Achilli ABS 3500-CE Manual - Braxton-Bragg.com

.

ABS3500-CE

AUTOMATIC BRIDGE SAW

OWNER’S MANUAL ENGLISH

MANUFACTURER

For any assistance or request for spare parts, please contact your local dealer or the manufacturer directly by telephoning or writing to:

ACHILLI S.R.L. Via Montescudo 148 P.O. Box Ag.10 Gros 47900 RIMINI (Italy) Tel +39 0541 387066 r.a. Fax +39 0541 389058

INTRODUCTION

This instruction manual is addressed to the user of the machine and contains all the information regarding installation, use and maintenance and provides all the necessary information concerning safety. The instruction manual must be kept near the machine, away from dirt and humidity and always at hand for reference. This machine is intended exclusively for the specific use for which it is designed. Any other use is considered improper and therefore dangerous. The manufacturer cannot be held responsible for possible damage deriving from improper use due to non-compliance with the safety and operating regulations indicated in this instruction manual. Throughout this instruction manual an exclamation mark in an equilateral triangle is used to point out an important warning to which particular attention must be paid. This symbol, located on the blade guard, signals the obligation to use hearing and eye protection. This symbol, located on the electric box, signals dangerous voltage which may be of sufficient intensity to constitute a risk of electric shock. This symbol, located on the blade guard, signals the obligation to read the instruction manual before installation of the machine.

INDEX “CE” DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 CHAPTER 1.0 1.1 1.2 1.3 1.4 1.5 1.6

# 1 MACHINE INFORMATION AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 INTENDED USE OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 CONTRAINDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2 MAIN MACHINE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4 SAFETY HINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4 IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6 NOISE LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9

CHAPTER 2.0 2.1 2.2 2.3 2.3

# 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10 UNLOADING THE MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10 LOCATION AND LEVELLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11 INSTALLING THE SLIDING GUIDE EXTENSIONS. . . . . . . . . . . . . . . . . . . . . . . . Page 12 ELECTRICAL CONNECTION AND GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . Page 12 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14

CHAPTER 3.0 3.1 3.2 3.3 3.4

# 3 MACHINE FUNCTIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15 GENERAL CONCEPTS OF PROGRAM FUNCTIONING . . . . . . . . . . . . . . . . . . . Page 15 GENERAL CONCEPTS OF ELECTRICAL FUNCTIONING . . . . . . . . . . . . . . . . . Page 15 MACHINE SAFETY SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15 MOTOR PROTECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16 ROLLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17

CHAPTER 4.0 4.1 4.2

# 4 MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 18 BLADE MOUNTING AND REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 18 BLADE SELECTION AND USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 19 START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 20

CHAPTER # 5 MAINTENANCE AND CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 23 5.0 MAINTENANCE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 23 CHAPTER 6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7

# 6 ADJUSTMENT AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 25 ADJUSTMENT OF HEAD BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 25 TRAVERSE-GUIDE WHEEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26 ADJUSTING THE BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26 “W” AXIS REDUCTION UNIT CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . Page 27 SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 28 MAIN MOTOR ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 29 REPLACEMENT OF ROLLER TABLE ROLLER (OPTIONAL) . . . . . . . . . . . . . . . Page 29 DISMANTLING THE ROLLER TABLE HYDRAULIC JACK (OPTIONAL) . . . . . . . Page 30

CHAPTER 7.0 7.1 7.2 7.3 7.4

# 7 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 31 TROUBLE-SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 31 PROGRAM MESSAGE DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 35 “CNC” AXIS CONTROL MESSAGE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . Page 38 INVERTER DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 39 ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 43

CHAPTER # 8 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 45 8.0 ELECTRICAL PANEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 45

8.1 WIRING DIAGRAMS 400 Volt 50/60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 48 8.2 OPTIONAL ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 53 8.3 HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 54 LIMITED WARRANTY CERTIFICATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 73

Rev. 08.2005

1.6

“CE” DECLARATION OF CONFORMITY

The company: ACHILLI S.R.L. Via Montescudo 148 I 47900 RIMINI

in the person of its legal representative and as manufacturer of the: AUTOMATIC BRIDGE SAW FOR MARBLE AND GRANITE MODEL SERIAL NO. YEAR OF MANUFACTURE

declares on its sole responsibility that the machine is constructed in compliance with all the essential safety and health requirements provided for by the Directives:

89/392/CEE - 91/368/CEE - 93/44/CEE - 93/68/CEE 89/336/CEE- 92/31/CEE 73/23/CEE and in conformity with the following regulations and regulatory documents: EN 292/1 - EN 292/2 - EN 60204/1 - EN 349 DLG 04/12/92 N° 476 (for Italy) DPR 24/07/96 N° 459 (for Italy) ACHILLI S.R.L. Legal Representative

CHAPTER # 1

MACHINE INFORMATION AND SAFETY

1.0 INTENDED USE OF THE MACHINE The bridge saw ABS/CE is extremely robust, easy to use and with suitable cutting precision. The head “9” (Fig.2) of the machine is motor-driven on three axis (longitudinal “X”, transversal “Y”, vertical “Z”). The longitudinal and transversal movements occur at a speed adjustable between 0 and 7 m/min., while for the vertical axis from 0 to 0.3 m/min. The main motor “2” (Fig.2) can be turned manually and fixed in 4 right-angle positions (0° - 90° - 180° - 270°) to allow executing perpendicular cuts without moving the slab (see Fig.1/a). The disc position is indicated on the “W” axis; rotation occurs at a speed of about 6 rpm.

Fig.1a

Furthermore, inclined cuts from 90° to 45° may be executed, by manually inclining the head (see Fig.1/b). A 45°-cut can be made with the disc in 90°-position on the “W” axis. The bridge saw is designed for cutting marble, granite and natural stone slabs with a maximum thickness of 140 mm. Nevertheless, slabs with a thickness of greater than 20 mm. must be cut in stages. The cutting tool must be a diamond blade with an external diameter of 500 mm. and specifically for the material to be cut.

Fig.1b

This machine is constructed in conformity with the following regulations: EN 292/1 - EN 292/2 - EN 349 - EN 60204/1 and, therefore, meet the essential requirements for safety and health protection.

1.1 CONTROINDICATIONS – The Achilli bridge saw may not be used to cut wood, plastics, metals or similar materials. – The machine cannot be used in any other way than that for which it was designed. – Do not carry out machining of materials of which the weight and dimensions are not proportionate to the structure of the machine. – Any modification which alters the characteristics of the machine must be made by the manufacturer only, who will attest to the conformity. Therefore, any modification or maintenance operation not included in this manual is to be considered unauthorized.

2

OWNER'S MANUAL - BRIDGE SAW MOD. ABS/CE

Fig.2


3

1.2 MAIN MACHINE PARTS The machine consists of the following main parts (Fig.2): 1) Electric panel 2) Main motor 3) Longitudinal feed motor “X” 4) Cross feed motor “Y” 5) Lifting/lowering motor “Z” 6) Work table 7) Longitudinal head sliding beam “X” 8) Traverse head sliding guide “Y” 9) Head 10) Blade guard 11) Identification plate 12) Water collector tank (optional) 13) Solenoid valve for water 14) Water recycling pump (optional) 15) Roller table 16) Hydraulic control unit 17) Mobile control panel 18) Water flow sensor 19) “W” axis electric motor

1.3 SAFETY HINTS – Carefully read this manual before installation of the machine and keep it for future reference. – Clear the working area from any objects which could be a source of danger. – Ensure that the surface on which the machine will be installed is strong enough too carry the weight and that the necessary stability is guaranteed. – Keep the working area clean and ensure adequate lighting. – Wear suitable clothing: always wear earphones, glasses, protection gloves, robust shoes and hair cover. Remove rings, watches and any other jewelry; button cuffs tightly around the wrist. – Install the power supply cable in such a way that accidental contact with hot, cutting or corrosive objects, or persons is avoided; it is also recommended to unwind it completely. – Do not use the machine when the power supply cable is damaged or not in perfect condition. – Ensure that the grounding connected to the electric line is efficient.

4


– Ensure that the diamond blade used is perfectly balanced, centered, straight and well tightened. – Avoid cutting too big or too small pieces or pieces too difficult to position for cutting. – Keep hands absolutely clear of the tool cutting line. – Before carrying out any maintenance, repair or replacement work, switch off the machine by turning the switch “QS1” (Fig.8) to the position “0” and lock it by means of a padlock; furthermore, ensure that nobody is near the machine to prevent any possible accidents. – Check that no moving part of the machine is blocked or damaged. Check that all the parts are mounted correctly in order to guarantee proper functioning of the machine. – Before starting the machine, ensure that the blade guard is well tightened. – Do not leave the machine unattended and do not allow it to be used by unauthorized or untrained personnel. – During cutting operations, the machine may produce a high level of noise; therefore, the use of earphones is obligatory to protect hearing. – In case of machine breakdowns or bad functioning, switch off the machine and call in assistance from the dealer or the manufacturer. – Do not expose the machine to atmospheric agents (rain, sun, humidity, etc.). – When it is decided to no longer use the machine because it is obsolete or irreparably damaged, shut it down completely to prevent accidents. Disconnect the machine from the mains and dismantle the tool. Proceed with disposal in conformity with the regulations in force, consulting local organizations set up for such operations. The machine is constructed with the following materials: Steel

Ac

Aluminium

Al

Polyamide

Pa

Copper

Cu

Wood Hydraulic oil (optional)


5

1.4 IDENTIFICATION PLATE The identification plate of the machine is located on the right shoulder “11” (Fig.2) and carries the following information (Fig.3): A) Machine model B) Serial number C) Power D) Voltage and frequency E) Current absorption F) Degree of IP protection G) Max. diameter of tool H) Weight I) Year of manufacture

Fig.3

L) CE marking NOTE: Each time the manufacturer is consulted, the serial number and machine model specified on the identification plate must be indicated.

