Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Starrett Service Center: +55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br
Instruction Manual for installation and maintenance bandsaw machine models:
S2032
The Original Manual was written in Portuguese
serial number: date:
Prior to installing or performing any operation, carefully read this Instructions Manual on the use of this machine. For fither information or clarifications, please contact Starrett. REV. 01 - MAR/16
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GENERAL INDEX 1. COMPLIANCE CERTIFICATE ..................................................................................... 1 2. WARRANTY............................................................................................................ 3 3. MACHINE IDENTIFICATION ..................................................................................... 5 4. TECHNICAL DATA .................................................................................................... 7 5. SAFETY RECOMMENDATIONS ............................................................................... 11 6. MACHINE DESCRIPTION ....................................................................................... 15 7. INSTRUCTION FOR USE AND OPERATION ............................................................. 27 7.1. ASSEMBLIES AND OPERATION ADJUSTMENTS .......................................................................... 27 7.1.1. PACKING AND CLEANING .................................................................................................... 27 7.1.2. ASSEMBLY AND ADJUSTMENTS OF CUTTING TABLE ......................................................... 27 7.1.3. ASSEMBLY AND GUIDE SETTING ......................................................................................... 30 7.1.4. BLADE TENSION ADJUSTENT ............................................................................................... 32 7.1.5 BLADE CAMBER DJUSTMENT ............................................................................................ 34 7.2. COMMAND ................................................................................................................................... 35 7.3. ACESSORIES .................................................................................................................................. 35 7.3.1. LINEAR CUTTING GUIDE ..................................................................................................... 35 7.3.2.ANGULAR CUTTING GUIDE ................................................................................................... 36 7.4. FIRST CUT.......................................................................................................................................37 7.4.1. CUTS IN ANGLE.....................................................................................................................40 7.5. PROCEDURES IN CASE OF EMERGENCY ......................................................................................41
8. CRITERIA FOR BAND SAW SELECTION ................................................................... 43 8.1. LIMITS AND RECOMMENDATIONS ............................................................................................. 43 8.2. CRITERIA FOR BAND SAW SELECTION ........................................................................................ 43 8.2.1. TEETH ΈPITCHΉ ...................................................................................................................... 44 8.2.2. CUTTING FEEDING AND BLADE SPEEDS ............................................................................ 44
9. TRANSPORT AND INSTALLATION ....................................................................... 45 9.1 TRANSPORT ............................................................................................................................... 45 9.2.INSTALLATION................................................................................................................................46
10. ELECTRICAL SYSTEM ........................................................................................... 49
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III
S2032 - ING 11. MAINTENANCE AND CONTROL........................................................................... 57 11.1. GENERAL MAINTENANCE CONSIDERATIONS .......................................................................... 57 11.2. GUIDE SYSTEM MAINTENANCE ............................................................................................... 57 11.3. REPLACEMENT OF BAND SAW BLADE ...................................................................................... 58 11.4. TENSIONING AND REPLACEMENT OF TRANSMISSION BELT...................................................59 11.4.1. ADJUSTING THE TENSION BELT.........................................................................................59 11.4.2. REPLACEMENT TRANSIMISSION THE BELT......................................................................60 11.5. MAINTENANCE PERIODIC..........................................................................................................60 11.6. PROBLEMS, CAUSES AND SOLUTIONS.......................................................................................61
12. SPARE PARTS...................................................................................................... 62 APPENDIX I .............................................................................................................. 79 APPENDIX II ............................................................................................................. 81 CATALOG BLAND BAND SAW .................................................................................... 83 NOTES
IV
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ATTENTION: •
Before starting any operation on the machine S2032 ;READ ALL the instructions in this manual so that you become familiar with the equipment
•
Note carefully the instructions for transport (Chapter 9);
•
Note carefully the instructions for transport (Chapter 9); OBSERVED the voltage (volts) of the machine being delivered;
•
All operations of transportation, installation, operation, maintenance, assembly, disassembly and repair should be performed by skilled, trained and trained for these types of services. A Starrett give all assistance and technical assistance to the user or company that owns the machine whenever requested in writing;
•
Observe and understand all signs contained in the machine;
•
If the standard machine, delivered to the user, is modified or altered their technical characteristics, without the prior knowledge and approval ofStarrett, and the loss of any guarantor, the civil and criminal liabilities will be borne by the owner of the machine. Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Starrett Service Center: +55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br
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V
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VI
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1. COMPLIANCE CERTIFICATE DECLARAÇÃO DE CONFORMIDADE CE DECLARATION EC-CONFORMITY ATTESTATION DE CONFORMITÉ CE Starrett Indústria e Comércio Ltda. Av. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Declara, sob sua exclusiva responsabilidade, que os Declara bajo su exclusiva responsabilidad que los We declare that it is our sole responsibility that the Nous déclaro ns sous notre exclusive responsabilité que produtos, productos, produtcs, produits,
Máquina de serra de fita, Máquina de sierra de cinta, Bandsaw machine, Scie à ruban,
modelos: modelos: modelos: modèles:
S2032 Auxquels se rapporte la présente déclaration sont conformes aux dispositions des directives suivantes: Os quais se referem a esta declaração, estão de acordo com as seguintes diretivas: Al cual se refiere esta declaración, están de acuerdo con las siguientes directivas: To which this declaration relate are in accordance with the provision of following directives: 2006/42/CE
of the European Parlament and of the Council;
e que estão em conformidade com as normas y que están en conformidad con las normas and are in conformity with the following standards et sont conformes aux normes suivantes EN 13898:2003+A12009 ISO 12100:2010 EN 60204-1:2006+A1 ISO 14121-1 : 2007 EN 61000-6 ED.-2:2005 EN 61000-6 ED.-4:2007
Itu/SP, September 2015. REV. 01 - MAR/16
1
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2. WARRANTY Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Starrett Service Center: +55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br
WARRANTY CERTIFICATE PRODUCT S2032.
The equipment manufactured and/or commercialized by Starrett Ind. e Com. Ltda is covered by 12-months warranty from the issuance of invoice, regardless or not the use of equipment. During the warranty period, the Technical Support of Starrett provided will loose its free characteristic if the defect allegation is unfounded. The replacement of parts or components, which are proven to have factory defects, shall be free of charge, not including the labor required, except when in reference to: •
Parts with foreseen natural wear caused by usage, such as bearings, protections, sealing, lamps, carbide plates, etc.;
•
Improper and undue handling for the purposes to which the product is intended;
•
Transport, falls, collisions, shocks, or improper storage;
•
Supply or usage of improper electric power;
•
Supply or usage of improper electric power;
•
Lack of observance of the instruction manual;
•
Interventions performed by third parties without Starrett Ind. e Com. Ltda.;
•
Extended lack of product usage.
Alterations in the specifications of the machine, structural, electrical or any unauthorized modification to the written Starrett Ind. e Com. Ltda also results in loss of warranty; The warranty does not include regular machine maintenance service, such as adjustments, cleaning, and band replacement. Parts or equipment eventually replaced during the fulfillment of such warranty are the property of Starrett.
Starrett Indústria e Comércio Ltda.
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4
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3. MACHINE IDENTIFICATION All machines Starrett has an Identification Plate (31) fixed in the column of Structure (02) (figure 03). The following data in engraved in the ID plate: Model, serial number, code, manufacturing year, weight, power and voltge. Below is showed an ID plate type:
S2032 J-0051-15/BR-S S2032-H4 2015 350 3,0 220
60
(ILLUSTRATIVE DATA)
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6
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4. TECHNICAL DATA:
S2032 220/400V - 50Hz - 2,2Hz
Band Saw Brakemotor (*): Band Saw Blade:
SEE APPENDIX I lenght (mm):
4550
width (mm):
19A34
Current (A):
220V
8,0
400V
5,0
Blade Speed (m/´):
20/40/60/80/100/150/200/400
Distance (Blade Column) (mm):
600
Cutting Heigth (mm):
430
Cutting Table Dimension (mm)
700 x 610
Cutting Table Tilt ( )
0 - 45
o
Weight (kg):
Liquid:
350
Gross:
370
Packing Size (mm):
1003 x 730x 2220
Noise Level (unloading) (dB (A):
78
(*) Before connecting the machine on electrical grid, check if the voltage (volts) of the grid is the same indicated in the machine.
STANDARD EQUIPMENT: 1 Band Saw Blade Starrett M42 1 Instructions Manual
WARNING: RISK OF INJURY!! This machine doesn´t have a coolant system incorporated. ALL cu ng should be made DRY, without lubricate on or coolant. If necessary, consult the Starre Technical Support before any interven on or modifica on on, because it may occur in the loss of guarantee.
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7
S2032 - ING COMPONENTS DESCRIPTION LIST IN THE FIGURES: POS
DESCRIPTION
POS
DESCRIPTION
02
STRUCTURE
47
CAMBER ADJUSTMENT WHEEL
03
GENERAL SWITCH- CIRCUIT BREAKER - QS1
48
SUPPORT BASE
04
DRIVEN FLYWHEEL
49
BELT TENSIONING WHELL
05
DRIVE FLYWHEEL
50
DRIVEN PULLEY
06
START BUTTON- SB2
51
TENSIONING PULLEY
07
EMERGENCY BUTTON - SB0
52
DRIVE FLYWHEEL LOCKING NUT
08
STOP BUTTON - SB1
53
CONTROL PANEL
09
CUTTING TABLE
54
LIFTING BOLT
10
LOWER DOOR
55
BLADE QUICK TENSIONING LEVER
11
UPPER DOOR
56
24V PILOT LAMP - HL1
12
LINEAR CUTTING GUIDE
57
SAFETY MODE - KS1
13
ANGULAR CUTTING GUIDE
58
LOCK LEVER OF ROTATING TABLE
14
BLADE BAND SAW BRAKEMOTOR
59
ROTATING TABLE DRIVE WHEEL
15
TRANSMISSION BELT
60
ROTATING INSERT ADJUSTMENT BOLT
16
GUIDE SUPPORT
61
COUNTER LOCKNUT
17
LINEAR CUTTING GUIDE
62
LATERAL ROTATING INSERT
18
SCALE
63
REAR ROTATING INSERT
19
INDICATOR
64
TENSION INDICATOR POINTER
20
CUTTING TABLE RIP
65
BLADE TENSION SCALE
21
KNOB
66
ROTATING INSERT ADJUSTMENT BOLT
22
LOCK HANDLE
67
FIXED PROTECTION OF MOBILE GUIDE
23
MOBILE GUIDE
68
CUTTING TABLE LOCK BOLT
24
FIXED GUIDE
69
RIPS OF SWIVEL TABLE SUPPORT
25
BAND SAW BLADE
70
STOP SCREW 0o OF CUTTING TABLE
26
LOCKING SYSTEM
71
LOCKNUT
27
ADJUSTMENT WHEEL OF MOBILE GUIDE
72
INSPECTION WINDOW
28
BRUSH
73
CAMBER LOCK WHEEL
29
SAFETY SWITC UPPER DOOR - KC2
74
POSITIONER WHEEL OF LINEAR CUTTING GUIDE
30
TENSIONING SYSTEM
75
TRANSFORMER - TR1
31
IDENTIFICATION PLATE
76
CONTACTOR - KM1
32
ELETRICAL BOX
77
CONTACTOR - KM2
33
TENSIONING WHEEL
78
FUSE F1 - ENTER TRANSFORMER - FU1
34
LOCK DOOR
79
FUSE F2 - ENTER TRANSFORMER - FU2
35
CLAMPING BOLT
80
FUSE F3 - OUT TRANSFORMER - FU3
36
CUTTING TABLE SUPPORT
81
DUST PORT
38
POINTER
82
SPEED CONTROL SWITCH - SA1
39
FIXATION SCREW
83
AUXILIARY CONTACTOR - KA1
40
INSERT
84
ELECTRICAL BOX SET
42
ANGULAR SCALE
85
FREQUENCY INVERTER - IN1
43
FIXED GUIDE FIXATION BOLT
86
GEAR BOX
44
MOBILE GUIDE SUPPORT
87
BLOWER MOTOR - M2
45
SAFETY SWITCH UPPER DOOR - KC1
88
AUXILIARY CONTACTOR - KA2
46
RESET BUTTON - SB4
8
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General View S2032
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9
S2032 - ING APPLICABLE LEGISLATION: From European Parliament and of the Council: Directive 2006/42 /EC - On Machinery; Directive 2004/108/EC - Electromagnetic Compatibility;
EUROPEAN TECHNICAL STANDARDS: EN 13898:2003+A1:2009 Machine Tools - Safety - Sawing machines for cold metal; ISO 12100:2010 Safety of machinery -- General principles for design -- Risk assessment and risk reduction EN 60204-1:2006+A1:2009Safety of machinery - Electrical Equipment of Machines - General Requirements; ISO 13857:2008 Safety Distances to Prevent Danger Zones being reached by Upper and Lower Limbs; IEC 61000-6-2: 2005 Electromagnetic compatibility (EMC) - Part 6.2 - Generic standards - Immunity for industrial environments; IEC 61000-6-4: 2007 Electromagnetic compatibility (EMC) - Part 6.4 - Generic standard - Emission standards for industrual environments; ISO/TR 14121-2:2007Safety of machinery - Risk assessment -- Part 2: Practical guidance and examples of methods; EN 1807-1:2003 Safety of woodworking machines - Band sawing machines - Part 1: Table band saws and band re-saws.
10
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5. SAFETY RECOMMENDATIONS This machine is equipped with several safety equipments to protect the user and the machine as well. However, all safety aspects cannot be summed by this. That is why each user must pay attention to the machine’s configuration, maintenance, and repair, and also carefully read all parts of this instruction manual. Obligatorily OBSERVE the following: •
Only qualified personnel with express authorization may operate and maintain this machine. These people must be trained regarding occupational safety standards of each country;
•
Without express authorization, it is strictly forbidden to perform changes or alterations to machine components that may compromise user or machine safety, exposing both to unnecessary risk. For the afore-mentioned changes, it is obligatory to request the authorization and approval of Starrett Technical Support;
•
All machine problems must be immediately communicated to the responsible personnel, that is, Starrett Technical Support;
•
Only persons authorized by the company owning the machine may handle, operate, feed material to be cut, prepare for cutting, perform maintenance, remove moving parts, change permanent components, and replace periodic maintenance components, such as: bearings, transmission belt, etc.;
•
To perform maintenance, changes, and repairs, or replace components of the machine’s electric system, the responsible and authorized person of the owner company must be qualified for such purpose, according to the pertinent law. According to the standards and laws valid in the country in which the machine is installed, it is implicit that only qualified persons must connect the machine to the electric power supplier and perform any works for this purpose.
•
When there is maintenance or any other intervention, it´s necessary to position the General Switch (03) in OFF (figura 04C) and disconnected from the electric power supplier, that is, the machine will not offer risk of electric discharge;
•
OBSERVE and ENSURE that the personnel responsible for handling, operating, feeding material to be cut, preparing for cutting, performing maintenance, repairing, removing moving parts, changing permanent components, replacing machine components, are NOT working under the influence of medicine, alcohol, or drugs that act on the central nervous system;
•
In case of machine problems, do NOT put it in operation before Starrett Technical Support;
•
In case of accidents, problems, or danger, quickly PRESS the EMERGENCY Button (07) (figura 03); REV. 01 - MAR/16
11
S2032 - ING •
To avoid machine operation irregularities, the operator must be well informed and trained on the operation of the machine before putting it into operation;
WARNING! RISK OF AMPUTATION OR SEVERE INJURY!
