Optimum SAW SD 500AV User manual

GB
Operating Instructions
Version 1.0.4
Metal band saw
Part no. 3292385

Version 1.0.4 - 2020-10-132 Translation of original instruction
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EN
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Table of contents
1 Safety
1.1 Glossary of symbols ...................................................................................................................................... 5
1.2 Rating plate.................................................................................................................................................... 5
1.3 Hazards Classification................................................................................................................................... 6
1.3.1 Other pictograms.............................................................................................................................. 6
1.4 Intended use.................................................................................................................................................. 7
1.5 Reasonably foreseeable misuses.................................................................................................................. 8
1.5.1 Avoiding misuse............................................................................................................................... 8
1.6 Possible dangers caused by the metal band saw.......................................................................................... 9
1.7 Qualification of personnel.............................................................................................................................. 9
1.7.1 Target group..................................................................................................................................... 9
1.7.2 Authorized persons........................................................................................................................ 10
1.8 User positions.............................................................................................................................................. 11
1.9 Safety devices ............................................................................................................................................. 11
1.9.1 Lockable master switch.................................................................................................................. 11
1.9.2 Emergency stop switch.................................................................................................................. 12
1.9.3 Saw bow......................................................................................................................................... 12
1.9.4 Saw band guide ............................................................................................................................. 12
1.9.5 Prohibition, warning and mandatory signs..................................................................................... 12
1.10 Safety check................................................................................................................................................ 12
1.11 Personal protective equipment.................................................................................................................... 13
1.12 Safety during operation................................................................................................................................ 14
1.13 Safety during maintenance.......................................................................................................................... 14
1.13.1 Disconnecting and securing the metal belt saw.............................................................................14
1.13.2 Using lifting equipment................................................................................................................... 15
1.13.3 Mechanical maintenance work....................................................................................................... 15
1.14 Accident report............................................................................................................................................. 15
1.15 Electrical system.......................................................................................................................................... 15
1.16 Hydraulic system ......................................................................................................................................... 16
1.17 Inspection deadlines.................................................................................................................................... 16
2 Technical specification
2.1 Electrical connection.................................................................................................................................... 17
2.2 General........................................................................................................................................................ 17
2.3 Weight.......................................................................................................................................................... 17
2.4 Speed of saw band...................................................................................................................................... 17
2.5 Operating material....................................................................................................................................... 17
2.6 Environmental conditions............................................................................................................................. 17
2.7 Emissions .................................................................................................................................................... 18
2.8 Dimensions.................................................................................................................................................. 18
3 Delivery, interdepartmental transport, assembly and commissioning
3.1 Notes on transport, installation, commissioning .......................................................................................... 19
3.1.1 General risks during internal transport........................................................................................... 19
3.1.2 Load suspension point................................................................................................................... 20
3.2 Set-up and assembly................................................................................................................................... 20
3.2.1 Scope of delivery............................................................................................................................ 20
3.2.2 Requirements regarding the installation site.................................................................................. 20
3.2.3 Assembly........................................................................................................................................ 21
3.2.4 Assembly of the hydraulic unit and the metal band saw................................................................ 21
3.2.5 Roller support assembly................................................................................................................. 23
3.2.6 Material stop................................................................................................................................... 24
3.2.7 Cleaning and lubricating................................................................................................................. 24
3.2.8 Top up hydraulic oil........................................................................................................................ 24
3.2.9 Fill with coolant............................................................................................................................... 25
3.2.10 Checks........................................................................................................................................... 25
3.3 First commissioning..................................................................................................................................... 26
3.3.1 Running-in process........................................................................................................................ 26
3.4 Electrical connection.................................................................................................................................... 26
3.4.1 Direct current on the PE conductor................................................................................................ 27
3.4.2 Regulated drives in connection with residual current devices........................................................ 28
3.4.3 Protection from Dangerous Shock Currents, use of ELCBs .......................................................... 28
3.4.4 Current in the protective earth conductor - Leakage current.......................................................... 28
3.4.5 When the ELCB triggers ................................................................................................................ 29
4Operation
4.1 Safety........................................................................................................................................................... 30

