manual olimpus.pdf
TRANSCRIPT
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Dear Customer,
Thank you for choosing an FMB s.r.l. machine.
FMB s.r.l. is a leading reference point in the field of systems and machines for blade cutting.FMB s.r.l. production has always meant reliability and safety.
All FMB s.r.l. machines have been designed and manufactured to ensure always the bestperformance.
To maintain high quality standards and lasting reliability, we recommend using only originalspare parts.
FMB s.r.l. machines are certified according to the European Directive 98/37(Machinery Directive 89/392).
On the machines you will find the identification plate in compliance with CE standards.Moreover, the enclosed instructions manual and the conformity with the European Directive
98/37 and all its amendments will allow you to sell FMB s.r.l. machines all over Europe.
We are certain we have met all safety requirements and have further improvedworking standards.
The management
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GENERAL CONTENTS
Introduction to the company PAGE 8Use of the manual PAGE 9Informative letter PAGE 10Warranty PAGE 12
TRANSPORT PAGE 14Transport in wooden crate or cage PAGE 14Transport on pallet PAGE 15Handling PAGE 15
Unpacking PAGE 16
Storage PAGE 16
Plate and labelling data PAGE 17Technical terms PAGE 19Description of the machine PAGE 20Technical features PAGE 22Field of application PAGE 22Cutting dimensions according to the angle PAGE 23STANDARD EQUIPMENT PAGE 23
OPTIONAL PAGE 24
Dimensions and weight PAGE 24
CONFORMITY PAGE 25Noise PAGE 25Vibrations PAGE 25Electromagnetic compatibility PAGE 25Electric tests PAGE 25
Control of the purchased product PAGE 26
Conditions for installation PAGE 26Room PAGE 27Free spaces PAGE 27Machine installation PAGE 28Electric connection PAGE 29
Safety rules during use PAGE 31Control panel (NOT FOR Phoenix) PAGE 32Phoenix control panel PAGE 33Preparation for the use PAGE 33
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Blade replacement PAGE 37
Work cycle PAGE 38Machine use PAGE 38Safety protections PAGE 40Residual risk PAGE 41
Oils toxicological information PAGE 41Clothes PAGE 43Emergency situations PAGE 43Wrong and dangerous uses PAGE 43Safety area PAGE 44
DESCRIPTION OF THE OPTIONAL PAGE 45NB1 NB2 PAGE 45VAT PAGE 50PN PAGE 50G PAGE 51V PAGE 52C1 PAGE 56SCC - SCS PAGE 56RF1 RF2 PAGE 57AM - RS PAGE 57
ORDINARY AND PREVENTIVE MAINTENANCE PAGE 58
Ordinary cleaning PAGE 58Chip and coolant discharge PAGE 59Suggestions for the user PAGE 60Greasing PAGE 60Recommended lubricators PAGE 61Maintenance table PAGE 62Operation recording table PAGE 62
Troubleshooting PAGE 63
SPARE PARTS PAGE 65
Order form PAGE 65
Sawing machine and blade storage PAGE 66Dismantling PAGE 66
User declaration PAGE 67
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INTRODUCTION TO OUR COMPANY
The company covers an area of 20.000 square metres, 6.000 of which are sheltered.It was built according to the most modern standards, in order to obtain the greatestfunctionality. Spaces are rationally divided into areas for the product creation - such asplanning, production and test - and commercial, administrative, storage and delivery offices.
FMBwas born in 1982. It was one of the first to propose band saws on a market dominatedby disk sawing machines.
Thanks to its ability to evolve, to find new products and to adapt the machine characteristics tothe user's needs, it has become one of the leaders on the market.The result of FMBs.r.l. experience in the sawing machine field has enabled to create new typesof machines using the most modern technological discoveries.FMBs.r.l. proposes innovative services and products and it aims at satisfying every Customer'sexpectations as well as at forecasting at the right moment the development trends of themarkets in which it works.Our purpose is to enable every Customer, also through our staff members' coherent behaving,
to check FMBs.r.l. service and product quality.
By offering the new "Customer Care" service we are convinced that it is no longer enough tooffer a good product, useful for the Customer at a good price, but it is fundamental to enrich itwith a full specific technical assistance before, during and after sale.
With this documentation we would like to make you understand our company philosophy andwe are open to our potential interlocutors' ideas and needs to find together "made tomeasure" solutions.
The management
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USE OF THE MANUAL
The use and maintenance manual is the document accompanying the machine from itsmanufacture untill its dismantling. Therefore, it is an integral part of the machine itself. Themanual must be read before starting ANY ACTIVITY involving the machine, including itshandling. For a better consultation, the instruction manual is divided into the following sections:
Transport, packaging, handling and check on the purchased product
Description of the machine and of its field of application (that is the work it can do). Italso lists all the technical features of the machine. This information can be comparedto that of an illustrative leaflet
Installation of the machine
Description of the controls to use the machine
Optional description
Ordinary and preventive maintenance
Troubleshooting
Dismantling
SYMBOL USED
The operations which are particularly delicate or even dangerous, especially if notcorrectly performed, are accompanied with the following symbols.
WE RECCOMEND TO DEVOTE A PARTICULAR CARE TO THE TRAINING OF THE PERSONNEL WHO ISGOING TO OPERATE ON THE MACHINE AND ALSO TO VERIFY THAT THE INSTRUCTIONS ARE
REALIZED AND PUT INTO PRACTICE.
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INFORMATIVE LETTER
The following maintenance and instruction manual is an integral part of the machine and mustbe kept into a proper place always available to the staff in charge of its use andmaintenance.Each sawing machine is accompanied by its instruction manual.The installer, the operator and the maintenance man must know the content of this manual.Besides, FMB s.r.l.organises, upon request, courses to instruct the personnel for the installation,the use and the maintenance.The descriptions and the pictures contained in this manual are notto be considered as binding. If there are parts that are not clear we will be glad to give youfurther information.
The aim of this manual is to deal with topics concerning the installation, operation and
maintenance of the machine components and to complete them with a qualified person'sexperience and mechanical ability.
Although the main features of the machine described in this manual are not subject to change,FMBs.r.l.reserves itself the right to modify those components, details and accessories it deemsnecessary to improve the machine or to meet manufacturing or commercial requirements withoutupdating the manual immediately.
To receive more copies of this manual , adjournments and/or any further information about themanual itself, please quote the data on the cover.
FMB s.r.l. assistance service is organised so to satisfy any exigency. We want our machines
always operate at their best, so that our customers may consider our band saw machines anexcellent investment.
ADVICE
Our technique department is pleased to answer any question concerning the operation, theinstallation, the starting up as well as reparations and modifications to get round unexpectedsituations. We kindly ask you to contact us for any information or suggestion you may need.Our sales department is ready to discuss with you any possible modification or installation.
CHECK
An FMB s.r.l. sawing machine will work for many years without particular care. A periodicalchecking programme will assure the best efficiency, avoiding difficulties in unsuitable moments.
SPARE PARTS
If you like, you can write us about your problems or about unusual wear problems and we willbe glad to give you useful suggestions. We have standard spare parts if necessary.
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CUSTOMER CARE
We have a team of highly qualified technicians in charge of customer care.They are specialized in cutting and attend to installations, inspections or repairs.It is possible to engage them with notice. The travelling expenses have to be added to thetravel and maintenance costs during the transfer period and to another extra for overtime.We will be glad to send you our present prices for this service.It is extremely important that the machine is installed and started correctly. A successful unitoften depends on the way it is installed. We suggest you to make a qualified and experiencedstaff install the machine. and to rely on our engineers who can train the operators for the unitmaintenance and use.
CUSTOMER CARE TECHNICAL SERVICE
WARNING
The machine original configuration must not be changed at all.On receiving it make sure that the supply corresponds to what has been ordered.
IN CASE OF NON-COMPLIANCE INFORM IMMEDIATELYFMB s.r.l.
Also make sure that the machine has not been damaged during transport
WARNING
FMB s.r.l.sawing machines are not designed to work in places withexplosion and/or fire risk danger.
In case of damage or malfunction, the machine must not be used until theCustomer Care Technical Service has repaired it
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ALLRIGHTSARERESERVEDACCORDINGTOTHE
INTERNATIONALCOPYRIGHTCONVENTIONS
The reproduction of this manual, in any given form, is forbidden without prior writtenauthorization of FMB s.r.l.The content of this guide can be modified without notice.Great care has been taking in collecting and checking the documentation contained in thismanual to make it as complete and comprehensible as possible.Nothing contained in this publication can be considered a warranty, either expressed or implied -including, not in a restrictive way, the suitability warranty for any special purpose. Nothingcontained in this guide can either be interpreted as a modification or confirmation of the termsof any purchase contract.
WARNINGAccording to the European norms concerning the improvement in workers safety andhealth in workplace, the main thing to be stressed is that the employer himself (in closecooperation with the prevention /protection service responsible and the workers safetyresponsible) must carefully analyse all the possible risks correlated to the installation ofany machine in the production cycle, providing to take the right measures in order toavoid these risks.
So, when a new machine is installed in the production cycle , the employer is required andobliged to identify the relevant risks and find the suitable remedy.