• NO is authorized to use this machine, UNDER ANY CIRCUMSTANCES, for CHILDREN or person(s) NOT qualified; • During the cu ng operaon, MUST NOT BE USED by the operator, UNDER NO CIRCUMSTANCES: short jacket or shirt or any kind of long-sleeved sweater, chain (s) or e or neck scarf, long hair loose, ring (s) in any finger, or any other object in the body that can pull the operator from the machine.
RISK OF ELECTRIC SHOCK
WARNING! DANGER OF INJURY OR MACHINE DAMAGE WARNING – RISK OF INJURY IN THE HANDS
• OBSERVE all signaling on the machine’s Structure (02). It is very important that the operator is familiarized with these indica ons;
CUTTING RISK
• DO NOT DAMAGE the machine´s technical plate;
DO NOT USE GLOVES FOR ANY PURPOSE, ONLY TO REPLACE THE BAND SAW BLADE
• NEVER touch machine moving parts with your hands or any other part of the body when it is in opera on; • ALWAYS KEEP the machine and the surrounding area clean. This way, it will prevent accidents to operator and also for people who are close to it;
RISK PROJECTION CAVACO
USE PROTECTIVE SHOES APPROPRIATE FOR THIS PURPOSE USE EARPLUGS APPROPRIATE FOR THIS PURPOSE USE PROTECTIVE EYEWEAR APPROPRIATE FOR THIS PURPOSE
► 12
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S2032 - ING ►
• Before cleaning the machine or star ng maintenance, put the General Switch (03) in the OFF posi on and the press the EMERGENCY Switch (07). NEVER REMOVE material chips and other residues with the machine in opera on. DO NOT LEAVE chips, and other residues to accumulate on or around the machine, because this may cause severe accidents or damage; • USE li ing and transport devices to handle the materials to be cut according to appropriate weight and dimension limita ons for a safe and ergonomic work. This opera on must be performed by responsible and qualified persons; • The operator must USE ALWAYS the protec ve personal equipment (PPE) legally approved in the country. The operator must use the following PPEs: Leather gloves, for only to replace the Band Saw Blade (25) (item 11.3), safety glasses and earplugs. Besides that, the company owner the machine must guide and train each operator appropriately on how to use and keep each PPE, crea ng or indica ng other individual protec ons especially for the operator; • Also it is necessary to observe the selec on of the type of band saw blade. OBSERVE: tooth, feeding and cu ng speed, appropriate for the type of material to be cut. This defini on avoids problems during the cu ng opera on ( seer Chapter 8 this Manual); • In case of machine maintenance, OBSERVE the safety recommenda ons (see Chapter 11 this Manual); • If necessary to replace the speed of Band Saw Blade (25), OBSERVE all Safety Recommenda ons to change the Belt (15), which is on the inside of Structure (02) (figure 04). So will avoid the risk of injury; • ALWAYS USE originals and new spare parts. Other spare parts or works not approved by the manufacturer, that present risks or cause accidents and damage are not under StarreƩ responsability; • ENSURE sufficient free space (1.5m minimum) around the machine, in order to provide work space and for people passage; • DO NOT PUT or LEAVE tools or others objects on the machine parts; • Always that the Linear Cut Guide (12) is u lized CERTIFY that it is properly locked on the Guide Support (16); • Always that the Angular Cut Guide (13) is u lized CERTIFY that it is properly locked in the Rip (20) on the Cu ng Table (09) and parts adjusted and locked.
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WARNING! RISK OF INJURY! IN DANGER ZONE, THE BAND SAW BLADE (25) IS NOT PROTECTED! The operator should be alert andNEVER to approach this area when the machine is on opera on.
DANGER ZONE
14
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S2032 - ING
6. MACHINE DESCRIPTION The model S2032 Starrett was developed under quality, safety, modernity, and technology criteria to meet the user’s needs, according to the EC Directives and harmonized standards. The band saw machine is designed exclusively for cutting steel materials such as steel, aluminum, copper alloys, and other metals. Also this model can cut plastics in the shape of bars, plates or pieces, or other material that requires low cutting speed. USE of this equipment should be performed only by trained and authorized persons. Any other form of use is considered incorrect and dangerous, voids warranty, and exempts the manufacturer from responsibility in case of accidents. For correct usage, the usage instructions and maintenance and control conditions must be observed, in order to meet the country’s valid occupational safety standards. Examples of materials to be cut: •
Construction Steels
•
Alloy Steels
•
Stainless Steels
•
Iron Casting
•
Aluminum Alloys
•
Carbon Steels
•
Copper
•
Brass
•
Aluminum
•
Plástics (nylon, teflon)
WARNING! RISK OF INJURY!! The bandsaw machine must not be used by unqualified personnel, and it is NOT made to cut: Materials such as meat, bone, ceramic, or irregularly shaped pieces, can not be performed by this machine model. ALWAYS if in doubt, refer to StarreƩ Technical Support.
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15
S2032 - ING BASIC CHARACTERISTICS: •
Structure (02) manufactured in welded steel plate, with phosphating treatment and powder coating with high wear withstand;
•
Combined Guides with Lateral Rotating Inserts (62) and Rear (63);
•
Pulley-belt type reducer with three-phase motor;
•
Starrett band saw blade;
•
Mobile Guide (23) height adjustment system, with Locking System (26);
•
Blade tensioning system;
•
Angular Cutting: Angle cutting: 0-45º with Cutting Table (09) turn swinging to the right or through the Angular Cutting Guide (13);
•
Brush (28) to clean the Flywheels (04) (05);
•
Full stop the machine when the Doors (10) (11) are opened and disarming the Safety Switches (29) (45) installed in the Structure (02);
•
THREE PHASE power supply: 220/400V/50Hz (check the Voltage request against the purchase order);
•
Compliance with technical standards ISO and EN.
Initially, the machine consists of a Structure (02), vertically placed, and made of welded steel plates, forming a rigid assembly. That assembly is phosphating treatment and powder painted, which assures wear withstanding and durability to the machine. 11 34
53
33
25
09 02
34
49 10
Figure 01A
16
REV. 01 - MAR/16
S2032 - ING Inside of that Structure (02), 2 flywheel assemblies are installed: one is Driven Flywheel (04) and the other, Driver Flywheel (05). The Driver Flywheel (05) is coupled with a Helical-bevel type Gearbox Set (86) by the Transmission Belt (15) (figura 01D). That Gerarbox Set (86) is driven by an electrical Brakemotor (14) ,THREE-PHASE. The Driven Flywheel (04) is assembled on the shaft of a dynamometric system, denominated Tensioning System (30) (figure 02B).
23 12 13
09
16 10 Figure 01B
A Band Saw Blade (25) is assembled on the two flywheels and properly tensioned by the Tensioning System (30), to keep it correctly tensioned on the Driven Flywheel (04) and the Driver Flywheel (05). A Pointer (64) coupled to the Tensioning System (30), due to the Band Saw Blade (25) width will indicate in the Tension Scale (65) when its tension is according to the item 7.1.4. (figure 01C). To facilitate the quicker replacement of the Band Saw Blade (25), this model has a quick tensioning device, Tensioning Lever (55). Thus, the operator can adjust the tension through the Tensioning Wheel (33), and afterwards relieve the Tensioning Lever (55) only, to the same Band Saw Blade (25) (figure 04B).
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17
S2032 - ING
04
64
30
65
33 Figure 01C
The Driver Flywheel (05) has 1 Brush (28) designed to clean the surface of this component. (figure 02A). The Doors (10) (11) have 2 Locks (34), being one in the upper door and other in the lower door. When any of them is opened, the electrical system will disable (shut off) the Brakemotor (14), and will stop it immediately. This is due to the 2 interlocked Safety Switches (29) (45), installed in each one of the doors (figures 02A and 02B).
Figure 01D
14
86
52
18
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S2032 - ING G
34
04
30 11 23 16 09
28
05
10
02
34 15 Figure 02A
29
04 11
45
33 64
Figu Fi g re gu e 02B 02B B Figure
REV. 01 - MAR/16
19
S2032 - ING
Figure 03 31
53
82 46 07
06
56
08
Inserted into the column Structure (02) is the Control Panel (53), whose function is to enable and disable the electrical system, respectively, by Button (06) (GREEN) and by Button (08). When pressing the Button (06), a Pilot Lamp 24V WHITE (56) will illuminate indicating that the energized electrical system. Along with this set is the EMERGENCY Button (07) that when pressed makes a complete stop of the machine By a Speed Control Switch (82) the operator can choose one of 8 cutting speeds preprogrammed in the equipment (20, 40, 60, 80, 100, 150, 200, 400 m /'). The Reset Button (46) the operator starts the Band Saw Blade (25), turning it to right. When positioned to the left the Band Saw Blade (25) will stop its movement. (fi gure 03). This model presents Guides, being one Fixed Guide (24) placed under the Cutting Table (09) (figure 04B) and the second, a Mobile Guide (23) placed above that table (figure 04A). The purpose of those guides is to keep aligned the segment of the Band Saw Blade (25) that cuts. For such alignment, 2 Rotating Inserts (62), one in each side of the Band Saw Blade (25) lateral, and one Rear Rotating Insert (63) on its back are used. Two Adjustment Bolts (60), placed in each side of the Guides (23) (24), regulates how rotating inserts approach on the band saw blade side. That adjustment allows the Band Saw Blade (25) alignment to avoid oscillations while cutting. One Rear Rotating Insert (63) is placed behind the Band Saw Blade (25) back to support its back when the material is performing a cutting strength, perpendicular to the cutting speed. Thus, those correctly adjusted rotary elements ensure the cutting quality (figure 04A). 20
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Figure 04A
61
63
60
62 62 25
63
25
Figure 04B
60
61
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62
21
S2032 - ING
26
55
Figure 04C
47 27 33 44
32
23
03
The Mobile Guide (23) is assembled on a Support (44) which is vertically Adjustable Wheel of Mobile Guide (27). Then, the operator can adjust it easily and without effort (figure 04C). For cuts requiring linearity or in angle, this machine has 2 standard devices: –
Linear Cutting Guide (12)
– figures 01B and 05;
–
Angular Cutting Guide (13)
– figures 01B and 06;
12
09
18
16
Figure 05 19 22
17 REV. 01 - MAR/16
S2032 - ING 21
Figure 06
22
09
13
With the machine set, electrically connected and the material to be cut duly positioned and placed on the Cutting Table (09), perform the machine starting procedure through the Control Panel (53), beginning the cutting jobs. This procedure is described on Chapter 7– item 7.4 – First Cut. This machine also has operator safety system. The safety systems are: The security system is basically composed of (a): •
EMERGENCY Button (SB0) (07), located on the Control Panel (53) (figure 03) in case of any abnormal situation, while operating, or in cases of problems or accident risks, the EMERGENCY Button (07) shall be actuated. This action instantly to the movement of the Saw Blade Brakemotor (14) and is monitored by security interface (Safety Mode KS1 (57));
•
Safety Switch (KC1) (45) electromechanical lock type of Upper Door (11) - to open it is necessary that all movement of Driven Flywheel (04) is eliminated (stopped) to allow the opening of this door. In this way, it is possible to perform maintenance or replacement of Band Saw Blade (25), if there is any movement, the Door (11) remains locked po this Safety Switch (45);
•
Safety Switch (KC2) (29) electromechanical of the Door (10) - to open the Door (10) access to the Driven Flywheel (05) to perform some maintenance or replacement of the Band Saw Blade (25), this switch disables all the electrical system, protecting the operator against accidental activation;
•
Safety Mode KS1 (57) - this machine is equipped with safety interface, responsible for monitoring the contactors KM1 (76) and KM2 (77), in addition to the Safety Switches (29) and (45) and EMERGENCY button ( 07)
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23
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Ligth indicator, i.e. Pilot Lamp (HL1) (56), indicating the presence of electric power in 24VAC in the electric panel of machine.
•
Frequency Inverter (IN1) (85) - the Brakemotor (M1) (14) Band Saw Blade (25) has its rotation (cutting speed) varied by a Frequency inverter, which in addition to this function, protects M1 14motor against possible overloads and short circuit. In case of any failure of the motor M114, the KM1 Contactor (76) and KM2 (77) disables this component, cutting the power supply to the same;
•
Circuit Breaker (QS1) (03) - This component beyond the sectioning function of the power circuit and electric machine control, also has the protection function of the entire circuit against overloads and short circuit of the electrical system;
•
Fixed Protection of Mobile Guide (67) - This component is designed to protect the operator from Band Saw Blade (25) on the Cutting Table (09), as illustrated in figures 07A and 07B.
67
Figure 07A
44
61
23
25 60
Figure 07B
61
67 60
09
25
24
REV. 01 - MAR/16
S2032 - ING
WARNING! RISK K OF INJURY!
07
DEFINITION THE WORK PLACE OF OPERATOR:
During the cutng process, the operator must be M A N D AT O R I LY close of Control Panel (53), observing the cu ng parameters, and with his hands free, to access, immediately the EMERGENCY Button(07)
WARNING! RISK OF AMPUTATION OR SEVERE INJURY! The length of the Band Saw Blade (25) that perform the cu ng opera on between Guides(23) (24), obviously does not count with protec on, therefore: NEVER touch any moving parts of the machine with your hands or any other part of the body while the machine is in opera on, especially the Band Saw Blade (25) .
WARNING! RISK INJURIES! Only qualified personnel with expressly authorized may operate and maintain this machine. These people must be trained according to the occupa onal safety standards, use protecve personal equipment correctly, and be well informed on the contents of this manual.
REV. 01 - MAR/16
25
S2032 - ING
26
REV. 01 - MAR/16
S2032 - ING
7. INSTRUCTION FOR USE AND OPERATION 7.1 ASSEMBLIES AND OPERATION ADJUSTMENTS
7.1.1 PACKING AND CLEANING The S2032 may be packed in wood case or factory assembled. check packing conditions. If the crate is damaged If the crate is damaged , immediately notify Starrett Technical Support to avoid to lose the warranty afterwards. When opening the case, verify whether all items are inside and if there are no damage signals, crushed, scratched or extremely oxidized parts. For that inventory, use the Instructions Manual, referring to Chapter 12 - Spare Parts. Should any type of damage or any missing item occur, immediately COMMUNICATE to the Starrett Dealer, under penalty of Warranty loss afterwards. Some parts, which surfaces are machined and rectified, are coated with anticorrosion protective oil. That protection shall be removed with solvent or suitable degreaser. Those products being used shall NOT cause any problem to the operator's health, to the environment and to the equipment paint. For a good operation performance of the S2032 it is necessary the total removal of that protection, mainly from the sliding mobile parts.
