Norton clipper CHW, clipper CHW500, clipper CHW600 Operating Instructions Manual

CHW

OPERATING INSTRUCTIONS

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Declaration of conformity

The undersigned manufacturer:

SAINT - GOBAIN ABRASIVES S.A.

Declares that this product:

190, BD J.F. KENNEDY
L- 4930 BASCHARAGE

Masonry Saws:

CHW 1.30.1 230V

Code:

70184614040

70184614039

is in conformity with the following Directives:

• European Machinery Directive 2006/42/EC

• “LOW VOLTAGE" 2006/95/EC

• Electromagnetic Compatibility Directive 2004/108/EC

and European standard:

• EN 12418 – Masonry and stone cutting-off machines – Safety

Pierre Mersch

Business Manager Machines Europe

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CHW

OPERATING INSTRUCTIONS AND SPARE PARTS LIST

1 Basic Safety Instructions 6

1.1 Symbols 6

1.2 Machine plate 7

1.3 Safety instructions for particular operating phases 7

2 Machine description 8

2.1 Short description 8

2.2 Layout 8

2.3 Technical Data 10

3 Assembly and commissioning 11

3.1 Head locking 11

3.2 Tool assembly 11

3.3 Electrical connections 12

3.4 Water cooling system 12

4 Transport and storing 12

4.1 Securing for transport 12

4.2 Transport procedure 13

4.3 Long period of inactivity 13

5 Operating the machine 13

5.1 Site of work 13

5.2 Cutting methods 13

6 Maintenance and servicing 16
7 Faults: causes and cures 17

7.1 Fault-finding procedures 17

7.2 Trouble-shooting guide 17

7.3 Circuit diagram 18

7.4 Customer service 20

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1 Basic Safety Instructions

The CHW is exclusively designed for the cutting of construction products mainly on construction
sites.
Uses other than the manufacturer's instructions shall be considered as contravening the regulations.
The manufacturer shall not be held responsible for any resulting damage. Any risk shall be borne
entirely by the user. Observing the operating instructions and compliance with inspection and
servicing requirements shall also be considered as included under use in accordance with the
regulations.

1.1 Symbols

Important warnings and pieces of advice are indicated on the machine using symbols. The following
symbols are used on the machine:

Read operator’s instructions Ear protection must be worn

Hand protection must be worn Eye protection shall be worn

Rotation direction of the blade Pump on Pump off

Danger: risk of cut Never move the machine with the blade running

idle.

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1.2 Machine plate

Important data can be found on the following plate located on the machine:

Machine Model Machine Code

Machine type Serial number Power Safety standard Blade speed

Weight

Year of production

Maximum blade diameter

Bore diameter

1.3 Safety instructions for particular operating phases

Before commencing work

• Before commencing work, make yourself familiar with the working environment at the place of
use. The working environment includes: obstacles in the area of work and manoeuvre, the
firmness of the floor, necessary protection at the site relating to public thoroughfares and the
availability of help in the event of accidents.

• Check for correct mounting of the blade regularly.

• Immediately remove damaged or badly worn blades, as they endanger the operator whilst

rotating.

• Only fit NORTON diamond blades to the machine! The use of other tools can damage the
machine!

• Attention is drawn to the use of BS2092 safety goggles in conformity with specified Processes
No.8 of the Protection of Eyes Regulation 1974, Regulation 2(2) Part 1.

• For security reasons, never leave the machine unattended, untied or unlocked.

Electrical powered machine

• Always turn off the machine and separate it from the main source of electricity before any work
on the machine is done.

• Make all electrical connections securely to eliminate contact of live wires with spray water or
dampness

• When the machine is used with water, it is IMPERATIVE that you earth the machine properly.
Let a qualified electrician check in case of doubt.

• In case of emergency, you can stop the machine by pushing on the front cover of the switch.

• In the event of the machine breaking down or stopping for no apparent reason, switch off the

main electricity supply. Only a qualified electrician is allowed to investigate the trouble and
remedy the fault.

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2 Machine description

Any modification, which could lead to a change in the original characteristics of the machine, may
be done only by Saint-Gobain Abrasives who shall confirm that the machine is still in conformity with
the safety regulations.

2.1 Short description

The CHW Masonry saw is designed for durability and high performance for onsite wet and dry
cutting operations of a wide range of masonry, refractory and natural stone products. As with all
other NORTON products, the operator will immediately appreciate the attention given to detail and
quality of materials used in construction. The machine and its component parts are assembled to
high standards assuring long life and minimum maintenance.

