eco 410 dg index a.pdf

8/14/2019 ECO 410 DG Index A.pdf

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Instruction manualMetal - bandsawing- machineo410 DG

Please read the instruction manual before beginning all works!


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Index

EDV.-no.: DE0 410DGPE Index: A page: 1

IndexCHAPTER 1 - TECHNICAL DATA......................................................................................................................... 3

1.1 TECHNICAL DATA.............................................................................................................................................................. 31.2 CONNECTIONS/ FILLING CAPACITIES .................................................................................................................................. 41.3 CUTTING RANGE ............................................................................................................................................................... 5

CHAPTER 2 - GENERAL REFERENCES............................................................................................................... 62.1 GENERAL NOTE ON SAFETY................................................................................................................................................. 6

2.1.1 Safety information during initiation...........................................................................................................8

2.1.2 Note on safety during the company................................................................................................8

2.1.3 Note on safety during maintenance.......................................... ........................................................ 10

2.1.4 Shut down of the machine.................................................. ................................................................10

2.1.5 Note on safety gravity roller conveyor......................................................................................................112.2 ADDRESS AND TELEPHONE ............................................................................................................................................. 122.3 DETAILS FOR ORDERING.................................................................................................................................................. 132.4 INSTALLATION................................................................................................................................................................ 142.5 INDICATIONS ................................................................................................................................................................. 15

CHAPTER 3 - CONTROL OF THE MACHINE .....................................................................................................163.1 DEFINITION - MITRE-....................................................................................................................................................... 163.2 OPERATING INSTRUCTION 410 DG..................................................................................................................................173.3 APPOXIMATE VALUE TABLE............................................................................................................................................... 233.4 ADJUSTMENT - CLUMBING PRESSURE (OPTION) ........................................................... ....................................................... 243.5 ADJUSTMENT - CUTTING SPEED ........................................................................................................................................ 253.6 ADJUSTMENT MITRE ....................................................................................................................................................... 253.7 CUTTING CHANEL ........................................................................................................................................................... 263.8 CALCULATION OF LENGTH ................................................................................................................................................ 273.9 CLAMPING EXAMPLES ..................................................................................................................................................... 28

CHAPTER 4 - MEBASAW BLADES ..................................................................................................................294.1 QUALITY AND RANGE OF APPLICATION OF MEBABI-METAL BANDSAW BLADES ........................................................................ 294.2 CHOOSEN TEETH PER INCH .............................................................................................................................................. 324.3 CUTTING PERFORMANCE LIST .......................................................................................................................................... 344.4 CHANGE OF SAW BLADE .................................................................................................................................................. 374.5 BLADE TENSION............................................................................................................................................................. 384.6 SAWING IN OF NEW BANDSAW BLADES .............................................................................................................................. 40

CHAPTER 5 - SERVICE AND MAINTENANCE...................................................................................................415.1 GENERAL INDICATIONS ................................................................................................................................................... 415.2 VIEW PLAN .................................................................................................................................................................... 42

5.3 OIL LUBRICATION POSITIONS ............................................................................................................................................ 435.4 GREASING LUBRICATION PLACES ...................................................................................................................................... 455.5 GEARING ...................................................................................................................................................................... 47

5.5.1 Safety...................................................................................................................................................475.5.2 Error......................................................................................................................................................48

5.6 HYDRAULICS ................................................................................................................................................................. 495.7 OIL SORTS - SUPPLIER NAME ........................................................................................................................................... 495.8 SAW BLADE GUIDANCE AND CHANGE OF THE GUIDANCE ELEMENTS........................................................................................ 50

CHAPTER 6 - SPARE PARTS LIST ....................................................................................................................51CHAPTER 7 - HYDRAULIC PLAN......................................................................................................................86CHAPTER 8 - ELECTRICAL CONNECTION............................................................................................ ............91


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Index


CHAPTER 9 - MIRCO COOLANT SPRAYER (OPTION).................................................................................... 1189.1 STARTUP UP THE MICRO COOLANT SPRAYER ..................................................................................................................... 1199.2 SETTING PARAMETER FOR MICRO COOLANT SPRAYER ........................................................................................................ 1209.3 SPARE PARTS LIST....................................................................................................................................................... 1219.4 HIGH PERFORMANCE - LUBRICATING OIL MEBA HL 30...................................................................................................123

CHAPTER 10 - CHIP CONVEYOR (OPTION) .................................................................................................. 124


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Technical data


Chapter 1 - Technical data1.1 Technical dataModel: o410 DGCutting range: ROUND RECT.90 410 mm 700 x 410 mm

(16,1) (27,55 x 16,1)

Mitre right: 45 410 mm 420 x 410 mm(16,1) (16,5 x 16,1)30 330 mm 330 x 410 mm(12,9) (12,9 x 16,1)

Mitre left 45 410 mm 430 x 410 mm(16,1) (16,9 x 16,1)

Bundle clamping: width: 5 - 430 mm (0,19 16,9)height: 5 - 410 mm (0,19 16,1)

Length of remaining piece: manual.: approx. 70 mm (2,75)Cutting speed: 15 - 150 m/min AC-drive (49 - 492 feet/min)Lowering speed: 0 - 600 mm/min stepless (0 23,62"/min)Saw blade dimension: 5800mm x 41mm x 1,3mm

(228,35 x 1,61 x 0,05)

Saw blade tension: hydraulicWeight: approx. 1850 kgs (net)Dimensions: approx. 1500 x 2800 x 2000 mmlength x width x height: (approx. 59,06 x 110,24 x 78,74)

Max. material weight: max. 250 kg/mworking height: 750 mm (29,53)with mounting elements: approx. 800 mm (31,5)option

Noise emission: 74 dB(A)technical changes kept in reserve


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Technical data


1.2 Connections / filling capacitiesElectrical connection:Power: 3 x 460 V / PE

60Hz

Air: only with options, 6-8 bar, min. 50 l/minDrive - saw blade: 5,5 kWCoolant pump: 0,1 kWHydraulic pump: 1,1 KWPower max.: min.: 6,7 KWRated current: 18 APrimr fuse: 25 A

Net phases and neutral wire are connected with Y-condenser with the ground wire. At power supply voltagea leakage current is floating over thise condenser to the ground wire.The maximum leakage current by asymmetric input is 80mA. If it is not possible to do without FI-circuitbreaker, the problem of the switch-on and switch-off can be defused by using a selective FI-circuitbreaker (turn-off delay) or FI-circuit breaker with increased release current (f.i. 300 mA).

Filling capacities:Hydraulic control unit: approx. 5 ltr

Coolant tank: approx. 120 ltr.

Micro-Sprayer: approx. 1,2 ltr.

technical changes kept in reserve


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Technical data


1.3 cutting rangeo410 DG

Round material

Flat material

All ranges mm

45 90 45 30

430 x 410(16,9x16,1)

700 x 410(27,5x16,1)

420 x 410(16,5x16,1)

330 x 410(12,9x16,1)

45 90 45 30

410 16,1

330 12,9

410 16,1

410 16,1


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General references


Chapter 2 - General references2.1 General note on safetyMEBAsawing machines and plants are provided with extensive protective and safety devices. A remainingrisk always yet remains while operation from machines. The sawing machines and plants can not beshaded function relatively completely from danger places, there to the one- and taking out of saw materialitself with full case machines apertures require. Therefore, absolute safety is not guaranteed. Therefore isit urgently necessary that the works at the machine and with the machine attentive carried out in this way,are not itself the user by wrong behavior of unnecessary danger stop.

Every personwho is concerned in the company with the list, service, maintenance, inspection and repairmust read and understandthe operating instructionof this machine.The machine is delivered with a manufacturer declaration. The operator has to guarantee, that the entiresystem in agreement with the EC machine guideline Nr.89/392 (moved in the 9th regulation for the devicesafety law dated 12.05.93, machine protective regulation 9.GSGV) operated is. In accordance with thelocal factors, protective measures, e.g. protective fences or light barriers are to be planned whereappropriate. These can become asked the company MEBA. Only after installation of these protectivedevices a CE - declaration of conformity may be constructed and a CE - sign may be positioned. Furthersecurity measures required of local trade cooperative associations possibly are not contained in our scopeof delivery. After determination of kind and extent of the measures, we are gladly ready to submit asupplementary offer if these are not produced by them herself.

No band saw is without danger places

Caution:The machine may only be employed for the purpose of its determination.Service and maintenance instructions of the manufacturer are to be considered always.Theservice, maintenance and repair may only occur from persons, which one sent thoroughly by aneducation and over companies- danger informed were.

Entry protection by laser light barrierInitial operation and yearly examinationThe safety rules of the main association of the professional associations demands according to ZH 1/281(powered pressing of the metalworking) respective recommends according to ZH 1/597 (powered means

of work) to start up our safety devices initially by an expert of the manufacturer, he tests the concurbetween the light barries and the control of the machine. After legislation for prevention of accidents VBG1 and VGB 5 there has to be carry out a yearly examination of the safty devices by an expert.


