USE AND MAINTENANCE MANUAL
ZIP 30
THOMAS
THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 97.61.05 - Fax 0444 / 97.69.34
MULTI - MODE
09/2005
Contents
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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" ....................... " 5
1.4 - Emergencies according to European Standard
"CENELEC EN 60 204-1" ......................................." 5
CHAPTER 2
Recommendations and advice for use ....................... " 5
2.1 - Recommendations and advice for using the machine ." 5
CHAPTER 3
Technical characteristics............................................. " 6
3.1 - Table of cutting capacity and technical details ......." 6
CHAPTER 4
Machine dimensions - Transport - Installation
Dismantling ................................................................... " 6
4.1 - Machine dimensions ............................................... " 6
4.2 - Transpor t and handling of the machine .................." 6
4.3 - Minimum requirements for the premises
housing the machine .............................................." 6
4.4 - Anchoring the machine..........................................." 7
4.5 - Instructions for electrical connection ...................... " 7
4.6 - Instructions for assembly of the loose parts and
accessories ............................................................. " 7
4.7 - Disactivating the machine ....................................... " 7
4.8 - Dismantling ............................................................." 7
CHAPTER 5
Machine functional parts ............................................. " 7
5.1 - Operating head or saw frame ................................. " 7
5.2 - Vice ........................................................................." 8
5.3 - Bed.........................................................................." 8
CHAPTER 6
Description of the operating cycle ............................. " 8
6.1 - Starting up and cutting cycle .................................. " 8
CHAPTER 7
Regulating the machine ............................................... " 9
7.1 - Blade tension assembly .........................................." 9
7.2 - Blade guide blocks .................................................." 9
7.3 - Vice.........................................................................." 10
7.4 - Spring adjustment ..................................................." 10
7.5 - Cutting angle adjustment ........................................" 10
7.6 - Saw frame lowering control device ......................... " 11
7.7 - Changing the blade ................................................. " 1 2
7.8 - Replacing saw frame return spring ........................ " 1 2
CHAPTER 8
Routine and special maintenance .............................. " 12
8.1 - Daily maintenance .................................................. " 1 2
8.2 - Weekly maintenance .............................................. " 12
8.3 - Monthly maintenance ............................................. " 12
8.4 - Six-monthly maintenance ....................................... " 12
8.5 - Maintenance of machine operating members ........ " 12
8.6 - Oils for lubricating coolant ...................................... " 1 2
8.7 - Oil disposal ............................................................." 12
8.8 - Special maintenance .............................................." 12
CHAPTER 9
Material classification and choice of tool .................. " 13
9.1 - Definition of materials ............................................." 13
9.2 - Selecting blade ....................................................... " 13
9.3 - Teeth pitch .............................................................." 13
9.4 - Cutting and advance speed...................................." 14
9.5 - Blade running-in......................................................" 14
9.6 - Blade structure ....................................................... " 14
9.7 - Blade type............................................................... " 1 4
Teeth shape and angle ..........................................." 14
Set..........................................................................." 15
9.7.1 - Table of recommended cutting parameters .................. " 15
CHAPTER 10
Machine components ................................................... " 1 6
10.1- List of spare parts .................................................. " 16
CHAPTER 11
Wiring diagrams ........................................................... " 22
CHAPTER 12
Troubleshooting ............................................................ " 25
12.1-Blade and cutting diagnosis...................................." 25
12.2-Electrical components diagnosis ............................" 28
CHAPTER 13
Noise tests ..................................................................... " 28
Ordering spare part
- 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 -
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
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MODEL
TYPE
SERIAL NUMBER
YEAR OF MANUFACTURE
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(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)
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REFERENCE TO A CCIDENT - PREVENTION REGULATIONS
1
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 ear thing 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 saw frame is in suspend mode (up) the toothed blade must not move.
- Only the blade section used for cutting must be kept unprotected. Remove guarding by operating on the adjustable head.
- It is forbidden to work on the machine without its shields (these are all blue or grey in colour).
- Always disconnect the machine from the power socket before blade change or carrying out any maintenance job, even in the case
of abnormal machine operation.
- It is forbidden to disconnect the "man present" de vice, kno wn more correctly in the EEC as the " saf ety s witch with hold-do wn action"
- Always wear suitable eye protection.
- Never put your hands or arms into the cutting area while the machine is operating.
- Do not shift the machine while it is cutting.
- Do not use any artful system or device (for ex. shim) to prevent the vice from locking the workpiece. Do not hold the workpiece with
your hand during the cutting process.
- Do not charge the workpiece from the right to the left-hand side with respect of the machine front.
- Do not wear loose clothing with slee v es that are too long, glo v es that are too big, br acelets , chains or an y 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.
- Perform 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 risk of even slight accidents.
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1.2 - Location of shields against accidental contact with the tool
- Blue, grey right and left hand metal shields, fastened with screws onto the guide blade stationary head ( RIF. A ).
- Blue or grey metal shield fastened with screws onto the blade guide adjustable head, ensures covering of blade section not used in
cutting operation ( RIF. B ).
- Grey metal guard, fastened with knobs onto the saw frame, to protect from flywheels ( RIF. C ).
A
C
B
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1.3 - Electrical equipment according to Euro-pean 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 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.
- The casual or voluntary removal of the protection shield of the flywheels causes the stepping-in of a microswitch that automatically
stops all machine functions.
NOTE:Resetting of machine operation after each emergency stop is achieved by reactivating the specific restart button.
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RECOMMEND ATIONS AND ADVICE FOR USE
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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, that must stand as shown in the picture.
- Before starting each cutting operation, ensure that the part is firmly gripped in the vice and that the end is suitably suppor ted.
These figures show examples of suitable clamping of different section bars, bearing in mind the cutting capacities of the machine in
order to achieve a good efficiency and blade durability.
