Hyd-Mech DM8 User manual

CA
YEAR OF MANUFACTURE: ______________
USE AND MAINTENANCE MANUAL
DM 8

Introduction and technical specifications 1---1.......................
Foreword 1---1..........................................................
Presentation of the machine 1---2..........................................
Machine specifications 1--- 2..............................................
N a m e p l a t e 1 --- 2........................................................
General Technical Data Table 1---2........................................
Dimensions 1---6........................................................
F u n c t i o n a l p a r t s 2 --- 1............................................
D M 8 M o d e l 2 --- 1.......................................................
Cutting head 2---2.......................................................
Vice 2 --- 2..............................................................
C o n t r o l p a n e l 2 --- 3......................................................
Tu r n t a b l e 2 --- 3..........................................................
Base 2 --- 4..............................................................
Safety and accident prevention 3---1................................
U s e o f t h e m a c h i n e 3 --- 1.................................................
General recommendations 3---2...........................................
Recommendations to the operator 3---3....................................
Machine safety devices 3---5..............................................
Reference standards 3---5................................................
Safety Protection against accidental contact with the blade 3---6................
Electrical equipment 3---6................................................
Emergency devices 3---7..................................................
M a c h i n e n o i s e l e v e l 3 --- 8.................................................
Noise level measurement 3---8............................................
Machine noise levels 3--- 8................................................
Electromagnetic compatibility 3---9........................................
Emissions 3---9.........................................................
Immunity 3---10..........................................................
Machine installation 4---1........................................
Packaging and storage 4---1...............................................
Anchoring the machine 4--- 4..............................................
Minimum requirements 4---4..............................................
C h e c k l i s t 4 --- 5..........................................................
Optionals to be requested with original order: 4---5...........................
O p t i o n a l s : 4 --- 5.........................................................
Balancing the cutting head 4---6...........................................
Connection to the compressed---air supply (MA version) 4---6..................
Connection to the power supply 4---7.......................................
Description of machine operation 5---1.............................
Description of the control panel 5---1......................................
Basic instructions for carrying out a cutting operation cycle. 5---3...............
Manoeuvring the cutting head 5---3........................................
Clamping the work piece in the vice 5---4...................................
Clamping the work piece in the Automatic Vice (MA version) 5---4.............
Rapid opening/closing of the vice 5---5......................................
Rapid translation of the vice 5---5..........................................
Wi d t h o f c u t 5 --- 6.......................................................
Preliminary check list for cutting operation 5---7.............................
Manual operating cycle 5---7..............................................

CCS (Cut Control System) functioning cycle 5---10............................
A n g l e d c u t s 5 --- 1 1........................................................
Angled cuts 45˚to the left 5---11...........................................
Angled cuts 60˚to the left 5---13...........................................
Angled cuts 45˚to the right 5---14...........................................
Diagrams, exploded views and replace---ment parts 6---1..............
D i a g r a m s 6 --- 1..........................................................
Pneumatic diagram (MA version) 6---1.....................................
How to read the wiring diagrams 6---2......................................
Standard version electrical diagram 208V (CSA standard) 6---7.................
L i s t o f c a b l e s 6 --- 1 1.......................................................
List of components 6---13..................................................
L i s t o f t e r m i n a l s 6 --- 1 4....................................................
Standard version electrical diagram 240V (CSA standard) 6---15.................
L i s t o f c a b l e s 6 --- 1 9.......................................................
List of components 6---21..................................................
L i s t o f t e r m i n a l s 6 --- 2 2....................................................
Standard version electrical diagram 575V (CSA standard) 6---23.................
L i s t o f c a b l e s 6 --- 2 7.......................................................
List of components 6---29..................................................
L i s t o f t e r m i n a l s 6 --- 3 0....................................................
Standard version electrical diagram 220V Single---Phase (CSA standard) 6---31....
L i s t o f c a b l e s 6 --- 3 5.......................................................
List of components 6---38..................................................
L i s t o f t e r m i n a l s 6 --- 3 9....................................................
Exploded views 6---40.....................................................
Motor assembly 6---40....................................................
Front flywheel assembly 6--- 42..............................................
Motor flywheel assembly 6--- 44.............................................
Cutting head cover 6---46..................................................
Vice assembly 6---48......................................................
Base assembly 6---50......................................................
C o n t r o l p a n e l 6 --- 5 2......................................................
H a n d g r i p 6 --- 5 4..........................................................
Re d u c t i o n g e a r 6 --- 5 6.....................................................
Fixed work table and turntable 6---58........................................
Optional Cut Control System 6---60.........................................
Supplementary pneumatic vice 6---62........................................
A d j u s t m e n t s 7 --- 1...............................................
Air treatment unit (MA version) 7---1......................................
Topping up and bleeding the cylinder (Cut Control System) 7---2...............
Topping up the head cylinder 7---2.........................................
Bleeding the head cylinder 7---3...........................................
Vice 7 --- 4..............................................................
Vice play adjustment 7---4................................................
Cutting head 7---5.......................................................
Blade tensioner slide play adjustment 7---5..................................
B l a d e t e n s i o n i n g u n i t 7 --- 6................................................
Cutting head stroke 7---8.................................................
Blade guide parts 7---9...................................................
Blade guide heads 7---9..................................................
Blade steady buttons 7---9................................................

