OPERATING MANUAL

S 320
S 320 L
S 350

BAUER MASCHINENBAU GmbH

D - 94424 Arnstorf
Mariakirchner Straße 19
Telephone 08723 / 96050, Telefax 08723 / 960555
Internet: www.bauer-maschinen.de
E-mail: info@bauer-maschinen.de
 EG-Konformitätserklärung
EC Declaration of Conformity
im Sinne der EG-Richtlinie 2006/42/EG über Maschinen (Anhang II A)
according to EC directive 2006/42/EC on machinery (Annex II A)

Name und Anschrift des Herstellers BAUER MASCHINENBAU GmbH

Name and address of the manufacturer: Mariakirchner Straße 19
94424 Arnstorf

Diese Erklärung bezieht sich nur auf die Maschine in dem Zustand, in dem sie in Verkehr gebracht wurde;
vom Endnutzer nachträglich angebrachte Teile und/oder nachträglich vorgenommene Eingriffe bleiben
unberücksichtigt. Die Erklärung verliert ihre Gültigkeit, wenn das Produkt ohne Zustimmung umgebaut oder
verändert wird.
This declaration relates exclusively to the machinery in the state in which it was placed on the market, and excludes
components which are added and/or operations carried out subsequently by the final user. The declaration is no
more valid, if the product is modified without agreement.

Hiermit erklären wir, dass die nachstehend beschriebene Maschine / Anlage

Herewith we declare, that the machinery described below

Produktbezeichnung / product denomination: Metallbandsägemaschine

Serien- / Typenbezeichnung / model/type: …………………………………….
Maschinen-/Seriennummer / machinery / serial number: …………………………………….
Baujahr / Year of manufacture: …………………………………….

allen einschlägigen Bestimmungen der Maschinenrichtlinie 2006/42/EG entspricht.

Ggf.: Die Maschine/Anlage entspricht zusätzlich den Bestimmungen der Richtlinien 2006/95/EG über elektrische
Betriebsmittel und 2004/108/EG über elektromagnetische Verträglichkeit.
is complying with all essential requirements of the Machinery Directive2006/42/EC.
Where appropriate: In addition the partly completed machinery is in conformity with the EC Directives 2006/95/EC
relating to electrical equipment and 2004/108/EC relating to electromagnetic compatibility.

Angewandte harmonisierte Normen / Harmonised Standards used

EN ISO 12100-1 Sicherheit von Maschinen - EN 61000-6-4 EMV – Fachgrundnorm:
4/2004 Grundbegriffe / Safety of Machinery 9/2007 Störaussendung Industriebereiche
- Basic concepts EMC - Generic standard:
Emission for industrial
environments
EN ISO 12 100-2 Sicherheit von Maschinen - EN 61 000-6-2 EMV – Fachgrundnorm:
4/2004 Technische Leitsätze / Safety of 3/2006 Störfestigkeit Industriebereiche
Machinery - Technical principles EMC - Generic standards:
Immunity for industrial
environments
EN 60204-1 Elektrische Ausrüstung von
Maschinen
6/2007 Electrical equipment of machines

Bevollmächtigter für die Zusammenstellung der relevanten technischen Unterlagen

The person authorised to compile the relevant technical:
Herr Othmar Bauer, Mariakirchner Straße 19, D-94424 Arnstorf

Arnstorf, Bauer Othmar, Geschäftsführer

Ort, Datum Name, Vorname und Funktion des Unterzeichners Unterschrift
Place, Date surname, first name and function of signatory Signature
Technical description and operation

Inhalt
Contents

1, Intended purpose, application possibilities

2, Residual risks

3, Saw operation

4, Cutting pressure

5, Cooling

6, Selection of the correct saw blade

7, Saw blade replacement

8, Vise, clamping of the material and miter shifting

9, Control panel

10, Drive and cutting speed

11, Tips on optimal sawing

12, Cutting pressure and saw frame advance

13) Tips for optimum sawing

14) Daily maintenance

Technical description and operation

1, Intended purpose, application possibilities

This BAUER band sawing machine is exclusively designed for sawing of metal, casting and
plastic rod material, as stated in our selection tables.