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General references


Safety distanceThere is a delay time between the interruption of a light barrier and the standstill of the machine. Themultiple light beam safety device must be mounted in such a way that the dangerrous area cannot be

reached during this delay time. For the calculation of the minimum safety distance there is a value for thegriffin rate with min. 1,6 m/s to be taken as a basis.Safty lights grates cannot protect against injury caused by flying objects.

RepairsRepairs at the light barriers may be performed only by the manufacturer or by a person authorised by themanufacturer.

Inventions and changes to the devices are not permitted.

Signal words in the operating manualThe construction of the operating manual is based on the recommendations of the ANSI for noteon safety (see table) as them (American national standards institutes) be given.

Signal word Use forDanger Danger threatening directly; possible results:Death or hardest injuries

Warning Dangerous situation; possible results:Death or hardest injuries

Caution Possibly dangerous situation; possible results:slight injuries; too possible for warnings before property damages

Reference Possibly noxious situation; possible results: the machine orsomething in its environment can be damaged

Important Application tips or useful information

In order to avoid the stated damages the following note on safety must be followed.


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General references


2.1.1 Safety information during initiation

Before initiation of the band sawing machine (subsequently, machine), theoperating manual must be read through attentively. A briefing is at automatic machines and plantsthrough MEBA- specialists is required.

Fill hydraulic oil as well as chilling emulsion before initiation (see chapter 1.2) and remove possiblelocking for transportation.

2.1.2 Safety information while operation Do not grab into saw blade while running!

There is a squeezing danger while fixing parts

The saw blade can tear clothing in the not protected field

Parts of the body can be cut off through the saw blade

The stock roller tracks and the saw frame can wedge and hurt parts of the body by movements

Measuring devices (if available) can catch and hurt parts of the body while moving up and down

Bar materials and sections which are pushed out of the machine on infeed and outfeed can hurtpersons. It is not allowed to stay at the machine ends.

Safety devices limit switch light, eye damages can occur through laser light. The machine may only be operated by admitted personnel.

New operating personnel must be admitted carefully.Neues Bedienungspersonal mu sorgfltigeingewiesen werden.

In addition to the universal safety regulations (UVV and EU definitions), subsequent points are to beconsidered especially:

The machine may only be used for its predetermined (determination appropriate) purpose. This isexclusively sawing metals. The saw property is held in a corresponding appliance and the saw courseis carry out semi- or fully automatically. The manufacturer undertakes no assurance or no guarantee

at improper use. A part to be sawed must at least show a length of 10 mm on the page of the material plant rim. In

such a way, conducts the section length less than 10 mm can it for a locking in position of the sawedpart between the saw volume and the removal sided material plant may get. This can lead to harm atthe saw volume and for the trouble of automatic switching.

Barrier guards and covers must not be removed while operation.

Generally, you have to wear protective gloves at loading or removing of saw material.

Do not load or remove sawing material while running saw blade or other machine functions.

Do not hold sawing material with the hand while the saw is cutting but use always the suitableclamping devices /manual/hydraulik vice, when required additional vertical clamping). Supplied andsawed off material have to be secured against dumping by adequate surfaces (f.i. Stock roller tracks)


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General references


Ensure before sawing that the sawing material is clamped fix

In the case of the saw course of events and/or during operation of the machine, always a lookcontact must exist to parts moving itself - especially on the saw balde and onto the chucked sawproperty. At plants, the periphery as gravity roller conveyor, measuring assault and replenishment tieare to be observed always also.

Do not adjust blade guide arms while the saw blade is running

Leave no tools, test equipment and other parts in the field of action of the machine.

Swarfs can lead to injuries and malfunctions, therefore, always hold machine clean.

Let machine not work unattended

Do not climb over the barrier and safety facility which are fitted ontot the machine, excepted at

maintenance of the machine. The machine has to be switched off and secured against reoperating

An laser light or shadow line worklight shows the danger points of the machine in on state andconsequently, is used acting for safety at the place of work. Both laser light and shadow lineworklight are available as options for all machines.

laser light shadow line worklight

The user is responsible for the danger zone and the persons which work in there.

Immediately press the the EMERGENCY STOP at a failure, accident or emergency. Thereby allmachine funcions are shut down.

Coolant lubricant may contain unhealthy cloths. More information can be read in thesafety data sheets. The safety data sheets also inducates compatible disposal .

Safty lights grates cannot protect against injury caused by flying objects.


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General references


2.1.3 Note on safety during maintenance Maintenance operations must be carried out regularly and carefully.

During maintenance operations or while removing protective devices, the machine must always bedisconnected and the main power switch with a castle be secured.

Works on the electric plant may only be carried out by specialists developed instead

During works on the hydraulic plant, this must first be made pressure-less.

Protective gloves and eye protection must be borne for cycle of the saw ribbon. Removethe plastic coating (tooth protection) only after the arrangement. At current saw volume,the plastic coating must not be diverted.

2.1.4 Shut down of the machineShut down the machine for maintenance, repair and repair works must become adjusted the machine. Forthis must be secured permanently after the proper switching off of the machine, is besides it the networkconnection disturbed and and with suitable averages secure against unauthorized or unintentionalreclosing. At power plug combinations is to be positioned at the connector mounting location as well as the

machine an unambiguous indication of maintenance and/or repair works in order to avoid a pocketing ofthe power plug.

Do not forget reference at the power plug and/or the socket viamaintenance and repair works


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General references


2.1.5 Note on safety gravity roller conveyor

The note on safety for not driven and driven runways is performed followingly. The note on safety is to bekept without fail around a perfect one and to guarantee troublefree company and to keep away damageboth from the user as well as of the machine.

General note on safety

Only hang up and decrease material with suitable pull

Do not step under floating burdens

Consider load-carrying capacity of the single roles at the most

Put on material gently

Protect rounding material against unwinding

Hang up structural steel topple certainly and secure against unwinding

With the bundle and/or situation saws must the situations against slip besecured (they if possible weld bundle together at the ends)

Do not move saw material parallel to the axis over the runway

Do not step between separate runway rungs

Runway not component or over-footpaths

Only remove concatenation and/or fencings in the case of driven roles formaintenance and maintenance works

During maintenance and repair, disconnect machine and driven gravity roller

conveyors and against start may secure

Only carry out maintenance operations at not engaged gravity roller conveyor


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General references


2.2 Address and TelephoneMEBA-Metall-Bandsgemaschinen GmbHLindenstrasse 872589 Westerheim /AlbTelephone: (+49) 07333 / 9644-0 sale, advice(+49) 07333 / 9644-20 service(+49) 07333 / 9644-30 purchaseTelefax: (+49) 07333 / 9644-44Internet: www.meba-saw.deE-Mail: [email protected] description:

Richtung Mnchen ( sterr.)

Richtung Fssen ( sterr.)

Richtung WrzburgMhlhausen
http://www.meba-saw.de/mailto:[email protected]:[email protected]://www.meba-saw.de/


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General references


2.3 Details for orderingSaw bladesWe need following details when ordering saw blades:

saw blade dimensions length x height x widthe.g. 5800 x 41 x 1,3

tooth pitch (teeth per inch) e.g. 4/6 TPI material tool steel, bimetal or hard metal

If you have difficulties with the choice of a saw blade or if you need a saw blade for a special application,kindly give us the following information:

name of material which will be cut, material number material dimensions (diameter, wall thickness, width, ...) material cross section (full material, profile, pipe,...) surface finish manner of cut (single cut, ply cut or cross cut) saw blade dimensions or type of machine special requirements (surface, cutting speed, ...)

On basis of these details we are able to choose the suitable saw blade.

Spare parts and parts subject to wearWe need following details when ordering spare parts and parts subject to wear:

MEBAEDV-number type of machine machine-number year of construction of the machine eventually description or drawing of the part or fitting position


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General references


2.4 InstallationInstallation, electrical and pneumatic connection

InstallationYou can inform yourself about boring distance and boring diameter in the dimension- orfundament diagram.The minimum supporting capability of the fundament you can calculate from the weight of themachine (look at Technical data) and the maximum weight of material.

Adjustment of the machine:Put the water balance on the border or the surface of the vise (in direction of flow of material andin saw direction). Level the machine by base supports or mounting elements. Afterwards themachine should be doweled if possible. It is absolutely necessary with machines connected withmeasuring devices or automatic conveyor systems for preventing off-size precision.

Add adequate hydraulic oil and coolant concentrates when there is danger of freezing or equip themachine with suitable heating device.

In standard construction the machine is not to be mounted outdoors.

Electrical connectionThe indicated operating voltage and the power-supply voltage must be identical.In the wiring diagram or Technical data you can see the connected value in kW.

The band wheels must turn clockwise. The saw blade must always work in direction to Firmclamping jaw (arrow for direction of rotation on the band wheel).

Changing of direction of rotation through exchange of two phases (not inside of the machine).

Pneumatic connectionFor additional equipment (coolant sprayer, measuring device...) dust-free, lubricated compressedair with 4-8 bar is required.


