Optimum Opti S 300 VG User manual

OPTIMUM
MASCHINEN - GERMANY
© 2008
GB
Page 15 February 2008 Version 1.1.0 Opti S 300 VG Metal belt saw
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Operating manual
Version 1.1.0
Metal belt saw
Opti S 300 VG
Keep for future reference!

OPTIMUM
MASCHINEN - GERMANY
© 2008 GB
Page 2 Metal belt saw Opti S 300 VG Version 1.1.0 5 February 2008
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Table of Contents
1 Safety
1.1 Safety warnings (warning notes) ............................................................................................5
1.1.1 Classification of hazards ............................................................................................. 5
1.1.2 Further ideograms ...................................................................................................... 6
1.2 Proper use ............................................................................................................................. 6
1.3 Possible dangers caused by the metal belt saw .................................................................... 7
1.4 Qualification of employees ..................................................................................................... 8
1.4.1 Target group ............................................................................................................... 8
1.4.2 Authorized persons ..................................................................................................... 8
1.5 Safety devices ........................................................................................................................ 9
1.5.1 Lockable main switch ................................................................................................ 10
1.5.2 EMERGENCY-STOP button ..................................................................................... 10
1.5.3 Saw arch ................................................................................................................... 10
1.5.4 Saw blade guide ....................................................................................................... 11
1.5.5 Prohibition, warning and mandatory labels ............................................................... 11
1.6 Safety check ........................................................................................................................ 11
1.7 Personal protective equipment ............................................................................................. 12
1.8 Safety during operation ........................................................................................................ 13
1.9 Safety during maintenance .................................................................................................. 13
1.9.1 Switching off and securing the metal belt saw .......................................................... 13
1.9.2 Use of lifting equipment ............................................................................................ 13
1.9.3 Mechanical maintenance work ................................................................................. 14
1.10 Accident report ..................................................................................................................... 14
1.11 Electric ................................................................................................................................. 14
1.12 Hydraulic equipment ............................................................................................................ 14
2 Technical data
2.1 Data plate ............................................................................................................................. 15
2.2 Power connection ................................................................................................................. 15
2.3 General ................................................................................................................................ 15
2.4 Weight .................................................................................................................................. 15
2.5 Speed of saw blade ............................................................................................................. 15
2.6 Environmental conditions ..................................................................................................... 15
2.7 Operating agents ................................................................................................................. 16
2.8 Emissions ............................................................................................................................. 16
2.9 Cutting area ......................................................................................................................... 17
2.10 Dimensions .......................................................................................................................... 18
3 Assembly
3.1 Delivery volume .................................................................................................................... 19
3.2 Optional machine accessories ............................................................................................. 19
3.3 Storage ................................................................................................................................ 19
3.4 Transport .............................................................................................................................. 19
3.4.1 Load end ................................................................................................................... 20
3.5 Installation and assembly ..................................................................................................... 20
3.5.1 Requirements to the installation sight ....................................................................... 20
3.5.2 Assembly ..................................................................................................................20
3.5.3 Installation of the motor ............................................................................................ 20
3.5.4 Installation plan .........................................................................................................26
3.5.5 Cleaning and lubricating ........................................................................................... 28
3.5.6 Checks ...................................................................................................................... 28
3.6 Power connection ................................................................................................................. 30
3.7 First use ............................................................................................................................... 30
4 Operation
4.1 Safety ................................................................................................................................... 31
4.2 Control and indicating elements .......................................................................................... 31
4.2.1 Control panel ............................................................................................................ 31
4.2.2 Control panel hydraulics ........................................................................................... 32
4.2.3 Control elements ....................................................................................................... 32
4.3 Inserting the work piece ....................................................................................................... 34
4.3.1 Turn saw bow ........................................................................................................... 34

