Dake 350SA User Manual
USE AND MAINTENANCE MANUAL
AUTOMATIC BAR - FEEDING SYSTEM
FOR MOD.
SUPER TECHNICS
350 SA
THOMAS
07/2001
THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 97.61.05 - Fax 0444 / 97.69.34
Contents
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TECHNICS 350 SATECHNICS 350 SA
TECHNICS 350 SA
TECHNICS 350 SATECHNICS 350 SA
Contents ........................................................................ " 2
Ordering spare parts .................................................... " 2
Guarantee ...................................................................... " 2
Machine certification and identification marking .... " 3
CHAPTER 1
Reference to accident-prevention regulations .......... " 4
1.1 - Advice for the operator ..........................................." 4
1.2 - Location of shields against accidental contact with
the tool ...................................................................." 4
1.3 - Electrical equipment according to European
Standard "CENELEC EN 60 204-1" (1992) ........... " 4
1.4 - Emergencies according to European Standard
"CENELEC EN 60 204-1" (1992) ..........................." 4
CHAPTER 2
Recommendations and advice for use ....................... " 4
2.1 - Recommendations and advice for using the machine "
4
CHAPTER 3
Technical characteristics............................................. " 5
3.1 - Table of cutting capacity and technical details ....... " 5
CHAPTER 4
Machine dimensions - Transport - Installation
Dismantling ................................................................... " 5
4.1 - Machine dimensions............................................... " 5
4.2 - Transport and handling of the machine .................." 5
4.3 - Minimum requirements for the premises
housing the machine .............................................." 5
4.4 - Anchoring the machine........................................... " 5
4.5 - Allineamento caricatore .......................................... " 5
4.6 - Instructions for electrical connection ......................" 6
4.7 - Instructions for assembly of the loose parts and
accessories ............................................................." 6
4.8 - Disactivating the machine ....................................... " 6
4.9 - Dismantling ............................................................." 6
CHAPTER 5
Machine functional parts ............................................. " 6
5.1 - Operating head....................................................... " 6
5.2 - Vice ........................................................................." 6
5.3 - Bed.........................................................................." 7
CHAPTER 6
Description of the operating cycle ............................. " 8
6.1 - Starting up and cutting cycle .................................. " 8
CHAPTER 7
Ordering spare parts
- When ordering spare parts you must state:
MACHINE MODEL
SERIAL NUMBER
PART REFERENCE NUMBER
Without these references WE WILL NOT SUPPLY the spares. See point 10.1 - list of spare parts -.
Regulating the machine ............................................... " 9
7.1 - Cutting head ..........................................................." 9
7.2 - Vice ........................................................................." 9
7.3 - Head return stroke limiting device .........................." 10
7.4 - Restoring oil level in head compensation cylinder
tank ........................................................................." 10
7.5 - Piece counter.......................................................... " 10
7.6 - Feed repeater ........................................................." 1 1
7.5 - Adjustment of pneumatic system pressure............ " 11
7.6 - Adjustment of cutting length................................... " 11
7.7 - Decimal lenght adjustment ....................................."11
7.8 - Adjustment of feeding system ................................ " 11
7.9 - Regulating arm blockage........................................ " 12
7.10-Changing the disk ..................................................." 1 2
7.11-Clutch adjustment ................................................... " 12
CHAPTER 8
Routine and special maintenance .............................. " 13
8.1 - Daily maintenance .................................................. " 13
8.2 - Weekly maintenance .............................................. " 13
8.3 - Monthly maintenance ............................................. " 13
8.4 - Six-monthly maintenance ....................................... " 13
8.5 - Oils for lubricating coolant ......................................" 14
8.6 - Oil disposal ............................................................. " 14
8.7 - Special maintenance .............................................." 14
CHAPTER 9
Material classification and choice of tool .................. " 14
9.1 - Definition of materials ............................................." 14
9.2 - Choosing the disk ................................................... " 14
9.3 - Teeth pitch .............................................................. " 15
9.4 - Cutting and advance speed...................................." 15
9.5 - Running in the disk ................................................." 15
9.6 - Disk structure .......................................................... " 15
9.7 - Type of disks ..........................................................." 1 5
Tooth shape ........................................................... " 15
Tooth cutting angle ................................................. " 15
9.7.1 - Table of recommended cutting parameters ................. " 16
9.7.2 - Table of cutting speed according to disk diameter........ " 16
CHAPTER 10
Machine components ................................................... " 1 7
10.1- List of spare parts .................................................. " 17
CHAPTER 11
Wiring diagrams ........................................................... " 26
CHAPTER 12
Troubleshooting............................................................ " 31
12.1-Blade and cutting diagnosis.................................... " 31
CHAPTER 13
Noise tests ..................................................................... " 33
Plates and labels .......................................................... " 33
Guarantee
- The Company guarantees that the machine to which this manual refers has been designed and built to comply with safety regulations
and that it has been tested for functionality in the factory.
