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USE AND MAINTENANCE MANUAL

YEAR OF MANUFACTURE: ______________

PH 211EN

EN

”CE” CONFORMITY DECLARATION(according to EEC MACHINES DIRECTIVE 98/37/CE annex II A)

The manufacturer:

SPA

SEGATRICIVia Enzo Magnani, 1

61045 Pergola (PU) ITALIATel. 072173721--Fax 0721734533

Hereby declares that the bandsawing machine:

Machine model:

Serial number:

Year of manufacture:

PH 211

is in specification with the following directives:

• DIRECTIVE EEC MACHINES DIRECTIVE 98/37/CE• DIRECTIVE 73/23 ”LVD”• DIRECTIVE 89/336 ”EMC”• DPR 459/96

Amministratore Delegato(William Giacometti)

valeria

fac-simile

Introduction and technical specifications 1---1. . . . . . . . . . . . . . . . . . . . . .Foreword 1---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machine presentation 1---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machine specification 1---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Name plate 1---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensions 1---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functional parts 2---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PH211 model 2---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cutting head 2---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vice 2---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Panel 2---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and accident prevention 3---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Use of the machine 3---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General recommendations 3---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recommendations to the operator 3---3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machine safety devices 3---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reference standards 3---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protection against accidental contact with the blade 3---6. . . . . . . . . . . . . . . . . . . . . .Electrical equipment 3---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency devices 3---7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Noise level of the machine 3---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Noise level measurement 3---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Noise level values 3---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vibration emission 3---9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electromagnetic compatibility 3---10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine installation 4---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Packaging and storage 4---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Anchoring the machine 4---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Minimum requirements 4---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check list 4---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Balancing the cutting head 4---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connection to the power supply 4---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of machine operation 5---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of the control panel 5---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic instructions for carrying out a cutting operation cycle 5---4. . . . . . . . . . . . . . . .Manoeuvring the cutting head 5---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clamping the work piece in the vice 5---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Width of cut 5---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preliminary check list for cutting operation 5---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual operating cycle 5---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating cycle with HB device 5---7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angled cuts 5---10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angled cuts 45˚ to the left 5---10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angled cuts 60˚ to the left 5---11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagrams, exploded views and replacement parts 6---1. . . . . . . . . . . . . . . .Standardised Wiring Diagrams (single---phase) 6---1. . . . . . . . . . . . . . . . . . . . . . . . . .Standardised Wiring Diagrams HB (single---phase) 6---2. . . . . . . . . . . . . . . . . . . . . . .Standardised Wiring Diagrams (three---phase) 6---3. . . . . . . . . . . . . . . . . . . . . . . . . .Exploded views 6---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Body frame assembly 6---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor assembly 6---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Handle assembly 6---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade adjustable assembly (rear) 6---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade adjustable assembly (front) 6---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Idler wheel and Drive wheel assembly 6---10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade back cover assembly 6---10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control panel assembly 6---12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Base assembly 6---14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control panel assembly HB 6---16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vise assembly (A) 6---18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vise assembly (B) 6---18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stand leg assembly 6---20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 7---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vice 7---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vice play adjustment 7---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cutting head 7---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade tensioning unit 7---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting operating head travel 7---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade guide parts 7---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade guide heads 7---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade guide plates 7---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade 7---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tool change 7---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade perpendicularity 7---10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Orthogonality of the blade 7---11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and choice of consumables 8---1. . . . . . . . . . . . . . . . . . . . . . .The role of the operator 8---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance requirements 8---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General maintenance 8---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily 8---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Weekly 8---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monthly 8---3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of working parts 8---3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Consumable materials 8---3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil for transmission box 8---3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil for lubricant/coolant fluid 8---3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cutting speed and choice of tools 9---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cutting speed 9---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard machine 9---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Choice of blade 9---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Saw tooth pitch 9---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cutting speed and downstroke speed 9---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Types of swarf: 9---2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricant/coolant fluid 9---3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade structure 9---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade types 9---4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Conventional rake 9---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Positive rake 9---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable pitch 9---5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable pitch blades with 0˚ cutting angle 9---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable pitch with positive rake (from 9 to 10 degrees) 9---6. . . . . . . . . . . . . . . . . . .Set: 9---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Standard or splayed set 9---6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Undulated set 9---7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alternating grouped sets 9---7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alternating set 9---7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blade selection table relating to cutting speed and downstroke speed 9---8. . . . . . .Classification of steels 9---9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Classification of steels 9---10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 10---1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting blade and cutting problems 10---1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting machine faults 10---8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--1

Introduction andtechnicalspecifications

Foreword

MEP S.p.A.,in response to modern production techniques, has developed the newPH211.

This work tool has been designed to satisfy the wide range of cutting needs of amodern workshop with simplicity and reliability, while at the same time comply-ing with all EEC safety standards.

The PH211 is structurally rigid, silent and safe: it produces a minimum of waste(1.2 mm) while its great versatility makes it suitable for cutting various materialssuch as stainless steel light alloys, aluminium, copper and bronze at high speedand with high precision.

Its high cutting capacity, which enables it to handle both single workpieces andbundles, combined with the possibility of making inclined cuts from 0˚ to 60˚ left,make this model the ideal solution for satisfying the wide strange of cutting needsof machine shops, turneries, structural steel shops and engineering workshops.

We congratulate our clients on having chosen this product, which will giveeffective and faithful service for many years, especially if the instructionscontained in this use and maintenance manual are carefully followed.

This cutting machine has been designed and made specifically for cutting me-tallic materials.

Machine presentation

Functioning is completely manual: the operator, after having checked theworkpiece in the vice, grips the control lever and presses the bandsaw startmicroswitch; with a downwards movement, the material is cut to the presetlength; the cutting head returns up at the end of the cutting operation, ready tostart a new work cycle.

Warning

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MEP S.p.A.

1--2 2Use and maintenance manual PH211

length; the cutting head returns up at the end of the cutting operation, ready tostart a new work cycle.

Machine specification

Name plate

The anodised aluminium name plate is riveted on the side of the machine; thesame data are reproduced on the declaration of conformity included with this useand maintenance manual.

MODELLO PH211

MATRICOLA

ANNODI COSTRUZIONE

MEPSPAVia EnzoMagnani, 161045 Pergola (PU) ITALYtel: 0721/73721

When communicating with the Technical Service department, the model, serialnumber and year of manufacture of the machine must be quoted.

CUTTING SPEEDS

1st Slow Speed mt/min 40

2nd Fast Speed mt/min 80

BAND SAW

Rated size mm 2085 x 20 x 0,9Max/min blade length mm 2075÷2095Blade height mm 20Blade width mm 0,9

Band saw tension Kgs/cm2 --- Lbs/in2 2250 --- 32000

When choosing the cutting tool, if its dimensions do not correspond to thoseincluded in the “Rated size” section, check that the dimensions at least fallwithin the admissible max/min specifications.

RATED ELECTRICAL POWER

Head spindle motor KW 1/1,3

Electric coolant pump motor KW 0,1

Max installed power KW 1,4

N.B.

Attention

1--33 Introduction and technical specifications

LUBRICANT/COOLANT FLUID AND OIL

Oil for transmission box capacità Kg 0,32

Lubricant/coolant fluid (oil concentration 5---6%) capacità Lt 10

VICE

Vice max. opening mm 200

SPINDLE MOTOR

No.of poles Current (Volts) Absorption(Amps)

Power (Kw) rpm Band saw spe-ed

2 230/400 4,1/3,0 1,3 2950 80 mt/min

4 230/400 2,4/1,7 1 1430 40 mt/min

Stator wound with enamelled copper wire, class H 200˚C.

Class F insulation (limit temperature TL 155˚C).

IP 55 protection rating (total against contact with live parts, water sprayed from all directions, with shaft oilseal).

Conforming to CEI norms, publication: IEC 34 of 01/07/1985.

Example of class F insulation: in air--cooled machines at an ambient tempera-ture of 40˚ C (according to CEI 2--3 and IEC 85), the allowable overtempera-ture is 100˚ C (where 100 C represents the allowable DT).

The machine is supplied with a 2/4 pole three phase motor giving 2 band sawspeeds:-- 1ª speed (4 poles) = 40 mt/min--- 2ª speed (2 poles)= 80 mt/min;

ELECTROPUMP MOTORSingle phase; Frequency 50 Hz.

Voltage(Volts)

Absorption(Amps)

Power (Kw) rpm Delivery rate lt/min Head (mt.)

230 0,3 0,1 2840 11 1,5

400 0,17 0,1 2840 11 1,5

Protection rating IP 55.

Conforming to CEI norms, publication: IEC 34 of 01/07/1985.

CUTTING CAPACITY

Section

0˚ 180 180 200 x 150

45˚ a 115 110 125 x 110

60˚ a 70 70 70 x 70

N.B.

Warning

MEP S.p.A.


Dimensions

MACHINE INSTALLED

Work table height mm 935

Weight Kg 180

1280

840

1600

PACKED WEIGHT

Wooden cage and pallet Kg 70

Wooden pallet Kg 20

2--1

Functional parts

PH211 model

In order for the user to move towards a full understanding of how the machineworks, which is described in detail in the chapter 5, this chapter deals with themain units and their locations.

Cutting head

The cutting head is the unit that cuts the material. It consists of a cast iron headon which the following are mounted: the band saw, the blade guide components,the blade tensioner components, the transmission box and the spindle motor. Thecutting head is limited in its movements by the joint on the work table, and itscutting stroke is manually guided by the operator.

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MEP S.p.A.


Vice

The vice is the unit that clamps the workpiece in place during cutting; it consistsof a vice support, commonly known as a lead nut, fixed to the work table, and alead screw with a slideway on which the mobile jaw is mounted. The vice isoperated manually by a handwheel, or by a pneumatic cylinder in the MA version(optional).

Control Panel

The control panel has a protection rating of IP 54 and contains the electricalequipment. Access is gained by removing the screws fastening a safety panel,while the operator’s safety is guaranteed by a key---operated safety switch,designed to prevent any intentional interference with the unit. In order to removethe panel from its mounting, the main switch has to be shifted to 0 (OFF), whichautomatically cuts off the electrical supply.

stand by STOP

3--1

Safety and accidentprevention

The PH211 has been designed and produced in accordance with Europeanstandards. For the correct use of the machine we recommend that the instruc-tions contained in this chapter are carefully followed.