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MASCHINEN - GERMANY
© 2008
GB
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4.4 Adjusting the saw blade guide ..............................................................................................35
4.5 Switching on the metal belt saw ...........................................................................................35
4.6 Switching off the metal belt saw ...........................................................................................35
4.7 Adjusting the speed of the saw blade ...................................................................................36
4.7.1 Recommended speed of the saw blade ....................................................................37
4.8 Coolant appliance .................................................................................................................38
4.8.1 Spray gun ..................................................................................................................38
4.9 Hydraulic Feed .....................................................................................................................38
5 General information concerning saw blades
5.1 Spacing ................................................................................................................................39
5.2 Set of saw teeth ....................................................................................................................41
6 Maintenance
6.1 Safety ...................................................................................................................................42
6.1.1 Preparation ...............................................................................................................42
6.1.2 Restarting ..................................................................................................................42
6.2 Revision and maintenance ...................................................................................................43
6.3 Repair ...................................................................................................................................49
7 Ersatzteile - Spare parts S300 VG
7.1 Zeichnung - Explosion drawing - S300 VG ..........................................................................50
7.2 Zeichnung - Explosion drawing - S300 VG .........................................................................51
7.3 Zeichnung - Explosion drawing - S300 VG ..........................................................................52
7.3.1 Schaltplan - Wiring diagram - S300 VG ....................................................................53
7.3.2 Ersatzteilliste - Spare parts list - S300 VG ................................................................53
8 Abnomalties
9 Appendix
9.1 Copyright ..............................................................................................................................61
9.2 Terminology/Glossary ..........................................................................................................61
9.3 Warranty ...............................................................................................................................62
9.4 Product follow-up ..................................................................................................................63
9.5 EC Declaration of Conformity ...............................................................................................64

Safety
OPTIMUM
MASCHINEN - GERMANY
© 2008 GB
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1 Safety
Glossary of symbols
This part of the operation manual
• does explain the meaning and how to use the warning references contained in this operation
manual,
• does explain how to use the metal belt saw,
• highlights the dangers that might arise for you and others if these instructions are not fol-
lowed thoroughly,
• informs you on how to prevent danger.
In addition to this operating manual, please note
• applicable laws and regulations,
• legal regulations for preventing an accident,
• the prohibition, warning and mandatory signs as well as the warning notes on the metal belt
saw.
European standards must be kept during installation, operation, maintenance and repair of the
metal belt saw.
If European standards are not applied at the national legislation of the country of destination, the
specific applicable regulations of each country are to be observed.
If necessary, the required measures must be taken to comply with the specific regulations of
each country before the metal belt saw is used for the first time.
Always keep the operating manual close to the metal belt saw for further reference.
INFORMATION
If you are not able to solve a problem using this manual, please do not hesitate to contact us for
further professional advice:
OPTIMUM Maschinen GmbH
Dr. Robert-Pfleger-Str. 26
D- 96103 Hallstadt
gives further advice
calls on you to get in action
• enumeration

OPTIMUM
MASCHINEN - GERMANY
Safety
© 2008
GB
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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 (ideogram) and warning signs for each specific danger and its (possi-
ble) consequences.
ideogram warning alert definition/consequences
DANGER! Threatening danger that will cause serious injury or death
to people.
WARNING! Risk: A danger might cause serious injury or death to a
person.
CAUTION! Danger or unsafe procedure that might cause injury to
people or damage to property.
ATTENTION!
Situation that could cause damage to the machine and to
the product and other types of damages.
No risk of injury to people.
INFORMATION
Application advice and other important or useful informa-
tion and notes.
No dangerous or harmful consequences for people or
objects.
In case of certain dangers, we replace the ideogram by
or
general dan-
ger, with a warning of, injuries of hands, hazardous electrical volt-
age,
rotating parts.