- Do not use blades of a different size from those stated in the machine specifications.
- If the blade 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 blade or its teeth are not broken. If they are broken, change the tool.
- Check saw frame return spr ing to ensure proper balancing.
- Before carrying out any repairs on the machine, consult the dealer or apply to THOMAS.
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TECHNICAL
3
CHARACTERISTICS
3.1 - T ab le of cutting capacity and technical details
0° 220 200 245 x 120
45° DX 140 140 140x140
60° DX 85 85 85 x 90
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MACHINE DIMENSIONS
TRANSPORT
4
INSTALLATION
DISMANTLING
4.1 - Machine dimensions
1800
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TECHNICAL DATA
ELECTRIC MOTOR - 3- PHASE - 2 SPEEDS
COOLANT PUMP MOTOR
REDUCTION RATIO
FLYWHEEL Ø
BLADE DIMENSIONS
BLADE SPEED
VICE OPENING
SAWFRAME INCLINA TION
WORKING TABLE HEIGHT
MACHINE DIMENSIONS
MACHINE WEIGHT
kW
kW
I
mm
mm
m/min
mm
°
mm
mm
Kg
1 - 1,4
0.07
40/1
295
2480x27x0.9
32 - 64
270
40
970
1200x1850x1850
300
1750
1000
4.2 - Transport and handling of the machine
If the machine has to be shifted in its own packing, use a forklift truck or sling it with straps as illustrated.
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%.
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4.4 - Anchoring the machine
750 1000
35
375375
750
- Position the machine on a fir m cement floor, maintaining, at
AA
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.
680
MACHINE FRONT
STAND CONTOUR
35
WALL
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SEZ. A - A
4.5 - Instructions for electrical connection
- The machine is not provided with an electric plug, so the customer must fit a suitable one for his own working conditions:
1 - WIRING DIAGRAM FOR 4-WIRE SYSTEM FOR THREE-
PHASE MACHINE - SOCKET FOR A 16A PLUG
4.7 - 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 electric supply panel
2)loosen blade
3)release the arch return spring
4)empty the coolant tank
5)carefully clean and grease the machine
6)if necessary, cover the machine.
4.8 - 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 ma-
terial (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 gen-
eral is in a state of continuous evolution and therefore
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
R = L1
S = L2
T = L3
PE = GND
4.6 - Instructions for assembly of the loose parts
and accessories
Fit the components supplied:
- Mount bar-stop rod
- Mount and align the roll supporting arm as per the
counter-vice table.
- Mount the coolant liquido holder.
MACHINE FUNCTIONAL
5
PARTS
5.1 - Operating head or saw frame
- Machine part consisting of the members that transfer the motion (gearmotor, flywheels), and tension/guide (blade-guides,
blade tension slide) and lowering control (optional) of tool.
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5.2 - Vice
- System fro clamping the material during the cutting operation, operated with approach handwheel and locking lever or
by a pneumatic device (optional).
5.3 - Bed
- Support structure for the OPERA TING HEAD OR SA W FRAME
(rotating arm for gradual cutting, with respective blocking system), the ELECTRIC BOX, the VICE, the BAR STOP, the material support ROLLER and the housing for the cutting coolant TANK and pump.
tected. Remo ve guarding b y operating on the adjustable head.
- Select the cutting speed on switch ( 2 ):
position 1 = 32 m/min
position 2 = 64 m/min
- Strike the start/reset push-button ( 3 ).
- Tur n the selector ( 4 ) to the desired function mode:
2
4
3
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 “Regulat-
ing the machine”).
6.1 - Starting up and cutting cycle
- Make sure the machine is not in emergency stop; if so, release the red mushroom push-button ( 1 ).
- Tur n the blade tension Handwheel clockwise untill it stops
against the microswitch .
- Only the blade section used for cutting must be kept unpro-
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1
Cutting cycle selection
MANUAL MODE WITH DOWNFEED DAMPER
- As you turn the selector ( 4 ) to the left ( see figure A ), you
can pull down the sawframe manually at the feed rate set on
the regulator ( 5 ).
- If you w ant to approach the sawframe to the workpiece quickly
( blade not started ), press the button located on top of the
trigger switch ( 6 - figure D ); as you release the button, the
sawframe stops.
- Press the trigger switch ( 7 - figure D ) to start the blade and
pull down the sawframe manually to cut the workpiece. The
motor will stop automatically as soon as you release the trigger
switch..
Note: the sawframe return spring ( 8 - figure E ) must be
tensioned as much as to counterbalance the weight of the
sawframe.
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FIGURE A
MANUAL MODE
- Tur n the selector ( 4 ) to the center ( see figure B ) to pull
down the sawframe with no damping.
- Start the blade by pressing the trigger switch ( 7 - figure D )
and pull down the sawframe to cut y our workpiece. The motor
will stop at the end of the cut as soon as you release the
trigger switch..
Note: the sawframe return spring ( 8 - figure E ) must be
tensioned as much as to counterbalance the weight of the
sawframe.
FIGURE B
FIGURE C
FIGURE D
Trigger switch
6
7
SELF DOWNFEED MODE
- As you turn the selector ( 4 ) to the right ( see figure C ), you
allow the automatic sawframe downfeed.
- Release the tension of the spring ( 8 - figure E ) by means of
the relevant handle.
- You can approach the sawframe to the workpiece quickly by
pressing the button ( 6 - figure D ); we advise to approach the
blade up to 10mm from the workpiece.
- Press the trigger switch ( 7 - figure D ) to start the blade. The
sawframe will feed down automatically to cut the workpiece.
The motor will stop automatically at the end of the cut by a
special endstroke microswitch.
- Adjust the sawframe downfeed rate on the regulator ( 5 ) according to the specifications of your workpiece.