Use of the machine

The PH211 band saw cutting machine is intended exclusively for cutting metallicmaterials, ferrous or non---ferrous, in section or solid.Other types of material and machining are not compatible with the specificcharacteristics of the saw.The employer is responsible for instructing the personnel who, in turn, areobliged to inform the operator of any accident risks, safety devices, noiseemission and accident prevention regulations provided for by internationalstandards and national laws regarding the use of the machine. The operator mustbe perfectly aware of the position and function of all the machine’s controls.Theinstructions, warnings and accident prevention standards in this manual must berespected without question by all those concerned.The following definitions arethose provided for by EEC MACHINES DIRECTIVE 98/37/CE :

H “Danger zone”: any zone in and/or around a machine in which the presence of aperson constitutes a risk for the safety and health of that person.

H “Person exposed”: any person finding himself either completely or partly in adanger zone.

H “Operator”: the person or persons given the responsibility of installing, operating,adjusting, maintaining, cleaning, repairing or transporting the machine.

The manufacturer declines any responsibility whatsoever, either civil or crimi-nal, should there be unauthorised interference or replacement of one or moreparts or assemblies on the machine, or if accessories, tools and consumablematerials are used that are different from those recommended by the manu-facturer itself or if the machine is employed in a plant system and its properfunction is thereby altered.

Attention

3

MEP S.p.A.


General recommendations

LIGHTING

Insufficient lighting for the types of operation envisaged could constitute a safetyhazard for the persons concerned. For this reason, the machine user must providelighting in the working area sufficient to eliminate all shadowy areas while alsoavoiding any blinding light concentrations. (Reference standard ISO 8995---89“Lighting in work environments”).

CONNECTIONS

Check that the power supply cables and pneumatic feed systems comply with themaximum machine absorption values listed in the “Machine Specification” tables;replace if necessary.

EARTHING

The installation of the earthing system must comply with the requirements set outin IEC STANDARD 204.

OPERATOR POSITION

The position of the operator controlling machine operations must be as shown inthe diagram below.

3--39 Safety and accident prevention

Recommendations to the operator

Always wear proper goggles or protective glasses.

Do not use the machine without the guards in position.

Do not allow hands or arms to encroach on the cutting zone while themachine is in operation.

Do not wear oversize clothing with long sleeves, oversize gloves, brace-lets, necklaces or any other object that may become entangled in the ma-chine during working; long hair must be tied back and bunched.

Always disconnect the power supply to the machine before carrying outany maintenance work whatsoever, including in the case of abnormaloperation of the machine.

Before starting cutting operations, support the material at both ends ofthe machine using the support arm --- standard, or OPTIONAL acces-sories such as the feed and discharge roller tables shown in the diagrambelow. Before removing the devices supporting and moving the material,fasten the latter in place using the machine’s clamping devices or othersuitable equipment.

mm. 1500 mm. 1500

FEED ROLLER TABLE DISCHARGE ROLLER TABLE

Any maintenance work on the hydraulic or pneumatic systems must becarried out only after the pressure in the system has been released.

MEP S.p.A.


The operator must not perform any risky operations or operations notrequired for the machining operation under way (e.g. remove swarf ormetal shavings from the machine while cutting).

Remove equipment, tools or any other objects from the cutting zone; al-ways keep the working area as clean as possible.

Before starting any cutting operations, ensure that the workpiece is secu-rely held in the vice and the machine has been set correctly. A number ofexamples of how to clamp different profiles correctly in our machines areshown below.

Do not use the machine to cut pieces that exceed the capacity of the ma-chine as listed in the machine specifications.

Never move the machine while it is cutting.

Do not use blades of different sizes to those recommended in the machi-ne specifications.

When cutting very short pieces, make sure that they are not dragged be-hind the support shoulder, where they could jam in the blade.

When working on the band saw, wear gloves only when handling mate-rials and for tool changing or adjustment operations. Only perform oneoperation at a time and do not hold more than one item or operate morethan one device simultaneously. Keep hands as clean as possible.

Warning: if the blade jams in the cut, press the emergency stop push---button immediately. If this does not free the blade, slowly loosen thevice, remove the piece and check the blade or blade teeth for breakage.Replace the blade if necessary.

Before carrying out any repair work on the machine, consult the MEPTechnical Assistance Service: this can be done through a representativein the country of use of the machine.


Machine safety devices

This use and maintenance manual is not intended as purely a guide for the use ofthe machine in a strictly productive environment, it is instead an instrumentproviding information on how to use the machine correctly and safely. Thefollowing standards are those specified by the EEC Committee in the directivesregarding safety of machinery, health and safety at work, personal protection andsafeguarding of the environment. These standards have been applied to thePH211 band saw.

Reference standards

MACHINE SAFETY

H EEC MACHINES DIRECTIVE 98/37/CE ;

H EEC directive no. 89/336 “EMC -- Electromagnetic Compatibility”;

H EEC Directive No. 73/23 known as “Low voltage directive”.

HEALTH AND SAFETY AT WORK

H EEC Directive No. 80/1107; 83/477;86/188;88/188; 88/642 for the protection ofworkers against risks caused by exposure to physical, chemical and biological ag-ents during working;

H EEC Directive No. 89/391 and Special EEC Directives No. 89/654 and No. 89/655for improvements in health and safety at work;

H EEC Directive No. 90/394 for the protection of workers against risks deriving fromexposure at work to carcinogenic substances;

H EEC Directive No. 77/576 and No. 79/640 on safety signs at work.

PERSONAL PROTECTION

H EEC Directive No. 89/656 and No. 89/686 on the use of personal protection de-vices.

ENVIRONMENTAL PROTECTION

H EEC Directive No. 75/442 on waste disposal;

H EEC Directive No. 75/439 on the disposal of used oil.

MEP S.p.A.


Protection against accidental contact with the blade

1. Metal guard screwed to the rear blade guide head (machine side);2. metal guard screwed to the front blade guide head (operator side);3. front head sliding support: when the head is at maximum aperture, the sup-port ensures that the blade is covered, leaving free only the part of the bladeengaged in the actual cutting, in accordance with Presidential Decree no.547/55, art. 108;

4. hinged protective cover over blade, fitted with “removable” closing devices;5. blade guide plates completely covering the blade teeth;6. Electric limit switch for stopping the band at the cutting head stroke end (HBmodels only).

5

1

4

32

6

Electrical equipment

In accordance with Italian standard CEI 60204---1, April 1998, derived fromEuropean Standard EN 60204---1 publication IEC 204---1, 1997:

H Access to electrical control panel limited by screws and panel---lock device,allowing panel to be opened only after the electricity supply has been turnedoff;

H 24 Vac Control voltage for actuators, in accordance with chapter 6 or Euro-pean Standard “Control and indication circuits”, paragraph 2 “Control Cir-cuits” sub---section 1 “Preferential voltage values for control circuits”;

H plant short---circuit protection by means of rapid fuses, earthing of all plantparts connected with work as well as all foreseeable accidental contact; a ther-mal---magnetic overload cutout switch shuts down the motor;

H protection from accidental start---up by a minimum voltage relay in case ofpower failure.


Emergency devices

In accordance with Standard CEI 204---1:

H Chapter 5 Section 6 Sub--section 1 “Emergency stop device”: «the emergencystop device immediately stops all the dangerous and other functions of the ma-chine»;

H Chapter 6 Section 2 Sub--section 4 Point 7 “Protective guards”: «the removalof protective guards designed to prevent access to dangerous parts or zones causesthe machine to stop immediately; replacing the guards does not restart the func-tions, which must be reset».

...Emergency devices applicable to the PH211:

1. Emergency stop: a non---return mushroom---head pushbutton, colour red onyellow background, is located on the control panel of the machine. To releasethe pushbutton, the actuator must be rotated 45˚. After the emergency situ-ation has been resolved, the machine must be reset.

2. Automatic thermal---magnetic cutout switch with thermal---magnetic relay:the machine auto switch, located on the control panel, has two protection sys-tems against voltage drops. In the case of a voltage drop, all electrical compo-nents are disengaged, the machine stops immediately, and automatic restartwhen the power supply returns is inhibited. Another function is that of reset-ting the thermal relay provided to protect against overcurrents.

3. Pressure contact for monitoring blade tension: the machine stops immedi-ately if the blade breaks or if the tensioner cylinder pressure drops.

4. Protective guard for blade: a coded key microswitch is operated if the bladecover is accidentally or intentionally opened during the machine operatingcycle, immediately shutting down all functions.

1

2

3

4

MEP S.p.A.


Noise level of the machine

Noise can cause hearing damage and represents one the problems faced by manycountries who adopt their own standards. In accordance with the EEC MA-CHINES DIRECTIVE 98/37/CE , we are listing the standards that specify noiselevels for machine tools. This chapter also reports the noise levels produced bythe PH211 during its various operating phases and the methods used for measur-ing these levels. The Italian standard governing this aspect is D.M.n.277/91 drawnfrom EEC Directives 80/1107, 82/605, 83/477, 86/188, 88/642, UNI EN ISO 4871(1998).

Noise level measurement

Noise levels are measured using an instrument known as an Integrator noise---meter which registers the equivalent continuous acoustic pressure level at thework station.The damage caused by noise depends on three parameters: level,frequency and duration. The equivalent level concept Leq combines the threeparameters and supplies just one indication. The Leq is based on the principle ofequal energy, and represents the continuous stationary level containing the sameamount of energy, expressed in dBA, as that actually fluctuating over the sameperiod of time.This calculation is made automatically by the integrator noise---meter. The measurements are taken every 60 seconds, in order to obtain astabilised value. The reading stays on the display for a sufficient time to enable areading to be taken by the operator.Measurements are taken by holding theinstrument at approximately 1 metre from the machine at a height of 1.60 metresabove the platform at the operator’s work station.Two measurements are taken: the first while the machine operates without cuttinganything, the second while cutting in manual mode.

Noise level values

Identification

Machine type Band saw for metal applications

Model PH211

Reference standard ISO 3746

Results

Description C 40 steel cut --- pipe 50x82 mmBimetal band 2085x20x09 S.VGLB Z 5/8

Test 1stResults

Mean sound level (Leq) 76,42 dB (A)Environmental correction (K) 3,54 dB(A)Peak sound power (Lw) 87,34 dB(A)

Descriprion C 40 steel cut --- solid rod 150 mm dia. ØBimetal band 2085x20x09 S.VGLB Z 5/8

Test 2ndResults

Mean sound level (Leq) 76,50 dB(A)Environmental correction (K) 3,54 dB(A)Peak sound power (Lw) 87,42 dB(A)

Description 34CND6 material cut ---pipe 140x130 mmBimetal band 2085x20x09 S.VGLB Z 5/8

Test 3rdResults

Mean sound level (Leq) 76,19 dB(A)Environmental correction (K) 3,54 dB(A)Peak sound power (Lw) 87,12 dB(A)


Vibration emission

This sawing machine complies with the norms EN1299 and EN1033, as themachine vibration emission on the devices controlled by the operator does notexceed the threshold of 2.5 m/s2

MEP S.p.A.


