Contractors Direct DCM-32 Sigma Professional Rebar Cutter Owner’s Manual

Contractors Direct DCM-32 Sigma Professional Rebar Cutter

Product Information

Specifications

• Machine Type: DCM 32 Rebar Cutting Machine
• Color: Not specified
• Motor Make: Not specified
• Motor Sr. No: Not specified
• Cutting Capacity Diameter Of Bar (650 N/mm2):
  • 32 (#10)
  • 25 (#8)
  • 12 (#4)
  • 10 (#3)
  • 6 (#2)
• Blade Size: 75mm (Width) x 75mm (Length) x 17mm (Thickness)
• Belt Used: V-belt A-39
• Machine Dimensions:
  • Width: 22.1″ (560mm)
  • Length: 41.375″ (1050mm)
  • Height: 39.37″ (1000mm)
• Operating Voltage: 3-Phase, 240/415 Volt,60Hz
• Cutting Motor Specifications:
  • Power: 3.7 KW, 5HP
  • Rotation: 1740 rpm
  • Voltage: 240/415 +/-10%V
  • Frequency: 60 Hz
• Weight: Approximately 370 kg
• Machine Tolerance: +/-5% of Final dimension

Product Usage Instructions

General Safety Instructions
This section provides important safety instructions for operating the DCM32 Rebar Cutting Machine.

Symbols
The symbol indicating live machine components signifies that enclosures may only be removed by authorized and suitably qualified staff.

Machine Features and Data

Application
The DCM32 Cutting Machine for Rebar is specifically designed for cutting rebars only. Other purposes of use are not allowed.

Specifications – Cutting Capacity
The machine can cut bars of various diameters with specific quantities per cut. The blade size, belt used, and machine dimensions are also provided.

Frequently Asked Questions (FAQ)

Q: What is the operating voltage of the DCM32 Rebar Cutting Machine?
A: The operating voltage is 3-Phase, 240/415 Volt, 60Hz.

DCM 32 REBAR CUTTING MACHINE
OPERATING AND MAINTENANCE MANUAL 2019-2020
REVISION NO -02

TOOLS & CHECKLIST

General Safety Instructions

Symbols
This symbol is used to indicate live machine components. Enclosures may only be removed by authorized and suitably qualified staff.

Personal Protective Equipment

Machıne-Related Instructions
Observe all safety and danger remarks at the machine!
In case of danger, immediately switch Off the starter. The machine comes to a standstill.
Use personal protective equipment when carrying out any work at the machine! When changing components and tools, always ensure that the motor of the machine are switched off!

MACHINE FEATURES AND DATA

Application
The DCM32 Cutting Machine for Rebar is designed and Manufactured for
Cutting Rebars only. All other purposes of use are not allowed.

Specifications-Cutting Capacity

Power Supply-Electricity

• Operating voltage: 3Phase, 240/415Volt, 60Hz

Installed Output

Cutting Motor Specifications

• Power: 3.7 KW, 5HP
• Rotation: 1740 rpm
• Voltage: 240/415 +/-10%V
• Frequency: 60 Hz

Weight
Machine with switch cabinet appr. 370 kg.

A. Process Tolerance/Machine Tolerance:
The Machine tolerance OR Process tolerance is +/-5% of Final dimension.

Recommended Lubricants
Grease Lubrication: Kluber Centoplex GLP200-000BH Multipurpose grease for long-term lubrication High pressure absorption capacity
Grease all parts in order to prevent rusting.

TRANSPORT AND SET−UP

Machine Delivery
The machine is delivered in transportation on a pallet.

• Pay attention to the center of gravity!
• Attach load chains, cables, belts etc. only at the marked points and secure against slipping.

NOTE− When storing the machine prior to installation, ensure that the entire consignment is kept dry and frost−free. Pay particular attention to protect it from the effects of moisture (humidity, rain).

Unpacking and Checking the Delivery

• Carefully remove the packaging.
• Check the delivery for completeness, compare with packing list.
• Report missing or incorrectly delivered parts immediately.
• Report transportation damage immediately

Transporting the Machine

• To avoid transport damage, do only use means of transportation with sufficient load−bearing capacity.
• The forklift may only be used when the machine is enclosed in the box.
• Use ropes or cables with sufficient load−bearing capability and with the specified length.
• Secure ropes or cables against slippage.
• When transporting using a lift truck, only engage at even surface of machine base.
• Lift machine only vertically.
• Do not move the means of transportation too fast to prevent the machine from falling down.
• To carry the machine in the boxed situation, a wedge should be inserted underneath the machine in a manner not allowing the wheels of the machine to contact with the box surface or the wheels will be pulled out. The steel rope chain and polyester sling shot should be used for lifting the machine. The lifting ring on the machine should be used for lifting without a box. Non−observance can endanger your life due to loads falling down!