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General references


2.5 Indicationsfor packing / warehousing / conservationUniversally:For transporting the machine by truck, put the machine on planks and protect it against dust with a clearplastics foil. In case of seaworthy packing, the machine should be welded or shrinked with a clear plasticsfoil before putting it on planks. It is absolutely necessary to attribute a bag with dry silicate.Before transport and warehousing uncovered parts have to be sprayed with a rust-preventing medium.Afterwards the sprayed parts must be lubricated again with noncorrosive grease.

Transportation indication:If the machine is carried with a crane it is important that the cables and chains are always kept indistance by a girder for preventing damage at the saw frame or at the control desk.

Hydraulics and gear unit:Before transport empty completely hydraulic oil container. The transmission lubricant filling wont bedrained off..When storing, the hydraulic oil container must be filled up to the prescribed level with the recommendedhydraulic oil.Every 6-8 weeks the machine should be started and all functions be tested. So you can prevent thehydraulic elements from irreparable seizure and being gummed up.If the machine has not been working for one year, renew all oil filling before return to service.

Coolant concentrate (emulsion):As a general coolant concentrate should only be filled into the machine when this machine is used. Coolantconcentrate only has a limited useful life and begins to decompose (this process is accelerated bystandstill).To prevent formation of corrosion you have to follow the rules of the coolant concentrate producer.

Add antifreezing mixture when there is danger of freezing.For transport and warehousing the coolant concentrate container must be completely empty.

For attention:Before filling the coolant concentrate container the first time, remove - if necessary - all transportedmachine parts and tools contained in it.


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Control of the machine


Chapter 3 - Control of the machine3.1 Definition - mitre-Pivot-action machines

60

45

30

90

135


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3.2 Operating instruction 410 DG

Buttons:Pos. 1 push-button hydraulics onPos. 2 push-button hydraulics offPos. 3 push-button start sawingPos. 4 push-button stop sawing and lift sawframePos. 5 push-button vice clampPos. 6 push-button vice releasePos. 7 push-button lowering saw frame with rapid powerPos. 8 display display feed speed (%)Pos. 9 rotary-button cooling(option)Pos. 10 rotary-button mitre clampingPos. 11 digital mitre indication and reference pointsPos. 12 push-button chip conveyor on / off (option)Pos. 13 rotary-button main vice close / open (option)Pos. 14 switch not ausPos. 15 rotary-potentiometer cutting speed (m/min)Pos. 16 rotary-potentiometer feed speed (mm/min)

7 15 3 6 2 14410 9

168

13 12

1511


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OperationHydraulics(pos. 1 and 2)

Switch on the hydraulics with the push-button pos. 1. Further functionsare only possible when hydraulics is turned on.

With the push-button pos. 2 you can switch off the hydraulics.

Attention: Hydraulic-drive should only be turned off during cutat dangeror when work is finished to avoid damage to the saw blade.

Single cut (pos. 3)With the push-button pos. 3 you can turn on the saw drive. The feed motion (downwardmotion) and the cooling function is releasedBoth vices are switched to CLOSE.

Adjustment of the cutting speed look at sheet Adjustment - cutting speed.Adjustment of the feed speed and the cutting pressure look at sheet Saw frame control - HS or

Saw frame control - standard.

In this duty the machine only makes one separate cut according to the adjusted values. Thelength infeed isnt activated. When the saw frame is completely lowered down, you operate a limitswitch which turns off the saw-drive and the coolant pump. The saw frame is raised hydraulicallyup to the height of band pass at the height scale.

Remark: The indication value at the batch counter must be at least 1. At the value0 the machine turns off.

Caution:

Before starting single cut or automatic function pleasegenerally clamp the material by hand (main vice andinfeed vice).


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STOP sawing and LIFT saw frame (pos. 4)By pressing button pos. 4 the already started sawing operation can be interrupted atany time. Simultaneous the saw frame will be lifted and the cooling function will be

switched off.

As long as the button pos. 4 is pressed, the saw frame will be lifted until the cylinderlimits are reached.

This button can also be used for the manual lifting of the saw frame, e.g. for putting raw materialin.

Vice CLAMP and vice RELEASE (pos. 5 and pos. 6)

By pressing the button pos. 5 the material vise will be closed hydraulically, that meansthe vise jaws will be put together.

By pressing the button pos. 6 the material vise will be opened hydraulically, that meansthe vise jaws will be put apart.

Both functions are active during the set-up of the machine (no operation) as long as thebuttons are pressed. After releasing the button the vise jaws stop moving.

When sawing, the function Vise CLAMP will automatically be switched on. That insuresthat the material is clamped while sawing. It is not possible to open the vise

jaws while sawing.

LOWERING saw frame (Rapide power) (pos. 7)By pressing the push-button pos. 7 the saw frame will be lowered quickly.This function is active as long as the button is pressed or until the saw frame islowered totally.

When using this function it is possible to lower the saw frame quickly until it hasreached the work piece or the supporting table without having to change the adjusted lowering orfeeding speed.

REMARK: Be careful when lowering quickly: there has to be enough space between the sawblade and the working piece danger of collisiondemolation of saw blade


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Display feed speed (%) (pos. 8)

At the display (Pos. 8) actual feed speed in per cent is indicated.

Cooling ( pos. 9)You can preset the kind of cooling or lubrication at the rotary button pos. 9.Turn to the left (water cock): cooling with cooling emulsion from the tank in the frameof the machine.Turn to the right (nozzle): spraying with the coolant-sprayer (option).At switch position "0" no function is active.

You can dose the coolant quantity by turning round the ball valves at the respective bladeguidances.

The respective cooling- or lubrication function is activated with the push-button pos. 3 or 4 anddeactivated after cut is finished.These functions are only active when saw blade is running.

Mitre clamping (pos. 10)By turning the rotary button pos. 10 according to the switch position it is possiblethe clamp or release the adjusted mitre.

Switch position 0: mitre is clampedThis switch position has to be adjusted while sawing.

If the rotary button is positionned at symbole saw frame the mitre angle can beadjusted between 90 til 30.

If the rotary button is positionned at symbole Vise the mitre angle can be adjusted between 90til 135, that means in this area the vise adjusts itself according to the adjustes mitre.

Admustment of mitre:After having switched on the machine with the main button the mitre indication does always haveto be checked. First of all the rotary button pos. 10 does have to be turned right hand (to symbolevise), then the saw frame will be swivelled left hand (seen from point of operator) until the viseis the front position at the stroke.Afterwards the rotary button has to be turned to the left side (symbole saw frame). Now theleft-swivelling of the saw frame can be contiuned until the stroke is reached. There it has to stayfor adjusting the reference value of the mitre (see mitre indication pos. 11).

Then the demanded mitre (from 30 til 90 ) can be adjusted. If 90 - 135 mitre has to beadjusted the saw frame has to be swivelled to the right hand til it has reached the stroke at 90 -please swivel slowly and feelingful.


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Now the rotary button can be turned right hand (symbole vise) and the saw frame can beswivelled to the demanded mitre. After having reached the demanded mitre it is absolutelynecessary to put the rotary button to postion 0.If the frame has to be swivelled backwards again, the rotary button has to be turned right hand

(symbole vise). Now the saw frame can be swivelled backwards together with the vise to 90 -please swivel slowly and feelingful til having reached the stroke.Now the rotary button has to be turned left hand (symoble saw frame) and the saw frame canbe swivelled to the desired mitre. After having reache the desired mitre it is absolutely necessaryto put the rotary button to position 0.

Mitre indication and reference points (pos. 11)The mitre indication pos. 11 indicates the currently adjusted mitre angle indegree. The resolution is at 0,1 degree.Pre-condition for an exact indication of angel is that the reference points havebeen set up correctly.

Set up of reference points:Swivel the saw frame totally to the left hand side to the 30-degree (see adjustment of mitre,above mentioned). This position should be hold by pressing slightly towards the stroke. Pressbutton F + SET at the digital indication. At the indication there appears a value which indicatesthe currently adjusted mitre.The value 30 is measured by MEBA Wert 30 and fix adjusted.Now any mitre can be swivelled. The indication is identical to the respective position. Theprocedure of setting up the reference points should be repeated and checked from time to time.

REMARK: When pressing button F + SET by mistake while sawing, the indicatedvalue is not identically any longer with the actual mitre.The reference points have to be set-up again.

All the other buttons on the indication device are of no use for normal sawing operation thatswhy they do not have any function.

Chip conveyor(pos. 12)(option)At the rotary button pos. 12 you can preset the method of operation of the chipconveyor.

Turn to the left (manuel): The chip converyor always works when the hydraulics isswitched on.

Turn to the right (automatic): The chip conveyor only works when the saw drive isswitched on. Now the chip conveyor works in intervals, that means the chip conveyoris turned on and off in regular intervals for that the coolant meduim can recede.

At switch position "0" the chip conveyor is turned off.