1.5 TECHNICAL DATA AUTOMATIC BRIDGE SAW modelABS3500CE ELECTRICAL DATA Main motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-phase Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 KW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 V~ Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz Rotation speed adjustable by means of inverter . . . . . . . . . . . . . . . . . . . . 800-3000 rpm Longitudinal or cross head feed motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-phase Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 KW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 V~ Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz Adjustable speed by means of inverter in both running directions . . . from 0 to 7 m/min. Lifting/lowering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-phase Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.37 KW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 V~ Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz Adjustable speed by means of inverter in both running directions . . from 0 to 0.3 m/min. W-axis rotation motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-phase Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 KW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 V~

6


Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 RPM

Water recycling pump (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single-phase Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 KW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 V~ Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz Max. head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/10 m Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160/30 l/min. Hydraulic control unit motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-phase Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 KW Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 V~ Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 RPM MECHANICAL DATA

– – – – – – – – – – – – – – –

Diamond blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E500 mm. Blade peripheral speed (min./max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.9/ 78.5 m./sec. Max. longitudinal motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3700 mm. Max. cross motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2080 mm. Max. vertical motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 mm. Cutting height with E500 mm blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm. Hydraulic pump oil type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ISO 15 Oil lubricating for W-axis rotation system . . . . . . . . . . . . . . . . “ROLOIL” ARM100PE type Head inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from 90° to 45° Main motor rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from 0° to 270° Net weight machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2730 kg Water collector tank capacity (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 470 l Shipping dimensions with packaging (WxLxH) . . . . . . . . . . . . . . . 2250x5380x2340 mm. Shipping dimension with packaging and transport wheel . . . . . . . 2250x5380x2540 mm. Machine frame galvanized and some parts with epoxy powder finish.


7

OVERALL DIMENSIONS AND ADJUSTMENT

NOTE: Measurements taken in mm.

8


1.6 NOISE LEVEL Noise level measurement in conformity with EN 24871 (CEN 23744) regulations: Acoustic pressure level at operator position empty 75.3 dB (A) Acoustic pressure level at operator position loaded 83.4 dB (A) The values indicated above were measured using a diamond blade of 500 mm. on a slab of marble 20 mm. thick. Factors which affect the noise level are:

– Time of exposure. – Characteristics of factory. – Adjacent machines, etc. The noise level may be contained by:

– Correct choice of tool. – Efficient cutting capacity of the tool. – Low-speed cutting.

It is recommended to use silenced diamond blades, in order to considerably limit the acoustic pressure level emitted by the machine during operation.

The employer is obliged to make the following provisions:

– Limit the exposure time by introducing shift work. – Supply individual means of protection and instruct the operator on its use. – Submit the machine operator to periodic health checkups.


9

CHAPTER # 2

INSTALLATION

2.0 UNLOADING THE MACHINE A forklift truck must be used for unloading of the machine (Fig.4).

WARNING: Take the following precautions for lifting the machine:

– Use a lift truck of adequate capacity for the weight and dimensions of the machine. – The forks “A” (Fig.4) of the lift truck must be at least as long as the width of the machine. – The gripping points for lifting are marked with two wooden panels positioned under the machine frame. – Take all the necessary steps to ensure maximum stability of unloading equipment and loads. – Announce and signal the manoeuvre in advance. – Avoid passing the suspended load over persons or places where dropping of the load could be dangerous. Take extreme care to safeguard the integrity of all the machine parts, particularly the longitudinal head sliding beam “7” (Fig.2) and the raceway for the cableholder chain located at the top of the machine. The machine is assembled and carefully tested at our factory in order to guarantee efficient operation and is packed in such a way as to ensure protection during freight. The condition of the packing must be checked before opening to be sure that the machine has not been damaged or tampered with during transport. If any signs of this are found, a complaint must be filled with the freight company, if possible accompanied by photographs.

Fig.4

10


2.1 LOCATION AND LEVELLING Place the machine in an area with a well-levelled floor in non-deformable material and far away from walls and pillars. Check that there is sufficient space around the machine to allow free movement of the piece to be machined. It is very important that the machine be placed level using a very long and accurate spirit level, placing the latter along the traverse slide guides “8” (Fig.2) of the machine (see Fig.6). Or use a short precision level positioning it in the zone indicated by an arrow engraved in the traverse sliding guide.

Fig.5

If necessary, act on the special adjusting screws located on the machine leg.

Fig.6

– Fix the machine to the floor with four threaded bars or four expansion plugs of adequate dimensions. For drilling refer to Fig.5. – Install the sliding guide extensions following the instructions in Chapter 2.2. – Properly position the mechanical stop of the mobile panel arm: • Remove the mechanical stop. • Turn the stop upside down and lock it with the special screw “B” Fig.6/a. Fig.6a


11

2.2 INSTALLING THE SLIDING GUIDE EXTENSIONS Re move the lock ing brack ets “T” (Fig.6/b), one for each shoulder. Fix the two extension guards “R” to the two shoulders with the three special screws. Install the extension “Q”, one for each shoulder. Join the extension to the fixing plate by means of the 4 screws “P”. The fixing plate “S” must be positioned behind the sliding guide. The top end of the guide must be perfectly aligned with the top end of the extension. Insert the two elastic pins “U”, tighten the 4 screws “P”.

Fig.6b

Move the limit switch “SQ3” (“Y-” axis) on the shoulder “DX” and fix it in the outermost position of the extension guard. Install the locking brackets “T” on the extension guards behind the sliding guides using the fixing nuts.

2.3 ELECTRICAL CONNECTION AND GROUNDING WARNING: Any intervention on the electrical system of the machine must be carried out by a qualified technician in conformity with EN 60204 regulations.

Check that the characteristics of the mains to which the machine will be connected are in conformity with current regulations for electrical installations and meet the technical specifications indicated on the identification plate of the machine (see Par.1.4 and 1.5). The power supply line must be preceded by the following protection devices: • Differential switch which trips in case of leakage to earth. The electric motors are driven by a frequency inverter, therefore use a delayed differential switch of 300 mA with “S” response curve.

Fig.7

• Magnetothermal switch or fuses which blow in case of short-circuit.

– The power supply line must be earthed. Have the efficiency checked by a qualified technician. A bad earthing connection may cause malfunctioning of the electronic equipment. – For the 400V three-phase version, the power cable of the machine must not be less than 6 mm² cross-section. – For the 230V three-phase version, the machine uses an external autotransformer. The power cable must not be less than 10 mm².

12


WARNING: The machine’s power supply cable must always be completely extended. Never leave it rolled. It must be protected by a metallic panel over its entire length.

Electrical connection for 400V three-phase version:

– Make sure that the main switch “QS1” (Fig.8) is at zero. – Open the electric panel “1” (Fig.2) with the special key provided with this manual and connect the power cables to the main switch “QS1” as follows: • Connect the three phase wires to terminals L1, L2, L3 of the terminal board as illustrated in Fig.7. • Connect the yellow-green ground wire to the yellow-green terminal (PE).

WARNING: The power supply cable input at the bottom of the electrical panel “1” (Fig.2) is made for a cable with protective sheath.

– Check that there is 400V three-phase voltage between the phases L1 L2 L3. Position the switch “QS1” on “1” and press the button “SB2”. If the LED of the “SSC” device is off, the three phases of the line are incorrectly connected. – Turn the main switch “QS1” to position “0”, reopen the electric panel and invert two of the three phase wires of the power cable on the main switch “QS1”. Warning! Voltage in the electrical connection between the switch and the mains. – Close the electric panel and repeat the power-on procedure of the machine described previously. Electrical connection for 230V three-phase version:

– Make sure that the main switch “QS1” (Fig.8) is at zero. The machine requires a voltage of 400V three-phase; if the power supply line has a different voltage use a power supply. – The power supply (Fig.7b) has the task of coupling the voltage of the power supply line with the voltage of the machine. Measure the voltage between the three phases of the power supply line, use the input of the autotransformer closest to the value measured in such a way as to obtain an output voltage of 400 V +-5%.

Fig.7a

– Insert the plug “A” (Fig.7a) of the electric panel power cable in the socket “D” of the autotransformer. – Connect the autotransformer power cable “C” to the power supply line.

Fig.7b

– Lift the levers “B” of the magnetothermal switch. Check that there is a voltage of 400 V three-phase between the phases “L1 L2 L3” of the switch “QS1". Turn the switch ”QS1" (Fig.8) to “1” and press the button “SB2”. If the LED of the “SSC” device is off, the three phases of the line are incorrectly connected.


13

– Lower the levers “B” (Fig.7a) of the magnetothermal switch and turn the switch “QS1” (Fig.8) to “0”. Open the electric panel and invert two of the 3 phase wires of the power cable on the switch “QS1”. – Close the electric panel and repeat the power-on procedure of the machine described previously.

2.3 ACCESSORIES Check that all the accessories are included with the machine: A) Instruction manual. B) Set of wrenches: • No. 24 single open-ended wrench • No. 46 single open-ended wrench • No. 19 combination wrench • No. 10-13 double open-ended wrench • No. 17-19 double open-ended wrench • No. 19 T-handle swivel-joint box wrench • No. 5 Allen wrench • No. 6 Allen key • No. 10 Allen key C) “Y” axis sliding guide extensions with the shoulder extension guards and fixing brackets.

14


CHAPTER # 3

MACHINE FUNCTIONING

3.0 GENERAL CONCEPTS OF PROGRAM FUNCTIONING. SEE THE ATTACHED "VISION PLUS SOFTWARE" MANUAL

3.1 GENERAL CONCEPTS OF ELECTRICAL FUNCTIONING The mushroom-head buttons “SB1” and “SB5” (Fig.8) “SB12” (Fig.19) stop all electrical functions of the machine. To reset these functions, proceed as follows:

– Pull out the buttons “SB1” and “SB5” (Fig.8) and “SB12” (Fig.19) until they return to the original position. – Press the button “SB2” (Fig.8) to restore power to the power circuit of the machine. The main motor “3” (Fig.1), the solenoid valve “13” for the water and the recycling pump (optional) operate together. The switch “QS2” (Fig.8) positioned on “1” powers the laser diode. It is recommended to switch off the laser diode when it is not used, positioning “QS2” on “0”. This ensures longer life of the laser.