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4.2 Control and indicating elements...................................................................................................................30
4.2.1 Control panel ..................................................................................................................................31
4.2.2 Inserting the workpiece and clamping it firmly................................................................................32
4.3 Switching the machine on ............................................................................................................................33
4.4 Switching off the machine ............................................................................................................................33
4.5 Resetting an emergency stop situation ........................................................................................................34
4.6 Power failure, Restoring readiness for operation .........................................................................................34
4.7 Turn the saw bow.........................................................................................................................................34
4.8 Adjusting the saw band guide ......................................................................................................................35
4.9 Coolant equipment .......................................................................................................................................35
4.10 General information concerning saw bands.................................................................................................36
4.10.1 Spacing...........................................................................................................................................36
4.10.2 Set of saw teeth..............................................................................................................................37
4.10.3 Recommended saw band speeds ..................................................................................................39
5 Maintenance
5.1 Safety...........................................................................................................................................................41
5.1.1 Preparation.....................................................................................................................................41
5.1.2 Restarting .......................................................................................................................................41
5.2 Inspection and maintenance ........................................................................................................................42
5.3 Recommended operating materials .............................................................................................................48
5.4 Cleaning.......................................................................................................................................................48
5.5 Repair...........................................................................................................................................................48
5.5.1 Customer service technician...........................................................................................................48
5.6 Hydraulic system..........................................................................................................................................50
5.6.1 Inspection and exchange of hydraulic hoses..................................................................................50
5.6.2 Personnel qualified to inspect hydraulic systems ...........................................................................50
5.7 Cooling lubricants and tanks........................................................................................................................51
5.7.1 Inspection plan for water-mixed cooling lubricants.........................................................................52
6 Ersatzteile - Spare parts
6.1 Ersatzteilbestellung - Ordering spare parts..................................................................................................53
6.2 Hotline Ersatzteile - Spare parts Hotline ......................................................................................................53
6.3 Service Hotline.............................................................................................................................................53
6.4 Ersatzteilzeichnung Bandsäge - Spare parts drawing band saw .................................................................54
6.5 Ersatzteilzeichnung Maschinenunterbau - Spare parts drawing machine stand..........................................56
6.6 Ersatzteilzeichnung Getriebe - Gearbox spare parts drawing......................................................................57
6.7 Hydraulikaggregat - Hydraulic unit...............................................................................................................61
6.8 Ersatzteilzeichnung Bedienpanel - Spare parts drawing operating panel....................................................63
6.9 Schaltplan - Wiring diagram.........................................................................................................................64
7 Malfunctions
7.1 Malfunctions on the frequency converter - Sinamics G110M.......................................................................71
7.1.1 Sinamics G110M, Operating Instructions, 06/2016, FW V4.7.6, A5E31298649B AG....................71
8 Appendix
8.1 Copyright......................................................................................................................................................73
8.2 Terminology/Glossary ..................................................................................................................................73
8.3 Change information manual .........................................................................................................................73
8.4 Storage.........................................................................................................................................................74
8.5 Liability claims for defects / warranty............................................................................................................75
8.6 Advice for disposal / Options of reuse:.........................................................................................................75
8.6.1 Decommissioning ...........................................................................................................................76
8.6.2 Disposal of new device packaging..................................................................................................76
8.6.3 Disposal of the old device...............................................................................................................76
8.6.4 Disposal of electrical and electronic components...........................................................................76
8.6.5 Disposal of lubricants and coolants ................................................................................................77
8.7 Disposal through municipal collection facilities ............................................................................................77
8.8 Product follow-up..........................................................................................................................................77

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Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions
and convince by an outstanding price performance ratio. Continuous enhancements and pro-
duct innovations guarantee state-of-the-art products and safety at any time.
Before commissioning the machine please thoroughly read these operating instructions and get
familiar with the machine. Please also make sure that all persons operating the machine have
read and understood the operating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, opera-
tion and maintenanceof the machine. The continuous observance of all notes included in this
manual guarantee the safety of persons and of the machine.
The manual determines the intended use of the machine and includes all necessary information
for its economic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which
the operator must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the
current state of construction of your machine. Being the manufacturer we are continuously see-
king for improvements and renewal of the products. Therefore, changes might be performed
without prior notice. The illustrations of the machine may be different from the illustrations in
these instructions with regard to a few details. However, this does not have any influence on the
operability of the machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors
are reserved !
Your suggestion with regard to these operating instructions are an important contribution to opti-
mising our work which we offer to our customers. For any questions or suggestions for improve-
ment, please do not hesitate to contact our service department.
If you have any further questions after reading these operating instructions and you are
not able to solve your problem with a help of these operating instructions, please
contact your specialised dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt, Germany
Fax (+49)0951 / 96555 - 888
Email: in[email protected]
Internet: www.optimum-machines.com

