle.

It has to be considered inappropriate also when the machine runs without enough surveillance to assure the operator
safety or to assure that the machine can run properly.

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5. TYPE OF USE ALLOWED

5.1. MACHINE ADDRESSEE

This machine was design and built to comply a professional use, meaning that, besides the technical knowledge required,
it is necessary to have a specific knowledge to operate the saw to obtain the required goals.

5.2. OPERATOR

The saw operator should have experience on similar type of machine. People with low or none experience must be edu­cated, followed and watched by a supervisor with enough experience and ability.

Therefore, the operator must be aware about dangers related to the use of this machine, and dangers due to normal han­dling of metallic materials, similar, or heavy .

This machine cannot be used by people with handicaps or disables.

5.3. REGULATION

Designing and building this machine we respected the following laws and rules :

9 UNI rules
9 CEI rules

and more in detail, concerning the safety features (type A and B rules):

9 European Community Machine directive 89/392;
9 CEI-EN 60204-1 and related rules concerning electrics, with respect of EC directive 73/23 ;
9 EN 292/1
9 EN 292/2

If not clearly specified, every component used on this machine was UNI and CEI approved at the time it was bought or
made.

5.4 TYPICAL USE

This machine was designed and built to cut metallic materials fed by automatic systems and with overall size non larger
than the ones listed in the chart below (5.4). The saw can move :

9 movement of the material before and after each cut ;
9 vertical movement of the cutting bridge ;
9 blade rotation.

All these movements could take place at the same time.
The saw has the following performance :

Tab. 5.4

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Characteristic MIN MAX
Cutting speed cmq/m 5 140
Material feeding speed Mt./m 30 300
Cutting bridge falling rate (w/o material) Mt./m 3 30
Bars size mm

Bar weight kg. 0 1500

5.5. LIMITS USING THE SAW

The machine has two limits of use due to :

9 operator’s inexperience
9 material size and weight

The operator’s experience is particularly necessary when the saw runs in manual cycle ;
material size and weight must be within the ones above shown.

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∅ 13 ∅ 530

5.6. WORKABLE MATERIALS

This machine can cut only metallic bars, pipes and tubing. Every other use will is considered inappropriate use of the ma­chine.

5.7. WORK AREA

This machine has to work in industrial environment. It is design to make mechanical machining under human control, but
the operator presence is not required continuously.

It is recommended to keep clean and free of interference the area close to the machine.

This machine use a mixture of oil and water as coolant liquid. Thus, the working area could be slippery and dirty.

HIS AREA MUST BE MARKED BY AN APPROPRIATE SIGNAL.

T

5.8. WORK PLACE

The machine has one work place in front of the control panel.

A second temporary work place is aside the vises, the register them, and to change the blade.

Each work place must be easy to reach when necessary, without interference, even temporary. The machine can work
automatically without operator, who must be present during the manual operations of loading and unloading, and control
the control panel operations.

No specific illumination is required, but the work place must be well illuminated to respect the requirements set by present
safety rules.
Only authorized people and maintenance personnel should be allowed to reach the saw work place.

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The operator must be equipped with personal protection instruments, like gloves and safety glasses.

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5.9. COMMAND MODES, STOP, EMERGENCY STOP AND OUT OF SERVICE.

5.9.1 Command modes

The saw can be controlled in two different ways, turning or pressing a selector switch or a push-button (different ways for
different models). The switch enable a relay which insert the manual mode.

9 Automatic mode ; the switch is on the automatic mode. All automatic commands are enable.
9 Manual mode, the switch is on the manual mode. All the commands are switched to the control panel push-button

and switches.

5.9.1.1. Stop

The saw stops when the cutting cycle is over.

5.9.1.2. Emergency stop

The emergency stop stops the machine removing tension from the control circuit.

5.9.1.3. Out of service

The saw can be turned out of service removing tension from the control circuit, switching off the main disconnect switch
located on the front face of the enclosure. A signal saying “Out of service” must be placed on the machine, and it is opera­tor’s duty to verify that the machine cannot generate danger situations.

5.9.1.4. Safety precautions

The machine cannot generate danger situation when it is completely without electric or hydraulic power.

Concerning the electrical power, the machine must be completely disconnected from electrical sources, turning of the elec­trical socket on the building electrical panel. The machine cannot be considered completely safe if the only main discon­nect switch of the machine is turned off.