7.1.2 ASSEMBLY AND ADJUSTMENT OF CUTTING TABLE
WARNING! RISK OF INJURY!! Before any assembly and adjustment interven on in the machine, it shall be DISCONNECTED from the power supply. Due to the weight of both some parts and the Cu ng Table (09) it is advisable that the assembly shall be done, at least, by 2 people. Thus, equipment accidents and damage hazards will be reduced.
With the machine properly supported on the floor, with another person to help place the Cutting Table (09) on the Cutting Table Support (36). OBSERVE the gear between the Rips of Table Support (69) with Rotating Table Wheel (59) (figure 08).
REV. 01 - MAR/16
27
S2032 - ING
09
Figure 08
42
58
36
02
59
38
Having it duly fit, install the 3 first Cutting Table Lock Bolt (68) in the positions indicated on figure 09A. Then, rotate the Cutting Table (09) at 30ยบ and install the 4th Lock Bolt (68) according to figure 09B.
69
68
Figure 09A
36
28
REV. 01 - MAR/16
S2032 - ING
68
70 10
71 Figure 09B
25 Figure 09C
40
REV. 01 - MAR/16
29
S2032 - ING After that operation, the Cutting Table (09) shall be adjusted. Next, check whether the Band Saw Blade (25) is in the Insert (40) Gap Center of the Cutting Table (09) (figure 09B). If not, keep the 4 Lock Bolt (68) loosen (figure 09A and 09B) and adjust the Cutting Table (09) to the left or to the right, until the Band Saw Blade (25) passes through the Insert (40) center. Having this in the center, tighten the 4 Cutting Table Lock Bolt (68). With the Cutting Table (09) adjusted to its center, place it at 90ยบ related to the Band Saw Blade (25), according to figure 09C. With the square on the table, verify if the Pointer (38) is on the indication 0ยบ of the Scale (42). If not, place the Pointer (38) on 0ยบ of the Scale (42), loosening and tightening the respective Screw (39) which fixes that Pointer (38) (detail of figure 08). Next, loosen the Levers (58) and rotate the Cutting Table at 30ยบ. Unlock the Stop Screw (70) through its Locknut (71). Place the Cutting Table (09) on the position 0ยบ. Lock Levers (58). Turn the Stop Screw (70) until it touches the bottom of the Cutting Table (09). At that point, lock it with the Locknut (71).
7.1.3 ASSEMBLY AND GUIDES SETTING It is important to perform the Guides (23) (24) periodical adjustment, because they decrease the Band Saw Blade (25) lateral motion during cutting operation. The Band Saw Blade (25) fitting gap between the Lateral Rotating Inserts (62), either the Mobile Guides (23) or the Fixed (24), shall ensure a maximum backlash of 0.3mm (figure 04A). Start such adjustment by the Mobile Guide (23), loosening the Bolt (60). Separate them 1mm away from the band saw blade. Loosen the Bolt (43) to avoid that Lateral Rotating Inserts (62) do not interfere (do not touch) with the teeth of the Band Saw Blade (25). They shall touch the blade smooth lateral surface only. Eliminating that interference, lock the Bolt (43). Next, place a paper tape (~0.10 a 0.15mm) between one of the Rotating Inserts (62) and the Band Saw Blade (25). Touch it slowly, with the piece of the paper as a spacer, until the lateral of the blade, WITHOUT FORCING (FLEXIONING) the same. Lock the Bolt (60) through its respective Locknut (61). Proceed the same way to the opposite side of the blade, for the other Lateral Rotating Insert (62). The same complete procedure shall be repeated in the Lateral Rotating Inserts (62) of the Fixed Guide (24). The Rear Rotating Insert (63) shall be 3.0mm away from the Band Saw Blade (25) back. The contact of the blade with that insert shall only occur when cutting some type of material. (figures 09D and 09E).
30
REV. 01 - MAR/16
S2032 - ING
66 23
43
Figure 09D 3mm
66
63
25
Figure 09E
43
60
61
62
WARNING! RISK OF DAMAGE WITH BAND SAW BLADE: In case of width below 19mm (< 19mm) the back of the blade can touch slightly in the Rear Rota ng Insert (63).
REV. 01 - MAR/16
31
S2032 - ING With the machine DISCONNECTED from the power supply, open the Upper Door (11) and clockwise rotate the Driven Flywheel (04) manually. After some turns, verify the Band Saw Blade (25) position relating to the Rear Rotating Insert (63) of the Guides (23) (24). If the back of the Blade (25) is touching the Rear Rotating Insert (63) of the Fixed Guide (24) (figure 09E), the Bolt (66) should be loosened and the Fixed Guide (24) moved away until the measure of 3mm is reached between the bearing and the blade. After this operation is accomplished, Fixed Bolt (43). Lower Fixed Guide (24) adjusted, according to the procedure above, the position of the Band Saw Blade (25) back relating the Rear Rotating Insert (63) of the Mobile Guide (23) shall be checked. If the blade back is touching the Rear Rotating Insert (63), loosen the Bolt (66) and SLIDE the Mobile Guide (23) assembly backwards, until the measure of 3mm away from the blade back and the rotating insert is reached. LOCK the Bolt (66) again (figures 09D and 09E). To check if everything is accordingly, turn the Driven Flywheel (04) by hand again. If both Guides are adjusted, CLOSE the Door (11).
7.1.4 BLADE TENSION ADJUSTMENT
WARNING! RISK OF INJURY: Before any assembly and adjustment interven on in the machine, it shall be DISCONNECTED from the power supply.
At first, OPEN the 2 Doors (10) (11) to access the Band Saw Blade (25) and MAKE SURE that the Quick Tensioning Lever (55) is on the left side. With it installed in the center of the Flywheels (04) (05), Tensioning Wheel (33) clock counter wise (figure 10A) until getting the conditions below: Other methods, but not precise, would press the lateral of the Blade (25) moderately, according figure 10B, until reaching the measure e=5.0 mm. Under those conditions, the Band Saw Blade will be correctly tensioned.
32
REV. 01 - MAR/16
S2032 - ING
Figure 10A
55
26
47 27 73 44
23
33
500mm
Figure 10B
3.5kgf
Another more accurate way to adjust the Band Saw Blade (25) is measuring that tension. Recommended is 25.000 pound/sq.2 (25kSI) or ~ 1750 Kgf/cm2. For that end, must be USE a tension gage Starrett 682 EMZ (EDP 57075 â&#x20AC;&#x201C; SAW TENSION GAGE), according to the figure below.
e=5mm blade width = 13mm
For a good blade performance, it would be advisable to constantly CHECK the tool tension every time the machine will have to be used..
Recommended tension 25.000 lbf/pol2 ( Tension Mete) Starrett 682
REV. 01 - MAR/16
33
S2032 - ING 7.1.5 BLADE CAMBER ADJUSTMENT
WARNING! RISK OF INJURY! Before any assembly and adjustment interven on in the machine, it shall be DISCONNECTED from the power supply.
First of all, with the Doors (10) (11) opened, manually TURN the Driven Flywheel (04) and CHECK if the Band Saw Blade is in the rubbery center (blade stop lateral ) of the referred flywheels. If the blade is too forward or too backward, UNLOCK the Camber Lock Wheel (73), and USE the Camber Adjustment Wheel (47) to move, forward or backward, the Band Saw Blade (25) relating to the Flywheels (04) (05) rubbery center (figure 10A). The Inspection Window (72), installed at the upper case side which houses the Driven Flywheel (05), allows viewing the Band Saw Blade (25) positioning on the flywheel. (figure 10C). Slowly turn the Camber Adjustment Wheel (47) in one of the directions, and manually turn clockwise the Driven Flywheel (04). After some turns, CHECK the Band Saw Blade (25). 5). REPEAT such procedure until reaching that condition.
Figure 10C
11 72
34
27
34
REV. 01 - MAR/16
S2032 - ING
WARNING! RISK OF DAMAGE WITH BAND SAW BLADE Daily, with the Band Saw Blade (25) duly adjusted on the Flywheels (04) (05), OBSERVE its posi on through the Inspec on Window (72). If the Band Saw Blade (25) is forcing one of the Rear Rota ng Insert (63) â&#x20AC;&#x201C; upper or lower, keep them away from the blade not to harm such camber adjustment. A er adjus ng the blade posi on rela ng to the flywheels, repeat the procedure 7.1.3 - ASSEMBLY AND GUIDES SETTING.
7.2. COMMAND The S2032 has an electrical command defined by a multifunctional Control Panel (53). The figure 03 illustrates the Control Panel (53), comprising the EMERGENCY Button (07) by the Start Button (06) and STOP Button (08) Lamp PILOT 24V (56), the Speed Control Switch (82) and the RESET Button (46). The machine will only start with Doors (10) (11) closed and locked. If the EMERGENCY Button (07) is activated, the machine will only have conditions to startup again if it is disabled The figure 04C shows the Electric Box (32) and the General Switch (03), whose purpose is to keep the machine powered down whenever there was some maintenance work in this system, thus protecting the electric shock worker.
7.3 ACESSORIES 7.3.1 LINEAR CUTTING GUIDE (12) To facilitate straight cuts in wooden boards or slats, a Linear Cutting Guide (12) is developed to ensure the linearity accuracy. Place a Linear Cutting Guide (12) on the Cutting Table (09). Therefore, fit the Cutting Table (09) rear part. With the aid of the Scale (18) and of Indicator (19) (to the right and left side of the band saw blade) and by the turn of the Positioner Wheel (74), either clockwise or counterclockwise, it is possible to bring the Linear Cutting Guide up due to the desired cut width. After positioning and adjusting the Linear Cutting Guide (12) to the desired cut width, lower the Linear Cutting Guide (17) to lock out the assembly motion (figures 11A and 11B).
REV. 01 - MAR/16
35
S2032 - ING
Figure 11
12
74
19 18
16
17
WARNING: RISK INJURIES! The use of this acessory is safe, but the operator must PLAN this opera on and BE AWARE of all movements during the cu ng process.
NEVER USE GLOVES AS PPE.
7.3.2. ANGULAR CUTTING GUIDE That device was developed for circumstances requiring cut in angle, either on wooden boards or slats. It can slide in one of the 2 Rips (20) of the Cutting Table (09). For that, this device shall be fit in that slot at first. The angle capability is ± 60º as per figure 12. That adjustment shall be performed loosening the Handle (22) tightness until the desired side and angle.
WARNING: RISK INJURIES! Turn the Handle (22) towards the ghtening direc on and MAKE SURE of this, to keep the angle during the cu ng opera on and to avoid accidents and damages to the equipment .
36
REV. 01 - MAR/16
S2032 - ING 22
13 FIGURE 12A
20 48
21
Use and adjust the vertical Support Base (48) for better supporting the part to be cut, however, check if the Knobs (21) are properly tightened.
7.4 FIRST CUT Before any intervention on the machine, the operator shall use Protective Personal Equipment – PPE´s, such as safety glasses and boots and ear protectors. Mandatorily, those PPE´s shall be approved and certified according to the local regulations in force.
WARNING! RISK OF INJURY!
DO NOT USE any kind of gloves during machine operaƟon. This procedure does not guarantee safety.
REV. 01 - MAR/16
37
S2032 - ING On those conditions, the operator is ready to work with the machine.. However, before the first cut, it is important to check the cutting parameters. Due to the material specification , dimension, form and hardness, teeth and the Band Saw Blade (25). The proper choice of those parameters is required for the good cutting process performance. The Chapter 8, or by Starrett Technical Support can guideline the operator on those parameters. Having done this, it is possible to carry on the first cut.
WARNING! RISK OF INJURY! Before connec ng the machine to the power supply, MAKE SURE the equipment is adjusted and regulated according to the instruc ons above. Before begin any cu ng work, carefully , PLAN the whole cu ng process.. Cleaning and maintenance condi ons are important factors for a safe opera on for the operator. If in doubt and/or in maintenance, report yourself to the Starre Technical Support. In case of spare parts,ALWAYS use original parts. This machine SHALL NOT BE OPERATED BY CHILDREN. The proprietary is liable by those equipment operators. CHECK the Band Saw Blade (25) status.
With the equipment connected to the power supply, and the devices duly installed, as per item 7.3 â&#x20AC;&#x201C; ACESSORIES, turn on the General Switch (03) (position I - ON through the Electric Box (32). The Pilot Lamp (56) WHITE and the RESET button (BLUE) should light immediately. SELECT the Speed Control Switch (82) of the 8 desired cutting speeds. CHECK if the 02 Doors (10) and (11) are properly closed and interlocked in their respective Safety Switch (29) and (45). Also, VERIFY if the EMERGENCY Button (07) is unlocked. PRESS the RESET Button (46). BLUE lamp should go out, and if it does not check for any Doors (10) or (11) open, or if the EMERGENCY Button (07) is pressed. If after this check is still on this lamp, REQUESTING serviceability by a properly trained and authorized professional to perform this type of service. PRESS the Star Button (06). Automatically Band Saw Blade (25) begins to move. Begin the work observing the cutting performance, that is, whether the Band Saw Blade (25) is cutting properly, without withstanding. CHECK also for any noise unfamiliar to the process. If in doubt, refer to Starrett Technical Support.
38
REV. 01 - MAR/16
S2032 - ING To end the cutting process, the operator must PRESS the STOP Button (08) (RED), stopping the movement of turning the Saw Blade (25). If cutting work is finally closed, the General Switch (03) to position O - OFF (figure 13). After work, it is advisable to CLEAN the machine to REMOVE the scrap originated from the cutting process. In cases of long periods without using the equipment, it is recommended to REMOVE the Band Saw Blade (25), to keep it free from chips, cover the Cutting Table (09) with protective oil, and clean and lubricate the Guides (23) (24) with Micro Oil Starrett M1. In this way the equipment will last longer.
32
03
14
Figure 13
86
REV. 01 - MAR/16
39
S2032 - ING 7.4.1 CUTS IN ANGLE The cuts in angle for wooden boards, scraps or blocks can be accomplished in 2 ways: First of them is using the Angle Cutting Guide (13), which procedure is described on item 7.3.2. The second way is moving the Cutting Table from 0 to 45ยบ to the right, as per figure 14. For such procedure, loosen the Lock Levers (58) and turn the Cutting Table (09) until the Pointer (38) reaches the desired angle at the Angle Scale (42) (figure 08). Next, tighten the Lock Levers (58). That option can be used together with the Linear Cutting Guide (12) on certain determined cutting conditions.
59
58 Figure 14
WARNING! RISK OF INJURY! The Angle Cu ng Guide (13) also can be used, however, it is recommended to plan and be very careful on working in that way.
40
REV. 01 - MAR/16
S2032 - ING
7.5. PROCEDURES IN CASE OF EMERGENCY:
If there is any occurrence where there is a need to press the EMERGENCY Button (07) in the Control Panel (53) (figure 03), the operator must follow the procedures below: 1. EMERGENCY! PRESS the Button (07) located in the Control Panel (53). If you need to completely shut down the machine through the General Switch (03), positioning it to OFF; 2. First step: STOP and VERIFY what is happening REQUESTING help a supervisor or other qualified person to VERIFY REMEDY and the occurrence; 3. DO NOT START the machine without first making sure that the EMERGENCY reason has been resolved; 4. VERIFY if the material to be cut is properly set if the Band Saw Blade (25) is full and standing out of the material and safe, and also no other eminent risks that must be removed; 5. Solved the problem and eliminated the risk of danger to position the main General Switch (03) ON, if necessary. Lamp 24V Pilot (56) located in the Control Panel (53) should light up; 6.
