P 250 - Trick Tools

Transcription

P 250 - Trick Tools

USE AND MAINTENANCE MANUAL
EN
P 250
YEAR OF MANUFACTURE: ______________
Use and manteinance manual for P 250 . . . . . . . . . . . . . . . . . . . . . . . .
1
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MACHINE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
CHAPTER 1 --- Main functional parts of the machine . . . . . . . . . . . .
4
1.1 --- Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 --- Vice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 --- Lubricant/coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
CHAPTER 2 --- Safety and accident prevention . . . . . . . . . . . . . . . . . .
5
2.1 --- Use of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 --- General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 --- Advice for the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 --- Machine safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 --- Reference standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 --- Protection against accidental contact with the blade . . . . . . . . . . . . . . .
2.4.3 --- Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 --- Noise level of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.1 --- Noise level measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2 --- Noise level values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 --- Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 --- Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 --- Immunity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
6
6
7
7
7
7
7
8
8
8
CHAPTER 3 --- Installation of the machine . . . . . . . . . . . . . . . . . . . . .
9
3.1
3.2
3.3
3.4
3.5
--- Unpacking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
---Minimum requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Handling the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
--- Connection to the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
9
10
CHAPTER 4 --- Description of machine operation . . . . . . . . . . . . . . .
11
4.1 --- Description of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 --- Manual cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
CHAPTER 5 --- Diagrams, exploded views and spare parts . . . . . . . .
12
5.1 --- Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 --- Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 --- Exploded diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 --- Motor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 --- Transmission unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 --- Carter group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 --- Vice unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5 --- Base assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.6 --- Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.7 --- Handgrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
19
19
20
23
23
24
25
25
27
29
31
33
35
37
CHAPTER 6 --- Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
6.1 --- Cutting vice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 --- Rag prevention device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 --- Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 --- Making angled cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 --- Changing the blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
39
39
40
CHAPTER 7 --- Cutting speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
7.1 --- Standard machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 --- Machine with 4 pole single---phase motor . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
CHAPTER 8 --- Maintenance and choice of consumables . . . . . . . . . .
41
8.1 --- The role of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 --- Maintenance requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 --- General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1 --- Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2 --- Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3 --- Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 --- Maintenance of working parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1 --- Transmission box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 --- Consumable materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.1 --- Oils for transmission box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.2 --- Oils for lubrication/coolant liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
41
41
42
42
42
42
42
42
42
CHAPTER 9 --- Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
9.1 --- Choice of blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.1 --- Tooth pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.2 --- Cutting and feeding speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.3 --- Lubricant/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.4 --- Blade structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.5 --- Types of blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.6 --- Blade selection table with respect to cutting speed and downstroke speed
9.2 --- Classification of steels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1 --- Steel nomenclature table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
43
43
44
44
46
47
47
CHAPTER 10 --- Troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . .
48
10.1. --- Troubleshooting blade and cutting problems . . . . . . . . . . . . . . . . . . . . . .
10.2 --- Troubleshooting machine faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
50
Use and manteinance manual for P 250
PREFACE
The machine P 250 is a pendulum bench sawing machine for cutting metals.
The operation of the machine is manual: after clamping the material in the vice, the operator selects the cutting speed from
the control panel, thus starting the disc and the lubrication and cooling system; the head is moved downwards manually
by the operator using the head control lever so as to control the cutting of the material. Once the cut is complete, the cutting
head is returned to position ready for a new cutting cycle.
TECHNICAL DATA
P 250
UNIT
VALUE
DISC BLADE
External disc diameter for light hollow sections / hollow
sections / solid bars
mm
250 / 225
Internal hole diameter
mm
32 / 32
Blade thickness
mm
2 / 1.9
Speed 1 three--phase
rpm
45
Speed 1 single--phase
rpm
45
Head spindle motor 1 speed three--phase
KW
0.9
Head spindle motor 1 speed single--phase
KW
0.5
Lubricant/coolant electric pump motor
KW
0,045
Maximum electrical installed power
KW
0.945
Oil for lubricant/coolant (conc. 5--6%)
capacity lt
4.5
Oil for transmission box
capacity lt
0.4
CUTTING SPEED
POWER AND CONSUMPTIONS
P 250
1
Presentation
INTRODUCTION
This working tool has been designed to provide a simple and reliable solution to the various needs of workshops and factory
departments that work with metals.
The P 250 is a pendulum sawing machine that can perform cuts angled by 45_ to the left. This capability, together with
its high cutting capacity, makes the P 250 an extremely versatile and economic machine.
We congratulate you on your choice of the P 250 which, together with careful following of the operating and maintenance
instructions in this manual, will provide you with first class results for many years to come.
MACHINE SPECIFICATION
NAME PLATE:
The anodised aluminium name plate is rivetted
on the side of the machine.
The Rock Solid Solution
IMPORTANT: when communicating with the
Technical Service department, the model,
serial number and year of manufacture of the
machine must be quoted.
HYD--MECH
model
air pressure
--
data code
1 PH
oil pressure
bar
V
-A
bar
--
-V
3 PH
A
DIMENSIONS:
740
995
825
1530
kg 70
400
850
400
CUTTING CAPACITY FOR HOLLOW SECTIONS OF THICKNESS < 5 mm:
2
Cross--section
Blade
diameter
0 degrees
250
70
60
90 x 50
45 degrees left
250
65
55
70 x 45
P 250
Presentation
CUTTING CAPACITY FOR HOLLOW SECTIONS OF THICKNESS FROM 6 TO 10 mm AND
SOLID BARS:
Cross--section
Blade
diameter
0 degrees
225
30
20 x 40
45 degrees left
225
20
20 x 30
Max vice opening: 100 mm.
DISC BLADE:
Dimensions: HSS 250 x 32 x 2 mm for hollow sections of thickness between 1 and 5 mm.
Dimensions: HSS 225 x 32 x 1.9 mm for hollow sections of thickness between 6 and 10 mm and for solid bars.
Cutting speed: standard 45 rpm.
SPINDLE MOTOR:
Spindle motor: asynchronous three--phase 4 poles; 50 Hz.
Characteristics:
Voltage Volt
Absorption Amp.
Power kW
rpm
4 poles
230
2.8
0.9
1.400
4 poles
400
2
0.9
1.400
Stator winding in enamelled copper class H 200 _C;
Insulation class F (temperature limit TL=155_C);
Example of class F insulation: in air--cooled machines at ambient temperature of 40_C (in accordance with CEI 2--3 and
IEC 85), the allowable overtemperature is 100_C (where 100_C represents the allowable ∆ T).
Protection rating IP54 (total protection against contact with live parts and against water sprayed from all directions).
Complies with CEI standards publication IEC 34 of 1st July 1985.
EXTRACTOR MOTOR (OPTIONAL):
Submerged electric pump for coolant/refrigerant fluid: single phase 48 Volt; 50 Hz.
Characteristics:
Voltage Volt
Absorption Amp.
Power watt
rpm
24
2.67
45
2.600
Complies with CEI Standards publication IEC 34 of 1 July 1985.
P 250
3
CHAPTER 1 - Main functional parts of the machine
1.3 -- Lubricant/coolant system
In order to fully understand how the machine works, described in
detail in the chapter ”MACHINE CYCLES”, lets first consider the
main units and their relative location.
The lubricant/coolant system consists of a submerged electric
pump located inside the base and an outflow nozzle fixed to the
blade protective cover.
1.1 -- Cutting head
NOZZLE
The cutting head is the unit that actually performs the cut and consists of a cast iron section on which the following parts are
mounted: the disc, the disc support units, the drive transmission
unit and the spindle motor. The cutting head is fixed to the turntable by means of a hinge and performs a downward travel to cut
the material. The upward and downward movements of the head
are controlled manually by the operator.
ELECTRIC PUMP
1.2 -- Vice
The cutting vice is the unit that clamps the material during the cut.
It consists of a vice support, on which the slide with the mobile jaw
and fixed jaw are mounted. The vice support is fixed to the upper
part of the base.
4
P 250
CHAPTER 2 - Safety and accident prevention
CONNECTIONS
The P 250 has been designed and produced in accordance with
European standards.
For the correct use of the machine we would recommend that
the instructions contained in this chapter are carefully followed.
Check that the power supply cables and pneumatic feed system
comply with the maximum machine absorption values listed in
the ”Machine Specification” tables; replace if necessary.
EARTHING SYSTEM
The installation of the earthing system must comply with the
requirements of IEC Standard 204.
2.1 -- Use of the machine
POSITION OF THE OPERATOR
The position of the operator controlling machining operations on
the machine must be as shown in the diagram below.
The P 250 pendulum circular saw is designed to cut exclusively
metal profiles. Other types of materials and machining are not
compatible with the specific characteristics of the machine.
The employer is responsible for instructing the personnel who, in
turn, are obliged to inform the operator of any accident risks,
safety devices, noise emission and accident prevention
regulations provided for by international standards and national
laws regarding the use of the machine. The operator must be
perfectly aware of the position and function of all the
machine’s controls.
The instructions, warnings and accident prevention
standards in this manual must be respected without
question by all those concerned.
The following definitions are those provided for by EEC
DIRECTIVE ON MACHINERY No. 98/37/CE:
2.3 -- Advice for the operator
` ”Danger zone”: any zone in and/or around a machine in
which the presence of a person constitutes a risk for the
safety and health of that person.
Always wear proper goggles or protective
glasses.
` ”Person exposed”: any person finding himself either
completely or partly in a danger zone.
` ”Operator”: the person or persons given the responsibility of
installing, operating, adjusting, maintaining, cleaning,
repairing or transporting the machine.
Do not use the machine without the guards in
position. Replace the polycarbonate windows , if
subject to corrosion.
WARNING!
The manufacturer declines any responsibility whatsoever,
either civil of criminal, in the case of unauthorised
interference or replacement of one or more parts or
assemblies on the machine, or if accessories, tools and
consumable materials are used that are different from those
recommended by the manufacturer himself or if the machine
is inserted in a plant system and its proper function is
altered.
Do not allow hands or arms to encroach on the
cutting zone while the machine is in operation.