Electromagnetic compatibility

As from 1 January 1996 all electrical and electronic appliances bearing the CEmarking that are sold on the European market must conform to Directive89/336/EEC and 70/23/CEE and 98/37/CEE. The prescriptions regard two specificaspects in particular:

1. “EMISSIONS: during its operation, the appliance or system must not emit spuriouselectromagnetic signals of such magnitude as to contaminate the surroundingelectromagnetic environment beyond clearly prescribed limits”;

2. “IMMUNITY: the appliance or system must be able to operate correctly even whenit is placed in an electromagnetic environment that is contaminated by disturbancesof defined magnitude”.

The following text contains a list of the applied standards and the results of theelectromagnetic compatibility testing of machine model PH211; Test report no.170201.

Emissions

H CEI EN 61000--6--4 (2002) Electromagnetic Compatibility (EMC) -- Generic stan-dard regarding emissions. Part 6--4: Industrial Environment.

H EN 55011 (1999) Industrial, scientific, and medical radio frequency appliances(ISM). Characteristics of radio frequency disturbance -- Limits and methods ofmeasurement.

H EN 55014--1 (2002) Electromagnetic Compatibility -- Prescriptions for domesticappliances, electric power tools, and similar equipment. Part 1: Standard Emissionin relation to product family.

CONDUCTED EMISSIONSGate A Freq. (MHz) Q---peak limit (dBuV) Mean value limit (dBuV) Result

A.C. power supplyinput

0.15 --- 0.5

0.5 --- 55 --- 30

79 --- 73(linear reduction withlog of frequency)

7373

66 --- 60(linear reduction with log of fre-

quency)

6060

Complies

CONDUCTED EMISSIONS --- ANALYSIS OF INTERMITTENT DISTURBANCESGate Result

A.C. power supply input Not applicable

IRRADIATED EMISSIONSGate Freq. (MHz) Q---peak limit (10 m)

(dBuV/m)Result

Enclosure 30 --- 230230 --- 1000

4047

Complies


Immunity

H CEI EN 61000--6--2 (2000) Electromagnetic Compatibility (EMC) -- Generic stan-dard on immunity. Part 6--2: Industrial Environment.

The EUT is deemed to fulfil the immunity requirements without testing, becauseit contains no electonic control circuitry.

4--1

Machine installation

Packaging and storage

MEP S.p.A. use packing materials that guarantee the integrity and protection ofthe machine during its transport to the customer.

The type of packing differs according to the size, weight and destination.Therefore the customer will receive the machine in one of two following ways:

1. on a pallet with straps and heat---shrink plastic;2. on a pallet with straps, heat---shrink plastic and a wooden crate.

In both cases, for correct balancing the machine must be handled using afork--lift truck, inserting the tines at the points indicated by the arrows, usingthe reference marks on the crate itself.

Before carrying out lifting operations, make sure that the weight of the ma-chine, as indicated on the crating or other packaging, is within the forklift truckload limit.

Warning

Attention

4

MEP S.p.A.


Do not handle the packed machine using slings.

When storing, machines palletized and shrink--wrapped must not be stackedtwo high, and machines pallettized and crated must not be stacked three high.

To install the machine, first remove the packing, paying particular attention not tocut any electric wires or hydraulic hoses; if necessary use pliers, a hammer and acutter.Open crate in the illustrated order:

Attention

Attention

4--320 Machine installation

1. remove nails and lift the top of the cage;2. remove nails and lower walls;

2

2

2

2

1

3. remove heat---shrink covering;4. remove the straps;5. remove nails from pallet securing planks and remove planks;6. remove the front panel and insert fork tines.

3

45

6

To locate the machine in the workplace, the machine dimensions and necessaryoperator working space, including the spaces laid down in safety standards, mustbe taken into account.

MEP S.p.A.


Anchoring the machine

The base of the machine is anchored to the floor by two permanent studs locatedon the sides of the base. The studs are screwed into nuts previously sunk into theconcrete, and tightened from above with lock nuts. The schematic specificationsset out in Chapter 1 should be taken into account when positioning the machine.

BASE

Ø 12 mm

Ø 12 mm

667,5mm

Minimum requirements

For the machine to function correctly, the room in which it is to be installed mustsatisfy the following requirements:

H power supply voltage/frequency: refer to the values on the rating plate;

H temperature of machine location: from -- 10 to + 50˚ C;H relative humidity: not more than 90%;

H lighting: not less than 500 Lux.

The machine is already protected against voltage variations, but will only runtrouble--free if the variations do not exceed ± 10%.

Warning


Check list

Before starting installation, check that all the accessories, whether standard oroptional, supplied with the machine are present. The basic version of the PH2112---SPEED machine is supplied complete with:

CHARACTERISTICS STANDARD OPTIONAL

Steel base with coolant tank and electric pump for band lubricating and cool-ing

n

Double return spring for head upstroke n

Bimetal blade for solid and section materials n

Vice with quick clamping lever n

Blade cleaning brush n

Electric control panel (totally identifiable cabling, stand---by, main switch withlockable panel---closing device, speed switch, emergency device, thermal---mag-netic overload cutout, minimum voltage relay, voltage drop protection, 24 Vlow---voltage plant)

n

IP 55 handgrip n

Adjustable stops at 0˚ and 60˚ left with clamping lever for in between angles n

Head pivoting with pre--- loaded taper bearings n

Adjustable stop to make cuts of the same length n

Accessory kit n

5 l can of emulsible oil n

2085x20x0.9 M42 bimetal band saw n

Discharge side roller table adaptor n

Adapter for laoding table K110 n

The bag of accessories is enclosed in the machine before being packed.

MEP S.p.A.


Balancing the cutting head

Before making the electrical connections, the head return springs must betensioned to balance the cutting head weight. Using a 10 mm. wrench, tighten thescrews until the distance between the first coil of the spring and the bracket is 8mm.

Connection to the power supply

Before connecting the machine to the power supply, check that the socket is notconnected in series with other machines. This requirement is fundamental for thegood operation of the machine.

To connect the machine to the power supply, proceed as follows:

" connect the power supply cable of the machine to a plug which matches thesocket to be used. (EN 60204---1; par. 5.3.2)

CONNECTION FOR ”5-CORE” WIRE SYSTEMS WITH NEUTRAL

R = L1

S = L2

T = L3

PE = GND

N = NEUTRAL

CONNECTION FOR ”4-CORE” WIRE SYSTEMS WITH NEUTRAL

S = L2

T = L3

PE = GND

R = L1

When using systems with a neutral wire, special care must be taken when con-necting the blue neutral wire, in that if it is connected to a phase wire it will dis-charge the phase voltage to the equipment connected for voltage: phase--neutral.

Attention


" Insert the plug in the socket, ensuring that the mains voltage is the same asthat for which the machine has been setup.

VOLT ?VOLT ?

" Power up machine by rotating the main switch located on the right side of thecontrol panel (The STAND BY LED lights up).

Check that the motor is rotating in the correct direction. For this check thefollowing operations must be carried out:

" set the blade tension to 70 BAR;" make sure the cover is properly closed: at the back of the cutting head there isa bayonet limiter for correct cover closure;

" make sure that the machine is not in an emergency condition (red mush-room---head pushbutton released);

" select a cutting speed using the polarity change switch;

MEP S.p.A.


" operate the jog button on the manual head control lever;

" if all the above operations have been carried out correctly, the blade motorwill start up and the blade will start rotating.

Ensure that the blade moves in the correct direction as shown in the abo-ve figure. If it does not, simply reverse two of the phase wires on the machinepower supply input.

The sawing machine is now ready to start the work for which it was designed.Chapter 5 provides a detailed description of the various functions of the machineand its operating cycles.

Attention

5--1

Description ofmachine operation

This chapter analyses all the machine functions. We begin with a description ofthe pushbuttons and other components on the control panel.

Description of the control panel

The components of the PH211 control panel are shown in the diagram below.Each arrow has a number which corresponds to the descriptions that follow.

3

5

6

1

2

3

2

4

1

45

PH261 HB PH261

5

MEP S.p.A.


1 - LED STAND BY

This either confirms machine start up or indicates an emergency state to theoperator.

2 - START BUTTON

During normal operation of the machine, this enables or disables the cutting cyclestart button.

3 - EMERGENCY STOP MUSHROOM BUTTON

Pressing this button immediately stops machine operation. The emergencybutton, designed to conform to all safety standards, is positioned so that it iseasily accessible at any time and is clearly visible --- being a red button on a yellowbackground. To reset the emergency button, rotate actuator by 45˚.

4 - POLARITY CHANGE SWITCH

This selects the blade cutting speed, 40/80 mt/min. on the standard 2---speedmachine.

5 -- AUTOMATIC THERMAL--MAGNET CUTOUTWITH MINIMUM VOLTAGE RELAY AND HATCH LOCKING DEVICE5 - AUTO-MATIC THERMAL-MAGNET CUTOUT WITH MINIMUM VOLTAGE RE-LAY AND HATCH LOCKING DEVICE

The machine is provided on the right of the control panel with a main switch witha locking device which, when set in the ON position (1), powers up the machineby resetting the minimum---voltage relay and the blade motor thermal magnetcutout. This device has three protection systems against power failure. Whenthere is a power failure the electrical devices are all shut down, instantly shuttingdown the machine and preventing automatic restoring of power on power return.A further function is to reset the thermal relay, which protects against overcur-rents.

6 - MOTOR ENABLING PUSH BUTTON

This push button enables the spindle motor at the band start. It must be pressedevery time the machine is switched on and when the emergency stop button (redmushroom button) is pressed.

HEAD CONTROL LEVER MICROSWITCH (for manual version only)

The grip of the manual head control lever incorporates a microswitch for manualcontrol of the blade motor.

MicroswitchOperatinglever

The microswitch is enabled when the machine is not in emergency state. Incompliance with the relevant existing standards, voltage is 24V and the micro-switch is installed in a housing (blue knob) sealed against external agents such asdust or moisture, with a protection rating of IP 55.