2.2 Purpose of use

The machine is designed for cutting a large range of building and refractory materials. It is not
designed for cutting wood or metals.

2.2 Layout

Foot and handles (1)

The jig-welded, reinforced all-steel construction of the feet ensures perfect stability. Precision
springs allow the feet to be folded up. Handles can be used for the transport of the machine when
the feet are folded up, and for locking the feet when the machine is standing on its feet.

Frame (2)

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Built in aluminium profile, the frame is light and resistant.

Cutting head (3)

Jig-welded steel console. Console supports the electric motor and the blade guard. The balancing of
the cutting head is achieved using a heavy-duty spring. A depth-locking device fixed to cutting head
and frame enables the operator to set the cutting head to desired or to maximum cutting depth.

Blade guard (4)

Jig-welded steel construction with 350mm-diameter blade capacity, which offers maximum operator
protection and increased visibility of the work piece. Incorporated in the blade guard is an outer
metal cover, which can be easily hinged opened. This allows easy access to shaft for inspection and
blade replacement when motor is switched off, while fully protecting the blade when in operation.

Down feed and cutting depth adjustment (5)

The spring-loaded cutting head, activated by hand with the grip on the blade guard ensures smooth
lowering of the cutting head for shock-free penetration of the work piece and improved control of the
cutting pressure.

Conveyor cart (6)

Large, heavy-duty conveyor cart fitted with water flow-control vents, mounted on 4 rollers to give
maximum stability and smooth movement. The conveyor cart is equipped with graduated scale on
the backstop and with a guide-a-cut device.

Water cooling system (7)

The coolant system comprises:

• A powerful, submersible electric water pump.

• Plastic suction pipe delivering the water from the water pan to the cutting head.

• A removable large capacity aluminium water pan supplied with drain plug.

• A water-tap, fitted to the blade guard, permitting controlled water flow.

• Two water nozzles located on the blade guard ensure adequate flow of water to both sides of

the cutting blade.

• A water curtain, fixed to head axle restricts water spray and minimises water loss.

• The pump switch is located on the right side of the main switch.

Electrical Motor (8)

Leroy-Somer motor. Low voltage trigger (NVR) built in the switch prevents the motor to restart for
example after a power cut. The electric motor has an overload protection. Thermal overload tripping
can occur for two reasons:
a. tripping under light load

If connection is incorrect

b. tripping under heavy load

If motor has been overloaded

The ON-OFF switch also serves as emergency stop.

Anti-tipping device (9)

Two sheaves located on each side of the conveyor cart stabilise the cart while its usage. It also
prevents the cart from tipping from the frame.

Blocking device (10)

The cart can be fixed on the frame to allow the machine to be transported without danger.

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2.3 Technical Data

2,2 kW 230V with thermal overload protection (99788 and

Electric motor

Electric motor protection IP54
Max. blade diameter 350 mm
Bore 25,4 mm
Rotation speed of the blade 2730 min-1
Flange diameter 90 mm
Cutting depth mm 110 mm (without reversing the material)
Water pan capacity 28l
Sound pressure level 80 dB (A) (ISO EN 11201)
Sound energy level 92 dB (A) (ISO EN 3744)

70184610052, 70184614039, 70184614077 : CHW500

Cutting length mm 500 mm
Table dimension 500x500 mm
Machine dimensions 1130x705x1350 mm
Weights
Without water pan and conveyor

cart:
Water pan: 4 kg
Conveyor cart: 15 kg
Machine ready for work: 110 kg

70184610053, 70184614040, 70184614078 : CHW600

Cutting length mm 600 mm
Table dimension 600x500 mm
Machine dimensions 1195x705x1350 mm
Weights
Without water pan and conveyor

cart:
Water pan: 4 kg
Conveyor cart: 16 kg
Machine ready for work: 112 kg

99789)
1,5kW 115V with thermal overload protection (99993 and

99994)

60 kg

61 kg

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3 Assembly and commissioning

The machine is delivered fully equipped and assembled (although without diamond blade) and is
ready for operation after connection to the appropriate power supply.

3.1 Head locking

To make sure the machine is not damaged during transport, the locking handle of the head is
removed. Remove the screw in the locking axle, and replace it by the locking handle (1) supplied as
indicated on picture 1.