The materials have to have such structure, that they can be securely clamped in the machine
vise (e.g. rod material).

For the achievement of the cutting capacity and angle tolerance stated by us, the correct
selection of saw blade, feed, cutting pressure, cutting speed and coolant is of decisive
significance.

For that, selection tables are available in the operating manual and also as stick-on labels at
the machine.

For very thin-walled tubes and sections special clamping devices might be required.

Any utilization beyond the above points is considered as not as directed. The manufacturer is
not liable for damage resulting from that. The risk for that bears the user alone.

2, Residual risks

The BAUER band sawing machines are constructed according to the state of the art and the
accepted safety rules. However, there can be some residual risks in working with the
machine.

Risk of injury for fingers and hands by the saw blade on improper intervention into the
working area of the machine.

Risk of injury by material cuttings falling off on improper pick-up of the cuttings.

Risk of injury on saw blade replacement by improper handling of the saw blade.

Endangering of health by hot chips squirting off on working without or with insufficient
cooling.

Endangering in handling of the materials on loading the machine.

Furthermore, there might be non-obvious residual risks despite all taken precautions.

Residual risks can be minimized by taking the notes on safety, the utilization as directed and
the operating manual into account.
Technical description and operation

3, Saw operation

Check the tension of the saw blade; possibly tension the saw blade by turning the clamping
lever.

Lift the saw frame by pressing the push button “T3” into his upper position.
(see drawing-no. 136-2004)

Insert material to be sawn and grip on by pressing the push button “T6”

Set desired miter

Before each sawing process, tighten clamping of the rotary tower.

Slide the saw blade guide arm on the side of the running wheel as near as possible to the
material to be sawn

4, Cutting pressure

The cutting pressure is generated with the weight of the frame and the cutting pressure spring. It can
be adjusted with a screw (see picture 01)

01
Technical description and operation

 ATTENTION For a high cutting pressure, a coarsely toothed saw blade is required,
since otherwise the chip area of the saw blade overcrowds
and the teeth break off!!!

5, Cooling

The coolant is brought to the saw blade guides by the coolant pump via the coolant hose and the
proportioning valve and is there directly lead onto the saw blade.

02

The proportioning valve should never be completely opened, since the coolant could be squirting
too strongly.
On putting the machine into operation anew (e.g. after the discharge of the coolant container), de-
aeration by pulling off the pressure hose might be necessary.

The mixture coolant concentrate : water is 1:20 for the normal saw operation.

For cutting larger quantities of non-ferrous metals or plastics, please infer the mixing ratio from the
cutting tables.
Technical description and operation

 ATTENTION On switching on of the saw motor, the saw blade must not fit to the
material, since otherwise the saw blade can be damaged!!!

Never lower the saw blade abruptly onto the material, since this shortens
the operating life of the saw blade!!!

When interrupting the sawing process, lift the saw frame

before continuing the sawing process again!!!

Always run in new saw blades (2/3 of the given feed for the first 300 cm²).
This significantly increases the operating time of the saw blade!!!

Never use blunt saw blades. This leads to oblique cuts!!!

In case you had to interrupt a sawing process, because teeth broke off
of the saw blade, continue the cut with a new saw blade not in this
cutting channel. The teeth broken off are still in the material and would
immediately damage the new saw blade!!!

Caution: There might be splashed water on the floor. Therefore take

local provisions into account!!!

For pipes there is the risk, that coolant is leaking form the pipe ends.
Take suitable protective measures according to the local provisions!!!

Carefully withdraw filled coolant containers from the saw, since the
coolant could easily slop over on jerky drawing off!!!
Technical description and operation

6, Selection of the correct saw blade

The selection of the correct saw blade for the respective material is decisive for the cutting values to
be achieved.