WARRANTYPag. 13 di 50a) F.M.B.undertakes to deliver its machines in compliance with the MACHINERY DIRECTIVE andfree from any fault making them unsuitable for the use they are destined to.
b) F.M.B. is not to be held responsible for electric and electronic faults, inadequatecompliance of the machine, or faults due to normal wear of all parts subject to rapid and
continuous wear (ex.: gaskets, brushes, fuses, blades, etc.). In the same way, F.M.B. is notliable for the machine compliance defects and of the faults caused by the non-complianceto the instructions contained in the use manual and by misuse or incorrect operation. F.M.B.is not to be held responsible for inadequate compliance or for faults deriving fromnegligence and/or incorrect operation or for alterations or repairs carried out withoutprior written permission of the manufacturing company. F.M.B.does not take upon itself theresponsibility for the machine positioning and installation.
c)This warranty has a 12 month validity from the date of commissioning of the machine at thebuyer's premises and in any case it will not exceed 15 months from the date of delivery of themachine. The warranty covering any replaced or repaired part will expire on the same dateas the machine warranty.
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d)The buyer, within 15 days from delivery, after checking and testing the machine carefully,will have to inform in writing of any inadequate compliance or machine fault. Failure to report
as above will make the warranty null and void.The warranty is also void if the buyer does not allow the seller to carry out all reasonablechekcs as required by F.M.B., or if the buyer does not return at his own expense any faultypart which the seller requires to be sent back within 8 days.
e)Once the buyer has reported the fault in compliance with point d), F.M.B., after checking thedefect or fault presence may either:
1. replace free all faulty parts or;2. carry out or have a third party carry out the repair work.The transport expenses for the faulty part replacement will be charged to the buyer.If some F.M.B. technical staff is required, the buyer will be charged all the expenses(performance, transfer, etc.).
f) Except in case of fraud (or serious fault) by the seller, compensation for any damagesuffered by the buyer shall never exceed the part value as in point e).
No claims may be made against F.M.B. after the warranty expiry.
THIS WARRANTY SUPERSEDES ALL WARRANTIES AND LIABILITIES PROVIDED FOR BY THELAW, EXCLUDES ANY OTHER LIABILITY OF THE SELLER ARISING FROM THE GOODSSUPPLIED, AND EXCLUDES ANY RESPONSIBILITY FOR LOST EARNINGS AND/ORPRODUCTION LOSSES. IN PARTICULAR THE BUYER IS NOT ENTITLED TO CLAIM FORFURTHER DAMAGE,PRICE REDUCTION OR CONTRACT CANCELLATION.
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TRANSPORT
To transport the machine only the systems below can be used. In any case, make sure thetransport and lifting device can bear the machine weight with its packaging (for dimensions seepage 2).
TRANSPORT WITH WOODEN CRATE OR CAGE TRANSPORT ON PALLET HANDLING ON LIFT TRUCK OR BRIDGE CRANE
WARNING
The staff in charge of handling the load must be trained toand should wear protective gloves
WARNING
While lifting or handling the machine, or any of its components, make surethe working area is cleared, by leaving a safety area around it,
to avoid damaging people or things inside it.
TRANSPORT IN WOODEN CRATE OR CAGE
The machine is wrapped in thermoplastic material to ensure the component protection. It is thenpacked in a wooden crate or cage to protect it from impacts and bad weather. To lift it use afork lift truck(See FIGURE 1).
WARNING - Follow the instructions on the packagingbefore handling and opening it.
WARNING- The packaging dimensions vary accordingto the type of machine ordered and to itsconfiguration.
WARNING- In the wooden crate or cage the machineis fastened by means of screws, to prevent it frommoving during transport (SeeFIGURE 3). FIGURE 1
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TRANSPORT ON PALLET
This type of transport is generally used for national deliveries or in case of short distances. Inthis case the machine is fastened on a pallet by means of the holes on the machine base; themachine is then loaded on a lorry and fastened with some ropes.To handle the pallet, use then a fork lift truck.
FIGURE2
FIGURE3
WARNING - Once loaded on the lorry, cover themachine with a tarpaulin.
WARNING - The machine must be fastened to thepallet as shown in FIGURE 3.
HANDLING
To handle the machine inside the departments or to position it perfectly in the firm production lines,a fork lift truck can be used. If available, use a bridge crane by inserting the hooks into theeyebolts on the machine. The eyebolt holes are protected by screws to prevent chips from entering.
Position the forks under the machine by avoiding damaging its components and then lift it.
WARNING- Act slowly while handling
WARNING-.. Always place the lift truck forks in barycentric position.
WARNING- Avoid swinging the machine while handling: move it carefully and lift ita few centimetres from the ground.
WARNING - Always check where the forks lean underneath the base to avoiddamaging some parts; if necessary put some polystyrene or soft wooden blocks.
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UNPACKING
If the machine is delivered in wooden cage, unpack it using a hammer with nail puller.Open the cage from the upper cover and then remove the side walls. Remove the crosspiecesfastening the machine feet and, by means of a lift truck (as described in the previous section),displace it from the pallet.
WARNING
Always wear protective gloves.
WARNINGAlways pay attention to anyprojecting nails.
WARNINGThe packaging (usually a wooden one)must be delivered to associations incharge of waste disposal and ofrecycling.
FIGURE 4
STORAGE
During transport and storage make sure the temperatures between -5 and 50 C [23and 122 F] are not exceeded.If the machine is to be stored, make sure it is not put in places with an excessiverelative humidity.
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PLATE AND LABELLING DATA
The manufacturer's identification and CE STANDARD 98/37 compliance plate is on the right
side of the head (see FIGURE5).
The plate must not be removed at all, even if the machine is resold. Always refer to the serial
number (written on the plate itself) when contacting the manufacturer.
WARNING- Several safety warnings are placed on some machine components; they must be
strictly followed by everyone dealing with the sawing machine.
The company is not to be held responsible for damage to property or accidents to people
which might occur if the above-mentioned warnings are not observed. In such a case, the
operator is the only person responsible.
FIGURE 5
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LEGEND
1 F.M.B.Name plate
2 Plate of danger for hands in the indicated area
3 Indications of obligation to read the Instruction Manual
4 WARNINGS:
- danger for the hand when the machine is moving;
- obligation to wear protective gloves;
- climbing on the machine forbidden;
- danger of falling near the machine;
- recommendation of wear ear defenders (d.p.i.);
- general warning;
5 Indicates the cutting capacity
6 CE plate and serial number
7 Transport and handling plate
8 Indicates the blade size development, rotation speed, direction and teeth direction
9 Blade tightener plate
10 Plate of no removing the antiopening guard
TABLE 1
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TECHNICAL TERMSHEADIts the top of the machine containing the cutting device .
BLADEIts the part that cuts.
BANDSee blade description
MOTORBLADEWHEEL
Its the disk upon which the blade rotates pushed by the reducer and the blade motor.
BLADEWHEELIts the disk , trailed by the blade, which allows the rotation of the blade with the help of theblade stretcher.
BLADETENSIONERIts a dynamometric mechanical device which allows the blade through the blade wheelpermitting its rotation.
GUIDEBLOCK
Its the blade guide placed before the motor blade wheel.
MOVINGGUIDEIts the blade guide placed after the loose blade wheel.
SPEEDVARIATORIts a mechanic device which allows to vary the blade rotation speed in a continuous way.
VICEIts a mechanic device to clamp the material to be cut.
REVOLVING
SUPPORTIts a mechanic piece connecting the vice to the permitting the rotation for the execution of mitre cut.
COOLANTIts the mixture water/oil which lubricates and cools the blade during the cutting phase.
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DESCRIPTION OF THE MACHINE
The machine described in this manual is a manual band saw.The machine is made up of a solid steel structural work with very thick metal sheets supportingthe moving parts. This solution gives remarkable strength to the whole structure and reducesvibrations and mechanical stresses to a minimum.The cutting head is assembled on a system provided with inclination adjustment and it islocated just in front of the operator. The piece to be cut is fastened by means of a manuallocking vice. The blade downward movement is manual; its starting occurs by means of a pushbutton located on the command handle lever. The blade is characterised by a precise, "soft"rotation and great performance.It is possible to adjust the blade rotation speed. Several parts of the machine require nomaintenance and those requiring maintenance are easily accessible.
NO DESCRIPTION
1 Tank (not for Phoenix)
2Coolant pump (not forPhoenix)
3 Machine base
4 Rotating support
5 Balance spring
6 Key limit switch
7 Electric motor
8 Pick up handle
9 Coolant tap
10 Head
11 Blade tensioner
12 Head guard
13 Stretcher register screw
14 Locking lever
15 Control panel
FIGURE 616
Instruction book holder (notfor Phoenix)
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NO DESCRIPTION
17 Vice
18 Cutting reference rod
19 Rear blade protection
20 Front blade protection
21 Movable blade guide
22 Anti-opening guard
23 Movable blade wheel
24 Handle
25 Blade tensioner
26 Band blade
27 Fixed blade guide
28 Motor blade wheel
29 Brush protector
FIGURE 7 30 Phoenix Coolant pump
TABLE 2
FIGURE 8
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TECHNICAL FEATURES(See FIGURE 6/7)
All machines are provided with high precision components and are carefully assembled.Every assembling stage is repeatedly checked by a skilled staff in order to ensure a highquality standard during each cycle phase.
