Cormak CS350 User manual

CS350

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Table of Contents
1 Safety
1.1 Safety warnings (warning notes)..............................................................................4
1.1.1 Classification of hazards ................................................................................4
1.1.2 Other pictograms............................................................................................5
1.2 Proper user...............................................................................................................6
1.3 Possible dangers caused by the circular metal saw.................................................6
1.4 Qualification of personnel.........................................................................................7
1.4.1 Target group...................................................................................................7
1.4.2 Authorised personnel .....................................................................................7
1.5 User positions...........................................................................................................8
1.6 Safety devices..........................................................................................................8
1.6.1 Prohibition, warning and mandatory labels ..................................................10
1.7 Individual protection gear .......................................................................................10
1.8 Safety during operation ..........................................................................................11
1.9 Safety during maintenance.....................................................................................12
1.9.1 Disconnecting the circular metal saw and making it safe.............................12
1.9.2 Using lifting equipment.................................................................................12
1.9.3 Mechanical maintenance work.....................................................................12
1.10 Accident report .......................................................................................................12
1.11 Electrical system.....................................................................................................13
2 Technical data
2.1 Type plate...............................................................................................................14
2.2 Power connection...................................................................................................14
2.3 Cutting range..........................................................................................................14
2.4 General...................................................................................................................14
2.5 Dimensions.............................................................................................................14
2.6 Speed of saw blade................................................................................................15
2.7 Environmental conditions .......................................................................................15
2.8 Operating material..................................................................................................15
2.9 Emissions...............................................................................................................15
3 Assembly
3.1 Extent of supply......................................................................................................16
3.2 Storage...................................................................................................................16
3.3 Installation and assembly.......................................................................................16
3.3.1 Requirements of the installation site ............................................................16
3.3.2 Fasten the substructure of the circular metal saw on the floor.....................17
3.3.3 Mount the saw on the machine substructure................................................18
3.3.4 Mount the lever arm .....................................................................................18
3.3.5 Mount the saw blade....................................................................................18
3.4 First use..................................................................................................................19
3.4.1 Checking ......................................................................................................19
3.4.2 Direction of the saw teeth.............................................................................19
3.4.3 Check the oil level in the worm gear ............................................................19
3.4.4 Fill in coolant ................................................................................................20
3.4.5 Power supply................................................................................................20
3.4.6 Check the running direction of the saw blade ..............................................20
4 Operation
4.1 Safety .....................................................................................................................21

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4.2 Control and indicating elements............................................................................. 21
4.3 Insert workpiece ..................................................................................................... 22
4.4 Saw blade speed.................................................................................................... 23
4.4.1 Speed change.............................................................................................. 23
4.4.2 Select the toothing and the shape of the tooth ............................................ 23
4.5 Switching on the machine ...................................................................................... 25
4.6 Switching off the machine ...................................................................................... 25
4.7 Sawing of angles.................................................................................................... 26
4.8 Cooling ................................................................................................................... 27
5 Maintenance
5.1 Safety ..................................................................................................................... 29
5.1.1 Preparation .................................................................................................. 29
5.1.2 Restarting..................................................................................................... 29
5.2 Inspection and maintenance .................................................................................. 30
5.3 Mounting and replacing the saw blade................................................................... 32
5.3.1 Dimensions of sawing flange ....................................................................... 33
5.4 Repair..................................................................................................................... 33
6 Ersatzteile - Spare parts - CS350
6.1 Ersatzteilzeichnung - Explosion drawing................................................................ 34
6.1.1 Einzelteile - Spare parts - CS350................................................................. .35
6.2 Schaltplan - Wiring diagram - CS350....................................................................... 37
6.2.1 Ersatzteilliste - Spare parts list - CS350......................................................... 38
7 Anomalies
7.1 Anomalies in the circular metal saw....................................................................... 40
8 Appendix
8.1 Copyright................................................................................................................ 41
8.2 Terminology/ Glossary ........................................................................................... 41
8.3 Warranty................................................................................................................. 42
8.4 Disposal ................................................................................................................. 42
8.5 RoHS , 2002/95/CE................................................................................................ 42
8.6 Product follow-up ................................................................................................... 43
8.7 EC-Declaration of Conformity................................................................................. 44