Safety
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MASCHINEN - GERMANY
© 2008 GB
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1.1.2 Further ideograms
1.2 Proper use
Use
WARNING!
Improper use of the metal belt saw
• will endanger personnel,
• will endanger the machine and other property of the operator,
• may affect proper operation of the machine.
The machine is designed and manufactured to be used in environments in which there is no
potential danger of explosion.
The metal belt saw is designed and manufactured to saw cold metal, cast material and plastics
or other material that are not health hazardous and do not generate dust.
The metal belt saw must not be used on wood.
The pieces to be cut must be of a shape that will allow them to be securely attached in the
workholder vice and ensure that the piece does not come loose when it is being sawed.
The metal belt saw must only be installed and operated in a dry and well-ventilated place.
Improper
use! If the metal belt saw is used in any way other than prescribed above, modified without autoriza- tion of Optimum Maschinen GmbH, then the metal belt saw is being used improperly.
We do not take liability for damage caused through improper use.
We would like to stress that any modifications to the construction, or technical or technological
modifications that have not been authorized 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 metal belt saw are complied with,
• the operating manual is constantly observed,
• inspection and maintenance instructions are observed.
 “Technical data“ on page 15
The decisive factor for achieving efficient cutting and the necessary angular tolerance is the cor-
rect choice of parameters such as the saw belt, feed, cutting pressure, cutting speed and cool-
ing agent.
Be aware of slip-
ping! Activation forbid- den! Pull the main plug! Use safety glasses! Use ear protec- tion!
Use protective
gloves! Use protective shoes! Wear a safety suit! Protect the envi- ronment! Contact address

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Safety
© 2008
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WARNING!
Very serious injury.
It is forbidden to make any modifications or alternations to the operating values of the
metal belt saw! They could endanger employees and cause damage to the metal belt saw.
1.3 Possible dangers caused by the metal belt saw
The design and construction of the metal belt saw are state of the art.
Nevertheless, there is a residual risk as the metal belt saw operates with
• electrical voltage and currents,
• hydraulic equipment,
• a continuous saw blade.
We have used construction resources and safety techniques to minimize the health risk to per-
sons resulting from these hazards.
If the metal belt saw is used and maintained by employees who are poorly qualified, then there
might be a risk resulting from incorrect operation and unsuitable maintenance of the metal belt
saw.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
• be duly qualified,
• strictly follow this operating manual.
Due to improper use
• there is a risk for the employee,
• the metal belt saw and further property might be endangered,
• the function of the metal belt saw could be affected.
Always disconnect the metal belt saw if cleaning or maintenance work is being carried out.
WARNING!
The metal belt saw may only be used with the safety devices activated. Disconnect the
metal belt saw immediately whenever you detect a failure in the safety device or when
they are not mounted!
All additional installations carried out by the operator must incorporate the safety
devices prescribed.
This is your responsibility being the operator!
 “Safety devices“ on page 9

Safety
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MASCHINEN - GERMANY
© 2008 GB
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1.4 Qualification of employees
1.4.1 Target group
This manual applies to
• the operators,
• the users,
• the maintenance staff.
Therefore, the warning notes refer to both operation and maintenance of the metal belt saw.
Determine clearly and make a permanent decision in who will be responsible for the different
activities on the machine (operation, maintenance and repair).
Vague and unclear assignment of responsibilities constitute a safety hazard!
Always disconnect the main plug of the metal belt saw. This will prevent the metal belt saw from
being restarted.
1.4.2 Authorized persons
WARNING!
Incorrect use and maintenance of the metal belt saw constitute a danger for the staff,
objects and the environment.
Only authorized persons may operate the metal belt saw!
Persons authorized to operate and maintain should be trained technical staff and instructed by
the ones who are working for the operator and for the manufacturer.
The operator must
Obligations
of the opera-
tor
• train the staff,
• instruct the staff in regular intervals (at least once a year) on
- all safety standards that apply to the machine,
- the operation,
- accredited technical guidelines,
• check the knowledge of the staff,
• document training/instructions,
• require the staff to confirm participation in training/instructions by means of signature,
• check if the staff is aware of safety rules and dangers in the workplace so that they observe
the operating manual.
The user must
Obligations
of the user • have followed a training on the operation of the metal belt saw,
• know the function and performance,
• before commissioning
- have read and understood the operating manual,
- be familiar with all safety devices and regulations.
Further
require-
ments to the
qualification
For working on the following machine parts, additional requirements are being applied:
• Hydraulic equipment: only specialists with special knowledge/experience in this field.
• Electrical parts or operating agents: shall only be performed by an electrician or under the
guidance and supervision of an electrician.