TENSION OF THE SAWFRAME RETURN SPRING:
- The spring tension adjustment can be effected through the
Handle ( 8 ).
Proceed as follows:
- Lift the sawframe to required position.
- Pull up the regulator knob.
- Release the Handle ( 8 ).
- Lock the Handle ( 8 ).
NOTE:
Lower the sawframe completely to release the spring if the
machine has been set for the controlled sawframe downfeed.
FIGURE E
8
9
- Once you selected the function mode ( see paragraph 6.1 ),
place the piece to be cut inside the vice ( 9 ) by moving jaw to
about 3 - 4 mm and lock with lever ( 10 ).
- Reach for handgrip ( 7 ) of the SAW FRAME control lever,
strike the push-button and check that the blade is turning in
the direction indicated ( if not, invert the two phase leads);
- Make sure that the cooling liquid flows regularly.
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7.2 - Blade guide blocks
The blade is guided by means of adjustable pads set in place
during inspection as per the thickness of the blade with minimum play as shown in the figure.
9
Note: In case the saw is not used for a period of time, release
the blade tension to avoid useless stress.
The band saw is now ready to start work, bearing in mind that
the CUTTING SPEED and the TYPE of BLADE - 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 c lassi-
fication and blade selection”).
- When starting to cut with a new blade, in order to safe-
guard 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 blade selection” in the section on
running-in
- Press the red emergency button when there are conditions
of danger or malfunctions in general, so as to stop machine
operation immediately.
).
Blade
REGULATING
7
THE MACHINE
0,2 mm
4
3
0,05 mm
12
Blade thickness should always be 0.9mm only. In fact, the blade-
guide pads have been especially adjusted for that very
thickness. Different blade thickness requires a re-adjustment
of the pads as follows:
- Use spanners (1=5mm), (2=4mm) and (3=12mm) to release
the screws and the nuts as shown here.
7
7.1 - Blade tension assembly
The ideal tension of the blade is achiev ed rotating the handwheel
until it the microswitch, that actuates the operation of the machine
, is actuated.
WARNING: the position of this switch is factory set during inspection, after having tightened the blade on the lengthening
values indicated by its manufacturer as per specific dimensions
set with the help of a special instrument. If, when replacing the
blade, the thickness and the width differ, it will be necessary to
correct the projection of the switch. F or this purpose we suggest
to strictly select blades having the same features as mounted
originally.
10
6 5
- Mount the new blade and put it under tension through the
relevant handwheel.
- First, adjust the mobile pad (use the spanner n.2) so that you
allow 0.05mm distance between pad and blade. Once you get
that distance, you can fix the screw (use spanner n.1) and the
nut (use spanner n.3).
- Use now the spanner n.4 so that you allow 0.2mm distance
between the fixed pad and top of the blade . Once you get that
distance, you can fix the screws (use spanner n.4) making
sure that the blade-guide block is perpendicular to the blade.
- Use the spanners n.7=11mm and n.6=3mm to release the
screws as shown here. Use now a screwdriver to rest the
bearing against the blade allowing a light pressure so that the
blade is driven to enter straight into the pads. After that is
done, you can fix both screws and nuts.
The above adjustment is very important to get straight cuts and
longer blade life.
Also, we recommend to clean and lubricate the parts making
sure that coolant liquid flows abundantly.
7.3 - Vice
- The device does not require any particular adjustment; in case
of excess play of the sliding guide, tighten slide screw
more.Place the piece to be cut inside the vice by moving jaw
to about 3 - 4 mm and lock with lever.
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7.5 - Cutting angle adjustment
- Unlock lever (8) and rotate the saw frame arm until you reach
mechanical stop and check if the index corresponds to 45°; if
not operate on the set screws to make measures meet.
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7.4 - Spring adjustment
The sawframe balance can be adjusted through the handle
( A ):
- Put the spring under tension when you operate the machine
manually so that the sawframe can easily raise up to the start
position.
- Reduce the spring tension before you switch to the self downfeed function so that the sawframe can descend according
to the downfeed speed adjusted on the regulator ( 5 ).
7.6 - Saw frame lowering control device
It is an optional accessory, ideal for the cutting of thin or STAINLESS STEEL section bars, that determines a constant lowering
and consequently a good efficiency of the blade throughout the
work phase. This device can be accommodated to the different
situations and applications. Defectiveness in the control of the
lowering may be caused by the drop in braking power of the
device due to the long-term blow-by of the braking fluid.
Push rod (2) back into its seat and loosen plug (3). Use recommended oil to top up oil tank (4) with the help of a syringe-type
pump. Bleed air, after having tightened plug ( 3 ) and loosen
screw (5) lightly until a little oil drip out; when this has been
completed, secure the screw.
Use SHELL HYDRAULIC OIL 32 or similar.
3
4
5
A
2
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BEFORE PERFORMING THE FOLLOWING OPERATIONS,
THE ELECTRIC POWER SUPPLY AND THE POWER CABLE
MUST BE COMPLETELY DISCONNECTED.
7.7 - Changing the blade
To change the blade:
- Lift the saw frame.
- Loosen the blade with the handwheel, remove the mobile
blade-guard cover, open the flywheel guards and remove the
old blade from the flywheels and the blade guide blocks.
- Assemble the new blade by placing it first between the pads
and then on the race of the flywheels, paying particular attention to the cutting direction of the teeth.
- Tension the blade and make sure it perfectly fits inside the
seat of the flywheels.
- Assemble the mobile blade-guide enf the flywheel guard and
fasten it with the relative knobs. Check that the safety
microswitch is activated otherwise when electric connection
will be restored the machine will not start.
WARNING: always assemble blades having dimensions speci-
fied in this manual and for which the blade guide
heads have be set: otherwise, see chapter on “Description of the operating cycle” in the section Starting-up.