There is a multitude of blade qualities and circular pitches available, which maybe make the
selection of the correct saw blade appear difficult to you.

Therefore, we would like to give you some tips before the detailed explanation:

If you are not sure, which is the correct saw blade for your application, contact us. We would
be delighted to assist you with the selection.

If you have to saw very different materials and cross sections or sections, we recommend
you to use saw blades with the circular pitches 4 t/inch (tooth form N) and 8/12 t/inch
(combination toothing).

You can use the saw blade with 4 t/inch for solid material from 20 to 200 mm and section
bars from 5 mm on.
With the combination toothing 8/12 t/inch you saw solid material from 10 to 60 mm and
section bars from 2 to 10 mm.

We basically recommend you to utilize bimetal saw blades, since with this quality all stated
materials can be sawn (especially when there are hard cavities) and fewer saw blade
replacements are required, since a longer operating time is achieved than with blades of
lower quality.

In some cases, however, it might be more cost effective, to use saw blades of the quality
“special”. This above all applies, when the saw blades more frequently fail due to tooth
break-off as a result of operating errors.

If you want to completely use the capacity of the machine, e.g. on sawing larger quantities of
the same material and cross section, select the optimum circular pitch, tooth shape and the
best quality of the saw blade.
Technical description and operation

7, Saw blade replacement

The saw blade replacement belongs to the works at your sawing machine with the highest risk of
injury, since here the sharp teeth of the saw blade are completely unprotected.

The operator therefore has to take into account, that this work is executed by authorized and
instructed personnel only.

 ATTENTION Always wear protective gloves for the saw blade replacement – very high
risk of injury!!!

For the saw blade replacement, follow the following sequence:

Switch off the saw motor and lift the saw frame

Remove material from the vise

Completely open the saw frame cover and bloc (see picture 03)

03
Technical description and operation

Put off the saw blade guard (see picture 04)

04

Put off the blade brush (see picture 05)

05

Release the saw blade as far as possible by means of the clamping lever and push the
clamping lever towards the running wheel

Push out the saw blade from the guides towards the bottom and remove it from the machine.
Grip the saw blade with both hands.

Grip the saw blade with both hands, as shown in the following drawing, twist it to a roll with
a turning movement in the wrist and secure it with a piece of wire or something similar.
Technical description and operation

Clean the saw blade guides and the saw frame from chips. Check the condition of the chip
brush (special accessory) and adjust or replace it, if applicable.

Twist the new saw blade

 ATTENTION  Risk of injury!!!

Firmly grip the saw blade with both hands, keep it far away from
the body and slowly untwist it!!!

In no case release it, while untwisting it!!!

Now check the direction of the teeth of the saw blade

The tooth tips have to point into the running direction of the saw blade. If this is not the
case, you have to change the tooth direction of the saw blade by “coiling the saw blade
through”.

For this process, you firmly hold the saw blade in the upper third between thumb and index
finger of both hands. For that, the thumb has to be at the outside of the saw blade. Now coil
the saw blade through by means of a unidirectional turning movement of both hands.
Technical description and operation

First of all, put the saw blade over the drive and running wheel, then press it into the guide
from below.

 ATTENTION The back of the blade (not the teeth) has to lie below the stop collar
of the running and drive wheel!!!

Between the guides the teeth have to point downward!!!

Slightly tension the saw blade and check the position until the red light on the machine is off
(see picture 06)

06

Relocate the chip brush in its basic position and fasten it. The brush schould be approx 5mm
in the blade (see picture 07).

07

Technical description and operation


Fix the blade guard and clamp the coverbloc on the cover (see picture 08)

08

Close the saw frame cover. Shortly switch on the machine.

The saw blade immediately runs in the correct position at the stop collar of the wheel.