2.2 -- General requirements
Do not wear oversize clothing with long sleeves,
oversize gloves, bracelets, necklaces or any
other object that may become entangled in the
machine during working; long hair must be tied
back and bunched.
LIGHTING
Insufficient lighting for the types of operation envisaged could
constitute a safety hazard for the persons concerned. For this
reason, the user of the machine must provide lighting in the
working zone sufficient to eliminate areas in shadow and prevent
dazzling light sources (reference standard ISO 8995--89
”Lighting in working environments”.
Always disconnect the power supply to the
machine before carrying out any maintenance
work whatsoever, including in the case of
abnormal operation of the machine.
P 250
5
Safety and accident prevention
Before starting to cut, support the material
adequately on both sides of the machine. Before
removing the devices supporting and moving the
material, fasten the latter in place using the
machine’s clamping devices or other suitable
equipment.
When working on the bandsaw, only wear gloves
when handling materials and tool change or
adjustment operations. Only carry out one
operation at a time and do not hold more than one
item or operate more than one device
simultaneously. Keep hands as clean as
possible.
Any maintenance work on the hydraulic or
pneumatic systems must be carried out only after
the pressure in the system has been released.
Warning: if the disc seizes while cutting, turn the
machine off immediately. If it is difficult to free the
disc, open the vice slowly, remove the workpiece
and check that the disc or the teeth are not
broken. If they are, replace the disc.
The operator MUST NOT perform any risky
operations or those not required for the
machining in course (e.g. remove swarf or metal
shavings form the machine while cutting).
Before carrying out any repair works on the
machine, consult the Technical Service; this can
also be done through an agency in the country in
which the machine is being used.
Remove equipment, tools or any other objects
from the cutting zone; always keep the working
area as clean as possible.
2.4 -- Machine safety devices
This use and maintenance manual is not intended as purely a
guide for the use of the machine in a strictly productive
environment, it is instead an instrument providing information on
how to use the machine correctly and safely. The following
standards are those specified by the EEC Committee in the
directives regarding safety of machinery, health and safety at
work, personal protection and safeguarding of the environment.
These standards have been applied to the P 250 band saw.
Before starting any cutting operations, ensure
that the workpiece is securely held in the vice and
the machine has been set correctly. A number of
examples of how to clamp the different profiles
correctly in our machines are shown below.
2.4.1 -- Reference standards
MACHINE SAFETY
` EEC Directive No. 98/37/CE of 14.06.1989 known as
”Machines directive”.
` EEC Directive No. 91/368 -- 93/44 -- 93/68 which modifies
EEC Directive No. 98/37/CE relating to machine safety.
` EEC Directive No. 73/23 known as ”Low voltage directive”
HEALTH AND SAFETY AT WORK
Do not use the machine for cutting pieces which
exceed the cutting capacity described in the
technical specifications or are less than 5mm
` EEC Directive No. 80/1107; 83/477;86/188;88/188; 88/642
for the protection of workers against risks caused by
exposure to physical, chemical and biological agents during
working.
Never move the machine while it is cutting.
` EEC Directive No. 89/391 and Special EEC Directives No.
89/654 and No. 89/655 for improvements in health and safety
at work.
` EEC Directive No. 90/394 for the protection of workers
against risks deriving from exposure at work to carcinogenic
substances.
` EEC Directive No. 77/576 and No. 79/640 on safety signs at
work.
Do not use blades of different sizes to those
recommended in the machine’s specifications.
PERSONAL PROTECTION
` EEC Directive No. 89/656 and No. 89/686 on the use of
personal protection devices.
ENVIRONMENTAL PROTECTION
` EEC Directive No. 75/442 on waste disposal.
When cutting very short pieces, make sure that
they are not dragged behind the support
shoulder, where they could jam in the blade.
6
` EEC Directive No. 75/439 on the disposal of used oil.
P 250
2.4.2 -- Protection against accidental contact with the
blade
2.5 -- Noise level of the machine
Noise can cause hearing damage and represents one the
problems faced by many countries who adopt their own
standards. In accordance with the EEC Machine Directive
98/37/CE, we are listing the standards that specify noise levels
for machine tools. This chapter also reports the noise levels
produced by the P 250 during its various operating phases and
the methods used for measuring these levels. The Italian
standard governing this aspect is D.M.n.277/91 drawn from EEC
Directives 80/1107, 82/605, 83/477, 86/188, 88/642, UNI EN
ISO 4871 (1998).
2
1
3
2.5.1 -- 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 the work station.
The damage caused by noise depends on three parameters:
level, frequency and duration. The equivalent level concept Leq
combines the three parameters and supplies just one indication.
The Leq is based on the principle of equal energy, and represents
the continuous stationary level containing the same amount of
energy, expressed in dBA, as that actually fluctuating over the
same period of time.
This calculation is made automatically by the integrator
noise--meter. The measurements are taken every 60 seconds, in
order to obtain a stabilised value. The reading stays on the
display for a sufficient time to enable a reading to be taken by the
operator.
Measurements are taken by holding the instrument at
approximately 1 metre from the machine at a height of 1.60
metres above the platform at the operator’s work station. Two
measurements are taken: the first while the machine operates
without cutting anything, the second while cutting in manual
mode.
¡ Metal disc cover fixed to the cutting head;
© mobile disc guard fixed to the cover and the lead nut body so
as to ensure that the blade is covered and the only part of the
disc exposed is that used for the actual cutting in accordance
with DPR 547/55 art. 108;
¢ vice with rag prevention device and double workpiece clamping to ensure optimum fixing of the material.
2.4.3 -- Electrical equipment
In accordance with Italian standard CEI 60204--1, September
1993, derived from European Standard EN 60204--1 publication
IEC 204--1, 1992:
- Access to electrical parts restricted by screws;
- earthing of all parts the operator may come into contact with
either during work or accidentally;
- power cut--out device constructed with a socket plug in
accordance with 5.3.2 sub--section C.
2.5.2 -- Noise level values
Identification
Machine type
Band saw for metal applications
Model
P 250
Reference standard
ISO 3746
Results
Description
50x15 mm pipe in FE37 steel
Disc blade HSS--DMO5 0 225 T6
Results
MEAN SOUND LEVEL (Leq) 100.82 dB (A)
Environmental correction (K) 2.78 dB(A)
Peak sound power (Lw) 111.16 dB(A)
Description
35 mm Ø solid tube in FE37 steel.
Results
MEAN SOUND LEVEL (Leq) 92.24 dB(A)
Description
20 mm Ø solid tube in FE37 steel.
Results
MEAN SOUND LEVEL (Leq) 89.12 dB(A)
Test 1
Test 2
Test 3
P 250
7
magnitude as to contaminate the surrounding electromagnetic
environment beyond clearly prescribed limits”;
2 “IMMUNITY: the appliance or system must be able to operate
correctly even when it is placed in an electromagnetic
environment that is contaminated by disturbances of defined
magnitude”.
The following text contains a list of the applied standards and the
results of the electromagnetic compatibility testing of machine
model P 250; Test report no. 061200.
2.6 -- Electromagnetic compatibility
As from 1 January 1996 all electrical and electronic appliances
bearing the CE marking that are sold on the European market
must conform to Directive 89/336/EEC and 70/23/CEE and
98/37/CEE. The prescriptions regard two specific aspects in
particular:
1 “EMISSIONS: during its operation, the appliance or system
must not emit spurious electromagnetic signals of such
2.6.1 -- Emissions
` CEI EN 61000--6--4 (2002) Electromagnetic Compatibility
(EMC) -- Generic standard regarding emissions. Part 6--2:
Industrial Environment.
` EN 55011 (1999) Industrial, scientific, and medical radio
frequency appliances (ISM). Characteristics of radio frequency
disturbance -- Limits and methods of measurement.
`
EN 55014--1 (2002) Electromagnetic Compatibility -Prescriptions for domestic appliances, electric power tools, and
similar equipment. Part 1: Standard Emission in relation to
product family.
CONDUCTED EMISSIONS
Gate A
A.C. power supply
input
Freq. (MHz)
0.15 --- 0.5
Q---peak limit (dBuV)
66 --- 56
(linear reduction with log
of frequency)
Mean value limit (dBuV)
56 --- 46
(linear reduction with log of frequency)
0.5 --- 5
5 --- 30
56
60
46
50
Result
Complies
CONDUCTED EMISSIONS --- ANALYSIS OF INTERMITTENT DISTURBANCES
Gate
A.C. power supply input
Result
Not applicable
IRRADIATED EMISSIONS
Gate
Freq. (MHz)
Enclosure
30 --- 230
230 --- 1000
Q---peak limit (10 m)
(dBuV/m)
40
47
Result
Complies
2.6.2 -- Immunity
` CEI EN 61000--6--2 (2000) Electromagnetic Compatibility
(EMC) -- Generic standard on immunity. Part 6--2: Industrial
Environment.
8
The EUT is deemed to fulfil the immunity requirements without
testing, because it contains no electonic control circuitry.
P 250
CHAPTER 3 - Installation of the machine
3.1 -- Unpacking the machine
3.2 -- Check list
Hyd--Mech use packing materials that guarantee the integrity and
protection of the machine during its transport to the customer.
The type of packing differs according to the size, weight and
destination. As a consequence, the customer will receive the
machine in one of two following ways.
-- packaging with pallet, straps and cardboard box with lid.
Before starting to install the machine, check all the accessories,
whether standard or optional, supplied with it. The basic version
of the P 250 1--SPEED sawing machine is supplied complete
with:
` pedestal with coolant liquid tank and turntable locking
system;
` 48 V electric pump for the lubrication and cooling of the disc;
` head control lever;
` mobile guard to cover the part of the blade not being used for
the cut;
` vice with rag prevention device and double workpiece
clamping;
` option of performing cuts from 0_ to 45_ left;
` 1--speed electric motor;
` bag of accessories.
The bag of accessories is enclosed in the machine before it is
packed and contains:
` 4 and 5 mm Allen keys;
` 13 mm open--end wrench;
` 19 mm open--end wrench;
` 20 mm diam. rod for cuts to measure with an 8 mm diam.
ratchet fork and lever and VCE M8x35 Allen grub screw;
` this use and maintenance manual.