Then, VERIFY the BLUE lamp of RESET Button (46) is on;
7. PRESS the RESET Button (46). The internal lamp BLUE must switch off. If it DO NOT swicth off, request help from the maintenance staff to CHECK what is happening, because there may be a problem with the electrical part that prevents the departure of the same; 8. If switch off the BLUE lamp, PRESS the Start Button (GREEN) (06) to put the machine in motion and continue the initial work; 9. Then COMMUNICATE and NOTE incidence, if necessary to a supervisor or immediate superior.
REV. 01 - MAR/16
41
S2032 - ING
42
REV. 01 - MAR/16
S2032 - ING
8. CRITERIA FOR BAND SAW SELECTION 8.1. LIMITS AND RECOMMENDATIONS: Prior to beginning any kind of work with the machine, see that the job to be carried out is within the limits specified in table TECHNICAL DATA. If it is out of the specified values, we recommend that an inquiry in writing be addressed to Starrett on the possibility of changing some technical specification. Starrett will answer, also in writing, advising on the appropriate solution to be implemented..
WARNING! MACHINE DAMAGE RISK: StarreĆŠ takes no responsibility for injuries or damages caused to persons or material property; it is userâ&#x20AC;&#x2122;s responsibility to carefully check out the characteris cs of the material to be cut in order to prevent any risk to operator and/or third par es.
If it is within the specified capabilities of the machine, selection of the band is now another important aspect for the good performance of the job to be carried out.
8.2. CRITERIA FOR BAND SAW BLADE SELECTION: The proper selection of a saw band for a given application must consider some factors: type of material, hardness, cutting section, capability of the machine itself, etc. Four basic variables exist in selecting the band saw blade: 1-
Blade Type;
2-
Tooth Shape;
3-
Pitch;
4-
Cutting Feeding and Blade Speeds.
Then, observe at the catalog of Starrett to band saw blade that wll gude what is the best type of tooth shape to use.
REV. 01 - MAR/16
43
S2032 - ING 8.2.1. TEETH (PITCH): The pitch is number of teeth per inch (25,4 mm), that operator must be choose in function of material cutting section. The normal or annealed materials require at least 3 teeth inside cross section to be cut. It is ideal between 6-12 teeth. In general, materials with thin section require a band saw blade with a larger number of teeth per inch (25,4mm), or a band saw blade with “teeth thinner” being this opposite for materials with larger section.
8.2.2. CUTTING FEEDING AND BLADE SPEEDS. It´s important that the feed and cutting speed will be corrects. Starrett can to send a table “slide chart” type, to fast and easy selection of band saw blade, with specification of feeding and cutting speed for each kind of material. The same informations are available in the Starrett Band Saw Catalog.
OBSERVATION: The best condi ons to cut are 3 to 12 teeth inside in the cross sec on to be cut, in the same me.
44
REV. 01 - MAR/16
S2032 - ING
9. TRANSPORT AND INSTALLATION 9.1. TRANSPORT WARNING! MACHINE DAMAGE RISK: The S2032 will come factory mounted or par ally disassembled in a crate for protec on in transport. Regardless the way it gets at the Customer's facili es, it is advisable to transport it with some transporta on device due to its 390Kg gross weight. Therefore, the whole installaƟon process will occur within safety condiƟons for the operator and the equipment.
WARNING! MACHINE DAMAGE RISK: For safety, this machine has, on the Structure (02) (figure 15B) upper part, a Li ing Bolt (54) for li ing and transporta on, through li ing and transporta on devices, to the installa on site.
54
Figure 15
REV. 01 - MAR/16
45
S2032 - ING
9.2. INSTALLATION The machine shall be placed in a rain free local, having a flat surface, considering the ground admissible load. It shall be supplied a surface enough to: •
Work with the machine (enough room for the operator circulation around the machine);
•
Handle the material to be cut (enough room for support and cutting long slats and boards, such as roller table);
•
Accomplish maintenance operations;
To increase the equipment installation safety, it can be fixed by the Structure base (02) on the floor. For that, use proper fixtures. The machine, for transportation purposes, has some components which are removed to avoid damage. Components below shall be reinstalled according to the following instructions:
1) The crank lever of Wheel (27) for height adjustment of the Mobile Guide (23) , by tightening it with a wrench of 1016mm;
Figure 16A 27 46
REV. 01 - MAR/16
S2032 - ING 2) The crank lever of Tensioning Wheel (49) for Transmission Belt (15) , by tightening it with a wrench of 1016mm;
Figure 16B
49
3) Dust Port (81) tightening it with 4 Phillips M5x16 screws and the respective M5 16flat washers.
81
Figure 16C
WARNING! RISK OF EXPLOSION: Do not install the machine wherever there are explosive and flammable materials, and in too hot and humid environments. Too dusty places have to be avoided too, concerning either the operator health or for saving the equipment. GROSS WEIGHT 370 Kg.
REV. 01 - MAR/16
47
S2032 - ING
48
REV. 01 - MAR/16
S2032 - ING
10. ELECTRICAL SYSTEM The S2032 was developed especially for cutting in general, following the requirements of EC Directives 2006/42, apart from technical standard EN 13898 and EN 1807-1. Therefore, this model is equipped with a system of Brakemotor M1 (14) 2.2kW with forced cooling (M2) coupled to the same housing. By means of a Frequency Inverter (IN1) (85) This Brakemotor M1 (14) can vary the rotation through 8 preset points. This Frequency Inverter (85) (IN1) also has the purpose to protect the Brakemotor (M1)(14) against possible overload and short circuit. By Control Panel (53), installed in the column Structure (02) of the machine, it can control the equipment. Below is a description of each component installed in the Electric Panel (figure 03).
– 01 EMERGENCY Bu on (07) (SB0), to be pressed when the is required a quick stopped of Brakemotor M1 (14); – 01 START Bu on (06) (SB2) of Breakmotor – GREEN color; – 01 STOP Bu on (08) (SB1) of Breakmotor – RED color; – 01 Pilot Lamp (56) (HL1) – WHITE, indica ng that the Control Panel (53) is ON and the commands are energized with 24V; – 01 Speed Control Switch (SA1) ( 82); – 01 RESET Bu on (46) (SB3 / HL2) - BLUE color.
In addition to the components installed in the box Control Panel (53), is installed in the Electric Box (32) (figures 13 and 17B), the components of the power circuit, as well as the safety control system. This Electric Box (32) consists of the following components:
– 01 Circuit Breaker M1 (03) (QS1), whose purpose is to protect all the electrical circuit against possible short circuits and overloads, also serving as an isolator system, ie as a General Switch (03); – 01 Transformer (75) (TR1), to supply the the command circuit with 24VCA; – 02 Contactor (76) (77) (KM1) (KM2) to drive the Brakemotor (14); – 01 Fuses Terminal Blocks (78) (79) (80), respec vely (FU1) (FU2) (FU3), to serve as Transformer (75TR1) (TC) protec on; ► REV. 01 - MAR/16
49
S2032 - ING ►
CONTINUATION: – 01 Frequency Inverter (85) (IN 1) to vary the cu ng speed by variable speed of the Brakemotor (14); – 01 Safety Mode (57) (KS1), whose purpose is to perform the monitoring func on of the contactors (76) (77) (KM1) (KM2) and Safety Switch (29) (45) (SQ1) (SQ2); – 01 Auxiliary Contactor (83) (KA1), whose purpose is to trigger the M2 Motor (87) of the forced cooling; – 01 Fail Monitor (KS2); – 01 Power Supply (U1) Installed in the Structure (02): – 01 Electromechanical Safety Switch, locking type SQ1 (45) installed in the Upper Door (11) (Figure 17A); – 01 electromechanical Safety Switch SQ2 (29) installed in the Lower Door (10). 04 11
45
Figure F gu Fi g re e 17A 0 02B 2B B
WARNING! RISK OF ELECTRIC SHOCK: VERIFY the power of the machine, if it is 220 or 400V/50Hz. In case you need to change the voltage CONSULT customer support Starre obligatorily See Name Voltage Plate (84) (Figure 17B).
50
REV. 01 - MAR/16
S2032 - ING
WARNING: RISK OF ELECTRIC SHOCK For the operator and circuit safety, this machine shall be electrically GROUNDED.
WARNING! RISK OF ELECTRIC SHOCK: ALL interven on in the electrical installa on of machine shall be accomplished by the qualified personnel by company that´s proprietary of equippment, following the work safety standards in force in the local country.
►
83
85 IN1 78, 79, 80 FU1, FU2, FU3 77 KM2
57 KS1 76 KM1
83 KA1 03 QS1
84
75 (TR1)
Figure 17B
REV. 01 - MAR/16
51
52
REV. 01 - MAR/16
Copyright - total or partial reproduction is prohibited
FORCED COOLING (BLOWER)
safety circuit and forced cooling
Drawn by:
Approved by:
SAW BLADE MOTOR
Responsable:
Title:
power circuit of saw blade motor power 24 VCC
ELECTRIC DIAGRAM - MODEL S2032 220/380V - 60Hz
BRAKE MOTOR CONNECTION PLATE
brake system
Number:
Revision: NEW
interlocked safety switch of upper door
interlocked safety switch of lower door
3
Sheet: 01
safety switches
S2032 - ING
ELECTRIC DIAGRAM S2032
Copyright - total or partial reproduction is prohibited
command circuit
Drawn by:
Approved by:
Responsable:
safety system circuit
Title:
ELECTRIC DIAGRAM - MODEL S2032 220/380V - 60Hz
saw blade rupture sensor
Number:
Revision: NEW
stop control circuit
REV. 01 - MAR/16 03
Sheet: 02
S2032 - ING
53
54
REV. 01 - MAR/16
Reversible contact
Drawn by:
Approved by:
Responsable:
General switch
Circuit breaker
Induction motor, three phase with grounding
Coil of relay or contactor
Power contact of contactor
NO contact on shutdown
Lamp
NC contact with delayed opening
Time relay on shutdown
Auxiliary contact of contactor, relay, button ou circuit breaker
Code: Description:
Time relay in connection
Symbol:
Circuit breaker thermal magnetic tripolar
GROUNDING protection
Thermal switch bimetal contact
Overload relay
Code: Description:
Copyright - total or partial reproduction is prohibited
Symbol:
Title:
Symbol:
Number:
Revision: NEW
Total: 03
Sheet: 03
Solenoid valve
EMERGENCY button, punh type, turn to unlock, with NC contact, positive rupture
ELECTRIC DIAGRAM - MODEL S2032 220/400V - 50Hz
Fuse terminal
Command operated by key
Push button
Command switch with three positions
CC power supply
Switch with restraint
Transformer
Command actuator operated by foot
Limit switch contact mechanical action
Code: Description:
Device box, Safety mode, Inverter
Symbol:
Contact trigger by magnetic actuator
Inductive sensor
Retroflective optical sensor
Pressure switch
Code: Description:
Symbols specified in the IEC 60617 standard
S2032 - ING
S2032 - ING TABLE OF THE ELECTRIC COMPONENTS
POS
STARRETT CODE
DESCRIPTION
MANUFACTURER
SK9012 1AF100LH/4 ARBRE20FF 220 380 - 440V.
NORD
M2
87
M1
14
KC2
29
64285-5
Safety Switch Upper Door
LS-S02-ZB-2NC
MOELLER
KC1
45
63075-1
Safetu Switch Upper Dorr
AZM 161 - SK-12/12RKA-02 + AT
SCHMERSAL
46
64283-3
M22-DL-B/K10/24
MOELER
SA1
82
63647-6
CA10 BRC 753-FT3
KRAUS NAIMER
SB2
06
SB1
08
HL1
56
SB0
07
63919-8
EMERGENCY Button
TR1
75
63347-3
Transformer 220/400V-24VAC
KS1
57
63015-5
Safety Mode
FU3
80
---
Fuse 2,0A
FU2
79
---
Fuse 0,5A
FU1
78
---
Fuse 0,5A
KM2
77
SB3 HL2
KM1
76
KA2
88
KA1
83
IN1
85
QS1
03
KS2 U1
61261-6
Blower Motor (75W)
MANUFACTURER CODE
Brakemotor (2,2kW)
RESET Button Blue Lamp Speed Control Switch START Button
63929-9
STOP Button
A22-QDDL-11/10/K11/24
White Pilot Lamp (24V)
MOELLER
A22-RPV/K01 ARBOR CP-D 24VCC3NA1NF A 3/250-90W
WEG
commercial
Contactor of Power 64015-6
Contactor of Power
DILEM-10-24V
Auxiliar Contactor
MOELLER
Auxiliar Contactor 64241-7 64239-4 63915-4 63913-3
CWF 08 - 220V
Frequency Inverter
CWF 08 - 400V PKZMC-10 (220V)
General Switch
PKZMC-10 (400V)
Fail Monitor Power Supplier
FWS 1206C
WEG MOELLER SCHMERSAL
PSS24-W-3,0
WEG
BAE PS-XA-1W-24-038-003 (alternative)
BALLUFF
REV. 01 - MAR/16
55
S2032 - ING
56
REV. 01 - MAR/16
S2032 - ING
11. MAINTENANCE AND CONTROL WARNING! RISK OF INJURY! Only qualified and authorized by the company owner of the machine can perform maintenance and control opera on . It´s very important to observe the work safety standards in force in the local country. Before any assembly and adjustment interven on in the machine, it shall be DISCONNECTED from the power supply.
11.1. GENERAL MAINTENANCE CONSIDERATIONS It is very important: –
PROCEED both the cleaning and the chips disposal off the Flywheels (04) (05), inside the Structure (02) and on the Cutting Table (09) daily;
–
CLEAN periodically the electrical cables ("whips") conservation status.
WARNING! RISK OF INJURY! In the case the operator u lizes compressed air or equivalent cleaning systems, he shall USE SAFETY GLASSES, to avoid needless accidents.
11.2. GUIDE SYSTEM MAINTENANCE The correct Lateral Rotating Inserts (62) (63) installed in the Guides (23) (24), defines the quality of both the cut and the useful life of the Band Saw Blade (25). The Lateral Rotating Inserts (62) shall be snugly adjusted with the Band Saw Blade (25) (see item 7.1.3). Those Lateral Rotating Inserts (62) must have a clearence,ie,a gap between them of 0,3mm + blade tickness to a motion appropriated. Those Lateral Rotating Inserts (62) shall have the clearance, that is, a space between them of 0.3mm + the blade thickness for a suitable displacement of it. That procedure will assure a longer useful life to the rotaing carbide inserts, besides avoiding noises at the moment of the cutting operation. For that cleanness, it is recommended to spray Micro Oil M1 Starrett (see appendix).
REV. 01 - MAR/16
57
S2032 - ING
11.3. REPLACEMENT OF BAND SAW BLADE WARNING! RISK OF INJURY! Before any assembly and adjustment interven on in the machine, it shall be DISCONNECTED from the power supply.
