Installation and maintenance instructions

for:

POLARIS
band sawing machines for metal

Before installing the machine and before attempting any operation,

please read the following instruction and operation manual carefully.
If you have any doubt or queries please contact:
F.M.B. s.r.l. FABBRICA MACCHINE BERGAMO, via Lodi, 7
24044 DALMINE (BERGAMO) - ITALY
Tel. +39 035 370555 - Fax +39 035 370668
Internet: http://www.fmb.it
E-mail: fmb@fmb.it
FIGURE 1
POLARIS STANDARD - SIDE A

1
FIGURE 2
POLARIS STANDARD - SIDE B

2
KEY
ITEMS DESCRIBED IN FIGURES 1 to 37

Pos. Description Page ref. Pos. Description Page ref.

1 Control panel 1-40-44 43 C40 column 14-66

2 ON pushbutton 1-40-44 44 Saddle return valve 17
3 Emergency 1-40-44 45 Plate 21
4 OFF pushbutton 1-40-44 46 Flywheel lubricators 20-70
5 Oil pump START pushb. 1-44 47 Saddle lubricators 20
6 Liquid ON pushbutton 1-44 48 Lubricators 20
7 Liquid OFF pushbutton 1-44 49 Pin 14
8 Auto. cycle drive pushb. 1-44 50 Sawband tensioner valve 12-17-40-70
9 Semi-aut.cycle drive pushb. 1-44 51 Index 40
10 Bow downstroke pushb. 1-44 52 Sensor 2-12-40
11 Bow upstroke pushbutton 1-44 53 Knob 40
12 Open vice A pushbutton 1-44 54 Micro pin 40
13 Saddle return pushbutton 1-44 55 Microswitch 2-12-40
14 Open vice B pushbutton 1-44 60 Bow 1-2-13-15-20-40-70
15 Close vice B pushbutton 1-44 61 Tap 1-19
16 Saddle feed pushbutton 1-44 63 Idle flywheel 20-42-66-70
17 Close vice A pushbutton 1-44 64 Drive flywheel 13-42-66-70
18 Keyboard 1-44 67 Pressure regulator 1-17
19 Display 1-44 69 Orange light 1-2-11-12
23 Downstroke valve 1-17-70 70 Sawband 2-12-13-62-70
31 Feed roller 2-14 71 Brush 2-13-66
33 Microswitch 2-14 72 Brush motor 1-2-11-13
34 Microswitch 2-14 74 Microswitch 1-2-11-12-40-70
36 Saddle cylinder 14-62 75 Plate 21
37 Gearmotor 14 76 Plate 21
39 Mobile support 62 78 Plate 21
40 Bow casing 1-40-66-70 79 Reduction gear 1-2-11-70
42 Tensioner 2-12-40 80 Motor 2-11

3
KEY
ITEMS DESCRIBED IN FIGURES 1 to 27

Pos. Description Page ref. Pos. Description Page ref.

83 Plate 1-21-40 136 Transformer 36

85 Feeler pin 1-2-12-13 137 Magnetic thermal switch 36
86 Bow cylinder 1-66 138 Fuse holder 2P 36
87 Micro screw 13 139 Auxiliary 36
90 Bracket 13 140 Relay 36
95 Microswitch 1-2-13-14 141 Inverter 36
97 Small casing 70 142 Thermal 36
98 Sawband guide 1-66-70 143 Fuse holder 3P 36
102 Power supply cable 2 144 Terminals 36
106 Cooling tank 2-19 145 Fuse holder 1P 36
107 Coil 17 146 Remote switch 36
112 Pump 2-13-19 147 Transformer 36
113 Front clamping screws 15 148 Inverter 36
114 Plate 1-21 149 Thermal 36
116 Bearings 66 150 Thermal 36
117 Tungsten carbide 42-66 151 Main switch 1-36
118 Sawband guide 1-19-40-66-70 160 Plate 1-21-40
119 Small casing 70 161 Bulb 1-21-40
120 Hydraulic piping 66 162 Bulb 1-21-40
121 Cutter vice 1-2-15-62-66 163 Plate 1-21-40
122 Worktop 1 164 Plate 1-21
124 Plate 21 165 Plate 2-21
128 Hydraulic gear-case 17-66 166 Column 2
129 Gear-case motor 2-17 167 Plate 21
130 Base 1-17-19 168 Plate 21
131 Saddle 2-14-15-20-62-66 169 Plate 21
135 Transformer 36 170 Plate 21

4
TABLE OF CONTENTS

1. EXCERPT FROM F.M.B. s.r.l. WARRANTY CONDITIONS page 7

2. TECHNICAL SPECIFICATIONS page 10

3. DESCRIPTION OF THE MACHINE page 11

3.1 DESCRIPTION OF THE BOW AND ITS COMPONENTS page 11
3.2 DESCRIPTION OF THE SADDLE-CUTTER VICE page 14
3.3 LAYOUT OF THE CONTROLS AND ELECTRICAL
EQUIPMENT page 16
3.4 LAYOUT OF THE HYDRAULIC EQUIPMENT page 17
3.5 COOLING PLANT page 19
3.6 LUBRICATING DEVICES page 20
3.7 PLATES ON THE MACHINE page 21

4. OPERATION OF THE MACHINE page 22

5. LIFTING AND INSTALLATION page 24

6. ELECTRICAL CONNECTION - WIRING DIAGRAM page 28

- GENERAL WIRING DIAGRAM page 30
- TABLE OF ELECTRICAL COMPONENTS page 34
- TABLE OF FUSE CAPACITIES page 35
- LAYOUT OF EQUIPMENT page 36

7. HYDRAULIC CONNECTIONS - HYDRAULIC DIAGRAM page 37

8. SETTING UP page 39

9. NOISE LEVEL page 43

10. DESCRIPTION OF THE CONTROL PANEL page 44

10.1 GENERAL DESCRIPTION page 44
10.2 DESCRIPTION OF THE KEYBOARD page 45
10.3 DESCRIPTION OF THE MANUAL CONTROLS page 46
10.4 MEANING OF THE LEDS ON THE MANUAL CONTROLS page 47

11. MACHINE PROGRAMMING page 48

11.1 SELECTING THE VARIOUS FUNCTIONS page 49
11.2 USING THE FUNCTIONS page 50
11.3 INTRODUCING THE SET-UP PARAMETERS page 60
11.4 MANUAL OPERATION OF THE CN page 64

5
12. GENERAL MACHINE MAINTENANCE page 65
12.1 ROUTINE MAINTENANCE POINTS AND SERVICE page 66
CHART
12.2 REPLACING THE SAWBAND page 68

13. USEFUL TIPS AND RECOMMENDATIONS FOR page 71

TROUBLESHOOTING
13.1 USEFUL TIPS AND RECOMMENDATIONS page 71
13.2 SAWBAND SELECTION CRITERIA page 72
13.3 GENERAL FAULTS page 73

14. SAFETY REGULATIONS page 76

15. SAFETY DEVICES page 77

16. SPARE PARTS page 80

17. LUBRICANT CHART page 94

17.1 LUBRICATING COOLANT page 94
17.2 HYDRAULIC OIL page 94

18. USER DECLARATION page 95

19. IDENTIFICATION PLATE page 96

20. OPTIONAL EXTRAS page 97

20.1 "RPM2" TYPE VICE PRESSURE ADJUSTMENT page 97
20.2 "MV-PO" TYPE VERTICAL VICES page 98
20.3 “P02” TYPE ROLLER STANDS page 99

21. CERTIFICATE OF COMPLIANCE page 100

22. DE-COMMISSIONING AND SCRAPPING OF THE SAWING
MACHINE page 102

6
1) EXCERPT FROM F.M.B. s.r.l. WARRANTY CONDITIONS

a) F.M.B. undertakes to deliver its machines in accordance with the European

“Machine Directive” and free from any fault preventing them from being used for
the purpose for which they were designed.

b) F.M.B. is not liable for electric or electronic faults, inadequate compliance of the
machine or faults due to normal wear and tear of all parts subject to rapid and
continuous wear (e.g. seals, brushes, fuses, sawbands, etc.).

In the same way F.M.B. is not liable for inadequate compliance of the machines
or for faults deriving from failure to observe the instructions contained in the
instruction manual or from misuse or incorrect operation.

Furthermore, F.M.B. is not liable for inadequate compliance of the machines or

faults deriving from negligence and/or incorrect operation by the buyer or from
alterations or repair work carried out without prior written permission from the
seller.
F.M.B. accepts no liability with regard to positioning and installing of the
machine.

c) This warranty will run for 12 months as from the date of commissioning of the
machine on the buyer's premises and in any case will not exceed 15 months as
from the date of delivery of the machine.

The warranty covering replaced or repaired parts will expire on the same date
as the machine warranty.

d) The buyer shall report to the seller any inadequate compliance or fault of the
machine, specifying the details in writing, within 15 days from the date of

7
 delivery after thorough examination and testing of the machine. Failure to report
as above will make the warranty null and void.

In addition the warranty is void if the buyer does not allow the seller to carry out
all reasonable checks as required by the seller or if the buyer omits to return at
his own expense any faulty part which the seller requires to be sent back within
8 days of being so requested.

e) After the buyer has reported the fault in accordance with point d) and F.M.B.
has checked the existence of the same, the seller may either:

1. supply the buyer free of charge with all necessary parts to replace the faulty
ones, or
2. carry out or have a third party carry out the repair work at his own expense:

- The cost of transport for replacements for faulty parts will be delivered ex
seller's works.

- If F.M.B. technical staff is required, the buyer will be charged all out-of-pocket
expenses (travel, work, etc.).

f) Except in the case of fraud (or gross negligence) by the seller, compensation
for any damage sustained by the buyer shall never exceed the value of the
parts as in point e).

8
This warranty includes and supersedes all warranties and liabilities provided for
by the law, excludes any other liability of the seller in any way arising from the
goods supplied, and excludes liability for lost earnings and/or production
losses; in particular the buyer is not entitled to claim for further damages, price
reductions or termination of the contract.

No claims may be made against F.M.B. after the expiry of the warranty.