Safety
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1 Safety
1.1 Glossary of symbols
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
defines the intended use of the metal band saw,
points out the dangers that might arise for you or others if these instructions are not obser-
ved and
informs you about how to avoid dangers.
In addition to these operating instructions, please observe
the applicable laws and regulations,
the statutory provisions for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the metal
band saw.
European standards must be met during installation, operation, maintenance and repair of the
metal band saw.
If European standards have not yet been incorporated in the relevant national legislation of the
destination country, the specific applicable regulations of each country must be observed.
If required, the relevant measures to comply with the country-specific regulations must be taken
before commissioning the metal band saw.
Always keep this documentation close to the metal band saw.
INFORMATION
If you are unable to rectify an issue using these operating instructions, please contact us for
advice:
Optimum Maschinen Germany GmbH
Dr. Robert-Pfleger-Str. 26
D- 96103 Hallstadt, Germany
Email: [e-mail]
1.2 Rating plate
provides further instructions
calls on you to act
listings
SD 500AV
NO
SN
Year
Netto
2,2 KW
400 V ~50 Hz
m/min.
Optimum Maschinen
Germany GmbH
Dr.-Robert-Pfleger-Str. 26
96103 Hallstadt / Deutschland
3292385 805 kg
DE Metallbandsäge
EN Metal belt saw
FR Scie à ruban
ES Sierra de cinta para metal
IT Segatrici a nastro per metalli
CS Pásové pila
DA Metalbåndsav
EL ζώνη είδε
FI Metallivannesaha
HU Fém SzalagfĦrész
NL Metaalbandzaagmachine
PL Przecinarka taśmowa do metalu
PT Serras de fita
RO Fierăstrău cu bandă metalică
RU Ленточная пила
SK Pásová pila
SL Žaga za železo
SV Metall bandsåg
TR Metal Şerit testere www.optimum-maschinen.de

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1.3 Hazards Classification
We classify the safety warnings into different categories. The table below gives an overview of
the classification of symbols (ideogram) and the warning signs for each specific danger and its
(possible) consequences.
1.3.1 Other pictograms
Symbol Alarm expression Definition / consequence
DANGER! Impending danger that will cause serious injury or death to people.
WARNING! A danger that can cause serious injury or death.
CAUTION! A danger or unsafe procedure that can cause personal injury or damage
to property.
ATTENTION!
Situation that could cause damage to the metal band saw and product
and other types of damage.
No risk of injury to persons.
INFORMATION
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.
In case of specific dangers, we replace the pictogram with
general danger with a warning of injury to hands, hazardous
electrical voltage,
or
rotating parts.
Warning: danger of
slipping! Warning: risk of stumbling! Warning: hot surface! Warning: biological hazard!
Warning: automatic start-
up! Warning: tilting danger! Warning: suspended loads! Caution, danger of explosive substances!

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1.4 Intended use
WARNING!
In the event of improper use, the metal belt saw
will endanger personnel,
will endanger the machine and other material property of the operating company,
the correct function of the machine may be affected.
The machine is designed and manufactured to be used in environments where 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 band 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 ventilated place.
Operations not in
accordance with
intended use!
If the metal belt saw is used in any way other than described above, modified without authoriza-
tion of Optimum Maschinen Germany GmbH, then the metal belt saw is being used improperly.
We will not be held liable for any damages resulting from any operation which is not in accor-
dance with the intended use.
We expressly point out that the guarantee or CE conformity will expire due to any constructive
technical or procedural changes which had not been performed by the company Optimum
Maschinen Germany GmbH.
It is also part of intended use that
observe the limits of the metal belt saw,
obey the operating instructions,
the inspection and maintenance instructions are observed.
 Technical specification on page 17
The decisive factor for achieving efficient cutting and the necessary angular tolerance is the
correct choice of parameters such as the saw band, feed, cutting pressure, cutting speed and
cooling agent.
Switching on forbidden! Area prohibited for persons
with implants! Read the operating instructions before
commissioning!
Pull out the mains plug! Wear protective glasses! Wear protective gloves! Wear safety shoes!
Wear a protective suit! Use ear protection! Protect the environment! Contact address