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1 Safety
Glossary of symbols
This part of the operating manual
• explains the meaning and use of the warning references contained in the operating manual,
• explains how to use the circular metal saw properly,
• highlights the dangers that might arise for you or others if these instructions are not obeyed,
• tells you how to avoid dangers.
In addition to this operating manual please observe
• applicable laws and regulations,
• legal regulations for accident prevention,
European standards must be observed during installation, operation, maintenance and repair of
the circular metal saw.
If European standards are not applied in the national legislation of the country of destination, the
specific applicable regulations of each country must be observed.
Where necessary, the required measures must be taken to comply with the specific regulation of
each country before the circular metal saw is first used.
ALWAYS KEEP THIS DOCUMENT CLOSE TO THE CIRCULAR METAL SAW FOR FUTURE
REFERENCE.
1.1 Safety warnings (warning notes)
1.1.1 Classification of hazards
We classify the safety warnings into various levels. The table below gives an overview of the
classification of symbols (pictograms) and warnings for the specific danger and its (possible)
consequences.
gives additional indications
calls on you to act
• enumerations
Pictogram Alarm expres-
sion Definition/Consequences
DANGER! Imminent danger that will cause serious injury or death to
personnel.
WARNING! Risk: A danger that might cause serious injury or death to
personnel.
CAUTION! Danger or unsafe procedure that might cause injury to
personnel or damage to property.
ATTENTION!
Situation that could cause damage to the machine and
product and other types of damage.
No risk of injury to personnel.

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1.1.2 Other pictograms
INFORMATION
Application tips and other important or useful information
and notes.
No dangerous or harmful consequences for personnel or
objects.
In the case of specific dangers, we replace the pictogram by
or
general danger with a warning
of injuries to hands, hazardous elec- trical voltage, rotating parts.
Pictogram Alarm expres-
sion Definition/Consequences
Caution
slide risk! Activation forbid-
den! Pull the mains plug! Use protective goggles! Use ear protec- tion!
Use protective
gloves! Use protective boots! Wear a safety suit! Protect the envi- ronment!

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1.2 Proper user
Usage
WARNING!
Improper use of the circular metal saw
• will endanger personnel,
• will endanger the machine and other material property of the operator,
• may affect proper operation of the machine.
The circular metal saw is designed and manufactured to be used in environments where there is
no potential danger of explosion.
The circular metal saw is designed and manufactured to saw cold metals, cast materials and
other plastic materials that are not harmful to health and do not generate dust.
The circular metal saw must not be used on wood.
The pieces to be cut need to be of a shape that will allow them to be securely attached in the
work holder vice and ensure that the piece does not come loose when it is being sawed.
The circular metal saw must only be installed and operated in a dry and well-ventilated place.
Improper
use If the circular metal saw is used in any way other than as described above, modified without the authorisation of Optimum Maschinen GmbH or operated with different process data, then it is
being used improperly.
We do not take liability for damage caused by improper use.
We would like to stress that any modifications to the construction, or technical or technological
modifications that have not been authorised by Optimum Maschinen GmbH will also render the
guarantee null and void.
It is also part of proper use that
• the maximum values of the circular metal saw are complied with,
• the operating manual is observed,
• inspection and maintenance instructions are observed.
 “Technical data“ on page 14
In order to achieve the required cutting performance and the angular tolerance the correct
choice of the saw blade, the cutting speed and the coolant are decisive.
WARNING!
Very serious injury.
It is forbidden to make any modifications or alterations to the operating values of the cir-
cular metal saw! These could endanger personnel and cause damage to the machine.
1.3 Possible dangers caused by the circular metal saw
The circular metal saw is state-of-the-art, but there is a residual risk, as the circular metal saw is
working with
• electrical voltage and currents
• a running circular metal saw blade.
We have used construction resources and safety techniques to minimise the health risk to per-
sonnel resulting from these hazards.
If the circular metal saw is used and maintained by staff who are not duly qualified, there may be
a risk resulting from incorrect operation or unsuitable maintenance.