5--328 Description of machine operation

HYDRAULIC CONTROL PANEL (for the HB version only)

The hydraulic control panel is placed on the control board supporting rod. Theupper knob is a flow adjuster to set the head lowering speed, while the lower knobenables or disables the upper one.

MEP S.p.A.


Basic instructions for carrying out a cutting operation cycle

Manoeuvring the cutting head

Cutting head movement is facilitated by perfect balancing of the head weight,thanks to the traction force exerted by the two return springs located at the backof the machine. Also, the grip on the head control lever enables the operator toachieve a firm grip in order to start up band saw rotation by pressing the micro-switch start lever, located in the handle itself.

Clamping the work piece in the vice

In the basic version, the work piece is clamped in the vice by rotating theopening/closing handwheel (in a clockwise/anticlockwise direction), as shown:

" each time the vice is closed make certain that the work piece is solidlyclamped. This can be done manually.


Width of cut

The machine is fitted with protections which protect the entire blade stroke,leaving exposed only the part of the blade required to make the cut itself asspecified by current standards. The width of the cut is determined by thelongitudinal section of the workpiece, so that only the part of the blade requiredto make the cut is actually exposed.

" Position the workpiece on the work table in proximity to the blade downstro-ke trajectory and clamp it in the vice.

" loosen the ratchet lever on the sliding shaft of the front blade guide head;

" the mobile front guide head must be positioned near to the material, leavingthe downstroke trajectory free to reach beyond the sliding vice jaw;

" Tighten the ratchet lever to lock the head slide.

MEP S.p.A.


Preliminary check list for cutting operation

To guarantee complete safety during cutting cycles, the operator should workthrough a check list of the entire apparatus, checking:

" blade tension;" that the blade guide head bracket is locked in the correct position;" that the widia inserts are correctly adjusted;" that the cutting angle is correct and the cutting head is locked;" that the work piece is properly clamped in place;" that the blade teeth are correct for the job to be begun;" that the speed selected is right for the kind of piece to be cut;" that all protections are in place and correctly locked;" the level of lubricant/coolant and that the electropump is activated;" that the blade downstroke speed and the cutting pressure are correct.

Manual operating cycle

Sequence of operations for performing a cut:

" power up the machine by pressing the reset button." Position the workpiece in the vice and calculate the length of cut (using themeasuring rod for cuts to measure).

" Clamp the workpiece in the vice;

" Select the cut using the polarity change switch according to the type of thematerial to be cut (shape, thickness, hardness, etc.).


" Grip the head control lever and start the blade rotating by pressing the micro-switch on the handgrip; the downstroke speed of the head is manually con-trolled by the operator.

" The motor starts up and sets the blade in rotary motion; the lubricant/coolantpump starts up at the same time.

" At the end of the cutting operation, the head can be raised.

" Remove the piece from the vice;

Operating cycle with HB device

Sequence of operations for performing a cut:

" power up the machine by pressing the reset button." Position the workpiece in the vice and calculate the length of cut (using themeasuring rod for cuts to measure).

MEP S.p.A.


" Clamp the workpiece in the vice;

" Select the cut using the polarity change switch according to the type of thematerial to be cut (shape, thickness, hardness, etc.).

" In the hydraulic control panel on the board supporting rod close the upperknob completely rotating it clockwise, then set the lower knob on STOP toprevent every head accidental start.


" Press the enabling button for the band motor and then the start key. The mo-tor starts up and sets the blade in rotary motion; the lubricant/coolant pumpstarts up at the same time.

¯ 22¯ 22 ¯ 22¯ 22

" Set the lower knob in the START position. Slowly open the upper knob tillsetting the correct cutting supply.

" The head lowers till the cut end: an electric limit switch stops the motor rota-tion. Set the lower knob on STOP again and take the head manually again inthe cut start position.

" Remove the piece from the vice;

MEP S.p.A.


Angled cuts

The machine can make angled cuts from 60˚ left to 45˚ right. Reference stops aremounted on the sides of the turntable to facilitate rapid 0˚, 45˚ and 60˚ cuts tothe left and 45˚ cuts to the right.

Angled cuts 45˚ to the left

" slacken the turntable lock/release lever.

" rotate the head from left to right, until it reaches the desired angle, which isshown on the angle graduations on the turntable.

Always rotate the head when it is in the upper position to avoid blade collisionwith the moving jaw on the clamp.

Attention


" Relock the turntable lock/release lever.

" Make the cut in the required operating mode, following the preliminarysafety instructions set out in this chapter.

Angled cuts 60˚ to the left

" Slacken the turntable lock/release lever;" pull the eccentric pin knob towards you (0˚reference stop) and rotate slightlyto raise it;

" swing the head from left to right until it is positioned at the required angle, asindicated by the graduated scale on the turntable;

" relock the turntable lock/release lever;" make the cut in the required operating mode, following the preliminary safetyinstructions set out in this chapter.

6--1

Diagrams, explodedviews and replace--ment parts

This chapter contains functional diagrams and exploded views of the PH211. Thisdocument is intended to help in identifying the location of the various compo-nents making up the machine, giving information useful in carrying out repair andmaintenance operations; This chapter will also enable the user to order replace-ment parts with no risk of misunderstanding, as all parts are given codes.

Standardised Wiring Diagrams (single--phase)

6

MEP S.p.A.


Standardised Wiring Diagrams HB (single--phase)

6--339 Diagrams, exploded views and replace--

Standardised Wiring Diagrams (three--phase)

MEP S.p.A.


Exploded views

This part of the manual contains detailed exploded views of the machine whichcan help to gain a deeper knowledge of how it is made.

Body frame assembly

6--541

NR. Code Description Quantity1 001.6101 BODY FRAME 12 001.6105 ANCHOR BLOCK 13 010.2135 SHAFT 14 010.1801 HEX. SOCKET HEAD SCREW 15 025.0273 ANTI--CHIP COVER 16 025.0072 TAPERED BEARING 17 010.1201 WASHER 18 010.1201 HEX. HEAD SCREW 19 010.1201 HEX. NUT 111 025.0966 BEARING 112 034.0291 KNOB 213 034.0291 BLADE TENSION HANDLE 114 010.4063 SPRING WASHER 915 010.3704 LEADSCREW 116 010.0402 HEX. NUT 117 010.1201 HEX. SOCKET HEAD SCREW 318 010.4025 FIXED BLOCK 119 010.1201 PIN 220 010.1201 HEX. SOCKET HEAD SCREW 221 010.1587 FIXED BLOCK 124 034.1001 GRIP 126 010.1201 HEX. SOCKET HEADLESS SCREW 228 010.1919 CONNECTING TUBE 129 090.0271 HANDLE ASSEMBLY 130 010.4024 FIXED PLATE 131 010.1201 WASHER 232 010.1201 WASHER 233 010.1201 HEX. SOCKET HEAD SCREW 234 022.0515 MICRO SWITCH BRACKET 135 031.2655 SCALE 136 010.1201 RIVET 439 031.2656 SCALE 140 022.0392 HOSE CLIP 441 010.1201 CROSS ROUND HEAD SCREW 455 022.0326 PLASTIC BUSHING 556 010.1201 HEX. SOCKET HEAD SCREW 257 010.1201 WASHER 264 010.1201 HEX. SOCKET HEADLESS SCREW 165 010.3711 FRAME PIVOT SHAFT 167 025.0967 TAPERED BEARING 168 010.1201 HEX. SOCKET HEAD SCREW 269 025.0277 ANTI--CHIP COVER 177 028.0191 PU TUBE 178 028.0131 HOSE FITTING 279 010.1201 HEX. SOCKET HEAD SCREW 280 010.2306 3 WAY VALVE 181 028.0192 PU TUBE 183 028.0132 HOSE FITTING 491 016.1245 POWER CUTTING BRACKET 193 010.1586 SPRING BRACKET 197 010.1201 SPRING WASHER 298 010.1201 HEX. SOCKET HEAD SCREW 2

MEP S.p.A.


Motor assembly

Handle assembly

6--743

NR. Code Description Quantity61 034.0423 COVER 1

62 010.1201 HEX. SOCKET HEAD SCREW 4

63 010.1201 SPRING WASHER 4

71 019.2331 MOTOR 1



74 025.0769 REDUCER (2/4P) 1




86 010.1201 WASHER 1

87 010.1201 ROUND HEAD KEY 1

88 010.2136 OUTPUT SHAFT 1

89 010.1201 ROUND HEAD KEY 1

90 025.0056 BEARING 1

NR. Code Description Quantity29--1 090.0271 HANDLE 129--2 090.0271 GASKET SERIES 129--3 090.0271 SPRING 129--4 090.0271 MICROSWITCH 129--5 090.0271 CYLINDRICAL PIN 1

MEP S.p.A.


Blade adjustable assembly (rear)

Blade adjustable assembly (front)

6--945

NR. Code Description Quantity37 010.2140 BEARING SHAFT 1

43 010.3336 ECCENTRIC GUIDE 1

44 025.0901 BEARING 5

45 010.1201 C--RETAINER RING 2


51 010.1201 HEX. NUT 2


53 016.1172 BLADE COVER (REAR) 1

54 010.2393 BLADE ADJUSTABLE (REAR) 1

58--1 010.0868 BRUSH SUPPORT 1

58--2 025.0552 BRUSH 1

58--3 010.2068 BUSHING 1

58--4 010.4062 SPRING 1

58--5 010.1201 HEX. SOCKET HEADLESS SCREW 1

58--6 010.2069 BUSHING 1

58--7 010.1698 BEARING SPACER 1

82 043.0655 VALVE 1

111 010.1201 ROUND HEAD SCREW 2

112 010.1201 WASHER 2

113 010.1201 WASHER 1


NR. Code Description Quantity22 010.1201 ROUND HEAD SCREW 2

23 010.1201 HEX. SOCKET HEADLESS SCREW 4

25 010.2353 BLADE ADJUST STICK 1

27 034.1116 PLUM HANDLE 1

37 010.2140 BEARING SHAFT 1

38 010.2392 BLADE ADJUST (FRONT) 1


44 025.0901 BEARING 5

45 010.1201 C--RETAINER RING 2



48 016.1171 BLADE COVER (FRONT) 1

50 010.1201 WASHER 2

51 010.1201 HEX. NUT 2


66 010.1201 WASHER 2

82 043.0655 VALVE 1

MEP S.p.A.