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6. TECHNICAL DESCRIPTION

6.1. MACHINE STRUCTURE

This saw is manly made by :

9 Base frame
9 Cutting bridge
9 Hydraulic power unit
9 Control Panel
9 Coolant system

Pos. Tab 6.1. Base frame

6.1.1. Base frame

6.1.4. Vices

6.1.1. Base frame

The machine frame is welded and machined. The material used is Fe 37. In the weldment there are two reservoirs, one
for the coolant liquid, and the second for the hydraulic oil.
The frame is machined to avoid corners or abrasive points that could be dangerous. It is painted with two layers of paint,
the first of which prevent corrosion.
It is machined to be assembled with other machine components.

6.1.4. Vices

It includes :

9 clamping vises, machined. Vises are controlled by hydraulic cylinders.

6.2.

Pos. Tab 6.2 Cutting bridge

6.2.1 Cutting bridge frame

6.2.2 Guiding columns

6.2.3 Columns connection

6.2.4 Lifting cylinder

6.2.5 Blade tension assembly

6.2.6 Blade drive assembly

6.2.7 Band brush assembly

6.2.8 Left and right band guide

6.2.9 Cutting servo-control

6.2.10 Wheels

6.2.11 Bland drive motor

6.2.1 Cutting bridge frame

The cutting bridge frame is a steel Fe37 weldment; it is machined to be assembled with other machine components.
The bridge was design and built to endure the cutting strength, keeping enough sturdiness.
The frame is mechanically machined and painted with anti-corrosion agents and with nitro paint.
The blade is completely protected where it does not work. Covering the wheels, there are two doors that can be opened to
change the blade. Two safety switches are mounted on these doors, so to stop the machine if the covers are not in position.
The blade rotates on the wheels, one of which is driven, and the other one is idler.

CUTTING BRIDGE

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6.2.2 Guiding columns

The columns guide vertically the cutting bridge movement. They are made with chrome bars, hardened and grinded.

6.2.3 Columns connection

Made using a Fe37 steel plate, the columns connection connects and makes the guiding columns sturdier. It is fastened to
the columns through two bolts.

6.2.4 Lifting cylinder

This is an hydraulic cylinder, with chrome rod and lapped cylinder. The lifting cylinder is a double effect cylinder. The cyl­inder head is attached to the cutting head, and the end head is fastened to the machine base frame.

6.2.5 Blade tension assembly

The C-M utilize an automatic band tension system. The proper band tension is assured by the cylinder.
The system has been designed to guarantee a proper tensioning of the band. (see 15.4 Band replacement).

6.2.6 Band drive assembly

The band is powered by an AC motor which automatically regulates the cutting speed. The motor is directly flanged on
the speed reducer: this application reduces vibration while providing best possible torque. On the other end of the reducer
there is the drive wheel, that is fastened to the reducer.

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Edition A

6.2.7 Band brush assembly

A band brush is powered by an hydraulic motor, and it cleans the teeth removing the chips.

6.2.8 Left and right band guides.

The band guides have to straighten the blade coming out the wheel, and keep it vertical helping the blade insertion between
the inserts.

Left guide arm : Moves horizontally on guides machined on the bridge, and it is moved by the movement of the vise.
Right guide arm : Fixed on the cutting bridge. It supports the cutting servo control.

Both the guide arms have carbide inserts.

6.2.9 Feed pressure control

The C-M utilizes a constant feed pressure control. The feed force is adjustable by turning the flow regulator valve, located
on the fix guide arm block.

6.2.10 Wheels

Made using cast iron G26, and lathe machined. They are fastened as follow :

9 the idler wheel is fastened on the band tension assembly, and it turns on ball bearings ;
9 the band drive wheel is fastened on the reducer shaft.

The wheels diameter is larger then the maximum material height that can be cut by the saw..

6.2.11 Band drive motor

The machine mounts a self-cooling 4Kw, AC electric motor.

6.3. HYDRAULIC POWER UNIT

The power unit is located in an easy to service spot of the machine frame. The valve manifold and solenoids lays on the
right side of the reservoir , over which the motor pump assemblies is installed. The power unit is made by :

Pos. Tab 6.3. Hydraulic power unit

6.3.1 Motor-pump assembly

6.3.2 Oil reservoir

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6.3.3 Solenoid valves

6.3.1 Motor-pump assembly

Electrical motor and pump are connected by an elastic coupling.