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Material vice close/open (pos. 13) (option)With switch close/open you can adjust if the main vice:

stays closed after ended sawing task opens after lifting the saw frame

NOT - AUS (pos. 14)By pressing the switch pos. 14- NOT-AUS - the complete machine is stopped.

You unlock the NOT-AUS - switch by extracting the red button.

Use NOT - AUS only in case of emergency

Cutting speed (pos. 15)You can adjust steplessly the cutting speed with the rotary potentiometer pos.11 from 15-150 m/min. You cant adjust it during the sawing process.

The rotary potentiometer is only installed if the machine is equipped with theAC-drive.

Feed speed (Pos. 16)With the rotary potentiometer (pos. 16) feed speed can adjusted steplessly.See also for this cape. 3.3!

Main switch:You find the main switch lateral of the control desk.At position "0" the control desk or the switch box is out of circuit. This switch position can besecured with a padlock.

Reparations can only be done after having switched off the main switchAttention: If the machine will be switched off at the main switch please wait 15 sec before

starting the machine again. If not you can destroy some pieces in the PLC.


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3.3 Appoximate value table

Legend

feed in mm/min.

cutting speed of the saw blade

material

Appoximatevalue table

stainless steel


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3.4 Adjustment - clumbing pressure (option)The clamping pressure can be adjusted by turning the pressure reducing valve (Pos. 1)By turning the valve clockwise the clamping pressure increases, turning anticlockwise theclamping pressure decreases.The clamping pressure is dependant of the material and the material dimensions.The pressure (in bar) can be read off of the manometer (Pos. 2).At sawing of thin-walled profiles, turn the clamping pressure regulator as low as possible to avoida deformation of the material or a jam of the saw blade in the cutting canal.

12


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3.5 Adjustment - cutting speedUniversallyAll indications concerning cutting speed are in m/min.Cutting speed depends firstly from the material and the quality of the bandsawing machine.

You can see approximate values at the enclosed tables with the standard values. If there should be a shrillnoise during sawing, the cutting speed must be corrected by small increase or decrease.

AC - driveYou can change the cutting speed steplessly within a certain range with an AC-drive.

You can choose between cutting speeds from 15 - 150 m/min(49 - 492 feet/min).You can adjust the cutting speed either by means of a rotary button on the control panel with directindication (analogous) on a scale or by means of keyboards on the monitoring (Touch-Panel) with directvalue indication (digital) - also look at the Touch-Panel instruction manual.

It doesnt matter if you change the speed atinoperative or runningdrive.These drives have no direct parts subject to wear.

3.6 Adjustment mitreATTENTION:The saw blade must stand above the saw material to avoid damages!!!

Look at chapter 3.2 operation ECO 410 DG

- mitre clambing (Pos. 10) and also- mitre indication and reference points (Pos. 11)


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3.7 Cutting chanelUniversally At cuts there is a so-called cutting canal, due to the tooth set. This

witdth of the cutting canal depends on the thickness of the sawblade, the teeth per inch and the kind of tooth set of the saw blade.

Approx. standard values are:cutting width saw blade thickness

1,5 mm / 0,059" 0,9 mm / 0,035"

1,7 mm / 0,067" 1,1 mm / 0,043"

1,9 mm / 0,075" 1,3 mm / 0,051"

2,2 mm / 0,087" 1,6 mm / 0,063"


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3.8 Calculation of lengthFormulas for the calculation of lengthExample 1

L

X

B

datum: length L, width B, angle unknown value: length X

X = L -B

tan

datum: length X, width B, angle unknown value: length L

X = L +B

tan

Example 2

L

X

B

datum: length L, width B, angle , angle unknown value: length X

X = L -B

tan-

B

tan

datum: length X, width B, angle , angle unknown value: length L

L = X +B

tan

+B

tan


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3.9 Clamping examplesfor rod stock

Clamping of the workpieceYou can increase considerably the cutting capacity and the service life when you clamp correctly the crosssection.The particular cross section must be all clamped tensionally, if possible also form-closed.The cut pressure should be chosen as high as possible and only be lessened with thin-walled cross section.The cross sections should be fitted in the way that the actual cutting channel length changes as little aspossible during the sawing process.

Clamping examples for pivot action - machines

Clamping examples for 2-column-guided machines

Clamping examples for both machine types


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MEBAsaw blades


Chapter 4 - MEBAsaw blades4.1 Quality and range of application of MEBABI-metalbandsaw blades

MEBABimetal: For general purpose cutting (factory) For profiles and bundle cuts For small and often changing workpiece dimensions

For often changing solid materials to approx. 150mm (5,91") cutting passage width

MEBABimetal -S-: For all steels up to 45 HRC For all workpiece dimensions For non iron metals For serial cuts For small and medium workpiece dimensions For refined steel profiles

MEBASpezial PB: Optimized, aggressive tooth profile Cutting of non solid material pieces, like profiles, I-beams, angle iron, channel profile, tubes, tube

bundles and conduit pipes Suitable for combined cutting of profile- and solid material Also cuts long and poor supported I-beams Avoids jamming of the blade by a wider saw slot for additional free space For steel with a low to middle chippability, like low-carbon steel, soft steel, profiles 1.0132, tubes

1.6523 For refined steel profiles due to higher wear resistance of the teeth

MEBASpezial H2 Suitable for all machining on medium to high toughness metal cutting materials For solid material and thick walled tubes like tool steel H13, D2, A2, and refined steel as well as

alloyed steel Suitable for alloys used in the space technology like Ti-6AL-4V, 17-4PH, Monel and Inconel Longer life cycle at higher cutting speed by very sharp cutting edge High cutting precision due to grinded, positive undercut.


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MEBA- Bimetal MEBA Bimetal "S"

MEBABimetal saw blades are manufactured by pre-fabricated band steel. The carrier band is connectedsolidly with the flanks of tooth by an electron beam welding process. The column support is produced with 4 %chrome as all other high quality Bi-metal bandsaw blades. With a high proportion of cobalt of about 8 % awear resistant toothed cutter is achieved and the reduced amount of tungsten and carbon gives a specialquality for the flanks of tooth for cutting vibration generating materials such as pipes, profiles and bundlecutting.

Advantages: high cutting accuracy High wearability by alloyed high cutting steel with

8% cobalt Long life cycle by oscillating sawing cuttings

Advantages: Increased cutting accuracy and wearability by

alloyed high cutting steel with 8% cobalt and 10%molybdenum

Increased edge life comparable for Bi-metalsawblade

Range of application: For all factory cuts For profiles and bundle cuts For small and often changing workpiece

dimensions For often changing solid material to approx.

150mm (5,91") width of cutting length

Range of application: For all steels up to 45 HRC For all workpiece dimensions For serial cuts im automatic operation For bundle cuts of large workpiece dimensions

and solid material For non iron metals and fine steel profiles

Teeth per inch (tpi)Dimensions 1,4/2 2/3 3/4 4/6 5/8 6/10 8/12 10/1427 x 0,9 mm B / BS B / BS B / BS B / BS B / BS B / BS B / BS

34 x 1,1 mm B / BS B / BS B / BS B / BS B / BS B / BS

41 x 1,3 mm B / BS B / BS B / BS B / BS BS

54 x 1,3 mm BS BS BS

54 x 1,6 mm BS BS BS BS

deliverable in quality: "B" = Bi-metal, "BS" = Bi-metal-S


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MEBA Special "PB" MEBA Special "H2"

MEBAspecial bandsaw blades with the quality "PB" and "H2" are used for extreme cutting tasks. With the helpof higher alloying constituents the heat-resistance and the wear resistance is considerable improved. With theoptimized tooth geometry a maximal machining performance and an extremely high tool life cycle at constantreliable precision is guaranteed.So the cutting of high-alloyed and special alloyed materials with the special bandsaw blades "PB" and "H2" ismuch more economical.

Advantages: Optimized aggressive tooth profile More resistant to tooth strippage Little tooth and blade wear Wide cutting channel for additional free space

avoiding nipping of the saw blade in the material Withstands higher cutting temperatures and thus

extremly high wearability High tool life while cutting long and poor support

profiles

Advantages: Ground tooth profile with specially constructed

precision tooth geometry Ground positive rake angle and ground teeth free

space Teeth with high speed cutting steel M-42 Very high fatigue limit, thermal stress and

wearability Reduced cutting force and higher cutting

precision, so a higher tool life cycle with highercutting speeds

Range of application: For bundle cutting with big workpiece dimensions For both cutting of big profiles and full materials For all kinds of profiles and bundle cuttings

For poorly supported long I-beam girders For steels with a low to middle chippability and

fine steel profiles

Range of application: Suitable for all machining on medium to high

toughness metal cutting materials For solid material and thick walled tubes of tool

steel and fine steel For alloyed steel and hardened materials For used alloys in the space technology like

Ti-6AL-4V, 17-4PH, Monel und Inconel

Teeth per inch (tpi)Dimensions 1,4/2 2/3 3/4 4/6 5/8 6/10 8/12 10/1427 x 0,9 mm H2

34 x 1,1 mm PB / H2 PB / H2 PB PB PB

41 x 1,3 mm PB / H2 PB / H2 PB

54 x 1,3 mm PB / H2 PB / H2 PB

54 x 1,6 mm PB / H2 PB / H2 PBdeliverable in quality "PB" = Spezial-PB, "H2" = Spezial-H2


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4.2 Choosen teeth per inchChoosen teeth per inch

Teeth per inch for solid material

The criteria for the choice of tooth pitch is the cutting width of the saw blade.In the list below you can choose the needed tooth pitch for solid material as a function of the width of the saw blade.