The machine mainly consists of: a welded steel structure base, on which the electric systems arelocated; on the head are located the motors and the mechanisms that make the blade and thehead move.The head (of very thick aluminium casting) is guided in a precise way and without vibrations.The blade tension is manually adjustable by the blade stretcher.The blade is assembled on two well sized blade wheels and guided in the cutting area by twocouples of sliding blocks (blade guide) that are already adjusted..The cutting head forward movement is manual with spring balance.The main cutting action is made electromechanically. The main motor activates the motor bladewheel by means of a reducer. The cutting blade is started by pressing the start pushbuttonlocated on the handle.The piece forward movement must be carried out manually; it is possible to perform cuttings ofdifferent lengths on the same piece by means of a scale.FMBs.r.l. carries out all the necessary tests before delivery. Thanks to this service the sawingmachine is tested and calibrated for the type of working required.
For technical specifications see below.
The technical data are only indicative and they can changed without prior notice. The machineproduction speed depends not only on its configuration, but also on the blade quality and onthe material to be cut.
FIELD OF APPLICATION
The machine has been designed to cut brass, aluminium, iron, cast iron, stainless steel etc. drawnproducts or sections. FMB s.r.l. is not to be held responsible for accidents caused by anUNAUTHORIZED and unskilled staff using the sawing machine for purposes that are differentfrom those mentioned above without the manufacturer's written consent and the technical
feature adaptation. FMBs.r.l. is not to be held responsible in case of machine installation thatdoes not comply with the standards in force or with this instruction manual, either.
WARNING
Cutting some particular materials may cause an accumulation of static charges.The user only is required to check and neutralize this risk.
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ITISFORBIDDENTOUSETHEBANDSAWTOCUTFLAMMABLE
MATERIALSORMATERIALSWHICHMAYBURST,SUCHASWOOD,PLASTICMATERIALSOROTHERSIMILARSTUFF
WARNING
The user, depending on the material to be cut and the employed coolant liquid, should take intoconsideration the possibility and risk of fire, smoke or dangerous suspensions in work-place and,accordingly, is obliged to take all the necessary precautions (room aeration, fume analysis , etc.)
CUTTING DIMENSIONS ACCORDING TO THE ANGLE
The table below shows the maximum thickness in mm/inches that can be cut, according to thecutting angle and to the piece shape for the different machine models.
0 45 60 45
a x b a x b a x b a x b
mm
PHOENIX 220 220x220 200x250 150 140x140 80x160 90 90x90 90x90 100x70TRITON 230 230x230 170x280 175 165x165 170x175 230x145 110 85x85 80x110
ANTARES 200 200x200 200x230 160 150x150 200x140 100 100x100 100x100 85 85x85 85x85 160x85
ORION 230 230x230 130x310 200x280 170 160x160 160x165 230x150 100 100x100 100x100 130 100x100 80x130 190x40
TITAN 240 240x240 230x356 240x350 230 215x215 160x230 240x200 140 140x140 140x140
a x b a x b a x b a x b
inch
PHOENIX 8,7 8,7x8,7 7,9x9,8 5,9 5,5x5,5 3,1x6,3 3,5 3,5x3,5 3,5x3,5 3,9x2,8
TRITON 9,1 9,1x9,1 6,7x11 6,9 6,5x6,5 6,7x6,9 9,1x5,7 4,3 3,3x3,3 3,1x4,3
ANTARES 7,9 7,9x7,9 7,9x9,1 6,3 5,9x5,9 7,9x5,5 3,9 3,9x3,9 3,9x3,9 3,3 3,3x3,3 3,3x3,3 6,3x3,3
ORION 9,1 9,1x9,1 5,1x12,2 7,9x11 6,7 6,3x6,3 6,3x6,5 9,1x5,9 3,9 3,9x3,9 3,9x3,9 5,1 3,9x3,9 3,1x5,1 7,5x1,6
TITAN 9,4 9,4x9,4 9,1x14 9,4x13,8 9,1 8,5x8,5 6,3x9,1 9,4x7,9 5,5 5,5x5,5 5,5x5,5
TABLE 3
STANDARD EQUIPMENT
All the standardsawing machines are usually delivered with the following equipment:
CUTTING BLADE;
USE AND MAINTENANCE MANUAL;
DECLARATION OF CONFORMITY TO CESTANDARDS;
WARRANTY;
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OPTIONALS
The following optionalare supplied upon request only (See TABLE4)
NB1NB2ONE-NOZZLE AND TWO-NOZZLE NEBULIZER;
VATCUTTING ANGLE DISPLAY;
PN;
G;GRAVITY FEED;
VBLADE ROTATION SPEED VARIATOR;
C1ONE ROLLER STAND;
SCCSCSCONNECTION;
RF1 RF2ROLLER TABLE;
AM-RS;MEASURE SHAFT;
NB1 NB2 VAT PN G V C1 SCC SCS RF1 RF2 AM-RS
ATLANTIS O O O O O O O O
PHOENIX O O O O O O O O O O O O
TRITON O O O O O O O O O O O O
ANTARES O O O O O O -- O O O OORION O O O O O O O O O O O O
TITAN O O O O -- O O O O O O O TABLE 4LegendO= Upon request optional, --= Current equipment,
DIMENSIONS AND WEIGHT
The machine dimensions (in mm/inch) are shown in TABLE5.
A B C WEIGHTcm cm cm kg
ANTARES 90 140 150 290ATLANTIS 70 130 140 200ORION 90 140 150 400
PHOENIX 67 62 140 240
TITAN 110 160 150 470TRITON 80 140 150 290
inch inch inch lb
ANTARES 35.5 55.2 59 640ATLANTIS 27.6 51.2 55.2 441ORION 35.5 55.2 59 882
PHOENIX 26.4 24.4 55.2 530TITAN 43.3 63 59 1036TRITON 31.5 55.2 59 640
TABLE 5
FIGURE9
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CONFORMITY
NOISE
The data below refer to studies effected on another machine which is almost the same to theone described in this manual.Granted that the noise of a band saw machine is due to different factors (such as installation,natural features of the material to be cut, blade typology, cutting speed, employed lubricantcoolant, etc.) according to the tests carried out in our premises on the idling machine aparticularly reduced noise has been surveyed (See TABLE6).Its the users task to survey the noise of the machine during the working phases taking into
consideration the materials to be cut and the location of the machine in the company lay out .Accordingly, its the users task to take the suitable measures in order to conform to theregulations in force.
Equivalent continuous sound pressure level at workstation
ATLANTIS 84,2 dB (A)PHOENIX 84,2 dB (A)
TRITON 78,8 dB (A)ANTARES 78,8 dB (A)
ORION 78,8 dB (A)TITAN 78,8 dB (A)
TABLE 6
VIBRATIONS
According to the tests effected in our premises the values of the stress transmitted both to thesystem arm-hand and to the whole body of the user are in compliance with the CE 98/37European Directive. These tests have been carried out referring to the ISO 5349:1986 and theISO 2631-1:1997 norms (less than 2,5 m/s2 value) [8,2 ft/s2].
ELECTROMAGNETIC COMPATIBILITY
With reference to the tests effected in our premises, in compliance with the CEE /89/336
European Directive, the values of the radiated and of the driven emissions are included into thelimits provided by the following reference norms (used also for test measuring):EN 50081-2, section2;EN 61000-4-2, section4, paragraph2;EN 61000-4-4, section4, paragraph4;EN 61000-4-6 section4, paragraph6;
ELECTRIC TESTS
All the electric tests have been performed by FMBs.r.l.For further information see attached notice at the end of the present manual.
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CHECK ON THE PURCHASED PRODUCT
Before using the machine check it has not been damaged during transport or storage.Also check if all the standard components are inside the packaging. In case of damage, informimmediately the forwarder and the manufacturer. When checking the machine pay attention to theconnecting pipes, since any impact could compromise the machine operation, or worse, theoperator's safety.
INSTALLMENT CONDITIONS
WARNINGTO ENSURE THE CORRECT WORKING OF THE MACHINE WITH ITS SAFETY DEVICES,
THE MACHINE ITSELF MUST BE INSTALLED BY QUALIFIED PERSONS.
The machine installation requires special care. It is advisable a qualified staff install the machine
and to follow the instructions below.
Check that the standard cable is integral. Connect it to a standardized plug, or in any case in
compliance with the standard in force in the country where the machine is installed.
The minimum section of the connecting cable must be chosen according to voltage, installed power
and distance between source and application. Check that the main electric line the machine is to beconnected to has the same voltage and frequency needed to operate the machine. Also check that
the external line of the power supply is protected by a differential switch according to the
regulations in force.
Carry out the connection workmanlike. All the electric components must be earthed.
All the connecting cables (phases + earthing) must be connected to avoid being torn or damaged.
The same goes for low-voltage pieces.
WARNING
DO NOT PLACE THE MACHINE NEAR HEAT SOURCES,WATER OR OTHER FREE LIQUIDS.
WARNING
ALL FMB S.R.L. MACHINES ARE NOT CONCEIVED TO WORK IN PLACES WITH
DANGER OF EXPLOSIONS AND/OR FIRE RISKS.
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ROOM
The machine must be put in a place with the following characteristics:
It is advisable to place the machine
in a room with a good ventilation to
avoid dangerous fumes caused by
the productive process, which could
be dangerous for the operator (see
drawing aside (see FIGURE 10).