OPTIONAL
ACCESSORIES AVAILABLE ON REQUEST:
` metal pedestal with drawer;
` HSS DMo5/M2 D.250x32x2 circular blade for hollow
sections;
` HSS DMo5/M2 D.225x32x1.9 circular blade for hollow
sections and solid bars;
` 5 l can of emulsible oil.
In both cases, the machine must be handled using a fork--lift
truck, inserting the forks at the points indicated by the arrows in
the photo and the marks on the crate.
WARNING! Do not handle the packed machine using
slings.
3.3 --Minimum requirements
In order for the machine to function correctly, the room in which
it is to be installed must satisfy the following requirements:
--
NO
----
power supply voltage/frequency: refer to the values on the
spindle motor rating plate.
ambient temperature: from --10 to +50 degrees C.
relative humidity: not more than 90%.
lighting: not less than 500 LUX.
WARNING!
The machine is already protected against voltage variations
occurring at the installation; However, the machine will only
run trouble--free if the variations do not exceed ±10%.
3.4 -- Handling the machine
To install the machine, first remove the packing, paying particular
attention not to cut any electric wires or hydraulic hoses; if
necessary use pincers, a hammer and cutters. To install the
machine at the work station, follow the procedures indicated in
paragraph 3.4.
When selecting the site, take into account the overall
dimensions of the machine, stated previously, and the
necessary space required for the operator to work in complete
safety.
If the machine has to be moved from its seat, use a fork lift truck
if the machine is mounted on a pallet or webbing and a crane if
the machine is on the ground:
to lift and move the saw
with belts, harness the machine as shown in the figure, right;
P 250
9
Installation of the machine
hook the belts to the lifting
hook, making sure that the
machine does not tilt.
3 -- Check that the motor turns in the correct direction. To do this,
proceed as follows:
a) select 1 on the polarity switch located on the control panel.
3.5 -- Connection to the power supply
b) Operate the jog pushbutton on the manual head control lever
Before connecting the machine to the power supply, check that
the socket is not connected in series with other machines. This
requirement is fundamental for the good operation of the
machine.
To connect the machine to the power supply, proceed as follows:
1 -- connect the power supply cable of the machine to a plug
which matches the socket to be used (EN 60204--1 § 5.3.2)
2 -- Insert the plug in the socket, ensuring that the mains voltage
is the same as that for which the machine has been setup.
c) if all the above operations have been carried out correctly, the
blade motor will now start up and the disc will start to turn.
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
R = L1
S = L2
T = L3
PE = GND
WARNING!
When using systems with a neutral wire, special care must be
taken when connecting the blue neutral wire, in that if it is
connected to a phase wire it will discharge the phase voltage to
the equipment connected for voltage: phase--neutral.
VOLT ?
VOLT ?
Make sure that the disc turns in the correct direction as
shown in the above diagram. If it does not, simply reverse two
of the phase wires on the machine’s power supply input.
The sawing machine is now ready to start the work for which it
was designed. Chapter four provides a detailed description of the
various functions of the machine and its operating cycles.
10
P 250
CHAPTER 4 - Description of machine operation
This chapter analyses all the machine’s functions. We shall therefore start with a description of the pushbuttons and other components
on the control panel.
4.1 -- Description of the control panel
The figure below show the components that make up the control panel of the P250;
2
1
1 -- SPEED SWITCH
2 -- HEAD CONTROL LEVER MICROSWITCH
Control lever
Microswitch
On the small control panel the machine has a main switch which,
when turned to the 1 position, provides electrical power to the machine.
4.2 -- Manual cycle
Sequence of operations for making a cut with the manual cycle:
1) Connect the machine to a suitable electric power point (see
chapter 3);
2) position the material in the vice
and calculate the length of the cut
(using the rods for cuts to measure).
In accordance with legislation in force, the voltage is 24 V and the
microswitch is assembled in an enclosure (blue handle) isolated
from external agents such as dust and moisture to an IP 55
protection rating.
6) Grip the head control lever and
start the disc turning by pressing
the microswitch on the handgrip;
the head descent speed is controlled manually by the operator.
At the same time the coolant/lubricant fluid pump starts.
7) At the end of the cut the head can
be raised; the springs behind the
head make this operation easier.
3) Clamp the workpiece in the cutting vice.
4) Make sure the workpiece is securely clamped in the vice by trying
to move it manually.
8) Remove the workpiece from the
vice using the handwheel. The
machine is now ready for a new
cutting operation.
5) Select the cutting speed using
the Speed switch selector.
P 250
11
CHAPTER 5 - Diagrams, exploded views and spare parts
This chapter contains functional diagrams of the machine and exploded views of the P 250. This document will allow you to identify the
location of the various components making up the machine, thus enabling repairs and/or maintenance work to be carried out. In addition,
this document will also enable you to order spare parts, correctly identifying them by part number and position number.
5.1 -- Diagrams
5.1.1 -- Wiring diagrams
How to read the wiring diagrams
With the introduction of the new standardised wiring diagrams, the following gives an illustration of the way in
which they have been drawn up. Each sheet of the project contains a box which gives the following information:
The numbers indicate the columns into which the entire drawing is divided
MARIO ROSSI
Indications of the
model of machine
Indications of the date production started
MARIO ROSSI
Identification of the designer
Identification of the Reference Standard
12
P 250
Indication of the page number
Diagrams, exploded views and spare parts
Each component in the wiring diagram is identified by a unique alphanumeric identification code, in compliance
with regulations:
The wire is identified by
the code --W4
This symbol identifies the wire
with its relative number and colour
MARIO ROSSI
These symbols, known as potentials, are used to provide page references: the first number indicates the page
to be referred to, the second number, after the dot,
identifies the column on that page; example /11.8 indicates that the wire continues on page no. 11 in column
8
The motor is identified by the code --M1
The pages following the wiring diagrams contain the following lists:
1.
components list (list of all components) and terminals list (list of all the terminals) with the following information:
H
H
H
H
H
in--house article code;
identification code;
reference, no. of the page and column on which it can be found;
description;
manufacturer
ART. COD.
ID
PRES.REF
DESCRIPTION
MANUFACTURER
022.2151
--B1
/5.2
Strain gauge
Deltatec
P 250
13
wires list (list of all wires) with the following information:
2.
H
H
H
H
H
H
H
CODE
022.0141
in--house article code;
identification code;
description
section of wire (mm2);
colour of wire;
start: indicates the component (identification code and contact number) at which the wire starts;
end: indicates the component (identification code and contact number) at which the wire ends; e.g.
CABLE
--W7
DESCRIPTION
RESET+EMERGENCY
SECTION
0.50
NO.
317
COLOUR
WHITE
START
--S3
4
END
--K10
14
In this example, wire no. 317 white, identified as ---W7, starts from contact no. 4 on component ---S3, and ends at
contact no. 14 on component ---K10.
Enclosed below is Appendix D2 to European Standard EN 60204---1
D2---Letter codes used to designate the type of component
LETTER
TYPE OF COMPONENT
EXAMPLES
Complex units
Laser
Maser
Regulator
B
Transducers converting a non
electrical signal to an electrical
signal and vice versa
Transistor amplifier
IC amplifier
Magnetic amplifier
Valve amplifier
Printed circuit board
Drawer
Rack
C
Capacitors
A
IDENTIFICATION OF THE APPLIANCE
A
AD
AJ
AM
AV
AP
AT
AR
C
D
Binary operators, timing devices, storage devices
Digital integrated circuits
and devices:
Delay line
Bistable element
Monostable element
Recorder
Magnetic memory
Tape or disk recorder
E
Various materials
Devices not specified in
this table
E
Lightning protectors
Arrestors
F
D
FA
F
Protective Devices
Instant action current threshold protector
Delayed action current
threshold protector
Instant and delayed action
current threshold protector
Fuse
Voltage threshold protector
FR
FS
FU
FV
14
P 250
LETTER
TYPE OF COMPONENT
EXAMPLES
Rotating generators
Crystal oscillators
G
H
Generators, feeders
Signaling Devices
Accumulator battery
Rotating or static frequency
converter
Power feeder
Buzzer
Optical signal, indicator
light device
G
GB
GF
GS
HA
HL
J
K
Relays, Contactors
Instant all or nothing relays
or instant contactors
Bistable relays or interdependent contactors
(All or nothing contactors
with mechanical contact or
permanent magnet etc.)
Contactors
Polarised relays
Reed relays
All or nothing timed relays
(timers)
Inductor
Stop coil
Reactor
KA
KL
KM
KP
KR
KT
L
Inductors, reactors
M
Motors
N
Analogue intgrated circuits
Operational amplifiers
Hybrid analog/digital appliances
N
P
Measurement equipment, test
devices
Indicator, recorder and integrator measurement devices
Signal generators
P
Q
Power circuit switching appliances
Automatic switch
Engine saver switch
Knife switch
R
Resistors
Fixed or variable resistor
(rheostat)
Command or control devices
Selector or switch
Button (including electronic
proximity switch)
Numerical all or nothing
sensors (single step) of
mechanical and electronic
type:
-- Liquid level sensor
--Pressure sensor
Position sensor (including
proximity)
--Rotation sensor
--Temperature probe
S
L
M
P 250
QF
QM
QS
R
SA
SB
SL
SP
SQ
SR
ST
15
LETTER
T
U
V
W
X
Y
Z
16
TYPE OF COMPONENT
EXAMPLES
TA
Transformers
Current transformer
Control circuit supply transformer
Power transformer
Magnetic stabiliser
Voltage transformer
Modulators, converters
Discriminator
Demodulator
Frequency converter
Coder
Converter
Inverter
Telegraphic repeater
U
Electronic pipes, semiconductors
Electronic pipe
Gas discharge pipe
Diode
Transistor
Thyristor
V
Transmission lines, wave guides, antennas
Conductor
Cable
Bar
Wave guide
Wave guide directional
coupler
Dipole
Parabolic antenna
W
Terminals, sockets, plugs
Connector bar
Test plug
Plug
Socket
Terminal connector band
XB
XJ
XP
XS
XT
Electrically operated mechanical appliances
Electromagnet
Electromagnetic brake
Electromagnetic clutch
Magnetic table spindle
Electromagnetic valve
Transformers, impedence
Line equalizer
adapters, equalizers, band limi- Compresser
ters
Crystal filter
P 250
TC
TM
TS
TV
YA
YB
YC
YH
YV
Z
STANDARDISED WIRING DIAGRAMS (CENELEC STANDARD)
P 250
17
18
P 250
List of cables
Code
Cable
022.0129
--W1
022.0129
022.0129
Description
Ø
No.