Cutting teeth per inch (tpi)in (mm / ") 10 / 14 8 / 12 6 / 10 5 / 8 4 / 6 3 / 4 2 / 3 1,4 / 2

0 - 20 (0 - 0,78)" 20 - 50 (0,78 - 1,97)" 25 - 60 (0,98 - 2,36)" 35 - 80 (1,38 - 3,15)" 50 - 100 (1,97 - 3,94)" 80 - 150 (3,15 - 5,91)" 120 - 350 (4,72 - 13,78)" 250 - 600 (9,84 - 23,62)"

Teeth per inch for tubes and profiles

D teeth per inch (tpi)S 20 40 60 80 100 150 200 300 500

2 mm / 0,08" 10 / 14 10 / 14 10 / 14 10 / 14 10 / 14 10 / 14 10 / 14 10 / 14 8 /123 mm / 0,12" 10 / 14 10 / 14 10 / 14 8 /12 8 /12 8 /12 6 / 10 6 / 10 6 / 104 mm / 0,16" 10 / 14 10 / 14 10 / 14 8 /12 8 /12 6 / 10 6 / 10 5 / 8 4 / 65 mm / 0,20" 10 / 14 10 / 14 10 / 14 8 /12 6 / 10 6 / 10 5 / 8 4 / 6 4 / 66 mm / 0,24" 10 / 14 10 / 14 8 /12 8 /12 6 / 10 5 / 8 5 / 8 4 / 6 4 / 68 mm / 0,31" 10 / 14 8 /12 6 / 10 6 / 10 6 / 10 5 / 8 5 / 8 4 / 6 4 / 6

10 mm / 0,40" 6 / 10 6 / 10 5 / 8 5 / 8 4 / 6 4 / 6 4 / 6 3 / 412 mm / 0,47" 6 / 10 5 / 8 4 / 6 4 / 6 4 / 6 4 / 6 3 / 4 3 / 415 mm / 0,59" 4 / 6 4 / 6 3 / 4 3 / 4 3 / 4 2 / 320 mm / 0,79" 4 / 6 4 / 6 3 / 4 3 / 4 3 / 4 2 / 330 mm / 1,18" 3 / 4 3 / 4 3 / 4 2 / 3 2 / 3 2 / 350 mm / 1,97" 2 / 3 2 / 3 2 / 3 1,4 / 275 mm / 2,95" 2 / 3 1,4 / 2 1,4 / 2

100 mm / 3,94" 1,4 / 2 1,4 / 2When 2 or more tubes are clamped, placed side by side, use above list in consideration of the double wall thickness(S).


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MEBAsaw blades


Geometry of a saw blade

The tooth pitch is the number of teeth per inch (ZpZ). In the MEBAproduct range a variable tooth pitch with differingtooth distance between a toothing interval is used.

Our saw blades are generally variable side set. This side setting allows cuts with low swing and low noise. Thefollowing teeth are periodically left / right side set.

TOOTH

B=WIDTH OF

s = thick of blade

WIDTH OF

MIN TOOTH MAX TOOTH

VARIABLE TOOTH PITCH

toothing interval


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4.3 Cutting performance listApproximate values for Bi-Metal and carbide saw blades

To reach an optimum cutting performanceand operation life cycle of the saw blade, the following listshould serve as guiding principle.Please contact your supplier referring materials which are not listed below ! (toughness or comparablematerial)

cutting speed (m/min)Material group DIN ma-terial no. Bimetal

< 100 mm < 3,94"

Bimetal < 500 mm < 19,69"

Bimetal > 500 mm > 19,69"

carbidecoolant

lubricantoil %

General structural ST 37 1.0037 90-100 60-90 50-70 100-130 10Steel: ST 42 1.0042 90-100 70-90 50-70 100-130 10

ST 52 1.0052 70-90 50-70 40-50 90-120 10ST 60 1.0060 70-90 50-70 40-50 90-120 10

Cemention steel: C 10 1.0301 95-110 80-95 60-80 110-140 15C 15 1.0401 95-110 80-95 60-80 110-140 15

16 MnCr5 1.7131 65-75 55-65 40-55 80-100 1020 CrMo5 1.7264 65-75 55-65 40-55 80-100 10

21 NiCrMo2 1.6523 55-65 45-55 35-45 70-90 10

Nitriding steel: 34 CrAl6 1.8504 40-45 30-40 20-30 45-60 5Free-cutting steel: 9 S20 1.0711 100-130 80-120 60-80 100-160 15Heat-treatable steel: C 35 1.0501 75-90 60-75 40-60 90-120 5

C 45 1.0503 75-90 60-75 40-60 90-120 5

42 CrMo4 1.7225 60-70 50-60 40-50 70-90 534 CrNiMo6 1.6582 60-70 50-60 40-50 70-90 5

Ball bearing steel: 100 Cr6 1.3505 65-75 55-65 30-50 70-90 3100 CrMo7 3 1.3536 50-60 40-50 30-40 60-80 3

Spring steel: 65 Si7 1.5028 60-70 40-60 30-40 65-85 350 CrV4 1.8159 60-70 40-60 30-40 65-85 3

Carbon tool steel: C 125 W 1.1663 50-65 40-50 30-40 65-80 3C 80 W 1 1.1525 55-70 45-55 35-45 70-85 3

Cold work tool steel: 125 Cr 1 1.2002 50-65 40-50 30-40 65-80 3X 210 Cr 12 1.2080 30-40 20-30 15-20 40-50 Trocken

X155CrVMo 12 1 1.2379 30-40 20-30 15-20 40-50 Trocken

90 MnCrV8 1.2842 35-45 30-35 20-30 45-55 3

Hot work tool steel: 40 CrMnMo7 1.2311 25-35 20-25 15-20 35-50 5X 40 CrMoV 5 1 1.2344 22-30 18-22 12-18 30-45 556 NiCrMoV 7 1.2714 30-40 25-30 20-25 40-60 5

40 CrMnNiMo 8 6 4 1.2738 25-35 20-25 15-20 35-50 5

High speed steel: S 6-5-2 1.3343 45-50 35-45 25-35 50-60 3S 3-3-2 1.3333 50-55 40-50 30-40 55-65 3

S 2-10-1-8 1.3247 40-45 30-40 20-30 45-60 3S 10-4-3-10 1.3207 40-45 30-40 20-30 45-60 3

S 18-0-1 1.3355 40-45 30-40 20-30 45-60 3Special steel 1.3964 48 13Stainless steel: X5 CrNi 18 10 1.4301 40-50 30-40 20-30 40-50 10

X6 CrNiMoTi 17 12 2 1.4571 40-50 30-40 20-30 40-50 10X20 Cr 13 1.4021 40-50 30-40 20-30 40-50 10


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Approximate values for Bi-Metal and carbide saw blades.

cutting speed (m/min)

Material group DIN ma-terial no. Bimetal < 100 mm

< 3,94"

Bimetal < 500 mm < 19,69"

Bimetal > 500 mm > 19,69"

carbide

coolant

lubricantoil %

Valve steel: X 45 CrSi 9 3 1.4718 45-55 35-45 25-35 50-60 5X 45 CrNiW 18 9 1.4873 40-50 30-40 20-30 50-60 5

High-temperature X 12 CrCoNi 21 20 1.4971 25-30 20-25 15-20 30-40 10resisting steel: X 20 CrMoWV 12 1 1.4935 35-40 30-35 25-30 40-50 10Heat resisting steel: X 15 CrNiSi 25 20 1.4841 20-25 15-20 10-15 30-40 15

X12 NiCrSi 36 16 1.4864 20-25 15-20 10-15 30-40 15

Special steel NiCr 19 NbMo 2.4668 15-20 10-15 8-12 15-20 20NiMo 30 2.4810 20-25 15-20 10-15 18-23 12

NiCr 13 Mo 6 Ti 3 2.4662 15-20 10-15 8-12 15-20 20

NiCo 20 Cr 20MoTi 2.4650 17-22 12-17 10-14 17-22 15X 8 CrNiAlTi 20 20 1.4847 18-23 13-18 11-15 18-23 15

Heat-treatable steel:1000-1200N/mm2 30-35 25-30 20-25 35-50 ~51200-1400N/mm2 25-30 20-25 15-20 30-45 ~51400-1600N/mm2 20-25 15-20 10-15 25-35 ~5

Hardened steel50 HRC 15-20 ~555 HRC 10-15 ~560 HRC 8-12 ~5

Cast steel: GS 38 60-70 50-60 40-50 70-100 ~3GS 60 50-60 40-50 35-40 60-85 ~3.

Casting: GG 30 50-60 40-50 30-40 60-80 TrockenGGG 50 45-55 35-45 25-35 55-75 Trocken

-alloyed (NiCrMo) 30-40 20-30 15-25 40-50 Trocken

Titan. Ti 1 3.7025 35-45 20-35 15-20 40-60 10-alloyed G-TiAl 6 V 4 3.7164 35-45 10

Copper: KE-Cu 2.0050 60-100 10Brass: CuZn 40 2.0360 80-120 3

CuZn 40 PB 2 2.0402 80-120 3CuZn 15 Si 4 2.0492 80-120 3

Bronzen:-tin bronze CuSn 6 2.1020 80-120 3

CuSn 8 2.1030 80-120 3

Red brass: CuSn 5 ZnPb 2.1096 60-100 3CuSn 10 Zn 2.1086 60-100

Al-bronze CuAl 8 2.0920 40-60 15CuAl 10 Fe 2.0940 30-40 15Ampco 18 40-65 15Ampco 25 30-50 15

stannous-leadbronze CuPb 20 Sn 5 2.1818 80-120 3


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Approximate values for Bi-Metal and carbide saw blades.cutting speed (m/min)

Material group DINma-

terial

no.

Bimetal

< 100 mm < 3,94"

Bimetal

< 500 mm < 19,69"

Bimetal

> 500 mm > 19,69"

carbide

coolantlubricant

oil %

Aluminium: Al 99,8 3.0285

80-120 25

Modelling alloy AlMg 33.353

580-120 25

AlMg 4,5 Mn3.354

780-120 25

Castin alloy G-AlSi 5 Mg3.234

180-120 25

G-AlSi 123.258

180-120 25

Pulb alloy AlSi 21 CuNiMg 80-120 25

Plastics-thermoplastic PVC 80-120 dry

Teflon 80-120 dry

Hostalen 80-120 dryFiber-glass reinforced 50-80 dry

Polyurethan 80-120 dry-thermosetting

Polystyrol 80-120 dryPolyester 80-120 dry

Further data to special steel 1.3964:

U- steel, antimagnetic, must be sawed by Bimetal-S- blade!Saw data: plates 300x18mm, v=48 m/min, oil rate 13%, cutting pressure 22 bar (customersspecification)


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4.4 Change of saw bladePut on protective glovesLift sawframe.

Open both band wheel covers, relax saw blade (mechanically: turn the hand wheel to theleft; hydraulically: selector switch "open").

Remove the present saw blade.

Insert the new saw blade over the sawframe into the blade protective chanel and into both band wheelcases. Place the saw blade on the bandwheel, pressing the teethless back of the saw blade against thebandwheel flange. Then insert the saw blade into the roller- and carbide guiding.

Take care that the saw blade is pushed in the guidings up to the back guide. Tighten the saw blade(mechanically: turn the handwheel to the right; hydraulically: selector switch "tighten").

Caution:

The teethless back of the saw blade must be placed at thebandwheel flange. Otherwise the bandwheel will be damaged!

Check if the saw blade is correctly placed on the band wheels and in the guidings.The tooth crest must point to the fixed jaw between the blade guides. Otherwise the saw blade must beremoved again and has to be turned in itself by 180 .

Close the band wheel cases and start the saw blade drive by pressing the key "saw motor on".

At last remove the saw blade guard.

Note:A new saw blade must be "sawed in" at first. As a result of the "sawing in" of the sawblade, the edge life resp. the stand area of the saw blade will be raised and the cuttingquality will be improved.see chapter 4.6 "Sawing in of new saw blades"

Caution:Take care, that the linear guides of the material insert are not damaged during the change of thesawblade!


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MEBAsaw blades


The hydraulic blade tension of all other machines is actuated by a hand valve. The actuation of the valve isonly possible as soon as the band wheel cover is opened and the machine has stopped itself thereby(cover end switch).

Change of the saw blade:Following steps are necessary to change the saw blade.

switch off the machine open the guard cover after the guard cover is opened, the hand valve can be actuated (release). The blade

tension releases. remove the old saw blade from the band wheels. place the new saw blade on the band wheels and insert it into the guidings (see

chapter 4.4) actuate the hand valve (tighten)=> blade is tightened check the seating of the saw blade close and lock the guard cover

tightenrelease


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4.6 Sawing in of new bandsaw bladesSawing in of new bandsaw blades

The sharp cutting edges of theMEBA-bandsaw blades achievetheir high cutting efficiency by anextremely small edge radius. Toget the full tool life cycle it is mostimportant to saw in the newbandsaw blades correctly. Find outin relation to the material type andthe size of the material to cut thecorrect cutting speed (m/min) and

the correct feed (mm/min).

The new saw blade should beinsert with 50 % of the determinedfeed. So you avoid the sharpcutting teeth being damaged by abig chip thickness.At the beginning new bandsawblades can tend to vibrations andswinging noise. .If it so, please reduce slightly thecutting speed.

In the case of small workpieceswe recommend to cut 300 mm2ofthe cutting material to sawing inthe new bandsaw blades.In case of big workpiecedimensions we recommend aperiod for the sawing in of approx.15 min.

After sawing in of the newbandsaw blades increase the feedslowly to the previouslydetermined value.

Picture scale 30:1

New cutting edge with extremesmall edge radius By a correct sawing in of the newsaw blade you get an optimalrounded cutting edgeExcessive load while sawing inimproperly the new blade causesmicro-damages at the cuttingedge.

Correctly sawing in guarantees a long tool life cycle of your bandsaw blades

Safety legislation

Please notice, that you always wear protective hand guards and protectiveglasses during working on the machine. Please remove the teethprotection only after the rfitting of the bandsaw blade. During the operationof the machine the bandwheel covers must be closed. Please positioncorrectly all security devices in the area of the saw blade in order to assure

the safety precautions in the dnger area. Please bear in mind the security instructions in

the instruction manual of the manufacturer.


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Service and maintenance


Chapter 5 - Service and maintenance5.1 General indicationsGood maintenance and regular service are positive for the cutting quality and the duration of life.

It is absolutely necessary to adhere to the time-limits and intervals prescribed in the servicingschedule.

You can maintain painted machine parts with non-aggressive machine- or household cleanser.

Keep clean the operation surface of control with water and washing medium, you can also useglass cleanser for the Touch-Panel.

If you use coolant emulsion you must pay attention to a correct mixing proportion for preventingcorrosion at unprotected machine parts.Aggressive coolant lubrication mediums shouldnt be used. Otherwise its not guaranteed that theoperation personnel isnt endangered and the machine parts get destroyed.

Chip sedimentation, especially in the zones around the bandwheel in the wheel box, in the zonesaround limit switches and electric lines and in the zones around material vices, are to be removedseveral times a day - depending on the quantity of chips.Chip sedimentations in the coolant tank are to be removed with each filling up to guarantee anorderly function of the coolant-lubrication element.

Oil- and coolant concentrate level must be checked at least once a day.

Please pay attention to that no contaminant gets into the system when filling in or up of hydraulicoil or transmission lubricant. Before filling in please filter oil.

When there is danger of frost, an antifreezing solution must be added. Hydraulic oil andtransmission lubricants must be adjusted to the ambient temperature.

The state of the saw blade guidances (carbide metal- and roller guidances) must be checkedoptically with each change of saw blade for unobjectionable state and chip sedimentation.

Do not use compressed air for cleaning the machine. Otherwise, it could be possible that the sawframe control or the measuring system fails because of blown chips.


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5.2 View plan


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5.3 Oil lubrication positionsRecommended lubricant:Viscosity VG 46 - 48 according to DIN 51519Within this viscosity range you can use oil with the mark HL,HLP (hydraulic oil) or CL, CLP(lubricating oil).


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positions for taking oil place

W= weekly M= monthly

Pos W M Place1 X lubricate backup guide, saw blade guidances left

and right2 X shackle toggle joint and link pin at hydrauliccylinders (approx. 5 - 10 drops)3 X guide and rollers of the height adjusting scale

4 X sliding surface and adjusting spindle of theblade tension5

678


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5.4 Greasing lubrication places

For lubrication only use lubricants of the NGLI quality DIN 51825TI.For feeding carriages of the linear guides (so far as grease nippels are existing) only use lithiumlubricant no. 2. For friction- and ball bearing you can also use this lubricant or conventionallubricant on mineral oil basis.

The linear guides must be lubricated after 500 working hours, at least however every half year, sofar as grease nippels are existing. When there are no grease nippels you should lubricate theguide bars once in a month.

You have to shorten the lubrication interval when there is heavy fouling.


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points for grease are on the pictures

POS. W M Place1 X linear guides and feeding carriage (see above)2 X bearing block at the saw frame appprox. 5 cm3 X band wheel (tension side) approx. 5 cm4 X clamping bars for mitre and vise (lubricate)5 X lubricate sliding surfaces6 Lubricate sliding surface of the blade tension7 Lubricate sliding surface of the guide arm8 Lubricate the blade tension spindle and guide9 X spindle nut

W = weekly M = monthly


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5.5 Gearing5.5.1 SafetyBefore installing and operating this equipment read these safety instructions and warningscarefully. Also read and obey all the warning signs attached to the equipment. Make sure that thewarning labels are kept in a legible condition and replace any missing or damaged labels.

WARNINGThis equipment must be installed, operated and maintained by suitably qualified personnelonly.

Use only permanently-wired input power connections. The equipment must be grounded(IEC 536 Class 1, NEC and other applicable standards).

Wait at least five minutes after the power has been turned off, before opening theequipment. The dc-link capacitor remains charged to dangerous voltages even when thepower is removed. When working on open equipment, note that live parts are exposed anddo not touch these parts.

Obey all general and regional installation and safety regulations relating to work on highvoltage installations, as well as regulations covering correct use of tools and personalprotective equipment.

Note that the following terminals can carry dangerous voltages even when the inverter isstopped:Power supply terminals L1, L2 and L3Motor terminals U, V and W.When using the analogue input, the jumpers must be correctly set and the analogue inputtype selected (P023) before enabling the analogue input with P006. If this is not done themotor may start inadvertently.

This equipment is capable of providing internal motor overload protection in accordancewith UL508C section 42.

WARNINGTake note of the general and regional installation and safety regulations regarding work onhigh voltage installations (e.g. VDE). Adhere to relevant regulations regarding correct use oftools and protective gear.

CAUTIONDo not allow children or the general public to access or approach this equipment.


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EUROPEAN LOW VOLTAGE & EMC DIRECTIVESThe COMBIMASTER product complies with the requirements of the Low Voltage Directive73/23/EEC and the EMC Directive 89/336/EEC.

The units are certified for compliance with the following standards:

EN 60204-1 Safety of machinery Electrical equipment of machinesEN 60146-1-1 Semiconductor converters General requirements and line commutated convertersBS EN50081-2 1995 General Emission Standard - Industrial EnvironmentBS EN50082-2 1995 General Immunity Standard - Industrial Environment.

The MICROMASTER Integrated product complies with the requirements of the Low Voltage Directive73/23/EEC.

The units are certified for compliance with the following standards:

EN 60204-1 Safety of machinery Electrical equipment of machinesEN 60146-1-1 Semiconductor converters General requirements and line commutated converters.

EUROPEAN MACHINERY DIRECTIVEThe MICROMASTER Integrated / COMBIMASTER products are suitable for incorporation into machinery.The MICROMASTER Integrated / COMBIMASTER must not be put into service until the machinery intowhich it is incorporated has been certified to be in compliance with the provisions of the EuropeanDirective 89/392/EEC.

Only valid for machinery to be operated in the European Community.

5.5.2 ErrorIf the Motor Does Not Start UpCheck the LEDs on the side of the inverter:

LED State COMBIMASTER / MICROMASTER Integrated StatusGreen Yellow

ON ON Mains power on, inverter not running (STANDBY)ON OFF Inverter running, as per control commands (ON)Flashing Flashing Current limit warningFlashing ON Inverter overtemperatureON Flashing Flashing Motor overtemperatureOFF ON Other fault (e.g. tripped)OFF Flashing Mains undervoltageOFF OFF Mains supply fault (e.g. faulty external switch)

ATTENTION:Never open the assembly by your own.Please always contact MEBAif there is an error!


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5.6 HydraulicsFilling capacity: look at Connections / filling capacities Check daily the hydraulic oil level at the oil-measuring stick!

Oil change: after 2500 working hours, at least however once in a year

Only use filtered hydraulic oil with a filter mesh of 10m

Take care of a clean environment ar refilling oil. Additionally, take care of a filter mesh of 10m

switch off the machine on the main switch and secure agains restart while working with the hydraulic

unit. Make the hydraulic system unpressured by open the throttle valve (Posl 10 spare parts list) Start workings on the hydraulic unit not before the hydraulic oil is totally cool.

Attention: Contaminations in the hydraulic oil can cause errors or failure malfunctions at thehydraulic unit

Please find out spare parts in the spare parts list in chapter 7

5.7 Oil sorts - supplier nameUnobjectionable function, proper functioning and working life of hydraulic plants depend essentially fromthe type of hydraulic oil. We recommend when being subject to normal operating conditions HLP hydraulicoil according DIN 51 524-2. The below mentioned types of oil correspond to these descriptions.

ambienttemperature

under 0 C 0 - 30 C over 30 C

indicationaccordingto DIN 51524-2

HLP32

HLP46

HLP68

ISO 11158HM32

HM46

HM68


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5.8 Saw blade guidance and change of the guidanceelements

The saw blade guidance is placed LH and RH of the saw frame orifice. On the LH the saw blade guidance isplaced in the movable guide bracket, on the RH in the firm guide block with integrated regulation ofpressure of cutting.By a combined roller- and carbide metal guidance, the saw blade is turned back in working direction.Essential for a good cutting quality is an impeccable state of the blade guidance. So it is necessary tocheck regularly and to change the guidance elements in time.

Do the installation of new guidance elements and guide bearings as follows:Remove the saw blade. Remove the old guide elements of the saw blade guidance, as for example roller

axles, guide pieces and backup guides. Clean off chips and rust from spring block and cup spring.

Put in cup springs. Put in spring blocks and backup guides in direction to the backside of saw blade. Nowthe blade guides R+L can be screwed on loosely.

Check that the blade guides are slightly, movable and placed correctly. Now the rollers (guide bearing) areput on the roller axles. Put spacer K on the roller axle K and spacer L on roller axle L. When the completepitch axis is screwed up tightly the K-unit (short screws) must be placed to the front - before the saw blade -and the L-unit (long screws) to the back - behind the saw blade - .

Before installation of the guide bracket please check whether the roller axles are firm, the blade guideshowever slightly - movable - and placed correctly.

After having installed the guide bracket you have to put on a saw blade for adjusting the blade guides.[lookat Change of saw blades].The blade guides R+L must be pressed together firmly and screwed up tightlywith the saw blade without pushing away the saw blade from its straight course between the rollers.

For obtaining the necessary blade clearance, you have to put a separator foil or paper (0,05 mm thick)between the saw blade and the carbide metal of the blade guides and prestress with a little clamp. Nowthe screws can be screwed up tightly.When the saw blade-drive is switched on, the separator foil or paper is automatically exhausted.

It is possible to recheck the blade clearance with a feeler gauge.

gap width without saw blade = thickness of saw blade 1,3 mm [recheck] + 0,05 mm bladeclearance.

gap width with saw blade = 0,05 mm blade clearance.

Even a small lateral deflection of the saw blade because of adapters causes diagonal cut or hollow sectionin direction of removal of metal by cutting tool.

Now the machine is again ready to run. The first saw cut tells you something about how exact the repairhas been done.

If the saw cut isnt satisfactory, you have to check, where the blade guides have not been put in correctly.


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Spare parts list


Chapter 6 - Spare parts list

for

MEBAo410 DG

We need following details when ordering spare parts and parts subject to wear:

MEBAEDV-number number of pieces type of machine machine number year of construction of the machine eventually description or drawing of the part or fitting position


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Spare parts list


Spare parts list 1 drive


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Spare parts list


PositionItemPiece

MengeQuantityQuantite

Bezeichnung Designation MEBA -NrMEBA numberNumero MEBA

1 1 Getriebemotor gear motor A GETR500432 1 Bandscheibe bandwheel 875 01 282 923 1 Distanzring distance ring 430 01 290 244 1 Scheibe disc 550 05 284 245 4 Sechskantschraube hexagon cap screw 00933 120706 1 Sechskantschraube hexagon cap screw 00933 20045

BaugruppenbezeichnungDesignation of subassembly

Designation de l ensemble

Antriebdrive

ModellModel

Modele410 DG

NummerNumber

Numbero

876 00 290 0XSeitePage

Page

1/1


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Spare parts list


Spare parts list 2 coolant unitPosition

ItemPiece



1 3m Schlauch hose F SCHL100022 2 Schlauchschelle hose clip F SCHE100173 6 Schlauchschelle hose clip F SCHE140094 2 Schlauchklammer hose clamp 301 35 002 245 1 W. Einschraubstutzen angle screwed plug F WESS10R386 1 Verschlustopfen plug 00908 001/47 2 Winkel elbow screw F WINK001/48 1 Y-Verbindung Y-coupling F YSST10000

9 1 Kupfer Dichtung gasket 07603 1401810 1 Khlmittelpumpe coolant pump F KHL10045



Khlmittelanlagecoolant unit

ModellModel

Modele410 DG

NummerNumberNumbero


Page1/1


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Spare parts list


Spare parts list 3 maschine pedestalPosition

ItemPiece



1 1 Maschinenstnder maschine pedestal 725 00100B02 1 Tankdeckel lid 320 21101243 1 Halteblech holding sheet 0 8612010054 1 Kabelabdeckung wire cover 320 22101235 1 Blinddeckel cap 725 0110023