Set the guide arm in the desired position and clamp it

The machine is now ready for operation again.

 ATTENTION  Each new saw blade should be run in!!!

For that, feed is reduced to 2/3 for the first 300 cm²!!!

Technical description and operation

8, Vise, clamping of the material and miter shifting

 ATTENTION Mind, that the material lies flush on the machine table, only then a
cut accurate in angle can be achieved!!!

The material has to be firmly clamped before sawing!!!

Before sawing, tighten the clamping of the rotary tower!!!

On handling and on insertion of the material, take the valid safety

regulations into account!!!

For long parts (e.g. for beams), the material has to be inserted in parallel
to the vise. Do not align parts by tensioning the vise jaws, since
otherwise the jaws could be shifted and a rectangular cut can no longer
be achieved!!!

Vice pressure is adjustable.

Standart pressure 15 – 20 bar.
During the cut the vices clamp all the time.

Vice pressure
adjustment

Technical description and operation


Bundle top clamp

Bundle
clamp

Bundle manuel
Top clamping can be moves with buttons ↓ and ↑

Bundle automatic
During the cut the top clamping always clamps.

Pressure can be adjusted

Technical description and operation

9, Control panel

Down feed speed:

The number 0 – 6 do not show a certain speed. This is only a speed relation.

Technical description and operation

10, Drive and cutting speed

Saw blade is driven by an electromotor and a contrate worm gear on bearing in the saw
frame. In standard execution there are two cutting speeds available.

Cutting speeds are geared by means of the pole changer (Q2) at the operating panel.

Step 1: 35m/min (e.g. for VA)

Step 2: 70m/min (e.g. for St. 37 at using a bimetal saw blade)

Select cutting speed according to material and saw blade quality in cutting table.

Attention !!

Never change cutting speed during sawing operation, since this may cause
damage to the saw blade.
Cutting speed adjustment at continuously adjustable rpm available as special
accessories is adjusted by means of a frequency transformer (FU).
(Position FU right-hand at the backside of saw)
Adjustment and indication are at operating panel. By tuning knob (P1) speed is being
changed - see scale - (directly to read in m/min).
Cutting speed should not be modified too fast, since this may lead to overload at the FU.

If vibrations resp. vibration noise occur, cutting speed should be corrected a little.
Correction can be either slower or faster.

Attention!!
At disturbance proceed as follows:

"Saw" off and press key "RESET".

Or:

Switch off main switch and wait until indication of FU extinguishes.

Switch on main switch and check function.

At further problems see chapter "J" Repair and Servicing or contact Fa. BAUER
Tel. +49 (0) 8723/96050 directly.

Speed

Technical description and operation

11, Tips on optimal sawing

1. Fundamentals

Break off of teeth

Each tooth of the saw blade can only bear a certain force of sectioning, which differs
according to the blade quality. If this limit is exceeded, the tooth breaks off. The force of
sectioning for the individual tooth gets too strong, when the chip area is overcrowded or the
chip removal is too high.

The “overcrowding” of the chip area above all takes place when larger cross sections are
sawn with finely toothed saw blades (e.g. diameter 100 mm with saw blade 10 t/inch) and
with high feed and cutting pressure. In the individual case, also larger cross sections can be
sawn with finely toothed saw blades. However, then the feed and the cutting pressure have to
be chosen respectively low.

Tooth break-offs caused by “too much chip removal” result from sawing of thin-walled
sections with a too large circular pitch and too high feed and cutting pressure or from errors
in the notch (the saw blade already fits closely to the material edge before switching on the
machine).

Operating time of the saw blade

When you do not adjust the blade quality to the material, you select a too high cutting speed
or saw without coolant, the saw blade does not achieve the planned operating time and
prematurely becomes blunt.

With the cutting speed being too high and/or a lack of coolant, the saw tooth is not
sufficiently cooled and looses its cutting edge due to overheating.