CUTTING DIRECTION
8.1 - Daily maintenance
- General cleaning of the machine to remove accumulated shavings.
- Clean the lubricating coolant drain hole to avoid excess fluid.
- Top up the level of lubricating coolant.
- Check blade for wear.
- Rise of saw frame to top position and partial slackening of the
blade to avoid useless yield stress.
- Check functionality of the shields and emergency stops.
8.2 - Weekly maintenance
- More accurate general cleaning of the machine to remove
shavings, especially from the lubricant fluid tank.
- Removal of pump from its housing, cleaning of the suction
filter and suction zone.
- Clean the filter of the pump suction head and the suction
area.
- Cleaning with compressed air the blade guide heads (guide
bearings and drain hole of the lubricating cooling).
- Cleaning flywheel housings and blade sliding surfaces on flywheels.
8.3 - Monthly maintenance
- Check the tightening of the motor flywheel screws.
- Check that the blade guide bearings on the heads are perfect
running condition.
- Check the tightening of the screws of the gearmotor, pump
and accident protection guarding.
7.8 - Replacing saw frame return spring
- When performing this operation it is necessary to keep saw
frame up using the lifting device.
- Replace the spring by loosening the upper coupling rod and
releasing it from the lower tie-rod.
ROUTINE
AND SPECIAL
8
MAINTENANCE
8.4 - Six-monthly maintenance
- Continuity test of the equipotential protection circuit.
8.5 - Maintenance of the operating machine
members
The worm drive gear box mounted on the machine is maintenance-free guaranteed by its manufacture.
8.6 - Oils for lubricating coolant
Considering the vast range of products on the market, the user
can choose the one most suited to his own requirements, using
as reference the type SHELL LUTEM OIL ECO.
THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER
IS 8 - 10 %.
8.7 - Oil disposal
The disposal of these products is controlled by strict regulations. Please see the Chapter on “Machine dimensions -
Transport - Installation” in the section on
Dismantling
.
8.8 - Special maintenance
THE MAINTENANCE JOBS ARE LISTED BELOW , DIVIDED
INTO DAILY, WEEKLY, MONTHLY AND SIX-MONTHLY INTERVALS. IF THE FOLLOWING OPERATIONS ARE NEGLECTED, THE RESULT WILL BE PREMATURE WEAR
OF THE MACHINE AND POOR PERFORMANCE.
12
Special maintenance operations must be carried out by skilled
personnel. However, we advise contacting THOMAS or their
dealer and/or importer. Also the reset of protective and safety
equipment and devices, of the reducer, the motor, the motor
pump and electric components is to be considered extraordinary maintenance.
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MATERIAL
CLASSIFICATION AND
9
CHOICE OF TOOL
Since the aim is to obtain excellent cutting quality, the var ious parameters such as hardness of the material, shape
and thickness, transverse cutting section of the part to
be cut, selection of the type of cutting blade, cutting
speed and control of saw frame lowering.These specifications must therefore be harmoniously combined in a single operating condition according to practical considerations
and common sense, so as to achieve an optimum condition
that does not require countless operations to prepare the
machine when there are many variations in the job to be
performed.The various problems that crop up from time to
time will be solved more easily if the operator has a good
knoledge of these specifications.
WE THEREFORE RECOMMEND YOU TO ALWAYS USE
GENUINE SP ARE BLADES THAT GUARANTEE SUPERIOR
QUALITY AND PERFORMANCE.
9.1 - Definition of materials
The table at the foot of the page lists the characteristics of the
materials to be cut, so as to choose the right tool to use.
words, the number of teeth per inch (25,4 mm) suitable for
thematerial to be cut, according to these criteria:
- parts with a thin and/or variable section such as profiles, pipes
and plate, need close toothing, so that the number of teeth
used simultaneously in cutting is from 3 to 6;
- parts with large transverse sections and solid sections need
widely spaced toothing to allow for the greater volume of the
shavings and better tooth penetration;
- parts made of soft material or plastic (light alloys, mild bronze,
teflon, wood, etc.) also require widely spaced toothing;
- pieces cut in bundles require combo tooth design.
9.3 - Teeth pitch
As already stated, this depends on the following factors:
- hardness of the material
- dimensions of the section
- thickness of the wall.