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MASCHINEN - GERMANY
Safety
© 2008
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Before starting work on electrical parts or operating agents, following measures are to be
performed in the following order.
- disconnect all poles
- secure against switching on
- check dead circuit
1.5 Safety devices
Operate the metal belt saw only with properly functioning safety devices.
Stop the metal belt saw immediately if there is a failure in the safety device or if it is not function-
ing for some reason.
It is your responsibility!
If the safety device has been activated or has failed, the metal belt saw must only be operated
again when
• the cause of the failure has been removed,
• you have made sure that there is no existing danger for persons or objects.
WARNING!
If you bypass, remove or override a safety device in any other way, you are endangering
yourself and other persons working on the metal belt saw. The possible consequences
are the following
• injuries due to components or parts of components flying off at high speed,
• contact with rotating and revolting parts,
• fatal electrocution.
The metal belt saw includes the following safety devices:
• a lockable main switch,
• an EMERGENCY-STOP button,
• a saw blade casing with protective cover and position switch,
• a protective cover of the V-belt (cover variator) to switch the speed of the saw blade,
• position switch for the saw blade tension,
• protective covers of the saw blade guide.

Safety
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MASCHINEN - GERMANY
© 2008 GB
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1.5.1 Lockable main switch
A lockable main switch can be secured by
a padlock in the position " 0 " against
switching on by mistake or unauthorized.
The power supply is interrupted by switch-
ing off the main plug.
Except for the positions which are marked
by the ideogram in the margin.
Illustr.1-1: main switch
WARNING!
Dangerous voltage even if the main switch is being switched off. In the positions of the
ideogram marked in the margin there might be voltage even if the main switch is being
switched off.
1.5.2 EMERGENCY-STOP button
The EMERGENCY-STOP button turns the
metal belt saw off.
INFORMATION
After actuation turn the EMERGENCY-
STOP button clockwise in order to turn the
metal belt saw on again.
Illustr.1-2: control panel
1.5.3 Saw arch
The arch of the metal belt saw is provided
with a protective cover. The protective
cover covers the belt guide reels and the
revolting saw blade.
The metal belt saw only switches on when
the protective cover is being closed.
Illustr.1-3: saw blade housing with
protective cover
WARNING!
Danger of injury! The teeth of the saw blade are sharp. Take great care when opening the pro-
tective cover to change the saw blade.
Close and mount all protective covers before restarting the metal belt saw.
main switch
EMERGENCY-STOP
button
saw arch

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MASCHINEN - GERMANY
Safety
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1.5.4 Saw blade guide
Refit the protective covers after each
exchange of the saw blade.
Illustr.1-4: protective covers
saw blade guide
1.5.5 Prohibition, warning and mandatory labels
INFORMATION
All warning labels must be legible. Check them regularly.
1.6 Safety check
Check the metal belt saw at least once per shift. Inform the person responsible immediately of
any defect or change in the 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 work.
Check that the prohibition, warning and information labels as well as the markings on the metal
belt saw
• are legible (clean them, if necessary),
• are complete.
INFORMATION
Use the following table to organize the checks.
p
rotective covers on the
right hand saw blade
guide
General checks
equipment check OK
protective covers fitted, firmly bolted and not damaged
labels, markings installed and legible
Date: Checked by (signature):

Safety
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MASCHINEN - GERMANY
© 2008 GB
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1.7 Personal protective equipment
For certain work, personal protective equipment is required, such as:
• safety helmet,
• protective glasses or face guard,
• protective gloves,
• safety shoes with steel caps,
• ear protection.
Before starting work, make sure that the prescribed personal protective equipment is available
at the workplace.
CAUTION!
Dirty or eventually contaminated personal equipment might cause disease.
Clean your personal protective equipment
• after each use,
• regularly once a week.
Personal protective equipment for special work
Protect your face and your eyes: Wear a safety helmet with a face guard for every work, espe-
cially for the kind of work where your face and eyes are exposed to hazards.
Use protective gloves when lifting or handling pieces with sharp edges.
Wear safety shoes when fitting, dismanteling or transporting heavy components.
Functional testing
equipment check OK
EMERGENCY-STOP
button The metal belt saw must disconnect when the EMER- GENCY-STOP button is activated.
position switch
protective cover
saw arch
The metal belt saw may only switch on when the protective
cover is being closed.
position switch
tension of the saw
blade
The metal belt saw may only switch on when the saw blade
is well stretched.
Date: Checked by (signature):