- The machine is guaranteed for 12 months: the guarantee does not cover the electric motors, electric components, pneumatic
components or any damage due to dropping or to bad machine management, the failure to observe maintenance standards or bad
handling by the operator.
- The buyer has only the right to replacement of the faulty parts, while transport and packing costs are at his expense.
- The serial number on the machine is a primary reference for the guarantee, for after-sales assistance and for identifying the machine
for any necessity.
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Machine certification and identification marking
MACHINE LABEL
via Pasubio, 32 36033 ISOLA VIC. - ITALIA
MODEL
TYP
SERIAL NUMBER
YEAR OF MANUFACTURE
SUPER TECHNICS 350
(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)
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REFERENCE TO ACCIDENT-
1
PREVENTION REGULA TIONS
This machine has been built to comply with the national and
community accident-prevention regulations in force.
Improper use and/or tampering with the safety devices will
relieve the manufacturer of all responsibility.
1.1 - Advice for the operator
- Check that the voltage indicated on the plate, normally fixed
to the machine motor, is the same as the line voltage.
- Check the efficiency of your electric supply and earthing system;
connect the power cable of the machine to the socket and the
earth lead (yellow-green in colour) to the earthing system.
- When the tool head is in rest position (raised), the toothed
disk must be stationary.
- It is forbidden to work on the machine without its shields (these
are all white, blue or grey in colour).
- Always disconnect the machine from the power socket before
changing the disk or carrying out any maintenance job, even
in the case of abnormal machine operation.
- Always wear suitable eye protection.
- Never put your hands or ar ms into the cutting area while the
machine is operating.
- Do not shift the machine while it is cutting.
- Do not wear loose clothing with sleeves that are too long,
gloves that are too big, bracelets, chains or any other object
that could get caught in the machine during operation; tie back
long hair.
- Keep the area free of equipment, tools or any other object.
- Perfor m only one operation at a time and never have several
objects in your hands at the same time. Keep your hands as
clean as possible.
- All internal and/or internal operations, maintenance or repairs,
must be performed in a well-lit area or where there is sufficient
light from extra sources so as to avoid the r isk of even slight
accidents.
overload, protection is provided by a thermal probe.
- In the event of a power cut, the specific start-up button must
be reset.
- The machine has been tested in conformity with point 20 of
EN 60204.
1.4 - Emergencies according to European
Standard "CENELEC EN 60 204-1"
- In the event of incorrect operation or of danger conditions, the
machine may be stopped immediately by pressing the red
mushroom button.
NOTE: Resetting of machine operation after each emergency
stop is achieved by reactivating the specific restar t
button.
RECOMMENDATIONS AND
2
AD VICE FOR USE
2.1 - Recommendations and advice for using the
machine
- The machine has been designed to cut metal building
materials, with different shapes and profiles, used in
workshops, turner’s shops and general mechanical structural
work.
- Only one operator is needed to use the machine.
1.2 - Location of shields against accidental
contact with the tool
- Grey metal shield screwed onto the disk head.
- Self-regulating mobile blue aluminium shield, fitted coaxially
with the fixed shield.
- Blue metal protection on the feeeding system.
1.3 - Electrical equipment according to European
Standard"CENELEC EN 60 204-1" which assimilates, with some integrating modifications,
the publication "IEC 204-1 "
- The electrical equipment ensures protection against electric
shock as a result of direct or indirect contact. The active parts
of this equipment are housed in a box to which access is limited
by screws that can only be removed with a special tool; the
parts are fed with alternating current at low voltage (24 V).
The equipment is protected against splashes of water and
dust.