An overheating of the tooth tip may also occur, when the saw blade “slides” over the
material nearly without chip removal (bad heat transfer, since there is only punctual contact
to the material).

Technical description and operation

2, Sawing of frequently changing cross sections

Sections

On sawing of sections, e.g. tubes, the cutting cross section permanently changes during one
cut.

For this sawing work, we therefore recommend to use a suitable combination toothing.

You can infer the suitable circular pitch from the table.

You should choose the feed setting not too large, for large, abrupt differences of the bar
cross sections rather a bit less, to avoid the risk of a tooth break-off.

Flat bars

On cutting flat bars, there are the most frequent tooth break-offs, since mostly a too fine
circular pitch is used.

However, when you clamp the flat bar slightly slanting, you can also saw with a circular
pitch, which actually is too fine, since due to the slant the effective cross section is reduced.

10, Electrical equipment

Limit switch “Cover” “Saw off”switch and screw”

Technical description and operation

12, Cutting pressure and saw frame advance

Technical background

Ideal cutting pressure for saw blade is obtained when there is a pressure of 50N per tooth.
This can be achieved in practice only at constant cross sections of material to be sawn. At
profiles and tubes, ideal cutting pressure cannot be achieved along the whole cross
sections. Use of devices like pressure pickups at the guides do not provide correct solution
of the problem either.

Application

Use of "hydraulic cutting pressure control" has proved to be very successful at this saw.
Hydraulic cutting pressure control controls both saw frame advance speed and cutting
pressure.
Cutting pressure is superimposed to advance, i.e. advance speed adjusted is corrected
automatically when cutting pressure set is obtained.
Cutting pressure is adjusted in the factory to about 8bar (1bar =70N).
Maximum pressure is shown on the manometer (M1) only at corresponding counter
pressure.

Tips for adjustment

Clamp piece of wood between saw frame and table (with function advance forward).

Maximum cutting pressure is shown on the display.

Loosen locknut M6 and adjust pressure by means of a hexagon socket screw key M3.

At cutting of hard materials (VA) it is recommendable to increase cutting pressure to about

12 - 14 bar at the adjusting screw (D1). Advance speed has to be reduced at the same time
(position ).

Adjustment of advance speed is carried out by means of the turning knob (V1) at the
operating panel. Scale 1-10 does not express a defined speed but only a ratio.
At normal cutting pressure (8 bar) you are sawing in position.......... . At cutting pressure 12-
14 bar in position ......... .

After finished cutting saw frame return hydraulically. Switch for return stroke is located
directly below the movable cheek.

Because of the many parameters (cutting speed, material, cross section of material, saw
blade quality) we have to dispense with giving adjustment values in tables.

Technical description and operation

Cutting capacity resp. cutting time has to be taken as guide line again. Please, ask your
saw blade dealer for respective values.

Operation, however, is very uncomplicated, that you will acquire sufficient experience in a
very short breaking-in period to handle adjustment without any help.

Downfeed speed

Cutting pressure

Main pressure
adjustment

Technical description and operation

13) Tips for optimum sawing

1. Generalities:

a) Breaking of tooth

Each tooth of the saw blade can only bear a defined cutting force which is different
depending on blade quality. If this limit is exceeded, the tooth will break. Cutting
force to the individual tooth will be too high, when chip space is overcharged or
cutting is too high.

"Overcharging" of chip space is mostly the case when larger cross sections are
sawn with fine-spaced saw blades (e.g. diameter 100 mm with saw blade 10
Z/inches) and high advance (position 6) and cutting pressure.
In particular cases fine-spaced saw blades can also saw larger cross sections.
Advance and cutting pressure, however, have to be selected accordingly slower
resp. lower. (e.g. position 1 or 2).