Picture 1 : assembling the locking handle

3.2 Tool assembly

Only NORTON blades with a maximum diameter of 350 mm can be used with the CHW.
All tools used must be selected with regard to their maximum permitted cutting speed for the
machine’s maximum permitted rotation speed.
Before mounting a new blade into the machine, switch off the machine and isolate it from the main
source of electricity.

To mount a new blade, follow these steps:

• Open the outside cover of blade guard by loosening the two knobs on the side of the guard.

• Loosen the hexagonal nut on the blade shaft, which holds the removable outer flange.

• Remove the outer flange.

• Clean the flanges and blade shaft and inspect for wear.

• Mount the blade on arbor ensuring that direction of rotation is correct. Wrong direction of rotation

blunts the blade quickly.

• Replace outer blade flange.

• Tighten hexagonal nut with spanner supplied for this purpose.

• Shut retractable blade guard cover and tighten the two knobs.

The blade bore must correspond exactly to the diameter of the blade shaft. Cracked or damaged
bore is dangerous for the operator and for the machine.

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3.3 Electrical connections

Electrical connections

Check that,

• the voltage/phase supply corresponds to the information indicated on the motor plate.

• Available power supply must have ground connection in conformity with safety regulations.

• The connecting cables should have at least a 2.5mm2-section per phase.

3.4 Water cooling system

Fill the water pan with clean water to approximately 2cm from top (ensure that bottom of pump is
fully immersed in water). Use the pump switch so you can use the pump.
Open water-tap at blade guard (note that handle on water-tap should be in line with water-flow).
Ensure that water is flowing freely in the circuit and is delivered adequately to both sides of the
blade, as insufficient water supply may result in premature failure of the diamond blade.
The water pump must never run without water. Always make sure that there is enough water in the
pan and refill if necessary.
In case of frost, empty the water cooling system from its water.

4 Transport and storing

4.1 Securing for transport

Before transporting or lifting the machine, always remove the blade and empty the water pan. You
can transport the machine mounted, or you can remove some parts from the machine so it is lighter.

Picture 2 : Securing the conveyor cart Picture 3 : Securing the water pan
a) If you want to transport the machine mounted, you have to secure the conveyor cart and the
water pan:

• To secure the cart (picture 2), loosen the wing nut (1) and turn the blocking device until it takes

the screw (3). Then retighten the wing nut.

• To secure the water pan (picture 3), make sure the blocking device (1) is in the shown position.
b) You can also remove the conveyor cart and the water pan:

• To remove the cart, loosen the wing nut (1 on picture 2) and turn the blocking device until it is

parallel to the scale. Loosen the knobs on each side of the conveyor cart (1 on picture 4), and
put the anti-tipping device in its lower position. Then remove the cart.

• Before removing the pan, take the water pump out of it. Open the blocking device (1 on picture

3) and pull the pan out of the profiles.

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Picture 4 : unlocking of the anti-tipping device

4.2 Transport procedure

The machine can be moved on a flat surface using its wheels. You must first fold away the feet. Lift
the rear handle and push lightly on the rear foot of the machine with your foot. The foot of the
machine will automatically fold away. You can then put the rear of the machine on the floor. Then
proceed the same way with the front foot.

4.3 Long period of inactivity

If the machine is not going to be used for a long period, please take the following measures:

• Completely clean the machine

• Empty the water system

• Take the water pump out of the slurry and clean it thoroughly.

The storage site must be clean, dry and at a constant temperature.

5 Operating the machine

5.1 Site of work

5.1.1 Siting the machine

• Remove from the site anything, which might hinder the working procedure!

• Make sure the site is sufficiently well lit!

• Observe manufacturer's conditions for connecting to power supplies!

• Place electric cables in such a way that damage by the device is excluded!

• Make sure you have a continual adequate view of the working area so you can intervene in the

working process at any time!

• Keep other staff out of the area, so you can work securely.

5.1.2 Space required for operation and maintenance
Leave 2 m in front of the machine and 1,5 m around it for usage and maintenance of the CHW.

5.2 Cutting methods

To use the machine correctly, you must face it with one hand on the handle of the cutting head, and
the other on the conveyor cart. Always keep your hands away from the moving blade. Open the
switch cover and press the green button to start the machine. To stop either use the red button or
press directly on the switch front cover.

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5.2.1 Full depth or fixed cutting
In full depth or fixed cutting, the cutting head is locked in a fixed position and the material is pushed

into it as shown.