Fig.19

WARNING: Never direct the laser beam directly into the eyes.

The buttons “SB3” and “SB4” (Fig.8) activate the ascent/descent movement of the roller table. N.B. When power is restored after a power failure, the machine remains off.

3.2 MACHINE SAFETY SYSTEMS The machine is fitted with the following electrical and mechanical protection devices: MECHANICAL PROTECTION For correct use of the machine, the blade guard “10” (Fig.2) must be installed. This protection prevents any accidental contact between the operator and the moving tool; it allows executing all the machining operations without compromising good functioning of the machine. The machine also has protections for the pinions (Chap 8 Tab.5 Pos.2-20, Tab.2 Pos.4) and for all the rotating parts.


15

WARNING: Before any machining, these guards must be correctly installed to guarantee their perfect functioning.

ELECTRICAL PROTECTION The electrical equipment of the machine is in conformity with EN 60204. Thus, the operator is protected against possible electric shock caused by direct or indirect contact. Furthermore, the control circuit is supplied with 24 V low-voltage. PROTECTION AGAINST DIRECT CONTACT The electric wires are insulated. The motors and the electric panel have an IP55 degree of protection. Each electric component on the electric panel has at least an IP20 degree of protection. PROTECTION AGAINST INDIRECT CONTACT All the metallic parts which contain electric wires are connected to the unipotential protection circuit in order to prevent possible isolation faults. The electrical equipment is fitted with protection devices against possible overcurrents or overloads. In case of voltage drop or power failure during machine operation, automatic restarting is prevented by the intervention of a minimum-voltage device.

3.3 MOTOR PROTECTIONS WARNING: Any intervention on the electrical system of the machine must be carried out by a qualified technician.

During machine operation it may happen that more power than the motor can supply is requested and it will tend to stop. Each motor has a protection against possible overloads and overcurrents. On the electric panel the following protections have been installed, connected to each motor (see Par.8.0): “QF1”.....Water pump protection (optional). “QF2”...... Hydraulic control unit protection “16” (Fig.2). “QF3”..... “W” axis electric motor protection. “QF4”......Main motor inverter protection (“2” Fig.2) “QF5”.....“CNC” axis control power supply protection (Fig.8). “QF6”..... “X-Y-Z” axis inverter protection. “QF7”.....Autotransformer protection (optional). In case the protections trip, switch off the machine by setting the switch “QS1” (Fig.8) to “0” and request assistance from a qualified technician. To reset the protections, first remove the cause of the fault, then open the door of the electric panel, re-enable them and finally close the door (See Par.8.0).

16


The motors for longitudinal feed “3” (Fig.2), cross feed “4”, ascent/descent of the head “5”, and the main motor “2” are powered by a variable frequency inverter (“INV” - “INVX” - “INVY” - “INVZ”). In the event of overcurrent, overvoltage or undervoltage of the power line, the inverter “locks”. This condition is a protection of its internal circuits. To exit from the lock condition, position the main switch “QS1” (Fig.8) of the machine on “0”, wait about 60 seconds, then reposition it on “1”. Press the button “SB2” (Fig.8) and check if the inverter functions properly. If the locked condition persists, avoid successive starting attempts as the inverter might get damaged. The electric panel can only be accessed when the main switch “QS1” (Fig.8) is set to “0”. In this position the power supply is interrupted and there is no voltage in the electric panel, except for the electrical connection between the switch “QS1” and the power supply line.

3.4 ROLLER TABLE To facilitate movement and positioning of the slabs to be machined, the machine is equipped with a hydraulically liftable roller table “15” (Fig.2) composed of 108 omnidirectional rollers which ascend through as many slots cut in the wooden tables making up the work bench “6” (Fig.2). The hydraulic control unit “16” (Fig.2) is housed in a container on the right-hand shoulder of the machine. To lift the roller table:

– Press the button “SB3” (Fig.8) until lifting the slab by a few millimetres. To lower the roller table:

– Press the button “SB4” (Fig.8).

WARNING: When the roller table is lifted, a sensor prevents cutting the slab in semiautomatic mode. The position of the raised roller table is shown by a flashing message.

The roller table cannot be moved during “W” axis rotation.


17

CHAPTER # 4

MACHINING

4.0 BLADE MOUNTING AND REPLACEMENT WARNING: Before mounting the blade, switch off the machine with the switch “QS1” (Fig.8) and lock it with a padlock.

– With the No. 13 wrench supplied, unscrew the 3 screws “A” (Fig.20) which fasten the blade guard “10” (Fig.2). – Remove the front part from the back section of the guard as illustrated in Fig.20. – Lock the motor shaft “B” (Fig.20) using the No.24 wrench and unscrew the tightening nut “C” turning it clockwise with the No. 46 wrench supplied. – Ex tract the ex ter nal flange “D” (Fig.20), clean the surfaces in contact with the blade and, in case of replacement, remove the old blade from the internal flange of the motor “E”. – Mount the new blade respecting the direction of rotation; in particular, the arrow engraved in the tool must be in the same direction as the adhesive arrow on the blade guard.

Fig.20

– Mount the external flange “D” and the tightening nut “C”. – Fasten the blade by turning the tightening nut “C” anti-clockwise, maintaining the motor shaft “B” locked with the No. 24 wrench supplied. – Remount the front part of the guard fastening it with the 3 screws “A” (Fig.20). – Check the proper functioning of the guard protection mechanism.

18


4.1 BLADE SELECTION AND USE The use of diamond blades is indispensable to obtain maximum performance and the optimal efficiency. Replace the blade as soon as necessary. A deformed blade is a source of danger. The blade is cooled by means of a continuous jet of water which can be obtained in two ways:

– connecting directly to the main water supply; – using the water recycling pump (optional). DIRECT CONNECTION TO THE MAIN WATER SUPPLY:

– Using the special fittings, connect the machine’s water tube to the water supply. – The machine has a solenoid valve for the water “L” (Fig.21) which connected to the water supply interrupts the water flow by stopping the main motor “2” (Fig.2).

Fig.21

– Make certain that the water supply is able to give water in sufficient quantity. The jet of water can be adjusted using the tap on the head. USING THE WATER RECYCLING PUMP (OPTIONAL)(see Fig.22):

– The pump is driven simultaneously with the main motor. – The pump must operate completely immersed in the water. – Daily drain the dirty water and clean the pump and the tank. USE OF THE WATER FLOW SENSOR (see Fig.23): The machine has a sensor that detects the flow of water used to cool the disc during cutting.

Fig.22

The sensor is adjusted to 10 litres/minute; lower values are considered dangerous for cutting because the disc is not properly cooled. If the water flow is insufficient, the program interrupts the cutting operation signalling an error message. As long as the water flow is below the safety threshold, it is not possible to execute cuts.

Fig.23


19

4.2 START-UP WARNING: Before starting the machine, ensure that the blade guard is well fastened.

To execute lengthwise or crosswise cuts, the main motor “2” (Fig.2) can be turned to the four orthogonal positions 0° - 90° - 180° - 270°. Press the keys “A, C, E, F” of the axis control keyboard to select the desired position. A mechanical coupling for each of the four positions guarantees exact perpendicularity.

WARNING: It is not possible to fix the main motor on intermediate positions to the right-angle positions given on the machine.

N.B. Always ensure, before carrying out any turning operation of the main motor, that it is free to move and that there are no sheaths or tubes obstructing movement. On the work table “6” (Fig.2) or in the area around it there must not be any objects which could be a source of danger or could in some way obstruct operation. 90° CUT

WARNING: For cutting operations, exclusively use 500 mm. diameter diamond blades for marble or granite.

Select the disc rotation speed according to the material to be cut. To modify the value, access the “OPERATING PARAMETER” window. Before carrying out any movement, remember that the head is fixed with 4 screws which lock the head tilting movement (“A” Fig.24).

– Before carrying out any head rotation operation, always ensure that it can move freely and that no sheaths obstruct movement. – To place the main motor in the horizontal position, loosen and/or remove the 4 screws “A” (Fig.24) and move the head by hand to the 90° position on the goniometer “C”. – Retighten the 4 screws “A” (Fig.24) in the far ends of the slots.

Fig.24

– For mounting of the blade, refer to Par.4.0. – Check that the blade is well tightened and that the blade guard is mounted correctly.

20


– Open the tap located on the water tube immediately before the disc guard. – Before starting the main motor, set the switch “QS1” (Fig.8) to “1” and turn the mushroom-head buttons “SB1”, “SB5” (Fig.8) and “SB12” (Fig.19) clockwise to check that a prior emergency lock condition is not still on. – Press the button “SB2” (Fig.8) and open the menu for cutting in manual mode following the instructions in Par.3.0. – Start the main motor by pressing the “F4” key (Fig.12) and lower the blade to 2-3 mm. below the work table (this is the optimal position for cutting). – Move the blade towards the piece to be cut with the “JOG” keys (Fig.14). – For the lengthwise cut in manual mode, set the cutting speed to minimum and then move the blade with the “TAB” keys of “JOG” (Fig.14). Adjust the cutting speed with the “F1” and “F2” keys (Fig.13) of the “OVERFEED”, so that the blade gently enters the material to be cut. Respect the same sequence for the crosswise cut, this time using the “PG UP” and “PG DW” keys of “JOG”. – Adjust the cutting speed, always bearing in mind that the absorbed current of the main motor, readable on the ammeter “A= ” (Fig.8), must never exceed the maximum value of 23 ampere. – When cutting has been completed, in the case of a lengthwise cut, adjust the return speed with the “F1” and “F2” keys (Fig.13) of the “OVERFEED” and then move the blade with the “TAB” keys of “JOG” (Fig.14), while for the crosswise cut, carry out the same procedure this time using the “PG UP” and “PG DW” keys of “JOG”. Press the “L” key to temporarily modify the “OVERFEED” speed with a set value. N.B. It is advisable not to switch of the main motor for the return.