- Protection of the system against short circuits is ensured by
means of rapid fuses and earthing; in the event of motor
4
- To obtain good running-in of the machine it is advisable to
start using it at intervals of about half an hour. This operation
should be repeated two or three times, after which the machine
may be used continuously.
- Before starting each cutting operation, ensure that the part is
firmly gripped in the vice and that the end is suitably supported.
- Do not use disks of a different size from those stated in the
machine specifications.
- If the disk gets stuck in the cut, release the running button
immediately, switch off the machine, open the vice slowly,
remove the part and check that the disk or its teeth are not
broken. If they are broken, change the tool.
- Before carrying out any repairs on the machine, consult the
dealer or apply to THOMAS.
TECHNICAL
3
CHARACTERISTICS
3.1 -
Table of cutting capacity and technical details
CUTTING
CA PACI TA ` DI
TAGLIO
CAPACITY
90° 60 120 105x105 160x90
45° DX - SX 60 100 85 x85 85x70
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2300
1450
2-speed three-phase electric motor KW 1,35 - 1,7
Oil-bath reduction unit i 32 : 1
Max. blade diameter mm 350
Blade rotation speed rpm 22 - 44- 88
Vice opening mm 170
Machine Weight KG 220
Coolant liquid L 5
Working table height with base mm 940
MACHINE DIMENSIONS
TRANSPORT
4
INST ALLATION
DISMANTLING
4.1 - Machine dimensions
4.2 - Transport and handling of the machine
If the machine has to be shifted use a fork-lift truck or sling it
with straps as illustrated.
1400
4.3 - Minimum requirements for the premises
housing the machine
- Mains voltage and frequency complying with the machine motor
characteristics.
- Environment temperature from -10 °C to +50 °C.
- Relative humidity not over 90%.
5
4.4 - Anchoring the machine
B
à
à
A
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POS. A
POS. B
- Position the machine on a firm cement floor, maintaining, at the rear, a minimum distance of 1000 mm from the wall; anchor it to the
ground as shown in the diagram, using screws and expansion plugs or tie rods sunk in cement, ensuring that it is sitting level.
- Adjust with a calibrated bar the level between the machine vice bed and the input roller by means of the screws located on the
supporting leg of the feeding system. The feeding system level should be 0.1- 0.2mm higher than the machine vice bed.
à
0,1-0,2 mm
PNEUMATIC VALVE
4.5 - Feeding system alignment
- The feeding system can be mounted to the machine base in two different positions:
POSITION A : allows mitre cutting 45° right and left. This is the position recommended to cut solid and shapes material up to 60
mm diameter.
POSITION B : allows rectangle cutting up to 160x90mm. (max.)
ATTENTION: make sure that the material supporting rollers are correctly aligned to the machine working table level.
6
ELECTRIC BOX
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4.6 - Instructions for electrical connection
- The machine is not provided with an electric plug, so the
customer must fit a suitable one for his o wn working conditions:
1 - WIRING DIAGRAM FOR 4 -WIRE SYSTEM FOR THREE-
PHASE MACHINE - SOCKET FOR A 16A PLUG
R = L1
S = L2
T = L3
PE = GND
4.7 - Instructions for assembly of the loose parts
and accessories
Fit the components supplied:
- part. 1 Fit the feeding system
4.8 - Disactivating the machine
- If the sawing machine is to be out of use for a long period, it is
advisable to proceed as follows:
1) detach the plug from the electr ic supply panel
2) empty the coolant tank
3) carefully clean and grease the machine
4) if necessar y, cover the machine.
MACHINE FUNCTIONAL
5
PARTS
5.1 - Operating head
- Machine part composed of the parts that transmit movement
(motor, reduction unit).
5.2 - Machine bed and Vice
- Support structure for the OPERATING HEAD (rotating ar m
for gradual cutting, with respectiv e bloc king system), the VICE,
and the housing for the cutting coolant TANK.
- System for gripping material during the cutting operation, by
means of the approach handwheel and pneumatic locking.
It is provided with an anti-burr de vice for blocking the part that
is to be cut.