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MASCHINEN - GERMANY
Safety
© 2008
GB
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1.8 Safety during operation
In the description of work with and on the metal belt saw we highlight the dangers specific to that
work.
WARNING!
Before activating the metal belt saw, double check that this will
• not endanger other people,
• not cause damage to equipment.
Avoid unsafe working practice:
• Make sure that your work does not endanger anyone.
• The instructions of this manual must be observed strictly during assembly, operation, mainte-
nance and repair.
• Do not work on the metal belt saw if your concentration is reduced, for example, because
you are taking medication.
• Observe the regulations for the prevention of accidents issued by your association for the
prevention of accidents and safety in the workplace or other inspection authorities.
• Stay at the metal belt saw until all rotating parts have come to a halt.
• Use the prescribed personal protective equipment. Make sure you wear a well-fitting work
suit and a hairnet, if necessary.
• Do not wear gloves when sawing parts, use the spray gun to remove sawdust during the
sawing proceedure.
• Inform the inspector of any danger or failure.
1.9 Safety during maintenance
Report and
document
any changes
Inform the operators on time of any maintenance and repair work.
Report all safety relevant changes or performance details of the metal belt saw. Document all
changes, have the operation manual changed accordingly and train the machine operators.
1.9.1 Switching off and securing the metal belt saw
Unplug the metal belt saw from electrical supply and secure the metal belt saw against restart-
ing by a padlock on the main switch.
Place a warning sign on the machine.
1.9.2 Use of lifting equipment
WARNING!
Use of unstable lifting and load-suspension gear that might break under load can cause
very serious injuries or even death.
Check the lifting and load-suspension gear on
• sufficient load capacity,
• perfect condition.
Observe the regulations for the prevention of accidents issued by your association for
the prevention of occupational accidents and safety in the workplace or other inspection
authorities.
Fasten the loads properly.
Do not walk under lifted loads!

Safety
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MASCHINEN - GERMANY
© 2008 GB
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1.9.3 Mechanical maintenance work
Remove all protection and safety devices before starting maintenance work and re-install them
once the work has been completed, such as:
• covers,
• safety indications and warning signs,
• earth (ground) cables.
If you remove protection or safety devices, refit them immediately after completing the work.
Check if they are working properly!
1.10 Accident report
Inform your superiors and Optimum Maschinen GmbH immediately in case of accidents, possi-
ble sources of danger and any action which almost lead to and accident „near misses“.
„Near misses“ may have many possible causes.
The sooner they are notified, the faster these causes can be eliminated.
INFORMATION
In the description of execution of work with and on the metal belt saw we highlight the dangers
specific to that kind of work.
1.11 Electric
Have the machine and/or the electrical equipment checked regularly, 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
case of an emergency.
Disconnect the metal belt saw immediately if there is a malfunction in the power supply!
1.12 Hydraulic equipment
The system has got a pressure of up to 280 bars.
WARNING!
Serious injury due to hydraulic fluid which escapes with high pressure!
Possible loss of the eyesight!
Make sure that the hydraulic equipment with valves is without pressure before you open a com-
ponent or a line. Wear protective glasses when working on the hydraulic system.
When you are having hydraulic fluids in your eyes rinse them immediately with lots of water.
Consult a doctor immediately.

OPTIMUM
MASCHINEN - GERMANY
Technical data
© 2008
GB
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2 Technical data
2.1 Data plate
Illustr.2-1: data plate
The following information give the dimensions and weight and is the manufacturer’s authorized
machine data.
2.2 Power connection
sawing engine 400V ~50Hz; 1,5 KW
cooling pump 400V ~50Hz; 0,1 KW
total connection rate 3x400V ~50Hz (60Hz); 1,7 KW
2.3 General
raising the saw arm manually
feed hydraulic by means of a lowering cylinder
speed of saw blade infinitely variable
dimensions of saw blade 27 x 0,9 x 3352
Height to machine vice 750 mm
2.4 Weight
weight metal belt saw [kg] 410
floor loading [ KN / m2 ]7
2.5 Speed of saw blade
for a connection of ~ 50Hz - [m/min] infinitely 25 ~ 100
for a connection of ~ 60Hz - [m/min] infinitely 30 ~ 120
2.6 Environmental conditions
temperature 5°-35 °C
humidity 25 - 80 %