BLADE TEETH SELECTION TABLE
THICKNESS MM
TILL 1.5 14 10/14
FROM 1 TO 2 8 8/12
FROM 2 TO 3 6 6/10
FROM 3 TO 5 6 5/8
FROM 4 TO 6 6 4/6
MORE THAN 6 4 4/6
Z CONTINUOUS
TOOTH DESIGN
Z COMBO
TOOTH DESIGN
9.2 - Selecting blade
First of all the pitch of the teeth must be chosen, in the other
TYPES OF ST EEL CHARACTERISTICS
USE
Construction
steels
Carbon
steels
Spring
steels
Alloyed steels for
hardening and
tempering and for
nitriding
Alloyed
casehardening
steels
Alloyed for
bearings
Tool steel
Stainless
steels
Copper alloys
Special brass
Bronze
Cast iron
I
UNI
Fe360
Fe430
Fe510
C20
C40
C50
C60
50CrV4
60SiCr8
35CrMo4
39NiCrMo4
41CrAlMo7
18NiCrMo7
20NiCrMo2
100Cr6 100Cr6 100C6 534 A 99 52100 207 95 690÷980
52NiCrMoKU
C100KU
X210Cr13KU
58SiMo8KU
X12Cr13
X5CrNi1810
X8CrNi1910
X8CrNiMo1713
Aluminium copper alloy G-CuAl11Fe4Ni4 UNI 5275
Special manganese/silicon brass G-CuZn36Si1Pb1 UNI5038
Manganese bronze SAE43 - SAE430
Phosphor bronze G-CuSn12 UNI 7013/2a
Gray pig iron G25
Spheroidal graphite cast iron GS600
Malleable cast iron W40-05
56NiCrMoV7C100K
D
DIN
St37
St44
St52
CK20
CK40
CK50
CK60
50CrV4
60SiCr7
34CrMo4
36CrNiMo4
41CrAlMo7
----
21NiCrMo2
C100W1
X210Cr12
----
4001
4301
----
4401
F
AF NOR
E24
E28
E36
XC20
XC42H1
----
XC55
50CV4
----
35CD4
39NCD4
40CADG12
20NCD7
20NCD2
----
----
Z200C12
Y60SC7
----
Z5CN18.09
----
Z6CDN17.12
GB
SB
---43
50
060 A 20
060 A 40
----
060 A 62
735 A 50
----
708 A 37
----
905 M 39
En 325
805 H 20
----
BS 1
BD2-BD3
----
----
304 C 12
----
316 S 16
USA
AISI-SAE
----
----
---1020
1040
1050
1060
6150
9262
4135
9840
---4320
4315
----
S-1
D6-D3
S5
410
304
----
316
S = THICKNESS
Hardness
BRINELL
HB
116
148
180
198
198
202
202
207
224
220
228
232
232
224
244
212
252
244
202
202
202
202
220
140
120
100
212
232
222
Hardness
ROCKWELL
HRB
67
80
88
93
93
94
94
95
98
98
99
100
100
98
102
96
103
102
94
94
94
94
98
77
69
56,5
96
100
98
R=N/mm²
360÷480
430÷560
510÷660
540÷690
700÷840
760÷900
830÷980
1140÷1330
1220÷1400
780÷930
880÷1080
930÷1130
760÷1030
690÷980
800÷1030
710÷980
820÷1060
800÷1030
670÷885
590÷685
540÷685
490÷685
620÷685
375÷440
320÷410
265÷314
245
600
420
13
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
TI MODETI MODE
TI MODE
TI MODETI MODE
SOLID Ø OR L MM
TILL 30 8 5/8
FROM 30 TO 60 6 4/6
FROM 40 TO 80 4
MORE THAN 90 3
Z CONTINUOUS
TOOTH DESIGN
Ø = DIAMETER L = WIDTH
Z COMBO
TOOTH DESIGN
4/6
3/4
9.4 - Cutting and advance speed
The cutting speed (m/min) and the advance speed (cm2/min =
area travelled by the disk teeth when removing shavings) are
limited by the development of heat close to the tips of the teeth.
- The cutting speed is subordinate to the resistance of the material (R = N/mm
sions of the widest section.
- Too high an advance speed (= lowering of the saw frame)
tends to cause the disk to deviate from the ideal cutting path,
producing non rectilinear cuts on both the vertical and the
horizontal plane.
The best combination of these two parameters can be seen
directly examining the chips.
2
), to its hardness (HRC) and to the dimen-
9.7 - Blade type
They differ essentially in their constructive characteristics, such
as:
- shape and cutting angle of tooth
- pitch
- set
Shape and angle of tooth
REGULAR TOO TH: 0° rake and constant pitch.
Most common form for transversal or inclined cutting of solid
small and average cross-sections or pipes, in laminated mild
steel and grey iron or general metal.
POSITIVE RAKE TOOTH: 9° - 10° positive rake and constant
pitch.
positive
Long spiral-shaped chips indicate ideal
cutting.
Very fine or pulverized chips indicate lack
of feed and/or cutting pressure.
Thick and/or blue chips indicate overload
of the blade.
9.5 - Blade running-in
When cutting for the first time, it is good practice to run in
the tool making a series of cuts at a low advance speed
(= 30-35 cm
spect to the cutting capacity and solid section of normal steel
with R = 410-510 N/mm
area with lubricating coolant.
2
/min on material of average dimensions with re-
2
), generously spraying the cutting
Particular use for crosswise or inclined cuts in solid sections or
large pipes, but above all harder materials (highly alloyed and
stainless steels, special bronze and forge pig).
COMBO TOO TH: pitch varies between teeth and consequently
varying teeth size and varying gullet depths. Pitch varies between teeth which ensures a smoother, quieter cut and longer
blade life owing to the lack of vibration.
distance between teeth
Another advantage offered in the use of this type of blade in the
fact that with an only blade it is possible to cut a wide range of
different materials in size and type.
COMBO TOO TH: 9° - 10° positive rake.
positive
9.6 - Blade structure
Bi-metal blades are the most commonly used. They consist in a
silicon-steel blade backing with electron beam or laser welded
high speed steel (HHS) cutting edge. The type of stocks are
classified in M2, M42, M51 and differ from each other because
of their major hardness due to the increasing percentage of
Cobalt (Co) and molybdenum (Mo) contained in the metal alloy.
14
This type of blade is the most suitable for the cutting of section
bars and large and thick pipes as well as for the cutting of solid
bars at maximum machine capacity. Available pitches: 3-4/4-6.
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
TI MODETI MODE
TI MODE
TI MODETI MODE
Set
Saw teeth bent out of the plane of the saw body, resulting in a
wide cut in the workpiece.
REGULAR OR RAKER SET: Cutting teeth right and left, alternated by a straight tooth.
Of general use for materials with dimensions superior to 5 mm.
Used for the cutting of steel, castings and hard nonferrous materials.
WAVY SET: Set in smooth waves.
9.7.1 - RECOMMENDED CUTTING PARAMETERS
This set is associated with very fine teeth and it is mainly used
for the cutting of pipes and thin section bars (from 1 to 3 mm).
ALTERNATE SET (IN GROUPS): Groups of cutting teeth right
and left, alternated by a straight tooth.