Colour
Start
End
Power Supply
1
AWG 16
BLACK 1
--S50:1
--W1
Power Supply
2
AWG 16
BLACK 2
--S50:3
--W1
Power Supply
3
AWG 16
BLACK 3
--S50:5
022.0129
--W1
Power Supply
AWG 16
YELLOW/GREEN
022.0129
--W2
Blade Motor
23
AWG 16
BLACK 1
--K1:2
--M1:U
022.0129
--W2
Blade Motor
25
AWG 16
BLACK 2
--K1:4
--M1:V
022.0129
--W2
Blade Motor
27
AWG 16
BLACK 3
--K1:6
--M1:W
022.0129
--W2
Blade Motor
AWG 16
YELLOW/GREEN
--X1/PE
--M1:PE
022.0130
--W4
Electropump
37
AWG 18
BLACK 1
--T1:0
--M2:U
022.0130
--W4
Electropump
38
AWG 18
BLACK 2
--F6
--M2:V
022.0130
--W4
Electropump
AWG 16
YELLOW/GREEN
--X1:PE
--M2:PE
022.0139
--W52
Micro Switch
031
AWG 20
BLACK 1
--F5
--S15:3
022.0139
--W52
Micro Switch
26
AWG 20
BLACK 2
--K1:A1
--S15:4
--X1:PE
022.0134G/V
--W100
T1:PE/X1:PE
AWG 16
YELLOW/GREEN
--T1:PE
--X1/PE
022.0134G/V
--W101
T1:0(0--24)/X1:PE
AWG 16
YELLOW/GREEN
--T1:0(0--24)
--X1/PE
022.0134B
--W102
S50:2/F1
05
AWG 16
BLACK
--S50:2
--F1
022.0134B
--W103
S50:4/F2
06
AWG 16
BLACK
--S50:4
--F2
022.0134B
--W104
S50:6/F3
07
AWG 16
BLACK
--S50:6
--F3
022.0134B
--W105
F1/K1:1
5
AWG 16
BLACK
--F1
--K1:1
022.0134B
--W106
F2/K2:3
6
AWG 16
BLACK
--F2
--K1:3
022.0134B
--W107
F3/K1:5
7
AWG 16
BLACK
--F3
--K1:5
022.0134B
--W108
K1:1/F4
5
AWG 16
BLACK
--K1:1
--F4
022.0134B
--W109
K1:3/T1:0(0--240)
6
AWG16
BLACK
--K1:3
--T1.0(0--240)
022.0134B
--W110
F4/T1:240(0--2408
11
AWG16
BLACK
--F4
--T1:240(0--240
022.0133R
--W111
T1:48/K1:14
36
AWG20
RED
--T1:48
--K1:14
022.0133R
--W112
K1:13/F6
036
AWG20
RED
--K1:13
--F6
022.0133R
--W113
T1:24/F5
31
AWG20
RED
--T1:24
--F5
022.0133BL
--W114
T1:0(0--24)/K1:A2
22
AWG20
BLUE
--T1:0(0--24)
--K1:A2
List of components
Code
ID
Rif
Description
Manufacturer
022.1136
--F1
1/3
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F1
1/3
FUSE--HOLDER ST
PHOENIX
022.1136
--F2
1/3
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F2
1/3
FUSE--HOLDER ST
PHOENIX
022.1136
--F3
1/3
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F3
1/3
FUSE--HOLDER ST
PHOENIX
022.1136
--F4
1/5
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F4
1/5
FUSE--HOLDER ST
PHOENIX
022.1136
--F5
1/8
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F5
1/8
FUSE--HOLDER ST
PHOENIX
022.1136
--F6
1/8
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F6
1/8
FUSE--HOLDER ST
PHOENIX
022.0093
--K1
2/2
CONTACTOR
ROCKEWELL AUTOMATION
019.1704
--M1
1/4
BLADE MOTOR 230VAC 60HZ
CARPANELLI MOTORI
028.0291
--M2
2/7
ELECTROPUMP SP/48 VAC 60HZ
SAP
034.1221
--S15
2/4
KNOB
BARDEGGIA
010.0928
--S15
2/4
SPRING
ADRIATICA MOLLE
P 250
19
Code
ID
Rif
Description
Manufacturer
025.0691
--S15
2/4
KNOB SEAL
BARDEGGIA
022.0023
--S50
1/1
POLE CHANGE SWITCH
ROCKWELL AUTOMATION
022.0440
--T1
1/6
TROANSFORMER 30+70W (0--240)SEC
(0--24/0--48)
WAN
List of terminals
Code
ID
Rif
Description
Manufacturer
022.2247
--X1
1/6
QUADRUPLE GROUND TERMINAL
PHOENIX
022.2247
--X1
1/6
PHOENIX
20
P 250
P 250
21
22
P 250
List of cables
Code
Description
Cable
Ø
No.
Colour
Start
End
022.0128
--W1
POWER SUPPLY
1
AWG 16
BLACK 1
--S50:1
022.0128
--W1
POWER SUPPLY
2
AWG 16
BLACK 2
--S50:3
022.0128
--W1
POWER SUPPLY
AWG 16
YELLOW/GREEN
--X1:PE
022.0128
--W2
BLADE MOTOR
23
AWG 16
BLACK 1
--K1:2
--M1:U
022.0128
--W2
BLADE MOTOR
25
AWG 16
BLACK 2
--K1:4
--M1:V
022.0128
--W2
BLADE MOTOR
AWG 16
YELLOW/GREEN
--X1/PE
--M1:PE
022.0130
--W4
ELECTROPUMP
37
AWG 18
BLACK 1
--T1:0
--M2:U
022.0130
--W4
ELECTROPUMP
38
AWG 18
BLACK 2
--F6
--M2:V
022.0130
--W4
ELECTROPUMP
AWG 16
YELLOW/GREEN
--X1:PE
--M2:PE
022.0139
--W52
MICRO SWITCH
031
AWG 20
BLACK 1
--F5
--S15:3
022.0139
--W52
MICRO SWITCH
26
AWG 20
BLACK 2
--K1:A1
--S15:4
022.0134G/V
--W100
T1:PE/X1:PE
AWG 16
YELLOW/GREEN
--T1:PE
--X1/PE
022.0134G/V
--W101
T1:0(0--24)/X1:PE
AWG 16
YELLOW/GREEN
--T1:0(0--24)
--X1/PE
022.0134B
--W102
S50:2/F1
05
AWG 16
BLACK
--S50:2
--F1
022.0134B
--W103
S50:4/F2
06
AWG 16
BLACK
--S50:4
--F2
022.0134B
--W105
F1/K1:1
5
AWG 16
BLACK
--F1
--K1:1
022.0134B
--W106
F2/K2:3
6
AWG 16
BLACK
--F2
--K1:3
022.0134B
--W108
K1:1/F4
5
AWG 16
BLACK
--K1:1
--F4
022.0134B
--W109
K1:3/T1:0(0--240)
6
AWG16
BLACK
--K1:3
--T1.0(0--240)
022.0134B
--W110
F4/T1:240(0--2408
11
AWG16
BLACK
--F4
--T1:240(0--240
022.0133R
--W111
T1:48/K1:14
36
AWG20
RED
--T1:48
--K1:14
022.0133R
--W112
K1:13/F6
036
AWG20
RED
--K1:13
--F6
022.0133R
--W113
T1:24/F5
31
AWG20
RED
--T1:24
--F5
022.0133BL
--W114
T1:0(0--24)/K1:A2
22
AWG20
BLUE
--T1:0(0--24)
--K1:A2
List of components
Code
ID
Rif
Description
Manufacturer
022.1136
--F1
1/3
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F1
1/3
FUSE--HOLDER ST
PHOENIX
022.1136
--F2
1/3
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F2
1/3
FUSE--HOLDER ST
PHOENIX
022.1136
--F4
1/5
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F4
1/5
FUSE--HOLDER ST
PHOENIX
022.1136
--F5
1/8
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F5
1/8
FUSE--HOLDER ST
PHOENIX
022.1136
--F6
1/8
FUSE 6,3X32 5A
COMAPEL SRL
022.2252
--F6
1/8
FUSE--HOLDER ST
PHOENIX
022.0093
--K1
2/2
CONTACTOR
ROCKEWELL AUTOMATION
019.3302
--M1
1/4
BLADE MOTOR 220VAC 60HZ
CARPANELLI MOTORI
028.0291
--M2
2/7
ELECTROPUMP 48VAC 60HZ
SAP
034.1221
--S15
2/4
KNOB
BARDEGGIA
010.0928
--S15
2/4
SPRING
ADRIATICA MOLLE
025.0691
--S15
2/4
KNOB SEAL
BARDEGGIA
022.0023
--S50
1/1
POLE CHANGE SWITCH
ROCKWELL AUTOMATION
022.0440
--T1
1/6
TROANSFORMER 30+70W (0--240)SEC
(0--24/0--48)
WAN
P 250
23
List of terminals
Code
ID
Rif
Description
Manufacturer
022.2247
--X1
1/6
PHOENIX
022.2247
--X1
1/6
PHOENIX
24
P 250
5.2 -- Exploded diagrams
The following section provides the exploded diagrams, which are extremely detailed and may help you to gain familiarity
with the machine.