6.3.2 Oil reservoir

It is in the machine frame, and it has a maximum and a minimum level indicators, and a suction filter. On the left side of the
infeed roller table there is a plug which allows to refill the reservoir. The hydraulic system has 2 filters :

9 a 250 micron 45 liters suction filter
9 a 60 micron 45 liters outflow filter

These two filters have to be removed when changing the oil for the first time (after 500 working hours), washed using tri­chloroethane and dried blowing air.

6.3.3 Solenoid valves

The solenoid valves are mounted on blocks, and the control the hydraulic movements.

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Edition A

6.4.

6.4.1 Control console

The control console is on the upper part of the control enclosure.

6.4.2 Control enclosure

It is made bending metal sheets and it complies the IP55 standards. Inside there is the electrical panel which supports all the
electrical devices (relays, circuit breakers,...) complying the CEI 60204.1 standards.

ELECTRICAL SYSTEM

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7. MACHINE PROTECTIONS

This machine is entirely protected where it can be dangerous. Despite of this, there are some parts that cannot be pro­tected, and where the operator must never work. The biggest of these parts is where the blade touches material.
There is a sticker close to every part which is not completely safe, to show to the operator that he should be extremely con­scious.

8. HOW TO MOVE THE MACHINE

This machine, when installed and fastened to the ground must be considered a fix equipment.
If it is necessary to move the machine or parts of it (because of maintenance or service), the operator must use a crank or a
fork lift, or a lighter lifter with regards of the weight of the part that have to be lifted.

9. HOW TO INSTALL THE MACHINE

The machine can be installed by :

9 the manufacturer/distributor ;
9 the customer ;

The machine is shipped completely mounted.

Moving the machine is one of the moment the risk of injuries is higher, thus it is important to make sure that :

9 Every operator wears the necessary safety equipment.
9 The lifting equipment must be enough big to lift the machine. Always use only one lifting equipment to lift the ma-

chine, never combine more then one.

9 Do not use a lift fork if the length and width of the forks are inadequate to lift the machine.
9 If using a crank, use metallic ropes and be sure they can support the weight of the machine. Put strong cartoon or

wood between the ropes and the machine. Never leave the ropes slide freely on the machine body.

9 Do not use metallic ropes if they show wear areas.
9 Lift the machine slowly so to have enough time to adjust the lifting if necessary or to avoid obstacles.
9 In the lifting area there should be enough people to move safely the machine, and do not allow anyone else to stay in

the lifting area during such operation.

9 Be sure that every movable part is well fastened to the machine. Remove or secure every part which falling can be

dangerous for the people in the work area.

9 Move the machine paying attention to the surrounding environment. Be extremely cautious so to avoid hitting any-

one or anything.

9 Moving the machine, stay as close as you can to the ground to avoid that a rope brake could generate dangers or seri-

ous machine breaks.

9 If necessary, put pieces of wood under the machine base before putting it down.

10. WHAT TO DO TO PREPARE THE MACHINE TO OPERATE

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This machine can be installed by:

9 the manufacturer;
9 a manufacturer representative ;
9 the customer.

It is customer duty to get the place ready to install the machine, arranging also the anchor bolts to secure the machine on the
ground.

To installed the machine it is necessary:

9 to be sure the place where the machine as to be placed is leveled;
9 prepare the anchor bolts to secure the machine ;
9 lift the machine and insert the anchor bolts ;
9 Level the machine on the ground working on the leveling screws ;

The machine needs only to be electrically connected.
Before to connect the power :

9 check if the operator uses the necessary safety devices ;
9 check if the disconnect switch is insulated ;
9 check if the control panel is insulated ;
9 check if the fuses and circuit breakers are operative ;
9 check the 3 phase electric source ;
9 if the machine does not work properly, do not try to fix it, but immediately disconnect the power and ask for a main-

tenance expert ;

9 check the correct electrical connection ;
9 check if the necessary protection devices work properly;
9 check if push buttons and select switch work properly ;
9 check the mechanical connections ;

The manufacturer cannot be responsible for injuries and/or damages due to the customer electric source, especially if
it does not meet the present safety requirements. (In Italy DLSG 94/626)

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Edition A

Check if the following motors rotate clockwise :

9 hydraulic power unit motor
9 coolant pump
9 band drive motor

The operator has to make sure:

1. That hydraulic oil and coolant fluid reservoirs are filled until the proper level.

2. The blade is installed (make reference to par. 15.4.)

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11. SAFETY DEVICES

11.1 LIMIT SWITCHES AND SIGNAL DEVICES

11.1.1. Limit switches

On the machine there are the following limit switches

DESIGNATION DESCRIPTION

FC3, FC4 Safety band wheel door interlock switches

FC6 Head down
FC9 Blade broken

11.1.2. Speed reducer

Not necessary

11.1.3. Mechanical extra stroke

The following extra stroke mechanical protections are mounted:

9 Head down;

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Edition A

11.1.4. Signals

See 12.1.2

11.1.5. Led, indicators and signals to
avoid danger situations

Information about emergencies and dangerous situation concerning machine normal operations are shown.
A red light in the electrical cabinet indicates that electrics are switched ON.

11.1.6. Protection devices

The blade is protected, where uncovered, by two guides that reduce the risk, but that cannot completely cover it.

11.2. FIX PROTECTIONS

The movable parts of the machine are protected by fix covers, which can be removed using tools.

11.3. MOVABLE PROTECTIONS

The wheels are covered by two removable doors which can be opened to inspect or replace the blade. Two safety inter­lock switches automatically stop the machine if the cover is opened while the machine is working.

11.4. SAFETY FEATURES SET-UP

The limit switches are set up at the factory.

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Edition A

12. USE OF THE MACHINE

12.1. Operate the machine

Machine
can be operated in manual or semiautomatic mode. Each machine movement is controlled di­rectly from the control panel by pushbuttons or selector switches.

12.1.1 Control panel

The control panel looks like the following drawing

1 Blade speed readout

2 Blade speed adjusting knob

3 Blade START - STOP

4 Coolant ON - OFF

5 Hydraulic power unit

6 Blade replacement selector

7

8 Vice open - close

9 Cutting head up - down

10 Reset

11 Emergency pushbutton

E1 Hydraulic power unit overload

Cutting cycle: when pressed, the vice closes, the blade starts and the head start
moving down

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E2 Coolant overload

E3 Blade motor overload

E4 Blade broken

E5 Blade cover open

E6 Emergency

12.1.2 To start the machine

To start the machine turn the main disconnect switch located on the front door of the electrical
cabinet on position (1).
Press the reset pushbutton (10) and the light will turn off.

12.1.2 To stop the machine

To shut the machine off, turn the main disconnect switch located on the front door of the elec­trical cabinet on position (0).

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Edition A

12.1.3 When an emergency occur

The emergency situation must be restored (i.e. Covers open alarm on: close the covers).Then
press reset pushbutton (10) and start the hydraulics again (pushbutton 5).

12.2. HEAD FEEDING CONTROL

Head feeding is controlled by a servo controlled valve located on the side of the control panel.

LOADING THE MATERIAL ONTO THE MACHINE

Moving bars, especially if they are in bundles, it is necessary to pay attention to the security
rules for the movement of heavy loads.
Keep the bundle with steel strips until it is in the vises, then remove the strap before starting
the cutting cycle.

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Edition A

13. CALIBRATION AND TUNE-UP

13.1. CALIBRATION

No calibration is needed, because the machine was calibrated by the manufacturer.

13.2. MACHINE TUNING-UP

No tuning-up is needed, because the machine was tuned-up by the manufacturer.

13.3. BLADE MOTOR INVERTER

13.3.1 Control panel

All functions of the inverter can be controlled by way of the ACM-D2 control panel. The 4 input
keys allow control of the motor and direct parameter programming. The functions are separated
into three levels in order to facilitate programming (function tables TAB1, TAB2, TAB3).

TAB1 Programming of the basic parameters

of the inverter and call-up of works
settings.

TAB2 Configuration of the analog and digi-

tal inputs, programming of the output
voltage and of the SECURITY func­tion.

TAB3 Configuration of the analog and digi-

tal outputs, the extended setting func­tions and call-up of the diagnosis
function.

BUTTONS DESCRIPTION

Function interrogation forward.

Function interrogation back.

a) Jump back to the first function of the function table or sub-menu.
b) Jump out of the table or sub-menu (starting from the first function of
the function table or sub-menu).

Increments the parameter value of the selected function.
To increase the speed at which scrolling through the value range takes
place, keep INC depressed and briefly press DEC.

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Reduces the parameter value of the selected function.

13.3.2 Display

An eight-position alphanumeric display provides the user with all important information, such as
inverter status messages and information on possible errors or faults and parameter setting
values. The language for the display readout is selectable.