This set is associated with very fine teeth and it is used for
extremely thin materials (less than 1 mm).
ALTERNATE SET (INDIVIDUAL TEETH): Cutting teeth right
and left.
This set is used for the cutting of nonferrous soft materials,
plastics and wood.
STEEL CUTTING SPEED LUBRICATION
CONSTRUCTION 60/80 EMULSIFIABLE OIL
CEMENTATION 40/50 EMULSIFIABLE OIL
CARBON STEEL 40/60 EMULSIFIABLE OIL
HARDENING AND TEMPERING 40/50 EMULSIFIABLE OIL
BEARINGS 40/60 EMULSIFIABLE OIL
SPRINGS 40/60 EMULSIFIABLE OIL
FOR TOOLS 30/40 EMULSIFIABLE OIL
FOR VALVES 35/50 EMULSIFIABLE OIL
STAINLESS STEEL 30/40 EMULSIFIABLE OIL
SPHEROIDAL GRAPHITE 20/40 EMULSIFIABLE OIL
CAST IRON 40/60 EMULSIFIABLE OIL
ALUMINIUM 80/600 KEROSENE
BRONZE 70/120 EMULSIFIABLE OIL
HARD BRONZE 30/60 EMULSIFIABLE OIL
BRASS 70/350 EMULSIFIABLE OIL
COPPER 50/720 EM ULSIFIABLE OIL
15
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
TI MODETI MODE
TI MODE
TI MODETI MODE
10
10.1 - List of spare parts
MACHINE COMPONENTS
MACHINE BED
19
23
24
20
REFERENCE N° DESCRIPTION
001 Pedestal
002 Swivel arm locking lever
003 Swivel arm locking bush
004 Bedplate
005 Spring coupling tie-rod
006 Filter
007 Nilos ring 32006 XAV
008 Bearing 32006 X
009 Hinge cam bushing
010 Swivel arm
012 Coolant pump
16
REFERENCE N° DESCRIPTION
013 Cooling liquid tap
014 Rubber ring coupling
015 Roller
016 Roller holding arm
017 Carter
018 Liquid holder
019 Electric box
020 Electric box cover
021
023 Microswitch support
024 Microswitch
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
LINEAR VICE ASSEMBL Y
TI MODETI MODE
TI MODE
TI MODETI MODE
REFERENCE N° DESCRIPTION
101 Linear countervice
102 Linear vice
103 Rapid locking spring
104 Straight vice screw
105 Saw frame arm rotation pin
106 O-Ring 3081
107 Bar-stop rod
108 Bar-stop
109 Bar-stop push rod
110 Millimetre ruller
REFERENCE N° DESCRIPTION
111 No-burr jaw
112 Counter vice jaw
113 Vice jaw
114 Vice lever bushing
115 Rapid locking vice lever
116
117 Bearing 51108
118 Rapid locking lever washer
119 Vice handwheel
120 Handwheel washer
17
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
SAW FRAME UNIT
TI MODETI MODE
TI MODE
TI MODETI MODE
REFERENCE N° DESCRIPTION
201 Saw frame
202 Brake cylinder spring coupling rod
204 Hinge pin
205 Ring nut GUK 35
206 Motor cover
207 Motor fan
208 Washer
209 Electric motor
210 Reduction unit
212 Motor/reduction unit flywheel
shaft
213 Key 8 x 7 x 50
214 Key 8 x 7 x 25
215 Radial bearing 6206-2RS
216 Two-way distributor
217 Mobile rod locking dowel
218
219
220 Band tightening slide gib
221 Transmission flywheel pin
222 Blade tightening slide
223 Blade tightening slide threaded
rod
224 Belleville washer
Ø 16,3/31,5x1,75
225 Blade tightening handwheel
226 Blade guide head movable rod
227 Handgrip
REFERENCE N° DESCRIPTION
228 Saw frame movement lever
229 Blade guide rod guard
230 Transmission flywheel
231 Nilos ring 30205 XAV
232 Bearing 30205 X
233 Ring nut GUK 25
234 Flywheel guard fastening knob
235 Blade left-hand guard
236 Flywheel guard
237 Motor flywheel washer
238 Motor flywheel
239 Guard airtight microswitch
240 Motor flywheel guard
241 Blade right-hand guard
242 Blade guide head fixed rod
243 Blade additional protection
244 Blade guide fixed block
245 1/8" rubber holder coupling
246 Blade guide fixed pad
247 Blade guide adjustable pad
248 Short eccentr ic pin
249 Long eccentric pin
250 Bearing 608 2RS
251 Microswitch
252 Adjustment blade guide block
18
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
BLADE GUIDE FIXED BLOCK
TI MODETI MODE
TI MODE
TI MODETI MODE
ADJUSTMENT BLADE GUIDE BLOCK
19
324
325
326
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
327
TI MODETI MODE
TI MODE
TI MODETI MODE
BRAKE UNIT
323
322
321
NR. RIFERIMENT O DENOMINAZIONE
320 Bracke cylinder
321 Saw frame spring
322 Rod
323 spring
324 Protection spring
325 Support
326 Handle
327 Cylinder articulation
328 Ring
328
320
20
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
TI MODETI MODE
TI MODE
TI MODETI MODE
KEY
410 Auxiliary relay
411 Remote-control switch
412 Fuse cartridge
413 Transformer
412
410
411
413
420
KEY
418 Reset push-button
419 Main switch
420 Emergency push-button
421 Cycle selector
422 Hydraulic regulator
422
419
421
418
21
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
TI MODETI MODE
TI MODE
TI MODETI MODE
11
WIRING DIAGRAMS
11.1 Electric diagram
THOMAS
THOMAS
CODE DESCRIPTION
M1 Band motor
M2 Pump
SA Speed switch
FU1 Fuse cartridge
FU2 Fuse cartridge
FU3 Fuse cartridge
TC1 Transformer
SQ1 Microswitch
SQ2 Microswitch
CODE DESCRIPTION
SB1 Mushroom button
SB2 Luminous button
HL Pilot lamp
KM Remote-control switch
ST1 Band motor temperature probe
22
THOMAS
THOMAS
Hydraulic diagram
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
TI MODETI MODE
TI MODE
TI MODETI MODE
430 431
NR. RIFERIMENT O DENIMINAZIONE
430 ...................................... Car tuccia ARON CRD
431 ...................................... Car tuccia ARON CRD
23
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
TI MODETI MODE
TI MODE
TI MODETI MODE
12
This chapter lists the probable faults and malfunctions that could occur while the machine is being used and suggests possible
remedies for solving them.