5.2.1 -- Motor unit
P 250
25
Spare parts
Code
007.1005
010.7103
010.7242
010.7604
010.7961
019.0084
022.0234
022.0244
025.0102
025.0628
26
Description
WORM SCREW SPACER
5 X 5 X 30 KEY
M17 LOW SELF--LOCKING SCREW NUT
0 8 WASHER
TE 8 X 20 SCREW
KW 0,5 4P.B5 0 120 V. 220--380
CORD PRESSER
LOCK NUT 3217B GREY PG 13,5
WORM SCREW 08/1
MOTOR GASKET
U. of M.
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
P 250
Quantity
1,000
1,000
1,000
4,000
4,000
1,000
1,000
1,000
1,000
1,000
5.2.2 -- Transmission unit
P 250
27
Spare parts
Code
001.0103
001.0110
005.1072
005.2003
007.1002
010.0907
010.1202
010.1491
010.1493
010.1906
010.7203
010.7204
010.7221
010.7226
010.7402
010.7452
010.7494
010.7554
010.7603
010.7606
010.7661
010.7731
010.7761
010.7830
010.7868
010.7871
010.7872
010.7961
010.7967
010.7986
011.0013
011.0106
016.0199
025.0203
025.1011
034.0901
090.0271
28
Description
ROTATING TABLE
GEAR BOX MOD.1010
FIXED PROTECTION
RING NUT
PIN
HEAD RETURN SPRING
OIL FILLER DIAM.8
SPRING FIXING BRACKET PUCK
SPRING FIXING BRACKET
BT/NOT--AUS LEVER
M6 SCREW NUT
M8 SCREW NUT
M16 LOW SCREW NUT
M6 SELF--LOCKING SCREW NUT
6 X 12 CYLIND.POINT VCE GRUB SCREW
6 X 16 CONICAL POINT VCE GRUB SCREW
16 X 10 FLAT POINT VCE GRUB SCREW
10 X 20 FEEDING PIN
0 6 WASHER
0 12 WASHER
THICKNESS WASHER DIAM. 6 X 3
CONIC PIN DIAM. 8 X 45
ELASTIC PIN DIAM. 4 X 20
5 X 10 BUTON SCREW
TCEI 6 X 12 SCREW
TCEI 6 X 20 SCREW
TCEI 6 X 25 SCREW
TE 8 X 20 SCREW
TE 8 X 40 SCREW
TE 12 X 35 SCREW
BLADE SHAFT
OUTER FLANGE
GUARD FIXED SUPPORT
SEAL 35X25X7
_
NR
1/2”GAS. OIL LEVEL CAP
COMPLETE MEP HANDLE
P 250
U. of M.
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
Quantity
1,000
1,000
1,000
1,000
1,000
2,000
2,000
1,000
1,000
1,000
3,000
1,000
1,000
2,000
1,000
1,000
1,000
2,000
8,000
1,000
2,000
1,000
1,000
2,000
4,000
2,000
2,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
5.2.3 -- Carter group
P 250
29
Spare parts
Code
005.1071
005.2002
005.2005
010.7013
010.7031
010.7454
010.7603
010.7861
010.7868
010.7993
016.0227
028.0101
034.0933
30
Description
MOVING PROTECTION
BLADE COVER
TAP SPRAYER
0 62 SEEGER RING
SK 0 8 SEEGER RING
0 6 WASHER
TCEI 5 X 20 SCREW
TCEI 6 X 12 SCREW
TSPEI 5 X 12 SCREW
GUARD BRACKET
TAP REGULATOR 8 X 1/4
BLADE COVER TAP
P 250
U. of M.
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
2,000
1,000
2,000
2,000
1,000
1,000
1,000
5.2.4 -- Vice unit
P 250
31
Spare parts
Code
001.0301
001.0302
007.1003
007.1004
007.1006
007.1008
010.0202
010.0501
010.1202
010.7204
010.7410
010.7454
010.7481
010.7604
010.7767
010.7893
010.7961
034.0102
034.0203
32
Description
LOWER VICE
UPPER VICE
ROD
UPPER VICE PLATE
VICE SCREW BUSHING
CENTRE PIN
VICE SCREW 190X20
ANTI BURR JAW
OIL FILLER DIAM.8
M8 SCREW NUT
8 X 35 FLAT POINT VCE GRUB SCREW
0 8 WASHER
ELASTIC PIN DIAM. 6 X 35
TCEI 8 X 20 SCREW
TE 8 X 20 SCREW
SMALL CUT TO MEASURE STOP
MEDIUM VICE HANDWHEEL
P 250
U. of M.
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
Quantity
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
1,000
4,000
1,000
2,000
2,000
1,000
1,000
5.2.5 -- Base assembly
P 250
33
Spare parts
Code
001.0101
001.0102
010.1000
010.7203
010.7221
010.7229
010.7603
010.7604
010.7605
010.7607
010.7830
010.7870
010.7963
010.7996
013.0032
016.0172
016.0398
016.1671
022.0232
028.0130
028.0151
028.0291
034.1112
043.0250
043.0280
34
Description
VICE CLAMPING LEVER
BASE PLATE
8 MA THREADED BAR
M6 SCREW NUT
M16 LOW SCREW NUT
M8 SELF--LOCKING SCREW NUT
0 6 WASHER
0 8 WASHER
0 10 WASHER
0 16 WASHER
5 X 10 BUTON SCREW
TCEI 6 X 16 SCREW
TE 8 X 25 SCREW
TSPEI 6 X 30 SCREW
STEEL BASE
TANK COVER
BASE
ROTATING TABLE STOP
BRASS CABLE PRESSER 1/4 BM 2450
JOINT 1/4--9 CL 2601
PLASTIC HOSE 07--11
SUBMERGED PUMP SP/48 V.48.50
O 40 M8 HANDWHEEL X STEEL BASE
M.F. ELBOW 1/4 CL 2020
1/4 M 4/4 -- CL 2543 SLEEVE
U. of M.
NR
NR
MT
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
KG
NR
NR
NR
NR
P 250
Quantity
1,000
1,000
1,000
1,000
2,000
1,000
4,000
2,000
2,000
1,000
3,000
4,000
2,000
1,000
1,000
1,000
1,000
1,000
1,000
2,000
0,120
1,000
1,000
1,000
1,000
5.2.6 -- Control panel
P 250
35
Spare parts
Code
010.7203
010.7603
010.7830
010.7872
016.0324
022.0234
022.0235
022.0244
022.0245
36
Description
M6 SCREW NUT
0 6 WASHER
5 X 10 BUTON SCREW
TCEI 6 X 25 SCREW
CONTROL PANEL
CORD PRESSER
CORD PRESSER
LOCK NUT 3217B GREY PG 13,5
LOCK NUT 3213B GREY PG 11
U. of M.
NR
NR
NR
NR
NR
NR
NR
NR
NR
P 250
Quantity
3,000
3,000
2,000
3,000
1,000
2,000
2,000
2,000
2,000
5.2.7 -- Handgrip
P 250
37
Spare parts
Code
010.0928
010.7409
010.7700
010.7800
022.0515
025.0691
034.1221
090.0011
090.0262
38
Description
MEP HANDLE SPRING
CYLINDRICAL PIN DIAM. 4 X 24
2,9 X 15 SELF--THREADING SCREW
MICROSWITCH V--21--1C6
GASKETS FOR MEP HANDLE
MEP HANDLE
VICE GROUP
COMPLETE HANDLE
U. of M.
NR
NR
NR
NR
NR
NR
NR
NR
NR
P 250
Quantity
1,000
1,000
1,000
3,000
1,000
1,000
1,000
1,000
1,000
CHAPTER 6 - Adjustments
This chapter describes the operations needed to adjust the
mechanical, hydraulic and pneumatic systems enabling the P
250 to be used properly. These instructions will enable you to
”customise” your machine to suit the type of cuts being carried
out, optimising the time required to complete them.
6.1 -- Cutting vice
The cutting vice, mounted as standard on the P 250, is fitted with
a rag prevention device and a 3--spoke opening/closing handwheel.
6.1.1 -- Rag prevention device
The vice is fitted as standard with a rag prevention device that
serves to support the material and prevent the formation of
ragged edges at the end of the cut.
The vice is fitted as standard with a rag prevention device which
serves both to support the material and to prevent the formation
of a ragged edge at the end of the cut.
--
with the turntable free, turn the body of the machine to the desired angle (45_), reading off the position on the graduated
scale located on the front section of the turntable body. In the
specific case of 45_, it is possible to use the fixed stops on the
lead nut rotating table.
45˚
To adjust the longitudinal position of the vice jaw, proceed as follows:
-- tighten the cutting vice completely;
-- slacken the two screws located to the side of the rag prevention device (1--2);
-- slacken the nut that locks the grub screw (3);
-- adjust the longitudinal position of the rag prevention vice jaw
by slackening or tightening the grub screw (4) until the position of the rag prevention jaw is aligned with that of the cutting
jaw;
-- hold the grub screw steady using the Allen key and tighten the
locking nut.
-- once the desired angle has been reached, fix the body of the
machine again by means of the locking lever;
6.2 -- Disc
The HSS cutting discs can be used for any kind of cut since they
combine good levels of toughness and elasticity thanks to various coatings, along with a good cutting resistance.
The discs are made of a single piece of Tungsten--Molybdenum
super--rapid steel with a hardness of about 64  1 HRC. A special characteristic of the discs during cutting is the excellent finish
of the cut surfaces.
6.2.1 -- Making angled cuts
The P 250 can make cuts angled at 45_ to the left. Carry out the
following procedures to make a cut angled at 45_ to the left.
-- Release the turntable by means of the locking lever located
on the front section of the base;
-- the machine is now ready for making angled cuts.
P 250
39
Adjustments
6.3 -- Changing the blade
--
now you can take off the blade using the tube key 40mm
which is inside the machine’s tool kit; the nut unscrews in the
same direction of the blade’s rotation;
--
remove the worn or damaged disc and insert a new disc.
Carry out the above procedure in reverse.
As we have already said, this machine uses different kinds of
blades according to the material to be cut. The procedures described below, however, also apply in the event of wear or breakage of the blade.
To replace, proceed as follows:
-- switch the machine off;
-- remove the plastic cap from its seat (1);
1
--
free the mobile disc guard from the eccentric rod by removing
the screw (2) shown in the figure;
2
The procedure described above for changing the disc is the
same irrespective of whether the disc is worn or broken.
Do not carry out the operations described above without
first switching off the machine!