– To turn off the main motor, press the “F5” key (Fig.12).

WARNING: Before cutting, it is important to check that the 3 screws “A” (Fig.24) which fix the head rotation are well tightened, otherwise not perfectly straight cuts might be obtained.

45° CUT To make out a 45 cut, proceed as follows:

– Turn the disc to the 90° position: press “F4” to access the manual menu and then press the “C” key. – Lift the main motor by means of the “HOME” key (Fig.14) so that the blade does not knock the table during head rotation. – Loosen or remove the 3 screws “A” (Fig.24) and turn the head until the arrow of the goniometer “C” (Fig.24) indicates 45°. – Relock the head by tightening the screws previously loosened in the far ends of the slot. – Enter the new “Z” axis origin value following the instructions in Par.3.0. This parameter must always be updated each time the head inclination is changed.


21

– Proceed as for the 90° cut.

WARNING: The 45° cut can only be executed lengthwise (“X”-axis), thus with the blade positioned in the front part of the machine.

WARNING: During blade positioning for the 45° cut, it is very important to hand-guide the movement of the 2 guard protections with the knob “A” (Fig.25).

Fig.25

22


CHAPTER # 5

MAINTENANCE AND CLEANING

5.0 MAINTENANCE AND CLEANING WARNING: Before beginning any machine maintenance or cleaning operation, set the main switch “QS1” (Fig.8) to zero locking it with a padlock.

The machine is designed and constructed in such a way as to reduce any type of maintenance to a minimum. However, it is very important to clean the machine after each working day, thus obtaining better performance and a longer life of the machine. Always remember that general cleaning of the machine (especially the work surface) and the surrounding floor area are important safety factors.

– Do not use toxic or inflammable substances for cleaning the machine. – Daily clean the surfaces of the longitudinal sliding beam “7” (Fig.2) and the traverse sliding guide “8” with a wet cloth to remove slurry marks. Clean the two magnetic strips (X and Y axis), remove any slurry deposits taking care not to damage them. These sensors have a steel film which protects them from any knocks or abrasions. Avoid exposing these sensors to external magnetic fields: altering the magnetic properties of the sensors results in axis movement detection errors.

Never grease the longitudinal sliding beam “7” (Fig.2) and the traverse head sliding guides “8” with oils or grease, since these products retain the impurities which are then compacted by the passage of the head bearings creating sliding problems.

– Weekly clean and lubricate the racks with a film of oil or very fluid grease. – Always keep the slideways and the threaded bar for lifting/lowering of the main motor lubricated with a film of oil. – Periodically you lift the lever of the oil tank (you see Fig.26). If the tank exhausts the oil lubricant, you insert new oil “ROLOIL” “ARM100PE” type, or to use oil with equivalent characteristics. – Periodically dismantle the blade guard “10” (Fig.2), clean all its internal parts and check the proper functioning of its protection mechanism. – It is very important to daily clean the roller table “15” (Fig.2) (optional) with a jet of water to remove any mortar deposits or fragments of material which, if trapped be tween the rollers (Chap.8 Ta ble 4 Pos.12), could lock them.

Fig.26

WARNING: Do not spray jets of water on the motors or electric panels.


23

– Empty daily the water tank, if installed. Eliminate any slurry which has formed on the bottom of the tank and on the pump filter using a powerful jet of water. – Dry the machine. – Periodically have the electrical system of the machine checked by a qualified technician.

24


CHAPTER # 6

ADJUSTMENT AND REPLACEMENT

6.0 ADJUSTMENT OF HEAD BEARINGS WARNING: operation to be carried out after authorization from manufacturer or dealer.

The adjustment of head bearings has to be carried out by qualified technicians only. After many hours of machining, the machine head “9” (Fig.2) could have a certain amount of play, as the bearings form their own paths on the longitudinal head sliding beam. This play could cause problems during machining. To avoid this, it is necessary to reset the pressure of the bearings on the beam in the following manner:

– Turn the switch “QS1” (Fig.8) to “0” and lock it with a padlock. – Clean the beam with a damp cloth of detergent.

Fig.27

– To spread the weight of the head equally over all the bearings, remove the 3 “A” screws (Fig.24) which lock head rotation until the head tends to remain in a balanced position. – Open the head taking off the two casings “P” (Fig.27) after having unscrewed the 4 “V” screws on each of them. The head runs on 8 double roller bearings, of which the upper 4 are concentric and lower 4 eccentric. Adjustment is carried out by trial and error on each of the 4 pairs of lower eccentric bearings in the following manner:

Fig.28

– Using a No. 22 wrench, loosen the bolt which locks a pair of lower bearings in its housing until it can be rotated on its axis, levering with a pin in the hole the centre of the bearings (see Fig.28). – Find the correct pressure of the bearing on the head beam by holding the bearing between the index finger and the thumb and moving the head back and forth by hand. – If by doing this, the bearing can be almost stopped, this means that it has been well adjusted, since it has the correct amount of pressure on the beam. – Fully tighten the bolt which blocks the pair of bearings after this adjustment. – Do the same with all the other bearings until all four lower pairs of eccentric bearings press equally on the head travel beam.


25

6.1 TRAVERSE-GUIDE WHEEL ADJUSTMENT The longitudinal head sliding beam “7” (Fig.2) runs on two traverse head sliding guides “8” on 8 wheels of which the upper 4 have concentric axis and the lower 4 eccentric axis. The adjustment is made by trial and error on the lower wheels of each traverse head sliding guide in the following way (see Fig.29):

– With the No. 27 wrench loosen the bolt which locks the lower wheel, so that it is possible to rotate it on its own axis, levering with a pin on the hole located at the centre. – Find the correct pressure of the wheel on the traverse head sliding guide, holding it between the thumb and index finger and moving the head forward and backward along the “Y” axis. – If by doing this the wheel can be held firm, it means that it is prop erly adjusted since it presses on the guide in the right measure. – Once the adjustment has been completed, securely tighten the bolt which locks the wheel.

Fig.29

– Carry out the same operation on the other wheels until both the lower pairs press on the traverse head sliding guide in the same measure.

6.2 ADJUSTING THE BRAKING SYSTEM The “X” and “Y” axis have a braking system which stabilizes movement. After many hours of machining, the braking system may need to be adjusted.

WARNING: operation to be carried out after authorization from manufacturer or dealer.

The “X” axis braking system is positioned inside the right casing.

– Remove the right casing by undoing the 4 fixing screws; the two blocks holding the braking system are positioned to the sides of the beam “F” (Fig.30). – Turn the Allen screw to adjust the pressure exercised by the brake on the beam. Increasing the braking system pressure results in a movement without mechanical play, but the electric motor might be forced due to the increased friction. – Adjust the pressure of the braking system in such a way as to find the right compromise. Perform a few movements of the “X” axis to check the adjustment made. – Remount the right casing and lock it with the 4 fixing screws.

26


The braking system of the “Y” axis is positioned under the left plate. Remove the bottom panel guard by unscrewing the 4 fixing screws. The braking system is fixed on two eccentric pins “G” (Fig.30), therefore make the same adjustment on both of them.

– Loosen the two fixing bolts with a No.27 wrench. Turn the eccentric pin, prising with a pin inserted in the hole. Identify the right pressure for the braking system, hold the pin firm and tighten the bolt with the No.27 wrench. – Fit the bottom panel guard and lock it with the 3 fixing screws. N.B: Optimal adjustment is obtained when the movement is smooth without recoil when starting and stopping. The electric motor must not be forced, i.e. it must not exceed the rated current value indicated on the plate.

Fig.30

WARNING: Any intervention on the electrical system of the machine must be carried out by a qualified technician in conformity with EN 60204 regulations.

Consult the “D02” inverter parameter for examine the electrical current absorbed by the motor. Switch off the machine, open the electric panel and detect the inverter display. Switch on the machine, through the “up arrow” key select code “D02”. The “D02” parameter indicating the electrical current value.

6.3 “W” AXIS REDUCTION UNIT CLUTCH ADJUSTMENT The “W” axis reduction unit used to turn the disk to the four orthogonal positions (0° - 90° - 180° 270°) is fitted with a clutch (torque limiter) whose function is to slip if a fault prevents the gearmotor from stopping. It may occur that after a certain number of engagements, the clutch loosens compromising good functioning. In these cases, recalibrate the clutch us ing a spe cial wrench.

– Tu r n t h e w r e n c h c l o c k w i s e o r anticlockwise depending on whether you want to tighten or loosen the adjustment. During “W” axis rotation, the torque limiter must intervene when a stall torque of about 1 kg/metre is exceeded (you see Fig.31).

Fig.31

– Run a few tests and check that the adjustment is correct.


27

6.4 SENSOR ADJUSTMENT The “CNC” axis control uses different types of sensors to display the movements of the “X - Y - Z W” axis. MAGNETIC STRIP + MAGNETIC HEAD The “X - Y - W” axis movement is controlled by means of a magnetic sensor. The sensor is composed of a magnetic strip with relevant magnetic reading head. It is important to keep the head alignment in tolerance with the magnetic strip. If not, the “CNC” axis control could display the movement incorrectly. This type of problem is detectable when the read error is not proportional to the distance covered by the sensor.

If there are any problems, check all the electrical connections between the magnetic head and the “CNC” axis control. The sensor has 6 wires; if one of them is broken or has an unstable electrical connection, it may result in incorrect reading. The magnetic head might not be aligned or too far away from the magnetic strip. Adjust the magnetic head respecting the tolerances indicated in Figure 32. ENCODER The “Z” axis movement is controlled by a sensor called encoder (see Fig.33). It is important that the encoder is well fixed with the threaded bar for the “Z” axis movement, otherwise in the event of slippage the “CNC” axis control might display incorrect movement.