13.3.3 Help - function and language - selection

When pressing SHIFT and INC, on the display appears a scrolling Help-text concerning the cur­rently active function. Releasing INC and pressing DEC while holding SHIFT inverts the text
scroll - direction. Pressing SHIFT and INC in TAB1, funct. 1 enters the language - select mode.
Select the language by pressing the corresponding key.

Italian
German
English

The selected language will be saved automatically. Press any key to return to TAB1, funct. 1.

To increase the speed at which scrolling through the value range takes
place, keep DEC depressed and briefly press INC.
Permits access to a sub-menu or a parameter table.

Help function: A Help text can be called for each function. A key
change from INC to DEC with depressed SHIFT key inverts the text
scroll-direction of the help text.
Software reset.

SELECT
INC
DEC

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Edition A

13.3.4 Inverter status
MESSAGE DESCRIPTION

OFF No ENABLE, terminals 10/11 open.

STOP

1 33.6Hz

JOG

DEFAULT

SECUR. 1
SECUR. 2

Dyn Brake

DC STOP

FreqScan

13.3.5 Warnings
M

ESSAGE DESCRIPTION

If the AUTOSTART function is deactivated, the inverter is stopped af­ter switching on (see TAB3, SUB XPAR, function SW7 = OFF). Acti­vate ENABLE or START/STOP to start the inverter.
Display of current actual values or changeable parameters (the first
number group indicates the function number and the 2nd number group
the value of the respective parameter).
JOG mode is activated; output frequency setting by means of the unit
keypad.
Default parameter values (works setting) have been loaded but not
saved.
SECURITY Level 1 is activated; parameter values cannot be saved.
SECURITY Level 2 is activated; parameter values can be neither
changed nor saved.
Switching on braking chopper.
DC brake is activated.
ACM - Synchronizer: the inverter measures the actual motor frequency.

Undervol
Overload

HYST

RAMP

Br_limit

MPtFault

Overtemp

Ot_motor

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The mains has been reached the Under voltage Limit.
The output current has almost reached the type-specific limit
The set limit value for the output current has been exceeded. The output
frequency is reduced step-by-step until the output current falls below the
limit value again (see TAB1, SUB IMOT, function S-INT =4).
The set limit value for the output current has been reached. The
acceleration ramp is stopped (see TAB1, SUB IMOT, funct. S-INT = 3).
The dynamic braking power is near the programmed limit (configurable
by TAB2, func. BrLim). This message can be signalized by the relays or
the open collector outputs. (TAB3, funct. REL, OC1, OC2)
Motor potentiometer function: it was enabled a preset frequency with a
motor rotation sense different of the actual. The output frequency re­mains unchanged (TAB1 funct. JOG = MPt). (Only with Softw. D2A­STD)
The inverter (heat sink) temperature reaches the limit value.
(Only with Softw. D2A-STD)
The motor temperature reaches the limit value.
(Only with Softw. D2A-STD)

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Edition A

13.3.6 Operating error messages
MESSAGE DESCRIPTION

UNDERVOL

OVERVOLT
OVERLOAD
OVERTEMP

ILIMIT

1<4Ma

Br_limit

Ot_motor

1. Inverter stopped. Automatic error reset as soon as the link voltage rises above the under volt-

age value.

2. Inverter stopped. If the AUTORESET function is activated (see TAB3, SUB XPAR, function

SW3), a reset is possible by setting or the START/STOP input, or the ENABLE input, or by
setting the set point to zero.

3. The motor is decelerated with the deceleration ramp and the inverter is stopped. An error re-

set can be performed as described in Item 2.

4. The motor is decelerated with the deceleration ramp and the inverter is stopped until the tem-

perature doesn’t fall below the limit value. If the AUTORESET function is activated (see
TAB3, SUB XPAR, function SW3), a reset is possible by setting or the START/STOP in-
put, or the ENABLE input, or by setting the set point to zero.

5. Behavior with Softw. D2A-STD: see 4) Behavior with Softw. D2A-1300: see 2)

Under voltage has been detected in the link.
The voltage in the link has reached the over voltage value.
The output current has exceeded the type-specific limit value.
The inverter (heat sink) temperature is too high.
The set limit value for the output current has been exceeded
(see TAB1, SUBIMOT, S-INT = 1 or 2).
The speed reference line is interrupted or the set point is less than 4 mA.
The dynamic braking power has reached its programmed limit.
The motor temperature has been reaching the limit
value for more than 7 seconds. (Only with Softw. D2A-STD)

13.3.7 Hardware error messages

An error which is established during the self-test phase or during operation is shown on the dis­play by the message ‘‘ERROR’’ together with an error number. The inverter is stopped by the
safety devices.