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INFORMATION
The metal band saw with frequency converter is built according to the standard EN61800 class
C2.
WARNING!
Class C2 (machine tools) is not intended for use in residential or mixed areas where the
power supply is provided by a low-voltage public power supply system. In these areas it
may possibly be difficult to guarantee electromagnetic compatibility due to lead bound
as well as emitted interferences.
Overview of EMC categories:
Categorie C1
required limit values Class B Group 1 according to EN 55011
Categorie C2
Required limit values class A Group 1 according to EN 55011, Installation by EMC
expertsand warning: “This is a product of category C2 according to EN 61800-3. This pro-
duct may cause radio interference in a residential area. In this case, it may be necessary for
the operator to take appropriate action.“
Categorie C3
Required limit values class A group 2 according to EN 55011, whereby these limit values
are below those of class A group 1, plus warning: „This type is not suitable for connection to
a public low-voltage network supplying residential buildings. When connecting to a public
low voltage network, radio frequency interference is expected. "
WARNING!
Extremely severe injuries.
It is forbidden to make any modifications or alternations to the operation values of the
metal belt saw! They could endanger people and cause damage to the metal belt saw.
1.5 Reasonably foreseeable misuses
Any other use other than that specified under "Intended use" or any use beyond the described
use shall be deemed as non-intended use and is not permissible.
Any other use has to be discussed with the manufacturer.
In order to avoid misuse, it is necessary to read and understand the operating instructions
before first commissioning. Operators must be qualified.
1.5.1 Avoiding misuse
Use the correct metal saw bands, tooth pitch, depending on the material to be sawed.
Correct belt speed and feed depending on the material to be sawed.
This machine
Categorie C1 C2 C3 C4
Environment Residential area Business area
Industrial area Industry
Voltage / Current < 1000 V > 1000 V
EMC knowledge no requirement Installation and commissioning by an EMC expert

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Clamp the workpiece firmly and as vibration-free as possible.
Long workpieces must be supported. Use a suitable support.
1.6 Possible dangers caused by the metal band saw.
The construction and design of the metal band saw are state-of-the-art.
Nevertheless, there is a residual risk as the metal belt saw operates with
electrical voltage and currents and
a circulating metal saw band.
We have used construction resources and safety techniques to minimize the health risk to per-
sonnel resulting from these hazards.
If the metal band saw is used and maintained by personnel who are not duly qualified, there
may be a risk resulting from incorrect or unsuitable maintenance of the metal band saw.
INFORMATION
Everyone involved in the assembly, commissioning, operation and maintenance must
be duly qualified,
and strictly follow these operating instructions.
In the event of improper use
there may be a risk to personnel,
the metal belt saw and further property might be endangered,
the correct function of the metal belt saw may be affected.
Always disconnect the metal belt saw from the electrical power supply when performing
cleaning or maintenance works.
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 devices or when
they are not mounted!
All additional devices installed by the operator have to be equipped with the prescribed
safety devices. This is your responsibility as the operator!
 Safety devices on page 11
1.7 Qualification of personnel
1.7.1 Target group
This manual is addressed to
the operating companies,
the operators,
the maintenance personnel.
Therefore, the warning notes refer to both operation and maintenance of the metal belt saw.
Determine clearly and explicitly who will be responsible for the different activities on the
machine (operation, maintenance and repair).
Unclear responsibilities constitute a safety risk!
Disconnect the main plug of the metal belt saw and secure the metal belt saw against restar-
ting.
The qualifications of the personnel for the different tasks are mentioned below:
Operator
The operator is instructed by the operating company about the assigned tasks and possible
risks in case of improper behaviour. Any tasks performed beyond operation in standard mode