Breaking of teeth due to "too high cutting " results from sawing of profiles with
thin walls at too large spacing and too fast advance and too high cutting pressure
or because of faults at first cut (saw blade already leans on edge of material before
switching on the machine).

b) Service time of saw blade

If you do no adapt blade quality to the material, select a too high cutting speed or
operate without using any coolant, the saw blade will not reach service time
planned and will become blunt prematurely.

At too high cutting speed resp. lack of coolant, the saw tooth will not be cooled
sufficiently and loses its sharpness because of overheating.

Overheating of point of tooth may also occur when saw blade "slides" across the
metal nearly without chip removal (bad heat transfer, since only point contact to
the material).

Technical description and operation

2) Sawing of frequently changing cross sections

a) Profiles

At sawing of profiles, e.g. tubes, cross section of cutting changes continuously at

cutting.

For these sawing operations, we therefore recommend use of an adequate

combined spacing.

Proper spacing can be seen in table point E 15.

Advance adjustment should not be selected too fast, at large, abrupt differences in
bar cross section even a little slower, in order to avoid danger of breaking of teeth.

b) Flat iron

It is at sawing of flat iron when most frequent breaking of teeth happen, because
in most cases a too fine spacing is being used.

But if you clamp flat iron a little bit diagonally, you can also saw with a fine
spacing, as effective cross section is reduced by diagonal position of flat iron.

Technical description and operation

14) Daily maintenance
Level of spray has to be checked daily.

Recommendation: If spray container is filled less than1/3 of capacity, re-fill immediately.

(further works of maintenance, see spray installation)

Level of coolant (special accessories) has to be checked daily.

Recommendation: If coolant container is filled less than 1/3 of capacity, re-fill immediately.

Vice
Vice spindle and vice rails should be always a little oiled. This is done best together with works
of cleaning.

Hydraulic installation oil level and impermeability:

Check oil level of hydraulic aggregate, impermeability of all pipes and screwing daily in the
first week of operation (approx. 50 operational hours), from then on weekly.

Attention !!

Damaged parts, in particular hoses, have to be replaced immediately.

Fill oil to max. level at very check.

Tighten loosened screwing (attention, do not exceed torque!!).

At all works at hydraulic installation, in particular at open pipes or open container,
take care for utmost cleanliness.

Only use hydraulics oil of viscosity 32 to 46 according to DIN 51519 and quality HLP
(e.g. Shell-Tellus 32).

50 hours interval of maintenance

After the first 50 operational hours all terminal connections in the switch cabinet have to be
re-tightened.

Cleaning of coolant container.

Check chip brushes on wear (see point E5 exchange of saw blade).

Exchange of oil and filter of hydraulic aggregate:

First after 50 to 100 operational hours. After that every 2.000 operational hours but at least
once a year.

Technical description and operation

Attention !!
 If intervals of oil and filter exchanges (above all after 50 to 100 operational hours) are
not being observed, there will be d anger that solenoid valves will fail due to dirty oil.
 Oil exchange omitted or neglected will lead to loss of guarantee.
 Check hydraulic installation on impermeability and damage (see daily maintenance).

100 hours interval of maintenance

Check and, if necessary, correction of saw blade guides (see works of service and repair).

1.000 hours interval of maintenance

Lubrication of linear guide carriage (see works of service and repair).

Cleaning and disposal of dust

Regular cleaning and disposal of dust according to use of machine is indispensable for
correct functioning.

At cleaning of machine also dust at the drive and running disks of saw blade and out of the
coolant container have to be removed. Care has to be take in particular that linear guides of
sawing frame are cleaned of dust and dirt at every exchange of the saw blade.

For disposal of saw local regulations have to be observed.

In all cases dust and coolant should be disposed separately.

Cleaning also comprises checking of adhesive signs on legible condition.

illegible signs have to be replaced immediately.

Attention !!

Never use inflammable solvents or cleaning agents which could emit dangerous
vapour!

Protect electrical components, like motors, switches, switch cabinet, etc., against
penetration of moisture at cleaning!

Hydraulic oil
filter