Technical data
OPTIMUM
MASCHINEN - GERMANY
© 2008 GB
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2.8 Emissions
The development of noise (sound pressure level) of the metal belt saw at the workplace could
exceed the level of 80 dB(A).
INFORMATION
We recommend the use of sound insulation and ear protection. Please note, the duration of
noise pollution, the type and characteristics of the working area, such as other machines which
are operated simultaneously, influence the development of noise at the workplace.
2.7 Operating agents
hydraulics hydraulic oil, viscosity from 32 to 46 according to DIN
51519,
quality HLP
gearbox high- performance gear-oil
Mobilgear 636, viscosity 680 mm2/s
spindle of the machine vice commercial lubricating grease
bushing- type bearing commercial lubricating grease
cooling appliance commercial cooling agent
maximum filling quantity 30 litres

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MASCHINEN - GERMANY
Technical data
© 2008
GB
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2.9 Cutting area

Technical data
OPTIMUM
MASCHINEN - GERMANY
© 2008 GB
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2.10 Dimensions

OPTIMUM
MASCHINEN - GERMANY
Assembly
© 2008
GB
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3 Assembly
INFORMATION
The metal belt saw is pre-assembled.
3.1 Delivery volume
When the metal belt saw is delivered, please check immediately that the machine has not been
damaged during transportation and that all components are included. Also check that the set
screws are well tightened.
• 1x metal belt saw
• 1x saw blade 4 to 6 teeth per inch
• 1x material stop
• 1x deflector for coolant and chips machine vice
• 2x additional mountable coolant drain pan
• 1x set of set screws
• 1x set of colours
• 1x operating manual
3.2 Optional machine accessories
3.3 Storage
ATTENTION!
Improper storage may cause important parts to be damaged or destroyed.
Store packaged or unpacked parts only under the following external conditions
 “Environmental conditions“ on page 15
Consult Optimum Maschinen GmbH if the metal belt saw and accessories have to be stored for
a period of over three months or under different ambience conditions to those given here.
3.4 Transport
WARNING!
Machine parts falling off forklift trucks or other trans-
port vehicles could cause very serious or even fatal
injuries. Follow the instructions and information on the
transport case:
• centre of gravity
• suspension points
• weights
• means of transport to be used
• prescribed shipping position Illustr.3-1: shipping position
WARNING!
Use of unstable lifting and load suspension gear that might break under load can cause
very serious injuries or even death.
Check that the lifting and load suspension gear has sufficient load capacitiy and that it is
in perfect condition. Observe the regulations for the prevention of accidents. Fasten the
loads properly. Do not walk under lifted loads!
designation part number
HSS bi-metal M42 saw blade (10 to 14 teeth per inch) 335 7532

Assembly
OPTIMUM
MASCHINEN - GERMANY
© 2008 GB
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3.4.1 Load end
Fasten the load end material on the
assigned load end positions on the machine
substructure.
Tighten all set screws. Assemble the secur-
ing device of the saw arch when the metal
belt saw is again being transported over a
long distance.
Use an adequate conveyor equipment; for
instance a crane.
Make sure that you have an equal load end
position and that the metal belt saw cannot
overturn when lifted.
Make sure that the load end does not dam-
age any accessories or causes damages to
the paintwork.
Illustr.3-2: Load end
The net weight of the machine is 410 kg.
3.5 Installation and assembly
3.5.1 Requirements to the installation sight
Organize the work area around the metal belt saw in accordance with the local safety regula-
tions.
Operation, maintenance and repair in the work area must not be hindered.
3.5.2 Assembly
Check the foundation of the metal belt saw with a spirit level on horizontal alignment. Equal-
ize unevenesses by metal plates or other adequate material.
Fasten the machine substructure to the machine foundation when the metal belt saw is being
connected to the power supply stationary.
3.5.3 Installation of the motor

Illustr. 3-3: Fix the motor plate. Illustr. 3-4: Fix the clamp.