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To reset the error message, switch off the mains supply and switch back on again. If the error is
not rectified by this, send the unit to the after-sales service for inspection.

ERROR CAUSE REMEDY

ERROR 1 Data error Reprogram parameters.
ERROR 2 Hard- and software is not compatible
ERROR 3 CPU error
ERROR 4 Keypad error
ERROR 5 Error in ROM
ERROR 6 Watchdog error
ERROR 7 Clock error
ERROR 8 Program error
ERROR 9 Output stage error

Have unit checked by technical
after-sales service.

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13.3.8 Programming structure

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Edition A

14. DISMANTLING OF THE MACHINE

Only experts can dismantle the machine.
It is important to require the dismantle to the constructor, especially if the plant has to be reposi­tioned.
Besides it is important to verify with the constructor the conditions to respect the security and
health requirements.

15. ORDINARY PROBLEMS

WARNING

It is defined as ordinary service the maintenance due to breaks or wear of parts. Even in these circumstances, only expert
operators should service the saw. They have to be able to work safely knowing which are the machine dangers, and avoid­ing unnecessary risks.
WHEN SERVICING THE SAW, ALWAYS DISCONNECT THE ELECTRIC SOURCE. THE OPERATOR
MUST USE THE ENTIRE SAFETY EQUIPMENT (GLOVES, GLASSES AND BOOTS).
The user must wear all the necessary protection devices: gloves, glasses and shoes.

THE MANUFACTURER CAN NOT BE JUDGED LIABLE FOR INJURIES OR
DAMAGES DUE TO UNATTENDED SAFETY RULES BY THE USER.

15.1. BASE

15.1.1. Base

Base dwg. 210/01-001

Vise wear status 06-012
Replace vise inserts 06-012
Vise guide 06-008

Pos.

15.2. CUTTING BRIDGE

15.2.1 Columns

Column dwg. 210/01-024 Pos. Tool

Check locknuts 01-025 Spanner

15.2.2 Connection bar

Head connection bar. 210/01-032

Check hydraulic hoses none

15.2.3 Lifting cylinder

Lifting cylinder dwg. 210/12

Pos.

Pos.

Tool

Tool

Tool

Check locknuts 12-017 Spanner
Check gaskets None

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15.2.4 Blade tension assembly
Blade tension assembly Dwg. 210/16 Pos. Tool

Adjust the guide track Spanner
Check locknut 03-052
Do not regulate the central screw of the blade tension guide

15.2.5 Band drive assembly

Band drive assembly dwg. 210/03 Pos. Tool

Check the electrical motor 03-001
Check the collect locking that connect the wheel to the reducer shaft 03-043
Check belts 03-019

15.2.6 Guide arms

Check guide arms dwg. 210/05 Pos. Tool

Check carbide inserts 05-045
When changing the blade, clean the inserts with gasoline
Check, and if necessary replace, the guiding ball bearings and the guide-arm inserts 05-023

05-026-029

Check and rotate the carbide backer 17-003

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Edition A

15.2.7 Band brush assembly

Band brush assembly dwg. 210/20 Pos. Tool

Check and if necessary replace the band brush 20-014 Spanner
Register the brush so to keep the blade teeth always clean

15.2.8 Wheels

Wheel. 03-042-0 Pos. Tool

Check the wheel adjustment
Check the blade position on the wheel. If the blade back touches the wheel, call the manu­facturer.
Check and keep clean the wheel grooves 03-042
Be sure the blade is not cutting the machine frame 03-042 Manufacturer
Keep lubricated all the bearings 03-051

03-042 Manufacturer

15.2.9 Servo-cutting device
Servo cutting assembly Dwg. 066/17 Pos. Tool

Check the servo-valve adjusting the cutting pressure. Turn the knob
Open the servo-valve cover and check the vertical movement of the unit. Spanner

15.4 HYDRAULIC POWER UNIT

Keep the pressure to 50 bar. Check the reservoir level and, if necessary, add oil type OSO46.

15.5 ELECTRIC CONTROL PANEL

Replace, if necessary, broken components.