--
40
move the mobile guard above the fixed guard so as to facilitate removal and refitting of the disc;
P 250
Before blocking, the disc must be put in traction on the
trascinamento pins turning it in the opposite direction to
that of the disc rotation.
CHAPTER 7 - Cutting speed
7.2 -- Machine with 4 pole single--phase motor
The cutting speed is determined by the speed of rotation of the
disc and the head speed. While the head speed is controlled by
the movement of the head and is manual, the disc rotation speed
is fixed. This chapter describes the cutting speed available in the
standard version of the machine with the 4 pole three--phase or
single--phase motor (optional).
OPTIONAL
The P 250 can be equipped with either a single-- or three--phase
4 pole motor:
7.1 -- Standard machine
Characteristics of OPTIONAL spindle motor:
asynchronous single--phase 4 poles, 50 Hz.
The standard version of the P 250 is supplied with the following
cutting speed:
Disc speed = 45 r.p.m.
4 poles
This speed is selected using the polarity change switch on the
control panel. The cutting speed must be set before starting the
cutting cycle as described in paragraph 4.2 in this manual.
Voltage Volt
Absorp. Amp
230
5,2
Power kW
0,5
rpm
1.360
Stator winding in enamelled copper class H 200 _C;
Insulation class F (limit temperature TL=155_C);
Example of class F insulation: in air--cooled machines at ambient
temperature of 40_C (in accordance with CEI 2--3 and IEC 85),
the allowable overtemperature is 100_C (where 100_C represents the allowable ∆ T).
Protection rating IP54 (total protection against contact with live
parts and against water sprayed from all directions).
Complies with CEI standards publication IEC 34 of 1st July 1985.
CHAPTER 8 -- Maintenance and choice of consumables
8.2 -- Maintenance requirements
The P 250 is a machine that has strength and long--life. In fact,
no particular maintenance is required, even if, as with other
machine tools, it may deteriorate in time especially if wrongly
used or no maintenance at all is carried out.
This chapter therefore serves as a guide to those who wish to preserve the characteristics of the machine for as long as possible.
- All routine and special maintenance operations must be
carried out with the plug disconnected from the electric power
socket.
- To guarantee perfect operation, all spare parts must be
Hyd--Mech originals.
- On completion of maintenance works, ensure that the
replaced parts or any tools used have been removed from the
machine before starting it up.
8.1 -- The role of the operator
The person operating and maintaining the machine must follow
these instructions for his own safety and that of the others, in
addition to safeguarding the production of the machine.
- check that his own work and that of the other operators of the
machine always complies with the relevant safety standards.
Therefore, check that the safety devices are in position and work
perfectly and that personal safety requirements are complied
with.
- Any behaviour not in accordance with the instructions for using
the machine may create risks for the operator.
- Therefore, read and follow all the instructions for use and
maintenance of the machine and those on the product itself.
8.3 -- General maintenance
- ensure that the working cycle is efficient and guarantees
maximum productivity, checking:
-- the functions of the main components of the machine
-- the sharpness of the blade and coolant flow
-- the optimum working parameters for the type of material.
8.3.1 -- Daily
The daily maintenance operations to carry out on the machine are
as follows:
- check that the quality of the cut is that required and that the
final product does not have any machining defects.
P 250
41
Maintenance and choice of consumables
----
remove all swarf from the machine (using compressed air or
preferably thread--free cloth;
top up the coolant level;
check the wear of the blade and change if necessary.
8.5 -- Consumable materials
It is essential to use specific oils for the pneumatic and
lubricant/coolant circuits. The oils suitable for each of these
circuits are listed below.
8.3.2 -- Weekly
8.5.1 -- Oils for transmission box
This paragraph lists the operations to be carried out for weekly
maintenance of the machine:
-- clean the machine of all swarf;
-- clean the vice and lubricate all the joints and sliding surfaces,
preferably using good quality oil.
-- check the oil level in the transmission box; if necessary top up
with oil through the filler plug.
The machine is supplied with AGIP BLASIA 460 oil, ISO and UNI
symbol CC460. However the following oils can be regarded as
compatible or with equivalent characteristics:
API DT 460 -- CASTROL Alpha SP 460 -- ARAL Degol BG 460
-- ARCO PENNANT NL 460 -- BP Energol GR/XP 460 -- ELF
Reductelf SP 460 -- ESSO Spartan EP 460.
8.3.3 -- Monthly
Transmission box:
-- capacity 0,4 litres.
This paragraph lists the operations to be carried out for monthly
maintenance of the machine:
-- check that the machine performs cuts perpendicular to the
work surface; if not contact our technical service department;
-- check that the blade is orthogonal to the workpiece rest
shoulder; if adjustment is necessary, contact our technical
service department;
-- thoroughly clean the water tank and the electric pump filter.
8.5.2 -- Oils for lubrication/coolant liquid
The oil used for the lubrication/coolant fluid in the machine is
CASTROL Syntolin TFX. Though there are no specific standards
for these types of oils, Hyd--Mech considers that CASTROL
Syntolin
TFX is the best product available with regard to quality:price ratio.
Nevertheless, the following oils of similar characteristics can be
said to be compatible:
8.4 -- Maintenance of working parts
During maintenance work on the P 250, special attention
should be paid to operating units such as the transmission box.
AGIP NB 200 -- SHELL Lutem TT -- IP Utens Fluid--F
8.4.1 -- Transmission box
Finally, one particular blade manufacturer (LENOX)
recommends and supplies a coolant under the name of LENOX
BAND--ADE SAWING FLUID.
Transmission box maintenance:
-- after the first 100 working hours, drain the transmission box
through the drain plug located in the rear lower section of the
unit and refill with new oil. If, in addition to the yellow filings
from the bronze rim, there are other impurities in the drained
oil, remove the cover and thoroughly wash the inside. The
washing should be carried out using flushing oil, avoiding the
use of cotton or threadbare rags for drying. Refill the transmission box;
-- after every 2000 working hours repeat the oil change operation.
42
Coolant tank:
-- tank capacity
-- oil concentration
P 250
4,5 litres
5--6%
CHAPTER 9 - Blades
the piece to be cut, the cross--section at any given point exceeds
the average cross--section given above.
When using the P 250, it is important to select the correct type of
blade for the material to be cut. This chapter explains the
limitations and specific applications of the different types of
blades.
Types of swarf:
A -- Very fine or fragmented swarf indicates that the downstroke
speed and/or cutting pressure is too low.
9.1 -- Choice of blade
- FINE TOOTH PITCH -- for thin wall materials such as sheet
steel, tubes and profiles;
- COARSE TOOTH PITCH
-- for large cross--sections;
-- for soft materials (aluminium
alloys and soft alloys in general).
B --
Thick and/or blue swarf indicates that the blade is
overloaded.
9.1.1 -- Tooth pitch
The choice of the most suitable tooth pitch depends on various
factors:
a) the size of the section;
b) the hardness of the material;
c) wall thickness.
Solid sections call for discs with a coarse tooth pitch, while small
cross--sections require blades with finer teeth. This is because
when cutting walls of small cross--section (1--7 mm) profiles, it is
important that the number of teeth actually making the cut should
not be too small, otherwise the effect obtained will be one of tearing rather than of swarf removal, leading to a large increase in
shearing stress.
On the other hand, when cutting
thick materials or solid sections using an excessively fine tooth pitch,
the swarf collects as a spiral inside
the gullet, and since fine tooth
pitches have small gullets, the accumulated swarf will exceed the
gullet capacity and press against
the walls of the workpieces, resulting in poor cutting (same situation
with soft materials), greater shearing stress and hence breakage of
the blade.
C -- Long coils of swarf indicate ideal cutting conditions.
9.1.2 -- Cutting and feeding speed
The cutting speed, in m/min, and the head feeding speed, in
cm2/min, are limited by the amount of heat generated near to the
points of the teeth. If the head feeding speed is too high, the cut
will not be straight in either the vertical or the horizontal plane. As
we have already said, the cutting speed depends on the strength
(kg/mm2) and hardness (HRC) of the material and the dimensions of the thickest section. The feeding speed depends on the
cross--section of the material. Solid or thick--walled materials
(thickness>5mm) can therefore be cut at high speed providing
there is sufficient swarf removal by the blade, while thin--walled
materials such as tubes or thin profiles must be cut with a low
feeding speed. A new blade requires a wearing--in period, during
which time a feeding speed of about half normal speed should be
used.
Choice of tooth pitch T as a function of cross--section to be
cut for light alloy solid pieces and profiles
S
S
sp
Pitch T
6
S and sp
in mm.
10 sp=0.5
30
8
30 sp=1.5
4--5
50
10
50 sp=2.5
6--7
70
12
70 sp=3.5
8--9
90
130
14
18
90 sp=4.5
130 sp=6.5
8--9
10
S in mm.
Pitch T
10
3--4
9.1.3 -- Lubricant/coolant
The lubricating/cooling fluid must ensure that the blade teeth and
material in the area of the cut do not overheat. Furthermore, the
quantity and pressure must be sufficient to remove the swarf from
the cutting zone. The fluid must be an excellent lubricant, such
that prevents abrasion of the teeth and welding of the swarf to the
teeth themselves (seizing).
KEY:
s = diameter or width of the solid piece to be cut in mm.
sp = thickness of the wall to be cut in mm.
T = tooth pitch in mm.
A larger pitch should be chosen when, as a result of the shape of
P 250
43
Blades
9.1.4 -- Blade structure
The circular blades most frequently used for cutting--off machines are HSS--DMo5/M2 consisting of a single piece and characterised by a high level of toughness and a good cutting
resistance. With non--ferrous materials it is normal to use circular
blades with brazed hard metal (HM) cutting edges, which offer excellent resistance to wear but low resistance to impact, which in
any case is not generally a problem with non--ferrous materials.
CHEMICAL COMPOSITION:
TYPE OF BLADE
HSS- DMo5/M2
C
Cr
0.85 4.15
W
Mo
V
Co
6.37 5.00 1.92
HRC
Coarse toothing with roughing tooth and finishing tooth. Used in saws with pitch greater than
or equal to 5 mm for cutting ferrous and non-ferrous materials with solid or solid--profiled
sections.