Fig.32

28

Fig.33


6.5 MAIN MOTOR ALIGNMENT WARNING: operation to be carried out after authorization from manufacturer or dealer.

To align the main motor, a dial indicator is required. The four screws which fix the main motor must be only partially tightened.

– Mount a blade with a core which is in good condition. Check lengthwise alignment of the main motor “2” (Fig.2) following the instructions below:

– Securely fix a metallic plate on the work bench “6” (Fig.2) of the machine. – Position the magnetic base of the comparator “A” on the metallic plate in such a way that the instrument tester operates in contact with the core of the blade (see Fig.34).

Fig.34

– Rotate the blade manually and check that the needle of the instrument does not move any more than a few hundredths of a millimetre. – Following the instructions in Par.3.0, access the menu for manual cutting mode. With the “TAB” keys of “JOG” (Fig.14) for disc forward and backward movement, move the position of the main motor at very low speed so that the instrument needle does not move beyond a few hundredths of a millimetre, then tighten the four screws which fix the motor. NOTE: When positioning the dial indicator, it is advisable to make the probe operate as close as possible to the flange of the blade in order to have a longer test run.

6.6 REPLACEMENT OF ROLLER TABLE ROLLER (OPTIONAL) In case of breakage or jamming of a roller proceed as follows to replace it:

– Remove the slotted table of the bench corresponding to the roller to be changed, unscrewing the special screw underneath it. – Remove the elastic ring which locks the movement of the roller holding pin. Remove the central roller pin, replace the roller and remount the assembly.


29

6.7 DISMANTLING THE ROLLER TABLE HYDRAULIC JACK (OPTIONAL) In case of replacement of one or more hydraulic jacks (Chap.8 Table 4 Pos.7) proceed as follows:

Ensure that the roller table is completely lowered so that the hydraulic circuit is not under pressure.

WARNING: Before carrying out the instructions below, be extremely careful with the proximity sensor positioned on the roller table.

– Unscrew the screws “V” (Fig.35) which fasten the support bracket “M” of the roller table. Fig.35

– Remove the bracket towards the bottom. The jack will remain suspended on the hydraulic pipes.

– Disconnect the jack by unscrewing the pipe or the “T” connector (depending on the position of the jack). – Remount the jack and carry out the procedure in reverse order.

CAUTION: Always remove only one bracket at a time to prevent the whole table form falling to the ground.

30


CHAPTER # 7

DIAGNOSIS

7.0 TROUBLE-SHOOTING

PROBLEMS

CAUSES

REMEDIES

The machine does not switch on (the “CNC” display (Fig.8) is off).

No power on one or more phase(s).

Have electrical connections and line voltage checked by a qualified technician.

Main switch “QS1” (Fig.8) at “0”.

Set the main switch “QS1” (Fig.8) at “1” and then push button “SB2”.

The protection “QF5” has tripped (Par.8.0).

Refer to Par.3.3 (motor protection).

The power supply “G1” (Par.8.0) does not function.

Have the power supply checked by a qualified technician.

No power sup ply as the “SB1" and/or ”SB5" button (Fig.8) or the “SB12" button (Fig.19) have been pushed.

Pull the button ”SB1" and/or “SB5" (Fig.8) or ”SB12" (Fig.19) until it returns to the original position, finally press the button “SB2" (Fig.8).

The cyclic direction module of the “SSC” phases has in ter vened (Par.8.0).

Have two of the three phases inverted by a qualified technician as described in Par.2.2.

The fuses “F1" and/or ”F2" and/or “F3" (Par.8.0) have blown.

Have them replaced by a qualified technician.

The menu for manual or semiautomatic cutting has been exited.

Access one of the two menus following the instructions in Par.3.0.

The feed speed is at the minimum value.

Increase the speed following the instructions in Par.3.0.



Inverter protection “INVX” or “INVY” (Par.8.0) has tripped.


The limit switches are electrically disconnected.

Have the elec tri cal con nec tions checked by a qualified technician.

The inverter “INVX” or “INVY” does not receive the electrical command.

Have the electrical connections of the inverter checked by a qualified technician.

The machine does not switch on (the “CNC” display (Fig.8) is on).

The machine is on, but the longitudinal head feed doesn’t work.


31

Longitudinal head feed blockage during machining.



Inverter protection “INVX” or “INVY” (Par.8.0) has tripped.


One of the limit switches has accidentally tripped.

Press the “ESC” key and re-enable with the “JOG” keys (Fig.14).

There is a foreign body between the rack and the pinion.

Move the head back with the “JOG” keys (Fig.14). Should the gearmotor be locked, position the switch “QS1” (Fig.8) on “0” and lock it with a padlock. Remove the feed motor fan cover and turn the fan by hand until removing the obstacle from the pinion.

The longitudianal head sliding beam “7” (Fig.8) is dirty.

Carefully and deeply clean the sliding beam.

The head bearings are dirty, locked or dented.

Check the state of the bearings, clean them carefully and possibly have them replaced by a qualified technician as explained in Par.6.0.

The head bumps at the end of the stroke, does not start again and the feed motor strains.

The limit switch lever is not adjusted correctly.

Set the switch “QS1” (Fig.8) to “0” and lock it with a padlock. Remove the fan cover of the feed motor and, turn ing the fan, free the head. Recalibrate the limit switch lever so that the head stops at 10-15 mm. from the machine support.

The lon gi tu di nal or cross feed of the head is locked during machining.



The “Z” axis inverter (Par.8.0) has tripped


The vertical slideways and/or the threaded bar which commands the lifting and lowering movement are not properly clean.

Clean the vertical slideways and bar as explained in Par.5.0.

The menu for manual or semiautomatic cutting has been exited.

Access one of the two menus following the instructions in Par.3.0.

One of the limit switches has accidentally tripped.

Press the “ESC” key and re-enable with the “JOG” keys (Fig.14).

The longitudinal head feed moves in jerks with vibrations.

32


The feed speed is at the minimum value.

Increase the speed following the instructions in Par.3.0.

The head lowers with jerks.

Too much play between the two axial bearings on the screw which drives the lifting/lowering movement.

Remove the excess play with compensation thrust bearings, or with the 4 screws which fix the lifting/lowering frame cover.

The main motor does not start.



Some electrical safety switches prevent the motor from starting.

Con sult Par.7.1 (pro gram messages).

The protection or “QF3" has tripped (Par.8.0).


Some electrical safety switches prevent the motor from starting.

Consult Par. 3.0 (general notions on program functioning).

Disc rotation motor clutch (“W” axis) loosened.

Have it checked by a qualified technician (see Par.6.6).

Electrical system fault of the hydraulic control unit “16" (Fig.2).

Have it checked by a qualified technician.

The hy drau lic con trol unit “16" (Fig.2) has too little oil.

Add ISO15 hydraulic oil to the hydraulic control unit.

There is a leak in the hydraulic system.

If the leak is at a connector, tighten it using a suitable wrench. If it is on a tube, replace the tube.

The maximum pressure sensor is uncalibrated.

Have the sensor checked by a qualified technician. The sensor must signal hydraulic pressure of about 55 bar.

The bottom part of the mechanical locking system for “W” axis rotation does not go down.


The wa ter re cy cling pump (if in stalled) works but the wa ter doesn’t work.



The wa ter re cy cling pump (if in stalled) works but the wa ter does not rise.

An air bubble has formed in the pump impeller.

Pour one or two glasses of water into the pump delivery tube at the first connector.

The disc (“W” axis) does not rotate.


33

The pump filter is clogged.

Carefully clean the pump filter and the water collector tank.

The pump impeller is blocked by dirt.

Set the switch “QS1” (Fig.8) to “0” and lock it with a padlock. Remove the pump from the tank, dismantle the lower part of the pump by means of the special screws to free the impeller. Carefully clean all the pump parts and reassemble.

The solenoid valve or the wa ter re cy cling pump (if in stalled) works but the wa ter does not rise.

The water tap on the head is closed.

Open the water tap located on the head.

The machine does not cut straight.

The machine is not level.

Repeat the machine levelling operation described in Par.2.1.

The blade is too hard or the diamond is glazed (diamond closed).

If the blade is too hard, replace it with a softer one. If the blade is glazed, the diamond must be dressed by cutting abrasive material such as sandstone or a cement block. On very hard granite step cutting may be required.

Feed rate is too high.

Reduce the feed rate.

The blade is bent or the blade flanges are dirty or dented.

Check the state of the blade’s core and the flanges using a dial indicator. Then repair or replace the damaged parts. Clean the surfaces extremely carefully when assembling inner flange-tool-outer flange.

Lifting/lowering and rotation movements have not been secured.

Using the screws and levers, lock all head movements (Par.4.2)

The main motor’s axis is not perfectly perpendicular to the beam.

Re-align the main mo tor (see Par.6.5).

The beam is buckled.

Contact the manufacturer.

Feed rate is too high.

Reduce feed rate.

The blade is bent or the blade flanges are dirty or dented.

Check the state of the blade’s core and the flanges using a dial indicator. Then repair or replace the damaged parts. Clean the surfaces extremely carefully when assembling inner flange-tool-outer flange.

The cut is chipped.

34


The rollers do not rise or lower.

The blade is too hard or the diamond is glazed (diamond closed).

If the blade is too hard, replace it with a softer one. If the blade is glazed, the diamond must be dressed by cutting abrasive material such as sandstone or a cement block. On very hard granite step cutting may be required.

The main motor’s axis is not perfectly perpendicular to the beam.

Re-align the main mo tor (see Par.6.5).

Electric problem in the hydraulic lifting unit “16” (Fig.2).


The hydraulic lifting unit “16” (Fig.2) has too little oil.

Add ISO15 hydraulic oil to the lifting unit.

There is a leak in the hydraulic system.

If the leak is at a connector, tighten it using a suitable wrench. If it is on a tube, replace the tube.

One or more hydraulic cylinders are blocked.

Remove the cylinder as described in Par.6.7, open it and free it carefully from rust and dirt using liquid rust remover.

The rollers are not free to rise or lower.