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16. MAINTENANCE

16.1 LUBRICATION

Reducer
A Loading plug
B Level
C Unloading plug

Columns
D Loading plug
E Level

Wheel
F Bearings

Hydraulic power unit
G Loading plug
H Unloading plug

AGIP BLASIA 150
ESSO SPARTAN EP 150
MOBILGEAR 632
BP ENERGOL GR-XP150
FINA GIRA 150

AGIP EXIDIA 68
BP ENERGOL HP 60-C
TOTAL CARTER EP 68

AGIP GR MU 2
BP MACH-GREASE LT2
TOTAL MULTIS MS

AGIP OSO 46
FINA HYDRAN 46
BP ENERGOL HLP 46
ESSO NUTO H 46
TOTAL AZOLLA 46

Pag.34

Edition A

Replace oil after first 100 hours
Check the level every 2000 hours
Replace every 4000 hours

Check weekly

Check weekly

Replace oil after first 500 hours
Check the level every 500 hours
Replace every 2000 hours

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16.2. PROBLEMS

Problems Reasons How to solve the problem

Twisted cut Feed rate

Blade is not perpendicular
The blade looses the sharpness
quickly
The blade vibrates

Blade teeth break Feed rate

Blade breaks The guides don’t work properly

Stripes on a side of the blade Only one guide guides the blade Regulate the guides
Blade stalls Feed rate Reduce the feed rate
The motors are off Problems with the electric source

Cutting speed

Wrong teeth

The blade slides on the material

Feed rate

Wrong teeth

Cutting speed

The cut begins on an irregular or thin section

Material unclamped

Blade in tension even when work is over

Wrong weldment

Blade installed incorrectly

Wrong circuit breakers

Short circuit

Reduce the feed rate
Register the blade
Reduce the speed
Use a blade with the right teeth
Increase the feed rate
Increase the band tension
Reduce the feed rate
Use a blade with the right teeth
Reduce the speed
Turn the material on the machine
Clamp the material
Check the guides and their carbide inserts
Remove tension when not working
Return the blade to the supplier
Check the blade

Look for the problem and solve it

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Edition A

16.3.

1. Raise completely the saw head.

2. Wear protection gloves.

3. Rotate the band tension wheel CW, so to release tension; (or work on the band tension handle for machines

4. Stop the hydraulic power unit and switch the machine off, putting it under “out of service” status.

5. Open both the band wheel doors, and secure them;

6. If stalling in a bar, remove the blade slowly;

7. It is suggested to cover the blade using the plastic teeth strip that was originally on the blade;

8. Take the old blade in a place where no one can be injured;

9. Clean using compressed air the wheel tracks and the band guides;

10. Put the new blade on the wheel paying ATTENTION TO THE CUTTING DIRECTION;

11. Make sure the blade sits completely on the wheel track;

12. Place the blade in the guide arms;

13. Tension the blade making sure it sits correctly on the track..

14. Remove, with the blade off, the tooth cap protection;

15. Close the doors and start the machine again.

BLADE REPLACEMENT

equipped with hydraulic band tension).

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Edition A

17. REMAINING DANGERS

This machine is powered by electrical power. The manufacturer, building the machine, used the state of the art solutions
also meeting the regarding regulations to assure maximum safety to the operator.

When servicing the machine with power on to check particular electrical components, always respects the basic safety
rules. Reduce as much as possible this type of operations.

The customer is required to provide a suitable power source respecting the CEI 64-8 or other countries special rules where
the machine was installed.

18. PERSONNEL TRAINING

This machine was design to be easily operated. It is not expressly required an expert to operate the saw, but an expert can
set as best as possible the machine so to obtain the maximum results.

Therefore, the operator needs a good experience in machine tools, especially in band saw machine.

The internal maintenance personnel should be able to read and understand an electrical and hydraulic schematic, and work
on the machine following the instructions contained in the schematics.

19. MACHINE DISMANTLE

This machine was built using only ecological materials. It is necessary to separately recycle only the hydraulic oils and the
coolant liquid.

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Exhibit A – Proof of test

This band saw machine:

TYPE SERIES SERIAL NUMBER

C- 530M M

Has been tested in accordance with the following norms:

¾ UNI-EN 292-1
¾ UNI-EN 292-2
¾ CEI 60204-1 (CEI 44-5)

The test had positive result as per testing sheet #

Hours of hydraulic power unit for testing purpose

Pag.37

Edition A

Numbers of cuts done for test purpose

Electrical test

Hydraulic test

Mechanic test

Check

Signed