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INFORMATION
All staff involved in assembly, commissioning, operation and maintenance must
• be duly qualified,
• follow this operating manual.
In the event of improper use
• there may be a risk to the staff,
• there may be a risk to the circular metal saw and other material property,
• the proper operation of the circular metal saw may be affected.
Disconnect the circular metal saw whenever cleaning or maintenance work is being carried out.
WARNING!
THE CIRCULAR METAL SAW MAY ONLY BE USED WITH THE SAFETY DEVICES ACTI-
VATED.
Disconnect the circular metal saw whenever you detect a failure in the safety devices or
when they are not fitted!
All additional installations carried out by the operator must incorporate the prescribed
safety devices.
Being the machine operator, this will be your responsibility!
 “Safety devices“ on page 8
1.4 Qualification of personnel
1.4.1 Target group
This manual is addressed to
•users,
• operators,
• maintenance staff.
The warning notes therefore refer to both operation and maintenance of the circular metal saw.
Determine clearly and irrevocably who will responsible for the different activities on the machine
(use, maintenance and repair).
Vague or unclear assignment of responsibilities constitute a safety hazard!
Always disconnect the circular metal saw from the power supply and secure the circular metal
saw against restarting.
1.4.2 Authorised personnel
WARNING!
Incorrect use and maintenance of the circular metal saw constitutes a danger for the
staff, objects and the environment.
Only authorised personnel may operate the circular metal saw!
The only staff authorised to use this machine and perform maintenance on it are trained and
instructed technical staff working for the operator and manufacturer.
The operator must
Obligations
of the opera-
tor
•trainstaff,

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• instruct staff regularly (at least once a year) on
- all safety standards that apply to the machine,
- operation,
- accredited technical guidelines,
• check staff‘s understand,
• document training/instruction,
• require staff to confirm participation in training/instruction by a signature,
• check whether the staff are aware of safety and of dangers in the workplace and whether
they observe the operating manual.
The user must
Obligations
of the user • have received training in operation of the circular metal saw,
• know the function and principle of operation,
• before the machine is first used
- have read and understood the operating manual,
- be familiar with all safety devices and regulations.
Additional
qualification
require-
ments
For work on the following machine components there are additional requirements:
• Electrical components or devices: This work must only be carried out by a qualified electri-
cian or person working under the instructions and supervision of a qualified electrician.
Before carrying out work on electric components or operating units the following measures
must be taken, in the order given.
- Disconnect all poles
- Ensure that the machine cannot be turned on again
- Check that there is no voltage
1.5 User positions
The user must stand in front of the circular metal saw.
INFORMATION
The mains plug of the circular metal saw must be freely accessible.
1.6 Safety devices
Use the circular metal saw only with properly functioning safety devices.
Stop the circular metal saw immediately if there is a failure in the safety device or if it is not func-
tioning for any reason.
It is your responsibility!
If a safety device has been activated or has failed, the circular metal saw must only be used
when
• the cause of the failure has been removed,
• it has been verified that there is no resulting danger for the staff or objects.
WARNING!
If you bypass, remove or override a safety device in any other way, you are endangering
yourself and other staff working with the circular metal saw. The possible consequences
are:
• damage as a result of components or parts of components flying off at high speed,
• contact with rotating parts,

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1.6.1 Prohibition, warning and mandatory labels
INFORMATION
All warning labels must be legible.
Check them regularly.
Positions of labels on the circular metal saw:
Illustr.: 1-2: circular metal saw CS350
Check the circular metal saw at least once per shift. Inform the person responsible immediately
of any damage, defect or change in operating function.
Check all safety devices
• at the beginning of each shift (with the machine stopped),
• once a week (with the machine in operation),
• after every maintenance and repair operation.
Check if the prohibition, warning and information labels and the markings on the circular metal
saw
• can be identified (if not, clean them),
• are complete.
1.7 Individual protection gear
For certain work individual protection gear is required. This includes:
• safety helmet,
• protective goggles or face guard,
• protective gloves,
• safety shoes with steel caps,
• ear protection.
Before starting work, make sure that the prescribed individual protection gear is available at the
workplace.