64+/--1
KEY:
”BW” TYPE SHARPENING DIN 1838--UNI 4014
C = Carbon
Co = Cobalt
Cr = Chromium
Mo = Molybdenum W = Tungsten
V = Vanadium
The numbers in the columns indicate the % of the element present in the steel.
Coarse toothing with teeth alternately raked to the right and left.
9.1.5 -- Types of blades
The P 250 uses discs of dimensions 250x32x2 and 225x32x1.9
made of HSS DMo5 and with type C sharpened teeth for cutting
hollow sections, while for solid bars it uses HSS discs; however
the tooth pitch is also important, as shown in the table below. In
addition to the size and pitch of the teeth, the blades also have
other geometric characteristics according to their particular use:
- tooth sharpening, which in this case may be BW with alternate raked tooth or C with roughing tooth raked on both sides and
non--raked finishing tooth;
- tooth pitch, the distance between the crests of two subsequent teeth (tooth pitch = T).
Tooth shape:
Toothing generally used on cutting-off machines for cutting ferrous and
alloy materials with tubular and profiled sections.
The blades fitted to the P 250 are of dimensions 250x2x32 and
225x32x1.9 and are made of HSS DMo5 since the machine is
designed for cutting ferrous materials. In addition to the size and
pitch of the teeth, the blades also have different geometric
characteristics according to their different uses:
”C” TYPE SHARPENING (HZ)
Coarse toothing with roughing tooth raked on both sides and
non--raked finishing tooth. The roughing tooth is about 0.3 mm
higher.
Disc selection table for PUCK machine. Other disc characteristics are: dimensions: internal hole diam.
32 mm, distance between fixing holes 63 mm, tooth shape type C.
Hollow
sections with
thickness from
1 to 5 mm
Hollow
sections with
thickness from
5 to 10 mm
Solid bars with
dimensions not
exceeding the
cutting capacity
PUCK
D.
250
44
250
T
4
Z
200
D.
T
Z
D.
T
Z
225
6
120
225
8
88
P 250
Blades
This table can be used to facilitate the choice of toothing
since it takes into account both the size of the material to be
cut and the diameter of the disc to be used.
SOLID SECTIONS
D. 200
S
10
30
t
z
5
130
6
100
t
z
6
100
8
80
50
225
250
275
t
z
5
140
6
120
t
z
6
120
8
80
t
z
5
160
6
128
t
z
6
128
8
100
t
z
5
180
6
140
t
z
6
140
8
110
8
90
10
70
8
100
10
80
8
110
10
90
10
90
12
70
70
90
300
315
t
z
t
z
t
z
t
z
6
160
8
120
10
90
7
140
8
120
8
120
12
80
14
70
8
120
10
90
12
80
110
S
350
370
400
425
t
z
t
z
t
z
t
z
t
z
t
z
t
z
t
z
10
100
10
100
12
80
9
120
11
100
10
110
12
90
10
110
11
100
11
100
12
90
10
120
12
100
10
130
12
80
14
70
12
90
14
80
12
90
12
100
14
90
12
80
14
70
12
90
14
80
12
90
14
80
14
80
12
100
14
80
16
70
14
80
16
70
6
180
7
160
5
220
7
160
130
450
500
t
z
t
z
12
110
10
140
12
110
14
94
14
90
12
110
14
90
14
90
16
80
16
80
7
160
8
140
6
200
7
160
8
140
7
180
8
140
9
120
9
120
9
120
8
160
9
140
9
140
9
140
150
t
z
t
z
12
120
10
150
12
130
12
120
14
100
12
130
14
110
14
94
12
120
14
100
12
130
14
110
14
94
14
94
16
84
16
84
14
100
14
100
16
90
16
90
14
110
14
110
16
100
16
100
7
180
6
220
7
190
6
230
7
200
6
260
7
220
8
160
7
190
8
160
7
200
8
180
7
220
8
200
8
160
9
150
9
150
9
150
8
180
9
160
9
160
9
160
8
200
9
170
9
170
9
170
D
10
S
HOLLOW S=0,005xD
SECTIONS
D
30
50
70
90
110
3
200
4
160
3
200
5
130
3
220
4
180
3
220
5
140
3
250
4
200
3
250
5
160
3
280
4
220
3
280
5
180
4
220
5
180
4
240
5
200
5
140
6
120
5
160
6
128
5
180
6
140
6
140
8
110
5
180
6
160
6
160
8
120
5
200
6
160
6
160
7
140
5
200
6
180
10
100
7
140
8
120
7
160
8
140
8
120
10
100
8
140
9
120
9
120
8
120
130
150
P 250
10
110
10
110
10
110
10
120
10
120
10
130
10
130
10
140
10
140
10
150
10
150
45
Blades
9.1.6 -- Blade selection table with respect to cutting speed and downstroke speed
α
γ
RECOMMENDED CUTTING
PARAMETERS
Vt m/1’
T mm
Av mm/1’
Vt m/1’
T mm
Av mm/1’
Vt m/1’
T mm
Av mm/1’
Vt m/1’
T mm
Av mm/1’
Vt m/1’
T mm
Av mm/1’
Vt m/1’
T mm
Av mm/1’
Vt m/1’
T mm
CUTTING ANGLE
10--20
20--40
40--60
60--90
90--110
110--130
130--150
Av mm/1’
RECOMMENDED LUBRICANTS
R = 350--500 N/mm2
30
18
100
35
16
110
40
14
130
40
12
140
45
10
150
45
7
160
50
5
8
20
Mild steel
90
R = 500--700 N/mm2
15
16
90
20
16
100
20
14
110
25
12
110
25
9
120
30
6
130
30
4
8
18
Medium steel
80
R = 750--950 N/mm2
12
16
70
14
16
80
15
14
50
17
11
100
18
8
110
20
6
110
20
4
8
15
Hard steel
60
R = 950--1000 N/mm2
12
14
45
13
14
45
13
12
50
14
9
50
14
6
60
15
4
60
15
3
6
12
Super hard steel
40
7
12
25
7
10
25
8
8
28
8
6
30
9
4
33
9
3
35
9
2
6
10
35
12
16
35
14
16
40
15
14
40
17
11
45
18
8
45
19
6
50
20
4
8
12
Hardened and
tempered steel
R = 950--1300 N/mm2
Austenitic stainless
steel
R = 500--800 N/mm2
22
15
12
4
22
10
100
25
1800
1100
6
50
45
8
100
23
12
1700
1000
1600
900
90
16
22
11
1400
800
80
18
20
14
1300
700
880
19
40
20
1100
600
70
900
500
20
60
16
16
17
16
35
12
16
35
14
16
15
14
40
17
11
45
18
8
19
8
4
R = 200--400 N/mm2
6
Aluminium and alloys
6
20
8
Grey iron
6
Martensitic stainless
steel
R = 500--800 N/mm2
Emulsion -- Cutting oil
R = 350--500 N/mm2
130
16
250
130
16
300
140
14
300
160
12
350
160
10
400
180
7
400
200
5
8
20
Aluminium and alloys
250
6
10
20
R = 300--500 N/mm2
120
20
500
150
18
500
200
17
550
250
14
550
300
11
600
350
8
600
400
Copper
400
R = 600--900 N/mm2
150
18
500
200
16
600
250
14
600
300
12
700
350
10
700
400
7
800
400
5
8
15
Hard bronze
400
50
16
100
60
14
110
70
12
130
90
10
140
100
8
150
110
8
160
120
4
8
12
450
18
800
500
18
900
500
16
900
550
12
1000
550
10
1100
600
6
1100
600
5
16
16
R = 400--600 N/mm2
Brass
800
Phosphor bronze
90
R = 200--400 N/mm2
5
16
12
R = 400--700 N/mm2
400
200
18
400
300
18
500
300
16
500
350
12
600
350
10
600
400
7
700
500
Alloyed brass
Cutting oil
Titanium and alloys
30
16
100
35
14
110
40
12
130
45
10
140
45
6
150
45
4
160
50
4
8
18
R = 300--800 N/mm2
90
18
15
3
19
130
4
18
120
5
18
110
6
17
110
6
16
100
8
16
90
10
15
80
80
24
6
90
26
6
100
28
5
110
30
5
110
30
4
120
33
3
130
35
2
8
Profiles and tubes with
wall thickness 0.25 D
R = 300--600 N/mm2
8
Profiles and tubes with
wall thickness 0.05 D
R = 300--600 N/mm2
Emulsion
P 250
46
CUTTING SECTION (IN MM)
Blades
9.2 -- Classification of steels
The tables on this page provide users with information on materials to cut, enabling their classification with respect to hardness and
consequently the correct blade to use.
Types of steel
Hardness
Rockw.
Kg/mm2
160 -- 170
160 -- 180
150 -- 175
34 -- 87
84 -- 89
81 -- 87
55 -- 59
55 -- 61
51 -- 59
1060
160 -- 180
84 -- 89
55 -- 61
ASTMA -- 36/68
160 -- 180
160 -- 180
84 -- 89
84 -- 89
55 -- 61
55 -- 61
160 -- 180
190 -- 215
84 -- 89
91 -- 97
55 -- 61
64 -- 73
UNI
DIN
BS
AISI
C 22 -- C 35
C 45
C 10 -- C 15
CK 22 -- CK 3
CK 45
CK 10 -- CK 15
En 2 C -- En 6
En 8
En 32 A -- En 328
1022 -- 1035
1040
1010 -- 1015
C 60
CK 60
En 9
17100
4360 -- 50 A
3706 -- 1.2.3.