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may only be performed by an operator if they are described in these instructions and if the ope-
rator has been specifically trained to perform them by the operating company.
Qualified electrician
With professional training, knowledge and experience as well as knowledge of respective stan-
dards and regulations, qualified electricians are able to perform work on the electrical system
and recognise and avoid any possible dangers.
Qualified electricians have been specially trained for the working environment, in which they are
working and know the relevant standards and regulations.
Qualified personnel
Due to their professional training, knowledge and experience as well as knowledge of relevant
regulations, qualified personnel are able to perform the assigned tasks and to independently
recognise and avoid any possible dangers.
Instructed person
Instructed persons were instructed by the operating company regarding the assigned tasks and
any possible risks of improper behaviour.
1.7.2 Authorized persons
WARNING!
Inappropriate operation and maintenance of the metal belt saw constitutes a danger for
the personnel, objects and the environment.
Only authorized staff may operate the metal belt saw!
Persons authorized to operate and maintain should be trained technical personnel and
instructed by the ones who are working for the operating company and for the manufacturer.
The operating company must
train the personnel,
instruct the personnel in regular intervals (at least once a year) on
- all safety standards that apply to the machine,
- the operation,
- generally accepted engineering standards.
check the personnel‘s knowledge level,
document the training/instruction,
have attendance at the training/instruction confirmed by signature and
check whether the personnel is working safety and risk-conscious and observes the opera-
ting instructions.
The operator must
have obtained a training regarding the handling of the metal belt saw,
know the function and mode of action,
before taking the machine in operation
- have read and understood the operating manual,
- be familiar with all safety devices and instructions.
Additional requirements apply for work on the following machine components:
Hydraulic: Only specialists with special knowledge/experience in these areas.
Electric components or operating materials: Must only be worked on by a qualified electri-
cian or person working under the instructions and supervision of a qualified electrician.

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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 restarting
- check that there is no voltage
1.8 User positions
The operator must stand beside or in front of the metal band saw.
1.9 Safety devices
Use the metal belt saw only with properly functioning safety devices.
Stop the metall band saw immediately if there is a failure on 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 metal belt saw must only be used if you
the cause of the fault has been eliminated,
you have verified that there is no danger to personnel 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:
injuries due to components or workpieces flying off at high speed,
contact with rotating and revolting parts,
and fatal electrocution.
The metal belt saw features the following safety devices:
a lockable main switch,
an emergency stop switch,
a saw band casing with protective cover and position switch,
position switch for the saw band tension,
protective covers of the saw band guide.
WARNING!
Although the isolating safety devices provided and delivered with the machine are desi-
gned to reduce the risks of workpieces being ejected or parts of tools or workpieces bre-
akingoff,theycannoteliminatetheseriskscompletely.
1.9.1 Lockable master switch
In the "0" position, the lockable main switch can be secured against accidental or non-authori-
sed switching on by means of a padlock.
The power supply is interrupted by switching off the main plug.
Except for the areas marked by the pictogram in the margin.
WARNING!
Dangerous voltage even if the main switch is switched off. The areas marked by the
pictogram might contain live parts, even if the main switch is switched off.

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1.9.2 Emergency stop switch
CAUTION!
Only press the emergency-stop button in a genuine emergency. The emergency stop
switch is not suitable for shutting down the machine operationally.
The emergency stop switch switches off the drives of the metal band saw.
INFORMATION
Turn the emergency stop button clockwise after pressing it to switch on the metal band saw
again.
1.9.3 Saw bow
The saw bow of the metal band saw is provided with a protective cover. The
protective cover covers the band guide rollers and the rotating saw band.
The metal belt saw only switches on when the protective cover is being closed.
WARNING!
Danger of injury! The teeth of the saw belt are sharp. Take great care when opening the
protective cover to change the saw blade.
Close and mount all protective covers before restarting the metal belt saw.
1.9.4 Saw band guide
Refit the protective covers after each saw band change.
1.9.5 Prohibition, warning and mandatory signs
INFORMATION
All warning signs must be legible.
1.10 Safety check
Check the metal belt saw at least once per shift. Inform the person responsible immediately of
any damage, defects or changes 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 all maintenance and repair work.
Check that prohibition, warning and information signs and the labels on the metal belt saw
are legible (clean them, if necessary)
and complete (replace them, if necessary).
INFORMATION
Organise the checks according to the following table;