The first paragraph provides diagnosis for TOOLS and CUTS, the second for ELECTRICAL COMPONENTS.
TROUBLESHOOTING
12.1 - Blade and cut diagnosis
FAULT PROBABLE CAUSE REMEDY
TOOTH BREAKAGE
Too fast advance
Wrong cutting speed
Wrong tooth pitch
Chips sticking onto teeth and in the
gullets or material that gums
Defects on the material or material too
hard
Ineffective gripping of the part in the
vice
The blade gets stuck in the material
Starting cut on sharp or irregular section bars
Poor quality blade
Previously broken tooth left in the cut
Cutting resumed on a groove made
previously
Vibrations
Wrong tooth pitch or shape
Insufficient lubricating refrigerant or
wrong emulsion
Teeth positioned in the direction opposite the cutting direction
Decrease advance, exerting less cutting
pressure. Adjust the braking device.
Change speed and/or type of blade.
See chapter on “Material classification
and blade selection”, in the section
Blade selection table according to cutting
and feed speed.
Choose a suitable blade. See Chapter
“Material classification and blade selection”.
Check for clogging of cooling liquid drain
holes on the blade-guide blocks and that
flow is plentiful in order to facilitate the
removal of chips from the blade.
Material surfaces can be oxidised or covered with impurities making them, at the
beginning of the cut, harder that the blade
itself, or have hardened areas or inclusions inside the section due to productive agents used such as casting sand,
welding wastes, etc. Avoid cutting these
materials or in any case perform cutting
with extreme care, cleaning and removing such impurities as quickly as possible.
Check the gripping of the part.
Reduce feed and exert less cutting pressure.
Pay more attention when you start cutting.
Use a superior quality blade.
Accurately remove all the parts left in.
Make the cut elsewhere, turning the part.
Check gripping of the part.
Replace blade with a more suitable one.
See “Material classification and blade
selection” in the
Adjust blade guide pads.
Check level of liquid in the tank. Increase
the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe
are not blocked.
Check the emulsion percentage.
Turn teeth in correct direction.
Blade Types
section.
24
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
FAULT PROBABLE CAUSE REMEDY
TI MODETI MODE
TI MODE
TI MODETI MODE
PREMATURE BLADE WEAR
Faulty running-in of blade
Teeth positioned in the direction opposite the cutting direction
Poor quality blade
Too fast advance
Wrong cutting speed
Defects on the material or material too
hard
Insufficient lubricating refrigerant or
wrong emulsion
See “Material classification and blade
selection” in the
tion.
Turn teeth in correct direction.
Use a superior quality blade.
Decrease advance, exerting less cutting
pressure. Adjust the braking device.
Change speed and/or type of blade.
See chapter on “Material classification
and blade selection”, in the section
Blade selection table according to cutting
and feed speed.
Material surfaces can be oxidised or covered with impurities making them, at the
beginning of the cut, harder that the blade
itself, or have hardened areas or inclusions inside the section due to productive agents used such as casting sand,
welding wastes, etc. Avoid cutting these
materials or in any case perform cutting
with extreme care, cleaning and removing such impurities as quickly as possible.
Check level of liquid in the tank. Increase
the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe
are not blocked.
Check the emulsion percentage.
Blade running-in
sec-
BLADE BREAKAGE
Faulty welding of blade
Too fast advance
Wrong cutting speed
Wrong tooth pitch
Ineffective gripping of the part in the
vice
Blade touching material at beginning
of cut
The welding of the blade is of utmost importance. The meeting surfaces must
perfectly match and once they are welded
they must have no inclusions or bubbles;
the welded part must be perfectly smooth
and even. They must be evenly thick and
have no bulges that can cause dents or
instant breakage when sliding between
the blade guide pads.
Decrease advance, exerting less cutting
pressure. Adjust the braking device.
Change speed and/or type of blade.
See chapter on “Material classification
and blade selection”, in the section
Blade selection table according to cutting
and feed speed.
Choose a suitable blade. See Chapter
“Material classification and blade selection”.
Check the gripping of the part.
At the beginning of the cutting process,
never lower the saw frame before starting the blade motor.
25
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
FAULT PROBABLE CAUSE REMEDY
TI MODETI MODE
TI MODE
TI MODETI MODE
STREAKED OR ETCHED BANDS
Blade guide pads not regulated or dirty
because of lack of maintenance
Blade too slack
Blade guide block too far from material to be cut
Improper position of blade on flywheels
Insufficient lubricating refrigerant or
wrong emulsion
Damaged or chipped blade guide
pads
Tight or slackened blade guide bearings
Check distance between pads (see “Ma-
chine adjustments” in the
Blocks
section): e xtremely accurate guiding may cause cracks and breakage of
the tooth. Clean carefully.
Check that the tightening handwheel is
against the microswitch that ensures ideal
tightening.
Approach bloc as near as possible to
material to be cut so that only the blade
section employed in the cut is free, this
will prevent deflections that would e xcessively stress the blade.