Transporting the Machine:

Transportation with Fork Lift Truck
Machine on a pallet
Machine with switch cabinet appr. 370 kg

Guidelines for Safe and Efficient Use

1. Lifting the machine properly as specified (See Figure 1).
2. Do not operate the machine without earthing connection.
3. Do not operate the machine without closing the blade casing.
4. Switch off the machine during the maintenance work.
5. Do not operate the machine when protective covers are opened.
6. Do not clean the machine by applying the air, use cotton cloth to clean the machine.
7. Do not operate the machine without greasing.
8. Do not remove the warning label stickers on the machine.
9. Do not perform the cutting with the blunt edge blade.
10. Do not allow untrained person to operate the machine.
11. If you are in doubt about a proper or safe procedure, stop work and ask for guidance.
12. Do not try to cut the bar in larger size than the specified one.
13. Refer the capacity plate on the machine for cutting process.
14. Do not wear loose or torn clothing, neckties or necklaces. Long hair can easily be caughtin cutting area. Tie back hair or wear a cap.
15. Do not allow to use any spare parts and apparatus other than the genuine ones from the manufacturer of machine only.
16. Switch off the machine if not in use
17. Do not operate the machine when it is wet.
18. Always follow the instructions for proper cutting.

Overview

Overview
The DCM32Cutting Machine for Rebar is designed and Manufactured for Cutting rebars only. All other purposes of use are not allowed. In order to get the best output from your machine, locate it in such a position so as to be operated easily and to more output from the Operator. Therefore, the site where the machine will be operated is to be near the storage area of Rebar, preferably under a covered shed.The machine can be easily transported within the short distances under the site conditions by the help of the wheels.

Machine Assembly:

• The machine is to be balanced by feeding with wedges underneath in a manner todisconnect the wheels from the ground on a smooth surface. (see Figure 2)
• The electrical connection of the machine should be installed by the authorized people.Operating voltage should be 415 V.
• The earthing should be provided for the safety purposes. The machine cannot be operatedwithout the earthing connection.

Important Warning
Prior to operate the machine read through this Operating & Maintenance Manual, carefully.
Only the qualified personnel are allowed to operate the machine.
Disconnect the power prior to make checks, maintenance, lubrication, and/or adjustments.
Observe all guidelines provided in this Operating & Maintenance Manual.

Installation Procedures

• Level the machine on a flat and sound ground(Figure 2).

• Make the power connection by a qualified electrician.
  Note: Power Connection

• Plug on the power supply cord of 4×4 Sq.mm to the feeding line of main power.

• Grounding is to be made for safety. Do not operate the machine without grounded power.

Grounding Connection:
Connect one end of the ground cable to a copper wire (minimum16Sq.mm) so as to ensure electrical conductivity. The other end of the cable is to be connected to a tube having ability of conductivity dipped sufficiently into the ground (into the damp soil, preferably), or to a copper plate buried under the soil as deeper as possible.

ELECTRICAL SYSTEM

Starter

Start up Procedure

Switching On
Switch on machine withStart Button.

Switching Off
Switch Off the machine withStop Button.

Initial Commissioning

• Check and ensure that the machine is installed in accordance with instructions.
• Press the Start Button and determine the direction of rotation of the machine.

Note: The clockwise rotation is accepted as the right rotation. If themachine rotates in opposite direction it mean that phases of powersource are reverse and change the connections with the qualified electrician.

Producing Operation

SEQUENCE OF OPERATION

• Make sure that the machine is installed in accordance with the assembly rules.
• Remove any objects to possibly exist between the machine and blade.
• Keep your hands away from the blades.
• Close the blade casing.
• The machine is started up by pressing on the start button (see Figure 3)
• The blade casing is removed and the steel to be cut is placed between the blades, then the shield is adjusted according to the bar size and bar is leaned onto the shield (See Figure 4 and Figure 5)
• The blade casing is closed.
• Cut the bar by operating the Hand lever.
  The machine is to be stopped after the completion of the cutting work by pressing on the Stop button.