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CAUTION!
Dirty or contaminated personal protection gear can cause disease. Clean your personal
protection gear after each use, regularly, at least once a week.
Personal protection gear for special work
Protect your face and eyes: During all work, and specifically work during which your face and
eyes are exposed to hazards, a safety helmet with a face guard should be worn.
Use protective gloves when lifting or handling pieces with sharp edges.
Wear safety shoes when fitting, dismantling or transporting heavy components.
1.8 Safety during operation
In the description of work with and on the circular metal saw we highlight the dangers specific to
that work.
WARNING!
Prior to activating the circular metal saw please double-check that this will
• not endanger anybody,
• not cause any damage to property.
Avoid unsafe working practises:
• Make sure your work does not endanger anyone.
• The instructions in this manual need to be observed during assembly, handling, mainte-
nance and repair.
• Do not work on the circular metal saw if your concentration is reduced, for example, because
you are taking medication.
• Observe the rules for preventing accidents issued by your association for the prevention of
occupational accidents and safety in the workplace or other inspection authorities.
• Stay at the circular metal saw until all rotating parts have come to a halt.
• Use prescribed protection gear. Make sure to wear a well-fitting work suit and, where neces-
sary, a hairnet.
• Inform the inspector of any danger or failure.

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1.9 Safety during maintenance
Report and
document
any changes
Inform operating staff in good time of any repair and maintenance work.
Report all safety-relevant changes or performance details of the circular metal saw. Document
all changes, have the operating manual changed accordingly and train the machine operators.
1.9.1 Disconnecting the circular metal saw and making it safe
Unplug the circular metal saw from the mains before beginning any maintenance or repair work.
Place a warning sign on the machine.
1.9.2 Using lifting equipment
WARNING!
Use of unstable lifting equipment and load-suspension devices that break under load can
cause very serious injuries or even death.
Check that the lifting and load suspension gear
• is of sufficient load capacity,
• in perfect condition.
Observe the preventing of accidents issued by your association for the prevention of
occupational accidents and safety in the workplace or other inspection authorities.
Hold the loads properly.
Never walk under suspended loads!
1.9.3 Mechanical maintenance work
Remove all protection and safety devices before beginning maintenance work and re-install
them once the work has been completed. They include:
• covers,
• safety indications and warning signs,
• earth (ground) connection.
If you remove protection or safety devices, refit them immediately after completing the work.
Check that they are working properly!
1.10 Accident report
Inform your superiors and Optimum Maschinen Germany GmbH immediately in the event of
accidents, possible sources of danger and any actions which almost led to an accident (near
misses).
These near misses can have many causes.
The sooner they are notified, the faster the causes can be eliminated.
INFORMATION
In the description of the execution of work with and on the circular metal saw, we highlight the
dangers specific to that work.

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1.11 Electrical system
Have the machine and/or the electric equipment checked regularly, and at least every six
months.
Eliminate immediately all defects such as loose connections, defective wires, etc.
A second person must be present during work on live components, to disconnect the power in
the event of an emergency.
Disconnect the circular metal saw immediately if there are any anomalies in the power supply!
 “Maintenance“ on page 28,  “Wiring diagram“ on page 39


/1.1KW
110
135 110
110 110
110
110 90
95 95
400
CS350
110x110 mm 110
95x95
1.1
400

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2.9 Emissions
The level of noise (emission) emitted by the circular metal saw is less than 80 dB(A).
If the circular metal saw is installed in an area where various machines are in operation, the
acoustic influence (emission) on the operator of the circular metal saw may exceed the legally
permitted peak value of 85 dB(A) in the workplace.
INFORMATION
We recommend the use of soundproofing and ear protection.
The duration of the noise pollution, the type of characteristics of the working area, such as other
machines which are operated simultaneously, influence the development of noise at the work-
place.
Height of work area [mm] 1540
Width [mm] 640
Weight circular metal saw [kg] 255
Saw blade diameter [mm] 350
“Dimensions of sawing flange“ on page 33
Range vice 145
2.6 Speed of saw blade
Two-step drive engine [m/min] 19 38
2.7 Environmental conditions
Temperature 5-35 °C
Humidity 5 - 80 %
2.8 Operating material
Helical gear Mobilgear 629, viscosity 40°C 150 mm2/
s , at 100°C 16 mm2/s
ISO VG 150
Spindle of the machine vice Commercial heavy grease
Plain bearing Commercial heavy grease
Blank steel parts e.g. machine oil (Mobil oil, Fina, ...),
motor oil, motor oil is acid-, stain- and
resin-free.
2.5 Dimensions