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1.11 Personal protective equipment
For some works you need personnel protective equipment as protective equipment. These are
safety helmet,
protective glasses or face guard,
protective gloves,
safety shoes with steel toe caps,
ear protection.
Before starting work make sure that the required personnel protective equipment is available at
the work place.
CAUTION!
Dirty or contaminated personnel protective equipment can cause illness.
Clean your personal protective equipment
after each use,
regularly once a week.
Personal protective equipment for special works
Protect your face and your eyes: Wear a safety helmet with facial protection when performing
work where your face and eyes are exposed to hazards.
Wear protective gloves when handling pieces with sharp edges.
Wear safety shoes when you assemble, disassemble or transport heavy components.
General check
Equipment Check OK
Guards Mounted, firmly bolted and not damaged
Signs,
Markers Installed and legible
Date: Checked by (signature):
Functional check
Equipment Check OK
Emergency stop switch After pressing the emergency stop button, the metal band saw
must switch off.
Positions switch
Protective cover saw
arch
The metal belt saw may only switches on when the protective
cover is being closed.
Positions switch
Saw band tension The metal belt saw may only switch on when the saw blade is well stretched.
Date: Checked by (signature):

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1.12 Safety during operation
WARNING!
Danger to life from electromagnetic fields. Electromagnetic fields (EMF) are generated by
the operation of electrical power equipment such as transformers, converters or motors.
People with pacemakers or implants are at a special risk in the immediate vicinity of
these devices/systems.
Ensure that the persons involved are the necessary distance away (minimum 2 m).
CAUTION!
Danger due to inhaling dust and mist that are hazardous to health.
Depending on the materials to be machined and the agents used, dusts and mists can
arise that are detrimental to health.
Ensure that the harmful dust and mist generated are safely sucked off at the point of
origin and routed away from the working area or filtered. To do so, use a suitable
extraction unit.
CAUTION!
Risk of fire and explosion by using flammable materials or cooling lubricants.
Extra precautionary measures must be taken before machining flammable materials (e.g.
aluminium, magnesium) or using combustible agents (e.g. spirit) to avert a health
hazard.
WARNING!
Before switching on the metal belt saw make sure that there are
no dangers generated for persons,
no objects are damaged.
Avoid any unsafe work methods:
Make sure that nobody is endangered by your work.
The rules specified in these operating instructions must be observed during assembly, ope-
ration, maintenance and repair.
Do not work on the metal belt saw, if your concentration is reduced, for example, because
you are taking medication.
Observe the accident prevention regulations issued by your Employers Liability Insurance
Association or other supervisory authorities applicable to your company.
Stay at the metal belt saw until all movements have come to a complete standstill.
Use the prescribed personnel protective equipment. Make sure to wear a well-fitting work
suit and, if necessary, a hairnet.
Inform the supervisor about all hazards or faults.
1.13 Safety during maintenance
Report and
document any
changes
Inform the operators in good time of any maintenance and repair works.
Report all safety relevant changes and performance details of the metal belt saw. Any changes
must be documented, the operating instructions updated and machine operators instructed
accordingly.
1.13.1 Disconnecting and securing the metal belt saw
Disconnect the main plug of the metal band saw and secure the metal band saw against restar-
ting.
Attach a warning sign on the machine.

Safety
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SD500AV EN
SD500AV_GB_1.fm
1.13.2 Using lifting equipment
WARNING!
The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death.
Check that the lifting and load suspension gear has
sufficient load capacity
and that it is in perfect condition.
Observe the accident prevention regulations issued by your Employers Liability
Insurance Association or other supervisory authorities applicable to your company.
Fasten the loads carefully.
Never walk under suspended loads!
1.13.3 Mechanical maintenance work
Remove or install protection safety devices before starting or after completing any main-
tenance work; this include:
covers,
safety instructions and warning signs,
grounding cables.
If you remove protection or safety devices, refit them immediately after completing the work.
Check that they are working properly!
1.14 Accident report
Inform your supervisors 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).
There are many possible causes for "near misses".
The sooner they are notified, the quicker the causes can be eliminated.
INFORMATION
We provide information about the dangers of working with and on the metal belt saw in these
work descriptions.
1.15 Electrical system
Have the machine and/or the electric equipment checked regularly. Immediately eliminate 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 metal belt saw immediately if there is a malfunction
in the power supply !
Comply with the required inspection intervals in accordance with the factory safety directive,
operating equipment inspection DGUV, formerly BVG.
The operator of the machine must ensure that the electrical systems and operating equipment
are inspected with regards to their proper condition, namely,
by a qualified electrician or under the supervision and direction of a qualified electrician,
prior to initial commissioning and after modifications or repairs, prior to recommissioning
and at certain intervals.
The deadlines must be set so that arising, foreseeable defects can be detected in a timely man-
ner.
The relevant electro-technical rules must be followed during the inspection.