To properly replace the Band Saw Blade (25) follow the following procedure: 1.
OFF electrically machine positioning the General Switch (03) O - OFF and the Emergency Button (07) pressioando and locked;
2.
REMOVE the Guide Linear Cutting (12) (if installed) and the Support tab (16) for Clamp Bolt (35) under the Cutting Table (09) (figure 18A);
3.
Open the Doors (10) (11).
4.
ROTATE the Tensioning Lever (55) counter-clockwise (Figure 04C);
5.
ROTATE the Tensioning Wheel (33) (Figure 04C) to decrease (loosen) and remove the tension of the tape Saw Blade (25);
6.
Carefully remove the Band Saw Blade wearing leather gloves;
7.
Before to install a new blade, clean thoroughly the area touched by the blade of the two Flywheels (04) (05) and also inside the Guides (23) (24) by injecting Micro-Oil M1 between the Lateral (62) and Rear (63) Bearings (figures 09D and 09E);
8.
ASSEMBLE the new Band Saw Blade (25), making sure that it has full dentition and compatible with the material being cut, noting that the teeth are in the direction of cutting. First, put in the gap of the Guides (23) (24) (between the Lateral Rotating Inserts (62)) and after on Driver Flywheel (05) and then on the Driven Flywheel (04) (figure 02A);
9.
ROTATE the Tensioning Wheel (33) to perform a pre-stretch until you feel a slight resistance;
10. ROTATE the Tensioning Lever (55)
in the sense schedule. See procedure7.1.4;
11. Position the General Switch (03) in OFF and the EMERGENCY Button (07) pressed; 12. GIVE starting the machine, according to procedure 7.4 - FIRST CUT.
WARNING: RISK OF INJURY! On removing the Band Saw Blade (25), handle it with care. During that procedure, USE Gloves to protect your hands, once the blade teeth could present hazards. 58
REV. 01 - MAR/16
S2032 - ING
11.4. TENSIONING AND REPLACEMENT OF TRANSMISSION BELT
WARNING! RISK OF INJURY! Before any assembly and adjustment interven on in the machine, it shall be DISCONNECTED from the power supply.
11.4.1. â&#x20AC;&#x201C; TENSION SETTING OF TRANSMISSION BELT To adjust the Transmission Belt (15) tension, OPEN the Lower Door (10); simply tension it through the crank of Tensioning Wheel (49) (figure 18A). Moderately, PRESS the Transmission Belt (15) with the thumb by its side between the Pulleys (50) and the pulley Driver Flywheel (05), as per figure 18B. OBSERVE whether the lateral displacement is according to the figure 18B. 16 28
35
10
51
52
Figure 18A
m
20m
15
05
Figure 18B
REV. 01 - MAR/16
59
S2032 - ING 11.4.2 REPLACEMENT OF TRANSMISSION BELT Before intervention, remove the Band Saw Blade (25) and open the Lower Door (10). Through the Tensioning Wheel (49), totally relieve the Transmission Belt (15) tension. Remove totally the Driver Flywheel Locking Nut (52) (figure 18A). By the internal side, pull the Drive Flywheel (05) and totally remove it off the machine. REPLACE the Transmission Belt (15) with a new, going to the Tensioner Pulley (51) located behind the Driver Flyweel (05). Next, assemble the Driver Flywheel (05) and tension the Transmission Belt (15) as item 11.4.1. Install again the Band Saw Blade (25) and adjust it as item 7.1.4.
11.5. MAINTENANCE TABLE Descrip on Clean the Guides(23) (24) (Rota ng Inserts (62) (63)) Check the wear of the Rota ng Lateral Inserts (62) (63) the guides (adjust clearances) Clean inside the Structure (02 and the Flywheels (04) (05)
Freqquency Daily Monthly
Daily
Daily
Remove and clean the sawdust oďŹ&#x20AC; machine internal part Clean and lubricate the sha s of Flywheels (04) (05) with Micro-oil M1 abundantly Adjust as per item 7.1.4.
Daily
Clean
Monthly Daily Weekly
Grease and adjust Replac, if necessary Adjust as per 11.4.1 or replace as per item 11.4.2. Cleanand check the condi ons of electrical components, as Brakemotor (14), Control Panel (53) and switch Safety (29) of the doors. Replace if necessary Adjust on the flywheels and/or replace
Weekly
Check the tension of Band Saw Blade (25) Clean the surface of Cu ng Table (09) and others surface of machine Tensioning System (30) Band Saw Blade (25) Check the tension of Transmission Belt (15) Check and clean the electrical system
Brushes (28) of Flywheels (04) (05)
60
Ac on Clean with Micro-oil M1 the Guides (23) (24) abundantly Adjust as per item 7.1.3
Monthly
Weekly
REV. 01 - MAR/16
S2032 - ING
11.6. TROUBLE, CAUSES AND SOLUTIONS
WARNING! RISK INJURIES! Before any interven on for solving any machine troubles, it shall be DISCONNECTED from the power supply for the operator safety.
Trouble The machine does NOT start with the Circuit Breaker (03) in ON.
Possible causes
SoluƟons
Some damaged cable Electrical supplying problem
Check the electrical cable damage Check if the Pilot Lamp (56) is light, or ie the Electric Panel with energy (24V) Open the cover of Voltage Plate (84) and to fit the handle correctly internally. Repair or replace the Circuit Breaker (03) Repair or replace the Brakemotor (14) Reset the Frequency Inverter (85) (see the manual of component) Turn off the Motor (14), and tension Band Saw Blade (25) by Tensioning Wheel (33)
The external handle is not fi ed properly in the sha of Circuit Breaker (03) Fail in the Circuit Breaker(03) Problem with the Brakemotor(14) Frequency Inverter disabled The Band Saw Blade (25) does NOT move with the Brakemotor (14) running
The Band Saw Blade (25) is not properly tensioning Wheel (33)
The Band Saw Blade (25) escaped from one Flywheels (04) or (05) Rupture of Band Saw Blade (25) Transmission Belt (15) is weak
The Band Saw Blade (25) does NOT cut in straight line
The Linear Cu ng Guide(17) is not being used or is not properly fiited Feeding of material is very fast
The teeth of Band Saw Blade are NOT cu ng (blunts) or damaged Guides (23)(24) are NOT properly adjusted REV. 01 - MAR/16
Open the Door (10)(11) check the Band Saw Blade (25), and replace it. Check the Band Saw Blade (25) and replace if necessary Check the Transmission Belt (15) and replace if necessary. Use the Linear Cu ng Guide (17) or check the correct alignment Use low pressure to cut the part to allow the band saw blade make the cut Replace the Band Saw Blade (25) damaged by a new one Adjust the Guides (23)(24)
►
61
S2032 - ING â&#x2013;ş Trouble
Blade (25) does NOT cut or the cut is too slow
Problem
Possible causes The teeth of Band Saw Blade are NOT cu ng (blunts) or damageds The Band Saw Blade (25) is being used with incorrect teeth pitchs to type of cut and material Blade Speed is NOT correct to type of cu ng and material The Band Saw (25) was mounted in the wrong direc on
The chip is This is NORMAL accumula ng inside the machine The Cu ng Table The floor surface is uneven (09) vibrates excessively The Transmission Belt (15) is damaged; Band Saw Blade (25) is damaged
EXTERNALS fuses or circuit breakers are frequently opening
62
Some screws ou nuts are released Motor (14) is overloaded Externals fuses or circuit breakers are NOT sized correctly or faulty The teeth of blade are NOT cu ng (blunts) or damaged Circuit Breaker(03), Contactor (76), (77), (83) e Inverter (85) or Motors (14) (87) damaged
REV. 01 - MAR/16
SoluĆ&#x;ons Replace the Band Saw Blade damaged by one new Replace the Band Saw Blade (25) by one with correct specifica on Adjust a be er indicated blade speed Posi on correctly the Blade Blade(25) Solu ons Regularly clean the chip from Band Saw Blade area (25). Use a suitable cleaning system to minimize this accumula on. Place the machine on the leveled surface Replace the Transmission Belt (15) by one new Replace the Band Saw Blade (25) damaged by one new Tighten ALL screws and nuts Feed the material against the Band SawBlade (25) slowly Replace the fuses ou Circuit Breakers Replace the Band Saw Blade (25) damaged by a new one Check, repair or replace the Circuit Breaker (03), Contactor (76), Inverter (85) or Motor (14). In case if persist the problem consult the Starre Tech nical Support - see the chapter 10.
REV. 01 - MAR/16
B5
B4
B2
B3
B39
B33
B1
B6
B7
B8
B22
B21
B38
B36
B35
B9
B34
B30
B23
B10
B31
B40
B32
B20
B12
B14
B29
B15
B17
B28
B27
B24
B25
B26
B13
B11
B41
B37
B18
B16
B19
S2032 - ING
12 SPARE PARTS
SET STRUTURE
63
64
REV. 01 - MAR/16
A118
A45
A44
A46
A47
A32
D9
D4
D3
D2
A49
A50
D7
A151
A52
D12
A53
D8
A54
D6
A63
A56
D5
A119
A62
A58
A64
A115
A30
A55
D13
D11
D65
A66
A40
A61
A31
A123
A25
A43
A42
A59
A57
A110
A35
S2032 - ING
SET MOBILE GUIDE
S2032 - ING SET FIXED GUIDE
D14 D12 D10
D7 D1
D13
D3
D19
D11
D17 D15
D18 D14
D8 D4 D5 D22 D9
D2 D21 D6
REV. 01 - MAR/16
65
A4
A5
A10
A6
A7
A12
A18
A9
A19
A8
A23
A13
A36
66 A20
A2
A1
A3
A29
A121
REV. 01 - MAR/16
A26
A25
A122
A24
A114
A27
A30
A124
A17
A16
A15
A37
A28
A35
A34
A31
A33 A32
S2032 - ING
SET DRIVEN FLYWHEEL
A4
A5
A8
A9
A6
A14
A7
A48
A73
A75
A72
A18
A87
A74
A91
A19
A89
A73
A90
A77
REV. 01 - MAR/16 A93
A92
A78
F2
F1
A25
A95
F3
A43
A96
F4
A42
F5
F6
F7
F11
F9
F10
F8
F14
F13
F15
F12
S2032 - ING
SET DRIVER FLYWHEEL
67
S2032 - ING SET TABLE
A44 A97 A98 A101
A27 A100 A38 A99 A102 A113 A108 A37 A107 A7 A112 A104 A110
A109 A96
68
A112
A106
A111
A28
REV. 01 - MAR/16
S2032 - ING SET ANGULAR CUTITNG GUIDE
C9
C5
C41 C7
C1
C44 C2 C6
C40 C3 C4
C16 C31 C15 C33
C42 C10 C32
C14
C19
C8
C18
C30 C29 C27
C17
C26
C24
C21
C35
C22
C36
C23 C34 C28 C37
C39
C20
REV. 01 - MAR/16
C25
69
S2032 - ING SET LINEAR CUTTING GUIDE
E15 E16
E1 E17
E2
E19 E18
E5 E14 E3
E20
E6
E7
E11 E13 E10
E12 E9
E4 E8
70
REV. 01 - MAR/16
S2032 - ING
POS
CODE
A1
31069-9
DESCRIPTION ALLEN SCREW M8X35
A2
CAM SHAFT
A3
BASE
A4
THINK HEX NUT M24
A5 A6
WASHER M24 41319-8
A7 A8
TYRE WHEEL SUNK HEAD SCREW M5x12
31071-2
BLOCK BEARING
A9
BEARING 6207
A10
SPACE UPPER WHELL
A11
UNNER SPACE UPPER WHEEL
A12
02237-4
UPPER WHELL
A13
31073-4
SHAFT UPPER WHELL
A14
02239-6
LOWER WHEEL
A15
61203-2
SPRING
A16
31075-6
SPRING SEAT
A17
INDICATOR BASE
A18
WASHER 30mm
A19
THIN HEX NUT M30
A20
31077-8
MOUNT. UPPER WHEEL
A21
ALLEN SCREW M6X25
A22
THINK HEX NUT M6
A23
BRACKET UPPER WHEEL
A24
THREAD UPPER WHELL
A25
SET SCREW M6X25
A26
41321-1
HAND WHEEL UPPER WHEE
A27
FLAT WASHER M8
A28
ALLEN SCREW M8X12
A29
31079-8
PARAWEL PIN
A30
WASHER M8
A31
SPRING WASHER M8
A32
HEX SCREW M8X16
A33
31081-3
LOCK CAN
A34
31083-5
LEVER, LOCK CAM
A35
41323-3
FLOWER SCREW M10X40
A36
41325-5
STAR LOCK KNOB, WHELL TILT
A37 A38 A39
WASHER M10 10643-4
POINTER MOUNT PAN HEAD SCREW M5X16
REV. 01 - MAR/16
71
S2032 - ING
POS
CODE
A40
WASHER M5
A41
THINK HEX NUT M5
A42
41327-7
A43
41329-9
A44
HAND WHELL BELL TENSION LEVER PAN HEAD SCREW M4X12
A45
10597-2
SLIDING GUARD
A46
10599-4
UPPER BLAD GUARD
A47
10595-0
BOLT GUIDE GUARD
A48
SPACER LOWER WHELL
A49
COVER UPPER GUARD
A50
COVER UPPER GUARD
A51
31085-7
A52
SPACE SUNK HEAD SCREW M5X10
A53
10601-8
RACK
A54
02261-1
SQUARE TUBE UPPER GUIDE
A55
ALLEN SCREW M5X50
A56
WORM
A57
31089-1
THEAD TUBE
A58
31091-4
MOUNT UPPER GUIDE
A59
THREAD GEAR
A60
BLOCK UPPER GUIDE M4X5
A61
31093-6
A62
41331-2
GEAR UPPER GUIDE THREAD GEAR
A63
BLOCK UPPER GUIDE
A64
ALLEN SCREW M6X16
A65
MOUNT UPPER GUIDE
A66
SHAFT UPPER GUIDE
A67
HEX SCREW M6X16
A68
WASHER M6
A69
72
DESCRIPTION
41333-4
BRUSH
A70
THIN HEX NUT M6
A71
SAW BLADE
A72
41335-6
MOTOR
A73
31095-8
SHAFT LOWER WHELL
A74
SPECIAL BOLT
A75
BRACKET LOWER WHEEL
A76
WASHER M16
A77
SPRING WASHER M16
A78
CAP NUT M16
REV. 01 - MAR/16
S2032 - ING
POS
CODE
DESCRIPTION
A79
HEX SCREW M8X180
A87
RING CIRCLE 20mm
A88
WASHER M20
A89