4.9 - Dismantling
(because of deterioration and/or obsolescence)
General rules
If the machine is to be permanently demolished and/or scrapped,
divide the material to be disposed of according to type and
composition, as follows:
1) Cast iron or ferrous materials, composed of
secondary raw materials, so they may be taken to an iron
foundry for re-smelting after having removed the contents
(classified in point 3);
2) electrical components, including the cable and electronic material (magnetic cards, etc.), fall within the category of material
classified as being assimilable to urban waste according
to the laws of the European community, so they may be set
aside for collection by the public waste disposal service;
3) old mineral and synthetic and/or mixed oils, emulsified oils
and greases are special refuse, so they must be collected,
transported and subsequently disposed of by the old oil
disposal service.
NOTE: since standards and legislation concerning refuse in
general is in a state of continuous evolution and theref ore
subject to changes and variations, the user must keep
informed of the regulations in force at the time of
disposing of the machine tool, as these may differ from
those described above, which are to be considered as
a general guide line.
metal alone, are
5.3 - Material feeding system
- Pneumatic device for material feeding.
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DESCRIPTION OF THE
6
OPERATING CYCLE
Before operating, all the main organs of the machine must be set in optimum conditions (see the chapter on “Regulating the
machine”).
6.1 - Starting up and cutting cycle
3
2 4 5 6
17
10
LINEA
9
11
MAN. AUTOM.
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CUTTING CYCLE:
- Vice locking;
- Head downfeed;
- Head lifting;
- Vice opening;
- Material feeding.
- Ensure that the machine is not in emergency stop condition; if
it is, release the red mushroom button ( 1 ).
- Make sure that the connection to the pneumatic system has
been carried our according to the chapter 7 paragraph 7.7.
- Ensure that the selector ( 8 ) is in "MANUAL" mode.
- Turn the main switch ( 3 ) in position ON.
- Press the start/reset button ( 2 ): its green light will go on.
- Select the cutting speed on the switch ( 4 ):
position 1 = 22 rpm
position 2 = 44 rpm
- Set the number of pieces to be cut on the piece-counter (10)
(see chapter 7 paragraph 7.5).
- Set the number of feed repetition on the feed repeater (11)
just in case the cutting length required is longer than the
mechanical stroke of the feeding system (see chapter 7
paragraph 7.6). Note: set “1” if no feed repetition is required.
- Place material to be cut in the vice. Close jaws against
piece,keeping a distance of approx. 3 - 4 mm.
- Adjust the cutting stroke by means of the selector ( 5 )
approaching the blade upto 10 mm from the workpiece. Position
the relevant mechanical endstroke.
- Set the required cutting length (
- Adjust the vice of the feeding system (
7.10
).
- Set the blade downfeed speed on the regulatorì according to
the specifications of the workpiece.
- Press Cycle Start and verify the following functions:
vice clamping, blade rotation anticlockwise, coolant liquid flow
and cutting cycle execution.
Turn the selector ( 8 ) to the "AUTOMATIC" mode while the
machine is performing the initial cutting cycle end press the
push button ( 9 ) . The machine will feed the material to the
preset cutting length.
- The machine will go on performing more cutting cycles as
long as the material to be cut is finished.
see chapter 7 para. 7. 8
see chapter 7 para.
).
- When starting to cut with a new disk, in order to safeguar d
its life and efficiency, the first two or three cuts must be
made while exerting a slight pressure on the part, so that
the time taken to cut is about double the normal time (see
below in the chapter on “Material classification and choice
of disks” in the section on
- Press the red emergency button ( 1 ) when there are conditions
of danger or malfunctions in general, so as to stop machine
operation immediately.
Running in the disk
).
REGULATING
THE
7
MACHINE
7.1 - Cutting head
- If excessive axial pla y is found on the hinge , it will be sufficient
to tighten the ring nuts ( A ), paying attention not to make the
joint too tight.
A
7.2 - Vice
- In case of wrong operation press Emergency Push-button
( 1 ).
CUTTING DIRECTION
The cropper is now ready to start work, bearing in mind that the
CUTTING SPEED and the TYPE of DISC - combined with a
suitable descent of the head - are of decisive importance for
cutting quality and for machine performance (for further details
on this topic, see below in the chapter on “Material classification
and choice of disks”).
- The device does not require any particular adjustment; in the
event of e xcessive pla y in the sliding guide, tighten the dowels
( B ) for adjusting the gib inside the slide.
- Approach the vice jaw upto 4-5mm from the material to be
cut.
B
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7.3 - Head return stroke limiting device
It consists in a mechanical adjustment system, mounted parallel to the head rise cylinder, to reduce the passive phases of the
operating cycle, in other words to eliminate the idle stroke that
takes place when the size of the part to be cut is much smaller
than the maximum cutting capacity. Practically, you adjust the
starting position of the disk in proximity of the part, independently
of its dimensions.
8
9
7.4 - Restoring oil level in motorhead compensation cylinder tank
- Braking fluid in the cylinder controlling the head, may consume
through the time.
- It is therefore important to restore the oil quantity inside the
compensation tank by removing the plug and then using a
syringe type injector to fill the tank.
- First, take the head to the upper position and disconnect
airs upply from the pneumatic system (disconnect the air
pipe from the machine). Switch on the machine and push
the Line button.
- Add oil making sure that the selector ( 5 ) is switched to the
right (head downfeed).
- Add oil until the rod, corresponding to the second mark on the
stem, has come out completely.
- Air must be bleeded from the tank by loosening the screw
located on the side of the cylinder (see arrow) until some oil
pours out (always keep the selector ( 5 ) to the right); when
this has been done, secure the screw, remove the injector
and put back the plug.
- Connect the machine to the pneumatic system.
- Use SHELL hydraulic oil 32 or similar.
7.5 - Piece-Counter
5
To carry out this operation you must:
- slightly open regulator.
- Rotate the selector ( 5 ) either to the right or left to lower or lift
the motorhead.
- position and secure the mechanical stop ( 8 ) against upper
plate of the cylinder, so as to press the upper limit micros witch.
- the lower limit switch ( 9 ) is set during inspection and limits the lower stroke of the motorhead. Do not change this
setting.
ATTENTION:
- It is not necessary to adjust the upper end-stroke everytime;
one can bring the disk near to the workpiece by means of
selector ( 5 ) and then start the automatic cutting cycle
wich will take place from the actual position of the disk.
Do notice that, once the cut is completed, the motorhead
will go to the upper end-stroke ( against the relevant
microswitch ).
- operate on regulator to modify motorhead return speed.
- Press Reset (A) and hold to release the Lever (B).
D
B
C
A
- Move the Lever (B) to the direction shown by the arrow and
leave it in this position. Release the Reset button (A). Now
the numbers appear on the window (C).
- Hold the Lever (B) and set the number required by pressing
the keys (D) starting from the left operating the two keys at
the same time.
- As soon as you set the first figure, you can go on towards the
right with more figures. On the surface of each key there is a
grooved area to set a single figure by means of a pencil.
- Release the Lever (B) as soon as the setting is completed.
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7.6 - Feed repeater
- You can set the number of feed repetition on the feed repeater
just in case the cutting length required is longer than the
mechanical stroke of the feeding system.
Set “1” if no feed repetition is required.
- Take into account the blade thickness and set the mechanical
stroke of the feeding system accordingly.
For example:
In case you need 1500mm cutting length
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B
1500 - 6
3
1500 = cutting lenght.
6 = blade thichness ( 3 x 2 )
3 = number of required feeding runs
498 = this is lenght the feeding stroke must be set to on the
metric scale .
= 498
7.7 - Adjustment of pneumatic system pressure
- The pressure in the pneumatic system necessary for the proper
operation of the sawing machine must be equal to 6 - 7 Bar.
- Check on pressure switch (11) the exact correspondence and
if necessary operate on regulator (12) to set the ideal pressure.
- Make sure that a drop of oil runs through the lubricator bulb
( 13 ) every 4/5 work cycle.
- Set the regulators A = forward
to absorbe the mechanical stop of the feeding system
during the cutting cycle.
I = backward
I
A
12
11
13
7.8 - Adjustment of cutting length
- Proceed as follows to adjust the cutting length:
- Loose screw ( A ).
- Turn handwheel ( B ) to set the required cutting lentgh on the
metric scale.
- Lock screw ( A ).
7.9 - Decimal adjustment
- This is a fine cutting length adjustment by means of a Vernier
(14).
- Release the screw (15) and turn the vernier as much as you
need with reference to the engraved marks.
- One mark is 0.05mm (metric system).
- One mark is 1/500 of a inch (English system)
- Lock the screw (15).
14
15
11
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