• Lower the cutting head to the desired cutting depth (in “through cutting”, lower cutting head until

blade periphery reaches max. 3mm under the surface of the conveyor cart) by means of the
handle on the blade guard

• Fix position by tightening the clamping device

• Put material on conveyor cart

• Push the conveyor cart slowly and without undue pressure towards the rotating blade and cut

the material as shown on the picture.

NOTE: While recommended, it is not absolutely necessary to lock the cutting head into a given
depth position when jam cutting. The desired cutting depth can be maintained by holding firmly the
depth feed handle on the blade guard. If the full depth of cut requires excessive pressure (on very
dense material e.g.) make 2 or 3 shallow cuts.

5.2.2 Multiple step cutting
Multiple step cutting consists of moving the conveyor cart with the material to be cut back and

forward under the rotating blade,

• Place the material to be cut on the conveyor cart firmly against the guide-a-cut and the

backstop, keeping the hands well away from the blade.

• Move conveyor cart forward near the blade and pull down the cutting head until blade is lowered

to a point where it will lightly contact the surface of the material.

• Then pass the material beneath with rapid full length strokes, taking a shallow cut

(approximately 3 mm deep as shown on the picture) on the forward. On the backward stroke, lift
the blade just clear over the cutting line.

• Complete each rapid stroke backward and forward by passing the material beyond the centre of

the blade before starting the reverse movement of the conveyor cart.

NOTE: the harder the material, the more rapid should be the forward and backward strokes.
Step cutting lessens the area of the blade circumference in contact with the material, keeping the

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blade cool, running free and cutting at peak efficiency.

5.2.3 Cutting thicker material
You can cut thicker material by reversing the material on the cart. In order to raise the head to pass

the material under it, you have to turn the upper head stop from position 1 to position 2 as shown on
the picture 5. You can then cut up to 220mm thick material. When you want to cut again under
110mm, turn the stop from position 2 to position 1.

Picture 5: cutting with reversing the material

5.2.4 General advice for the cutting

• Material weighting under 30 kg and having dimensions smaller than 500x500x220mm for the

CHW500 and 600x500x220mm for the CHW600 can be cut with the machine.

• Before commencing work make sure tools are firmly seated!

• Before using the machine, make sure the two anti-tipping devices are tighten correctly. Loosen

the knob (1 on picture 6), and tighten the anti-tipping device (2) so the sheave (3) leans firmly on
the profile (4).

Picture 6: tightening of the anti-tipping device

• Select the right tools as recommended by the manufacturer depending on the material to be

worked, the working procedure (dry or wet cut) to be carried out and the required efficiency.

• Apply cooling water continuously whilst cutting and in good time! Make sure the water pan

contains enough water.

• When dry cutting, ensure sufficient dust extraction and wear a dusk protection mask!

• When cutting work is finished, close the water-tap so you can remove the cut pieces from the

conveyor cart without getting wet.

• In case the thermal protection trips, wait until the motor has cooled down before starting the

machine again.

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6 Maintenance and servicing

To ensure a long-term quality from the cutting with the CHW, please follow the maintenance plan
below:

Begin of the day

During the changing of tool

End of the day

or more often if required

Every week

After a fault

Whole machine

Flange and blade fixing devices Clean
Motor cooling fans Clean
Water pump Clean
Water pan Clean
Water hoses and nozzles Clean
Water pump filter Clean
Cart guiding bars Clean
Motor housing Clean
Reachable nuts and screws Tighten up

Visual control (general aspect,
watertightness)

Clean

Maintenance of the motor

Always perform the maintenance of the motor with the machine isolated from the electrical supply.

Lubrication

The CHW uses life-lubricated bearings. Therefore, you don’t need to lubricate the machine at all.

Cleaning of the machine

Your machine will last longer if you clean it thoroughly after each day of work, especially water
pump, water pan (which can be removed for easy cleaning), motor and blade flange.
Never use acid-based cleaning products, as the aluminium parts (water tray, rails, motor housing)
can be corroded by these cleaning products. Always clean the machine when any cutting dust and
debris is still fresh, never allow the deposits to solidify. To make the cleaning of the pump tank
easier, you can open it as shown on picture 7:

After a damage

Picture 7: open the water pump tank to clean it

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7 Faults: causes and cures

7.1 Fault-finding procedures

Should any fault occur during the use of the machine, turn it off, and isolate it from the electrical
supply. Any works dealing with the electrical system or supply of the machine can only be carried
out by a qualified electrician.

7.2 Trouble-shooting guide

Trouble Possible source Resolution
Motor is not running

Motor stops during the cutting,
but can be restarted after a
short period (overload
protection)

No electricity Check the electrical supply

(fuse for example)

Connection cable section too
small

Defective connection cable Change connection cable

Defective switch CAUTION : can only be solved

Defective motor Change motor or contact motor

Cutting advance too quick Cut slowly

Blade is blunt or glazed Sharpen the blade in

Change connection cable

by qualified electrician

manufacturer

calcareous stone

No water on the blade

Defective blade Change blade

Wrong blade specification for
the application

Not enough water in the pan Refill the water pan
Water pump is switched off Switch the water pump on
Water tap is closed Open tap on blade cover
Water supply system is blocked

up
Water pump is not working Prime the pump

Change blade

Clean water supply system

Reactivate switch
CAUTION : if switch trips again,

problem can only be solved by
a qualified electrician

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7.3 Circuit diagram

230V Motor

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115V-Motor

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7.4 Customer service

When ordering spare parts, please mention:

• The serial number (7 digits).

• The code of the part.

• The exact denomination.

• The number of parts required.

• The delivery address.

• Please indicate clearly the means of transportation required such as "express" or "by air".

Without specific instructions, we will forward the parts through the means which seem
appropriate to us --- but which is not always the quickest way.

Clear instructions will avoid problems and faulty deliveries.
If not sure, please send us the defective part.
In the case of a warranty claim, the part must always be returned for evaluation.
Spare parts for the motor can be ordered with the manufacturer of the motor or with their dealer,
which is often quicker and cheaper.

This machine has been manufactured by Saint-Gobain Abrasives S.A.

190, Bd. J.F.Kennedy
L- 4930 BASCHARAGE
Grand-Duché de Luxembourg.
Tel. : [phone]

Fax : [phone]
http://www.construction.norton.eu
e-mail: [e-mail]

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Guarantee can be claimed and technical support obtained from your local distributor where
machines, spare parts and consumables can be ordered as well:
Benelux and France:
From Saint-Gobain Abrasives S.A.
Free telephone numbers:
Belgium : 0 800 18951
France: 0 800 90 69 03
Holland: 0 8000 22 02 70
e-mail: [e-mail]

Czech Republic

Norton Diamantove Nastroje Sro
Vinohrdadska 184
CS-13000 PRAHA 3
Tel: [phone]
Fax : [phone]
e-mail : [e-mail]

Spain

Saint-Gobain Abrasivos S.A.
Ctra Guipuzcoa km7,5
E-31195 BERRIOPLANO (Navarra)
Tel: [phone]
Fax: [phone]
e-mail:[e-mail]

Italy

Saint-Gobain Abrasivi S.p.A.
Via per Cesano Boscone, 4
I-20094 CORSICO-MILANO
Tel: [phone]
Fax : [phone]
e-mail : [e-mail]

United Kingdom

Saint-Gobain Abrasives Ltd.
Doxey Road
Stafford
ST16 1EA
Tel : [phone]
Free fax : [phone]
e-mail : [e-mail]

Germany

Saint-Gobain Diamond Products GmbH
Birkenweg 45-49,
D-50389 WESSELING
Tel : [phone]
Fax : [phone]
e-mail: [e-mail]

Austria

Saint-Gobain Abrasives GmbH
Telsenberggasse, 37
A-5020 SALZBURG
Tel : [phone]
Fax : [phone]
e-mail: [e-mail]

Hungary

Saint-Gobain Abrasives KFT.
Banyaleg Utca 60B
H-1225 BUDAPEST
Tel: ++36 1 371 2250
Fax: ++36 1 371 2255
e-mail: [e-mail]

Poland

Saint-Gobain Diamond Products Sp.zO.O.
AL. Krakowska 110/114
PL-00-971 WARSZAWA
Tel: [phone]
Tel/Fax: [phone]
e-mail: [e-mail]

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SAINT-GOBAIN ABRASIVES

190, Bd. J. F. Kennedy
L-4930 BASCHARAGE
LUXEMBOURG

Tel.: ++352 50401-1
Fax: ++352 501633

e-mail: [e-mail]

www.construction.norton.eu

06.11.2008

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