6 Linsen Flachschrauben fillister-head srew M LINS060106 1 Fhrungsverlngerung rechts guide extension right 415 06100B37 1 Fhrungsverlngerung links Guide extension left 415 07100B3

4 Sechskantschraube hexagon cap screw 00933 100304 Zylinderstift cylindrical pin 07979 08030

8 1 Wasserblech water sheet 415 08100234 Linsen Flachschrauben fillister-head srew M LINS05010



Maschinenstndermaschine pedestal

ModellModel

Modele410 DG

NummerNumber

Numbero


Page

1/1


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Spare parts list


Spare parts list 4 swivelling beam

415


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Spare parts list


PositionItemPiece



1 1 Schwenktrger swivelling beam 415 00180B02 1 Einschnittablage cutting line cover 415 3218023

4 Zylinderschraube cheese-head screw 00912 060253 1 Schrgkugellager inclient ball bearing 00628 03210

1 Innenring ring M INNE000454 1 Schwenkachse swivel axle 415 30180235 4 Rillenkugellager grooved ball bearing 00625 619106 1 Lagertrger bearing bolt 415 01180B3

2 Zylinderschraube cheese-head screw 00912 10030

3 Zylinderschraube cheese-head screw 00912 100402 Zylinderschraube cheese-head screw 00912 100802 Zylinderstift cylinder pin 07979 08040

7 1 Wellenhalter shaft holder 415 31180236 Zylinderschraube cheese-head screw 00912 100801 Zylinderschraube cheese-head screw 00912 20050

8 1 Wasserblech water sheet 415 33180204 Linsen Flachschrauben fillister-head srew M LINS05010



Schwenktrgerswivelling beam

ModellModel

Modele410 DG

NummerNumber

Numbero


Page

1/1


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Spare parts list


Spare parts list 5 angle transmitter digitalPosition

ItemPiece



1 1 Sensorhalter sensor holder 737 07184242 Zylinderschraube cheese-head screw 00912 06025

2 1 Sensorhalter Alu sensoe holder alu 350 01191543 1 Deckel cover 350 0319124

2 Zylinderschraube cheese-head screw 00912 050302 Senkschraube countersunk screw 00963 03006

4 1 Lngenmesystem measuring system E MESS000012 Zylinderschraube cheese-head screw 00912 03015

5 0,810m Magnetband magnetic tape E MAGB000016 2 Abstreifer scraper 350 0219154

4 Zylinderschraube cheese-head screw 00912 050127 2 Pratze bracket 350 0519124

2 Zylinderschraube cheese-head screw 00912 040128 1 Haltewinkel holding angle 415 0119123

2 Linsenkopfschraube fillister-head srew M LINS060089 1 Schaltnocke switch cam 705 1056354

2 Zylinderschraube cheese-head screw 00912 06008



Winkelgeber digitalangle transmitter digital

ModellModel

Modele410 DG

NummerNumber

Numbero


Page

1/1


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Spare parts list


Spare parts list 6 clamp mitrePosition

ItemPiece



1 1 Zylindermantel zylinder pipe 415 01386232 1 Kolben piston 320 6038624

1 Kolbendichtung piston seal H KOLB060103 1 Klemmstange clamping rod 415 04386244 2 Stellring setting ring 00705 250005 1 Aufnahme Klemmzylinder zylinder holder 415 0838624

4 Zylinderschraube cheese-head screw 00912 100306 1 Scheibe disc 415 0938624

2 Senkschraube countersunk screw 07991 060167 1 Gelenkkopf swivel head M GELE16000

1 Mutter nut 00934 160008 1 Aufnahmeplatte Gelenkkopf swivel head holder 415 05386249 1 Pass-Schulterschraube fitting screw 07379 16040

1 Mutter nut 00934 12000



Klemmung Gehrungclamp mitre

ModellModel

Modele410 DG

NummerNumberNumbero


Page1/1


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Spare parts list


Spare parts list n 7 main vice

415

00

301

0x


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Spare parts list


PositionItemPiece



1 1 Spannbacke fest fixed vice jaw 415 01 300 B32 1 Spannbacke bew. movable vice jaw 415 02 300 B33 1 Wangenplatte 1 side plate 1 415 03 301 B34 1 Wangenplatte 2 side plate 2 415 04 301 B35 1 Schlittenplatte sliding plate 415 05 300 B26 2 Linearfhrungsschiene linear guidance M GSR30068S

7 4 Linearfhrungswagenlinear guidancecarriage

M GSR30T00W

8 1 Zylinderplatte cylinder plate 415 08 300 23

9 1 Zylinder A - 40 - 20 - 720 Hub cylinder 720 stroke H ZYLI0207710 1 Auflageplatte base plate 415 10 300 2311 1 Auflageplatte 2 base plate 2 415 11 300 2312 1 Linearfhrungsschiene linear guidance M HSR30092S

13 2 Linearfhrungswagenlinear guidancecarriage

M HSR30R00W

14 1 Spannbacke Drehpunkt clamping jaw mitrepoint

415 14 300 B3

15 1 Spannleiste clamping bar 320 02 325 2316 1 Sicherungsblech safety plate 415 15 300 23



Hauptspannstockmain vice

ModellModel

Modele410 DG

NummerNumberNumbero 415 00 301 0X

SeitePagePage 1/1


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Spare parts list


Spare parts list 8 clamping vicePosition

ItemPiece



1 1 Zylindermantel Zylinder barrel 320 01385232 Zylinderschraube cheese-head screw 00912 080501 Zylinderstift cylinder pin 07979 08030

2 1 Kolben piston 320 04380241 O-Ring o-ring 03770 03050

3 1 Klemmstange clamping rod 415 01385244 1 Kugelscheibe rounded washer 06319 170305 1 Kegelpfanne taper pan 06319 19030

1 Mutter nut 00934 160001 Splint splint 00094 04050

6 2 Stellring setting ring 00705 25000



Klemmung Spannstockclamping vice

ModellModel

Modele410 DG

NummerNumber

Numbero


Page

1/1


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Spare parts list


Spare parts list 9 saw framePosition

ItemPiece



1 1 Sgerahmen saw frame 415 00200B02 1 Fhrungsschiene guidance rail 415 02200233 1 Abdeckblech cover sheet 415 2520024

2 Linsen Flachschrauben fillister-head srew M LINS05010



Sgerahmensaw frame

ModellModel

Modele410 DG

NummerNumberNumbero


Page1/1


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Spare parts list


Spare parts list 10 electrical lifting

415

00

128

0X


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Spare parts list


PositionItem

Piece

MengeQuantity

Quantite

Bezeichnung Designation MEBA -NrMEBA number

Numero MEBA

1 1 Hubspindel mit Mutter spindle with screw 738 01128232 1 Federblock spring block 738 02129533 3 Druckfeder pressure spring 02076 339T14 1 Schalteraufnahme switch adapter 738 03129235 1 Pass-Schulterschraube fitting screw 07379 120206 1 AC - Antrieb AC variable speed srive A GETR305507 1 Passfeder adjusting spring 06885 060328 1 Axial-Rillenkugellager axially grooved ball bearing 00711 51204

9 1 Sicherungsmuttersafety nut

N SICH0151010 1

Lagertrger elektr.Heben

bearing beam electric lifting738 0412923

11 1 Faltenbalg rubber gaiter M FALT0000212 1 Faltenbalghalter Gaiter holder 738 05129B413 1 Nhrungssensor sensor E FHL50000



Elektrisches Hebenelectrical lifting

ModellModel

Modele410 DG

NummerNumberNumbero


Page1/1


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Spare parts list


Spare parts list 11 portal - linear guidance


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Spare parts list


PositionItemPiece



1 1 Portalkonsole rechts portal console right 737 01125B22 1 Portalkonsole links portal console left 738 02125B23 1 Schutzblech safety sheet 737 19125244 1 Befestigungswinkel fixing bracket 737 05125B25 1 Linearfhrung 820 mm linear guidance 820mm M LINE308206 1 Linearfhrung 960 mm linear guidance 960mm M LINE309607 0,585 m Energiefhrungskette drag chain M KETT780418 1 Winkelsatz elbow joint M WINK451619 1 Endschalterwinkel limit switch angle 737 1212524



Portal-Linearfhrungportal - linear guidance

ModellModel

Modele410 DG

NummerNumberNumbero

738 00 125 0X

SeitePagePage

1/1


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Spare parts list


Spare parts list 12 portal console crosswise with controlPosition

ItemPiece



1 1 Portalkonsole quer portal console across 415 03 125 232 8 Federring spring ring 00127 100003 2 Zylinderstift cylinder pin 07979 080304 1 Blechabdeckung cover sheet 415 10 125 22



Portalkonsole quer mit Bedienungportal conso

eco 410 dg index a.pdf

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