Safety
Version 1.0.4 - 2020-10-1316 Translation of original instruction
SD500AV
EN
SD500AV_GB_1.fm
The inspection prior to initial commissioning is not required if the operator receives confirma-
tion from the manufacturer or installer that the electrical systems and operating equipment com-
ply with the accident prevention regulations, see conformity declaration.
Permanently installed electrical systems and operating equipment are considered constantly
monitored if they are continually serviced by qualified electricians and inspected by means of
measurements in the scope of operation (e.g. monitoring the insulation resistance).
1.16 Hydraulic system
The system is under a pressure of up to 280 bar.
WARNING!
Serious injuries from hydraulic liquid escaping under high pressure!
Possible loss of the eyesight!
Make sure the hydraulic system is depressurized before opening any component or line. Wear
safety goggles and protective clothing when carrying out any work on the hydraulic system.
Even after switching off the central power supply at the machine, the hydraulic system can still
be under stored pressure.
If hydraulic liquid squirts into your eyes, immediately rinse it with plenty of water. Immediately
seek medical assistance.
1.17 Inspection deadlines
Define and document the inspection deadlines for the machine in accordance with § 3 of the
Factory Safety Act and perform an operational risk analysis in accordance with § 6 of the Work
Safety Act. Also use the inspection intervals in the maintenance section as reference values.

Technical specification
Version 1.0.4 - 2020-10-13 17Translation of original instruction
SD500AV EN
SD500AV_GB_2.fm
2 Technical specification
The following information represents the dimensions and indications of weight and the manu-
facturer‘s approved machine data.
2.1 Electrical connection
Drive motor of saw 400V ~50Hz (60Hz) ; 2,2 kW
400V ~50Hz (60Hz) ; 3 kW from construction year end 2020
Hydraulic pump 400V ~50Hz (60Hz) ; 1,4 kW
Coolant pump 400V ~50Hz (60Hz) ; 0,1 kW
Total connected load 3x400V ~50Hz (60Hz); 3.8 kW
2.2 General
Raising the saw bow manual and hydraulic
Feed hydraulic by means of a lowering cylinder
Dimensions of saw blade [mm] 3770 x 34 x 1.1 mm
Dimensions  Dimensions on page 18
2.3 Weight
Net weight of the metal belt saw [kg] 645
Floor loading [KN/m2]7
2.4 Speed of saw band
G110M Inverter, basic frequency ~50Hz 20 - 80 m/min
2.5 Operating material
Gear Mobilgear 636, viscosity 680 mm2/s (about 1.5 liters)  „5.3
Recommended operating materials“ on page 48
Spindle of the machine vice Commercial lubricating grease
 Recommended operating materials on page 48
Slide bearing Commercial lubricating grease
 Recommended operating materials on page 48
Coolant equipment commercial lubricant and coolant, approx. 36 litres
 Recommended operating materials on page 48
2.6 Environmental conditions
Temperature 5 - 35 °C
Humidity 25 - 80 %

