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.

Version 24DM
Introduction and technical specifications 1--5
The machine is supplied with a 2/4 pole three phase motor giving 2 band saw
speeds:
-- 1ª speed (4 poles) = 36 mt/min (11.21 ft./min)
-- 2ª speed (2 poles)= 72 mt/min (22.43 ft./min);
The OPTIONAL 4/8 pole motor gives speeds of 36/18 mt./min. (11.21 / 5.61
ft./min).
Warning

MEP S.p.A.
1--6 Use and maintenance manual DM 8
ELECTROPUMP MOTOR
Single phase; Frequency 60 Hz.
Voltage (Volts) Absorption (Amps) Power (HP) rpm Delivery rate
lt/min
Head (mt.)
208 0.22 0.1 3380 11 1.5
240 0.2 0.1 3380 11 1.5
575 0.16 0.1 3380 11 1.5
Protection rating IP 55.
Conforming to CEI norms, publication: IEC 34 of 01/07/1985.
CUTTING CAPACITY
Section Ølxl bxh
0˚210 mm = 8.27 in. 200 mm = 7.87 in. 270x200 mm = 10.63x7.87 in.
45˚left 180 mm = 7.09 in. 180 mm = 7.09 in. 180x190 mm = 7.09x7.48 in.
60˚left 100 mm = 3.94 in. 90 mm = 3.54 in. 120x90 mm = 4.72x3.54 in.
45˚right 130 mm = 5.12 in. 130 mm = 5.12 in. 120x150 mm = 4.72x5.90 in.
PACKED WEIGHT
Wooden cage and pallet Kg 70
Wooden pallet Kg 20
1700 mm
1000 mm
1900 mm
66.93 in.
39.37 in.
74.80 in.

Version 24DM
Introduction and technical specifications 1--7
Dimensions
MACHINE INSTALLED
Work table height mm
in.
870
34.25
Weight Kg 430
900 700470 410 550
170
1800
1830
870
1315
72.05
18.50 35.43 16.14 6.70 27.56 21.65
34.25
51.77
70.87

2--1
DM 8 Model
In order for the user to move towards a full understanding of how the machine
works, which is described in detail in the chapter DESCRIPTION OF MA-
CHINE OPERATION, this chapter deals with the main units and their locations.
CUTTING
HEAD
VICE
CONTROL
PANEL
BASE
TURNTABLE
2
Functional parts

MEP S.p.A.
2--2 Use and maintenance manual DM 8
Cutting head
The cutting head is the unit that cuts the material. It consists of a cast iron head
on which the following are mounted: the band saw, the blade guide components,
the blade tensioner components, the transmission box and the spindle motor. The
cutting head is limited in its movements by the joint on the work table, and its
cutting stroke is manually guided by the operator.
Handwheel
Blade guide head plate
Handgrip
Blade guide heads
Head joint pivot
Transmis-
sion box
Motor
Vice
The vice is the unit that clamps the workpiece in place during cutting; it consists
ofavicesupport,commonlyknownasaleadnut,fixedtotheworktable,anda
lead screw with a slideway on which the mobile jaw is mounted. The vice is
operated manually by a handwheel, or by a pneumatic cylinder in the MA version
(optional).
Slideway Turntable
Handwheel
Vice support
(lead nut) Fixed platform

Version 24DM
Functional parts 2--3
Control panel
The control panel has a protection rating of IP 54 and contains the electrical
equipment. Access is gained by removing the screws fastening a safety panel,
while the operator’s safety is guaranteed by a key---operated safety switch,
designed to prevent any intentional interference with the unit. In order to remove
the panel from its mounting, the main switch has to be shifted to 0 (OFF), which
automatically cuts off the electrical supply.
Panel fastened by
screws
Control
panel
Main switch
Turntable
A cast iron casting forms the fulcrum for the cutting head, and the support for the
work table and the control panel. Releasing the locking lever on the slideway
allows the cutting head to be rotated to the right and to the left.
Cutting head mechanical limiting switch

MEP S.p.A.
2--4 Use and maintenance manual DM 8
Base
On opening the door in the base, you will find the air treatment unit (optional
extra only on versions with MA automatic vice) and the drawer with the coolant,
complete with electric pump.
Lubricant/coolant tank Electric pump

3--1
The DM 8 has been designed and produced in accordance with European
standards. For the correct use of the machine we recommend that the instruc-
tions contained in this chapter are carefully followed.
Use of the machine
The DM 8 band saw cutting machine is intended exclusively for cutting metallic
materials, ferrous or non---ferrous, in section or solid. Other types of material
and machining are not compatible with the specific technical characteristics of
the saw.
The employer is responsible for instructing the personnel who, in turn, are
obliged to inform the operator of any accident risks, safety devices, noise
emission and accident prevention regulations provided for by international
standards and national laws regarding the use of the machine. The operator must
be perfectly aware of the position and operation of all the machine controls.
The instructions, warnings and accident prevention standards in this manual must
be respected without question by all those concerned with the operation of the
machine.
The following definitions are those provided for by EC DIRECTIVE ON MA-
CHINERY No. 98/37/CE:
=”Danger zones”: any zone in and/or around a machine in which the presence
of a person constitutes a risk for the safety and health of that person.
=”Person exposed”: any person finding himself either completely or partly in a
danger zone.
=”Operator”: the person or persons given the responsibility of installing, oper-
ating, adjusting, maintaining, cleaning, repairing or transporting the machine.
The manufacturer declines any responsibility whatsoever, either civil or
criminal, should there be unauthorized interference or replacement of one or
more parts or assemblies on the machine, or if accessories, tools and
consumable materials are used that are different from those recommended by
the manufacturer itself or if the machine is employed in a plant system and its
proper function is thereby altered.
Attention
3
Safety and
accident
prevention

MEP S.p.A.
3--2 Use and maintenance manual DM 8
General recommendations
LIGHTING
Insufficient lighting for the types of operation envisaged could constitute a safety
hazard for the persons concerned. For this reason, the machine user must provide
lighting in the working area sufficient to eliminate all shadowy areas while also
avoiding any blinding light concentrations. (Reference standard ISO 8995---89
”Lighting in work environments”).
CONNECTIONS
Check that the power supply cables and pneumatic feed systems comply with the
maximum machine absorption values listed in the ”Machine Specification” tables;
replace if necessary.
GROUNDING
The installation of the grounding system must comply with the requirements set
out in IEC STANDARD 204.
OPERATOR POSITION
The position of the operator controlling machine operations must be as shown in
the diagram below.

Version 24DM
Safety and accident prevention 3--3
Recommendations to the operator
Always wear proper goggles or protective glasses.
Do not use the machine without the guards in place.
Do not allow hands to encroach on the cutting zone while the machine is
operating or still in motion.
Do not wear oversize clothing with long sleeves, oversize gloves, brace-
lets, necklaces or any other object that may become entangled in the ma-
chine during working; long hair must be tied back and bunched.
Before starting cutting operations, support the material at both ends of
the machine using the support arm (standard) or OPTIONAL accessories
such as the feed and discharge roller tables shown in the diagram below.
FEED SIDE ROLLER
TABLE 1500 mm
(59.05 in.)
DISCHARGE SIDE
ROLLER TABLE 1500 mm
(59.05 in.)
Alwaysdisconnectthepowersupplytothemachinebeforecarryingout
any maintenance work whatsoever, including when the machine is oper-
ating abnormally.
Any maintenance work on the hydraulic or pneumatic systems must be
carried out only after the pressure in the system has been released.