The back of blade rubs against the support due to deformed or poorly welded
bands (tapered), causing cracks and
swelling of the back contour.
Check level of liquid in the tank. Increase
the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe
are not blocked. Check the emulsion percentage.
Replace them.
Adjust them (see Chapter “Machine ad-
justments” in
Blade guide
Blade Guide
section).
CUTS OFF THE STRAIGHT
Blade not parallel as to the countervice
Blade not perpendicular due to the
excessive play between the guide
pads and maladjustment of the blocks
Too fast advance
Blade guide block too far from material to be cut
Blade too slack
Worn out blade
Wrong tooth pitch
Check fastenings of the blade guide
blocks as to the counter-vice so that they
are not too loose and adjust blocks ver tically; bring into line the position of the
degrees and if necessary adjust the stop
screws of the degree cuts.
Check and vertically re-adjust the blade
guide blocks; reset proper side guide play
(see Chapter “Machine adjustments” in
Blade guide
Decrease advance, exer ting less cutting
pressure. Adjust the braking device.
Approach it as near as possible to material to be cut so that only the blade section employed in the cut is free, this will
prevent deflections that would e xcessively
stress the blade.
Check that the tightening handwheel is
against the microswitch that ensures ideal
tightening.
Replace it.
Blade with major density of teeth is being
used, try using one with less teeth (see
Chapter “Material classification and
blade selection” in the
tion).
section).
Blade T ypes
sec-
26
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
FAULT PROBABLE CAUSE REMEDY
TI MODETI MODE
TI MODE
TI MODETI MODE
FAULTY CUT
STREAKED CUTTING SURFACE
Broken teeth
Insufficient lubricating refrigerant or
wrong emulsion
Worn out flywheels
Flywheel housing full of chips
Blade too slack
Too fast advance
Poor quality blade
Worn out blade or with chipped and/
or broken teeth
Wrong tooth pitch
Blade guide block too far from material to be cut
Blade too slack
Insufficient lubricating refrigerant or
wrong emulsion
Irregular work of the blade due to the lack
of teeth can cause deflection in the cut;
check blade and if necessary replace it.
Check level of liquid in the tank. Increase
the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe
are not blocked.
Check the emulsion percentage.
The support and guide flange of the band
are so worn out that they cannot ensure
the alignment of the blade, causing faulty
cutting; blade rolling and drawing tracks
can have become tapered. Replace them.
Clean with compressed air.
Check that the tightening handwheel is
against the microswitch that ensures ideal
tightening.
Decrease advance, exer ting less cutting
pressure. Adjust the braking device.
Use a superior quality blade.
Replace it.
Blade used probably has too large teeth;
use one with more teeth (see “Material
classification and blade selection” in
the
Blade Types
Approach it as near as possible to material to be cut so that only the blade section employed in the cut is free, this will
prevent deflections that would e xcessively
stress the blade.
Check that the tightening handwheel is
against the microswitch that ensures ideal
tightening.
Check level of liquid in the tank. Increase
the flow of lubricating refrigerant, checking that the hole and the liquid outlet pipe
are not blocked.
Check the emulsion percentage.
section).
NOISE ON GUIDE BLOCKS
Chipped bearings
Worn out or damaged pads
Dirt and/or chips between blade and
guide bearings. Replace them.
Replace them.
27
ZIP 30 - MULZIP 30 - MUL
ZIP 30 - MUL
ZIP 30 - MULZIP 30 - MUL
12.2 - Electrical components diagnosis
FAULT PROBABLE CAUSE REMEDY
TI MODETI MODE
TI MODE
TI MODETI MODE
MACHINE DOES NOT WORK
Power supply
Fuses “FU 1”
"SQ 1" safety microswitch
Blade tightening microswitch
Speed switch “SA” in position “0”
Emergency button “SB 1” on
Cycle reset or line button “SB 2”
Thermal probe built into the stator
winding has tripped due to motor overheating
Transformer “TC 1”
Fuse “FU 2 - FU 3”
Check: - phases
- cables
- socket
- plug
Voltage must arrive upstream from the
fuses (terminal board).
Check electrical efficiency and check for
shorts that trigger such protections.
Check closing of the flywheel guard.
Check the efficiency of the device; replace
it if damaged.
Make sure to have tightened the blade
with the relevant handwheel and to have
actuated the microswitch.
It must be turned to position 1 or 2.
Ensure that it is off and that its contacts
are unbroken.
Check mechanical efficiency; replace if
damaged.
Check current continuity on the two wires
in the prone after letting the motor cool
for about 10-15 minutes. If after this time
there is no current continuity in the two
wires, the motor must be changed or rewound.
Check that the supply voltage is the same
as the line voltage and that it gives a value
of 24 V at output.
Check fuse efficiency and ensure there
are no short circuits causing the protection to trip.
MOTOR STOPPED WITH PILOT
LIGHT “HL” LIT
13
In accordance with point 1.7.4.f of the Machines Directive EEC 98/37
2 measurements with the machine operating unloaded.
- The microphone was been located close to the operator's head, at medium height.
- The weighted equivalent continuous acoustic pressure level was 65,6 dB (A).
- The maximum level of the WEIGHTED instantaneous acoustic pressure C was always less than 130 dB.
NOTE: with the machine operating, the noise level will vary according to the different materials being processed. The user must therefore assess the intensity and if necessary provide the operators with the necessary personal protection, as required by Law 277/
1991.
28
NOISE TESTS
Microswitch “SQ 2” in the handle
Remote-control switch “KM”
Motor “M 1”
Check operation and/or efficiency;
replace if broken
.
Check that phases are present at both
input and output; ensure that it is not
blocked, that it closes when fed, that it
does not cause short circuits; otherwise
change it.
Check that it is not burnt and that it turns
freely.
It may be rewound or changed.
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