Idler wheel and Drive wheel assembly

Blade back cover assembly

6--1147

NR. Code Description Quantity5 025.0273 ANTI--CHIP COVER 1

6 025.0072 TAPERED BEARING 1

96 001.6102 IDLER WHEEL 1

99 010.0363 NUT 1

101 010.6103 DRIVE WHEEL 1

102 010.1201 DRIVE SHAFT WASHER 1

103 010.1201 HEX. HEAD SCREW 1

NR. Code Description Quantity100 031.0876 BLADE 1

104 016.0949 BLADE BACK COVER 1


106 010.1201 WASHER 4

MEP S.p.A.


Control panel assembly

6--1349

NR. Code Description Quantity92 010.4061 SPRING 2

95 010.1201 LOCK NET 2

202 010.1682 BOLT 2

208 031.5002 WARNING PASTER 1

209 016.0232 CONTROL BOX BASE 1



213 010.1201 WASHER 4

214 367.9133 LABLE FOR NAME PLATE 1

215 016.0715 CONTROL SWITCH ASSEMBLY 1

MEP S.p.A.


Base assembly

6--1551

NR. Code Description Quantity67 025.0967 TAPERED BEARING 169 025.0277 ANTI--CHIP COVER 1161 031.5001 SCALE 1162 010.1201 RIVET 2194 001.6106 SWIVEL ARM 1195 010.1201 HEX. NUT 2198 010.1201 HEX. HEAD SCREW 2200 010.2070 BUSHING 1201 010.0354 NUT 1203 010.2083 COVER 1204 010.1201 HEX. SOCKET HEAD SCREW 2205 010.1201 SPRING WASHER 2207 010.1201 HEX. SOCKET HEADLESS SCREW 1210 034.0900 OIL LEVEL GAGE 1216 034.0903 HEX SOCKET PLUG 1218 025.0255 O--RETAINER RING 1219 010.1201 SPRING WASHER 6220 010.1201 HEX. SOCKET HEAD SCREW 6221 013.0202 STAND 1221--1 001.6107 SWIVEL ARM BASE 1222 016.0193 FILTER 1223 010.1201 CROSS ROUND HEAD SCREW 2224 010.1201 HEX. HEAD SCREW 2225 010.1201 HEX. NUT 2227 010.1201 HEX. HEAD SCREW 2228 010.1201 SPRING WASHER 2229 016.1246 FIXED PLATE 1230 010.1201 ROUND HEAD SCREW 4231 010.1201 HEX. SOCKET HEAD SCREW 1232 010.3463 NUT 1233 001.6001 ADJUSTABLE HANDLE 1240 028.0271 COOLING PUMP 1241 010.1201 CROSS ROUND HEAD SCREW 2242 010.1201 SPRING WASHER 2243 043.0227 MICRO CONTROL BLOCK 1244 043.0204 STRAIGHT CONNECTOR 1245 028.0193 PU TUBE 1247 010.1201 CROSS ROUND HEAD SCREW 2248 016.0193 FLUID COLLECTED PLATE 1249 016.1040 FEED SUPPORT 1

MEP S.p.A.


Control panel assembly HB

6--1753

NR. Code Description Quantity67 025.0967 TAPERED BEARING 169 025.0277 ANTI--CHIP COVER 1161 031.5001 SCALE 1162 010.1201 RIVET 2194 001.6106 SWIVEL ARM 1195 010.1201 HEX. NUT 2198 010.1201 HEX. HEAD SCREW 2200 010.2070 BUSHING 1201 010.0354 NUT 1203 010.2083 COVER 1204 010.1201 HEX. SOCKET HEAD SCREW 2205 010.1201 SPRING WASHER 2207 010.1201 HEX. SOCKET HEADLESS SCREW 1210 034.0900 OIL LEVEL GAGE 1216 034.0903 HEX SOCKET PLUG 1218 025.0255 O--RETAINER RING 1219 010.1201 SPRING WASHER 6220 010.1201 HEX. SOCKET HEAD SCREW 6221 013.0202 STAND 1221--1 001.6107 SWIVEL ARM BASE 1222 016.0193 FILTER 1223 010.1201 CROSS ROUND HEAD SCREW 2224 010.1201 HEX. HEAD SCREW 2225 010.1201 HEX. NUT 2227 010.1201 HEX. HEAD SCREW 2228 010.1201 SPRING WASHER 2229 016.1246 FIXED PLATE 1230 010.1201 ROUND HEAD SCREW 4231 010.1201 HEX. SOCKET HEAD SCREW 1232 010.3463 NUT 1233 001.6001 ADJUSTABLE HANDLE 1240 028.0271 COOLING PUMP 1241 010.1201 CROSS ROUND HEAD SCREW 2242 010.1201 SPRING WASHER 2243 043.0227 MICRO CONTROL BLOCK 1244 043.0204 STRAIGHT CONNECTOR 1245 028.0193 PU TUBE 1247 010.1201 CROSS ROUND HEAD SCREW 2248 016.0193 FLUID COLLECTED PLATE 1249 016.1040 FEED SUPPORT 1

MEP S.p.A.


Vise assembly (A)

Vise assembly (B)

PH 211

6--1955

NR. Code Description Quantity170 034.0293 HANDWHEEL 1

171 010.1201 PIN 1

172 010.2085 BEARING COVER 1

173 025.0965 BEARING 1

174 001.6002 VISE HANDLE 1

175 010.0892 SPRING 1

176 010.1700 BUSHING 1

180 001.6108 VISE JAW BRACKET 1

181 010.0528 VISE 1

182 010.1201 HEX. SOCKET FLAT HEAD SCREW 2

183 010.1201 WASHER 1


190 010.0237 LEADSCREW A 1

191 010.1201 HEX. SOCKET HEADLESS SCREW 1

192 010.1201 HEX. NUT 1


NR. Code Description Quantity162 010.1201 RIVET 2

164 034.0104 DISTANCE SET BRACKET 1

164--1 034.0104 PLUM HANDLE 1

164--2 010.1201 HEX. HEAD SCREW 1

165 010.2355 DISTANCE SET ROD 1

166 010.1201 HEX. NUT 1

178 010.1201 WASHER 1


186 001.6109 VISE JAW BRACKET 1

196 010.3705 VISE JAW ADJUSTABLE ROD 1

197 025.0257 O--RETAINER RING 1

MEP S.p.A.


Stand leg assembly

6--2157

NR. Code Description Quantity234 010.1201 WASHER 4


250--1 013.0203 STAND LEG (FRONT) 2

250--2 013.0203 STAND LEG (RIGHT) (LEFT) 2

253 010.1201 HEX. HEAD SCREW 12

254 010.1201 WASHER 24

255 010.1201 HEX. NUT 12

7--1

Adjustments

This chapter illustrates the regulations and adjustments of the mechanicalsystems for correct use of PH211. These instructions will enable you to “custo-mise” your machine to suit the type of cuts you want, optimising the timerequired to complete them.

Vice

Vice play adjustment

Vise Jaw Bracket has been adjusted in the perfect situation. After your long termuse, if you feel vise jaw bracket slide irregular, you could use hex. wrench toadjust it by these two holes.

7

MEP S.p.A.


Cutting head

Blade tensioning unit

Before use the machine, please turn blade tension handle until shore up the screwA. To maintain the blade tension is tightened.

Also, make sure the blade tension within green area.

How to adjust blade tension:

7--360 Adjustments

" Loosen the blade tension and set the blade tension indication on the back ofblade.

" Making the blade tension go back to zero and adjust the blade tension until2250 Kgs / cm2 (32,000 Lbs / in2)

MEP S.p.A.


" Take off the blade tension chart and let the screw shore up the blade tensionhandle.

The machine enters emergency status if the blade tension is too slack. A pres-sure contact (pressure switch) disables blade start--up if the blade is not cor-rectly tensioned, since it might otherwise slip off the wheels, cut poorly or wearprematurely. This should always be born in mind when using the machine.

Adjusting operating head travel

During the cutting cycle the cutting head stroke is limited by the FCTI (HeadUpstroke Limit) and FCTA (Head Downstroke Limit). The cutting head has amechanical limiting switch that determines its downstroke:

" to change this setting, two hexagonal spanners must be used, one to keep thenut in position, and the other to tighten and loosen the stop screw.

Attention

7--562 Adjustments

Blade guide parts

Band saw blade guides offer enormous advantages where the cutting process inconcerned, without requiring any special attention by the operator. The bladeguide adjustments necessary to ensure that the blade operates correctly aredescribed below.

Blade guide heads

Blade guide heads are used to carry out a part of the blade adjustment, andinclude the blade guide bearing to control the longitudinal setup.

Bearing

Blade guide head

Bearing

Blade guide plates

The plate contact points feature widia inserts which guide the blade longitudinal-ly. A small amount of play must exist between the plates and blade to ensure thatthe blade runs smoothly and perpendicular to the work table.

Thanks to the widia inserts, the working life of the guide plates is practically thesame as that of the machine itself. However, if due to wear or the assembly of anew blade with a different thickness, the amount of play between the plates andblade changes, the plates must be adjusted as follows:

" disconnect the machine from the power supply;" slacken the blade tension using the handwheel;

MEP S.p.A.


" open the front blade guard by undoing the fixing screw and rotating it as illus-trated in the figure below;

" wear protective gloves when making this adjustment;" make sure there is a small amount of play between the blade and guide plateinserts;

7--764 Adjustments

" if the amount of play is not sufficient for the blade to run smoothly, adjust thelocking torque of the two grub screws with an Allen key;

" replace any worn plates by removing the plate fixing screw;" repeat the above sequence of steps on the rear blade guide head;" refit the front blade guard;" tension the blade and power up the machine again.

MEP S.p.A.


Blade

The adjustments required to ensure correct operation of the blade are describedbelow. For further information about band saw blades, refer to Chapter 9 whichprovides a more detailed description of the different types of blade.

Tool change

Optimum working conditions both enhance operator safety and extend the tool’sservice life. The cutting tool should in any case be replaced when poor cuttingperformance starts to affect productivity. The tool changeover procedure isdescribed as follows:

" disconnect the machine from the power supply;" slacken the blade tension using the handwheel;" open the cutting head cover by 4 screws and take off the body frame cover

" open the front blade guard by undoing the fixing screw and rotating it as illus-trated in the figure below;

7--966

" remove the rear blade guard by undoing the two fixing screws using an Allenkey;

" wear protective gloves when changing the blade;" remove the worn blade by sliding it off the flywheels and front and rear heads;" fit the new blade into the front blade guide head;" make sure the back of the blade is facing the flywheel stop and that the teethalong the lower part of the blade are inclined towards the head pivot.