Brinel HB
45 Cr Si 9
17115
4360
En 20 A
34 Cr Mo 5
17221
970 -- 1955
1065
180 -- 205
89 -- 94
61 -- 69
34 Cr Mo
En 18 B
En 19 B
5135 -- 5145
4135
180 -- 200
200 -- 230
89 -- 93
93 -- 99
61 -- 67
67 -- 77
En 111
En 36
3135
3310 -- 3315
190 -- 230
200 -- 230
91 -- 99
93 -- 99
64 -- 77
67 -- 77
En 362
4315
200 -- 225
93 -- 98
67 -- 75
En 100 D
8645
190 -- 220
91 -- 97
64 -- 74
DX
En 31
B2
W1
52100
L6
150 -- 190
210 -- 230
190 -- 230
80 -- 91
96 -- 99
91 -- 99
51 -- 64
71 -- 77
64 -- 77
217 -- 248
97 -- 102
73 -- 83
18 % W
T1
1507 -- 825
A2
1310
M 13
217 -- 248
160 -- 220
97 -- 102
84 -- 91
73 -- 83
55 -- 64
200 -- 230
93 -- 99
67 -- 77
210 Cr 46
A1
D3
215 -- 240
97 -- 101
73 -- 81
4845
En 58 G
309 S
150 -- 200
80 -- 93
51 -- 67
X 12 Cr 13
4001
En 56 A
410
X 6 Cr Ni 1810
X Cr Ni 1910
4301
En 58 E
304
150 -- 200
130 -- 170
80 -- 93
74 -- 86
51 -- 67
45 -- 58
X 8 Cr Ni Mo 1713
4401
1501 -- 845
316
35 Cr Mo 4
36 Ni Cr 6
20 Nc Cr Mo 2
1880 X C 95
100 Cr 6
100 Cr 6
52 Nc Cr Mo KU
56 Ni Cr Mo V 7
2750 (280W18)
160 -- 200
84 -- 93
55 -- 67
Phosphor bronze
Aluminium bronze
Manganese bronze
60 -- 100
56,5
36
70 -- 90
95 -- 120
49
51 -- 69
32
34 -- 42
Silicon bronze
70 -- 100
56,5
36
9.2.1 -- Steel nomenclature table
Material
Carbon steels
Carbon steels
Alloy steels
SS
Sweden
AISI
U.S.A.
C 22 -- C 35
1311
1572
1650
1880
DIN
Germany
1015 -- 1035
1040 -- 1064
1770 -- 1880
2120
1335 -- 1345
2255
4130 -- 4140
BS
Great Britain
050 A 20
CK 22 -- CK 50
080 M 46 -- 50
120 M 19
150 M 28
CK 60 -- CK 101
060 A 40 -- 060 A 96
36 Mn 5
070 M 55
Cm 45 -- Cm 55
080 A 40 -- 080 A 62
20 Mn 5 -- 28 Mn 6
UNI
Italy
C 15 -- C 35
XC 18
C 22 Mn
XC 38 H 1
C 28 Mn
20 M 5
C 45 -- C 60
XC 60 -- XC 75
40 M 5
XC 42 H 1
XC 55 H 1
1717 CDS 110
25 Cr Mo 4 -- 42 Cr Mo 4
708 A 37
AFNOR
France
25 CD 4
25 Cr Mo 4 -- 42 Cr Mo 4
42 CD 4
708 M 40
2541
Alloy steels
2230
2258
Tool steels
4337 -- 4340
50100 -- 52100
6145 -- 6152
8630 -- 8645
D -- 2, D -- 3
Stainless steels
Stainless steels
2324
2333
40 Ni Cr Mo 2 -- 40 Ni Cr Mo 7
35 NCD 6
817 M 40
30 Ni Cr Mo 8 -- 35 Ni Cr Mo 6 KB
50 CV 4
34 Cr Ni Mo 6, 100 Cr 6
311 tipo 6 e 7
50 Cr V 4, 100 Cr 6
100 C 6
X 205 Cr 12 KU
Z 160 CVD 12
X 155 Cr V Mo 121 KU
Z 200 C 12
X 155 Cr V Mo 121
BD 2, BD 3
55 W Cr V 8 Ku
60 W Cr V 7
2550
2710
735 A 50, 534 A 99
40 Ni Cr Mo 73
X 210 Cr 12
2310 -- 12
2754 -- 55
Tool steels
40 Ni Cr Mo 6
S -- 1
55 Ni Cr Mo V 6
304 S 15
X 2 Cr Ni 18.11
Z 2 CN 18.10
X 5 Cr Ni 189
304 C 12
X 5 Cr Ni 18.10
Z 6 CN 18.09
G -- X 2 Cr Ni 189
304 S 12
G -- X 2 Cr Ni 19.10
Z 3 CN 19.10
302, 304
314, 316
2353
317
55 NCVD 7
55 Ni Cr Mo V 6
X 2 Cr Ni 189
201, 202
2343
BS 1
X 16 Cr Ni Si 2520
X 15 Cr Ni Si 2520
316 S 16
X 5 Cr Ni Mo 1812
Z 12 CNS 25.20
X 5 Cr Ni Mo 1713
317 S 16
X 5 Cr Ni Mo 1815
X 5 Cr Ni Mo 1713
P 250
Z 6 CND 17.12
47
CHAPTER 10 -- Troubleshooting tables
This chapter describes the inspection and troubleshooting procedures for the P 250. Regular inspections and efficient maintenance are
essential to ensure your machine gives you a long, trouble--free service life. The chapter is divided into two sections: the first being dedicated specifically to TROUBLESHOOTING BLADE AND CUTTING PROBLEMS, while the second TROUBLESHOOTING section concerns troubleshooting general machine operating faults. Taken together they form a comprehensive troubleshooting guide which will
enable you to follow a methodical procedure for solving any problem.
10.1. -- Troubleshooting blade and cutting problems
PROBLEM
Cuts not at 90 degrees or angled
Teeth breaking
PROBABLE CAUSE
SOLUTION
Head speed too high
Reduce head speed
Disc with worn teeth
Replace disc
Orthogonality of disc to workpiece rest
shoulder
If this is not the case, contact our
technical service department.
Perpendicularity of disc to work surface
If this is not the case, contact our technical
service department.
Broken teeth
Check the hardness of the material being
cut.
Incorrect lubricant/coolant fluid
Check the water and oil emulsion; check
that the holes and hoses are not blocked;
direct the nozzles correctly.
Material too hard
Check the cutting speed, feed speed and
disc pressure parameters and the type of
disc you are using.
Disc not worn--in correctly
48
P 250
With a new disc it is necessary to start
cutting at half feeding speed. After the
wearing--in period (a cutting surface of
about 300 cm2 for hard materials and
about 1000 cm2 for soft materials) the
cutting and feed speeds can be brought
up to normal values.
Trouble shooting tables
PROBLEM
Rapid tooth wear
Broken blade
PROBABLE CAUSE
SOLUTION
Disc with excessively fine tooth pitch
The swarf wedges into the bottom of the
teeth causing excessive pressure on the
teeth themselves.
New blade inserted in a partially completed
cut.
The surface of the cut may have
undergone local thermal alteration,
making it harder: when starting work
again, use a lower cutting speed and
head feed speed. A tooth from the old
blade may be left in the cut: check and
remove before starting work again.
Workpiece not clamped firmly in place
If the workpiece moves during cutting it
can cause the teeth to break: check the
vice, the jaws and the pressure with
which the workpiece is clamped.
Vibration
The workpiece vibrates in the clamp:
check that the slide is adjusted correctly;
check the pressure with which the
workpiece is clamped.
Head speed too slow
The blade runs over the material without
removing it: increase head speed.
Cutting pressure too high
Reduce the cutting pressure.
Insufficient coolant
Check the coolant level and clean piping
and nozzles.
Incorrect fluid concentration
Check and use the correct concentration.
Material defective
The materials may present altered zones
either on the surface, such as oxides or
sand, or in section, such as
under--cooled inclusions. These zones,
which are much harder than the blade,
cause the teeth to break: discard or clean
these materials.
Head speed too high
Reduce head speed.
Teeth in contact with material before
starting the cut
Always check the position of the blade
before starting a new job.
Insufficient coolant
Check the coolant level and clean piping
and nozzles.
Vibrations
The workpiece vibrates in the clamp:
check that the slide is adjusted correctly;
check the pressure with which the
workpiece is clamped and if necessary
increase.
P 250
49
Trouble shooting tables
10.2 -- Troubleshooting machine faults
This section of the chapter concentrates on troubleshooting any machine faults or operating problems which may occur during work with
the P 250.
PROBLEM
Spindle motor will not turn
50
PROBABLE CAUSE
SOLUTION
Electrical power supply
Check:
Contactor
Check that the phases in it are present both
on the input and output, that it is not
jammed, that it closes when powered and
that it is not causing short circuits. Change if
any of these problems are found.
General switch
Check that the phases are present on both
the input and output. If not, replace.
Motor
Check that it has not burnt out, that it turns
freely and that there is no moisture in the
connection terminal board box. The
winding can be rewound or replaced.
P 250
the phases;
the cables;
the plug;
the socket.
Also check that the motor connections are
in place.
WARRANTY
Hyd-Mech Group warrants each new Cold Saw to be free from failure resulting from defective
material and workmanship under proper use and service for a period of one year following the
date of shipment to the user. Hyd-Mech’s sole obligation under this warranty is limited to the
repair or replacement without charge, at Hyd-Mech’s factory, warehouse, or approved repair
shop, of any part or parts which Hyd-Mech’s inspection shall disclose to be defective.
Return freight must be prepaid by the user.
This warranty, in its entirety, does not cover maintenance items, including but not limited to
lubricating grease and oils, filters, V-belts, saw blades, etc., nor any items herein which show
signs of neglect, overloading, abuse, accident, inadequate maintenance or unauthorized altering.
Liability or obligation on the part of Hyd-Mech for damages, whether general, special or for
negligence and expressly including any incidental and consequential damages is hereby
disclaimed. Hyd-Mech’s obligation to repair or replace shall be the limit of its liability under this
warranty and the sole and exclusive right and remedy of the user.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED
WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This warranty may not be changed, altered, or modified in any way except in writing by Hyd-Mech
Group.
HYD-MECH GROUP LIMITED
1079 Parkinson Road
P.O. BOX 1030
Woodstock, Ontario
N4S 8A4
Sales Toll Free: 1-877-276-SAWS (7297)
Phone: (519) 539-6341
Fax: (%19) 539-5126
Website: www.hydmech.com
e-mail: info@hydmech.com

P 250 - Trick Tools

Transcription

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