Blade guide plates 7---9..................................................
Blade 7 --- 1 1.............................................................
Tool change 7---11........................................................
Blade perpendicularity 7---13..............................................
Orthogonality of the blade 7---14...........................................
Front flywheel 7---17......................................................
Motor flywheel 7---18.....................................................
Maintenance and choice of consumables 8---1.......................
The role of the operator 8---1.............................................
Maintenance requirements 8---1...........................................
General maintenance 8---2...............................................
Daily 8 --- 2.............................................................
Weekly 8 --- 2............................................................
Monthly 8 --- 2...........................................................
Maintenance of operating parts 8---3.......................................
C o n s u m a b l e s 8 --- 3.......................................................
Oil for blade tensioner cylinder 8---3.......................................
Oils for Cut Control System hydraulic circuit 8---3............................
Oil for transmission box 8---3.............................................
Oil for lubricant/coolant fluid 8---4.........................................
Cutting speed and choice of tools 9---1..............................
Cutting speed 9---1......................................................
Standard machine 9---1..................................................
Machine with 4/8 pole motor (optional) 9---1................................
Machine with Inverter (optional) 9---1......................................
Choice of blade 9---2....................................................
Saw tooth pitch 9---3.....................................................
Cutting speed and downstroke speed 9---3..................................
Lubricant/coolant fluid 9---4..............................................
Blade structure 9---5.....................................................
B l a d e t y p e s 9 --- 5........................................................
Blade selection table relating to cutting speed and downstroke speed 9---8.......
Classification of steels 9---9...............................................
Steel nomenclature table 9---10.............................................
Troubleshooting 10---1............................................
Blade and cutting problems 10---1..........................................
Troubleshooting 10---7....................................................
Warranty 10---9..........................................................

1--1
Foreword
This work tool has been designed to satisfy the wide range of cutting needs of a
modern workshop with simplicity and reliability, while at the same time comply-
ing with all EEC safety standards.
The DM 8 is structurally rigid, silent and safe: it produces a minimum of waste
(1.2 mm = 0.05 in.) while its great versatility makes it suitable for cutting various
materials such as stainless steel light alloys, aluminium, copper and bronze at
high speed and with high precision.
Its high cutting capacity, which enables it to handle both single workpieces and
bundles, combined with the possibility of making inclined cuts from 60˚left to
45˚right, make this model the ideal solution for satisfying the wide strange of
cutting needs of machine shops, turneries, structural steel shops and engineering
workshops.
We congratulate our clients on having chosen this product, which will give
effective and faithful service for many years, especially if the instructions
contained in this use and maintenance manual are carefully followed.
This cutting machine has been designed and made specifically for cutting me-
tallic materials.
Warning
1
Introduction and
technical
specifications

MEP S.p.A.
1--2 Use and maintenance manual DM 8
Presentation of the machine
Functioning is completely manual: the operator, after having checked the
workpiece in the vice, grips the control lever and presses the bandsaw start
microswitch; with a downwards movement, the material is cut to the preset
length; the cutting head returns up at the end of the cutting operation, ready to
start a new work cycle.
In the MA version (Automatic Vice), a pneumatic cylinder applied on the vice
blocks the material between the jaws: the open/close control is located on the
base of the machine.
With the CCS (Cut Control System), the machine can also perform a semi---auto-
matic work cycle. The operator, after using the selector located on the control
panel to choose the semi---automatic work cycle, clamps the material in the vice
and presses the button on the cutting head handgrip to start up the bandsaw; the
saw begins turning and the head commences its downstroke, the speed of which
can be adjusted using the control valve (head downstroke speed regulator)
located on the control panel. The head performs the cutting operation; once the
cut has been made, a limiter stops the cutting cycle, after which the head is
manually returned to its upper position so that, when a new workpiece is in place,
a new cycle can be started using once more the handgrip button.
The Automatic Vice is optional for the DM 8 model; it can be factory installed
on request made during the ordering procedure, or may be installed by the
user after the machine has been bought.
Machine specifications
Name plate
Theanodisedaluminiumnameplateisrivetedonthesideofthemachine;the
same data are reproduced on the declaration of conformity included with this use
and maintenance manual.
DM 8
When communicating with the Technical Service department, the model, serial
number and year of manufacture of the machine must be quoted.
General Technical Data Table
CUTTING SPEEDS
1st Slow Speed mt/min
ft./min
36
11.21
2nd Fast Speed mt/min
ft./min
72
22.43
Warning
N.B.