Check that no foreign bodies are to be found between the rollers and the worktable.

7.1 PROGRAM MESSAGE DIAGNOSTICS

ERROR NO.

DESCRIPTION

REMEDIES

205=MACHINE STOPPED!!!

General alarm. A number is displayed at the top right of the di splay. This num ber identifies the type of error.

Consult the message diagnostics of the “CNC” axis control (see paragraph 7.2). Identify the type of problem from the number of the error message shown at the top right.

The “STOP” and then the “ESC” key has been pressed. The program is in pause.

Consult paragraph 3.0.

occurred STOP number (990=MACHINE EMERGENCY) KEY ESC TO RESTART 207=MACHINE STOPPED!!! occurred STOP number 991=ESC keyed after STOP KEY ESC TO EXIT PROGRAM KEY START FOR MAIN MENU


35

208=MACHINE STOPPED!!! occurred STOP number 992=BLADE INVERTER TRIP

The “CNC” axis control starts the main motor. The “INV” inverter is enabled to turn the disc but the command is not carried out.

The “INV” inverter has a problem, check the elec tri cal connections.

The “CNC” axis control executes a cut, but the sensor “SQ9" signals that the roller table is raised.

Check the electrical connection of the sensor ”SQ9" and its functionality.

When cutting starts and the water flow to cool the disk is insufficient.

Check functioning of the sensor “SQ11" and that there is water in the hydraulic circuit.

The “CNC” axis control runs a procedure, but the oil pressure is incorrect.

Check fun ctio ning of the hydraulic circuit. Check the oil pressure sensor “SQ10".

The “CNC” axis control switches on the hydraulic control unit but it does not work.

Check the electrical components “QF2" and ”KM2". Check fun ctio ning of the hydraulic control unit.

“W” axis rotation activated with the disc near the machine shoulders.

Move the disk away from the machine shoulders. Move the “X” axis until passing the safety distance.

When the disc has a “Z” axis position of less than 10 mm, “W” axis rotation is not permitted.

Lift the disc to pass the “Z” axis safety position.

KEY ESC TO EXIT PROGRAM 209=MACHINE STOPPED!!! occurred STOP number 993=Roller Up KEY ESC TO EXIT PROGRAM 210=MACHINE STOPPED!!! occurred STOP number 994=No water flow KEY ESC TO EXIT PROGRAM 212=MACHINE STOPPED!!! occurred STOP number 996=Oil Pressure KEY ESC TO EXIT PROGRAM 213=MACHINE STOPPED!!! occurred STOP number 997=Hydraulic unit KEY ESC TO EXIT PROGRAM 214=BEWARE!!! 998=Blade near shoulder KEY ESC TO EXIT PROGRAM 218=MACHINE STOPPED!!! occurred STOP number 984=Z axis to 0 & 10 mm KEY ESC TO EXIT PROGRAM

36


219=MACHINE STOPPED!!! occurred STOP number

The “CNC” axis control activates mechanical release of the “W” axis rotation system, but it does not occur.

Check functioning of the sensor “SQ7". Check the mechanical locking system for ”W" axis rotation.

The me cha ni cal loc king system for “W” axis rotation has uncoupled. This condition impedes the procedure from continuing.

Check functioning of the sensor “SQ7". Check the mechanical locking system for ”W" axis rotation.

The “CNC” axis control activates the “Z” axis movement, but the movement does not occur.

Check functioning of the mechanical and electrical parts of the “Z” axis movement.

One of the four orthogonal “W” axis positions has been selected, but the final position has not been reached.

Check functioning of the electrical parts which drive the “W” axis movement (KM3 KM4 - QF3).

The LINE DRIVER MODULE is trip, because one sensor axis is fault (the “X”or “Y” or “Z” or “W” axis sensor).

Check the electrical connections of the “BANX” or “ BANDY " or “ E N C Z” o r “BANDW” sensor. The LINE DRIVER MODULE doesn’t re ce i ve the di gi tal si gnal, maybe one sensor is faulty.

“X” axis motions activated, but the inverter (INVX) not run.

Check the “INVX” inverter, this inverter is trip. Read the error message on the inverter display.

“Y” axis motions activated, but the inverter (INVY) not run.

Check the “INVY” inverter, this inverter is trip. Read the error message on the inverter display.

988=Head engaged KEY ESC TO EXIT PROGRAM 220=MACHINE STOPPED!!! occurred STOP number 987=Head not engaged KEY ESC TO EXIT PROGRAM 221=MACHINE STOPPED!!! occurred STOP number 986=Z axis timeout KEY ESC TO EXIT PROGRAM 222=MACHINE STOPPED!!! occurred STOP number 985= W axis motor stopped KEY ESC TO EXIT PROGRAM 223=MACHINE STOPPED!!! occurred STOP number 983=axis sensor problem KEY ESC TO EXIT PROGRAM 224=MACHINE STOPPED!!! occurred STOP number 982=X-axis inverter trip KEY ESC TO EXIT PROGRAM 225=MACHINE STOPPED!!! occurred STOP number 981=Y-axis inverter trip KEY ESC TO EXIT PROGRAM


37

226=MACHINE STOPPED!!! occurred STOP number

“Z” axis motions activated, but the inverter (INVZ) not run.

Check the “INVZ” inverter, this inverter is trip. Read the error message on the inverter display.

980=Z-axis inverter trip KEY ESC TO EXIT PROGRAM

7.2 “CNC” AXIS CONTROL MESSAGE DIAGNOSTICS

38

ERROR NO.

DESCRIPTION

REMEDIES

100

“X” axis movement error

101

“Y” axis movement error

102

“Z” axis movement error

103

“W” axis movement error

Check the axis movement sensor; the sensor transmits incomplete electrical pulses to the “CNC” axis control. The sensors are: “BANDX - BANDY - BANDW - ENCZ”. Check the axis movement inverter, the “INVX-INVY-INVZ” in ver ter has tripped.See the inverter display.

104

“X” axis exceeds negative limit

105

“Y” axis exceeds negative limit

106

“Z” axis exceeds negative limit

107

“W” axis exceeds negative limit

108

“X” axis exceeds positive limit

109

“Y” axis exceeds positive limit

110

“Z” axis exceeds positive limit

111

“W” axis exceeds positive limit

Negative limit (X-,Y-,Z-,W-) of the work table exceeded, correct the cutting data. A limit switch has tripped accidentally, check functioning. The limit switches used are: “SQ1 - SQ2 - SQ3 - SQ4 - SQ5 - SQ6".

Positive limit (X+,Y+,Z+,W+) of the work table exceeded, correct the cutting data. A limit switch has tripped accidentally, check functioning. The limit switches used are: “SQ1 - SQ2 - SQ3 - SQ4 - SQ5 - SQ6".


ERROR 990 EXAMPLE: When you cut in semiautomatic mode and the axis movement trip, then the “CNC” interrupt the cut program. In this case you see a er ror mes sage on the “CNC” screen. For example: If you have “ERROR 990” error message, you look the number located on the upper-right side of the pop up message. In this example you see the “101" number, therefore you have the “Y” axis mouvement problem (see the table).

ERROR

990

Check the electrical connection of the “Y” axis sensor or the “INVY” inverter has tripped. If the inverter has tripped, you see the error message visualized on the keypad display (the keypad display is inside). Open the electric panel door to read the inverter error message, but if you switch off the machine, the inverter error message is eraset. You read the inverter error message if the inverter is switch on, if you switch off the inverter, then you lose the inverter error message.

7.3 INVERTER DIAGNOSTIC The keyboard is connectedto the inverter with an hexadecimal cable (max 2m) whose shield is ground connected on the inverterside. 1) ENTER KEY: It goes to the selected paramete. Confirmation of the set value. 2) MENU SELECTION KEY: It allows to scroll through the parameters. Confirmation of the set value. 3) GREEN LED: Forward run. 4) GREEN LED: Backward run. 5) YELLOW LED: If flashing, the change has not been stored permanently

X - Y - Z axis inverter display

6) DECREASE KEY: It selects the parameter inside a menù, it decreases the parameter value, speed decreasing 7)INCREASE KEY: It selects the parameter inside a menù, it increases the parameter value, Speed increasing

Main motor inverter display


39

INVERTER AXIS "X - Y - Z" ERROR CODE TABLE CODE ON DISPLAY

40

FUNCTION

DESCRIPTION

C. ERR

Configuration memory error. It is enabled at inverter startup if the configuration memory is not working properly . To avoid this try to turn the inverter off and restart it after some minutes.

P. ERR

Full lock Parameter memory error. It is enabled if the memory contains inconsistent parameters. Causes: accidental loss of parameters (turning off during storage phase), memory failure. In case of accidental loss: turn the inverter off and restart it after some minutes. The factory-preset parameters will be stored.

Full Lock

CODE

FU

Fuse breakage protection: enabled in case of inner fuse breakage. Autoreset is not allowed.

11

S - OH

Temperature Heatsink sensor broken. Autoreset alarm not allowed.

13

EF

External protection: enabled by the EXTFLT input on terminal board. Autoreset can be enabled only if parameter b-11=1.

1

OC

Overcurrent protection: enabled when the output current exceeds, even the momentary, the max. Allowed threshold to protect the inverter. It signals short circuit between phases and to ground too

2

OU

Lock that can be reset

Overvoltage protection: enabled when the voltage at the filter capacitor ends exceeds the max programmed threshold to protect the inverter.

3

UU

(alarm contact e nabling and stor age of alarm type, the dis play is flashing).

Undervoltage protection: enabled when the voltage at the filter capacitor ends falls below the min. threshold programmed to avoid troubles due to torque reduction. Autoreset is allowed. If b-37=0, the alarm storage is disabled.

4

OH

Overtemperature protection: enabled when the heat sink temperature exceeds the max. threshold programmed to protect the inverter. Autoreset is not allowed.

5

OL 1

Inverter overload protection: enabled when the direct current exceeds the max. threshold for the max. allowed time (IxT) to protect the inverter. Autoreset is not allowed (FOXPM).

6


OL N

Motor overload protection: enabled when the direct current exceeds the max. threshold for the max. allowed time (I2xT), to protect the motor. The levels and times depend on setting of the motor characteristic data. Autoreset is not allowed (FOXPM) .

7

OL R

Braking resistor overload protection: enabled when the power dissipated by the braking resistorexceeds the max. threshold for the max. allowed time. The levels and times depend on setting of the resistor characteristic. Autoreset is not allowed.

8

OT

Protection for momentary motor overload: it is active, after enabling (b-17=1), when the torque delivered by the motor exceeds the programmed level for the preset time, to protect the connected mechanical parts or the worked material (FOXPM).

9

PH

Protection for lack phase supply (it’s valid for 3-phase supply): It’s active after 30s from the disconnecting of one between the phase supply. Autoreset isn’t possible.

10

OCH

Protection overcurrent: it's active (in option to OC)

12

OHR

Overtemperature of regulation card (switch-of the device and waiting the cooling)

14

When the inverter trip, the error message appear on the display. Open the electric panel and read the message error, this procedure is effect by a qualified technician. If the inverter is switch off, you lose the error message. Only for "X - Y - Z" inverter, read the “D12” parameter value to find the last error message. In the "MAIN MOTOR"'s inverter, read the "D-800" parameter value. “D12” or "D-800" reading procedure: Press the “M” key to select the “D00” parameter, then scroll up the “D” parameter with “ARROW UP” key. Press “E” key and read the message error. To when the torque delivered by the motor exceeds the programmed level for the preset time, to protect the connected mechanical parts or the worked materialrestore the inverter default configuration, select the “D00” parameter (the motor speed value).


41

INVERTER "MAIN MOTOR" ERROR CODE TABLE A L A R M CODE

42

DESCRIPTION

AUTO - R ESET

EF

When a digital input programmed as "external fault NO" or "External fault NC" become active

YES

OC

Overcurrent protection: enabled when the output current, relieved by a current sensor exceeds. Verify the type of load applied and the ramp of rising.

YES

OU

Overvoltage protection: enabled when the voltage in the dc bus exceed. it's in function of the line tension

YES

UU

Undervoltage protection: enabled when the voltage ends falls below the min. threshold programmed, in function of the line voltage.

YES

OH

Overtemperature protection: enabled when the heat sink temperature, relieved by the thermal drop, exceeds the max. threshold programmed to protect the inverter.

NO

OHS

Overtemperature protection: enabled when the heat sink temperature, relieved by the analogical sensor, exceeds the max. threshold programmed to protect the inverter.

NO

OL 1

Inverter overload protection: enabled when the direct current exceeds the max. threshold for the max. allowed time (IxT) to protect the inverter.

NO

OL N

Motor overload protection: enabled when the direct current exceeds the max. threshold for the max. allowed time, to protect the motor. The levels and times depend on setting of the motor characteristic data, and the execution cycle

NO

OT

It is active when the torque delivered by the motor exceeds the programmed level for the preset time, (parameter P.241)

NO

ST

It's active when the Time-out of the serial line exceed the setup threshold value with, (Parameter I.604)

YES

BF

Occur when the communication between the regulation card and the field bus is failured

NO

LF

It's active when the drive is working in a border condition, caused by the output current, by the "DC Bus", by the setup of "PI", or by the overload of the motor.

NO

SHC

inverter execute a control of the load when come the march command: the alarm occur in case of an output short circuit.

NO


7.4 ASSISTANCE For any request, necessity or information, the user must communicate the following data to the local dealer or the manufacturer:

– Machine model – Serial number – Year of manufacture – Date of purchase – Approximate number of operating hours – Detailed description of fault.


43

CHAPTER # 8

WIRING DIAGRAMS

8.0 ELECTRICAL PANEL LAYOUT VERSION 400 VOLT 50/60 Hz

PENDANT CONTROL (OPTIONAL)

ELECTRIC PANEL

DOOR

POWER SUPPLY (ONLY VERSION 230 VOLT)


45

46

NAME

CODE

DESCRIPTION

AT

TRA280DEE01

CNC BANDX-BANDY ENCZ F1/F3 G1 INV INVX-INVY INVZ KA1/KA8 L1 LINE DRIVER MODULE KE1 KE2 KE3 KE4 KEM KM1 KM2 KM3+KM4 LASER LM1 M1 M2 M3 M4 M5 M6 P1 P18 P19 QF1

CON280CEE02 TES280CNE01 ENC280CEE01 POR031CEE01 ALI280CEE01 INV280CEE01 INV280CEE02 INV280CEE03 REL270VEE01 IND280CEE01

Auto-Transformer for power supply machine version 230V (optional) Axis numerical control VISION PLUS Head magnetic strip “X/Y” axis “Z”-axis encoder Fuse socket Power supply Main motor frequency inverter “X-Y” axis feed frequency inverter “Z” axis feed frequency inverter Control relay Inductance for the “INV” inverter

MOD280CEE05

Line driver module for X-Y-Z-W axis sensor

ELE250CED01 TEL240VEE01 TEL240CEE03 TEL240CEE03 TEL240CEE03 LAS280CEE03 LED250CEE01 MOT280CME02 MOT280CME02 MOT240CME02 MOT280CME01 MOT240CME04 MOT280CME03 POM280CED01 MOD280CEE04 MOD280CEE04 INT241VEE01

QF2

SAL240VEE01

QF3 QF4 QF5

SAL240VEE01 INT280CIE04 INT280CIE02

Electrovalve for water Oil release electrovalve for hydraulic unit Hydraulic electrovalve for roller table Hydraulic electrovalve for “W” axis rotation Emergency magnetic switch Pump magnetic switch Hydraulic control unit magnetic switch “W”-axis motor magnetic switch Laser diode Reset lamp “X”-axis feed motor “Y”-axis feed motor “Z”-axis lifting/lowering motor Motor for main motor Motor for hydraulic control unit Motor for “W” axis Water recycling pump (optional) Terminal connector module with 64 pin Terminal connector module with 64 pin Magnetic switch for water recycling pump Adjustable magnetic switch for hydraulic control unit Magnetic switch for “W” axis motor Magnetic switch for main motor inverter Magnetic switch for axis numerical control


NAME

CODE

QF6

INT280CIE03

QF7

INT280CIE01

QS1 QS2 QS3 SB1-SB12 SB5 SB2 SB3-SB4 SQ1-SQ2 SQ3-SQ4 SQ5-SQ6 SQ7 SQ8 SQ9 SSC TR Z1

INT240VIE01 SEL250CEE01 SEL251CEE02 PUL250VEE04 PUL200CEE01 PUL250VEE05 PUL250VEE07 FIN250CIE01 FIN250CIE01 FIN250CIE01 PRO270CEE01 PRO270CEE01 PRO270CEE02 SCH100CEE01 TRA240CEE01 FIL280CEE02


DESCRIPTION Magnetic switch for “INVX-INVY-INVZ” inverter Magnetic switch for power supply machine version 230V (optional) Main switch Diode laser switch Switch for the pendant control (optional) Locked mushroom button Box locked mushroom button Reset button Roller table lifting/lowering button “X”-axis limit switch “Y”-axis limit switch “Z”-axis limit switch Head proximity sensor Zero “W” axis proximity sensor Roller table proximity sensor Cyclic direction module of phases Transformer “INVX-INVY-INVZ” inverter filter for radio interference

47

8.1 WIRING DIAGRAMS 400 Volt 50/60 Hz

48



49

50



51

52


8.2 OPTIONAL ACCESSORY


53

54

Kw 0,18 ELECTRIC MOTOR

VALVE OIL PRESSURE RELEASE

VALVE OIL W-AXIS

VALVE OIL ROLLER TABLE

PUMP TANK

OIL PRESSURE ACCUMULATOR

OIL FLOW ADJUSTMENT

W-AXIS PISTON

ROLLER TABLE PISTONS

8.3 HYDRAULIC DIAGRAM


CODICE

GAM280DFP03 GAM280DFP04 LON280DFP01 TIR280DFP01 LON280DFP02 SPA280DFP02 GAM280DFP02 SUP280DFP07 DIS250DFP01 STA250DFP01 STA280DFZ01 GUI280DFZ02 SPA280DFP01 CRE280DFZ07 PRO280DFP02 PIA280DFZ03 PRO280DFZ01 GAM280DFX01 BAN280CNE11 FIN250CIE01 CRE280DFZ06 GUI280DFZ01 TAV280DNX01 TAV250DNX02 PRO280DFP01

POS.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Right front leg Right rear leg Side sill Diagonal tie rod Inner sill panel Right shoulder Right rear leg Support for main electric panel “U” spacer for inner sill panel Diagonal tie rod fastening bracket Stop bracket for “Y” axis guide Left sliding guide Left shoulder Left sliding guide rack Protection sliding guide Plate of fixage guide extension Left sliding guide extension Left rear leg Magnetic strip axis “Y” “Y”-axis limit switch Right sliding guide rack Right sliding guide Wooden table Slotted wooden table Cable protection bracket

DESCRIZIONE 1 1 2 2 2 1 1 1 1 2 2 1 1 1 2 2 1 1 1 2 1 1 4 13 1

Q.TÀ

CODICE

MOT280CME02 TES280CNE01 SUP280DFP08 RID280CNX02 PRO280DFP04 SPA280DAX01 PUL200CEE01 SUP280DFP02 SUP280DFP01 PIA280DFX03 SUP250CNX02 ALB280DLZ03 CUF280DFP02 FLA280DLU01 SUP280DFZ05 CIL280DLU01 CIL280DHU01 FRE280DFZ02 PAT280DPX01 STA280DFZ07 CUS280CLX01 SUP280DFZ02 STA280DFZ08

SUP280DFZ01 CUF280DFP01 SOS280DFP01 RAC280CPE01 GUA280CPE01 DAD280CFE01

CRE280DFZ11 BAN280CNE12 TRA280DFC01 CRE280DFZ12 CRE280DFZ10 SPA250DAX01

POS.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29

30 31 32 33 34 35

Right rack X-axis magnetic stripe X-axis head sliding beam Central rack Left rack Brush L=30