9
2) TECHNICAL SPECIFICATIONS

- weight Kg 2540
- overall dimensions mm 2200 x 1900 x 1800
- main motor kW 4
- gear-case motor kW 1.5
- lubricating coolant pump motor kW 0.09
- brush motor kW 0.06
- CN motor kW 0.185
- ST motor kW 0.09
- main motor speeds m/1’ 15 to 100
- recommended sawband sizes mm 4500 (±5) x 34 x 1.1
- standard electrical tension voltage V 400
- standard electrical frequency Hz 50

MAXIMUM CUTTING SIZE

TABLE

10
3) DESCRIPTION OF THE MACHINE

3.1 DESCRIPTION OF THE BOW AND ITS COMPONENTS

The bow (60) bears 2 flywheels - an idle flywheel (63) and a motor flywheel (64) - onto
which a toothed sawband (70) is fitted. The type of the sawband and the number of the
teeth vary according to the material to be cut and the cut type. The cutting edge of the
sawband (70) runs between two sawband guides (98 and 118) fitted with bearings
(116) and tungsten carbide plates (117).
An inverter (141) controls the rotation of the sawband (70); the inverter acts on the
electric motor (80) and on the reduction gear (79) connected to the drive flywheel (64).

FIGURE 3
The sawband (70) and the flywheels (63
and 64) above the bow (60) are
protected by two casings (40) and the
part of the sawband (70) near the guides
not actually used for cutting is further
protected by two casings (97 and 119)
that are screwed onto the sawband
guides, thus guaranteeing total
protection from the sawband (70).

ATTENTION!
The cutting edge of the sawband (70) is NOT protected.

11
FIGURE 4

The sawband is tensioned using the

oleodynamic cylinder (42) which allows
for the forwards/backwards movement of
the tensioning saddle.
The cylinder (42) is controlled in turn by
the valve (50) by turning its knob, as
shown in figure 4.

The tension of the sawband (70) can vary due to its breaking, checked by the micro
(55); while the sensor (52) checks the variation in rotation speed of the sawband (70).

FIGURE 5

The column has a light (69) indicating

the status of the machine (see fig. 5).
When the orange light (69) flashes, this
means that the machine is in movement
and so the operator must adopt all the
relevant safety precautions.

12
The bow (60) controlled by the cylinder (86) must allow for the actual cutting operation.
The area affected by this movement is determined by the micro (95) and by the
electro-mechanical feeler pin (85).

FIGURE 6

Press the micro (95) to end the cutting

operation: turn the screw (87) to adjust
the contact with the micro (95). The bow
(60) rises automatically thanks to the
electro-mechanical feeler pin (85) that
stops the upstroke to suit the size of the
material to be cut.

The machine is fitted with a steel driven brush (71) (see fig. 7) for constant cleaning of
the sawband (70). This automatically cleans the sawband (70) every time that the
sawband (70) turns.

FIGURE 7

13
3.2 DESCRIPTION OF THE SADDLE-CUTTER VICE

The metal sawing machine consists of a cutter vice (121) that firmly holds the bar to be
cut and a saddle vice (131) that feeds the material and also holds this in position
during cutting. The mobile sections of the vices (121-131) and the clamping/release of
the material are controlled by the hydraulic drive by means of the pushbuttons (12, 14,
15 and 17) on the control panel (1). The saddle (131) runs along two C40 chrome-
plated steel columns (43), its stroke being controlled by the micros (28 and 33).
The micro (33) controls the return stop of the saddle (131).
The hydraulic system has a slowing valve that is energized by the micro (34) by means
of pin (49) and determines the slowing down (see fig. 8) and so avoid excessive stress
on the micro (33).
FIGURE 8

For better precision (± 0.1 mm) in the stroke of the saddle (131), the two micros (33-
28) are delayed to allow for safe stopping when in contact with the 4 pre-set screws
(111-113).

14
The bottoms of the vices (121-131) are fitted with hardened steel plates to prevent
these from wearing out. The bar rest surface (122) has an independent roller stand to
offset the weight of the bar.
Two operating cycles are possible: cycle A and cycle B (see fig. 9).

FIGURE 9
CYCLE A
This is for better clamping of material as
during cutting, the two vices (131 and
121) are closed and close to the
sawband (70).

CYCLE B
This is for faster machining as during the
cutting, the saddle vice (131) moves to a
position ready for feeding the bar.

N.B.: The vice pressure can be adjusted on request (RPM 2).

15
3.3 LAYOUT OF THE CONTROLS AND ELECTRICAL EQUIPMENT

The control panel (1) is on the front of the machine in a safe and ergonomic position
for the operator.

The main switch (151) is under the control panel (1).

The switchboard can be accessed by turning the main switch (151) to 0 and
unscrewing the 2 screws on the top and bottom of the door.

Appropriate plates indicate the direction in which the motors turn.

16
3.4 LAYOUT OF THE HYDRAULIC EQUIPMENT

The hydraulic gear-case (128) is found inside the frame in structural work (130) (see
fig. 10). The hydraulic gear-case (128) can contain up to 50 litres of hydraulic oil.

FIGURE 10

It indicates the minimum oil level that must be present in the hydraulic gear-case (128).

17
A Balanced valve and bow cylinder control solenoid valve
B Saddle feed cylinder control solenoid valve
C Saddle vice control solenoid valve
D Cutter vice control solenoid valve
E Hydraulic tensioner control solenoid valve

The MAX valve is set at 20 bar, at a temperature of 60°C.

The saddle vice slow-down valve is already set to allow for soft contact with the micro
(33). These valves are found on the side of the block.
The downstroke speed of the sawband (70) during the work cycle is regulated by the
balanced valve (23).

18
3.5 COOLING PLANT
FIGURE 11

The cooling tank (106) is found inside the bearing structure of the machine (130) and
can contain up to 50 litres of lubricating coolant. The pump (112) inside the tank (106)
allows for the lubricating coolant to flow to the distributors (61).
The distributors (61) are fitted with flow regulating taps. The distributors (61) on the
bow deliver the lubricating coolant inside the sawband guides (98 and 118); excess
lubricating coolant is conveyed and recovered in the special tank (106).
N.B. Make sure that the lubricating oils and coolants are not dispersed in the
environment.
3.6 LUBRICATING DEVICES

19
The moving parts of the machine have lubricators that allow the operator to carry out
precise and thorough lubrication during maintenance.
The lubricators are on the flywheels (46, 47 and 48) and on the saddle (131) (see fig.
12).

FIGURE 12

See the general machine maintenance table on page 67 for use and frequency.

20
3.7 PLATES ON THE MACHINE
FIGURE 13

45) Indicates the progress of the sawband

75) Indicates the generic danger during machine movement
76) Indicates the risk of crushing limbs
78) Indicates the motor rotation direction [also on the pump (112), the gear-case motor (129) and the brush motor
(72)]
83) Serial no. plate
114) Indicates the machine voltage rating
124) FMB identification plate
160) Indicates the cutting parameters options
164) Sign stating that the instruction manual must be read
167-168) Indicates the sawband tensioning depending on the position of the lever (see FIG. 4)
169) Indicates the risk of crushing limbs when the swarf conveyor is moving
170) Sign indicating that gloves must be worn

21
4) OPERATION OF THE MACHINE

The band sawing machine is designed for cutting bars, both ferrous and non-ferrous
material, made of different shapes and sizes.

The physical characteristics of the material above, such as toughness and density, do
not have to cause safety problems for the operator during cutting.

FMB declines all liability for damage to objects and personal injury. It will be the user's
concern to verify the characteristics of the material to rule out any possible risks for his
own safety and that of third parties.

The bars can be loaded onto the machine either:

- manually, or by means of
- an overhead crane controlled by the operator at a safe distance.

When loading the bars, the operator must:

a) keep at the required safety distance
b) extra care must be taken when actually laying the piece(s) on the machine itself.

WARNING!
THE SAWING MACHINE MUST BE POSITIONED IN AN AREA SUITABLY MARKED
BY FLOOR PAINTING AND A POST+CHAIN BARRIER.
YOU MUST FIT THE SAWING MACHINE WITH ROLLER STANDS
ON WHICH TO REST THE WORKPIECE. THIS WILL ALLOW YOU
WORK CORRECTLY AND SAFELY.

22
 USES OTHER THAN THOSE DESCRIBED ABOVE
ARE NOT PERMITTED

The band sawing machine can not be used in environments with risk of explosion or
fire.

Before using the band sawing machine, fill the tank (106) inside the frame in structural
work (130) with an emulsion of oil and water (50 l) suitable for the cutting operation.

It is the responsibility of the user to:

- check the harmfulness of the oil used;
- to choose oils and all the other lubricants required for the machine in
conformity with prevailing laws in the user's country governing the use and
disposal of waste oils;
- take extreme care that the lubricating oils and coolants are not dispersed in
the environment.

23
5) LIFTING AND INSTALLATION

5.1 The machine is designed to be installed in a standard working environment

(workshop), normally lighted, on an industrial type floor of suitable capacity,
according to the laws in force in the country of installation.

5.2 The machine does not necessarily need anchoring to the floor; nevertheless,
once installed, it should be checked for stability.

5.3 Special care should be taken in lining up the roller stands and/or stands with
the feed rollers (31) and the surfaces of the vices (121 and 131).

5.4 For correct installation, after removing all the packing and carefully reading the
use and maintenance manual enclosed within, the sawing machine must be
lifted according to the following diagram:

24
SLINGING DIAGRAM FOR LOADING - MOVING - POSITIONING THE BAND
SAWING MACHINE FOR METALS

FIGURE 14

25
FIGURE 14
1. Make sure that the sling is sound before attempting to lift the machine.
2. Make sure that the machine is balanced at all times when lifting it.
3. Only lift the machine by as much as necessary to move it.
4. Do not allow the machine to swing when moving it with the overhead crane.

When slinging the machine, use a rope with a minimum load capacity of 3000 kg.
It is important that the machine is lifted only by as much as necessary to move it. The
crane operator must keep at a minimum safety distance which depends on the length
of the rope.

5.5 Once the machine has been installed, the installer or the staff in charge must
make sure that all the machine parts:

• are perfectly sound (without cracks or faults). In particular: the main switch
(151), the control panel (1), the electric motor (80), the pump (112), the vices
(121 and 131) with their drives, the gearmotor (79), the brush motor (72), the
swarf evacuator and the bow (60) with all its components;
• conform to the manual in all its parts.

If any parts are found to be damaged or do not comply with the manual, the
user shall apply to F.M.B. in writing for instructions on how to proceed in the
circumstances. F.M.B. will inform the user of its final decision by writing in each
case.

NOTE!
The installer must in no case start the machine before replacing any
components that do not comply, are unsound or differ from the
requirements in this instruction and operation manual.

26
5.6 The sawing machine must be positioned in a suitably marked area with
yellow and black painted stripes on the floor and chains supported by
sliding bars that prevent the operators from entering the danger zone
during operation.
A flashing orange light on the bow (60) indicates that the sawing machine
is in operation.

FIGURE 15

27
6) ELECTRICAL CONNECTION - WIRING DIAGRAM

The switchboard is found in a special container at the front of the machine.

6.1 Check that all parts of the cable (102) provided are in good condition and
connect it to a standard plug or one complying with the regulations in force in
the country of installation.

6.1.1 Always check that the earth cables are connected to the earthing
system and are not with the neutral cable. The neutral cable should be
used as such and the earth cable for earthing only.

6.1.2 The minimum section of the cables supplying the socket to which the
machine is to be connected must suit the envisaged voltage rate, the
installed power and the distance between the power source and the
machine.

6.2 Check that the power mains to which the machine is to be connected has the
same voltage and frequency as the machine itself.

6.3 If the mains rating and/or frequency are not the same as those intended and
indicated in the “technical characteristics” tables (see page 10), the machine
must not be started up otherwise all the motors, the electronics and the
electrical drive equipment could be irretrievably damaged.
If so, all equipment and drive parts must be replaced to suit the new
rating/frequency of supply.
N.B. All alterations of the electrical and electronic parts of the machine must be
carried out by qualified and authorized personnel.

28
6.4 After connecting the machine, check that the voltage at the supply terminals is
the same as the mains and that it is across all three phases. Turn the main
switch (151) to “I” and check that the white light (162) and the green light (161)
on the console are on and that the luminous OFF pushbutton (4) is lit up.
Press the ON pushbutton (2).
Check the sense of rotation by pressing the pre-heating pushbutton (5) and
then check that the pressure gauge reads about 20 bar.
If the pressure gauge does not read any pressure, the machine has the sense
of rotation inverted. If so, invert any two phases of the power supply cable (102)
and repeat the check.
N.B. All electric motors indicate the correct sense of rotation.

29
6.5 GENERAL WIRING DIAGRAM (page 1)

INVERTER = INVERTER
MOTORE LAMA = SAWBAND MOTOR
MOTORE VENTILATORE = FAN MOTOR
MOTORE SPAZZOLA = BRUSH MOTOR
MOTORE SCARICATORE = EVACUATOR MOTOR
MOTORE CENTRALINA IDRAULICA = HYDRAULIC GEAR-CASE MOTOR
MOTORE REFRIGERANTE = COOLING MOTOR
MOTORE RISCONTRO = LOCATOR MOTOR

30
6.5 GENERAL WIRING DIAGRAM (page 2)

VERDE = GREEN
GIALLA = YELLOW
BIANCA = WHITE
MORSETTI DOPPI = TWIN TERMINALS
SCHEDA QEM = QEM SHEET
USCITE MACCHINA = MACHINE OUTPUTS

1 18 VAC 12 OUTPUT POLARITY

2 18 VAC 13 SLOW SADDLE FEED SOLENOID VALVE
3 GROUND 14 BOW DOWNSTROKE SOLENOID VALVE
4 15 VAC 15 OUTPUT POLARITY
5 15 VAC 16 FAST BOW DOWNSTROKE SOLENOID VALVE
6 OUTPUT POLARITY 17 BOW UPSTROKE SOLENOID VALVE
7 CLOSE CUTTER VICE SOLENOID VALVE 18 OUTPUT POLARITY
8 CLOSE SADDLE VICE SOLENOID VALVE 19 HYDRAULIC PUMP REMOTE SWITCH
9 OUTPUT POLARITY 20 SAWBAND MOTOR REMOTE SWITCH
10 SADDLE FEED SOLENOID VALVE 21 COOLANT PUMP REMOTE SWITCH
11 SADDLE RETURN SOLENOID VALVE 22 LOCATOR MOTOR REMOTE SWITCH

31
6.5 GENERAL WIRING DIAGRAM (page 3)

SCHEDA QEM = QEM SHEET

USCITE MACCHINA = MACHINE OUTPUTS
VERDE = GREEN
ROSSO = RED
NERO = BLACK
GIALLO = YELLOW
BLU = BLUE
ENCODER 12V = 12V ENCODER
MORSETTI DOPPI = TWIN TERMINALS

23 INPUT POLARITY 37 SADDLE FORWARD MICRO

24 CUTTER VICE EMERGENCY 38 SADDLE BACKWARD MICRO
25 HYDRAULIC PUMP THERMAL SWITCH 39 SADDLE SLOW-DOWN MICRO
26 COOLANT THERMAL SWITCH 40 NO BAR MICRO
27 BRUSH OR FAN THERMAL SWITCH 41 CASING OPEN MICRO
28 SWARF EVACUATOR THERMAL SWITCH 42 SAWBAND BREAKAGE MICRO
29 HYDRAULIC LOCATOR THERMAL SWITCH 43 MUSHROOM EMERGENCY MICRO
30 ON-OFF INPUT 44 FEELER PIN MICRO
31 INPUT SUPPLY 47 ENCODER POLARITY
32 INPUT POLARITY 48 ENCODER STAGE 1
34 SAWBAND ROTATION SENSOR 49 ENCODER STAGE 2
35 BOW RAISED MICRO 50 ENCODER ZERO PULSE
36 BOW LOWERED MICRO

32
6.5 GENERAL WIRING DIAGRAM (page 4)

SCHEDA QEM = QEM SHEET

USCITE MACCHINA = MACHINE OUTPUTS
V. RIFERIMENTO = SEE REF.
INDIETRO = BACKWARDS
AVANTI = FORWARDS
CONTATTO SU INVERTER = INVERTER CONTACT

45 + 10V POWER SUPPLY 61 INPUT POLARITY

46 0V POTENTIOMETER GND 62 INVERTER ALARM INPUT
51 NC FORWARDS MOVEMENT 63 KEY SELECTOR INPUT
52 NC BACKWARDS MOVEMENT 64 + 24 V DC COMMON VICE RELAY
53 SEE REF. NC 65 OPEN SADDLE VICE COMMAND
55 + 10V POWER SUPPLY 66 CLOSE SADDLE VICE COMMAND
56 0V POTENTIOMETER GND
57 SEE REF. SAWBAND POWER

N.B.: THE “KEY SEL” CONTACTS ARE CONTACTS UNDER THE SWITCH THAT ARE ENABLED USING THE KEY PROVIDED.

33
6.6 TABLE OF ELECTRICAL COMPONENTS

POS. MARK DESCRIPTION TYPE

135 TR Transformer 400 VA

136 TR40VA Transformer 40 VA
137 IG Magnetic thermal switch 3 X 20A
138 CF4-CF5-CF6-CF7-CF8 Fuse holder 2P 10 X 38
139 KM4 Remote switch + auxiliary 3 NO + 1 NC
140 EV9-EV10 Relay 024Vac 2P
141 Inverter U V W Sawband motor inverter 4kW – 3PH
142 RT4-RT5-RT6-RT7 Thermal relay 0.63 ÷ 1A
143 TF2-TF3-TF4-TF5 Fuse holder 3P 10 x 38
144 Ø N50 Terminal 4 mm² cross section
144 ╧ N9 Earth terminal 6 mm² cross section
145 F1-F2-F3-F4-F5-F6-F7-F8-F9-F10 Fuse holder 1P 10 x 38
146 KM2-KM Remote switch 3 NO + 1 NC
147 TR2 Transformer 250 VA
148 Inverter Locator inverter 0.37 kW - 1PH
149 KM3 + RT8 Remote switch + thermal relay 3 NO + 1 NC 1.7÷2.4 A
150 KM1 + RT5 Remote switch + thermal relay 3 NO + 1 NC 4.5÷6.5 A
151 IBP Main switch 16A

34
6.7 TABLE OF FUSE CAPACITIES

35
6.8 LAYOUT OF EQUIPMENT

FIGURE 16

36
7) HYDRAULIC CONNECTIONS - HYDRAULIC DIAGRAM

VICE 1 VICE 2 SADDLE

BOW

NOTE FOR DISPATCH OFFICE: THE DETAILS MARKED HERE ARE

NOT ASSEMLED BUT NEED TO BE ADDED TO THE SHIPMENT.

SIZE OF HYDRAULIC FITTINGS.

37
 POS. Q.TY DESCRIPTION AND CATALOGUE CODE PRODUCT SEE
CODE NOTE
1 01 SPECIAL BASE M10700260 M10700260
2 01 SOLENOID VALVE AD3E02EMS12 AD3E02EMS12
3 03 SOLENOID VALVE AD3E01CMS12 AD3E01CMS12
4 01 SOLENOID VALVE AD3E03CMS12 AD3E03CMS12
5 01 MAX. PRESSURE VALVE CMP10C1002 CMP10C1002
6 01 CARTRIDGE SOLENOID VALVE CRP02NAAEMS11 CRP02NAAEMS11
7 01 CARTRIDGE SOLENOID VALVE CRP02NCASMS11 CRP02NCASMS11
8 01 PRESSURE REDUCING VALVE RLPC1001 R33341853
COMPONENTS

9 01 PILOTED STOP VALVE AM3UPAB1003 AM3UPAB1003

10 01 M8x1 SCREW (HOLE ø 1) M89100010 M89100010
11 01 QCV REGULATOR BASE M10700188 M10700188
12 01 SPECIAL FLOW REGULATOR QCV32GQ11RAG5 QCV32GQ11RAG5
13 16 M5X30 UNI 5931 SCREW Q26074068 Q26074068
14 08 M5X70 UNI 5931 SCREW Q26074075 Q26074075
15 02 M5X40 UNI 5931 SCREW Q26078070 Q26078070
16 01 LINE FLOW REGULATING VALVE QFMU071001 QFMU071001
17
18
19
20
21 01 CARTRIDGE ONE-WAY VALVE VUH1G38 V70052202
COMPONENTS

22 01 MOTOR/PUMP SUPPORT P200 V22202200

RETAIL

23 01 TWIN-GEAR PUMP PLP10. 10+10. 5 Dx V26420110

24 01 LANTERN LS211 V22020300
25 01 SPRING COUPLING ND65B+ND65P1M+R62 V27010320

38
8) SETTING UP

1. Check the oil level in the reduction gear (79).

2. Fill the appropriate tank (106) mounted inside the machine structure (130) with a
water-oil emulsion (50 l with 3% to 5% mix proportion).

3. Check the sawband (70) for efficiency and soundness.

4. Check the tension of the sawband (70) by moving the valve (50) knob.

5. Check for the correct type of sawband (70); i.e. the number and type of teeth
suitable for the thickness of the material to be cut.
Use the keyboard (18) to view advice on the cutting parameters (see page 54).

6. Adjust the speed of the sawband (70) on the control panel during the
programming stage.

39
BOW WITH DETAIL OF SAWBAND TENSIONER, SAWBAND AND CONTROL
PANEL
FIGURE 17

40
Check that the bar sits properly on the feed rollers (31) and the roller stands. Make
sure that it is perfectly even across the entire surface of the vices (121 and 131).

Use the appropriate keys (12, 14, 15 and 17) to clamp or release the workpiece
between the mobile sections of the vices (121-131).

ATTENTION!
Depending on its size, the cut bar could drop and/or slide
onto the appropriate recess near the vices,
or even fall to the ground, causing possible injury
to arms and legs.

F.M.B. recommends that all current safety regulations be followed carefully, including
the use of personal protective equipment (gloves, protective footwear, etc.).

A correct use of the machine is achieved by cleaning the sawband guides (98 and 118)
regularly, thus ensuring an abundant flow of lubricating coolant at all times. We also
recommend checking the wear of the steel brush (71) under the sawband guide (98)
for better cleaning and performance of the sawband (70).
The lubricating coolant can be stopped using the key (7) and re-introduced at any point
using the key (6).

41
In order to obtain good cutting efficiency one must:

• mount the sawband (70) correctly, tension it correctly before starting work and
release it at the end of the job by using the valve (50) knob;
• know the exact characteristics of the material to be cut;
• set the right cutting speed for the material to be cut;
• use good quality sawbands;
• choose the correct sawband (70) tooth configuration for the width, thickness or
characteristics of the material;
• make the first few cuts gently, without forcing: a new sawband (70) requires a
certain running-in period;
• use plenty of good quality lubricant;
• clean the sawband guides (98 and 118) often;
• check the state of repair of the bearings (116) and the tungsten carbide plate (117);
• the cutting feed rate is strictly dependent on the above-mentioned conditions and
can be left to the common sense of the operator;
• always use the brush (71).

FIGURE 18

Do not force! Sawband should just touch

42
9) NOISE LEVEL
Certification of noise levels recorded by instruments on an identical machine to that of
this manual.
ATTENTION: when cutting thin or open profiles or whenever the noise during
cutting exceeds 85 dB, the operator must be provided with the appropriate
personal acoustic protection.

43
10) DESCRIPTION OF THE CONTROL PANEL

FIGURE 19

10.1 GENERAL DESCRIPTION

The control panel (1) consists of:

- 11 machine inputs and 8 machine outputs
- 7 panel inputs and 4 panel outputs
- Scratch-proof membrane keyboard
- Extractable polarized terminal board
- Back-lit LCD display with 4 lines of 20 alphanumeric characters
- 9 bit analog output
- EPROM memory
- Luminous ON pushbutton (2)
- Emergency STOP pushbutton (3)
- Luminous OFF pushbutton (4)
- Manual control pushbuttons (5 - 17)
- Programming keyboard (18)
- Display (19)
- Conventional representation of the machine (20)

44
10.2 DESCRIPTION OF THE KEYBOARD FIGURE 20

a) For entering data.

b) Press after the F key, to select the various functions.

a) Press repeatedly to view the next display page.

b) Press for more than 1 sec. to view the previous page.

Enables the selection of the various functions.

Enables manual operation.

Enters the decimal point when entering data.

Enters or removes the sign when entering data.

Cancels the last data entered and restores the previous data when
entering data.

Confirms the entered data when entering data.

In automatic mode, for an interruption after the current bar has been
finished.

45
10.3 DESCRIPTION OF THE MANUAL CONTROLS

(15) Enabled in manual mode, closes the vice B.

(14) Enabled in manual mode, opens the vice B.

(16) Enabled in manual mode with upper band entry active, moves the
vice B forwards.

(13) Enabled in manual mode, moves the vice B backwards.

(17) Enabled in manual mode, closes the vice A.

(12) Enabled in manual mode, opens the vice A.

(11) Enabled in manual mode, for the bow upstroke.

(10) Enabled in manual mode, for the bow downstroke.

(8) Starts the automatic machine cycle.

(9) Starts the semi-automatic machine cycle.

(6) Opens the coolant circuit.

(7) Closes the coolant circuit.

(5) Starts up the oil pump motor for pre-heating, if no other key has
already been pressed.

46
10.4 MEANING OF THE LEDS ON THE MANUAL CONTROLS

(16) On when the saddle is fully advanced.

(13) On when the saddle is fully returned.

(11) On when the bow is at the upper limit switch.

(10) On when the bow is at the lower limit switch.

(8) On during automatic mode.

(9) On during semi-automatic mode.

(7) On when the coolant is excluded.

(5) On to indicate the pre-heating of the hydraulic oil.

47
11) MACHINE PROGRAMMING

Switch on the machine by turning the main switch (151) to (I). The following come on:
the white light (162) and the green light (161) on the console, the luminous OFF
pushbutton (4) and the display (19).

48
11.1 SELECTING THE VARIOUS FUNCTIONS
On switching on, the display (19) shows:

Band sawing machines for

metals
Instructions ENTER
To work

Set speed ∅ mt/1’ FUNCTION F+1

Actual speed ∅ mt/1’ Insert passwords
CYCLE A COOLANT ON
PR.1 α = 0° 0’ [CLEAR]

The operator can choose whether to view

FUNCTION F+2
the messages explaining the functions
Pieces no. ∅ Edit program possible on the control panel (1) by using
Length ∅
[CLEAR] the ENTER key, or to go directly to the
job pages using the up-down key ( ).
Band sawing machines for FUNCTION F+3
metals Change parameters on active
Instructions ENTER program
To work
[CLEAR]

FUNCTION F+4 Band sawing machines for

Select. program to run metals
Instructions ENTER
[CLEAR] To work

FUNCTION F+5
Restore conditions

[CLEAR]

The functions are selected by pressing the

FUNCTION F+6 F key and then the number corresponding
Select material from list
to the required function.
[CLEAR]

FUNCTION F+7
Edit data for semiauto. cycle

[CLEAR]

FUNCTION F+8
Select step and pieces no.

[CLEAR]

FUNCTION F+9
Enable
Controls
[CLEAR]

FUNCTION F+0
Input/output check
[CLEAR]

49
11.2 USING THE FUNCTIONS

Below is an example of how to program and start a cycle:

the automatic sawing machine can be programmed in terms of the number and length
of the pieces to be cut.

Suitable cutting parameters must be selected to suit the hardness and the section of
the bars. The F6 function recommends the choice of cutting parameters with the help
of the plate (160).

A = Main international classifications

B = Material classes with similar characteristics

50
 Function F + 6
Let us imagine that we have to cut a C40 ferrous material. The corresponding number
is 2 in table (160).

BAND SAWING MACHINES

FOR METALS Using the numeric keys (18), enter 2 and confirm
INSTRUCTIONS ENTER with ENTER.
TO WORK
The display (19) automatically shows the
F recommended rotation speed and the required
SELECT FUNCTION
percentage of oil in the coolant.

Using the up-down key, you can select the

6 section of the material to be cut.
MAT 1 V = 80÷100m/1’
COOLANT 3%
DIAMETER 0.0 The following appear in succession Written at the side
TOOTHPITCH Z 5/8
full bar diameter
2 full square max. base
round tube tube thickness
ENTER |
—
| bottom-opened profile profile thickness
MAT 2 V = 60÷75m/1’ square tube tube thickness
COOLANT 3%
MAX. BASE 0.0
|
—
| top-opened profile profile thickness
TOOTHPITCH Z
5/8

ENTER
MAT 2 V = 80÷75 m/1’
COOLANT 3%
MAX. BASE 0.0
TOOTHPITCH Z 5/8

9 0
Having confirmed the section of the
material to be cut with the numeric keys
ENTER (18), enter its size.
MAT 2 60÷75M1’ The display (19) shows the
COOLANT 3%
MAX. BASE 90.0
recommended toothing of the sawband
TOOTHPITCH Z (70).
3/4

F
BAND SAWING MACHINES
FOR METALS
INSTRUCTIONS ENTER

51
TO WORK

52
BAND SAWING MACHINES
FOR METALS
INSTRUCTIONS ENTER
TO WORK

F
SELECT FUNCTION
Function F + 2
The [F2] function is for programming a work
cycle. Let us suppose that we have to
2 program the machine to cut 8 pieces
PROGRAM
NO.
measuring 200 mm in length from a bar of
C40 material. Using the numeric keys (18),
0
assign the number of the program.
1 Then enter the values for:
- rotation speed of the sawband (70)
ENTER - cutting angle
- no. pieces to be cut and their length.
SPEED 0
COOLANT OFF
ANGLE CUT 0.0
CYCLE A

7 0

ENTER
SPEED 70
COOLANT OFF
Using the up-down key, select
ANGLE CUT 0.0 coolant OFF ON
CYCLE A
cycle A B
and vice-versa
(description of cycles A and B at page 15).
ENTER
SPEED 70
COOLANT ON
ANGLE CUT 0.0
CYCLE A

ENTER
SPEED 70
COOLANT ON
The machine is now programmed. Up to
ANGLE CUT 0.0 10 programs with 10 different cutting
CYCLE A
lengths can be set.
Use the F4 function to activate the
program.
ENTER
PIECES NO.
LENGTH ∅

8
ENTER
PIECES NO. 8
LENGTH ∅

2 0 0
ENTER
BAND SAWING MACHINES
FOR METALS
INSTRUCTIONS ENTER
TO WORK

52
BAND SAWING MACHINES
FOR METALS
Function F + 4
INSTRUCTIONS ENTER
TO WORK
To execute the set program using F2,
F press the numeric keys (18) 1 and confirm
SELECT FUNCTION
with ENTER.
Press the key (8) to start the work
cycle.
4
SELECT
PROGRAM TO RUN

ENTER
BAND SAWING MACHINES
FOR METALS
INSTRUCTIONS ENTER
TO WORK

53
Function F + 7
This function is for entering the machining data for a semi-automatic cycle.

Press the F and 7 keys in succession. The display (19) shows:

SEMIAUTO CYCLE
Speed 128
Coolant ON
Angle cut 18° 25°

The value for the speed of the sawband (70) will flash and the operator can enter the
required value using the numeric keyboard (18). On confirming this with ENTER, the
speed value stops flashing and the coolant value starts flashing. Using the up-down
key, the operator can choose whether to have the cycle with (ON) or without (OFF)
coolant. On confirming this with ENTER, the coolant value stops flashing and the
cutting angle value starts flashing. The operator can enter the cutting angle value
using the numeric keyboard (18), valid only as a memory aid. On confirming with
ENTER, this function is exited and the display (19) returns to show the current values.

To exit semi-automatic programming at any moment, press the F key: the display (19)
will return to show the current values.

Function F + 8
When a current program [F+4] is interrupted, you can complete it by entering the step
number and the number of pieces already executed.
Then press the pushbutton (8) to execute.

54
Press the F and 8 keys in succession. The display (19) will show:

SELECT STEP
Program 1
Step 1/3
Pieces n. 4/15

The data for the current program are shown and that for the current step will start
flashing. The value on the right indicates the number of steps in the program. On
confirming with ENTER, the step value stops flashing and the number of pieces still to
be executed starts flashing. The value on the right indicates the set number of pieces
in the program. On confirming with ENTER, the function is exited and the display (19)
returns to show the current values.
To exit at any moment, press the F key: the display (19) will return to show the current
values.

Function F + 9
To enable or disable the following controls:
- sawband (70) speed
- locator position
follow these steps:
press the F and 9 keys in succession. The display (19) will show:

Enable
sawband speed
control
∅

The instrument checks the speed at which the sawband (70) turns and, if this is
outside the speed limit in the set-up parameter (see page 60), “TENSION TO
RELEASE BLADE”, the current cycle is stopped and the display (19) shows the
message “sawband blocked”. To enable this control, use the numeric keyboard (18) to
set the value 1 and confirm with ENTER. To disable the control, enter 0 and confirm
with ENTER.

55
To exit the control enable/disable function at any moment, press the F key: the display
(19) will return to show the current values.
On confirming with ENTER, the display (19) will automatically show:

Enable
locator tolerance
control
∅

The instrument checks the position of the locator (39) and, if this is outside the set-up
tolerance, stops the current cycle and the display (19) shows the message “Locator not
positioned”.
To enable this control, set the value 1 using the numeric keyboard (18) and confirm
with ENTER.
To disable the control, set the value ∅ and confirm with ENTER.

56
Function F + 0
This function is for viewing the state of the inputs and the outputs on the
control panel (1).

Press the F key and then the 0 key. The display (19) shows:

1 = l1 and U1
2 = l2 and U2
3 = l3 and U3
4 = I4 and U4
5 = I5 and U5
6 = I6 and U6
Inputs 7 = I7 and U7
123456789ABCDEFGHI 8 = I8 and U8
Outputs 9 = I9 and U9
123456789ABCDEFGHI A = I10 and U10
B = I11 and U11
C = I12 and U12
D = I13 and U13
E = I14 and U14
F = I15 and U15
G = I16
H = I17
I = I18
L = I19
M = I20

To exit this function at any moment, press the F key: the display (19) will return to
show the current values.

57
DESCRIPTION OF CONTROL PANEL INPUTS / OUTPUTS

DISPLAY INPUT/ No. INPUT DESCRIPTION

OUTPUT TERMINAL ENABLE
S

1 I1 34 ON FLYWHEEL ROTATION: input reserved for the proximity used for reading the
sawband speed (max. frequency 10 kHz).

2 I2 35 ON BOW UP: signals that the bow is in the up position. When activated during the
upstroke of the bow, the upstroke stops.

3 I3 36 ON BOW DOWN: signals that the bow is in the down position. When activated
during the downstroke of the bow, the downstroke stops.

4 I4 37 ON SADDLE IN FRONT POSITION: signals that the saddle is in the front position.
When activated during the advance of the saddle, the saddle stops.

5 I5 38 ON SADDLE IN BACK POSITION: signals that the saddle is in the back position.
When activated during the saddle return, the saddle stops.

6 I6 39 ON SADDLE SLOW-DOWN: signals that the saddle is in the slow-down position.

When activated during the saddle return, controls the exchange between fast
and slow.

7 I7 40 ON NO BAR: signals that there is no bar. Its activation enables the manual
controls.

8 I8 41 OFF CASING OPEN: signals that the casing is open. When deactivated, only the
manual controls are enabled.

9 I9 42 OFF SAWBAND BREAKAGE: signals that sawband is broken. When deactivated,

only the manual controls are enabled.

A I10 43 OFF EMERGENCY: signals that the machine emergency has tripped.

B I11 44 OFF NO WATER: signals that there is no cooling water. Reading is enabled after 15
seconds from the activation of the “water motor remote switch” output (U11)
and the alarm is tripped if the input remains deactivated for 15 seconds at a
time.

C I12 24 ON SAWBAND THERMAL: signals that the sawband motor thermal has tripped. If
using an inverter for sawband drive, also the “faulty inverter” signal needs to be
associated.

D I13 25 ON OIL PUMP THERMAL: signals that the oil motor thermal has tripped.

E I14 26 ON WATER PUMP THERMAL: signals that the water pump motor thermal has
tripped.

F I15 27 ON CLEANER THERMAL: signals that the cleaner motor thermal has tripped.

G I16 28 ON SWARF EVACUATOR THERMAL: signals that the swarf evacuator motor
thermal has tripped.

58
DESCRIPTION OF CONTROL PANEL INPUTS / OUTPUTS

DISPLAY INPUT/ No. INPUT DESCRIPTION

OUTPUT TERMINAL ENABLE
S

H I17 29 ON LOCATOR THERMAL: enabled only when the optional “PQ001/C/U” accessory
is fitted. Signals that the locator motor thermal has tripped and “faulty inverter”
signal.

I I18 30 ON START/STOP: signals the machine status. On activation, it automatically sets

the manual mode.

L I19 ON INVERTER ALARM

M I20 ON ALARM SILENCER

1 U1 7 CUTTER VICE SOLENOID VALVE: controls the closing of the cutter vice.

2 U2 8 SADDLE VICE SOLENOID VALVE: controls the closing of the saddle vice.

3 U3 10 SADDLE ADVANCE SOLENOID VALVE: controls the forwards movement of

the saddle.

4 U4 11 SADDLE RETURN SOLENOID VALVE: controls the backwards

movement of the saddle.

5 U5 13 SLOW SADDLE SOLENOID VALVE: activated together with the “saddle return
solenoid valve” output, it controls the slow backwards movement of the saddle.

6 U6 14 BOW DOWNSTROKE SOLENOID VALVE: controls the bow downstroke.

7 U7 16 FAST BOW DOWNSTROKE SOLENOID VALVE: activated together with the

“bow downstroke solenoid valve” output, it controls the fast downstroke of the
bow.

8 U8 17 BOW UPSTROKE SOLENOID VALVE: controls the bow upstroke.

9 U9 19 OIL PUMP REMOTE SWITCH: controls the rotation of the oil pump motor.

A U10 20 SAWBAND MOTOR REMOTE SWITCH: controls the rotation of the sawband
motor, of the cleaner motor and the swarf evacuation motor.

B U11 21 WATER MOTOR REMOTE SWITCH: controls the rotation of the water motor.

C U12 22 LOCATOR MOTOR REMOTE SWITCH: enabled only if the optional

“PQ001/C/U” accessory is fitted, it feeds the locator motor inverter. The locator
movement controls must occur by means of the outputs on the same expansion
board.

D U13 7 LOCATOR INVERTER RELEASE: when activated, it enables the rotation of

the locator motor.

E U14 8 LOCATOR INVERTER INVERSION: when activated, it inverts the rotation

direction of the locator motor.

F U15 6 SAWBAND INVERTER RELEASE: when activated, it enables the rotation of

the sawband motor.

59
11.3 INTRODUCING THE SET-UP PARAMETERS

These parameters determine the operating mode of the machine and can only be
accessed by the installer. Programming is done by F.M.B.
For reasons independent of the machine, these values can change or become
cancelled. If so, the machine will not work correctly and so the operator is authorized to
check the set-up conditions as follows:

11.3.1
Press the F and 1 keys in succession. The display (19) will read Password ?.
Enter 2 + 0 + 1 using the numeric keys (18) and press ENTER. The parameters will
then be accessed. Enter the following values using the numeric keys (18) and confirm
with ENTER each time.
FREQUENCY 36
Using the up-down key, you can
FREQUENCY OF CUT 50
DUTY-CYCLE 10 change the page on the display (19):
READING MEAN VALUE 10
STABILIZING MEAN VALUE 5
press it and release it immediately to
MAX SPEED OF BLADE 120 view the next page; press and hold
MIN SPEED OF BLADE 15
TENSION TO RELEASE BLADE 20%
down for more than 1 second to view
DECIMAL DIGITS 1 the previous page.
MAXIMUM QUOTA 420
STROKE REF. ENABLE 2
HIGH DEFINITION READING 1 ***: 0= ABB Frequency Variator
ENCODER MULTIPLER 0.09992-0,1
DECELERATING DISTANCE 2
NEGATIVE TOLERANCE 0.2
POSITIVE TOLERANCE 0.2
DECELERATING TIME 0.5
AXIS STARTING DELAY 0.5
MINIMUM QUOTA 3
BACKLASH CORRECTION 2
BACKLASH CORRECTION OVERRIDE 3
INVERSION TIME 0.5
CONFIGURATION OF MEMORY 10
BOW RISE TIME 0.1
BAND THICKNESS 1.5
OUTPUT STROKE REF. FUNCTION 1***
CLOSING VICES FUNCTION 1
11.3.2

60
Press the F + 1 keys in succession and the display (19) will read Password ? ∅, enter
1 + 4 + 7 using the numeric keys (18) and press ENTER. The display (19) will show
(enter with the numeric keys (18) the values and confirm with ENTER each time):

SADDLE VICES CLOSING DELAY 0.30

SADDLE VICES OPENING DELAY 0.30
SADDLE BACK STARTING DELAY 0.30
SADDLE FORWARD STARTING DELAY 0.30
SADDLE BACK STOPPING DELAY 0.30
SADDLE FORWARD STOPPING DELAY 0.30
BOW COMING DOWN/DELAY 0.30
CUT VICES CLOSING DELAY 0.30
CUT VICES OPENING DELAY 0.30

Having confirmed with ENTER the last value, press the F key to exit this function.

11.3.3
Press the F + 1 keys in succession and the display (19) will read Password ? ∅, enter
2 + 5 + 8 using the numeric keys (18) and press ENTER. The display (19) will show:

CHOICE UNITS
OF MEASUREMENT
∅

“mm” “inch”

0 1

ENTER ENTER

If you wish to view and set the values in “inches” and “feet”, enter 1 and confirm with
ENTER. If, on the other hand, you want to use “mm” and “metres”, enter 0 and confirm
with ENTER. On confirming with ENTER, the function is exited and the display (19)
returns to the current values.

61
11.3.4 CORRECTING THE CUTTING LENGTH
If the set measurement is not the real cutting distance, enter a new value for the bar
locator count as follows:
take the saddle (131) forwards until it touches the limit stop (check that the led of key
16 is on) and press the keys F + 1. The display (19) reads Password ? ∅. Enter 1 + 6
+ 9 using the numeric keys (18) and press ENTER. The display (19) will read:

INPUT VALUE
ON COUNT
LOCATOR AXIS
(XYZ)

Some numbers of no importance will now appear - these will be cancelled when you
enter the xyz value, which is the distance measured between the locator support and
the saddle vice, as in fig. 21.

FIGURE 21

DISPLAY

SAW
BAND

MOBILE CUTTER
SUPPORT VICE VICE

ADVANCE
CYLINDER

62
Using the numeric keys (18), enter the xyz value measured using a ruler and then
confirm with ENTER.
Check the set value by making a cut.
The entered measurement (xyz) is correct if it corresponds to the length of the cut
piece.
If, for instance, the cut piece is 0.2 mm longer than the xyz value, the error is
eliminated as follows:
Press F + 1 ⇒ Password ∅. Enter 1 + 6 + 9 using the numeric keys (18) and confirm
with ENTER.

The display (19) will show:

INPUT VALUE
ON COUNT
LOCATOR AXIS
XYZ

Again enter the new xyz value corresponding to xyz + 0.2 mm and confirm with
ENTER.
Check the new measurement as described above.

63
11.4 MANUAL OPERATION OF THE CN

BAND SAWING MACHINES

FOR METALS
INSTRUCTIONS ENTER
TRAVAIL

7 This enables the gearmotor (37) for the

← return of the locator (39).

The key 8 H/L is for

LOCATOR BACKWARDS 7
LOCATOR BACKWARDS 7 selecting the speed at which
SPEED CHANGE
LOCATOR FORWARDS
8
9
8 SPEED CHANGE
LOCATOR FORWARDS
8
9 the locator (39) moves; this
SLOW 290.0 (A)
FAST 290.0 (A)
H/L
is shown on the display (19).
The speed can be “FAST” or
“SLOW”.

This enables the gearmotor

9 (37) for the advance of the
→
locator (39).
IMMEDIATE QUOTA

COUNT
0,0
9 5
290,0 (B)

ENTER
IMMEDIATE QUOTA
95.0
Press the key 7 or 9, i.e. make the locator (39)
COUNT move, and the numeric value A is shown on the
29.9
display (19) indicating the actual position of the
locator (39).
IMMEDIATE QUOTA BAND SAWING MACHINES
95.0 FOR METALS
COUNT INSTRUCTIONS ENTER
95.0 TO WORK

It is possible to enter the point at which the locator (39) is to be positioned by using the
numeric keys and then confirm with ENTER. The locator (39) automatically moves to
the set point without the need to use the keys 7 or 9.
The numeric value B indicates the actual position of the locator (39) and can vary up to
a maximum of 95.0.

64
12) GENERAL MACHINE MAINTENANCE

The efficiency of the machine depends on routine checking of all its components at
regular intervals, depending on the amount of work carried out.

CLEANING

It is very important to:

- remove all swarfs from the drive wheel (64), from the idle wheel (63) and from the
sawband guide unit (98 and 118);
- regularly (at least once a month) clean the lubricating coolant tank (106) and the
swarf collection bin (110);
- if necessary, clean the pump filter (112);
- top up (or replace, if necessary) the emulsion in the tank (106) and keep it at the
correct level;
- regularly remove any swarfs from the vice (121 and 131) guides;
- regularly remove any swarfs from the base (130);
- regularly clean the linear bow guides (DETAIL 2 in TABLE 6).

65
12.1 ROUTINE MAINTENANCE POINTS AND SERVICE CHART

ROUTINE MAINTENANCE

FIGURE 22

66
ROUTINE MAINTENANCE

POS. DESCRIPTION FREQUENCY OPERATION OR MEDIUM

98-118 CLEAN SLIDES, SAWBAND AND BEARINGS DAILY LUBRICATING COOLANT OR

COMPR. AIR

117 CHECK SAWBAND GUIDE SLIDES FOR WEAR MONTHLY THICKN. GAUGE (SEE FIG.
18)

79 CHECK GREASE IN THE REDUCTION GEAR MONTHLY RESTORE

106 CHECK LEVEL OF COOLANT IN THE TANK DAILY RESTORE

112 CHECK FILTER FOR CLOGGING DAILY CLEAN

40 CASING DAILY CLEAN

63-64 SAWBAND HOLDER FLYWHEELS WEEKLY CLEAN - GREASE

50-51 CHECK SAWBAND TENSION AND TENSIONER DAILY OPTIMIZE

122-31 CLEAN VICE CUT SURFACE AND MACHINE WORK DAILY CLEAN
SURFACE

50 TENSIONER SIX-MONTHLY REPLACE SEALS IF

NECESSARY

70 SAWBAND DAILY REPLACE IF NECESSARY

128 TANK OIL LEVEL CHECK MONTHLY RESTORE

128 OIL YEARLY CHENGE

128 CHECK OIL FILTER EFFICIENCY SIX-MONTHLY REPLACE IF NECESSARY

120 CHECK OF WEAR OF HOSES MONTHLY REPLACE IF NECESSARY

120 HOSES 3 YEARS REPLACE

86 UPPER AND LOWER CYLINDER CONNECTIONS MONTHLY OIL

71 CHECK STATE OF WEAR OF BRUSHES DAILY REPLACE IF NECESSARY

67
12.2 REPLACING THE SAWBAND (FIG. 23)

In order to replace the sawband (70) correctly proceed as follows:

DISCONNECT THE MACHINE USING DEVICE 151 - FIG. 1, and:

1) open the two protection doors (40);

2) opening the casing (40) activates the safety micros (74) located on the bow (60)
which protect the operator against accidental starting up of the machine. These
micros (74) must never be mishandled by the operator;
3) remove the small casings (119 and 97) on the sawband guides (98 and 118)
using the screws;
4) turn the valve (50) knob to reduce the distance between the two wheels (63 and
64) and then remove the sawband (70) by sliding it out first from the idle wheel
(63) and then gradually easing it off the drive wheel (64). Clean the surfaces
between the two wheels (63 and 64) carefully when fitting the new sawband (70)
and within the bow (60). By reducing the distance between the two flywheels (63
and 64), the sawband breakage micro (55) is no longer energized and so the
operator is guaranteed against the risk of the sawing machine starting up
accidentally;
5) choose a new sawband (70). Make sure that its characteristics are suitable for
the material to be cut and check that it is in good working condition and with the
teeth facing the direction shown on the plate (45);
6) insert the sawband (70) between the sawband guide slides (98 and 118), then fit
it onto the drive wheel (64) and finally onto the idle wheel (63);
7) pre-tension the sawband (70) using the knob on the valve (50) to guarantee
correct use;
8) fit small casings (97-119);
9) close the casings (40);
10) the micros (74) automatically trip;
11) activate the machine using the start devices (151) and (2), let it run briefly as
indicated in the paragraphs above;

68
12) set the tension of the sawband (70) to the correct value by turning the knob on
the valve (50) so that the index indicates the required tension and then check
that the sawband breakage micro (55) is energised. If this is not the case, adjust
the contact pin (54) using the knob (53) until the micro (55) is energised.

AT THIS POINT THE MACHINE IS READY TO OPERATE!

N.B.

Before carrying out any type of maintenance on the machine the operator must always
make sure that:

- the machine is off: switch (151) in the “0” position (OFF)

- the machine is disconnected from the mains supply
- no objects that might endanger the operator are on the machine.

The operator must wear suitable forms of protection (such as protective goggles) when
carrying out maintenance work, when using compressed air or similar.

69
REPLACING THE SAWBAND

FIGURE 23

70
13) USEFUL TIPS AND
RECOMMENDATIONS FOR TROUBLESHOOTING

13.1 USEFUL TIPS AND RECOMMENDATIONS

Remember that the efficiency of the machine depends on it being clean.

In addition to all the above observations concerning correct use of the machine, the
operator must bear in mind that:

- Adjust end-cutting limit switch (95) whenever the dimensions of the sawband (70)
need to be changed (to suit the different widths of the sawbands currently on the
market).
- Even when the casings (97 and 119) are properly fitted, a particularly hazardous
area remains just behind the vice (121), left unguarded to avoid restricting the
machine's capacities, but a source of danger for the hands. This area is, however,
clearly marked out (75). Handle with extreme care and all due safety precautions.
- The machine must be fitted with appropriate roller stands to suit the size of the
material to be cut.
- A container to collect any lubricating coolant must be placed at the end of the roller
stands.
- When sawing off pieces that could be a danger owing to their size or weight, every
precaution must be taken to avoid risks to the operator or anybody standing nearby.
- Never, for any reason whatsoever, switch off the micros (74) of the sawband
casings (40).
- Never alter, tamper with and/or move the plates applied on the machine.

71
13.2 SAWBAND SELECTION CRITERIA

The following table gives general indications for sawband selection.

TABLE 3

thickness 1÷2 mm Z/1” 18 - 14 - 10/14

thickness 2÷5 mm Z/1” 10 - 8 - 8/12

thickness 5÷10 mm Z/1” 6 - 6/10 - 5/8

Ø 10÷30 Z/1” 6 - 5/8

Ø 30÷80 Z/1” 4 - 4/6

Ø 80÷150 Z/1” 3 - 3/4

Ø 150÷240 Z/1” 3 - 3/4- 2/3

72
13.3 GENERAL FAULTS

A list of possible faults their causes and remedies follows:

FAULTS POSSIBLE CAUSES AND REMEDIES

Crooked cut Check:

- efficiency of sawband guide unit (98 and 118) bearings
(116)
- that the distance between the tungsten carbide plates
(117) is as shown in figure 18 on page 42
- that sawband guide (118) is next to the workpiece
- that the material to be cut is not so badly shaped as to
cause crooked cutting
- that the sawband is properly tensioned
- roller stands or other supports must be levelled
with the vice surface (121 and 131)

Teeth breakage - Excessive cutting pressure (67)

- Excessive cutting rate (23)
- Unsuitable teeth configuration for sawband (70)
- Faulty bearings (116)
- Sawband (70) turning speed too low

Quick wear of sawband teeth - Sawband (70) not suitable for the workpiece
- Sawband (70) turning speed too high
- Too low cutting pressure (67)
- Too slow cutting rate (23)

The sawband breaks at welding point Faulty sawband welding

The sawband breaks outside the Causes:

welding point - if this occurs after only a few hours, then the problem is
related to the machine
- if the breakage occurs after several hours, it is due to
normal wear (due to rotation)

73
FAULTS POSSIBLE CAUSES AND REMEDIES

The sawband cannot be tensioned Check that length of sawband (70) is 4,500 mm +/-
5 mm

The sawband slips off the wheel Check:

- the sawband (70) tension
- for possible play in the wheel bearings (63 and 64)
- that the rake of idle wheel (63) is as shown on page 42

No lubricating coolant at the sawband Check:

- that the tank (106) is filled with lubricating coolant
- that the tap (61) is open
- that the switch (6) is at ON
- TF3 fuses (143)
- that the pipe connecting the pump (112) and the taps (82
and 61) is not choked

Cutting length differs from programmed Causes:

length - incorrect manual adjustment of the saddle vice (131) and
cutter vice (121) engage and release
- whether the front and back mechanical stops (111
and 113) on the saddle stroke (131) are not properly
calibrated

The bow (60) does not drop or rise Check:

- fuses F6, F8 and F9 (145)
- that the solenoid valve leds come on when the
corresponding control pushbuttons are used

The saddle does not advance or return Check:

- fuses F3 and F4 (145)
- that the solenoid valve leds come on when the
corresponding control pushbuttons are used

The saddle slow-down does not work Check:

- fuse F5 (145)
- that the solenoid valve leds come on when the
corresponding control pushbuttons are used
- the efficiency of the valve on the side of the block

74
FAULTS POSSIBLE CAUSES AND REMEDIES

The cutter vice cylinder does not Check:

engage or release - fuse F1 (145)
- that the solenoid valve leds come on when the
corresponding control pushbuttons are used

The saddle vice cylinder does not Check:

engage or release - fuse F2 (145)
- that the solenoid valve leds come on when the
corresponding control pushbuttons are used

The brush does not turn Check:

- fuses TF4 (143)

Generic causes Check the inputs-outputs using the F+0 function (see
page 57)

75
14) SAFETY REGULATIONS

Before carrying out any maintenance work, make sure that:

- the machine is disconnected from the mains and/or

- the main switch (151) is in the position “0” (OFF).

Always apply a warning sign whenever the machine is undergoing maintenance or

repairs and padlock the device (151, Fig. 1).

76
15) SAFETY DEVICES

- When the main switch (151) is turned to I, the STOP light (4) comes on as well as
the white and green lights (67 and 68) indicating the presence/absence of mains
potential difference (see fig. 5). Press the START pushbutton (2) to have the
machine ready to carry out any movement or programming.

- The mushroom emergency button (3). Press this to disable the controls. The light
on the START pushbutton (2) goes off and the light on the STOP pushbutton (4)
comes on. The machine cannot work. To reset, turn the emergency button.

- STOP pushbutton (4). Press this and the controls are disabled and the machine
stops.

- Limit switch (55) on tensioning device (50). If the sawband (70) breaks, the limit
switch (55) trips and the controls are thus disabled. The light on the START
pushbutton (2) goes off. When the micro (55) trips, the operator is protected against
any accidental starting up of the sawing machine. Never tamper with the micro (55)
for any reason.

- Limit switch (74) indicating the presence of the sawband casings (40) on the bow
(60).
When the casings (40) are removed, the safety micros (74) on the bow (60) trip.
When the micros (74) trip, the operator is protected against any accidental starting
up of the sawing machine. Never tamper with the micros (74) for any reason.

- Limit switch (41) indicating the presence of material in the saddle vice (131).
When the bar is too big or too small to be clamped by the saddle vice (131), the
micro (41) trips and interrupts the work cycle.

- Orange flashing light (69). This indicates that the machine is in operation.

77
 - The magnetic thermal switch (154). When this trips, the controls are excluded.

- The thermals RT3, RT6, RT5 and RT4 protect the motors from overloads. When
these trip, they take the machine to the STOP position (4).

- Fuses TF3, TF4, CF4, CF5, CF6, F1, F2, F3, F4, F5, F6, F8 and F9 protect the
operator and the corresponding electrical equipment.

- The sawband (70) is protected by the casings (40) and the small casings (97 and
119) on the sawband guides (98 and 118). Never tamper with these casings for any
reason!

- The selector (163) can be used to enable all movements in manual mode, thus
disabling the automatic settings.

78
 DISPLAY MESSAGES - FIGURE 24
CASING OPEN

EMERGENCY
LIMIT SWITCH
ERROR
CLEAR TO CONTINUE
SAWBAND MOTOR
THERMAL

OIL PUMP
THERMAL

COOLING PUMP
THERMAL

CLEANER
THERMAL

CASING OPEN

NO MATERIAL
SAWBAND BLOCKED
CLEAR TO CONTINUE

SAWBAND BROKEN
LIMIT SWITCH
ERROR
CLEAR TO
CONTINUE

The machine can diagnose its own efficiency and, if there are any defects, the causes
that have provoked an interruption of the work cycle are shown on the display (19) on
the control panel (1).

79
16) SPARE PARTS

The tables in the following pages list the main spare parts and their code numbers.

IMPORTANT

When ordering spare parts please state:

TYPE OF SAWING MACHINE ......................................................................................

SERIAL No. ...................................................................................................................

PART IN TABLE No. ............... POS. No. .............. CODE No. .....................

QUANTITY REQUIRED .................................................................................................

N.B. FILL IN ALL PARTS OF THE FORM.

80
POS. CODE

1 612339
2 515041
3 515043
4 212215
5 212207
6 515066
7 212456
8 515069
9 515068
10 515065
11 515067

81
POS. CODE POS. CODE

1 515008 11 212402
2 515032 12 515084
3 515078 13 412131
4 312203 14 515046
5 212456 15 515047
6 515019 16 515014
7 212706 17 212349
8 212211 18 515077
9 515018 19 515036
10 515076 20 312205

82
POS. CODE POS. CODE POS. CODE

1 515051 12 212735 23 312205

2 412131 13 515629 24 515079
3 515080 14 520168 25 515052
4 212406 15 212604 26 212706
5 212451 16 520372 27 212330
6 515072 17 212602 28 212349
7 212211 18 515009 29 515085
8 515083 19 412192 30 515056
9 515040 20 515013 31 412109
10 515082 21 515021
11 515081 22 312203

83
POS. CODE POS. CODE POS. CODE

1 515050 10 515048 19 515102

2 212456 11 212219 20 515115
3 515045 12 212227 21 515114
4 515086 13 212347 22 113709
5 515049 14 515113 23 212850
6 212714 15 515007 24 413208
7 312329 16 512582 25 513827
8 515087 17 312307 26 612295
9 515003 18 212515

84
POS. CODE

1 113108
2 212451
3 112303
4 413123
5 412163
6 412212
7 412181
8 412187
9 412161
10 412225
11 412226
12 412312

85
POS. CODE

1 515010
2 312501
3 312507
4 515020
5 212211
6 212706
7 212339

86
POS. CODE POS. CODE POS. CODE POS. CODE POS. CODE

1 515074 22 312319 43 515090 64 515028 85 312209

2 515004 23 312161 44 515089 65 515015 86 412101
3 520207 24 513772 45 513737 66 515030 87 513847
4 515117 25 515116 46 513824 67 212347 88 212509
5 513732 26 513800 47 212304 68 412341 89 515063
6 212214 27 513746 48 112113 69 515042 90 412136
7 512347 28 412334 49 515034 70 212985 91 212330
8 212191 29 513743 50 515070 71 112360 92 412122
9 112109 30 312320 51 112101 72 513719 93 412103
10 212451 31 513744 52 513821 73 212208 94 515038
11 212306 32 513745 53 412342 74 515092 95 212305
12 515005 33 515071 54 513728 75 513815 96 212614
13 515001 34 515002 55 212331 76 112361 97 515035
14 513762 35 515064 56 512537 77 520168 98 412138
15 512328 36 212456 57 212730 78 212604 99 612146
16 112129 37 412159 58 112112 79 212705 100 712335
17 212507 38 112203 59 212217 80 212205 101 515037
18 212602 39 513730 60 513727 81 212707 102 412137
19 212207 40 212301 61 513822 82 212212
20 513747 41 312318 62 513823 83 312211
21 713748 42 515073 63 515029 84 515091

87
POS. CODE POS. CODE

1 612273 11 212618
2 112205 12 212324
3 212601 13 212703
4 212705 14 212212
5 513450 15 612262
6 212313 16 513519
7 515093 17 413204
8 513776 18 212701
9 412202 19 312210
10 212509

88
POS. CODE POS. CODE POS. CODE POS. CODE

1 112512 14 515054 27 113802 40 113029

2 515060 15 515055 28 913038 41 113064
3 112350 16 112134 29 913033 42 113061
4 513863 17 112433 30 913039 43 113049
5 212451 18 112144 31 113121 44 113112
6 513862 19 515088 32 412134 45 113011
7 112358 20 112511 33 412127 46 113135
8 112415 21 515057 34 113010 47 113710
9 212363 22 112425 35 113716 48 113012
10 112353 23 112351 36 113071 49 113038
11 515061 24 913084 37 113111
12 515053 25 913060 38 113068
13 113035 26 913083 39 113722

89
POS. CODE POS. CODE

1 113095 11 112303
2 413132 C 12 413123
3 413106 13 413101
4 413112 14 412336
5 413137 15 412313
6 413102 16 412217
7 612342 17 412203
8 513849 P 18 412314
9 413207 19 412223
10 612358

90
POS. CODE

1 513768
2 212614
3 312437
4 312438
5 513751
6 312425
7 312423
8 612355
9 515022
10 513753
11 312435
12 312436
13 513754

91
POS. CODE POS. CODE POS. CODE POS. CODE POS. CODE

1 612366 11 312447 21 212303 31 513490 41 515111

2 312419 12 412323 22 312430 32 212451 42 515106
3 520216 13 712334 23 512638 33 513472 43 515105
4 312423 14 312421 24 312429 34 515075 44 312426
5 515025 15 312420 25 515023 35 513475 45 312424
6 312422 16 520215 26 612343 36 413108 46 312449
7 515027 17 515024 27 712319 37 412327 47 312428
8 212303 18 612350 28 212509 38 612370 48 312448
9 312446 19 412316 29 412309 39 515107 49 712335
10 413150 20 712318 30 412302 40 515110 50 412305

92
POS. CODE POS. CODE POS. CODE

1 312308 10 412206 19 212325

2 520379 11 212326 20 312207
3 212517 12 520383 21 520382
4 520381 13 520385 22 412208
5 520378 14 212603 23 212703
6 212727 15 413203 24 212212
7 212451 16 520380 25 515006
8 520386 17 412135 26 212501
9 412207 18 212191

93
17) LUBRICANT CHART

Oil for the reduction gear:

* SHELL TI VELA OIL SC 320

* IP TELIUM OIL VSF 320

17.1 LUBRICATING COOLANT

Recommended oils for preparing the lubricating coolant mix:

* IP FLUSOR OIL BHS/1

* AGIP U LE X 250/EP
* BP ELMUT EP
* ESSO SOLUBLE EP 589
* FINA VULSOL IT 4/061
* MOBIL MET 150-170
* SHELL LUTEM D
* TOTAL LACTUCA EP
* ELF SARELF EP

17.2 HYDRAULIC OIL

Recommended oils for use in the hydraulic system:

* IP HYDROIL 46
* IP VENUSIA OIL 46
* BP ENERGOL HLP 46
* ESSO NUTO H 46
* MOBIL HYDRAULIC HM, M/DTE 46
* SHELL HYDRAULIC 46
* SHELL TELLUS 46
* TOTAL AZZOLLA ZS 46

94
18) USER DECLARATION

MACHINE TYPE:
SERIAL No.:
DATE OF MANUFACTURE:

The undersigned ..........................................................................................................

position in the firm ........................................................................................................
in the name and on behalf of ........................................................................................
declares that:
- he has received .......... instruction and operation manuals;
- he has read the contents of the aforesaid manuals properly and carefully;
- he has understood and grasped all safety matters connected with the machine and is
therefore able to use it responsibly as regards his own safety and that of any persons
who may happen to be near the machine.

STAMP AND SIGNATURE

..........................................

N.B. - PLEASE RETURN FILLED IN TO

F.M.B. S.r.l. - VIA LODI 7, I - 24044 DALMINE (BERGAMO)

95
19) IDENTIFICATION PLATE

KEY :
MODELLO: MODEL
N° DI SERIE: SERIAL NO.
ANNO FABBRICAZIONE: YEAR OF MANUFACTURE

96
20) OPTIONAL EXTRAS

20.1 "RPM2" TYPE VICE PRESSURE ADJUSTMENT FIGURE 25

POS. DESCRIPTION CODE

1 Screw 212151
2 Screw 212309
3 Screw 212451
4 Nut 212602
5 Washer 212703
6 Tube 412167
7 Rubber holder 412191
8 Nipple 412314
9 Curve 112303
10 Pressure gauge 412407
11 Valve 412510
12 Pipe fitting 413122
13 Pipe fitting 413123
14 RPM 2 panel 513473
15 RPM 2 box 513517
16 RPM 2 hydraulic piping 612299

This optional allows you to adjust the pressure of the clamping of the cutter vice (121)
and the saddle vice (131).
Adjustment must be made separately for each vice and is done by hand, using the
handwheel of the valve (11 - fig. 25). The pressure gauge (10 - fig. 25) lets you read
the pressure change (in BAR).

97
20.2 "MV-PO" TYPE VERTICAL VICES
FIGURE 26

We recommend using this optional for strip cutting.

Take special care when strip cutting round bars as the round bar could accidentally
slip, thus breaking the sawband teeth (70).

98
20.3 “P02” TYPE ROLLER STANDS

The machine must be equipped and completed with roller stands of various types to
support the workpiece(s) and make the cutting process easier:

FIGURE 27

“P02” TYPE ROLLER STANDS, CODE 913080

POS. DESCRIPTION Q.TY CODE

1 HEAVY ROLLER STAND 1 513336

2 ROLLER PIN 6 512740
3 SNAP RING 12 312157
4 WASHER 12 212714
5 BEARING 12 312329
6 ROLLER 6 515059
7 SCREW 4 212330
8 WASHER 24 212707
10 NUT 8 212608
11 SCREW 8 212218
12 LEG 2 515058
13 NUT 4 212616
14 FOOT SCREW 4 512580
15 FOOT 4 520317
16 SNAP RING 4 312162

99
21) CERTIFICATE OF COMPLIANCE

We, F.M.B. s.r.l . - via Lodi 7 - 24044 Sabbio-Dalmine (Bergamo) ITALY

DECLARE ON OUR OWN RESPONSIBILITY THAT THE PRODUCT

F.M.B. metal band sawing machine, model “POLARIS” Series no.

TO WHICH THIS CERTIFICATE REFERS CONFORMS WITH THE FOLLOWING

PROVISIONS:

∗ EEC DIRECTIVE 89/392 AND AMENDMENTS (machine directive)

∗ EEC DIRECTIVE 89/336 AND AMENDMENTS (electromagnetic compatibility)
∗ EEC DIRECTIVE 98/37 AND AMENDMENTS
∗ EEC DIRECTIVE 86/188 AND AMENDMENTS (noise levels)
∗ EEC DIRECTIVE 73/23 AND AMENDMENTS (electrical materials for use within
certain voltage limits)

The following norms and technical specifications have been used:

- Presidential Decree no. 547 dated 27.04.55 Health and Safety at Work regulations
- Presidential Decree no. 459/96 Standardisation of EU member states legislation
regarding machines and the “Machine Directive”.
- EN 292/1 Machinery safety - Fundamental concepts, general design principles -
Basic terminology and methodology.
- EN 292/2 Machine safety - Fundamental concepts, general design principles -
Technical specifications and principles.
- EN 60204-1 Machine safety - Machine wiring - General requirements.
- EN 55022 Limits and methods of measurement of interference characteristics of
information technology equipment.
- EN 50081 Electromagnetic compatibility - General emission regulations -
Residential, commercial and light industrial areas.
- EN 50081-2 Electromagnetic compatibility - General immunity regulations -
Residential, commercial and light industrial areas (industrial area).
- ISO 7000 Graphic symbols
- IN-HOUSE CONSTRUCTION SPECIFICATIONS

Dalmine, SOLE DIRECTOR

FRANCO BONASCHI

100
101
 22) DE-COMMISSIONING AND SCRAPPING OF THE SAWING
MACHINE

The sawing machine must only be de-commissioned and scrapped by authorised

personnel having the required experience and training.
N.B.: Before de-commissioning, shut the machine down completely by
disconnecting all energy supplies.
Open the various guards and start disconnecting the wiring, having first made sure that
the mains cable has been unplugged. The ground wire must be the last to be removed.
Thoroughly clean the machine and remove the chip tray. Then drain the machine of all
cooling lubricant.
Drain the oil in the hydraulic gearcase and loosen the hydraulic piping connections
carefully (these may still be under pressure).
Avoid coming into direct contact with the hydraulic oil and cooling lubricant.
Take care not to spill or disperse the hydraulic oil, lubricant and any other substances
in the environment.
Follow the steps described in the relevant chapters when it comes to lifting and
handling the machine. Before starting to dismantle the machine components, consult
F.M.B. s.r.l. for full details.
N.B. All components, substances and oils in the machine must be scrapped in
full compliance with the current local legislation to this effect.

102