Correct placement of the Bar between the blades:
Correct Cutting

Wrong Cutting

For multi-cutting operations, place one steel on the top of the other in an amount indicated in the capacity plate.

Correct Cutting

Checks & Adjustments of Belt on the machine:

Belt adjustment:
The V-belts placed on the machine are loosened over time. Also the belt adjustment is necessary as it will be misadjusted after the belt replacements. If the belt is loose, it causes noise during the running of the machine and shortens the life time of the belt. The machine fails to cut if the belt is too loose. However, it may cause the roller bearings on the motor and body to warm up if the belt is set very tightly.The tightness of the belt should be adjusted from the motor adjustment bolt, so that the distance between the two sides of the belt should be 9 cm when it is pressed at the middle of both of the pulley centers.

Sequence of demounting of the V-belt from the machine:

1. Demount the protective cover at the pulley side of the machine.
2. Loosen the motor connection bolt.
3. Unscrew the contra-nut of the motor adjustment bolt.
4. Make the pulleys close to each other by turning the motor adjustment bolt.
5. Remove the V-belt firstly from the small pulley and then from the bigger one.
6. To fit the belt in position, fit it firstly to the big pulley and then to the smaller one.
7. Set the tension of the belt by means of the motor tension bolt.
8. Tighten the motor connection bolt.
9. Complete the belt replacement process by fastening the protective cover.

Blade replacement on the machine
Remove first the movable blade and then the stationery blade while replacing the blades. Ensure that the cutting edges are matching each other while fitting the blades.

Troubleshooting

Refer to the Troubleshooting Chart below for the failures, errors and/or troubles, which may betake place during utilization of the machine.

Warning! Disconnect first the power by turning the main switch to the (0) position in case of a need to open the lid of power panel for troubleshooting. Do not allow the people other than a qualified electrician to make a check and/or a repair in the power panel.

MAINTENANCE AND LUBRICATION

Note that the proper maintenance is very important in order to prolonge the service life of the machine, and to ensure the safe Cutting. We recommend the users are to establish a reliable system to control and maintain the machine. Please refer to the following instructions .

Daily Maintenance

• Check the machine for the noise when running.If the machine is operated in open air conditions, protect from rain when it is rainy.
• Clean the blade spaces with a brush.
• Check the blades for crushes and cracks, and replace if necessary.

Weekly Maintenance

• Replace the broken grease nipples fitted on the machine with the new ones.
• Lubricate the machine with the grease pump using the grease nipples fitted on the machine.
• Check the blade bolts for tightness.
• Check the machine belts for their tensions.

Monthly Maintenance

• Check the bolt connections on the machine for their tightness.
• Demount the protective covers of the machine and lubricate the movable sections of the gear parts and engagement parts.
• Demount the protective cover and clean the steel tuffs accumulated between the movable sections.

6 months Maintenance

• Demount the protective covers of the machine and remove the contaminated oil on the movable parts and re-lubricate them.
• Check the movable running gears, engagers and carriers, machine bodies and machine components for crushes, breaks and cracks.
• Check if cavities are formed due to wear on the bronze bearings of the machine, and replace the bronze bearings if so.
• Check the roller bearings of the machine for proper functioning

Annual Maintenance

• Check if cavities are formed due to wear on the bronze bearings of the machine, and replace the bronze bearings if so.
  Check the roller bearings of the machine for proper functioning and replace if necessary.

WARRANTY

Manufacturer will only accept the warranty and responsibility subject to the following terms and conditions are met :

• Observe all protective precautions.
• Observe the warning signs.
• Do not operate the machine without grounded power.
• Do not replaced failed parts and apparatus other than the genuine one manufactured

By Manufacturer.

• Observe the instructions specified in the safety guidelines.
• Observe the guidelines for safe and efficient use.
• Observe the instructions for installation.
• Observe the conditions for loading, transportation and unloading of the machine.
• Operate the machine by qualified operators.
• Observe the measurements, dimensions and the quality of material specified in the capacity plate.
• The power connection is to be made by a qualified electrician.
• Do not allow the machine to be operated when any of its part is disassembled.
• Observe the instructions for proper service and maintenance.
• Do not try to cut the material in larger size than the one specified.

Electrical Circuit Diagram

Spare Parts List

Assembly Layout

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