Upper support for head bearing Right hood head Support for head cable drop Straight connector for cable sheath Sheath cable protection Nut PG36

X longitudinal feed motor X-axis magnetic head sensor X-axis bracket for magnetic head sensor Gearmotor for longitudinal feed X-axis pignon protection Brush L=110 mm. Mushroom emergency push-button with cover Support for mushroom emergency push button Support for X-axis gearmotor Longitudinal feed gearmotor enhancement plate Support for x-axis bearin of the shaft with pinion X-axis shaft with pinion Left hood head Flange for head sliding cylinder Fixing support for left hood head Head sliding cylinder Head rotation cylinder X-axis brake support X-axis brake Fixing bracket for bearing adjustment support Head bearing UNI623052RS Lower support for head bearing Adjustment bracket for bearing adjustment support

DESCRIZIONE

1 1 1 1 2

1 1 1

4 1

1 1 2 1 4 16 4

1 1 1 1 1 4 1 1 1 1 1 1 1 2

Q.TÀ

CODICE

SCA260CPE01 TUB280CGD03 RID280CFD01 CIL280CLD01 POM280CND01 PRO280CEE01 PIA280DFP04 DIS280DFZ01

MOT280CME03 RID280CNX01 ALB280DLZ01 PIG280CLZ01 BAR280DLZ01 CUS280CLX02 BOC280DFZ01 MOL150DLX01 SUP280DFP03 ENC280CEE01 PER280DLZ01 RID280CNX04 MOT280CNE04

STA280DFP03 PIA280DFP02 FIN200CEE01 SUP280DFP05 CMI280DOU01 CUS240CLX01

BAR280DLU01

COL280DLX01 TEL240DFP01 BOC280CNX01 CIL280DHU01

POS.

1 2 3 4 5 6 7 8

10 11 12 13 14 15 16 17 18 19 20 21 22

24 25 26 27 28 29

31

34 35 36 37

Column Chassis rise\fall Bushing Head rotation jack

Threaded bar for main motor ascendent/discendent TpN 50

“Z"-axis limit-switch bracket Plate “Z”-axis limit-switch “Z”-axis limit-switch support Bracket with lead nut Bearing

“W”-axis motor “W”-axis gearmotor Shaft Pinion Threaded bar Bearing UNI 51206 Bushing for spring Spring "Z"-axis encoder support. “Z”-axis encoder “Z”-axis encoder shaft “Z”-axis gearmotor “Z”-axis motor

Electric box for W-axis sensor Idraulic tube L= Nipple “W”-axis jack Lubrification oil pump for head rotation Nipple Lower plate for main motor divider Spacer

DESCRIZIONE

4 1 8 1

1

1 1 2 1 1 1

1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Q.TÀ

CODICE

DAD240CFZ01 FLA280CLZ02 FLA280CLZ01 MOT280CME01 CAR230DFP04 CAR230DFP03 PRO230DFP01 POM240CPS01 PRO230DFP02 FLU280CFE01 RUB240CFD01 TUB240CPD01 SUP200DAX02 LAS280CEE03 STA250DFP05 PER250DFZ04 SUP280DFP04 DAD280CFE01 RAC280CPE01 PIA280DFP01 PRO280DFP03 SUP200DAX01

PIA280DLU01 PIA280DHU01 FUN250DFU01 PRO280CEE01 TES280CNE01 SFI260CND01 CUS240CLX03 RAL240CLX01 DOS280CND01 BAN280CNE13 COR280DLZ01 ANE280DFZ

POS.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

24 25 26 27 28 29 30 31 32 33 34 35

Lower plate for main motor divisor Upper plate for main motor divisior Stopping pin Proxmity sensor of the axis origin “W”-axis magnetic head Air filter Bearing Spacer for axial bearing engage divisor plate proximity sensor “W”-axis magnetic stripe head rotation barbed crown ring for magnetic stripe of head rotation

N ut External flange Internal flange Main motor Fixed protection of the carter rear Fixed protection of the carter front Protection left carter Ball knob Ø 30 mm. M6 Protection carter right Water flow sensor Water flow tab F-F 3/8” Wired hose for water Laser adjustment bracket Las er Laser fastening bracket Pin for laser fixing Support for motor sheat junction N ut Tube Main motor plate Protection for motor rotation group Support for laser regulation

DESCRIZIONE

1 1 2 1 1 1 1 2 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Q.TÀ

CODICE

CAR250DFP03 SPA250DAX01 FRE280DPS01 CUS010CLX02 RUO250DFZ01 PER250DFZ01 CAL250CLX01 PIG250DFZ01 PER250DFZ02 PRO280DFP06 SUP280DFZ04 TES280CNE01 PIA280DFZ01 SUP250CNX01 RID280CNX03 MOT280CME02 ALB280DFC01 TUB280DFP01 CAL280CLX01 SUP250CNX02 TUB280DFP02 CAR250DFP04 PIA280DFZ02 CAR250DFP02 BOC250DPU01 CAR250DFP01

POS.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Upper square carter left Brush L=30 "y"-axis brake Radial bearing (6205 2RS) Sliding wheel Concentric pivot for wheel Coupling “Y”-axis right shaft pinion Eccentric pin for wheel Protection for head cable “Y”-axis magnetic head bracket “Y”-axis magnetic head Wheel holder plate left for beam “Y”-axis lateral bearing holder “Y”-axis gearmotor Transverse feed motor “Y”-axis feed shaft Left “Y”-axis anti-torsion tube coupling anti-torsion tube Bearing support for central “Y”-axis shaft Right “Y”-axis anti-torsion tube Right square upper carter Wheel holder plate right for beam Left square lower carter "Y”-axis end-run stop Lower right protection cover

DESCRIZIONE

16 8 4 2 1 4 1 1 1 1 2 1 1 1 1 4 1 1 1 1 1 2 1 1

1 10

Q.TÀ

CODICE

GUI280DFP01 FIN250CIE01 CAT280DPE01 SCAO21CPE01 BRA280DFP01 BOC250DPU02

STA280DFP02 MEN280DFP02 MEN280DFP01 CAT280DPE02 GUI280DFP02 MEN280DFP03

POS.

1 2 3 4 5 6

9 10 11 12 13 14

"Y"-axis central support regulation bracket Right bracket for cable guide Left bracket for cable guide “Y”-axis cable chain “Y”-axis cable chain guide Bracket for“Y”-axis cable chain guide

Guide for “X”-axis cable chain “X”-axis limit switch “X”-axis cable chain Box for guide "X"-axis Support bracket for chain “X”-axis end-run stop

DESCRIZIONE

1 1 1 1 1 2

1 2 1 2 1

Q.TÀ

CODICE

PRO280DFP05 SUP280DFP06 RAC280CPE01 DAD280CFE01 CAS280CME01 BRA280DFP02 ELE250CED01 FIL250COD01 CAV280CEE06 CAV280CEE07 PIG280DFP02 MAN010CPS01 MOD280CEE01 BOC280DFZ02 ANE280DPU01 GHI280DFU01 GUA280CPE01 CON280CEE02 PAN280VDE04 PAN280VDE03 PUL280VEE01 ALL250DFP01 -

POS.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Protection for support of mobile electric panel PProtection for "Y"-axis head cable Tube N ut Main electrical panel box Control panel jointed arm Electrovalve Water filter Shielded cable with 2 connector “P18” Shielded cable with 3 connector “P19” Control panel box Handle 26 poles Interface module Bushing for mobile panel rotation nylon ring for mobile panel bushing Threaded ring nut Flexible sheat axis control CNC “VISION PLUS” Mobile electric panel Main electric panel External pendant control with cable Lodge for external pendant control Button for enable external pendant control C or k Switch for external pedant control

DESCRIZIONE 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 6 1 1

Q.TÀ

CODICE

MIC280CND01 ELE280CND01 ELE280CND02 TUB280CGD04 ACC280CND01 RAC240CFD02 TUB280CGD01 TUB280CGD02 TUB250CGD03 TUB280CGD03 PRE280CND01 SOS280DFZ01 CON280DFP01 RAC240CFD01 BAN280DFZ01 MEN280DFZ01 PRO270CEE02 MAR250VND01 RUL250CPS01 PER250DFZ03 TUB250CGD02 REG250CFD01

POS.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Idraulic lifting unit Oil exhaust Electro-valve “W”-axis rotation electro-valve / roller-table Tubo Oil accumulator Junction Idraulic tube L=1950 mm Idraulic tube L=3350 mm Idraulic tube L=600 mm Idraulic tube L=10800 mm Oil pressure sensor Support for oleodinamic box Idraulic control unit box junction Roller-table chassis Bracket for roller-table Roller table proximity sensor J ac k Omni-directional roll Pivot for omni-directional roll flexible tube Flow regulator

DESCRIZIONE

1 1 1 4 1 4 1 4 108 54

1 1 1 1 1

Q.TÀ

LIMITED WARRANTY CERTIFICATE BRIDGE SAW mod. ABS/CE

Achilli s.r.l. warranties the excellent quality and perfect operation of the ABS/CE machine under the following conditions: 1. The warranty is valid for a period of 12 months from the date of sale to the end user. 2. Achilli undertakes to repair or replace free of charge any mechanical part proven to have a manufacturing defect after being inspected by its technicians, while electrical and electronic components are covered by warranty only if the defects are acknowledged as such by the respective manufacturers. 3. The warranty is no longer valid if the machine or parts of it are modified or altered by unauthorized personnel. 4. The warranty is not valid for any breakage or malfunction caused by poor maintenance or incorrect machine operation. 5. Freight or packing expenses for returning parts to the factory for repair or replacement and for their replacement are payable by the client.

ACHILLI S.R.L.

DEALER’S STAMP AND SIGNATURE SERIAL No. DATE OF SALE