" Make sure there is a small amount of play between the blade and guide plateinserts;

" repeat the above sequence of steps on the rear blade guide head;" fit the blade on the flywheels and remount the front and rear blade guards;" close the cutting head cover, correctly tension the blade and power up the ma-chine.

MEP S.p.A.


Blade perpendicularity

The perpendicularity of the blade to the work surface, and also the blade tension,are vital for achieving straight cuts. This adjustment is carried out with the help ofa workshop square, which should be placed adjacent to the blade resting on thework surface.

" Position the square on the cleaned work surface and rest it against the blade,close to the right vice jaw at a point where the blade teeth do not prevent con-tact.

" Slacken the TCEI head fixing screw (A) and adjust the two grub screws (B) ifthe blade touches the square at its lower part. If the point of contact is at theupper part, slacken the TCEI screw (A’) and tighten grub screws (B’) equallyuntil the blade is perpendicular to the square.

7--1168

" Position the square on the work surface close to the front head.

" Repeat the squaring operations as for the rear head.

Orthogonality of the blade

The procedure for correcting and adjusting the blade to 0˚, 45˚ right and 45˚ and60˚ left, to make cuts at right angles to the fixed vice jaw is described below.To make orthogonal adjustments at 0˚, use a workshop goniometer or a simple90˚ square. Operation sequence:

" lower the head;" position the goniometer or square, resting it on the fixed vice jaw adjacent tothe blade;

MEP S.p.A.


" Slacken the head locking lever, by gripping it from the operator side and pu-shing it forwards.

" Slacken the nut and, holding it firm with a hex wrench, adjust the stop screwuntil the right angle error shown on the goniometer is corrected.

" Retighten the nut to lock the stop screw in the correct position." Finally, lock turntable and head rotation by pulling the locking lever back to-wards you.

To adjust the 45˚ and 60˚ fixed points, you will need a workshop goniometeror an instrument that can measure the exact angle of the blade.

Warning

7--1370

" Operation sequence:" Slacken the head locking lever by pushing it forwards." With the head raised, rotate the unit to 45˚ or 60˚." Lower the head." Position the goniometer or graduated square against the fixed vice jaw, adja-cent to the blade.

" Slacken the nut (opposite side to previous one) on the stop screw while hol-ding it firm with a hex wrench.

" Adjust the stop screw until the angle error registered by the goniometer iscorrected. This done, lock the nut while holding the screw steady.

" Make sure all the stops are secure and that the locking lever is pulled back(locked).

8--1

Maintenance andchoice ofconsumables

PH211 is built to be sturdy and long---lasting It has no need of any specialmaintenance, though, like all other tools, it needs adjusting from time to time,especially if not regularly looked over or used without due care.

This chapter, therefore, is intended as a guide for those who want to look afterthe machine and get the most out of it for as long as possible.

The role of the operator

The person operating and maintaining the machine must follow these instructionsfor his own safety, as well as for the safety of other personnel, and in the interestsof machine productivity:

H check that his own work and that of the other operators of the machine alwayscomplies with the relevant safety standards. Therefore, check that the safetydevices are in position and work perfectly and that personal safety requirements arecomplied with.

H Ensure that the working cycle is efficient and guarantees maximum productivity,checking:

n the functions of the main components of the machine;

n the sharpness of the blade and coolant flow;

n the optimum working parameters for the type of material.

H Check that the quality of the cut is that required and that the final product does nothave any machining defects.

8

MEP S.p.A.


Maintenance requirements

H All ordinary and extraordinary maintenance must be carried out with the powerswitched off and the machine in emergency condition.

H To guarantee perfect operation, all spare parts must be MEP S.p.A originals.

H On completion of maintenance works, ensure that the replaced parts or any toolsused have been removed from the machine before starting it up.

H Any behaviour not in accordance with the instructions for using the machine maycreate risks for the operator.

H Therefore, read and follow all the instructions for use and maintenance of the ma-chine and those on the product itself.

General maintenance

Daily

The daily maintenance operations to carry out on the machine are as follows:

" remove all swarf from the machine (preferably with a non---fibrous cloth);

" empty the swarf drawer (this is located on the right side of the base);

" top up the lubricant/coolant level;

" check state of blade wear and replace if necessary;

" check the blade cleaning brush, clean and relocate; if worn, replace;

" at the end of the working day, slacken the blade to 5 Bar (70 Kg) tension toprevent unnecessary and damaging stress on the machine.

Weekly

The weekly maintenance operations are as follows:

" remove all swarf;

" clean the vice and lubricate all joints and sliding surfaces with a good qualityoil;

" check vice sliding; if it is not precise and has transversal play, adjust as in-structed in Chapter 7.

8--373 Maintenance and choice of consumables

Monthly

This section lists the operations to be carried out for the monthly maintenance ofthe machine:

" check the perpendicularity of the blade to the work surface; if it is necessaryto adjust the blade setting, follow the instructions set out in Chapter 7;

" check on blade orthogonality with respect to the workpiece rest shoulder; ifadjustment is necessary, proceed as instructed in Chapter 7;

" check that the 0˚ notch on the work table is in line with the graduation on theturntable; if not, readjust by regulating the 0˚ stop; then re---check that theblade is perpendicular and orthogonal;

" check the precision of the 45˚ left stop; if out---of---set, adjust following thesteps indicated in Chapter 7;

" check the state of the widia inserts and the blade steady button; replace ifworn or chipped; check their positions and adjust if necessary (see Chapter7);

" thoroughly clean the bottom of the water tank and the electropump filter;

Maintenance of working parts

In maintenance work on the PH211, special attention should be paid to operatingunits such as the blade tensioning cylinder, already dealt with in Chapter 7,topping up levels, the air treatment unit, the pneumatic vice on the MA version,and the optional CUT CONTROL SYSTEM. The transmission box equippingthe machine needs no maintenance.

Consumable materials

Only specified oils must be used for the hydraulic and pneumatic and forlubricant/coolant devices. Below is a list of compatible oils for each of thesecircuits.

Oil for transmission box

The machine is equipped with a worm gear which is permanently lubricated andtherefore maintenance---free. The box has no filler cap, level checker and drain,as it already contains the correct quantity of synthetic oil, guaranteeing perpetuallubrication of the crown and worm gear. Below is a short list of synthetic oils forpermanent lubrication:

BP Energol SG XP220 --- KLUBER Syntheso D220EP ESSO Glycolube Range220 --- IP CT614 --- SHELL Tivela Oil SC 320 FINA Girans.

--- transmission box capacity Lt. 0.320

Oil for lubricant/coolant fluid

The oil used for the machine lubricant/coolant fluid is CASTROL Syntolin TFX.Though there are no specific standards for these types of oils, MEP considers

MEP S.p.A.


that the above product has the best price/quality rapport. The following oils canalso be said to have similar characteristics and are therefore compatible:

AGIP NB 200 --- SHELL Lutem TT --- IP Utens Fluid---F

Finally, a lubricant/coolant guaranteed and distributed by a band saw manufactu-rer (LENOX) is BAND---ADE SAWING FLUID LENOX.

--- tank capacity Lt. 13--- oil concentration 5---6 %

9--1

Cutting speed andchoice of tools

The cutting speed is determined by the blade speed and the head feed speed.While the head speed is provided by the downstroke movement of the head, theblade rotation speed can either be fixed or variable. This chapter describes thecutting speeds the machine can operate at in the standard version, as well as thespeeds for which the optional electronic speed controller (inverter) is necessary.When using the PH211, it is important to select the correct type of blade for thematerial to be cut. This chapter explains the limitations and specific applicationsof the different types of blades.

Cutting speed

Standard machine

The basic version with 2/4 pole motor, is provided with the following cuttingspeeds:

H 1st speed = 40 m/min. (4 pole)H 2nd speed = 80 m/min. (2 pole)

These speeds are selected using the polarity change switch situated on the controlpanel.

Choice of blade

When using band saws to cut metals, an important factor is the choice of pitch,i.e. the number of teeth per inch (25.4 mm.), which must be suitable for theworkpiece material. The following recommendations may be taken as generalguidelines:

H thin---walled materials, such as sheet steel, tubes and profiles require a finepitch frequency. 3 to 6 teeth should be engaged in the breadth of the materialat any one time;

H large section cutting requires a coarse pitch to cope with the higher volume ofswarf and optimal tooth penetration;

H soft materials (aluminium alloys, soft bronze etc.) also require a coarse toothpitch.

Saw tooth pitch

The choice of teeth per inch, therefore, depends on various factors:

H the size of the section;H the hardness of the material;H workpiece wall breadth.

9

MEP S.p.A.


Very large dimensions require coarse teeth, while small dimensions require finerteeth. Whatever the case, ensure that there are always at least six teeth engagedin the cut, with reference to the thinnest vertical walls positioned transversally tothe blade.Concerning the type of Shark machine, a first broad distinction can be madeaccording to the hardness of materials:

< 61 HRB > 65 HRB< 55 Kg/mm2 > 65 Kg/mm2

3 / 4

4 / 6

8 / 12

5 / 8

6 / 10

10 / 14

Mild steels

MINIMUM

OPTIMUM

MAXIMUM

Hard steels

NR. TEETH/INCH NR. TEETH/INCH

Cutting speed and downstroke speed

The cutting speed (m/min) and the downstroke speed (cm2/min) are limited bythe heat generated around the points of the teeth. If the downstroke speed is toohigh, the cut will not be straight, either vertically or horizontally.

The cutting speed depends, as indicated above, on the tensile strength of thematerial (kg/mm2), its hardness (HRB) and the thickness of largest sections. Thedownstroke speed depends on the material thickness. Therefore, large---section,solid or thick---walled materials (s > 5 mm), can be cut at high speeds, providingthere is sufficient swarf removal from the blade; thin---walled materials, such asslim piping or profiles, must be cut using low and especially constant downstrokespeeds.

A new blade must be worn in, which in effect means lowering the downstrokespeed to about half that of normal (from 60 to 70 cm2/min on normal steels),equal to a removed surface area of about 300 --- 600 cm2.

Types of swarf:

H Very fine or fragmented swarf indicates that the downstroke speed and/or cuttingpressure is too low.

9--377 Cutting speed and choice of tools

H Thick and/or blue swarf indicates that the blade is overloaded.

H Long coils of swarf indicate ideal cutting conditions.

Lubricant/coolant fluid

The lubricant/coolant fluid must ensure so that neither the saw teeth nor the workpiece material in the cutting zone overheat. Furthermore, there must be asufficient quantity and pressure of lubricant/coolant to remove swarf from thecutting zone. The lubricant/coolant fluid must be of the highest quality in order toprevent tooth abrasion and welding of swarf to the teeth themselves (seizing).

MEP S.p.A.


Blade structure

The most commonly used blades are the bimetal types, i.e. manufactured with asilicon steel body and having a high fatigue strength, and super high---speed steelteeth; the two parts are welded by electronic or laser---welding.

Standardised teeth types are termed M2 and M42; the difference being that M42teeth are harder due to the addition of cobalt to the steel used to make the teeth.

Key

Mo Molyb-denum

Ni Nickel Si Silicon V Vanadium W Tungsten

Al Aluminium C Carbon Co Cobalt Cr Chromium Mn Manganese

HSS M2

HSS M42

C Mn Si W Mo V Ni Co Al HRCCr

0,47 0,75 0,22 1,00 1,00 0,12 0,52 0,08 45--50

0,85 0,25 0,30 4,15 6,37 5,00 1,92 64--66

1,07 0,25 0,20 3,75 1,50 9,50 1,15 8,00 67--69

HRC 67--68

HRC 45--50

HRC 65--66

HRC 45--50

TYPE OFBLADE

The numbers in the columns indicate the % content of the element in the steel.

Blade types

The blades mounted on the PH211 are 2.085 x 20 x 0,9 mm.; the length can varybetween 2.075 mm. and 2.095 mm., thanks to the blade tensioner device. Theblades, however, apart from size and tooth pitch, are differentiated by othergeometrical characteristics which determine their specialised uses:

H tooth cutting angle (rake), can be 0 or positive;

H the tooth pitch can be constant or variable;

H the set, i.e. the various teeth alignments, have many possible configurations.

N.B.


Conventional rake

Cutting angle 0˚, constant pitch.

In general use, for small or medium section cast iron or steels and rolledmaterials, for straight or angled cuts.

Positive rake

Positive cutting angle 9---10˚, constant pitch.

Can be used for cutting all types of materials, and is particularly suited tolow---carbon and non---ferrous steels. Used for cutting very large sections anddiameters.

Variable pitch

These blades have groups of teeth having different pitches and, as a consequence,have various tooth dimensions and differing relief angles. These are also availablein M2 and M42 types with zero and positive rakes. The alternation of thedifferent types of teeth helps to prevent vibration and noise. Elimination ofvibration increases the useful life of the tool and improves the cut surface finish.

A further advantage in using these types of blades lies in the fact that a widerange of different material types and dimensions can be cutwith the same blade.

MEP S.p.A.


Variable pitch blades with 0˚ cutting angle

This type of tooth formation is ideal for cutting single pipes or medium sizebundles, in accordance with the capacity of the machine.

Pitches available: 3---4 / 4---6 / 5---7 / 5---8 / 6---10 / 8---12 / 10---14.

Variable pitch with positive rake (from 9 to 10 degrees)

This toothing type is the most suitable for cutting large dimension pipes andprofiles, including large sections, as well as for cutting solid sections up to themachine capacity limit.

Pitches available: 3---4 / 4---6.

Set:

The term set refers to the section of material removed by the blade during thecutting operation, i.e. relating to width of cut and the offset position of the teethwith respect to the blade back.

Standard or splayed set

This term is used to describe an alternated angling of the teeth: one to the right, oneto the left and one straight.


For general use on materials over 5 mm. thick. Suitable for cutting steels, castingsand non---ferrous hard materials.

Undulated set

Used to describe groups of teeth undulating alternatively to the right and left.

This type of set is used with very fine teeth for cutting thin pipe walls andsmall---section profiles (from 1 to 3 mm).

Alternating grouped sets

These are groups of teeth angled to the right, one straight tooth, then a furthergroup angled to the left.

This set is used for very fine teeth for cutting very thin sections (less than 1 mm).

Alternating set

This set is one tooth to the right followed by one to the left.

This set is used for soft non---ferrous materials, plastics and wood.

MEP S.p.A.


Blade selection table relating to cutting speed and downstrokespeed

50/70

40/50

30/40

30/40

90/150

90/300

20/40

80/800

90/400

14 14 14 14 14 14 14 14 14

10 10 10 10 10 10 10 6 6

8 8 8 8 6 6 6 4 4

6 6 6 6 4 4 4 3 4

4 4 4 4 3 3 3 3 3

3 3 3 3 3 3 3 3 3

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

10/14

6/10

6/10

6/10

6/10

5/8

5/8

5/8

4/6

4/6

5/8

5/8

5/8

5/8

4/6

4/6

4/6

3/4

4/6

4/6

4/6

4/6

4/6

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

60--70

50--60

15--20

15--20

75--90

80--90

25--40

70--80

80--90

S<10

10<S<30

30<S<50

50<S<80

80<S<120

120<S<230

Dimensionsofthecutting

sectionS(m

m)

Cutting

speed

mt./min

Cuttingmaterial

Bladepitch

Number

ofteethper

inch

Lubrication

sq.m

t./

min.cut

Structuralsteel

Casehardenedsteel

Steelforturning

Mild

steel

High--dutycastiron

Rolledsteel

Springsteel

Alloysteel

Toolsteel

Valve

steel

Stainless

steel

Nodularcastiron

Copper

Softbronze

Brass

Hardbronze

Aluminium

Plastics

Cuttingfluid

Emulsibleoil

Emulsibleoil

Emulsibleoil

Emulsibleoil

Emulsibleoil

Emulsibleoil

Emulsibleoil

Emulsibleoil

Cuttingfluid

Emulsibleoil


Classification of steelsThis page provides a table giving the user specific information on the cuttingmaterials, in order that they can be classified on the basis of their hardness, andthus the correct tool can be selected for the task in hand.

AISI

DIN

BS

UNI

C22

--C35

C45

C10

--C15

C60

45CrSi9

34CrMo5

35CrMo4

20NcCrMo2

X8CrNiM

o1713

XCrNi1910

X6CrNi1810

X12

Cr13

100Cr6

52NcCrMoKU

CK22

--CK3

CK45

CK10

--CK15

CK60

17115

17221

34CrMo

36NiC

r6

1880

XC95

2750

(280W18)

4401

4301

4001

4845

210Cr46

17100

100Cr6

56NiC

rMoV7

En2C--En6

En8

En32

A--En328

En9

4360

970--1955

En18

B

En19

B

En111

En362

En100D

DX

B2

18%W

1507

--825

1501

--845

En58

E

En56

A

En58

G

A1

A2

En36

4360

--50

A3706

--1.2.3.

En20

A

En31

1022

--1035

1040

1010

--1015

1060

1065

5135

--5145

4135

3135

4315

8645

W1

L6

T1

1310

316

304

410

309S

D3

M13

3310

--3315

ASTMA--36/68

52100

BrinellH

BHRB

Kg/mmq

160--170

160--180

150--175

160--180

160--180

180--205

180--200

200--230

190--230

200--225

190--220

150--190

190--230

217--248

217--248

160--200

130--170

150--200

215--240

200--230

160--220

200--230

160--180

160--180

190--215

210--230

150--200

60--100

70--90

95--120

70--100

34--87

84--89

81--87

84--89

84--89

89--94

89--93

93--99

91--99

93--98

91--97

80--91

91--99

97--102

97--102

84--93

74--86

80--93

97--101

93--99

84--91

93--99

84--89

84--89

91--97

96--99

80--93

56,5

49

51--69

56,5

55--59

55--61

51--59

55--61

55--61

61--69

61--67

67--77

64--77

67--75

64--74

51--64

64--77

73--83

73--83

55--67

45--58

51--67

73--81

67--77

55--64

67--77

55--61

55--61

64--73

71--77

51--67

36 32 34--42

36

Types

ofsteel

Phosphorbronze

Aluminiumbronze

Siliconbronze

Manganesebronze

Hardness

MEP S.p.A.


Classification of steels

1311

1572

1650

1880

2120

2255

2541

2230

2258

2310

--12

2754

--55

2550

2710

2324

2333

2343

2353

1015

--1035

1040

--1064

1770

--1880

1335

--1345

4130

--4140

4337

--4340

50100--52100

6145

--6152

8630

--8645

D--2,D--3

S--1

201,202

302,304

314,316

317

C22

--C35

20Mn5--28

Mn6

CK22

--CK50

CK60

--CK101

36Mn5

Cm45

--Cm55

25CrMo4--42

CrMo4

40NiC

rMo6

40NiC

rMo73

34CrNiM

o6,100Cr6

X210Cr12

X155CrVMo121

60W

CrV7

55NiC

rMoV6

X2CrNi189

X5CrNi189

G--X2CrNi189

X15

CrNiSi2520

X5CrNiM

o1812

X5CrNiM

o1713

050A20

080M46

--50

120M19

150M28

060A40

--060A96

070M55

080A40

--080A62

1717

CDS110

708A37

708M40

735A50,534

A99

817M40

311tipo6e7

BD2,BD3

BS1

304S15

304C12

316S16

317S16

XC18

XC38

H1

20M5

XC60

--XC75

40M5

XC42

H1

25CD4

35NCD6

50CV4

100C6

Z160CVD12

Z200C12

55NCVD7

Z2CN18.10

Z6CN18.09

Z3CN19.10

Z12

CNS25.20

Z6CND17.12

304S12

C15

--C35

C22

Mn

C28

Mn

C45

--C60

40NiC

rMo2--40

NiC

rMo7

30NiC

rMo8--35

NiC

rMo6KB

50CrV4,100Cr6

X205Cr12

KU

X155CrVMo121KU

55W

CrV8Ku

55NiC

rMoV6

X2CrNi18.11

X5CrNi18.10

G--X2CrNi19.10

X16

CrNiSi2520

X5CrNiM

o1713

X5CrNiM

o1815

25CrMo4--42

CrMo4

XC55

H1

42CD4

Material

Carbonsteels

Carbonsteels

Alloysteel

Stainlesssteel

Stainlesssteels

Toolsteel

Toolsteels

Alloysteels

10--1

Troubleshooting

This chapter describes the inspection and troubleshooting procedures for thePH211. Regular inspections and efficient maintenance are essential to ensureyour machine gives you a long, trouble---free service life. The chapter is dividedinto two sections: the first being dedicated specifically to TROUBLESHOOTINGBLADE AND CUTTING PROBLEMS, while the second TROUBLESHOOT-ING section concerns troubleshooting general machine operating faults. Takentogether they form a comprehensive troubleshooting guide which will enable youto follow a methodical procedure for solving any problem.

Troubleshooting blade and cutting problems

PROBLEM PROBABLE CAUSE SOLUTION

Blade scored or scratched ' Widia inserts chipped or worn .Replace

' Widia inserts loose or tight .Adjust

' Widia inserts dirty .Clean and re--adjust correctly

Cutting surfaces scored ' Blade teeth worn .Replace blade' Head downstroke speed toofast

.Reduce downstroke speed

' Cutting speed too slow .Increase cutting speed' Blade teeth too wide .Change for wider teeth' Free blade guide head toofar away

.Move blade guide head clo-ser so as to leave only thatpart of the blade free which isneeded to effect the cut

' Blade tension low .Reset tension to rated ten-sion

' Broken teeth on blade .Check and replace blade

10

MEP S.p.A.


SOLUTIONPROBABLE CAUSEPROBLEM

Rapid tooth wear ' Teeth pointing in the wrongdirection

.Set teeth in correct direction

' Blade worn in wrongly .With a new blade cuttingshould be done at half--spe-ed and with downstroke spe-ed also at half normal speed.After the blade has beenworn in (about 300 cm2 ofwork for hard cutting ma-terials and about 1000 cm2

for soft cutting materials) thecutting and downstrokespeeds can be brought up torated levels

' Material too hard .Check cutting speed, down-stroke speed and blade pres-sure, as well as type of bandsaw being used

' Material defective .Surface defects: oxides,sand, surface hardening.Hardened inclusions in sec-tion.Reduce cutting and down-stroke speeds or clean surfa-ce.

' Cutting speed too high .The teeth slide on the mate-rial without cutting: reducecutting speed

' Head downstroke speed tooslow

.The band saw runs over thematerial without removing it:increase downstroke speed

' Insufficient coolant .Check coolant level andclean pipes and jets

' Incorrect fluid concentration .Check and use the correctconcentration

' New blade inserted into apartially--made cut

.The cutting surface might ha-ve been subject to a locali-sed heat--induced alteration,making it harder: recommen-ce cut using a slower cuttingand downstroke speed. The-re may be a broken toothfrom the old blade lodged inthe cut: check and removebefore recommencing work

' Flutter .Blade tension too low:tighten.Tooth shape or pitch unac-ceptable: change type of bla-de used.Widia blade steady buttonstoo far from the blade back:adjust guide heads, rotatingthem slightly to bring themcloser to the blade back.

10--387 Troubleshooting


Cuts not orthogonal or inclined ' Head downstroke speed toofast

.Reduce head downstrokespeed

' Widia inserts worn .Replace' Inserts loose .Adjust width' Blade guide head positionedwrongly

.Move mobile head up to theworkpiece using the guideplate to leave free only thatpart of the blade actuallyneeded to make the cut

' Orthogonality of blade toworkpiece rest shoulder

.Check and realign the bladeguide heads, then reset theblade orthogonality with theshoulder using the adjust-ment pin at 0˚; then set thestops at 45˚ right and left bymeans of the appropriatescrews

' Perpendicularity of the bladeto the work surface

.Check and realign the bladeguide heads then adjust theblade using the appropriatescrews so that it is perpendi-cular to the work surface

' Blade tension incorrect .Bring pressure up to 60 Bar' Blade worn .Replace blade' Tooth pitch unsuitable .Probably a blade with too

many teeth per inch is beingused; change for a coarserblade

' Cutting speed too slow .Increase the cutting speed' Wrong coolant .Check the water and oil

emulsion; check that none ofthe holes or hoses are bloc-ked; direct the jets correctly

' Broken teeth .Check the hardness of thematerial being cut

Broken teeth ' Cutting speed too high .Reduce cutting speed

' Downstroke speed too high .Reduce downstroke speed

MEP S.p.A.



Broken teeth ' Cutting pressure too high .Check and set to correctpressure

' Tooth pitch unsuitable .Teeth too close together:change blade for one with acoarser tooth pitch

' Swarf welded to teeth andgullets

.Check blade--cleaning coo-lant jets. Check the blade--cleaning brush. If the swarf isnot removed from the blade itwill be drawn back into thecut and weld to the teeth,causing tooth breakage

' Swarf welded to teeth andgullets

.Check blade--cleaning fluidjets. Check blade--cleaningbrush. If the swarf is not re-moved from the blade it willbe drawn back into the cutand weld to the teeth, caus-ing the teeth to break.

' Material defects .The material may have al-tered surface areas, such asoxides or sand, or subcooledinclusions in the section.These areas are muchharder than the blade andwill cause the teeth to break:scrap or clean these ma-terials.

' Workpiece not clamped .The blade may break if theworkpiece moves during cut-ting: check the vice, jaws andclamping pressure

' The blade stops in the cut .Cutting pressure too high:check and restore to ratedpressure. Downstroke speedtoo fast: reduce speed. Cut-ting speed too slow: in-crease. The blade slips onthe flywheels: either thewheels are worn and need tobe replaced or the blade ten-sion is incorrect (too low) andmust be re--adjusted.

' New blade inserted in a par-tially made cut

.The cutting surface mayhave been subjected to a lo-calised heat--induced alter-ation, making it harder: re-commence cut using aslower cutting and down-stroke speed. A tooth fromthe old blade may be left inthe cut: check and removebefore restarting work.



Broken teeth ' Widia inserts positioned in-correctly

.Adjust the position of the in-serts, especially the width,since blade thicknesses canexceed the manufacturer’sdeclared tolerance ratings

' Widia blade steady buttons .Two widia blade steady but-tons are located in the top ofthe blade guide heads whichpress on the back of theblade to transmit cuttingpressure. If these buttons aretoo far from the blade, theblade may be prone to an upand down undulating actionor abnormal vibrations, liableto cause the teeth to break:adjust the position of theheads by rotating themdownwards so as to bring theblade steady buttons upagainst the back of the blade

' Sections with large thicknessvariations

.The cutting speed and down-stroke speed must be chosento suit the most critical part ofthe cut

' Teeth angled in the wrongdirection

.Fit blade so that teeth pointin the right direction

' Blade run in wrongly .When using a new blade, thecutting and downstrokespeeds must be reduced tohalf the normal operatingspeed. After the blade hasbeen worn in (about 300 cm2for hard materials and about1000 cm2 for soft materials)the cutting and downstrokespeeds may be returned totheir rated levels

' Insufficient coolant .Check coolant level andclean fluid lines and jets


' Blade tension too high or toolow

.Check and reset to rated ten-sion

MEP S.p.A.



Blade path fault ' Front flywheel position incor-rect

.Check that the band saw iscorrectly positioned on theflywheel. Adjust the positionof the flywheel under the bla-de, moving the shaft of theflywheel

' Flywheels worn .Replace

' Gaps full of swarf .Clean inside machine usingblown air.

' Blade guide head alignment .Check and adjust

Blade broken ' Cutting speed too high .Reduce cutting speed' Head downstroke too fast .Reduce head downstroke

speed' Cutting pressure too high .Check and set to correct

pressure' Tooth pitch unsuitable .Teeth too close together:

change the blade for onewith coarser tooth spacings

' Workpiece not clamped pro-perly

.The blade may break if theworkpiece moves during cut-ting: check the vice, jaws andclamping pressure.

' Widia inserts positioned in-correctly

.Adjust inserts position, espe-cially the width, since bladethickness can exceed themanufacturer’s declared tole-rance ratings

' Widia blade steady buttons .Can have a milling action onthe back of the blade if wornor chipped, causing cracksfrom the back towards the te-eth.

' Position of blade on flywhe-els incorrect

.The blade may be scrapingon the edges of the flywhe-els: this problem is generallycaused by blades which aredeformed or wrongly welded(conical) Adjust the positionof the front flywheel by mo-ving the pin, or change theblade

' Blade tension incorrect .If the blade tension is toohigh or too low, the blade willbe subjected to abnormalstress: set the tension backto the rated value.



' Blade weld fault .The point at which a blade iswelded is its most criticalpoint; problems could becaused by welds which arenot aligned perfectly or haveinclusions or blowholes

' Free blade guide head .The head is too far awayfrom the workpiece: move thehead closer, leaving free onlythat part of the blade actuallyneeded to make the cut

' Teeth in contact with the ma-terial before starting the cut

.Always check the position ofthe blade before starting anew job, especially for thesemi--automatic cycle

' Widia inserts .If worn, the inserts can scorethe blade, weakening it evento breaking point. If the in-serts are too far apart, theblade will whip, striking boththe inserts and the material.Replace or adjust

' Insufficient coolant .Check coolant fluid level;clean pipes and jets


' The blade stops in the cut .Cutting pressure too high:check pressure and reset torated pressure.Head downstroke speed toofast: reduce.Head downstroke speed tooslow: increase.The blade slips on the flyw-heels: incorrect or low bladetension; readjust or increase.

MEP S.p.A.


Troubleshooting machine faults

PROBLEM PROBABLE CAUSE SOLUTION

The main switch does not work ' Electrical supply .Check: phases, cables, plug,socket

' Minimum voltage relay .Check that it is correctly sup-plied and not burnt out

The STAND BY LED doesnot come on

' LED burnt out .Replace

' Electrical supply .Check: phases, cables, plug,socket

' Minimum voltage relay .Check that it is correctly sup-plied and not burnt out

' Transformer supply .Check transformer input fu-ses 1 and 2.Check transformer 24 V se-condary output.Check 24V output fuse.

Spindle motor will not turn ' Electrical power supply .Check: the phases; thecables; the plug; the socket.Also check that the motorconnections are in place.

' Motor contactor .Check input and output pha-ses and check whether whensupplying A1 and A2 relaythe contactor closes.

' Polarity change switch .Check input and output pha-ses

' Head control lever micros-witch

.Check that it is functioning; ifbroken, replace

' Blade tensioning .If the blade is not correctlytensioned to 60 Bar, thepressure contact does notclose and the machine is inEMERGENCY state

' Blade protection cover .Check that the closure is cor-rect and the limit stop pres-sed

' Current drop .Check connections on thehandgrip switch, the bladeprotection limiter and thepressure gauge on the bladetensioner group



BMT not energised (MinimumTension Coil)

' Electrical power supply .Check: the phases; thecables; the plug; the socket.

' BMT Reset switch .Make sure that the minimumtension coil is energisedwhen switch is turned from 0to 1. If it is not, replace theswitch.

' Emergency stop pushbuttonin

.Make sure the emergencystop button is released: turnit clockwise through 1/4 of aturn to release it.

Electropump is not working ' Electrical supply .Check: phases, cables, plug,socket and fuse no. 5 in theelectrical plant

' No--return valve .Clean, if blocked replace' Filter .Clean

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