Version 24DM
Introduction and technical specifications 1--3
All models can be equipped with the Inverter,anoptional device, which offers
a range of speeds comprised between 20 and 90 mt/min. (from 6.23 to 28.04
ft./min). As the machine is predisposed for the Inverter, it can be installed by
the client or factory pre--installed on request made during the ordering proce-
dure.
Technical Characteristics of the Inverter
Protection rating IP 31
Vibration and Shock resistance
(EN50178)
0.6gnfrom10to50Hz
2gnfrom50to150Hz
Max. relative humidity 93% without condensation or drop--forming
Acceptable Temperature Range
(EN 50178)
For warehouse storing: from --25˚Cto+65˚C For functioning purposes:
from --10˚Cto+40˚C
Max. altitude 1000 mt. with no derating
-- single phase: 200V -- 15% to 240V + 10%
Supply -- three--phase: 200V -- 15% to 230V + 10%
380V -- 15% to 460V + 10%
Frequency 50/60 Hz ¦5%
Output voltage Maximum voltage equal to the supply voltage
Output frequency range 0.5 to 320 Hz
Max transients 150% of electronic speed control rated current for 60 secs.
Frequency resolution --- D i s p l a y : 0 . 1 H z
--- Analog inputs: 0.1 Hz per 100 Hz max.
Switching frequency Adjustable from 2.2 to 12 Hz max
galvanic insulation between power and control panel
Electronic speed control protec-
tion and safet
y
de
v
ices
Short circuit protection:
-- of available internal supplies
-- between U--V--W phases
-- between phase and earth for calibres from 5.5 to 15 Kw
t
i
o
n
a
n
d
s
a
f
e
t
y
d
e
v
i
c
e
s
Heat overload protection for overheating and overcurrents
Mains under and overcurrent safety protections
Braking overload protection
Motor protections Protection integrated in the electronic speed controller with 12t calcula-
tion
BAND SAW
Rated size mm
in.
2750 x 27 x 0.9
108.27x1.06x0.03
Max/min blade length mm
in.
27602740
from 108.66 to 107.87
Blade height mm
in.
27
1.06
Blade width mm
in.
0.9
0.03
Band saw tension bar / Kg / psi 70 / 900 / 1015
Warning

MEP S.p.A.
1--4 Use and maintenance manual DM 8
When choosing the cutting tool, if its dimensions do not correspond to those
included in the ”Rated size” section, check that the dimensions at least fall
within the admissible max/min specifications.
RATED ELECTRICAL POWER
Spindle motor HP 2.5/2
Lubricant/coolant fluid electropump motor HP 0.1
Max electrical power rating HP 2.6
WORKING PRESSURE MODEL MA (Automatic Vice)
Max. working pressure for opening/closing vice Bar / psi 6/87
Air consumption for a complete cycle Nl/min 1.34
The ”air consumption for vice” value refers to standard conditions (temperature
0˚and pressure 1.013 bar, i.e. density 1.3 x 10-- 3 Kg/l) where 1 Kg/min. = 772
Nl/min.
LUBRICANT/COOLANT FLUID AND OIL
Oil for blade tensioner unit Vol. L t. 0.5
Oil for transmission box capacity in KG 0.32
Oil for Cut Control System cylinder capacity in Litres 0.7
Lubricant/coolant fluid (oil concentration 5---6%) capacity in Litres 11
VICE
Vice max. opening mm
in.
275
10.83
SPINDLE MOTOR
T h r e e --- p h a s e 2 --- 4 p o l e a s y n c h r o n o u s ; F r e q u e n c y 6 0 H z
No.of poles Current (Volts) Absorption (Amps) Power
(HP)
rpm Band saw speed
2/4 208 11/8.2 1.8/1.5 3150/1580 72/36 mt/min
22.43/11.21 ft./min
2/4 240 8.9/6.5 1.8/1.5 3480/1730 72/36 mt/min
22.43/11.21 ft./min
2/4 575 3.4/2.6 1.8/1.5 3360/1690 72/36 mt/min
22.43/11.21 ft./min
Stator wound with enamelled copper wire, class H 200˚C.
Class F insulation (limit temperature TL155˚C).
IP 55 protection rating (total against contact with live parts, water sprayed from all directions, with
shaft oil seal).
Conforming to CEI norms, publication: IEC 34 of 01/07/1985.
Example of class F insulation: in air--cooled machines at an ambient tempera-
ture of 40˚C (according to CEI 2--3 and IEC 85), the allowable overtempera-
ture is 100˚C (where 100˚C represents the allowable ∆T).
Attention
N.B.
N.B.