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3 Assembly
INFORMATION
The circular metal saw comes pre-assembled.
3.1 Extent of supply
When the machine is delivered, immediately check that the circular metal saw has not been
damaged during shipping and that all components are included. Also check that no fastening
screws have come loose.
INFORMATION
In the default delivery volume, no saw blade is included. If required, you can order saw blades of
three different toothings.  “Spare part list“ on page 37
3.2 Storage
ATTENTION!
Improper storage may cause important parts to be damaged or destroyed.
Store packed or unpacked parts only under the intended environmental conditions. 
“Environmental conditions“ on page 15
Consult Optimum Maschinen Germany GmbH if the circular metal saw and accessories have to
be stored for a period of more than three months or under different environmental conditions to
those given here.
3.3 Installation and assembly
3.3.1 Requirements of the installation site
Organise the work area around the circular metal saw in accordance with local safety regula-
tions.  “Dimensions“ on page 14
Operation, maintenance and repair in the work area must not be hindered.
INFORMATION
The mains plug of the circular metal saw must be freely accessible.

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3.3.2 Fasten the substructure of the circular metal saw on the floor
Fasten the substructure on the floor with shear connector screws M12.
Illustration: 3-1: Machine substructure
Fastening holes
Machine substructure

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3.3.3 Mount the saw on the machine substructure
ATTENTION!
Danger of crushing
and overturning.
Proceed with caution
during the work
described below.
CAUTION!
The circular metal saw
needs to be mounted
on the machine sub-
structure by at least
two persons.
Illustr.: 3-2: Mount the saw on the machine substructure.
Put the circular metal saw on the machine substructure.
Fasten the circular metal saw with the hexagon socket screws on the machine substructure.
3.3.4 Mount the lever arm
Mount the lever arm on the saw
head.
Illustr.: 3-3: Mount lever arm
3.3.5 Mount the saw blade
Mount your saw blade  “Mounting and replacing the saw blade“ on page 32
Machine substruc-
ture
Hexagon socket
screw
Hand-actuated
auxiliary switch
Lifting arm
Strain relief
Connecting cable
Connecting cable
Hand-actuated
auxiliary switch

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3.4 First use
WARNING!
Personnel and equipment may be endangered if the circular metal saw is first used by
inexpert staff.
We do not take liability for any damage caused by incorrect commissioning.
3.4.1 Checking
Check the following.
ATTENTION!
Danger of cutting! Proceed with caution during the work described below. Use the pre-
scribed protection equipment.
3.4.2 Direction of the saw teeth
Check the direction of
the saw teeth. The saw
teeth need to be ori-
ented in the direction of
the illustrated arrow.
Illustration: 3-4: Running direction of saw blade
3.4.3 Check the oil level in the worm gear
Check the oil level in the worm gear of the circular metal saw.
 “Check oil level, change gear oil.“ on page 30
Fill in gear oil, if required.
Running direction
Saw blade

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3.4.4 Fill in coolant
CAUTION!
Danger of destroying the pump by dry running.
When the circular metal saw is switched on, the coolant pump is switched on.
The pump is lubricated by coolant.
Do not operate the pump without coolant.
“Filling in / Rinsing / Replacing“ on page 31
3.4.5 Power supply
Connect the mains plug of the circular metal saw with your power supply. Control the fusing
(fuse) of the power supply according to the technical indications for the power input of the circu-
lar metal saw.
INFORMATION
For the connection, a CEE-415V-16 A connection cable needs to be connected.
CAUTION!
Please pay attention that all 3 phases (L1, L2, L3) are connected correctly.
Most engine failure result from incorrect connection, for instance the neutral conductor
(N) is being connected to a phase.
This might lead to following results:
• The engine does get quickly very hot.
• The engine noise increases.
• The engine has no power.
3.4.6 Check the running direction of the saw blade
CAUTION!
Mind the rotary field!
The saw blade is running clockwise.
Check the turning direction of the circular metal saw. The circular metal saw has to turn
in direction as described in Illustration: 3-4: “Running direction of saw blade“ on
page 19.
If the turning direction is wrong, please exchange two of the three phases on your cable
connection or on your power supply.
Make sure that the turning direction of any other power supply is not wrong. “Quali-
fikation des Personals“ on page 8