Technical specification
Version 1.0.4 - 2020-10-1318 Translation of original instruction
SD500AV
EN
SD500AV_GB_2.fm
2.7 Emissions
The noise emission of the metal band saw is 76 to 80 dB(A). If several machines are operated
at the location of the metal band saw, the noise exposure (immission) to the operator of the
metal band saw at the workplace may exceed 80 dB(A).
INFORMATION
This numerical value was measured on a new machine under the operating conditions specified
by the manufacturer. Depending on the age or wear of the machine, or the duty cycle of the
hydraulic unit, the noise behaviour of the machine may change. Furthermore, the noise emis-
sion also depends on production engineering factors, e.g. speed, material and clamping conditi-
ons.
INFORMATION
The specified numerical value represents the emission level and does not necessarily a safe
working level.
Though there is a dependency between the degree of the noise emission and the degree of the
noise disturbance it is not possible to use it reliably to determine if further precaution measures
are required or not.
The following factors influence the actual degree of the noise exposure of the operator:
Characteristics of the working area, e.g. size or damping behaviour,
other noise sources, e.g. the number of machines,
other processes taking place in proximity and the period of time, during which the operator
is exposed to the noise.
Furthermore, it is possible that the admissible exposure level might be different from country to
country due to national regulations.
This information about the noise emission should, however, allow the operator of the machine
to more easily evaluate the hazards and risks.
CAUTION!
Depending on the overall noise exposure and the basic threshold values, machine
operators must wear appropriate hearing protectors.
We generally recommend the use of noise and ear protectors.
2.8 Dimensions
1687
1206 900
2129
990
1046

Delivery, interdepartmental transport, assembly and commissioning
Version 1.0.4 - 2020-10-13 19Translation of original instruction
EN
in-house_transport_en.fm
3 Delivery, interdepartmental transport, assembly and
commissioning
3.1 Notes on transport, installation, commissioning
Improper transport, installation and commissioning is liable to accidents and can cause damage
or malfunctions to the machine for which we do not assume any liability or guarantee.
Transport the scope of delivery secured against shifting or tilting with a sufficiently dimen-
sioned industrial truck or a crane to the installation site.
WARNING!
Severe or fatal injuries may occur if parts of the machine tumble or fall down from the
forklift truck or from the transport vehicle. Follow the instructions and information on the
transport box.
Note the total weight of the machine. The weight of the machine is indicated in the "Tech-
nical data" of the machine. When the machine is unpacked, the weight of the machine
can also be read on the rating plate.
Only use transport devices and load suspension gear that can hold the total weight of
the machine.
WARNING!
The use of unstable lifting and load suspension equipment that might break under load
can cause severe injuries or even death. Check that the lifting and load suspension gear
has sufficient load-bearing capacity and that it is in perfect condition.
Observe the accident prevention regulations issued by your Employers Liability Insur-
ance Association or other competent supervisory authority, responsible for your com-
pany. Fasten the loads properly.
3.1.1 General risks during internal transport
WARNING: TILTING DANGER!
The machine may be lifted unsecured by a maximum of 2 cm.
Employees must be outside the danger zone, i.e. the reach of the load.
Warn employees and advise them of the hazard.
Machines may only be transported by authorized and qualified persons. Act responsibly during
transport and always consider the consequences. Refrain from daring and risky actions.
Gradients and descents (e.g. driveways, ramps and the like) are particularly dangerous. If such
passages are unavoidable, special caution is required.
Before starting the transport check the transport route for possible danger points, unevenness
and faults.
Danger points, unevenness and disturbance points must be inspected before transport. The
removal of danger spots, disturbances and unevenness at the time of transport by other
employees leads to considerable dangers.
Careful planning of interdepartmental transport is therefore essential.

Version 1.0.4 - 2020-10-1320 Translation of original instruction
SD500AV
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SD500AV_GB_3.fm
3.1.2 Load suspension point
Fasten the load end material on the assigned load end positions on the machine sub-
structure.
Use an adequate conveyor equipment, for instance a crane.
Make sure that you distribute the loads evenly so that the metal belt saw cannot turn over
while lifting.
Make sure that no add-on pieces or varnished parts are damaged due to the load suspen-
sion.
Fig.3-1: Load end, center of gravity
3.2 Set-up and assembly
3.2.1 Scope of delivery
INFORMATION
The metal belt saw is delivered pre-assembled.
When the metal belt saw is delivered, please check immediately that it has not been damaged
during transport. Also check that no fastening screws have come loose.
3.2.2 Requirements regarding the installation site
Organize the working area around the metal band saw according to the local safety regulations.
INFORMATION
In order to achieve high levels of functionality and machining accuracy, as well as a long ser-
vice life of the machine, the set-up location should meet certain criteria.
The following points should be noted:
The device must only be installed and operated in a dry and well-ventilated place.
4x DIN 580-M16