BEARING 6204
A90
RING CIRCLE 42mm
A91
31101-6
TENSION PULLEY
A92
31103-8
SHAFT TENSION PULLEY
A93
COLLAR TENSION ROD
A94
INNER SPACE LOWER WHELL
A95
31105-0
A96
THREAD TENSION ROD WASHER M12
A97
10605-2
INSERT TABLE
A98
02241-9
TABLE
A99
PAN HEAD SCREW M5X6
A100
50285-0
SCALE TABLE TIL
A101
02243-1
TABLE TRUNNION UPPER
A102
ALLEN SCREW M8X30
A103 A104
ALLEN SCREW M10X20 41337-8
RATCHET LEVER TABLE TILT
A105
BLOQUE TRUNION
A106
POINTER TILT
A107
31107-2
LOCK SHAFT TRUNION
A108
31109-4
WASHER LOCK SHAFT
A109
41339-1
KNOB TABLE TILT
A110
SET SCREW M8X8
A111
31111-7
GEAR TABLE TILT
A112
02245-3
TABLE TRUNION LOWER
A113
LOCK NUT M10
A114
TRUHST BEARING 8201
A115
61201-0
SPRING
A116
HEX NUT M12X1
A117
HEX NUT M30
A118
SCALE
A119
ALLEN SCREW M5x8
A120
SUPPORT BUSH
A121
CABLE FAST TENSIONER
A122
SEAT RING STEERING TENSIONER
A123
ALLEN SCREW M6X8
A124
PINO ELASTIC M3X20
REV. 01 - MAR/16
73
S2032 - ING
POS
CODE
B1
DOOR LOCK PIN
B2
WASHER M6
B3
HEX NUT M6
B4
PAN HEAD SCREW M4X12
B5
WASHER M4
B6
KEY MICRO SWITCH
B7
HEX NUT M4
B8
UPPER DOOR
B9
COPPER WASHER
B10
HEX NUT M10
B11
WASHER M10
B12
RING LIFT UP
B13
BUSH WIRE
B14
VIEW WINDOWS
B15
PAN HHEA SCREW M4X50
B16
RIVET
B17
ALLEN SCREW M6X25
B18
41341-3
DOOR LOCK
B19
LOCK NUT M6
B20
MICRO SWITCH
B21
HEX SCREW M8X30
B22
HEX NUT M8
B23
WASHER M8
B24
41343-5
B25
74
DESCRIPTION
SUCTION COVER TAPING SCREW ST3.5X12
B26
10607-4
CHAIN SUCTION
B27
41345-6
SUCTION CONNECTOR
B28
PAN HEAD SCREW M5X16
B29
WASHER M5
B30
HEX NUT M5
B31
PAN HEAD SCREW M5X16
B32
CLAMP WIRE
B33
PUSH STICK
B34
HOLDER PUSH STICK
B35
PAN HEAD SCREW M5X25
B36
COVER SWITCH BOX
B37
SEAL BOX
B38
SWITC BOX
B39
LOWER DOOR
B40
SA
B41
PUNTEIRO
REV. 01 - MAR/16
S2032 - ING POS
CODE
DESCRIPTION
C1
SCREW THREAD SUPERB ST4.2X10
C2
RULER BACK COVER
C3
FIXING PLATE
C4
SCREW ALLEN CAB. SCREW M4x10
C5
RULER LINEAR
C6
41349-1
BUTTERFLY NUT M6
C7
CHAPA THREADED
C8
SCREW ALLEN CAB. TAB. M5x8
C9
BOLT M6X70 ALLEN
C10
SUPPORT SUPPORT
C11
PHILLIPS SCREW M4x6
C12
ELASTIC RING
C13
LENS
C14
SCREW ALLEN M6x12
C15
COVER LEFT SIDE CAR GUIDE
C16
CARRA GUIDE
C17
41351-4
C18 C19
HANDLE LATCH HEX NUT M8
02247-5
ECCENTRIC CAM LATCH
C20
NUT SQUARE M5
C21
FLAT WASHER M5
C22
PHILLIPS SCREW M5x10
C23
SCREW ALLEN S / CAB. M6X6
C24
41353-6
KNOB ROTARY FINE ADJUSTMENT
C25
61205-4
SPRING
C26
31113-9
ECCENTRIC BUSH SET THIN
C27
31115-1
SEAT BLOCK FINE ADJUSTMENT
C28
31117-3
DRIVE SHAFT
C29
31119-5
GEAR
C30
FLAT WASHER M6
C31
SCREW ALLEN CAB. SCREW M6x12
C32
COVER RIGHT SIDE CAR GUIDE
C33
WORLD CAR DRIVE GUIDE
C34
LINEAR DUCT RANGE
C35
LEFT SIDE RAIL COVER
C36
RAIL
C37
31123-0
RACK
C38
41355-8
BOLT BUTTERFLY M8
C39
RIGHT SIDE RAIL COVER
C40
PLATE LOCKING THREADED
C41
PROFILE L RULER OF SUPPORT
C42
LOCKING PLATE
C44
RULER FRONT COVER REV. 01 - MAR/16
75
S2032 - ING
POS
CODE
D1 D2
PRESSURE WASHER M6 41357-0
D3 D4
ADJUSTING SCREW LOCK-NUT
31177-9
ADJUST SEAT
D5
SCREW PHILLIPS M4X8
D6
FLAT WASHER M4
D7
31179-1
BUSH COPPER
D8
31181-4
ROTARY TABLET BASE
D9
41363-7
ROTARY TABLET HARD METAL
D10
PRESSURE WASHER M4
D11
BOLT M8X12 ALLEN
D12
31131-9
ADJUSTABLE AXLE
D13
10621-0
BASE GUIDE
D14
SCREW ALLEN M6x12
D15
WASHER M6
D16
PRESSURE WASHER M8
D17
WASHER M8
D18
10619-7
MOUNTING BRACKET
D19
HEX BOLT M8x12
D20
FLAT WASHER M5
D21
10617-6
LOWER GUIDE PROTECTION
D22
10615-3
LOWER GUIDE PROTECTION
D23
76
DESCRIPTION
SCREW ALLEN S / CAB. M8X10
REV. 01 - MAR/16
S2032 - ING
POS
CODE
E1
41361-5
E2 E3
DESCRIPTION HANDLE THREAD FLAT WASHER M6
41359-2
transferring BASE
E4
PHILLIPS SCREW M5x10
E5
INDICATOR
E6
31129-6
WINDOW FIXING BASE
E7
31127-4
STOP PINO
E8
SCREW ALLEN CAB. SCREW M5x8
E9
ROLLER
E10
PINO GUIDE
E11
31125-2
RULER GUIDE
E12
SCREW PHILLIPS M4X18
E13
NUT HEX M4
E14
50287-9
WIDE RANGE
E15
SCREW THREAD SUPERB ST4.8X10
E16
PLASTIC CAP SIDE
E17
BASE SUPPORT VERTICAL
E18
PLASTIC CAP SIDE
E19
BOLT M6X32 ALLEN
E20
HANDLE M6
POS
CODE
F1
SCREW ALLEN M8x20
F2 F3
DESCRIPTION WASHER POLEA
31017-2
F4
POLEA MOTIVE 2A SCREW ALLEN M10X60
F5
41281-6
RING ELASTIC HOLE Ã&#x2DC; 90
F6
61195-2
ROLLING 6308
F7
30993-4
FLANGE GEARMOTOR
F8
31015-0
DRIVESHAFT
F9
30997-0
Gib PULLEY MOTIVES
F10
31119-4
REDUCING THE keyway
F11
61261-6
GEARMOTOR 1AF100LH SK9012 / 4 ARBRE20TF F220-380 - 440V
F12
31021-7
WASHER SPECIAL
F13
40463-7
SCREW ALLEN CAB. SCREW M10X25
F14
40093-6
FLAT WASHER M10
F15
40189-2
SCREW ALLEN M10X45
REV. 01 - MAR/16
77
S2032 - ING
78
REV. 01 - MAR/16
S2032 - ING
APPENDIX I
________________________________ STARRET INDUSTRIA E COMERCIO LTDA AV. LAROY S STARRETT 1880 PINHEIRINHO ITU - SP 13306-900
Technical Data Sheet Number/Date Reference no. PO date
201702437 /14.01.2016 53254
Cust. no. Field representative Phone Fax Email
Item
Description
100
SK9012.1AF-100LH/4 AR BRE20 TF F Product name Motor speed Ratio Output speed Service factor Output Torque M2 (Nm) Max. output torque M2 max (Nm) Motor Type Power (kW) Voltage (V) Frequency (Hz) Mode of operation Type of enclosure Insulation Class Nominal current 1 (AMP) Nominal current 2 (AMP) Cosinus 1 Mounting pos. of the gearbox Type of housing Shaft dimension Flange diameter (mm) Position of flange Breather Thermal motor protection Fan Type Voltage external fan Position of terminal box Terminal box position of force Brake torque (Nm) Brake voltage Type of protection brake Lubricant type class oil Quantity of Lubricant (l) Colour Paint type Painting instruction CE Logo
Material
90000000007912
Qty 1 PC
Helical-bevel geared brake mot 1.725 1/min 8,09 213,000 1/min 1,80 98,50 180,00 AR 2,200 220/380-440 60 S1 IP55 F 7,83 4,52 0,84 M4 Hollow shaft with flange 35H7 200 Flange at side A Spring-loaded breather PTC resistor, 3x155 °C Auxiliary fan 3P. 220-290V D/380-500V Y 50Hz 2/I 2/I 20 220VAC-205VDC IP55 ISO VG 220 mineral oil CLP 220 2,200 RAL 7031 Standard paint Paint type 2 standard Yes
REV. 01 - MAR/16
79
S2032 - ING
80
REV. 01 - MAR/16
S2032 - ING
APPENDIX II ÓLEO PARA LUBRIFICAÇÃO E LIMPEZA DAS GUIAS
Product: Micro-Oil Prevents Rust M1
Manufacter: Starrett
SpecificaƟon: Color Odor Specific Gravity Viscosity Lubrifica on Flash Point Percent Non-Vola lel Percent vola le maximum Pour Point Evapora on Rate Coverage Bolling Point, Ini al Weight, Applied Coa ng Film Tickness Humity Salt Spray Indoor Protec on - at lasts Outdoor Protec on
Amber (clear) pleasant 0,788 @ 60 oF (15,5 oC) 2,2 cSt (cen Stokes) connverts to 10,5 SUS 680Kg (1500 lb) of pressure (independent tes ng) Miminum 53 oC Toledo open cup 15% by weight 85% by weight petroleum dis late -73 oC Excelent low temperature stability 0,7 (water = 1 ) 85 to 100 m2 / liter = 3500 to 4000 sq. per U.S Gal. (4,5 liters) 173 oC 8 x 10 -3 Kg/m2 0,010 mm average According with ASTM-D 655. Zero rust a er 1000 hours According with ASTM-B 117. Zero rust a er 48 hours up to a year reapply as needed
Packages Types: Case of 12 / 12 oz. (0.3 liter) Aerosol Cans 1 Gallon (3.8 liters) Containers 5 Gallons (19 liters) Pall 53 Gallons (200liters) Drum
Nº Catalog M1.95173 M1.01 - 5 M1.05 M1.53
REV. 01 - MAR/16
Nº EDP 95173 93221 93227 93233 81
S2032 - ING
82
REV. 01 - MAR/16
S2032 - ING
CATALOG BLADE BAND SAW: NOTES
REV. 01 - MAR/16
83
170% MORE WELD CONTACT AREA
A - WIDTH Tip of the cutting edge to the back of the blade. B - LENGTH Measurement along the back edge of the blade.
MULTIPLE CUTTING EDGES
C - THICKNESS Measurement of the body of the blade. D - BACK EDGE Opposite side of the blade from the teeth. E - TOOTH PITCH Distance from the tip of one tooth to the next tip. F - TEETH PER INCH/25MM Number of teeth per inch/25mm. G - GULLET The curved area between two teeth. H - TOOTH FACE Surface of the tooth where the chip is formed. The tooth can have a positive or straight angle when measured against a line perpendicular from the back of the blade.
SPLIT CHIP ADVANTAGE
®
I - TOOTH SET The bending of the teeth, right and left, to allow blade clearance through the cut.
6
starrett.com
Constant Pitch
INTENSS
.8-1.3 to 14-18
INTENSS PRO-VTH
VERSATIX MP
REGULAR
HOOK
SKIP
Variable Pitch
6 to 32
1-2 to 4-6
Positive rake (up to 12º) product with a patented surging cutting action. Use with nickel alloys, stainless steels, and heat treated steels (up to HRc 45).
2-3 to 6-10
Computer designed product with a resultant robust positive rake tooth aimed specifically for intercept cuts on beams, channels, and tubes. Works well for all general cutting. M-42 - 8% cobalt teeth.
8-12 to 14-18
A standard 0º rake tooth form good for general and light duty cutting applications.
2 to 6
A 10º rake angle available in the carbon line. Good for fast cutting of hardwoods and nonferrous materials.
3 to 6
0º rake tooth with expanded gullet area. Works well in soft woods, nonferrous and non-metallics.
1 to 3
CNC ground triple chip tooth form. Excellent for high production rates on hard metallic and abrasive nonmetallics. Advanz™ FS is for shock, foundry applications. Advanz™ TS is for heat treated, difficult to machine materials.
ADVANZ FS & TS (Carbide Tipped)
Aggressive positive rake (up to 12º). Use for high production cutting of solids or heavy wall profiles. M-42 high speed edge with 8% cobalt.
.9-1.1 to 3-4
7
TOOTH CONSTANT PITCH
All teeth on the blade have uniform spacing, gullet depth and rake angle throughout the full length. Typically for general purpose cutting. Identified by one pitch number.
VARIABLE PITCH
Size of tooth and depth of gullet varies to substantially reduce noise levels and vibrations. Cuts all structurals, tubing and solids smoothly and quickly. Identified by two pitch numbers.
SETS RAKER SET
A recurring sequence of teeth set left and right, followed by one tooth unset. Frequency of unset teeth on variable pitch blades varies depends on the tooth configurations.
WAVY SET
Groups of teeth set to each side of the blade, with varying amounts of set in a controlled pattern.
ALTERNATE SET
A recurring sequence of teeth set alternately left and right.
TRAPEZOIDAL
Special carbide cylinder welded in the tooth edge, being slightly thicker than the blade, and triple chip grind.
8
starrett.com
BLADE TYPE Use this guide to choose the blade that will work best for the material to be cut, or provide an acceptable result, as necessary.
BLADE WIDTH Use the widest blade your machine will take except for contour cutting. Use this chart for cutting radii:
EXOTIC & NICKEL-BASED ALLOYS Intenss™ PRO or Intenss™ VTH TOOL & STAINLESS STEEL Intenss™ PRO or Intenss™ VTH ALLOY & HIGH CARBON STEEL Intenss™ PRO GENERAL PURPOSE Intenss™ PRO CARBON STEEL Intenss™ PRO-DIE STRUCTURAL STEEL Intenss™ PRO-ST or Versatix™ MP ALUMINUM Intenss™ PRO or Intenss™ PRO-DIE or Duratec™ FB CAST ALUMINUM Advanz™ FS THIN FERROUS SECTIONS Duratec™ FC COMPOSITES, FIBERGLASS, GRAPHITE & CERAMICS Advanz™ CG or Advanz™ DG WOOD & PLASTIC Woodpecker™ Premium or Woodpecker XF™ FOAM, PAPER PRODUCTS & RUBBER Band Knives FRESH OR FROZEN MEAT OR FISH (WITH OR WITHOUT BONES) Meatkutter™ Premium or Meatkutter™ Stainless
TOOTH SHAPE Regular - A conventional tooth used for general purpose sawing, straight or zero rake. Intenss™ PRO - Large teeth, up to 12º positive rake angle, for optimum production cutting of steels up to HRc 45, stainless, nickel based and nonferrous alloys. Hook - A positive rake for fast cutting of nonferrous metals and non-metallics. Skip - Zero rake and shallow gullets for cutting large sections of soft, nonferrous material.