Comply with the free spaces
required which are indicated in this
manual. FIGURE 10
The electric and hydraulic systems must be sheltered as much as possible from dust,
noxious vapours and humidity.
The band saw is to be placed in a sheltered place out of bad weather and not left
in rain.
The room temperature inside the machine room must be kept between 5 and 40 C
[41 and 104 F].
If necessary (ACCORDING TO THE PRODUCT TO WORK) arrange some suction
systems near the machine.
Some materials cutting can create sparks. Avoid placing the machine near
inflammable substances.
The slightest luminosity in the work place must be of 400 luces.
FREE SPACES
To operate freely on the machine, by opening all doors and carry out equipment and
maintenance interventions, the minimum distance from the walls must be as shown inFIGURE11.
WARNING
We recommend leaving a suitable space for the piece loadingand unloading system, especially if a roller system is used.
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FIGURE11
MACHINE INSTALLATION
Before placing the machine on the ground or on a slab, check if the floor is perfectly
levelled by means of a level. Also check if it can bear the loads near the foot support
points. Check previously that the floor has a foundation and a sub-foundation as the ones
indicated in the drawing below and that it can bear the machine weight.
Floor composition
FIGURE12
To fasten the machine use the fastening holes used for transport (see FIGURE12) by fixing itto the floor by means of 4 tirax screws.
MACHINES OVERALLDIMENSIONS AREA
2,5 meters8,2 ft
minimum
minimu
m
minimum
2met
ers
6,6
ft
2meters
6,6
ft
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WARNING
WARRANTY AND RESPONSIBILITY ARE NULL AND VOID IF THE INSTALLATION ISNOT IN COMPLIANCE WITH THE STANDARDS INDICATED BYF.M.B. s.r.l.
FIGURE13
ELECTRIC CONNECTION
Electric connection must be carried out by skilled and export technicians.First of all, make sure that the lines can feed the machine correctly, in compliance with thesafety standards (for the required features see page 2).
WARNING
The machine voltage is indicated on the identification plate locatedon the control panel placed on the head.
The machine is supplied with electric cable, but without plug. The electric cable must be connectedwith a suitable plug.
WARNING
It is advisable to install upstream a differential "life saving" deviceand to check that the earth circuit is effective.
WARNING
Before operating on the feeding cables unplug the socket
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WARNING
Check that the connection has been made by acting on the main switch
(the green warning light on the control panel must be light up).
WARNING
All the connections and the electric protections must be in compliance with the
Motive Power and the Plate Data values (voltage, current and frequency),
required by the different electric circuits.
The main switch is in the middle of the control panel.
The control panel can be reached by placing the main switch on 0, and by unscrewing the 2
screws at the door ends.
The electric circuit feeds the motor of the blade and the coolant pump.
The machine is equipped with earthing.
WARNING
Put to earth the structure of the machine connecting it to the ground
using the contact screw already placed on the basement near the exit of the feeder
WARNING- Any defective earthing can cause danger in the work. The damages will not
be at FMBs.r.l. expense.
Once the connections are made, check that the feed clamp voltage is the same of the
network voltage, and that it is present on the three phases. Place the main switch on 1
and check that the green warning light on the control panel.Check the direction of rotation by pressing the pushbutton located on the handle.
In this case the blade rotates in the reverse direction, exchange two phases of the feeding
cable and check again.
WARNING
All electric motor rotation is indicated.
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SAFETY RULES DURING USE
This section describes how to use the machine and the safety rules to follow to use it correctly.
Read this section carefully. TO USE the machine COMPLY WITH the following precautionsand safety criteria.
USE THE SAW WITHOUT PROTECTIVE GLOVES AND CLOTHES REQUIRED BY THELAW IN FORCE.
CLEAN THE MACHINE USING COMPRESSED AIR, EVEN THOUGH PROTECTIVE VISOR IS WORN.
PLACE YOUR HANDS IN THE CUTTING AREA WHEN THE MACHINE IS ON.
INSERT YOUR HANDS BETWEEN MOVING PARTS.
CLEAN THE BLADE, THE SAW BLADE GUIDES OR THE CUT SURFACE WHEN THEMACHINE IS ON OR THE BLADE IS TURNING.
KEEP THE HANDS CLOSE TO THE CUTTING AREA OR WHERE THE BLADE IS UNPROTECTED.
Remove the guards (FIGURE6/7, POSITION 12-19-20-22-29).
Cut a piece without clamping it in the vice; do not retighten while cutting.
Disable or damage the safety devices.
Change or add any device to the electric system, without the written consent or thetechnical intervention of FMB s.r.l.confirming the changes introduced.
Use the machine for purposes that are different from the ones that it is interdet to,which are described in the use and maintenance manual.
Use the machine with toxic products.
Put the hands close to the material block vice.
Work very long pieces without using any support system.Start the machine when other operators are near it.
Allow unauthorized staff to use the machine.
Displace bars to cut using a crane or other means above the machine.
Operate if the blades have broken teeth or are cracked.
Use the machine until all the protection covers have been installed.
Cut a piece without regulating the blade guides that must be as near as possible to
the piece to be cut.
DO NOT
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WARNING
EQUIP THE SAW WITH SOME ROLLERS TO SUPPORT THE MATERIAL TO BECUT. THIS WILL ALLOW TO WORK CORRECTLY AND SAFELY.
FMBs.r.l. is not to be held responsible if the user does not follow these instructions.The company also declines all responsibility for any type of negligence while using it.This machine can be used by skilled and trained workers only.
CONTROL PANEL (NO PHOENIX)The electric drivers are located on a front panel easy to be reached as shown in FIGURE 14.
FIGURE14Legend1. Cutting angle display (VAT optional)2. Choice of manual mode/gravity (G optional )3. Blades approaching to the piece to be cut (with G optional )4. Emergency5. Warning light6. Main switch7. Reset8. Choice of blade speed
9. Choice of refrigerant (with NB optional ) TABLE 7
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PHOENIX ELECTRICAL CONTROL PANEL
IMM.15Legend1. Blade approaching to the piece to be cut (with G optional)2. Selection manual/gravitational use (G optional)3. Main switch4. Tension warning light5. Blade speed selection6. Reset7. Alarm
PREPARATION TO THE USE
After checking the gear motor oil level, fill the tank, located inside the machine structure, with
20l [5,3 US gallon]of oil-water emulsion (percentage of mixtures between 3% and 5%).
Check the efficiency and integrity conditions of the blade and of its tension, by acting on
the blade tensioner handwheel, until the sliding indicator reaches the yellow field.
Check that the type of blade, that is the blade toothing is suitable for the thickness that
must be cut (see the toothing measures suggested in TABLE8). Before starting the working
cycle push the reset pushbutton.
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WARNING
Selecting position "1", the blade rotates with a speed of 35 m/1' [115 ft/min] thisspeed is suitable for "hard" metals (function to be used for occasional cuttings only);selecting position "2", the blade rotates with a speed of 70 m/1' [230 ft/min] (thisspeed is suitable for softer metals).
We remind you that the single-phase machines are not provided with the speed selectorand the blade rotates at a speed of 70m/1'[230 ft/ min].
THE TABLE BELOW INDICATES HOW TO CHOSE THE BLADE TO BE USED:
THICKNESS 12mm0.0390.079inch t.p.i. 18 14 10/14
THICKNESS 25mm 0.0790.2inch t.p.i. 10 8 8/12
THICKNESS 510mm 0.20.4inch t.p.i. 6 6/10 5/8
1030mm0.41.2inch t.p.i. 6 5/8
3080mm 1.23.15inch t.p.i. 4 4/6
80150mm 3.155.9inch t.p.i. 3 3/4
150230mm 5.99inch t.p.i. 3 3/4
TABLE 8
CHOICE METHODS OF THE BLADE SPEED WITH VARIATOR:
TABLE 9
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BLADE SPEED OF THE DIFFERENT MODELS:
V
m/1
[ft/min]mm [inches]
slow fast
m/1
[ft/min]
ATLANTIS 2450x27x0,9 96.5X1.06X0.035PHOENIX 2450x27x0,9 96.5X1.06X0.035
TRITON 2700x27x0,9 106.3X1.06X0.035ANTARES 2700x27x0,9 106.3X1.06X0.035
ORION 2700x27x0,9 106.3X1.06X0.035TITAN 3180x27x0,9 125.2X1.06X0.035
35
115
70
230
20 100
65.6-328
TABLE 10
When the blade is NOT rotating: approach the blade to the piece to be cut, unlock the
movable blade guide by means of the lever and, making it slide, fit the cutting with to thepiece dimensions. Block the movable blade guide by means of the lever.
FIGURE16 Vice Atlantis FIGURE17 Vice Triton/Phoenix/Titan
FIGURE18 Vice Antares FIGURE19 Vice Orion
1 Revolvin su ort 7 De rees lever2 Support vice 8 Vice carriage3 Vice base 9 Vice handwheel
4 Fixed vice 10 Clamping/unclamping lever5 Degrees plate 11 Closing handle6 Moving vice TABLE 11
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Make sure the work piece is property located on the cutting table (it must be flat
against the whole table surface).
By means of the wheel, move the vice to the piece to be cut and firmly clamp it.
For those models supplied with clamping/unclamping fast manual drive lever (FIGURES
17/18/19, POS.10)the material to be cut must not be entirely clamped by the vice hand
wheel so to allow to carry out this operation using the clamping/unclamping lever.
Make sure that the lubrication tap located on the head is open (N.B.: some materials can
be cut without coolant liquid use)
WARNING
Because of its dimensions, the cut piece might come out and/or fall in the tank closeto the vices or even fall on the ground, presenting the risk for the operator ofpersonal injury. Its consequently necessary to use a roller table (optional) on whichthe material to be cut can be safely positioned.
To obtain angled cuts, unlock the lever and, keeping the head in position of cut end, rotateit to the right, up to the desired angled.Read the angle stated on the revolving support plate and on the reference small plate.The 0, 45 and 60 positions are provided with mechanical retainers already calibrated.Anyway it is possible to carry out possible adjustments.FOR ORION MODEL ONLY:In order to carry out cuttings inclined between 45 and 0,it is necessary, before revolving the head, to turn the two closing handles out and translate
the moving vice unit from the left to the right side of the working surface and afterwards,block the two closing handles. For 0 to 60 cuttings follow the inverse operation.
For a good machine operation, we recommend to keep always the blade guides clean andlubricated with cooling, lubricating fluid. A good cut can be obtained, following thefollowing instructions:
Assemble the blade correctly, tension and release it respectively before and after use
by means of the blade tensioner handwheel
Know well the material to be cut.
Adjust the cutting speed for the type of material to be cut.
Use quality cutting blade. Use blade teeth fitted to the thickness and to the other features of the material to be cut.
Carry out the first cuts without forcing; a new blade must be properly run in.
Use abundant quality lubricant.
Clean the blade guide frequently.
Check the bearing and the carbide guide efficiency status inside the blade guides.
The cutting forward movement depends on the above.
We recommend the operator to act carefully.
IMPORTANT:The distance between the carbide guide tips should range from 0,95 mm up to 1 mm
[0,037 in up to 25.4 in]. This record can be carried out screwing and unscrewing thebearings support screw(FIGURE 20 Pos.2).
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DO NOT FORCE!SAWBAND SHOULD JUST TOUCH
Legend1Blade2 Bearing3Carbide
FIGURE 20
BLADE REPLACEMENT
If the blade is broken or consumed, it should be replaced. To effect this operation carefullyfollow the instructions below:
WARNING
THE BLADE MUST BE REPLACED ONLY BY A SPECIALIZED STAFF
WARNING
OPERATE ONLY WITH PROTECTIVE GLOVES AND GLASSES.
WARNING
REPLACE THE BLADE ONLY WHEN THE MACHINE IS TURNED OFF
Switch off the machine.
Remove the small guards fixed on the head and/or on particular pieces on the head. Disconnect the hinges fixing the head guard to the guard itself.
Dismantle the head guard. Simultaneously the key of the head safety micro and the
blade polishing brush will go out .
Release the blade stretcher hand wheel (which may cause the blade loosening) and
tap it towards the inner part of the head.
Unthread the blade from the head starting from the upper part, then from the blade
wheel and last from the motor wheel.
Unthread the blade from the fixed blade guide first and then from the movable one.
The blade should be disposed of, after having it rolled up and fast tied up with a
suitable wire , as ordinary iron residue according to the regulations in force . Clean the blade wheel, the motor wheel and both the fixed and movable blade guides.
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Now you can mount the new blade following the instructions hereby:
Always use blades provided with a plastic teeth protection. Repeat, in reverse order, the above described operations for the blade dismantling. Verify that the cutting side of the blade is positioned as shown in the blade details plate. ATTENTION Its compulsory that all the guards are reassembled. Make the blade make 3 / 4 complete turns, then check the tension of the blade itself
acting on the blade stretcher blade wheel. Ensure that the tension value fits with theposition quoted on the stretcher plate.
Now the plastic teeth protection may be removed.
WORK CYCLE
Clamp the main switch into position I, the green led will light on so indicating thepresence of current.
Press the button reset which prepares the machine to the work cycle. Press the button on the handle which sets in action the blade rotation. Keep the above mentioned button pressed, firmly push on the handle towards the bottom.
Effect this operation with a force and a speed proportional to the material to be cut , to itsshape and dimensions and proportional also to the blade toothing and wear.
The work cycle can be voluntarily interrupted stopping pressing the button on thehandle or, in case of emergency, pressing the mushroom-shaped button.
What better indicates if the cut is correct or not is the form of the chips produced by
the cut . This metal chips should be soft, open and light as indicated in FIGURE 21.
OK
CORRECT PRESSURE
NO
TOO LOW PRESSURE
NO
TOOHIGHPRESSUREFIGURE 21 FIGURE 22 FIGURE 23
MACHINE
USE
The band sawing machine is conceived to cut iron bars of different shapes and dimensions.The natural features of the above mentioned material, such as the toughness and theconsistency, should present no problems for the operator's safety during the cutting operation.F.M.B.is not to be held responsible for any damage to people or things. The user must checkcarefully the features of the material to be cut in order to avoid any risk of personal injury.The material to be cut can be loaded manually or by means of bridge crane, controlled bythe operator at a safety distance.During the loading operations, the operator must observe the safety distance and be
careful to lean the piece/s on the machine.
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WARNING
During the machine use, the operator must always wear: proper protective glasses,
ear defenders, safety shoes, specific gloves,
BEING CAREFUL NOT TO APPROACH THE BLADE WHILE IT IS MOVING,IN ORDER TO PREVENT FROM BEING DRAGGED BY THE BLADE ITSELF.
WARNING
Some protection devices (ear defenders, glasses, gloves) might sometimes be dangerous(as for example gloves).According to the rules about the Safety Hygiene and Health protection at Work, the usermust take into consideration all the risks concerning and deriving from the use of themachine, included the relative and/or consequent risks.
WARNING
The possible risks due to the machine use (type of cut material, vapours, particular oils,
piece falling etc.), that is all the risks and problems concerning and deriving from the useof the machine must be solved, as it is provided for the firm rules.
WARNING
If during the cut the blade breaks, the stretcher would not keep the sufficient blade tension.The blade would collapse at once and stop turning.The motor located on the head would keep turning, with no danger at all, until the operatorpresses the button driving the blade rotation.To keep the work cycle on, it is necessary to substitute the broken blade with a new one(see above mentioned procedure).Be particularly careful when the head guard is taken down and the blade is unthreadedfrom the blade wheels and from the head. During these operations always use protectivegloves.
In case the blade is locked in the piece to be cut, unthread the blade first from the head asdescribed in chapter blade replacement, and then, with the help of pincers, pull theblade upwards and, at the same time , in the opposite direction than that of rotation.
The manufacturer of the machine is NOT responsible for any hazardous situationsderiving from a lack of observance of what is written in this manual.
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SAFETY PROTECTION
The saw is provided with several safety systems to protect the user during the work: PULLEY PROTECTION OF BLADE DRAGGINGThe pulleys dragging the blade are protected by the head guard and the head guarditself is equipped with a micro switch if removed, the machine stops.Besides, a supplementary anti opening guard, prevents from the opening even partial ofthe head guard at the users side.
INSTALLATION PROTECTIONAll the equipments (electrical,coolant pump) are protected with panels which can beopened just by a special tool. Some panels are equipped with a micro switch. The electricpanel can not be opened if the main switch is not in 0 (off) position.
WARNING
THETOOLNECESSARYTOOPENTHE PROTECTIONPANELSISTOBEUSEDONLYANDEXCLUSIVELYBYTHE
RESPONSIBLEOFTHEASSISTANCESERVICE.
PROTECTION FOR BLADE BREAKING
If the blade broke while working, it is no longer dragged and a guard prevents it fromcoming out of its seat.
BLADE PROTECTIONThe machine is equipped with some steel protections placed on the blade outside thecutting area to prevent chips from hitting the operator's hands, or to avoid the unintentionalcontact with the blade teeth.
EMERGENCY PUSH BUTTONIn case of emergency press the mushroom-shaped button and the saw will stopimmediately. To switch the emergency button off, turn it. Push the RESET button in order torestore the machine.
WARNING
USE THE EMERGENCY BUTTON ONLY WHEN REALLY NECESSARY AND NEVER FORSTOPPING THE MACHINE. IT IS NOT POSSIBLE TO START THE WORKING CYCLE WHEN
THE EMERGENCY BUTTON IS PRESSED.
RESET BUTTONIn case of lack of current, the machine handlings stop and when the current is restored, themachine can be restarted pressing the light orange button of reset (ON).
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RESIDUAL RISKS
One of the residual risks the machine may present is the high temperature of some of itscomponents (motors, bearings, hydraulic power pack, blade, etc) even after when it hasstopped working. It is therefore important, once all working operations are over, tomake sure nobody accidentally touches these parts until they have cooled to atemperature lower than 40-50C [104 122 F].
The blade is not protected inside the cutting area: it is therefore forbidden to touch itduring operation and the user must be adequately trained for that.
It may occur that the user touches the piece and the vice while they are clamping(only intentionally).
According to the shape of the piece to be cut, a part of the blade can remainuncovered during the cutting phase.
CUTTING VERY THIN, SMALL AND/OR MOULDED PIECES, A PART OF THE BLADE
(BETWEEN THE VICE SLIDING PART AND THE MOVABLE BLADE GUIDE)
REMAINS UNCOVERED, THOUGH THE BLADE GUIDE IS PROVIDED
WITH A GUARD. THIS PART CAN NOT BE FURTHER REDUCED
AND IS SIGNALLED BY MEANS OF A WARNING PLATE.
THE OPERATOR MUST NEVER APPROACH THE BLADE, WHEN IT IS MOVING
The coolant liquid, used to lubricate and cool the blade, may spill on the floor andcause falls. Be careful! Keep the floor clean. To avoid this risk the use of the NBoptional is suggested.
Cooling and lubricant products if employed in the proper and correct way, do notpresent any risk for the user.
Nevertheless, the continuous and prolonged contact with these products, if not carefullywashed away, may cause skin reddening, irritations and dermatitis
During the blade replacement operations, the risk of abrasions may occur: wear alwaysprotective gloves and safety glasses. Do not remove the plastic protection covering theblade teeth until when the blade is not mounted on the band saw.
The machines equipped with inverter or condenser, after switching off , may retain
residual current: its consequently necessary to wait a few minutes before touchingelectric components.
For machines equipped with G optional only:When machine is on, do not put the hands in the pneumatic cylinder moving areaDANGER OF LIMBS CRUSHING!A relevant plate signals this danger.
OILS TOXICOLOGICALINFORMATION (see TABLE 14)
All the lubricants listed below, if correctly employed, are not dangerous for the user.Nevertheless, in case of emergency, adopt the following remedies.
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WARNING
In case of CONTACT WITH THE SKINabundantly wash with water and soap.Avoid prolonged skin contact with contaminated clothes.
In case of CONTACT WITH EYEScarefully remove the productand immediately rinse with abundant water.
TENNEX GRASSO C EP 0-1-2-3: If normally used, no danger for vapour inhalationoccurs. In case of persistent irritation consult a doctor. In case of ingestion do not inducevomiting, but call for a doctor.
ES INOX B/ES T.M.F. 65: Vapour inhalation causes no problem. In case of irritationconsult a doctor. Accidental ingestion should cause no problem. Nevertheless, if more
than litre [5,3 gallon]is drunk or if one feels ill, let him drink 1 or 2 glasses of waterand consult a doctor . Do not induce vomiting or give any medicine if the involvedperson fainted.
CUTTYCOL 4: In case of inhalation, take the involved person outdoor in the open air, incase of problems call for a doctor.In case of ingestion, call for the doctor.
HIDROMATIC - DX: In case of inhalation take the involved person outdoor in the open airand call for the doctor. In case of ingestion, call for the doctor. Do not induce vomiting.
WAY SI 32 PNEUOIL: In case of exposure to highly concentrated oil smokes take theinvolved person outdoor. If the product has been inhaled take the person to the hospital
urgently. In case of ingestion do not induce vomiting but call for a doctor.
SHELL TIVELA OIL SC: In the unlikely inhalation event of dizziness or nausea, takecasualty to fresh air. In case of ingestion do not induce vomiting. Wash out mouth withwater and obtain medical attention.
SHELL TVX COMPOUND B: If normally employed, in case of inhalation no sideeffects occur as this product is not particularly volatile. This product presents noacute oral toxicity.
EP 13 PERREL: In case of contact with eyes abundantly rinse with water for ten
minutes. In case if ingestion induce vomiting and go to the doctor specifying which kindof product has been ingested. Coal dissolved in water or in medicinal white mineraloil can be given.
In case of FIRE, wear suitable clothes and, if necessary, an oxygen mask.In case of ACCIDENTAL DISPERSION, avoid contact with eyes and skin.
If spraying is unavoidable, wear protective gloves, boots and clothesas well as safety glasses or a mask.
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CLOTHES
WARNING
It is strictly forbidden to wear, during work, inspection or maintenance operations: necklaces, bracelets, foulard,
clothes such as scarves or wide sleeved shirt that may get entangled in the machine.
EMERGENCY SITUATIONSFIRE:
The working area must be provided with some powder extinguishers and some ways ofescape as required by the LAW for the machines that must operate in areas without risksof explosion.DO NOT USE WATER TO BURN OUT FIRES.The staff should be trained in order to know how to operate in such situations.
THE MACHINE CANNOTOPERATE IN AREAS PRESENTING FIRE RISK.
LIQUID/OIL SPILLING:
In case of accidental pouring of coolant and/or lubricant liquids/oils, stop the loss withearth or sand. If this product flow into rivers or into water drains, so contaminating the soiland the vegetation, advise the competent authority. After cleaning, wash with water thedirty parts and area.
WRONG AND DANGEROUS USES
Using the machine in a different way than that indicated by the manufacturer coulddamage the equipment and be dangerous for the operator.The machine is not designed to work dangerous, explosive and/or toxic materials such asthose containing fiber glass or asbestos, etc. The operator must ask for the manufacturer'swritten permission to use materials which differ from the ones indicated by FMBS.r.l.
WARNING
Even when the user willingly inserts his hands or an object in the cutting areawhile the machine is on, is to be considered an incorrect use.
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SAFETY AREA
The FIGURE24below shows the area where the operator must be while working with the
saw. It also indicates the minimum distance the operator should keep from the machine tobe in the best working position.
WARNING
The machine must be used byONE OPERATOR ONLY!The operator has a complete view of the working area, so he can prevent
other people from entering dangerous areas.
WARNING
During piece loading and unloading operations it is possible to operate on the side of themachine, but you must never be in these areas when the saw is working.
FIGURE 24
8 inches
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OPTIONAL DESCRIPTION
NB1NB2This band saw machine is equipped with a blade and cutting cooling device. To improve
the cutting quality and reduce pollution risk, moreover to avoid the risk of pools of cooling
liquid on the floor (possible cause of accidental falls) , we suggest to use the NB optional.
A small amount of lubricant injected in a low-pressure airflow proved effective in carrying
out high impact lubricant-coolant functions. This is obtained by means of positive
displacement micro-pumps injecting the oil through a capillary tube to a final nozzle. At the
same time, the low-pressure air flowing inside another tube, coaxial to the first one,
reaches the final nozzle as well.
The lubricant atomizes into the airflow that leads it to the desired area by means of a well-aimed spout, without producing polluting fumes.
USE AND MAINTENANCE
a) Steadily fasten the group close to the machine, if possible;
b) Carefully connect the 8x6mm [5/16x15/64] air tube, with the 2,5x1,5mm
[3/32x1/16] capillary oil tube inside, (see further on). Check the proper
deformation of the sealing bicones.
FIGURE 25
c) Fill the tank with clean new oil. Only use oils with 100cStoke/40C max. viscosity
[100cStoke/104F] , not aggressive with regards to nylon tubes and rubber and
Vitonseals.
d) Beware of compounded oils containing chlorine. Chlorinated oils etch polymers
(rubbers and thermoplastics).
e) Carry out the compressed air connection from the network to the input filter,
ensuring a 4 to 6 bar pressure [58 to 87 PSI].
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FIGURE 26 FIGURE 27
f) Finally, the Lubrostar group is ready to function. It is yet necessary to adjustthe pumping frequency and the capacity of micro-pumps by rotating the red
knobCOUNTER-CLOCKWISE ROTATION
increases the capacity - max 30mm3
/stroke[1.18 inch3/stroke] - CLOCKWISE ROTATION reduces the capacity - min3mm3/stroke [0.18 inch3/stroke].
FIGURE 28 FIGURE 29
g) Also set the air sent from the pressure adjuster towards the mixer. Set between 0,5and 2 bar [7.3 and 29 PSI].
h) Do not forget the min. level check, where it is present. And oil filters periodiccleaning operations.
INTERVENTIONS DURING START-UP OR WORKING OPERATIONS
a) The pump does not engage:
Loosen the damp valve S, let the lubricantoutflow until the pump engages, tighten thevalve back.
FIGURE 30
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b) Air has been registered inside the tank
Clean the delivery valve. Improper sealing isdue to dirt underneath the O-Ring. Removethe T plug and clean
FIGURE 31
c) There is air inside the2,5x1,5mm[3/32x1/16]diameter oil capillary tube:Check the correct tightening on the tube.
d) The tubes empty out.Clean the delivery valve (see point 2.2), and check the correct tightening of the the2,5 mm [0.098 inch]diameter capillary tube.
CONSUMPTION
From 10 to 100 ml/h [from 0.0026 to 0.026 US gallon/h] according to cutting sections; in
order to obtain proper lubrication, the lubricant minimum quantity shall not drop below 30ml/h [0.0079 US gallon/h], therefore granting an autonomy varying from 12 to 40working hours.
RECOMMENDED OILS
OIL FOR NORMAL MATERIALS MEDIUM MACHINING OPERATIONS ES 103High quality, odorless, clear, inactive cutting oil - suitable for broaching, cutting, drilling,threading, tapping and similar operations.
OIL FOR NORMAL MATERIALS LIGHT MACHINING OPERATIONS ES T.M.F. 65/CHigh quality, clear, inactive cutting oil - suitable for brass and ferrous metals medium-light machining.
OIL FOR ALUMINIUM BRASS ES T.M.F. 16
High quality, low viscosity, odorless, clear, cutting oil - especially suitable for aluminiumand brass machining operations.
OIL FOR STAINLESS STEEL ES INOX B
Dark color, active cutting oil for heavy machining of hardly machinable steel; suitable
for stainless steel.
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SPARE PARTSNB1NEBULIZER-MINIMUMLUBRICATION-COOLING(1Nozzle)
FIGURE 32
P MAX =6 bar87PSI
0,6 MPa
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NB2NEBULIZER-MINIMUMLUBRICATION-COOLING(2Nozzles)
FIGURE 33
P MAX =6 bar87PSI
0,6 MPa
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VAT
The value (in degrees and degree tenths) of inclined cuts is visualized by the VAToptional, on a digital display (FIGURE 34,POS.1).In order to calibrate this value turn the head on 0 position and then press the resetbutton located near the display (FIGURE 34,POS.2).
FIGURE 34
PN
If the machine is provided with PN optional, a pneumatic cylinder effects the clamping andunclamping of the piece to be cut. This operation is granted to a manual operating levervalve placed over the control panel (FIGURE 35, POS.1). The appropriate air compressedquantity (max 6 bar/ 87 PSI) is controlled by a pneumatic circuit (see attached scheme). Amanostat constantly check that the lowest pression level doesnt drop under 4 bar [58 PSI],see the relevant picture enclosed into the Technical Enclosure showing the PN optional.
FIGURES 35
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G
The G optional allows to cut the material without the users manual intervention through a
manual operating lever. The material feed is due to a gravitational fall obtained acting on
the blade wheel which sets down the spring balancing. The appropriate gravity force value
for the different materials and shapes is stated on a relevant plate..
Legend
1 Blade approaching
to the piece to be cut
2 Key selector
(MANUAL/AUTOMATIC)
3 Descent setting valve
4
Stroke end5 Idraulic cylinder
6 Blade wheel
7 Spring fixing clamp
(not for Titan)
FIGURE 36
GOPTIONAL USE
a) After locking the piece to be cut into the vice, select the cutting pressure releasing thesprings by turning the hand wheel.
b) Choose, by the key selector, the proper gravity cycle.
c) Make the blade go down to the piece to be cut pressing the relevant button
d) Adjust the blade drop speed by the valve .
e)
Press the button on the handle which drives the blade rotation and the cutting drop.
f) At the end of the cut a micro stops the blade rotation and the cut drop.
g) In order to begin a new cut the user should manually lift the head up to the desired
height.
h) In case the blade breaks, a micro near the blade stretcher stops the work cycle.
WARNINGIn case of danger press the emergency
stop to stop all the above described operations
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WARNINGIt is quite normal to experience a slight leakage from the rod and piston seals
and this may eventually drain the regulator. Periodically check that the level
indicator (when unit is in retracted position) is at least 5mm from the face of the
reserve tank. To refill inject class H hydraulic oil into the inlet valve marked
OIL. Using the correct syringe any excess oil will discharge automatically from
a small hole in the side of the main reservoir body.
V
The blade rotation speed is proportional to the material toughness; this means that the
tougher the material is, the slower the blade rotation should be (See TABLE 7/8). The
standard machine is equipped with only two speeds; the slow one, if constantly used , may
cause the motor fall down because of the not sufficient blade motor cooling ventilation.
The V speed variator allows to constantly range the rotation blade speed from 20 to
100m /1 [3940 to 19685 foot/hour]so giving the opportunity to choose the most suitable
speed without causing any problem to the blade motor.
VARMEC variators are built on the principle of the transmission of force by dry friction
between a friction cone and a friction ring on a shaft with two moving parts along the axis
(See FIGURE37).
The force of pressure between the friction cone and the ring is generated by the thrust
given by a dovetail coupling depending on the couple drawn on the output shaft. A spring
between the friction ring and the output shaft maintains a slight contact pressure between
the two elements when the machine is used unload, hence the possibility to adjust the speed
from standstill.
The speed is regulated gradually and continuously thanks to the control wheel which moves the
friction cone along the radius of the friction ring by means of the pinion coupling and rack.
The usual speed variation range is 1:5; this can be increased using twin-polarity motors.
The adjustment pinion can be moved using the handwheel.
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Variator sectional view
Legend:
1) CONE SHAPED PLATE2) FRICTION RING3) CAM CONNECTION4) EXIT SHAFT5) THRUST SPRING6) CALIBRATION BLADE
WHEEL7) CONTROL PIGNON8) RACK9) BLIND CAP
FIGURE 37
ISTRUCTION FOR USE AND MAINTENANCE
a) When installing, check that the main voltage corresponds to that shown on the ratingplate (FIGURE 5,POS.5). We remind you that is compulsory the use of a protection device.
b) The motor variator must be mounted in the specific position for which it has been ordered:call the supplier for advice if this is not the case.
c) If the motor variator is intended for use in dusty or humid conditions, you will need to fit aprotection cover.
d) The variators are supplied complete with lubricant and have already had a short
running-in period. However, we recommend that you do not use the variator withmaximum loads during the first 20/30 hours of operation.
e) The variators are supplied complete with lubricant and have already had a shortrunning-in period. However, we recommend that you do not use the variator withmaximum loads during the first 20/30 hours of operation. If using solvents, make surethat these do not come into contact with the lips of the oil seal. All output shafts have athreaded hole on the top, for use in fitting the drive elements. Do not key on the drivepulleys, frictions, pinions and so on by hammering as this is likely to affect the variatoroutput shaft, so damaging the bearings and graphite ring in variators. Loosely mount allthe components on the shaft, applying only enough manual pressure to mount them or bytightening a washer screw at the top of the output shaft.
f)
If the variator keeps slipping, these are the possible causes:
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check that the friction ring is not worn down to its
metal support. If so, replace it;
check that the graphite ring and the friction cone are
not greasy. If so, clean them with a clean cloth,
slightly soaked in trichlorethylene;
momentary overloading from a possible blockage in the
driven machine can cause knocking from spalling or
partial dipping of the friction wheel. Small grooves maydisappear by themselves. If noise continues, the friction
ring should be replaced (before doing this, check with
our technical department).
FIGURE 38
g) If the number of output revolutions happens to vary by itself, i.e. without your giving aspecific command, you will need to tighten the screw (POS.2,FIGURE 38)which adjusts the
correct friction of the control wheel.h) The motor variator can function with either clockwise or anti-clockwise rotation, and you
can even adjust the speed when at standstill
LUBRICATION
TYPE QTY LUBRICANT
VARIATOR
10/2
REDUCTION
GEAR
RP 999
0,50 kg
17.6 Ounce
SHELL TVX COMPOUND B
TABLE 12
The reduction gear section of the VARMEC variator and the RP 999 reduction gear comeswith permanent lubricating grease for the gears.The quantities of lubricant quoted in TABLE 12 must be should be checked at least onceevery 1000 working hours.To check the level of synthetic grease (FIGURE36) in a variator, use the hole in the upperpart of the reduction gear housing, having first unscrewed the vent valve (FIGURE 38,POS.1).With the machine in motion, check the quantity of the remaining grease thrown against theinsides by the action of the gears.To add any extra lubricant, use either a grease nipple or a syringe in the hole to add 1/4the amount of the grease shown in grease TABLEabove 8.
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INSTRUCTION FOR MOTOR ASSEMBLING IN VARMECVARIATORS (See FIGURE 39)
a) Remove the cover, pos. 81 (2 screws, pos. 51).
b)
Turn the clamping ring, pos. 80, to the position indicated .c) Use a hexagonal wrench to loosen, but do not remove, the screw, pos. 50, in the
clamping ring (the clamping ring is held by another screw, pos. 49).
d) Introduce the motor shaft into the friction cone hub without forcing it (do not grease the
motor shaft for any reason).
e) Tighten the four motor assembly screws.
f) Make the motor turn in both directions about 20 times, either by giving it voltage for a
short period or by turning the fan, pos. 96, manually once you have removed the fan
cover, pos. 95. This is important to avoid excessive internal axial forces
g) Tighten the screw, pos. 50.
h)
Replace and tighten the cover, pos. 81.i) Replace and tighten the cover, pos. 81.
j) Move the rack, pos. 83, using the control wheel or adjustment device, to allow the
wrench easier access.
FIGURE 39
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C1 SCC
Its a bar bearing support equipped with aroller. It can be used in addition to the rollertable. It should be suitably ballasted andfixed to the floor (See FIGURE 40).
Its the loading side connection betweenmachine and roller table (See FIGURE 41).
FIGURE 40 FIGURE 41
SCS
Its the unloading side connection between machine and roller table (See FIGURE 42).
FIGURE 42
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RF1 RF2
To work safely, the material to be cut should lean on roller tables as long as necessary onboth loading and unloading sides. FMBs.r.l. can supply this optional.
RF1 RF2
Its the one meter roller table [3.3 ft] to behooked to the RF2 or to another RF1previously attached to a RF2 roller table (SeeFIGURE 43).
Its the one meter roller table [3.3 ft] to behooked to the SCC/SCS optionals (SeeFIGURE 43).
FIGURE 43
AM RS
The material must always be cut according to a prearranged length. The machine maybe equipped with a measure shaft for 1 to 6 meter [3.3 to 19.7 ft]measure stops tobe installed on the RF roller tables.
FIGURE 44
RF2
RF1
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ORDINARY AND PREVENTIVE MAINTENANCE
An appropriate maintenance is important for a long lasting life of the machine. It allows to
keep it in excellent and efficient working conditions and ensures lasting safety standardsthroughout the years. It is advisable that a skilled and authorized staff carry outmaintenance operations. The planning and the materials used to manufacture FMB s.r.l.sawing machine ensure very few maintenance operations. The staff should be equippedwith the individual safety measures commonly used in such cases and should follow thesafety rules described in the following section.
WARNINGFOR ANY INTERVENTION SUCH AS REPAIRS,MAINTENANCE,EQUIPMENT REPLACEMENT,WHICH ARE NOT PROVIDED IN
THIS MANUAL,PLEASE CONTACT FMB SERVICE SO TO HAVE ALL THE INFORMATION YOU MAY NEED
MAINTENANCE SAFETY RULES:When carrying out maintenance operations on the machine:
Put a warning notice: DO NOT USE: MACHINE UNDER REPAIR. Disconnect power supply before removing any protection panel or replacing any
electric component. Do not wear rings, watches, necklaces, bracelets, etc during maintenance operations. Always use individual protective devices (gloves). Do not use naked flames, points or pins for cleaning. Do not smoke.
Carefully check that no circuit is under pressure. If so, discharge any circuit with caution.
ORDINARY CLEANINGOrdinary cleaning operations must be carried out at the end of each working day to keepthe unit in good working conditions. FIGURE45shows the parts which must be kept clean.To clean the machine use a soft cloth soaked with alcohol and a vacuum.
Machine protection doors and
panels (dust residues).
Control panel (dust and chip
residues).
Inlet and outlet transport rolls
(chip residues).
Piece clamping vice (chip and
coolant residues).
Blade guide (chip and coolant
residues).
FIGURE 45 TABLE 13
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CHIP AND COOLANT DISCHARGE
At the end of the working day or every 100 cuts, empty the chip tray on the bottom of themachine (See FIGURE 46 / 46A).
TRITON TITAN ORION - ANTARES PHOENIX
FIGURE 46 FIGURE 46A
WARNING
Use a water solution with a 3 - 5% of cutting oil and pour it by means of acontainer in the chip tray into the refrigerant tank.
WARNING
The top of the chip tray is equipped with a filter that must be accurately cleanedafter having removed the biggest chips.
WARNING
During chips clearing, wearing protective gloves is compulsory.
CHIP TRAY
REFRIGERANT
TANK
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SUGGESTIONS
A constant cleaning of the sawing machine is necessary to obtain a good performance.
In addition to what has been previously said above about the correct use of the machine,follow the instructions below:
Act on the head limit switch nut, when the blade dimensions must be modified; inparticular as for the different range of heights available on the market.
The sawing machine blade is provided with protective guards; anyway there is anarea, which is not protected and is particularly dangerous for the hands; this area islocated behind the vice and it is signalled by the proper pictogram, be particularlycareful and adopt all the precautions.
The machine must be provided with proper rollers according to the dimensions of the
material to be cut. Position a suitable container, collecting the cooling and lubricating fluid, at the end of
the rollers.
Adopt all the necessary precautions in order to avoid that any projection of cutmaterials can cause injury for the user or for other people near the machine.
NEVER DISABLE the safety micro switch of the blade cover.
It is strictly forbidden to change, tamper with and/or remove the plates fixed on themachine.
ALL THE AREA NEAR THE BLADE IS DANGEROUS WHEN THE BLADE IS MOVING.ONCE THE CYCLE HAS STARTED, THE OPERATOR MUST BE PARTICULARLY CAREFULNEVER TO APPROACH THE BLADE WITH THE LIMBS (HE SHOULD NOT ALLOW
ANYONE TO APPROACH TOO).
GREASING
The machine mobile parts are equipped withsome lubricators allowing a precise lubrication ofall components.After about 500 working hours the blade wheelbearings must be greased.
FIGURE 47
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All the bearings assembled on the machine are already lubricated with an
appropriate quantity of grease to protect the internal parts and to prevent anydust and humidity intrusion.Be careful not to put too much grease since this can cause some mechanicaldeformations to the seals. Lubricate not only the blade wheel bearings but alsothe roller slide ways by means of a brush.
RECOMMENDED LUBRICATORS
Grease forBearings
Oil forOptional
Oil for Gear(Phoenix, Atlantis)
OilVAR 10/2 -
RP 999Coolant
NB
ES INOX B(heavy works)ES T.M.F. 65(medium to lightworks)
CUTTYCOL 4G HIDROMATIC - DX
TENNEXGRASSO
C EP 0 - 1 - 2 - 3
PN WAY SI 32 - PNEUOIL
SHELL TIVELAOIL SC
SHELL TVXCOMPOUND B
EP13PERREL
TABLE 14
NOTE: The suppliers of lubricant products have comparative tables with other marks.Do not use non corresponding products; the machine could be seriously damaged..
WARNING
CHOOSE HIGH VISCOSITY FOR HOT AREAS AND VICEVERSA.
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MAINTENANCE TABLE
The table below contains a simple CHECK - LIST of the maintenance controls to be carried out.
DESCRIPTION FREQUENCYINTERVENTION ORMEANS TO USE
CLEANING OF BLADE SLIDING BLOCKS ANDBEARINGS
DAILYCOOLING AND LUBRICATING FLUIDOR COMPRESSED AIR
CHECK OF BLADE GUIDE SLIDING BLOCK WEAR MONTHLY FEELER GAUGE
OIL CHECK INSIDE THE REDUCTION UNITEVERY 6MONTHS
RESTORE
COOLANT LEVEL CHECK INSIDE THE TANK DAILY RESTORECHECK OF COOLANT TANK FILTER CLOGGING DAILY CLEAN
CLEANING OF BLADE HOLDER BLADE WHEELGUARD
DAILY CLEAN / GREASE
CHECK OF BLADE AND BLADE TENSIONER TENSION DAILY OPTIMIZECLEANING OF VICE CUTTING SURFACE ANDMACHINE SURFACE
DAILY CLEAN
CHECK OF THE RETURN SPRING MONTHLY REPLACE IF NECESSARY
TENSIONEREVERY 6MONTHS
REPLACE IF NECESSARY
BLADE DAILY REPLACE IF NECESSARYTABLE 15
OPERATION RECORDING TABLE
Fill in the table below specifying all the details of the intervention which has been carriedout on the machine.
DATEMACHINE
COMPONENTSINTERVENTION
INTERVENTION
TIMENOTES SIGNATURE
TABLE 16
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TROUBLESHOOTING
This section describes how to solve the typical problems that may happen in the equipment.
THE BLADE DOES NOT TURN
Ensure the main switch is in ON position
Check reset is relayed (light off)
Check that the emergency button is disabled
Make sure the safety micro switch for guard closing is pressed (the guard must beclosed
Check that the warning light is onCheck that the fuses for the transformer are efficient (FU1-FU2-FU7)
If the machine is equipped with a G optional, ensure that the blade breaking micro isdeactivated
If the machine is equipped with a PN optional, check the input compressed air is at least4 bar / 58 PSI(max 6 bar/87 PSI)
If the machine is equipped with the optional PN, check the vice operates in the correctposition
THE 0-60ROTATION IS STIFF
Bad quality of the oil
The sawing machine surface is too dirty
Clean and grease among the sliding surfaces
THE BLADE IS NOT TENSIONED
Ensure the blade length corresponds to the values stated in the technical features tableat page 2.
THE BLADE COMES DOWN THE BLADE WHEEL
Check the blade length
Check the blade tension
Check the clearances inside the blade wheel bearings
Make sure there is no clearances among the components (FIGURE6POS.11/13), removeit, by acting on the screws POS.13
Check the motor wheel and blade wheel wear condition
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NO COOLING AND LUBRICATING FLUID AT THE BLADE
Check the fluid quantity inside the tank is enough
Check that the tap is open
Check that the connecting pipe between pump and tap is not chocked
Ensure the pump is turning and the selector is located in the correct position
Ensure the fusibles are working (FU3-FU4)
CROOKEDCUT
Check that the blade guide bearings are efficient
Check the distance between the carbide plates
Check that the mobile blade guide is located as nearest as possible to the piece to be cut
Check that the material to be cut is not so uneven to cause a crooked cut
Check that the blade is well tensioned
Check that any rollers or stands are aligned with the vice surface
Ensure the blade rotation speed is correct
Use first rate blades
BLADE TEETH BREAKING
Excessive cutting pressure
Unsuitable teeth
Bearing breaking
Too slow blade revolving speed
EARLY WEAR OF BLADE TEETH
The blade is unsuitable for the material to be cut
Excessive blade revolving speed
Insufficient cutting pressure
The blade running-in has not been effected in the correct way
BLADE BREAKING NEAR THE WELDING
Faulty blade welding
BLADE BREAKING OUTSIDE THE WELDING
If it occurs after a few hours, the problem is due to the machineNormal wear (due to rotation) may occur after many hours
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SPARE PARTS
The technical enclosure contains the exploded view of each machine with the relevantspare parts references. In case of need, please kindly send the form below properlyfilled in to FMBs.r.l.
ORDER FORM
Company Mr/Ms
Address
Phone Fax E-mail
Machine model Serial number
TableNo.
Spare partNo.
Spare partcode
Description Q.ty
Stamp here your company details in full (name, address, VAT no, phone, fax, etc).
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SAW MACHINE AND BLADE STORAGE
If the machine is not to be used for a certain period, the following operationsare to be executed:
Disconnect the machine from the electric supply. Remove the lubricant liquids. Clean the w