9
BLADE LENGTH The blade length varies according to the band saw machine type and specifications. Please find the correct blade length on your band saw machine user manual.
PITCH Pitch is the number of teeth per inch or 25mm. Cutting thinner sections requires a finer pitch (more teeth per inch/25mm). Thick sections require coarser pitches (fewer teeth per inch/25mm). The charts are good guidelines. Because the cross section limits in the chart are broad and overlap, choose a coarser pitch if the speed of cut is most important. Choose a finer pitch if finish is most important. Section Size (Inch)
Constant Pitch (TPI)
Variable Pitch (TPI)
5/32 - 3/8
32 or 24
14-18
1/4 - 1/2
18 or 14
10-14
1/2 - 3/4
14 or 10
8-12
3/4 - 1
10 or 8
6-10
1 - 1-1/2
8 or 6
5-8
1-1/2 - 3-1/2
6 or 4
4-6
3-1/2 - 7
4 or 3
3-4
7 - 10
3
2-3
10 - 16
1.4-2
14 - 20
1-2
16 - 32
1-1.2
Over 30
.8-1.3
Wall Thickness
Outside diameter of tube or maximum profile section length (Inch)
(Inch)
3/8
3/4
1-5/8
2-3/8
3-1/4
4
4-3/4
6
8
12
16
20
24
3/32
14-18
14-18
10-14
10-14
10-14
10-14
8-12
8-12
8-12
8-12
6-10
6-10
5-8
1/8
10-14
10-14
10-14
10-14
10-14
8-12
8-12
8-12
6-10
6-10
6-10
5-8
5-8
5/32
8-12
8-12
8-12
8-12
6-10
6-10
6-10
5-8
5-8
4-6
4-6
4-6
3/16
6-10
6-10
6-10
6-10
5-8
5-8
5-8
5-8
4-6
4-6
4-6
4-6
1/4
5-8
5-8
5-8
5-8
5-8
5-8
5-8
4-6
4-6
4-6
4-6
3-4
5/16
4-6
4-6
4-6
4-6
4-6
4-6
4-6
4-6
3-4
3-4
3-4
3/8
4-6
4-6
3-4
3-4
3-4
3-4
3-4
3-4
3-4
2-3
2-3
1/2
4-6
3-4
3-4
3-4
3-4
3-4
3-4
2-3
2-3
2-3
5/8
4-6
3-4
3-4
3-4
3-4
3-4
2-3
2-3
2-3
2-3
3/4
4-6
3-4
3-4
3-4
3-4
3-4
2-3
2-3
2-3
2-3
1
3-4
3-4
3-4
3-4
2-3
2-3
2-3
1.4-2
1.4-2
1-1/4
3-4
3-4
3-4
3-4
2-3
2-3
2-3
1.4-2
1.4-2
1-5/8 2 2-3/8
10
starrett.com
3-4
3-4
3-4
2-3
2-3
2-3
1.4-2
1.4-2
3-4
3-4
2-3
2-3
1.4-2
1.4-2
1-2
2-3
2-3
1.4-2
1.4-2
1-2
Intenssâ&#x201E;˘ Pro Blade Width x Thickness
Blade Pitch with Material Numbers (all are Positive Rake)
Inch
mm
.8-1.3/P
3/4 x .035
19 x 0.90mm
1 x .035
25 x 0.90mm
1-1/4 x .042
32 x 1.10mm
1-1/2 x .050
38 x 1.30mm
2 x .063
50 x 1.60mm
99928
2-5/8 x .063
67 x 1.60mm
3-1/8 x .063
79 x 1.60mm
1-1.2/P
1-2/P
1.4-2/P
2-3/P
3-4/P
4-6/P
5-8/P
6-10/P
8-12/P
10-14/P
99191
99902
99903
99206
99222
99234
99905
99906
99907
99908
99318
99329
99334
99500
99911
99096
99912
99913
99914
99915
99917
99919
99921
99923
99924
99926
99927
99929
99930
99931
99932
99933
99962
99934
99937
99939
99941
99942
99943
99945
99947
3/4 to 1-1/4 sizes available in 250 (76m) coils. 1-1/2 to 2 sizes available in 150 (45m) coils. 2-5/8 and larger available in welded bands only.
POCKET LASER TACHOMETER KIT WITH CASE Cat. No. S7793Z • EDP No. 68930 The Pocket Laser Tachometer is a digital, battery-powered portable optical tachometer that can operate up to 25 feet from a reflective target using a laser light source. This powerful 32 function Tachometer/ Ratemeter, Totalizer/Counter and Timer is programmable in both inch and metric rates. It has TTL compatible pulse output to trigger devices such as data collectors or strobocopes. Ergonomic design makes measurement of speed and RPM simple.
RANGE Optical: 5 to 200,000 RPM Contact: 0.5 to 20,000 RPM Accuracy: Optical: ±0.01% of reading Contact: ±0.05% of reading Kit includes: Tachometer, RCA, contact tips,10cm linear contact wheel, 5 of T-5 reflective tape, (2) AA batteries, carrying case
SAW TENSION GAGE Cat. No. 682EMZ • EDP No. 57075 The Saw Tension Gage will check for proper blade tension in either English or metric, and is graduated both in pounds and kilograms. The tension gage can be read directly on either band saws of any type, or power hacksaws. It is graduated to read up to 60,000 PSI or 4,000kg per cm2 and is furnished with instructions, including suggested tensions.
BAND SAW BLADE ALIGNMENT GAGE Cat. No. PT92925 • EDP No. 65049 The alignment of your band saw blade is a key factor to guarantee blade life and accuracy with Starrett Band Saw Blades. This gage enables you to make sure your blade is running square to the cut.
187 SLIDE CHART FOR BAND SAW SELECTION AND OPERATING GUIDE Our popular band saw slide chart selection and operating guide includes a wealth of useful information printed on both sides. This slide chart recommends the pitch suitable for the cross section to be cut as well as surface feet per minute speed plus the optimum cutting rate. This tool was developed by our R & D group from actual tests.
193 CUTTING RATE SELECTION CHART This cutting rate selection chart is a heavy-weight, laminated, two sided sheet with a chain for easy attachment to a band saw machine. It also includes recommended tension for Starrett band saw blades and a quick reference troubleshooting table.
121 CRESCENT STREET ATHOL, MA 01331 978 249 3551
starrett.com M1, M2, M7, M10, M50 M3, M4, M30-M47 High Speed Steels
T1, T2, T6 T4, T5 T15
Free Machining Stainless Steels
303 416, 420F, 430F
Austenitic Stainless Steels
201, 202, 301-304 305, 308, 321, 347, 348
Ferritic
Monel K500 Hastelloy, Rene 41 99% Titanium
Molybdenum Refractory Metal
Tantalum
405, 409, 430, 434, 436, 442, 446
99% Copper
403, 410, 420, 422, 501, 502 440A-C, 414, 431
Cast Iron
15-5PH, 17-4PH, 17-7PH
INSTRUCTIONS: Set ARROW on slide at material to be cut. Check ARROW in lower right corner for correct blade type. For Intenss™ PRO-VTH increase scale speed/feed by 15%. For Advanz™ carbide tipped, increase scale speed/feed by 25%-30%. Use Versatix™ MP for structurals, pipe, tube, channel and small diameters. Instructions on reverse side. CUTTING STRUCTURALS SPEEDS: 250-325 wet; 200-250 dry NOTE: Break in blade at about 1/2 normal cutting rate for the first 50-100 square inches on easy to cut material. Tough work hardening material, break in at about 3/4 normal cutting rate for the first 25 square inches, gradually increasing feed to reach maximum cutting rate after 50 square inches. Always remove a chip and maintain recommended band speed. (Avoid vibration.)
Free Cutting Brass Yellow/Red Brass Copper Alloys
Phosphor Bronze
Class 20
Aluminum Bronze
Class 40
Aluminum Bronze (Hardened)
Free Machining Carbon Steels
Beryllium Copper
Ductile 80-55-06, 225HB
Beryllium Copper (Hardened)
Medium Carbon Steels
Most Aluminums
High Carbon Steels
1/2"-1"
1"-2"
320 5-7
300 6-8
270 8-10
10-14
8-12 6-10
5-8 4-6
TEETH PER INCH
SPEED ft./min. sq. in./min. CUTTING RATE
1211-1215
5040-5060
1110, 1117-1118
5115-5120
1137-1151
5130-5160
1005-1012
50100, 51100, 52100
Low Carbon Steels
Ductile 60-40-18, 150HB
MATERIAL WIDTH <1/2"
Titanium Alloys
Alpha, Alpha-Beta, Beta
Columbium
Prec. Hardening
Nickel Alloys
Monel 400, 401
A286, 309, 310, 314, 316, 317, 330
Martensitic Stainless Steels
Front
Inconel 625, 718, X-750 Waspaloy Inconel 600, 601
1015-1026
6118
1030-1055, A36
6150
MATERIAL WIDTH 2"-5"
5"-10"
250 8-10
250 6-7
4-6 3-4
3-4 2-3
>10"
Intenss™ PRO
PREFERRED 180 BAND TYPE 4-6 Intenss™ 1-2 3/4 - 1-1/4 PRO-VTH
TEETH PER INCH
Manganese Steels
8115, 8615-8622
1330-1345
8720, 8822
1513-1527
8145, 8625-8637
1536-1552
8640-8660, 8740
1561-1572
9310
4012-4024
9430-9445
4030-4042
9255-9262
4047-4068
A2-A6, A8-A10
or Advanz™
Molybdenum Steels Intenss™ PRO-VTH recommended for cutting these materials GENERAL INFORMATION Consult our technical dept. for appropriate Advanz™ carbide style 1) When cutting materials of various hardness other than normal listing on speed chart, multiply speed or cutting rate given on chart by these factors to arrive at speeds and cutting rates for hardened material. CUTTING RATE FACTOR Rockwell Brinell SPEED FACTOR 0 0 225Bhn Up to 20Rc .75 .75 225-275Bhn 20-28Rc HARDNESS .54 .60 275-325Bhn 28-35Rc .40 .50 325-375Bhn 35-40Rc 2) Cutting normal or annealed materials requires at least 3 teeth to be in contact with the work, with the optimum being 6-12 teeth, and 24 teeth being too many. 3) When using Duratec™ PH or Duratec™ FB, reduce speed by 50% and cutting rate by 85%. 4) When cutting dry, reduce band speed 40-50%, and cutting rate 40-50%. Blade life will also be shorter by approximately 40-50%. 5) To choose correct Versatix™ MP for cutting tubing, pipe and structurals, first find the total square inches and divide by the distance the saw blade must travel to finish cut. This figure can be used as material width to determine Teeth Per Inch (Pitch). 6) To find estimated cutting rate for pipe, tubing and structurals, multiply factor for minimum wall thickness of section to be cut by the cutting rate shown for the same size solid material. 7) For foundry applications (aluminum, non-ferrous) use Advanz™ FS carbide tipped at 1000-5000FPM 8) For case hardened & hardened steels, use Advanz™ CS. (+) Up to 3/16 .4
3/16 - 3/8 .5
3/8 - 5/8 .6
5/8 - 1 .7
1 and Over .8
1/2 3/4 1 1-1/4 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4
.20 .44 .79 1.22 1.76 2.40 3.14 3.97 4.90 5.93 7.06 8.25 9.62 11.04 12.56
4-1/4 4-1/2 4-3/4 5 5-1/4 5-1/2 5-3/4 6 6-1/2 7 7-1/2 8 8-1/2 9 9-1/2
14.18 15.90 17.72 19.63 21.64 23.75 25.96 28.27 33.18 38.48 44.17 50.26 56.74 63.61 71.00
10 10-1/2 11 11-1/2 12 12-1/2 13 13-1/2 14 14-1/2 15 15-1/2 16 16-1/2 17
78.53 86.60 95.00 104.00 113.00 122.75 132.00 143.06 153.86 165.04 176.62 188.59 200.96 213.71 226.86
17-1/2 18 18-1/2 19 19-1/2 20 20-1/2 21 21-1/2 22 22-1/2 23 23-1/2 24 24-1/2
240.40 254.36 268.66 283.43 298.49 314.00 330.09 346.18 362.86 379.94 397.40 415.26 433.51 452.16 471.19
4142-4161
L2, L6 S1-S7
4815-4820
1/2"-1"
1"-2"
Tool Steels (Air and Oil Hardening)
D2, D3, A7 W1-W5
4340
MATERIAL WIDTH <1/2"
Nickel Chrome Moly Steels
Silicone Steels
O1, O2, O6, O7, P20
4320
4615-4626
Intenss™ PRO-VTH recommended for cutting these materials
Carbon Tool Steel
Special Purpose Shock Resistant Hot Work Steel
H10-H19 H21-H42
SPEED
MATERIAL WIDTH 2"-5"
5"-10"
4-6 3-4
3-4 2-3
>10"
Intenss™ PRO
ft./min. sq. in./min. 10-14
WALL THICKNESS FACTOR
Diameter Area in Diameter Area in Diameter Area in Diameter Area in in inches Sq. Inches in inches Sq. Inches in inches Sq. Inches in inches Sq. Inches
4130-4140
Chrome Moly Steels
Nickel Chrome Moly Steels
Nickel Moly Steels
Chrome Steels
Chrome Vanadium Steels
1060-1095
8-12 6-10
TEETH PER INCH
5-8 4-6
CUTTING RATE
PREFERRED BAND TYPE Intenss™ 1-2 3/4 - 1-1/4 PRO-VTH
TEETH PER INCH
starrett.com
or Advanz™
SPECIFICATIONS SUBJECT TO CHANGE BULLETIN 110-25M/PG-04/09
No Varnish Area
BLADE BREAK-IN Using the right break-in procedures for a bimetal blade assures longer blade life, faster cuts for a longer period of time and consistent performance. Conversely, blade life can be significantly compromised if the proper break-in procedures are not followed.
LONGER BLADE LIFE
NEW BLADE WITH RAZOR SHARP TEETH
TOOTH CORRECTLY BROKEN IN
The teeth on a new band saw blade are razor sharp. To withstand the cutting pressures of band sawing, the tip of each tooth should be honed to create an extremely small radius on its tip. Easy-to-cut material such as carbon steel and aluminum: A. Run the normal surface feet per minute (SFPM). B. Adjust the feed pressure to about one-half the normal cutting rate for the first few cuts or for 50-100 square inches (323-645 sq.cm). C. Increase to the normal cutting rate. D. Avoid vibration. Hard-to-cut materials such as nickel-based alloys like inconel, hardened steels,tool steels and stainless steels: A. Run the normal surface feet per minute (SFPM). B. Adjust the feed pressure to about threequarters of the normal cutting rate for the first few cuts or for 25-75 square inches (161-484 sq.cm). C. Then increase the cutting rate part way to normal for the next few cuts. D. Then increase to the normal cutting rate. E. Avoid vibration.
BAND SAW SERVICE & SUPPORT Starrett service technicians are available to tune up and perform preventative maintenance on your production sawing machine using Starrett Band Saw Blades, at no additional cost. They fully review machine condition, blade mounting and operation in detail, making adjustments, as required, to help maintain good sawing and long life for both the machine and blades.
TRAINING
TOOTH INCORRECTLY BROKEN IN
START TO CUT MATERIAL AT REDUCED CUTTING RATE
Starrett service technicians can also instruct saw operators on achieving the best performance of blade and machine for your applications. Contact your Starrett Band Saw distributor about arranging a visit to your workplace by a Starrett service technician.
AFTER BREAK-IN WHEN THE BLADE HAS FULLY ENTERED THE WORKPIECE, INCREASE THE FEED RATE OVER A SERIES OF CUTS UNTIL THE RECOMMENDED CUTTING RATE IS ACHIEVED
BAND SAW BLADE INSTALLATION GUIDELINES Always follow the machine manufacturer’s instructions and recommendations for blade changes and the safe operation for the band saw machine. The guidelines are not intended to replace the machine manufacturer’s instructions or recommendations. The general information contained in the guidelines is intended to assist in the proper installation of band saw blades. Proper blade installation achieves more efficient blade performance. Please contact your machine manufacturer for appropriate procedures for blade changes for your specific machine and your saw blade manufacturer for appropriate cutting recommendations. The L. S. Starrett Co. nor its employees, shall not be held responsible for the accuracy or completeness of these guidelines. Wear gloves when handling band saw blades.
Wear eye protection, safety shoes, and hearing protection.
FOLLOW INSTRUCTIONS CAREFULLY Follow all the safety instructions shown in the band saw machine operator’s manual and on the machine labels. Recognize and read safety and warning signs such as Danger, Warning and Caution. Follow the saw blade installation instructions for the make and model of the band saw machine.
BASIC BLADE CHANGE GUIDELINES Position saw head to appropriate location to facilitate ease of blade change. Follow required lock out tag out procedures. Position chip brush away from saw blade. Relieve saw blade tension and remove blade. Remove any chips from saw guides and band wheels. Select appropriate blade for cutting application. (Refer to saw blade selection chart) Unfold blade properly. Do Not Throw. Throwing the blade will result in tooth damage that will reduce saw blade performance. (Refer to unfolding procedure) Install blade with saw teeth pointing in proper direction.
Apply appropriate tension to the blade. Be aware of pinch points and keep hands and clothing clear of rotating blade.
Adjust guide arms to appropriate positions to workpiece. Adjust blade guides for proper blade support. Adjust chip brush to fully engage saw blade teeth to ensure proper chip removal. Check hydraulic fluid levels if applicable. Ensure appropriate cutting fluid placement and mix ratios as applicable per machine, cutting fluid, and blade manufacturer’s recommendations. Break in blade properly before reaching desired cutting rates.
53
Steel Specification USA (AISI)
Feet per Minute
Meters per Minute
Sq Inch per Minute
Sq cm per Minute
1211-1215
230 - 310
69 - 93
12 - 18
78 - 117
1110, 1117-1118
220 - 300
66 - 90
9 - 15
58 - 97
1137-1151
165 - 245
50 - 74
5 - 11
32 - 71
1005-1012
220 - 300
66 - 90
9 - 14
58 - 97
1015-1026
210 - 290
63 - 87
8 - 13
52 - 91
1030-1055, A36
140 - 220
42 - 66
5-9
32 - 58
1060-1095
120 - 200
36 - 60
5-8
32 - 52
1330-1345
140 - 220
42 - 66
4-8
26 - 52
1513-1527
220 - 300
66 - 90
8 - 12
52 - 91
1536-1552
165 - 245
50 - 74
6 - 10
39 - 65
1561-1572
120 - 200
36 - 60
5-8
32 - 52
4012-4024
150 - 230
45 - 69
4-9
26 - 58
4030-4042
140 - 220
42 - 66
4-8
26 - 52
4047-4068
130 - 210
39 - 63
4-8
26 - 52
4130-4140
130 - 210
39 - 63
4-8
26 - 58
4142-4161
120 - 200
36 - 60
3-7
20 - 45
4320
130 - 210
39 - 63
4-8
26 - 52
4340
120 - 200
36 - 60
3-7
20 - 45
4615-4626
140 - 220
42 - 66
4-8
26 - 52
4815-4820
130 - 210
39 - 63
4-8
26 - 52
5040-5060
130 - 210
39 - 63
4-8
26 - 52
5115-5120
150 - 230
45 - 69
5-9
32 - 56
5130-5160
130 - 210
39 - 63
4-8
26 - 52
50100, 51100, 52100
90 - 160
27 - 48
3-5
20 - 32
6118
150 - 230
45 - 69
5-9
32 - 58
6150
130 - 210
39 - 63
4-8
26 - 52
8115, 8615-8622, 8720, 8820
130 - 210
39 - 63
5-9
32 - 58
8145, 8625-8637
130 - 210
39 - 63
5-9
32 - 58
8640-8660, 8740, 9430-9445
130 - 210
39 - 63
4-8
26 - 52
9310
110 - 190
33 - 57
2-4
13 - 26
Work Material Type
Free Machining Carbon Steels
Low Carbon Steels Medium Carbon Steels High Carbon Steels
Manganese Steels
Molybdenum Steels
Chrome Moly Steels
Nickel Chrome Moly Steels
Nickel Moly Steels
Chrome Steels
Chrome Vanadium Steels
Nickel Chrome Moly Steels
Steel Specification USA (AISI)
Feet per Minute
Meters per Minute
Sq Inch per Minute
Sq cm per Minute
130 - 210
39 - 63
4-8
26 - 52
140 - 220
42 - 66
3-6
20 - 39
A2-A6, A8-A10
130 - 210
39 - 63
2-4
13 - 26
01, 02, 06, 07
130 - 210
39 - 63
2-6
13 - 29
D2, D3, D7 (CUT DRY)
50 - 100
15 - 30
2-3
13 - 20
W1-W5
130 - 210
39 - 63
2-6
13 - 39
L2, L6
120 - 200
36 - 60
2-6
13 - 39
S1 - S7
90 - 160
27 - 48
2-4
13 - 26
H10 - H19
130 - 210
39 - 63
2-5
13 - 32
H21 - H42
90 - 160
27 - 48
2-4
13 - 26
M1, M2, M7, M10
75 - 130
22 - 39
2-4
13 - 26
M3, M4, M30 - M47
50 - 100
15 - 30
1-3
7 - 20
T1, T2, T6
75 - 130
22 - 39
2-4
13 - 26
T4, T5
60 - 120
18 - 36
1-3
7 - 20
T15
50 - 90
15 - 27
1-3
7 - 20
303
75 - 140
22 - 42
2-5
13 - 32
416, 420F, 430F
100 - 180
30 - 54
3-6
20 - 39
201, 202, 301-304, 305, 308
70 - 120
21 - 36
2-4
13 - 26
321, 347, 348
70 - 120
21 - 36
2-4
13 - 26
A286, 309, 310, 314
50 - 80
15 - 24
1-2
7 - 13
316, 317, 330
50 - 80
15 - 24
1-2
7 - 13
405, 409, 430, 434
60 - 100
18 - 30
1-3
7 - 20
436, 422, 446
60 - 100
18 - 30
1-3
7 - 20
403, 410, 420, 422, 501, 502
70 - 130
21 - 39
2-4
13 - 26
440A-C, 414, 431
60 - 100
18 - 30
1-3
7 - 20
15-5PH, 17-4PH, 17-7PH
50 - 90
15 - 27
1-3
7 - 20
CLASS 30
120 - 200
36 - 60
8 - 14
52 - 91
CLASS 40
80 - 160
24 - 48
5 - 11
32 - 71
DUCTILE 60-40-18 150HB
160 - 240
48 - 72
4 - 10
26 - 65
DUCTILE 80-55-06 225HB
80 - 160
24 - 48
2-7
13 - 45
Work Material Type Silicon Steels
9255-9262
Nitriding Steels
Tool Steels (Air & Oil Hardening)
Carbon Tool Steel
Special Purpose Shock Resistant Hot Work Steel
High Speed Steels
Free Machining Stainless Steels
Austenitic Stainless Steels
Ferritic Stainless Steels
Martensitic Stainless Steels Precision Hardening Stainless Steels
Cast Iron
Diameter
AREA CALCULATION
Area
Inches
Centimeters
Square Inches
Square Centimeters
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 24
2.5 3.8 5.1 6.4 7.6 8.9 10.2 11.4 12.7 14 15.2 16.5 17.8 19.1 20.3 21.6 22.9 24.1 25.4 26.7 27.9 29.2 30.5 31.8 33.0 34.3 35.6 36.8 38.1 39.4 40.6 41.9 43.2 44.5 45.7 47.0 48.3 49.5 50.8 52.1 53.3 54.6 55.9 57.2 58.4 61.0
0.8 1.8 3.1 4.9 7.1 9.6 12.6 15.9 19.6 23.8 28.3 33.2 38.5 44.2 50.3 56.7 63.6 70.9 78.5 86.6 95.0 104.0 113 123 133 143 154 165 177 189 201 214 227 241 254 269 284 299 314 330 346 363 380 398 415 452
4.9 11.3 20 32 45 62 82 102 127 154 186 214 249 287 324 366 412 456 507 560 611 670 731 794 855 924 995 1064 1140 1219 1295 1379 1466 1555 1640 1735 1832 1924 2029 2132 2231 2341 2454 2570 2679 2922
In order to calculate the best cutting progress, you can select an option from the charts below.
ATTENTION Make all the measurements in centimeters to get the area in cm2
SQUARE area = L2
ROUND area = D2 x 0,7854
ROUND TUBE area = (De2 - Di2) x 0,7854
SQUARE TUBE area = = Le2 - Li2
RECTANGULAR area = E x L
HEXAGONAL area = L2 x 2,598 E2 x 0,866
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Blade Effect
Blade Breakage
Straight break indicates fatigue.
Prematurely Dull Teeth
Inaccurate Cut
Band Leading in Cut
Chip Welding
Teeth Fracturing - Back
Probable Cause
Solution
Incorrect blade
Check tooth selection
Band tension too high
Reduce band tension, refer to operator’s manual
Excessive feed
Reduce feed pressure
Incorrect cutting fluid
Check coolant recommendations
Wheel diameter too small for blade width
Use narrower blade
Worn or chipped pressure block
Replace worn pressure blocks
Blade rubbing on wheel flange
Adjust wheel alignment
Teeth in contact with work before starting saw
Allow blade clearance above work
Side guides too tight
Refer to operator’s manual
Blade on machine backwards
Install blade correctly
Improper blade break-in procedure
Refer to recommended procedures
Hard material or heavy surface scale
Check material hardness and surface condition
Material is work-hardening
Increase feed pressure
Improper cutting fluid or mix ratio
Follow coolant mixing procedures
Speed or feed too high
Check cutting recommendations
Guide arms too far apart
Adjust guide arms closer to material
Blade worn out
Replace blade
Over or under feeding
Check cutting recommendations
Improper tooth pitch
Use proper tooth selection
Cutting fluid not applied properly
Adjust coolant nozzles
Too many teeth for material cross section
Use proper tooth selection
Guides worn or loose
Tighten or replace guides
Over feeding
Check cutting recommendations
Low band tension
Refer to operator’s manual
Tooth set damaged
Check material hardness
Guide arms loose or space too wide
Adjust guides and guide arms
Worn or missing chip brush
Replace or adjust chip brush
Improper or lack of cutting fluid
Check coolant flow and fluid type
Wrong coolant ratio
Check coolant type and ratio
Excessive feed or speed
Reduce feed or speed
Incorrect blade pitch
Use proper tooth selection
Saw guides not properly adjusted
Align or adjust saw guides
Incorrect feed or speed
Refer to cutting recommendations
Incorrect blade
Use proper blade type and pitch
Material moved in vise
Inspect and adjust vise
Indexing while blade in work
Adjust index sequence
Blade not high enough before index
Adjust height selector
Saw head drifts into work while neutral
Check hydraulic cylinder
Back of tooth indicates spinning in vise.
Irregular Break
Indicates material movement.
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starrett.com
Blade Effect
Teeth Stripping
Wear on Back of Blade
Rough Cut
Washboard surface, vibration and/or chatter
Wear Lines - Loss of Set
Twisted Blade
Contour sawing
Blade Wear
Teeth blued.
Teeth Fracturing - Front
Front of tooth indicates work spinning in vise.
Probable Cause
Solution
Improper blade break-in procedure
Follow proper break-in procedure
Speed too slow
Refer to cutting recommendations
Feed pressure too high
Reduce feed pressure
Tooth jammed in cut
Do not enter new blade in that cut
Poor cutting fluid application or ratio
Adjust coolant flow and ratio
Hard material or heavy scale
Check material or surface hardness
Wrong blade pitch
Use proper tooth selection
Work spinning or loose nested bundles
Tighten vises or use nesting clamps
Blade on backwards
Install blade correctly
Excessive back-up guide preload
Adjust pressure blocks
Low blade tension
Refer to operator’s manual
Incorrect blade (carbon steel type)
Switch to a bi-metal blade
Excessive feed rate or pressure
Reduce feed rate or pressure
Damaged or worn pressure block
Replace pressure block
Guide arms spaced too far apart
Adjust guide arms closer to work
Blade rubbing band wheel flanges
Adjust wheel alignment
Dull or damaged blade
Install new blade
Incorrect feed or speed
Refer to cutting recommendations
Blade not supported properly
Adjust or tighten guide arms
Low blade tension
Refer to operator’s manual
Incorrect tooth pitch
Use proper tooth selection
Guide arms too far apart
Adjust guide arms closer to material
Saw side guides too tight
Adjust guides properly
Blade riding too high in guide
Adjust rollers or pressure blocks
Blade teeth riding on band wheel surface
Adjust tracking or replace wheel
Wrong blade width for machine
Refer to operator’s manual
Chips being carried back into cut
Replace or adjust chip brush
Worn or damaged pressure block
Replace pressure block
Insufficient coolant flow
Adjust coolant flow
Blade binding in cut
Adjust feed or use heavy set blades
Side guides are too tight
Adjust guides
Work loose in vise
Adjust vise
Feed too heavy
Reduce feed pressure
Guide arms too far apart
Adjust guide arms closer to material
Incorrect blade
Use proper tooth selection
Heavy feed or too fast speed
Refer to cutting recommendations
Lack of cutting fluid
Adjust coolant flow or ratio
Blade installed backwards
Install blade correctly
Material loose in vise
Adjust vise
Incorrect tooth pitch
Use proper tooth selection
Feed too heavy
Reduce feed rate
Speed too fast
Refer to cutting recommendations
59
NOTAS:
NOTAS: