ALTENDORF F45 ProDrive Sliding table saw Operating Manual

The F45 ProDrive is a sliding table saw designed for cutting wood and similar materials. It features various safety devices, including a riving knife, top safety hood, and automatic brake. The machine is intended to be operated from multiple positions and features adjustable cutting height and tilt adjustments. The F45 ProDrive can also be fitted with optional modules such as a scoring saw and a CNC crosscut fence.

PDF

Document

1.1/2015

GB

Operating Manual F45 ProDrive

1 Foreword

1 Foreword

Please read these operating instructions carefully before commissioning the machine.

No liability will be accepted for any injury, damage or disruption to operations resulting from failure to comply with these operating instructions!

Persons operating this sliding table saw must have had sufficient instruction and be suitably qualified!

These operating instructions cannot be regarded as a binding type description as the manufacturer may have carried out technical modifications.

The operating instructions must always be available where the machine is being used. They must be read and heeded by any person performing the following activities at or on the machine:

• Operating including set-up, troubleshooting during operation, elimination of production waste, care, disposal of operating and auxiliary materials

• Maintenance, repair, inspection

• Transport

It is necessary to comply with national regulations on health and safety at work and environmental protection, in addition to the operating instructions.

The removal of safety devices, especially safety hoods for the saw blade cover and riving knives, will endanger the operator and may lead to accidents.

Safe work is only possible with a clean machine and a clean environment!

Reproduction of this document or parts thereof is only allowed with our permission!

Foreword

2

2.1

Identification

Machine identification

The type plate fitted to the machine frame serves for identifying the machine and other important machine data.

Meaning of the stated descriptions:

Fig. 2-1 Type plate

Type:

Number:

Machine designation

Machine specific identification number

Year of construction:

Year of manufacture

Saw blade min Ø

Diameter of the smallest permissible saw blade

Saw blade max

Guide slot width of the riving knife:

Diameter of the largest permissible saw blade

Diameter of the guide bolts for the riving knife in the riving knife holding fixture

Identification

2.2 Certificates

Conformity declaration as defined by the machinery directive, Annex II 1A

-Original / Translation of the original

Manufacturer:

Wilhelm Altendorf GmbH & Co. KG Maschinenbau

Wettinerallee 43/45

32429 Minden

Germany

Rolf Tweer, Technology Management,

Wilhelm Altendorf GmbH & Co. KG Maschinenbau

Person authorised to compile the technical documentation:

Product:

Machine number:

Sliding table saw, type F45

Authority named for prototype testing according to annex IX:

DGUV Test Prüf-und Zertifizierungsstelle Holz

Fachbereich Holz und Metall

Vollmoellerstraße 11

70563 Stuttgart

Germany

Identification number 0392

We hereby declare that the above-mentioned product conforms with all applicable regulations of machinery directive 2006/42/EC. It fulfils the requirements of the following applicable directives:

- Low-voltage directive 2006/95/EC

- EMC directive 2004/108/EC

The following harmonised standards have been applied:

- DIN EN 1870-18:2007:2013, Safety of woodworking machines - Circular sawing machines - Part 18:

Dimension saws

- DIN EN ISO 12100 :2011-03 Safety of machinery - General principles for design - Risk assessment and risk reduction

- DIN EN 60204-1:2007:-06, Safety of machinery - Electrical equipment of machines - Part 1: General requirements

Minden, 20/05/2015

_______________________________________________

Piotr Szablewski, Manager of Development & Construction

Identification

EC prototype testing certificate

Identification

GS test certificate

Identification

DGUV Test Certificate

Identification

C US-Certificate

Identification

2.3 Marks of conformity

CE symbol GS symbol

Wood dust approved mark

C US mark

Identification

3

3.1

Product description

Marking, pictographs

Danger warning Hand injury warning Laser beam warning

3.2

Crushing risk warning Voltage warning

Note: Wear ear protection

Intended use

The sliding table saw and the workpiece guide equipment supplied with it are intended to be used for cutting wood and similar materials such as:

• Laminated and unlaminated board materials (e.g. chipboard, coreboard,

MDF board, ...)

• Solid wood

• Veneer with a suitable clamping device

• Gypsum plasterboard

• Cardboard

• Dimensionally stable plastics (thermoset plastics, thermoplastics). Sawing these materials does not normally involve any risks in respect of dust, chips, and thermal degradation products.

• Aluminium and aluminium alloys

Product description

The sliding table saw and the workpiece guide equipment supplied with it are

not intended to be used for cutting materials such as:

• Sheet steel

• Sheet brass

• Sheet copper

• Round wood without the use of a suitable clamping device

Tools:

• The chosen saw blade must be suitable both for the specific work cycle

(e.g. longitudinal cutting or crosscutting) and for the specific material.

• Only circular blades which are solid chrome vanadium (CV) or tungsten carbide tipped (TCT) and have a maximum width of 20 mm are permitted for the main saw and milling/grooving cutter. The middle table strip and the cushioning disc must be removed when using a milling/grooving cutter.

• Saw blades with a maximum diameter of 120 mm are allowed for the scoring saw.

•

Saw blades made of high-alloy high-speed steel (HSS) may not be used.

•

Wobble units may not be used.

Usable saw blades:

250 - max. 500 mm diameter with scorer

250 - max. 550 mm diameter without scorer

Site of installation/use:

• The machine is not suitable for use outdoors or in rooms that are subject to moisture or the risk of explosions.

• The intended use of the machine involves connection to a suitably dimensioned extraction system.

• Intended use also involves compliance with ALTENDORF's specified operating, maintenance and repair conditions and adherence to the safety information contained in the operating instructions.

• The sliding table saw may only be used, set up and maintained by persons who are familiar with the machine and aware of the dangers.

• The pertinent accident prevention regulations as well as any other generally recognised technical safety and industrial medicine rules must be observed.

• Repair work must be carried out by our own customer service or by an organisation that we have authorised. Only original ALTENDORF spare parts may be used for this. ALTENDORF will assume no warranty for any damage that is caused by using non-original spare parts.

Coolant spray device: (Option)

It is advisable to use a coolant spray device when sawing aluminium and plastics. When using such a spray device, make sure you only use coolant that does not impair the function of safety-relevant parts such as protection hoods!

(The transparent parts of the protection hood are made of polycarbonate, and the grey hood support of polyamide.)

Clamping device:

A suitable clamping device should be used for small workpieces, in particular.

Product description

Machine operator positions:

The sliding table saw is intended to be operated from the following operator positions:

On the left of the sliding table at the front of the machine, seen in the feed direction (main operator position).

At the front cross-end of the machine on the right of the sliding table when working with the rip fence (make sure you do not move your body or parts of it into the blade rotation area).

Any person removing the workpieces must stand at the rear cross-end of the machine behind the main table length extension (under no circumstances in the sliding table traverse area)!

Fig. 3-1 Machine operator positions

Warning!

When removing workpieces at the rear of the machine, ensure that you keep sufficient distance from the extending telescopic tube.

Non-adherence may lead to knee injuries!

Note!

Any other use is deemed as unintended. ALTENDORF will not be liable for any kind of injury or damage that may result from such unintended use; the risk thereof is borne by the user alone.

Unauthorised modifications by users to the machine or its electrical parts and the use of non-original parts on the machine exclude any liability by the manufacturer for any resultant injury or damage.

Product description

Foreseeable misuse:

• Working with the safety hood swung up

• Working with the safety hood swung away

• Failure to use the push stick or push block for cuts < 120 mm

• Moving the sliding table without using the handle

• Trimming without the trimming shoe

• Touching or manual infeed with automatically moving stops

• Saws without a riving knife

• Incorrect setting of the straight edge on the rip fence

Warning!

Always, under all circumstances avoid the above-mentioned types of work.

All types of foreseeable misuse can lead to severe injuries!

Product description

Residual risk:

Even when the machine is operated in accordance with its intended use and all pertinent safety regulations, the following residual risks may be encountered because of design changes caused by the intended use in question:

• Contact with the main saw blade and the scoring blade in the cutting area, in particular when the saw blade is tilted in the -45° position and the protection hood is not correctly adjusted.

• Contact with the main saw blade and the scoring blade from beneath the table level when the sliding table is pushed fully forward or pulled fully back.

• Kick-back of workpiece or workpiece parts.

• Individual teeth spinning off tungsten carbide tipped blades.

• Breakage and ejection of the saw blade.

• Crushing at the manual or motor-driven sliding table.

• Crushing between the motor-driven tilt movement of the saw blade and the rip fence or workpieces lying in the tilting area.

• Contact with live parts when the electrical installation area is open.

• Damage to hearing as a result of working for long periods of time without hearing protection

• Emission of health-endangering dust from operation without extraction.

• Wear suitable gloves due to the risk of cuts when handling saw blades, grooving tools and when pushing the wood into the machine, as well as during maintenance work

• Do not remove chips while the saw blades are turning

• Do not use the machine before all protective devices/guards required for processing have been installed and are in perfect condition

Warning!

Avoid the potential dangers posed by these remaining risks by paying increased attention when setting up, operating and servicing the machine!

Always adhere to the specified working positions when operating the machine.

3.3 Dimensions and weights

3400

3800

4300

5000

[mm]

2250

3000

3200

[kg] [kg]

855-1282 970-1495

[kg]

114

158

170

205

212

249

[kg]

175

234

250

289

304

350

855-1282 970-1495 269 385 131-142

The weights depend on the machine equipment!

[kg]

131-142

[kg] [mm] [mm]

2580x660x330 2060x960x500

203-230

3330x660x330 2060x960x500

203-230

3530x660x330 2060x960x500

203-230

3730x660x330 2060x960x500

203-230

4130x660x330 2060x960x500

203-230

4630x660x330 2060x960x500

203-230

5330x660x330 2060x960x500

Product description

3.4 Auxiliary power/power requirements

The permissible tolerance of the specified mainsvoltage is + 5 % and - 10 %.

Greater deviations will impair functionality.

Only connect the machine to a three-phase AC mains with phases L1, L2 and

L3, otherwise the brake module or the frequency converter may be destroyed.

Operating the machine together with phase converters, frequency converters or transformer-capacitor combinations will destroy the brake module or the frequency converter and power supply unit!

Screw-in fuse links of the type NEOZED D02 (utilisation category gL) should preferably be used as back-up fuses.

The supply line must be dimensioned such that it cannot be overloaded and a max. voltage drop < 3% occurs at nominal current.

The loop impedance and suitability of the overcurrent protection device must be inspected/tested at the machine installation site.

Note!

Devices for differential protection (to be provided by the customer!)

In 230V400V systems, devices are generally used that detect leakage currents

< 300 mA. For switch-off in the event of a fault, RCDs (residual current devices) with a rated differential current < 300 mA are normally used, and for indication, fault current indicators (relays) or RCMs (residual current monitors) are used.

Mains voltage independent devices for differential protection that also detect differential currents (leakage currents) with DC components are to be used.

If leakage current indicators or RCMs are used, ensure that additional switchoff devices, e.g. circuit breakers, are provided.

(Extract from VDS Directive 2033)

If there are special safety requirements for persons setting up the equipment, then frequency converters complying with EN 50178 must be replaced by

RCMAs with an isolator (preferably) or by type-B RCDs (universal-current-sensitive residual-current circuit breakers).

The following devices can be used:

Manufacturer: Doepke switching devices; these switching devices can also be purchased via Altendorf.

• DFS4 040-4/0,30-B NK, release current 300 mA

• DFS4 040-4/0,03-B NK, for personal protection

Product description

Motor

[kW]

5.5

7.5

Auxiliary power/power requirements

Voltage

[V]

230

400

200 - 220

5.5

7.5

VARIO tilting to one side

VARIO 5kW tilting to both sides

VARIO 6.5kW

tilting to both sides

380 - 420

380-420

5.5

7.5

5.5

7.5

200 - 220

600

Frequency

[Hz]

50/60

Nominal current

Without/with scoring blade

[A]

12.4 / 15.8

7.2 / 8.7

19.8 / 23.2

26.5 / 29.9

11.5 / 13.5

15.5 / 17.5

22.5 / 24.5

36.0 / 38.0

36.0/38.30

20.0 / 23.5

24.0 / 28.0

7.5 / 8.5

9.5 / 10.5

Fusing

[A]

Product description

3.5 Emissions

3.5.1 Noise - characteristic values

Sound power level

[dB (A)]

Idling_____L

Cutting__L

Idling_____L

= 101.3

Cutting__L

= 104.2

Idling_____L

Cutting__L

= 96.6

= 87.3

= 93.9

= 98.7

Emission sound level at the workplace

[dB (A)]

Idling_____L

=77.4

Cutting__L

= 84.0

Idling_____L

Cutting__L

=95.7

= 92.1

Idling_____L

=84.1

Cutting__L

= 89.9

Idling_____L

= 93.9

Cutting__L

= 99.1

Idling_____L

= 87.7

Cutting__L

= 96.3

Idling_____L

=84.5

Cutting__L

= 86.0

Idling_____L

=78.1

Cutting__L = 84.6

Tools

Circular saw blade

300x3.2/96 WZ

n = 3987 rpm

Circular saw blade

350x3.5/54 WZ

n = 3987 rpm

Circular saw blade

350x3.5/84 WZ n = 3987 rpm

Circular saw blade

303x3.2/60 DH n = 3987 rpm

LOW NOISE

Circular saw blade

303x3.2/90 WZ

n = 3987 rpm

LOW NOISE

The noise emission values determined according to DIN EN ISO 3746 for the sound power level or DIN EN ISO 11202 and for the sound pressure level at the workplace on the basis of the working conditions stated in ISO 7960 Appendix A are as listed in the table.

A measurement uncertainty allowance of K = 4 dB (A) applies to the stated emission values.

The stated values are emission levels and therefore not necessarily levels for safe working. Although there is a correlation between emission and immission levels, it cannot be reliably deduced from this whether or not additional precautionary measures are needed to protect operators.

Product description

Factors that influence the immission level at the workplace include the duration of exposure, room characteristics, other sources of noise such as the type and number of neighbouring machines, and other working processes involving noise emission.

Product description

3.5.2 Dust

The dust emission values – measured in accordance with the “Principles for

Testing Dust Emission (Concentration Parameters) from Woodworking Machines” issued by the German trade association's technical committee for wood – are below 2 mg/m

When the machine is attached to a correctly functioning extraction system with an air speed of at least 20 m/s (measured after the join of the two extraction connections) you can assume it is and will stay compliant with the technical reference concentration (TRK) limit for wood dust that is in force in Germany.

The machines are tested concerning wood dust in accordance with the BGI

739-1. The machines bear the DGUV mark with the additional wood dust mark

"holzstaubgeprüft". Consequently, a company operating the machine in Germany is exempt from the obligation to perform measurements at the workplace in accordance with TRGS 553.

3.5.3 Electromagnetic compatibility

EMC (Electromagnetic Compatibility) is the ability of an electrical device to function in its electromagnetic environment without disruptively influencing this environment, which also includes other devices, or being disturbed by it.

The machine complies with the requirements set out in the European electromagnetic compatibility directive 2004/108/EC (EMC directive).

Product description

3.6 Ambient conditions

Transport and storage

The machine must not be used in an environment with explosive or corrosive gases.

The ambient temperatures for transport and storage range from - 25° C to +

55° C, and + 70° C is permissible for a short time.

The maximum air humidity must not exceed 90%, and condensation must be avoided in all cases.

Product description

3.7 Safety information

3.7.1 Operational safety

The operation of woodworking machines with manual feed involves a high risk in the event of incorrect handling. Therefore always observe the safety information that is summarised in this chapter as well as government and other industrial safety regulations (e.g. accident prevention regulations)!

Note!

Ensure that the operators are suitably trained in the use, setting and operation of the machine!

• Never operate the machine without the protective devices intended for the specific work cycle (also refer to “Working safely with the sliding table saw

– working examples”), and do not make any changes that could impair safety.

• Before all work, make sure that the protective and working devices are securely fitted and are not damaged.

• Before changing a tool, rectifying any faults and carrying out repairs, make sure that the machine cannot be turned on accidentally, for example by padlocking the main switch.

• Only use correctly sharpened tools designed to conform with the requirements of the European standard EN 847-1:2005+A1:2007.

• When grooving with milling tools, only use milling tools for manual feeding with a groove width less than or equal to 20 mm (5 mm for machines with the option "Saw blade tilting to both sides"), marked with MAN according to the European standard EN 847-1:2005+A1:2007.

• Only fit saw blades with the dimensions described in the technical data.

The diameter of the mounting hole must always measure 30 mm. Loose intermediate rings are not allowed to be used.

• Select the rotational speed so that the maximum permissible rotational speed specified for the tool is not exceeded when using tungsten carbide tipped saw blades or grooving cutters.

• HSS saw blades and cracked or deformed saw blades may not be used.

• Always wear tight-fitting work clothes and do not wear rings, bracelets or watches.

• Make sure that the workplace is uncluttered, slip-proof and well lit.

• Do not cut workpieces that are too large or too small for the machine to handle.

• When working at the machine, always stand to the side of the saw blade outside a possible kick-back area.

Product description

• Remove any loose parts from the vicinity of the saw blade before switching on the machine.

• Only start cutting when the saw blade has reached its full rotational speed.

• Always use the top protection hood!

• Adjust the height of the top protection hood to the thickness of the workpiece to be cut. When operating with a tilted saw blade, exchange the narrow hood for a wide hood. For machines with the option "Saw blade tilting to both sides", move the protective hood to the respective work position by pushing it to the correct side!

• Always guide the workpiece safely and use the appropriate stops/fences.

• Use a push stick when cutting narrow workpieces (< 120 mm) at the rip fence.

• Crosscuts and longitudinal cuts in round wood are not permitted with the standard feeding aids or fences/stops.

• Always use the riving knife except for insert cuts. The riving knife must not be thicker than the cutting line width or thinner than the main blade. Adjust it so that it is at a distance of least 3 mm and at most 8 mm from the gear rim. The guide slot must be 13 + 0.5 mm wide. The riving knives supplied with the machine cover the entire range of diameters for the saw blades that are allowed to be used – from 250 mm to 550 mm. With respect to their thickness, they match the cutting line widths of commercially available tungsten carbide tipped saw blades. If other saw blades, e.g. made of chrome vanadium (CV), are used, select a riving knife thickness that lies between the cutting line width and the main blade thickness. Such riving knifes can be obtained from the trade or directly from ALTENDORF.

• Use an anti-kick device for insert cuts, e.g. the front of the clamping shoe.

Fix this in the sliding table groove, ensuring that the sliding table is locked with its interlock to prevent movement. Following insert cutting, refit the riving knife and the top protection hood immediately.

• Only do angle cuts when the cross-slide is fixed to the sliding table. Make sure that small cut-off workpieces cannot be taken up by the gear rim and kick out, for example by using a deflection wedge.

• For trimming, use the clamping shoe fixed to the sliding table to hold down the workpiece.

• When using a feeding unit, use at least the riving knife as an anti-kick device.

• Replace worn-out table strips immediately.

• Wobble units or wobble cutting devices are not allowed to be used.

• The sound pressure level at the workplace generally exceeds 85 dB(A).

For this reason, wear hearing protection when working.

• Only qualified electricians are permitted to work on the electrical equipment of the machine.

Product description

• Regular cleaning of the machine and, in particular, the main table, sliding table and guides (e.g. rip fence) is an important safety factor. Before starting this work, make sure that the machine cannot be switched on unintentionally.

• The sawdust generated during cutting not only impairs visibility but is partially also hazardous to health. Therefore, the machine must be connected to a chip extraction system with both extraction sockets. The minimum air speed at the lower extraction socket must be at least 20 m/s. When the machine is switched on, the extraction system must switch on at the same time.

Warning!

Always use a deflector wedge fastened to the table top when small waste pieces are produced during cutting that could be kicked out by the saw blade.

Fig. 3-2 Deflector wedge

3.7.2 Safety devices

Altendorf's sliding table saws have been developed in compliance with European standard DIN EN 1870-18 "Safety of woodworking machines – circular sawing machines –: circular saw benches (with and without sliding table) and dimension saws”.

During the design stages great importance was attached to creating optimum working conditions, ranging from numerous mechanical and electrical safety devices to noise insulation and reduction of dust emission.

The machine is equipped with all the necessary safety devices to protect against operating risks that could not be eliminated by its design. These safety devices include, in particular:

• Rip fence with straight edge adjustable in cutting direction: Can be pulled back to prevent parts of crosscut workpieces from jamming between the fence and the rising gear rim, or can be switched over to a low guide surface for cutting narrow and flat workpieces, allowing adequate space for the guide hand together with the possibility of lowering the top safety hood onto the workpiece here, too.

• Trimming hold-down to clamp and hold down untrimmed solid wood to secure against slippage in the course of trimming.

• Electrical interlocking of the door in the machine frame to change over the belt to change the rotational speed (only with three-speed model). It is not possible to switch on the machine when the door is open, and if the door is opened while the machine is running, the drives will switch off.

• Sliding table arresting device to prevent workpiece kick-back for insert cuts together with the cross-stop.

• Automatic brake which, after switching off, brings the main saw blade to a standstill in less than 10 seconds, regardless of the saw blade diameter and rotational speed.

• Ergonomic arrangement of the operating elements at readily accessible positions.

Product description

3.7.3 Top safety hood/riving knife

For a max. tool diameter of 400/500/550 mm:

• Top safety hood fitted separately from the riving knife for max. saw blade diameter of 400/500/550 mm, available in a narrow and a wide format made of polycarbonate to optimally cover the section of the blade not required for sawing above the machine table with a safeguard against lifting beyond the maximum cutting height of + 5 mm. Rollers integrated in the safety hoods at the leading and trailing ends facilitate both feeding workpieces and pulling back workpieces if workpieces have a slightly different thickness.

• Laterally displaceable protective hood for machines with the option "Saw blade tilting to both sides"

• 3 riving knives for saw blades between 250 and 400/500 (550) mm diameter to avoid workpiece kick-back as a result of jamming in the cutting line.

Product description

3.7.4 Handling batteries / accumulators

Information on battery regulations

Note!

Dispose of used batteries according to the applicable laws and regulations at a communal collection point or return them to your retailer free of charge.

Danger caused by lithium batteries

If lithium batteries are used or stored outside of their specification, they may be dangerous. Dangers result primarily from incorrect handling and improper use.

Examples of improper use:

• mechanical damage (internal short-circuit)

• thermal stress (internal short-circuit)

• overloading (strong temperature increase due to exothermic processes).

In Germany:

According to § 5 ArbSchG (German Occupational Safety and Health Law), § 3

BetrSichV (German Industrial Safety Law), the owner/user must create a risk assessment to assess the dangers caused by technical equipment and devices.

Measures for damage prevention

The risk potential of lithium batteries is, in addition to the product design, primarily determined by the module or system capacity. The types used by Altendorf are low-capacity lithium batteries (batteries > 1 kg). The information for damage prevention applies to both new and used batteries.

General safety regulations

Always observe the following safety regulations:

• Adhere to all specifications by manufacturers and on safety data sheets

• Prevent external short-circuits

• Prevent internal short-circuits (protect from mechanical damage)

• Immediately and properly dispose of damaged products (even in case of slight damage)

• Do not expose directly and permanently to high temperatures or sources of heat (e.g. direct sunlight)

• Train employees in the proper handling of lithium batteries (as with hazardous materials)

Product description

Source: VdS 3103 : 2012-06 (01)

Lithium batteries - Excerpt of the GDV leaflet for damage prevention

4

4.1

Definitions

Description of machine

Fig. 4-1 Description of the sliding table saw

Definitions

Riving knife

Saw blade, protective hood

Protective hood support

Fixed guards beneath the table

Rip fence

Trimming hold-down device (clamping shoe)

Table insert

Machine table

Table length extension

10. Fixing elements

11. Protective hood holding fixture

12. Push stick

13. Sliding table

14. Crosscut fence

15. Sliding table handle

16. Movable operating terminal

17. Additional fixing elements on the rear end of the sliding table (optional)

4.2 Terms

Scoring

Creation of a shallow cut in the surface of a workpiece, deep enough to pass through any coating on the workpiece, so as to prevent damage to the underside when the main saw blade makes its cut.

Scoring blade

A blade that is located in front of the sawing blade, used to score the workpiece and rotate along with the feed direction.

Grooves

Creation of cuts in the surface of the workpiece not deep enough to pass through using the saw blade or a milling tool.

Machine drive

Power driven device to effect a machine movement

Hand feed

Holding and/or guiding the workpiece manually.

Definitions

Removable feeding device

Feeding mechanism fastened to the machine such that it can be tilted out of the work position without tools or similar equipment

Safety appliance

Additional device that is not an integral part of the machine but helps the operator to feed the workpiece safely, e.g. a push block or push stick.

Kick-back

Unexpected sudden movement of the workpiece or parts of it opposite to the direction of feed in the course of sawing.

Riving knife

Protection against workpiece kick-backs and unintentional contact with the rising gear rim.

Fig. 4-2 Force-guided riving knife

Definitions

5

5.1

Transport, siting and installation

Transport

When transporting the sliding table saw by elevating truck or fork lift truck (forks only with unchangeable length), only lift the machine up slightly and secure it against tipping!

Packaging

The type of packaging depends on the type of transport. Unless otherwise contractually agreed, the packaging corresponds to the HPE guidelines established by Bundesverband Holzmittel, Paletten, Exportverpackungen e.V. (the

German Association for Wooden Materials, Pellets, Export Packaging) and the

VDMA.Observe the symbols on the outside of the packaging!

Degree of dismantling

The degree of dismantling of the sliding table saw depends on the transport conditions and the options supplied with the machine.The sliding table is always shipped dismantled into several installation assemblies.

Sensitivity

Particular care must be taken when transporting the sliding table saw in order to avoid damage from force or poor loading and unloading.Knocks and condensation due to extreme temperature fluctuations must be avoided during transport.

Intermediate storage

If the sliding table saw or its assemblies are not installed immediately after delivery, make sure that they are stored in a protected location.They must be correctly covered to prevent any ingress of dust or moisture.Bare, non-surfacetreated parts of the sliding table saw are protected with a conserving agent which will protect them for approx. 1 year. Reconservation is necessary if storage is to last longer than this period.

Transport, siting and installation

5.2 Safety measures before use/installation

Installation site

No special foundations are required at the installation site for the sliding table saw. The floor must have a load bearing strength suitable for the machine weight and should be flat and level.

Select an installation site that provides enough clearance around the sliding table saw, allowing for the space requirements shown in the figure and the size of the workpieces to be cut. In addition, observe the safety clearances to parts of the building and other machines in order to eliminate the risk of crushing the operator or other personnel.

Fig. 5-1 Foundation plan

Transport, siting and installation

Danger!

Danger of crushing!

• For operation with the max. workpiece weight, secure the machine against tilting!

• Ensure that there is sufficient safety clearance from building parts and other machines!

Transport, siting and installation

Fig. 5-2 Space requirement

Key

Dimension A:

Manual adjustment PA: Cutting width + 280 mm

Motor-driven adjustment PA: Cutting width + 3600 mm

Dimension B: Sliding table length + 360 mm

Dimension C: Sliding table length + 290 mm; sliding table length + 30 mm with

TSD

Dimension D:

Crosscut fence: 1890 - max. 3420 mm

Crosscut mitre fence and PQS: 1960 - max.3690 mm

CNC crosscut fence UNO/DUO: 2200 - max.3670 mm

Transport, siting and installation

Fixing

A fixing element is provided on the side of the machine frame to ensure the machine stays in position. Once the sliding table saw has been set up, loosen the screws and lower the fixing down to the floor. Then retighten the two screws.

Transport, siting and installation

5.3 Installation

5.3.1 Telescopic tube for swinging arm

Fig. 5-3 Installing the telescopic tube

[1] Undo the cheese head screw

[2] Push in the telescopic tube from the front through the housing for the swinging arm

[3] Insert and tighten the cheese head screw

Transport, siting and installation

Fig. 5-4 Installing the telescopic tube, 4th axis

5.3.2 Main table length extension

Fig. 5-5 Installing the main table length extension

[1] Guide the bolts of the table length extension into the front holes of the main table.

[2] Loosely secure to the main table with two M10 nuts and U-shaped washers

[3] Place the main table length extension on the eccentrics.

[4] Tighten the M10 nuts.

[5] If necessary, correct the alignment and flushness by readjusting the eccentrics and the support screws.

For table length extensions with floor support:

Transport, siting and installation

5.3.3 Rip fence

Fig. 5-6 Installing the main table width extension

[1] Guide the bolts of the main table width extension into the front holes in the table, and place the extension on the eccentrics

[2] Loosely secure to the main table with two M10 nuts and U-shaped washers

[3] Tighten the M10 nuts.

[4] If necessary, correct the alignment and flushness by readjusting the eccentrics and the support screws.

Fig. 5-7 Installing the measuring bar

[1] Fit the measuring bar easily with M6x30 countersunk screws (1)

[2] Knock a 6x45 clamping pin (2) through

[3] Tighten the countersunk screws(1)

Transport, siting and installation

5.3.4 Cross-slide and crosscut fence

Cross-slide

The cross-slide must be attached to every point of the exterior round bar of the sliding table, and must be clamped.

Carry out installation as follows:

- Place the supporting pipe of the cross-slide on the bolt of the telescopic tube

- tilt the cross slide to the sliding table, hook it in and clamp it using the eccentric lever; for the operation of the eccentric lever, refer to the following pages.

[1] Support pipe

[2] Eccentric clamping lever

[3] Workpiece support

[4] Crosscut fence

[5] Crosscut fence clamping

[6] Extendable crosscut fence extension

[7] Extendable cross-slide width extension (option)

Fig. 5-8 Installing the cross-slide

Transport, siting and installation

Description of the cross-slide clamping mechanism WA/WGA/CNC crosscut fence UNO

Fig. 5-9 Clamping lever

[1] Clamping lever

[2] Safety locking mechanism

[3] Stop, safety locking mechanism for displacing the cross-slide

[4] Drill hole, safety locking mechanism for removing the cross-slide

To push the cross-slide to other positions on the sliding table, undo the clamping lever [1] up to the stop of the safety locking mechanism. It is now possible to displace the cross-slide without a risk of the cross-slide falling down.

To remove the cross-slide, pull out the safety locking mechanism and push up the clamping lever. The safety mechanism engages in the hole [4]. The crossslide can now be removed completely.

When assembling the cross-slide, first hook it in, pull out the safety locking mechanism, push the clamping lever all the way to the fixed stop. Release the safety locking mechanism.

Transport, siting and installation

Description of the cross-slide clamping mechanism CNC crosscut fence

Fig. 5-10 Cross-slide clamping, CNC crosscut fence DUO

[1] Eccentric clamping lever

[2] Safety locking mechanism

To push the cross-slide to other positions on the sliding table, undo the clamping lever [1]. It is now possible to displace the cross-slide without a risk of the cross-slide falling down.

To remove the cross-slide, pull out the safety locking mechanisms and turn them. The safety locking mechanisms engage. The cross-slide can now be removed completely.

When assembling the cross-slide, first hook it in and push the clamping lever all the way to the fixed stop. Undo the safety locking mechanism and turn to engage.

Transport, siting and installation

Crosscut fence, 90° only

Fig. 5-11 Installing the 90° crosscut fence

Place the crosscut fence on the cross-slide such that the clamping bolts [1] can be inserted in the grooves [2]

Tighten the clamping bolts [1], positioning is carried out by means of the tapered surfaces

Changing the 90° crosscut fence

Undo the clamping bolts [1]

Move the crosscut fence to a new position; ensure that the clamping bolts are inserted into the grooves

Tighten the clamping bolts, positioning is carried out by means of the tapered surfaces

Warning!

In the case of the "tilting to both sides" option, only use the crosscut fences supplied with this machine!

Transport, siting and installation

Crosscut-mitre fence

Fig. 5-12 Crosscut-mitre fence operating elements

[1] Clamping lever 90° position

[2] Indexing bolt for angle measurement

[3] Clamping pivot point

Installing the standard crosscut-mitre fence / with DIGIT L + LD:

• Place the crosscut-mitre fence on the rear fence surface

• Push the ball bearing over the groove in the sliding table

• Unscrew the handle of the degree scale clamping

• Carefully turn the crosscut-mitre fence by 90° so that the ball bearing can be inserted in the groove of the sliding table and the threaded bolt of the clamping degree scale in the groove of the profile

• Fasten the handle of the clamping degree scale

Transport, siting and installation

[1] Clamping degree scale

[2] Clamping pivot point

[3] Ball bearing

Fig. 5-13 Installing the crosscut-mitre fence

Transport, siting and installation

90° clamping

[1] Support roller

[2] Clamping lever

[3] 90° stop

[4] Pressure piece on the clamping lever

[5] Guide groove

Fig. 5-14 90° clamping

Transport, siting and installation

[1] Clamping screw, telescopic extension

[2] Clamping piece, 90° position

[3] Guide pin

Fig. 5-15 Crosscut-mitre fence left-hand side

Transport, siting and installation

Crosscut-mitre fence WGA_LD

Crosscut-mitre fence with digital angle and length measurement

Fig. 5-16 WGA_LD

[1]

[2] Lower the crosscut-mitre fence so that the bolt enters the guide carriage hole

[3] Turn in clamping screw 1 loosely

Transport, siting and installation

Operating elements:

[1] Telescopic extension

[2] Clamping, telescopic extension

[3] 90° stop

[4] Guide pin, 90° position

[5] Clamping degree scale

[6] Clamping pivot point

[7] Guide roller, sliding table

[8] Clamping lever, 90° position

[9] Indexing bolt, angle measurement

Fig. 5-17 WGA_LD

Transport, siting and installation

[1] Support roller

[2] Clamping lever

[3] 90° stop

[4] Pressure piece on the clamping lever

[5] Guide groove

Fig. 5-18 90° clamping

Transport, siting and installation

[1] Clamping screw, telescopic extension

[2] Clamping piece, 90° position

[3] Guide pin

Fig. 5-19 WGA_LD, LH side

Transport, siting and installation

CNC crosscut fence

Operating elements, CNC crosscut fence UNO

[1] Stop fence

[2] Axis drive

[3] Axis extension

[4] 90° stop

[5] Clamping screws

[6] Indexing bolt, extension

[7] Clamping screw, extension

Fig. 5-20 CNC crosscut fence DUO

Transport, siting and installation

Extension:

Fig. 5-21 Extension, CNC crosscut fence UNO

[1] 1000 mm extension piece

Installing the extension:

• Insert the extension into the guide until the indexing bolt engages

• Tighten the clamping screw.

• When using the second throw-over stop, the adjustable dimension increases by 1000 mm

[1] Locking hole, extension

[2] Indexing bolt

[3] Clamping, extension

Transport, siting and installation

Fig. 5-22 Extension installation

5.3.5 Sliding table

Fig. 5-23 Bottom carriage stop

[1] Place the bottom carriage on the machine frame and push against the stop screws.

[2] Screw on the bottom carriage using the outer fixing screws.

[3] Only tighten the middle fixing screw loosely.

Fig. 5-24 Installing the middle carriage

[1] Place the middle carriage on the bottom carriage so that the interlock is pointing to the right.

[2] Push the middle carriage to the right until the 1st double roller is still just resting on the round bars. If this is not observed, in the case of the TIP-SERVO-DRIVE the end position sensors could be destroyed when the top carriage is pushed on!

Transport, siting and installation

Fig. 5-25 Installing the top carriage

[1] Carefully push on the top carriage making sure it is not skewed, watch the e-chain.

[2] Carefully push the guide rails onto the double rollers.

[3] Push the top carriage towards the left, all the way to the stop.

Fig. 5-26 Back stop

[1] Fit the back stop

Transport, siting and installation

[1] Tighten the central fixing screw.

[2] Check that the sub-rollers are correctly adjusted.

Fig. 5-27 Central fixing

Fig. 5-28 Bracket on the bottom carriage

[1] Fix the bracket to the bottom carriage with 3 screws.

Transport, siting and installation

Fig. 5-29 Bracket on the bottom carriage

Fig. 5-30 Position of e-chain

[1] Place the bottom e-chain on the bracket on the bottom carriage.

[2] Run the cable into the machine frame through the opening in the bottom carriage.

Transport, siting and installation

Fig. 5-31 Fastening the e-chain

[1] Screw the first link of the e-chain onto the bracket using 2 screws.

Fig. 5-32 Switch cabinet

[1] Connect the plug to the switch cabinet.

[2] Tighten the cap nut.

Warning!

The connectors have 3 and 5 poles.

Ensure you plug the 3-pole connector into the 3-pole socket, otherwise the connector will be destroyed!

Transport, siting and installation

[1] Remove all the packing tape.

[2] Screw on the cover profile.

Fig. 5-33 Fastening the e-chain / cable

Transport, siting and installation

5.3.6 Electrical connection

Warning!

Dangerous electric voltage!

All work on the electrical equipment, including connection to the mains supply, may only be performed by a qualified electrician.

Disconnect the machine from the mains supply before working on the electrical equipment.

• After connecting the supply line, check the rotationaldirection of the main saw motor by briefly starting up and, if necessary, correct it by interchanging the two outer conductors in the mains connection box.

• Pay attention to the rotational direction arrow on the saw blade cover!

• As far as machines with a VARIO drive are concerned, check the rotational direction of the scoring saw motor, because the frequency converter ensures that the directional rotation of the main saw motor is always correct, regardless of the phase position.

• Only connect or disconnect plug-in connectors when the main switch has been turned off or disconnected!

Fig. 5-34 Mains connection

Transport, siting and installation

The mains connection is in the RH switch cabinet on the right-hand side. The terminals for the supply line are marked L1, L2, L3, N and PE, the terminalsfor the potential-free contact with the control system of an extraction system are marked POT. The supply line cross-section and the fuses to be fitted by the user depend on the installed motor rating.

If the machine is connected via a flexible supply line, a rubber-sheathed cable

(wire marking H07RN-F) must be used. Required plug-in device: Round connector in accordance with DIN 49463.

Transport, siting and installation

Fig. 5-35 Circuit diagram

Transport, siting and installation

S 2

S 3

S 1

E 1

F 1 - F 2

F 4 - F 6

F 7 - F 9

F 10 - F11

M 1

M 2

MR 1

S 1

Designation

GL 1

Q 1

S 26

F 12 - F 14

K 1 M - K 5 M

K 5 E

K 14 M

Designation

Rectifier

Main switch

LASER option switch

Main saw motor

Scoring saw motor

Temperature monitor for main saw motor

Sliding table safety switch

EMERGENCY STOP button

Temperature monitor for scoring saw motor

Machine door/cover plate safety switch

Multifunction module

Control fuses (primary)

Scorer motor (option)

Control fuses (secondary)

SPRAY / LASER control fuse (option)

CEKON (option)

Motor contactors

Supply voltage contactor for adjustment drives

CEKON contactor (option)

Transport, siting and installation

5.3.7 Connecting the extraction system (customer side!)

Fig. 5-36 Bottom extraction connection

Total extraction system connection D = 140 mm

Vmin = 1150 m

/h at 20 m/s

Bottom extraction connection D =120 mm

The hoses and Y-tube are not supplied as standard with the machine.

The dust emission values – measured in accordance with the “Principles for

Testing Dust Emission (Workplace-Related Dust Concentration) from Woodworking Machines” issued by the German trade association's technical committee for wood – are under 2 mg/m

. When the machine is attached to a correctly functioning extraction system with an air speed of at least 20 m/s (measured at the connection socket) you can assume it is and will stay compliant with the technical reference concentration (TRK) value for wood dust that is in force in

Germany. For perfect and safe operation, the machine must be connected to the extraction system at the extraction sockets (rear of machine frame and protection hood support). The minimum air speed at the extraction sockets must be 20 m/s. The 80 mm extraction hose from the hood to the connection socket on the support tube is not supplied as standard. The extraction socket and hoses are not supplied as standard!

Make sure that the extraction system is switched on together with the machine.

For this, you can use the existing potential-free contact (POT - refer to circuit diagram) or a current transformer installed in the supply line. When using spray device (SPRAY), make sure that you use a suitable moisture extraction system in order to avoid faults.

Transport, siting and installation

5.4 Basic machine setting

5.4.1 Sub rollers on the sliding table

Basic machine setting is carried out at our factory during final assembly. It may be necessary to correct the machine's basic settings due to removal of various assembly groups, and transport and installation on site. The machine elements to be checked are described below.

Check the sub-rollers

Fig. 5-37 Sub-rollers

The sub-rollers must run smoothly against the start slope at the start and end of the raceway. They should be set so that they can be held by hand with noticeable force and that they slip while the sliding table is moved.

Setting of the sub-rollers

Fig. 5-38 Sub-rollers

Transport, siting and installation

The sub-rollers have eccentric bearings and can be adjusted.

The sub-rollers are set so that they can be held by hand with noticeable force and that they slip while the sliding table is moved. Adjusting them too tightly will result in stiff movement of the sliding table, and can lead to unwanted cutting results.

Transport, siting and installation

5.4.2 Main table

Checking the main table

Place a rip fence straight edge on the sliding table, and move the table into the middle position. Move the sliding table forward and backward; the main table must be approx. 1/10 mm lower.

Adjusting the main table

Release the lock nuts (1) of the 4 stay-bolts, adjust the main table, and tighten the lock nuts.

Transport, siting and installation

5.4.3 Swinging arm

Check

Rest the swinging arm against the machine frame, fully extend the telescopic tube of the swinging arm and check dimensions A and B. Set dimensions A and

B with a tolerance of 0.5 mm; if necessary correct the setting with EX 1 and EX

The dimension between the bottom edge of the crosscut fence profile and the top edge of the top carriage profile (see fig. 2) is a feature for the tolerance of the swivel arm setting. The dimension must not exceed the cut length possible with the cross-slide between 0.1 and 0.9 mm (check with feeler gauge).

Transport, siting and installation

5.4.4 Cross-slide height

Check

Fig. 5-39 Checking the cross-slide height

Push a piece of cardboard of approx. 0.5 mm thickness between the crosscut fence and the sliding table; it must be possible to move the cardboard freely in every position. The crosscut fence must be parallel to the surface of the sliding table!

Setting

Fig. 5-40 Adjusting the cross-slide height

Transport, siting and installation

Adjust the height of the swinging arm bolt and fix it with a lock nut. Check that the swinging arm is parallel if the gap changes in accordance with the position of the sliding table!

Transport, siting and installation

5.4.5 Setting free cut

Sliding table

Definition:

The sliding table, the saw blade and the rip fence are not parallel to each other, so the crosscut fence and the rip fence do not form a 90° angle. The sliding table runs to the left out of the direction, by a fraction of a millimetre. in the same way, the rip fence points slightly to the right so that a gap is created behind the saw blade.

The rising saw blade tooth must not recut, but free cut should be set as small as possible. When using a scorer, make sure that both free cuts are of an equal size.

Check:

Set the saw blade to maximum cutting height, and cut off an approx.100 mm piece from an MDF test piece at the cross-cut fence. The noise difference between the cutting and non-cutting teeth lets you identify whether the sliding table is set correctly. When the rising teeth pass, only a slight fluttering should be heard compared to the noise of the cutting teeth.

Setting:

Release the sliding table mounting components at both ends and in the centre

(if installed). Release the lock nuts of the stop screws. Adjust them as required and fix them with lock nuts again. Then push the sliding table against the stop screws and re-tighten all fastening screws.

Rip fence

Check:

Set the saw blade to maximum cutting height, and cut off a test piece of about

300 x 450 mm (if possible MDF) at the rip fence. The sound of the rising teeth must be the same as when cutting free on the left, with the sliding table correctly set.

Cross-check:

Move the rip fence approx. 0.5 mm closer to the saw blade, push the riving knife with the workpiece slightly to the side and cut in backward approx. 50 – 80 mm. Pull out again in the normal direction, turn it once around the cross-axis, and cut in approx. 20 mm deep in the normal way. The difference between these two cuts should be almost invisible but easily felt.

When using a scorer, make sure that both free cuts are set as equal as possible!

Transport, siting and installation

Setting: Manually adjustable rip fence

Fig. 5-41 Setting free cuts, standard rip fence

• Undo the nuts on the bolts connecting the round bar and the table width extension

• The degree of free cut on the rip fence can be altered by adjusting the middle lock nuts

• Tighten the nuts on the bolts connecting the round bar and the table width extension

Setting: Electromotive rip fence

• Release clamping screws 1

• Set the free cut by adjusting setscrews 2

• Tighten clamping screws 1

Fig. 5-42 Free cut setting, electromotive PA

Transport, siting and installation

5.4.6 Angle cut

Checking the angle cut

Before checking the angle cut, check the settings of the sliding table and of the swinging arm, and correct them if necessary.

Carry out the check as follows:

Fig. 5-43 Angle cut

As the tool, use a sharp saw blade, D = 350 mm/ 3.5/2.5/72 teeth alternate bevel at n = 5000 rpm. Take a 1000 x 1000 mm chipboard or MDF board, minimum board thickness 19 mm. Perform 5 cuts (see fig.), laying the last cut side at the crosscut fence for the next cut (turn the board counterclockwise). For the

5th cut, cut off a strip with a width of approx. 10 mm. Measure the thickness at both ends of the strip with a vernier caliper. The difference between the two dimensions divided by 4 gives the angular error per metre cut length.

Check:

The angle cut must be checked at a minimum of 2 different positions on the cross-slide of the sliding table.

Factory setting:

The cross-slide is clamped to positions of approx. 300 mm and 1300 mm from the sliding table end. In these two positions, the angle cut is checked and adjusted as described above. Ensure that the setting does not exceed the maximum permissible tolerance of < 0.2 mm (for the 5th cut (dimension 1 - dimension 2)).

Transport, siting and installation

5.4.7 0° setting of the saw blade

Check:

• Set the tilt adjustment to 0°.

• Position 2 strips (approx. 100 mm wide) vertically in front of the crosscut fence, cut in this position and butt the cut surfaces against each other.

• If the setting is correct, the cut surfaces should be parallel, i.e. no gap can be seen between the cut surfaces.

Fig. 5-44 Cutting a test piece

Setting:

Recalibrate the machine if a gap is detectable!

Fig. 5-45 Checking the 0° -setting

Transport, siting and installation

6 Operating

6.1 Working safely with the dimension saw

6.1.1 Cross-slide/crosscut fence

Fig. 6-1 Cutting boards

The crosscut fence can be installed at two positions on the cross-slide.

Position 1: Cutting boards

The operator presses the workpiece against the fence in the cutting direction.

Operating

Fig. 6-2 Cutting solid wood

Position 2: Cutting solid wood and boards up to 600 mm wide

The operator pulls the workpiece along the fence against the cutting direction.

Function description of the crosscut-mitre fence

• The crosscut-mitre fence can be swung by 49° (angle indicated on scale), plus angle-dependent adjustable length compensation via a scale.

• Ball bearings run in the sliding table groove, preventing the stop fence coming into the cutting plane when swung

• Clamping of the stop profile at the pivot and on the degree scale

• Additional clamping at the 90° position

• Movable, fixable C profile as an additional workpiece support

Operating elements

Fig. 6-3 Position of clamping screws

[1] Clamping screw 1

[2] Clamping screw 2

Adjusting the angle

• Release the clamping screws

• Set the crosscut-mitre fence to the desired angle

• Carry out length compensation

• Tighten clamping screw 1

• Set and tighten clamping screw 2

Operating

Length compensation

Fig. 6-4 Length compensation scale

By shifting the crosscut-mitre fence, the length dimension can be adjusted for the set angle.

Changing the crosscut-mitre fence

• Release the clamping screw and clamping lever

• Push the crosscut-mitre fence to the 2nd position

• Push the guide piece of the eccentric clamping system into the pivot groove as far as it will go and clamp it

• Tighten the clamping screws

Note!

When dimensions need to be adjusted with the stop bar, make sure that the flip stop is against the fence of the extension!

6.1.2 Rip fence

Fig. 6-5 Position of the clamping screw

For cutting parallel, the rip fence is pushed up to the required dimension. The set dimension is read off from the edge of the aluminium profile.

The dimension scale can be adjusted to the individual tool thickness after releasing the knurled screw.

Stop fences

Fig. 6-6 Upright position of the stop fence

Operating

The stop fence of the rip fence can be adjusted in the cutting direction and to the profile height. Clamp it in the required position with the top eccentric lever.

For crosscutting short workpieces and for recessing or other work cycles during which offcuts can become jammed between the stop and the saw blade, the stop fence is moved forward until its rear end is in front of the saw blade.

Fig. 6-7 Flat position of the stop fence

The stop fence is moved into the flat position when cutting flat and narrow workpieces. This means there is more space for workpiece guidance and the fence can be moved closer to the saw blade, in particular when the saw blade is tilted, without hitting the protection hood.

Warning!

Danger of injury!

When cutting widths of less than 120 mm, make sure that the material is fed with a push stick and that the stop fence is laid flat.

6.1.3 Double roller carriage

Sliding table operating elements:

Fig. 6-8 Sliding table operating elements, manual

Fig. 6-9 Sliding table operating elements, TIP SERVO

Operating

Fig. 6-10 Sliding table operating elements, vacuum suction cups

The vacuum suction cups are exclusively operated by means of the operating panel.

6.2 Working examples

General information

The Altendorf sliding table saw is a universal machine that can be used for various saw cuts. However, the machine must be set up appropriately.

Tools

First, make sure that you only use saws in perfect condition, that the riving knife is correctly set and that the top protection hood is lowered close above the workpiece to be cut. The latter is also particularly important for ensuring perfect functioning of the top extraction system.

Rotational speed

Note!

Make sure that the correct rotational speed is set and, after the machine has been switched on, do not start pushing the workpiece forward until the saw blade has reached its full rotational speed.

Position of the hands

Lay your hands flat on the workpiece with fingers and thumbs close together, and with sufficient safety clearance from the saw blade.

For further information about safe working, refer to the following description of the individual work steps.

Operating

Edge cutting (trimming)

Fig. 6-11 Edge cutting

Tool: Circular saw blade for longitudinal cuts

Work cycle: Fit the clamping shoe on the sliding table. Lay the workpiece with the hollow side down, and press underneath the clamping shoe. Push the workpiece forward by applying pressure with the ball of your right hand on the workpiece edge. Place your hands with sufficient safety clearance from the tool.

Longitudinal cutting of narrow workpieces

Fig. 6-12 Longitudinal cutting

Workpiece width < 120 mm

Tool: Circular saw blade for longitudinal cuts

Work cycle: Set the rip fence to the required cutting width. Lower the top protection hood according to the workpiece height. Push the workpiece (aligned along the fence) and sliding table forward, using the push stick in the vicinity of the saw blade, and push the parted workpiece beyond the riving knife. Use the push stick from the very beginning when cutting short workpieces.

Cutting strips

Tool: Circular saw blade for fine cuts

Fig. 6-13 Cutting strips

Operating

Work cycle: Set the aluminium straight edge of the rip fence to the low guide surface. Lay the workpiece on the sliding table and press against the rip fence with your left hand. Push the workpiece forward with the sliding table; use the push stick in the vicinity of the saw blade to push the strip beyond the riving knife.

Crosscutting wide workpieces

Fig. 6-14 Crosscutting

Tool: Circular saw blade for crosscuts

Work cycle: Lay the workpiece against the crosscut fence; when pushing forward, push firmly against the fence with your left hand. When using the throwover stop, raise the stop and remove the workpiece from the saw blade before pulling back after the cut, or remove the workpiece behind the rising gear rim.

Concealed cutting, rebating

Fig. 6-15 Concealed cutting

Tool: Circular saw blade for fine cuts

Work cycle: When rebating, select the cutting sequence so that the cut-out strip is produced on the side of the blade opposite the fence. Lower the protection hood onto the workpiece and ensure good workpiece guidance (left hand presses the workpiece against the rip fence).

Concealed cutting, grooves

Fig. 6-16 Grooves

Tool: Grooving tool permitted for manual feeding (max. width 20 mm)

Operating

Operating i

Work cycle: Close the table opening with a table strip matched to the grooving tool. Set the tool to the required groove depth. Leave the riving knife in as a rear tool cover. When pushing forward, firmly press the workpiece onto the table (otherwise danger of unintentional insert operation.).

Note!

Always use the crosscut fence when cross-grooving narrow workpieces.

Crosscutting against the rip fence

Fig. 6-17 Crosscutting

Lay the material against the crosscut fence of the cross-slide. Set the required dimension at the rip fence, pulling back the stop fence to the front of the saw blade after releasing the clamping, and guide the workpiece with the sliding table. When the stop fence is pulled back, the workpiece cannot jam between the saw blade and fence.

Crosscutting short and narrow workpieces

Fig. 6-18 Crosscutting

Tool: Circular saw blade for fine cuts

Work cycle: Adjust the deflector wedge featuring a magnet (not part of the scope of supply) such that the workpiece cuts cannot touch the rising section of the saw blade. Only feed workpieces using the crosscut fence. Never remove off-cuts by hand from the vicinity of the tool.

Operating

Dividing large boards

Fig. 6-19 Dividing

For this work cycle, the dimension can be set both on the rip fence and on the crosscut fence. If several pieces of the same size are to be cut from a large board, it is best to first cut off parallel strips at the rip fence and then cut them to the required dimension. However, if the workpieces exceed the cutting width of the machine, the dimension is set at the machine's crosscut fence.

Cutting with a negative cutting angle

100

Operating

Fig. 6-20 Cutting with a negative angle

For this work cycle only the crosscut fence or crosscut-mitre fence is used.

Do not use a DUPLEX fence!

Do not use a clamping shoe as the saw blade is tilted above the sliding table for a negative cutting angle.

6.3 Machine operation

6.3.1 Main switch

Fig. 6-21 Main switch

The main switch is located on the outside of the RH switch cabinet.

Before turning on the saw drives, the main switch must be moved to setting I.

The machine control unit carries out a self-test, after which the available axes and their current values are displayed.

Grey/black main switch

The main switch does not have an EMERGENCY STOP function! When the machine is turned off with the main switch, the saw drives run down unbraked!

Red/yellow main switch

The main switch has an EMERGENCY STOP function! When the machine is turned off at the main switch, the main saw drive is braked.

101

Operating

6.3.2 Switching the saw drives on and off

Fig. 6-22 Switches for saw drives

Warning!

• Before switching on the machine, make sure that all protective devices required for the respective work cycle are attached and operative. In addition, check that the saw blades are correctly fitted and that there are no workpieces or other objects in their vicinity. Check whether the correct rotational speed has been preselected to match the saw blade and the work cycle to be performed. Check that the circular saw blade is running in the correct direction by briefly switching on.

• Make sure that the extraction system switches on at the same time as the saw drives.

Press the white push button I with the main saw symbol in the operating panel to start the main saw drive. After switching on the main saw, this button is lit.

The scoring saw can only be started when the main saw has reached its operating speed. To do so, press the white push button I with the symbol of the scoring saw. This button lights up when the scoring saw has been switched on.

To switch off, press the black button marked “0”.

102

Operating

Fig. 6-23 Switches for sliding table saw drives

The drives can also be turned on and off with the switches on the sliding table

(option).

In addition, the machine can be switched off with one of the EMERGENCY

STOP buttons. However, this possibility should only be used in case of an emergency.

103

Operating

6.3.3 Setting the speed

Three rotational speeds can be set for the main saw drive by moving over the

V-ribbed belt:

• 3000 / 4000 / 5000 rpm

Changing the rotational speed

104

Operating

Fig. 6-24 Changing the rotational speed

[1] Switch off the drive.

[2] Open the machine door.

[3] Turn screw 1 counterclockwise until it engages.

[4] Set belt guide 2 to the required rotational speed.

[5] Place the V-ribbed belt so that it runs in the recess of the belt guide and into the vertical opposite grooves of the belt pulley.

[6] Turn screw 1 clockwise.

The belt tension is automatically set when the screw is turned back!

A rotational speed of only 3000 rpm is permissible with a saw blade diameter of D = 550 mm (only for machines without scoring unit), for VARIO

3500 rpm.

Optimum position for changing speed/belt: Tilt saw unit to 25°!

6.3.4 Fitting the main saw blade

AKE clamping system

Warning!

The following points must always be observed:

Non-adherence may lead to severe injuries!

• Do not fit any saw blades that are cracked or damaged in any way.

• Only fit saw blades with a diameter between 250 and 550 mm.

Machines with a scoring unit have a maximum saw blade diameter of only 500 mm!

• The maximum rotational speed n max stated on the tool must not be exceeded.

Fig. 6-25 Front flange

Fig. 6-26 Lock on the middle carriage

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Switch off the drive.

Set the saw blade to the maximum cutting height and tilt to 0°.

Turn off the main switch.

Move the top carriage to the middle of the saw shaft, and unlock the lock at the saw blade centre by pressing the knob on the middle carriage.

Move the top carriage to the end position in the cutting direction.

Raise the red cover plate.

Use the wrench to release the screw in the expansion-head screw.

Undo the expansion-head screw by turning it counterclockwise with the flange.

Before fitting the new saw blade, remove any adhering chips and dust from both flanges.

10. Place the saw blade and front flange onto the saw shaft, turn in the expansion-head screw by hand and tighten it with the wrench.

11. Check the riving knife for strength and distance from the saw blade.

12. Close the red protective cover and perform a short test run to see whether the saw blade is running freely. Do this by lowering the top protection hood down to the table so that the saw blade is completely covered.

Warning!

Check that saw blade clamping system is tight before operating the machine!

Fitting a milling tool

In order to use a milling tool (max. cutting width 20mm), first proceed as described in point 1-8 in the previous section.

Then proceed as follows:

Remove the riving knife, cushioning disc and screws in the centre table strip

Fig. 6-27 See point 1

Remove the front part of the centre table strip

Place the milling cutter and front flange onto the saw shaft, turn in the expansion-head screw by hand and tighten it with the wrench.

Retract the riving knife block completely and tighten the clamping screw of the riving knife holding fixture

Close the red protective cover and perform a short test run to see whether the milling cutter is running freely. Do this by lowering the top protection hood down to the table so that the milling cutter is completely covered.

Warning!

When returning to normal processing with a saw blade, adhere to the following:

Non-adherence to these points may lead to severe injuries of the operator!

• Reinsert the disassembled centre table strip; only use original brass screws for fastening

• Reinstall the cushioning disc

• Reinstall and correctly adjust the riving knife

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Warning!

After changing a saw blade, always check that the riving knife is correctly set.

Non-adherence to these points may lead to severe injuries of the operator!

• Select the riving knife according to the saw blade size and main blade thickness

• Ensure that the riving knife thickness is min. 0.2 mm larger than the main blade thickness

• The distance of the riving knife from the gear rim must be between 3 mm and 8 mm.

• The highest point of the riving knife must be set to between 0 and -2 mm beneath the topmost tooth.

• The riving knife must be at least 0.2 mm thicker than the main saw blade.

Fig. 6-28 Adjusting the riving knife

6.3.5 Saw blade recommendation

Warning!

Please note that only main saw blades with side holes can be fitted.

This is necessary to prevent loosening of the saw blade mounting in the course of braking!

• Do not use high-speed steel (HSS) saw blades!

• The tools require a hole diameter of 30 mm and carrier holes of 10 mm diameter on a pitch circle diameter of 60 mm!

• The scoring blades have different diameters and are described in the respective chapters of this manual.

Choosing the correct saw blade in accordance with the material to be cut and its thickness, alongside the correct cutting speed, is very important for a clean cut and low stress for the operator. For a selection of saw blades for ALTEN-

DORF sliding table saws, refer to the tool manufacturers' documentation. As some of the stated cutting speeds cover large ranges, it is indispensable to empirically determine the best speed for optimum cutting results!

Cutting speed in m/sec. for the adjustable rotational speeds and saw blade diameters:

Diameter

[mm]

250

300

350

400

450

500

550

3000 rpm

4000 rpm

106

115

5000 rpm

105

118

132

144

Tbl. 6-1 Cutting speed

The areas marked grey may not be adjusted!

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6.3.6 Table locking

The sliding table interlock can lock the sliding table in any position, so that the workpiece can be pushed against the crosscut fence without the easy-running sliding table being set in motion unintentionally. It is actuated by means of a handle at the end of the top carriage.

Fig. 6-29 Sliding table unlocked

Fig. 6-30 Sliding table locked

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6.4 Screen controls ProDrive

F1

F2

F3

F4

F5

Fig. 6-31 Screen controls ProDrive

Actuate the green buttons to select the required setting; the symbol in question will then be shown in inverse format. Enter the dimensions via the numeric keypad and press the yellow START button to carry out positioning. The operation can be interrupted at any time by pressing the STOP button. Positioning is completed when the dimension display switches over from inverse to normal format with the numbers in green.

Note:

It is also possible to change the dimension of several axes and then adjust them together by pressing the START button.

Infinitely variable fine adjustment is possible by pressing the Plus or Minus button. Adjustment takes place in creep speed mode. Pressing the button for more than 3 seconds switches adjustment to rapid speed mode. Briefly touching the Plus or Minus button causes adjustment of 0.1 mm (0.1°).

Attention!

Safety area

• For cutting widths that are smaller than 180 mm the rip fence is in the safety area. The axes can possibly only be changed in inching mode, i.e. adjustment only takes place while the START button is pressed.

Inching mode is indicated by a flashing START symbol at the top left of the display as well as by an illuminated Start button.

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6.4.1 Function button block

[1] Back to previous dimension

[2] Program call-up

[3] Vacuum carriage (option)

[4] Delete input

[5] Menu call-up

[6] Calibration

[7] Rotational speed adjustment VARIO (option)

[8] Scorer (option)

Fig. 6-32 Function keypad

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6.4.2 Height adjustment

Fig. 6-33 Height adjustment

• Press the axis selection button for the cutting height; the symbol in the cutting height display is shown in inverse format.

• Enter the required dimension via the numeric keypad; the new dimension is shown in inverse format.

• Press the START button to carry out positioning.

Calibration

• Press the axis selection button for the cutting height.

• Press the Cal button for longer than 1 second; CAL will appear on the display.

• Enter the measured cutting height via the numeric keypad.

• Press the Cal button; the new cutting height will be shown on the display.

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6.4.3 Tilt adjustment

Fig. 6-34 Tilt adjustment

Warning!

Always observe the following points prior to tilting the saw blade:

• Use the wide safety hood!

• Clear the main table of any workpieces in the tilting area.

• When cutting widths less than 180 mm, set the rip fence straight edge to the flat position.

• When the tilt has been adjusted, the cutting height that has been set is automatically set to its value. Collisions can occur if the above points are not followed!

• In the case of large cutting heights, the selected cutting height may be impossible to achieve with the entered tilt angle.

• Press the axis selection button for the tilt adjustment; the symbol in the cutting height display is shown in inverse format.

• Enter the required dimension via the numeric keypad; the new dimension is shown in red.

• Press the START button to carry out positioning.

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Calibration

• Press the axis selection button for tilt adjustment.

• Press the Cal button for longer than 1 second; CAL will appear on the display.

• Enter the measured tilt angle via the numeric keypad.

• Press the Cal button; the new tilt angle is shown on the display.

Fig. 6-35 Function button block

Fig. 6-36 Rip fence dimension correction

When the saw blade is tilted, the dimension of the rip fence may be changed by up to 1.5 mm. As soon as a dimension correction is necessary due to tilting, the correction dimension will be displayed in the third line from the top on the display. No value is shown on the display if no correction is necessary.

Note!

In the case of machines equipped with a rip fence with motorised adjustment, this dimension correction is automatically performed by the control system.

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6.4.4 Motor driven rip fence (option)

Fig. 6-37 Rip fence adjustment

• Press the axis selection button for the rip fence; the symbol for the rip fence is shown in inverse format.

• Enter the required dimension via the numeric keypad; the new dimension is shown in red.

• Press the START button to carry out positioning, see also the note about the safety area.

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Calibration

• Press the axis selection button for the rip fence.

• Press the Cal button for longer than 1 second; CAL will appear on the display.

• Enter the measured cutting width via the numeric keypad.

• Press the Cal button; the new cutting width is shown on the display.

Fig. 6-38 Function keypad

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6.4.5 Infinitely variable speed adjustment (option)

Fig. 6-39 Selection button for rotational speed adjustment

• Press the axis selection button for VARIO; the following mask appears:

Fig. 6-40 Selecting the rotational speed

[1] The saw blade diameter of the saw blade currently fitted and its maximum permitted speed are displayed.

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• Change the rotational speed in steps of 50 by pressing the + / - button, or enter the speed via the numeric keypad in units of five revolutions.

• Save the rotational speed that has been set by pressing the START button, or select another speed level.

Saw blade

∅

250 - 350 mm

400 mm

450 mm

500 - 550 mm

Permitted speeds

2000 - 6000 rpm

2000 - 5000 rpm

2000 - 4000 rpm

2000 - 3500 rpm

Tbl. 6-1 Permitted speeds

Note!

For safety reasons, the maximum rotational speed that can be set is restricted in accordance with the saw blade diameter. This means that it is not possible to set the machine's maximum rotational speed when it comes to larger saw blades.

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6.4.6 Scoring saw

Fig. 6-41 Selection button for scorer adjustment

• Press the axis selection button for the scorer; the following display appears:

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Fig. 6-42 Adjusting the scorer

[1] The cutting height of the scorer and the side position can now be defined with the aid of buttons F2 - F5.

[2] When this function is exited (F1 button), the scorer travels down if the motor is off.

Otherwise it moves down when the scorer motor is switched off, on returning from an EMERGENCY STOP, and when the machine is switched on. The height position that has been set is saved.

Side adjustment:

• Briefly touching the F4 / F5 buttons causes minimal adjustments of approx.

0.03 mm.

• Holding these buttons down causes bigger adjustments.

Height adjustment:

• Briefly touching the F2 / F3 buttons causes minimal adjustments.

• Holding these buttons down causes bigger adjustments.

• The height that has been set is saved when you exit the scorer function.

When the scorer motor is on, the scorer is in the top position. Otherwise it is moved up when the function is invoked.

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6.4.7 RAPIDO Plus scoring saw

RAPIDO Plus is a 3-axis scoring system with motorised adjustment of the cut-

ting height and the right and left-hand side of the scoring saw blade. All settings can be made while the machine is running, so they can be done very quickly.

Press the axis selection button for the scorer; the following display appears:

Fig. 6-43 Selection button for scorer adjustment

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Button 1 <> Back to previous page

Button 2 <> Cutting height adjustment

Button 3 <> Position of right saw blade side

Button 4 <> Position of left saw blade side

Button 5 <> Reference

Fig. 6-44 Adjusting the scorer

Note!

The positions given for the saw blade sides are guide figures only.

Adjustment:

• Press the + or - button to change the dimension.

• Enter the dimension on the numerical keypad and press the START button.

Calibrating the scoring saw

• Select the saw blade position to be calibrated with button 2, 3 or 4; the symbol of the selected position will be shown in inverse format.

• Press the Cal button on the function keypad for longer than 1 sec. CAL will appear on the screen for the selected position, with the current value in inverse format.

• Enter the value and press the Cal button; the entered value will be shown on the display.

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Setting the scoring saw blade

• Setting the cutting height

• Set the blade protrusion by pressing button 2.

• Set the position of the right saw blade side

• so that both cutting edges are congruent when a test cut is made.

• Enter + 0.05 so that the scorer cuts wider than the main saw blade.

• Set the position of the left saw blade side.

• Set the scoring blade to the thickness of the main saw blade.

• If a test cut is OK, increase the cutting width by + 0.05.

When you exit the menu, the electronics saves the last values set. When the scoring saw is switched on, the scoring blade is automatically moved to the previously set values. When the saw drives are switched off, the scoring blade is automatically moved to its lowest position.

If you select this menu item when the scoring saw is running, the scorer will not travel down to its lowest position when the saw drives are switched off!

Reference:

The reference is the 2nd way of storing all 3 scoring saw blade positions.

• Pressing the Reference button for more than 3 seconds saves the values that have been currently set.

• After adjustments have been made, the stored values can be set by pressing the Reference and START buttons.

6.4.8 CNC crosscut fence UNO

Fig. 6-45 CNC crosscut fence UNO

To adjust the crosscut fence, actuate the function key and enter a new value.

When you press the yellow START button, the dimension field changes colour.

The value is displayed in green once the position is reached.

If a manual rip fence is equipped, the correction values for the crosscut fence are displayed as a function of the tilt angle.

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6.4.9 Vacuum clamping in the sliding table

Fig. 6-46 Vacuum table

Actuate the remote control to cause the workpiece to be vacuum held or released. During vacuum holding, the button turns from grey to green.

Actuate the marked function key to access the vacuum table menu, where it is possible to configure the active suction cups.

Note!

If the option Vacuum clamping in the sliding table is selected, separate instructions are enclosed!

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6.4.10 Menu

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Fig. 6-47 Main menu

Pressing the function key Menu in the function keypad takes you to the main menu.

User menu

Fig. 6-48 User menu

When the function key User menu is pressed, the respective mask appears.

Fig. 6-49 Operational performance of the axes

When the function key Operational performance of the axes in the user menu is pressed, the respective mask appears.

Basic settings

Fig. 6-50 Basic settings

When the function key Basic setting is pressed in the user menu, the respective mask appears.

When the function key "Switch over to inches" is pressed, the unit of measurement is directly changed to inches.

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Fig. 6-51 Selecting a language

When the function key Select language is pressed, the respective mask appears. Use the Down arrow button to display additional languages that can be selected.

Fig. 6-52 Technician level

When the function key Technician level is pressed in the user menu, the respective mask appears.

The technician level is password protected and is not required for operating the machine!

6.4.11 Programs function

Running programs

Press the "Prog" button on the function keypad. The following mask appears:

Fig. 6-53 Running programs

A program can be called up by entering the two-digit program number.

Button functions:

• Button 1 <> Back to previous page

• Button 2 <> Scroll up through programs

• Button 3 <> Scroll down through programs

• Button 4 <>

• Button 5 <> Change programs

Press the START button to position the selected program.

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Changing programs

Press button 5 in the "Run programs" function to call up the "Change programs" function.

Button functions:

• Button 1 <> Back to previous page

• Button 2 <> Up one line

• Button 3 <> Down one line

• Button 4 <> Delete program

• Button 5 <> Create program

Fig. 6-54 Changing programs

Creating programs

Press button 5 in the "Change programs" function to call up the "Create programs" function.

Fig. 6-55 Creating programs

Button functions:

• Button 1 <> Back to previous page

• Button 2 <> Next free program location

• Button 3 <> Next free program location

• Button 4 <>

• Button 5 <> Create program

Note!

Saving current axis positions

Hold down the Prog button on the function keypad for longer than 3 sec. to save the current axis positions to program location 20.

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6.5 Protection hood

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Fig. 6-56 Protection hood swung away

Swing away the protection hood as follows:

• Turn off the main switch and secure against turning on again

• Actuate the release lever

• Swing the protection hood away

Warning!

You may only work with the protection hood swung away in special cases and with increased caution, e.g. for bulky workpieces.

Fig. 6-57 Normal working position

[1] Unlocking/locking lever

Note!

After completing the work cycle, immediately swing the protection hood back into the normal working position and lock it with the lever.

Pull the lever forward until it noticeably engages.

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Changing the protection hood sections

Fig. 6-58 Swivel out the hood section

When changing between wide and narrow, it is not necessary to completely exchange the hood but only the respective hood section by means of a snap fit.

For exchanging the hood section, press the red pusher down and swivel out the hood section. Suspend the other hood section and swivel in until the snap fit engages.

Fig. 6-59 Large protection hood with wide hood section

Protection hood, machine tilting to both sides

Installing the wide protection hood, see photo and text on previous page.

For tilting in the negative range (-), the protection hood is pulled out after unlocking the lever at the rail guide.

Fig. 6-60 Lateral displacement, protection hood

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6.6 Optional modules

6.6.1 Scorer, tilting to one side

When processing boards coated on both faces, the scoring unit makes it possible to cut without breakouts on the underside of the board. The scorer cuts into the material from below approx. 1-2 mm; then the main saw blade cuts through it. Make sure that the scoring blade is exactly in line with the main blade and is set to the corresponding width. To achieve optimum cutting results, the scoring blade runs in the workpiece advance direction, i.e. the opposite direction to the main saw blade.

The scoring saw can only be started once the main saw has reached its operating speed (after approx. 5 sec.). It is started by pressing push-button I labelled with the scoring saw symbol on the panels.

Saw blades

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Fig. 6-61 Two-part scoring blade

We recommend using two-part scoring blades which can be set to the required blade thickness by inserting spacer discs. The cutting line of the scoring blade should be approx. 1/10 mm wider than the main saw blade, i.e., 5/100 mm to each side. In addition, the two scoring blades should have carrier pins and their thickness should be marked on the spacer discs.

The RAPIDO scoring tool facilitates and accelerates cutting width adjustment. Compared with two-part scoring blades, this represents a potential saving of up to 30 minutes since the cutting width can (without removing the saw blades) be adjusted infinitely to the cutting width of the main saw blade.

Fig. 6-62 RAPIDO scoring tool

Fitting the saw blade

The description for fitting the saw blade applies both to two-part scoring blades and to RAPIDO scoring tools.

Only use saw blades with a diameter of 120 mm and a hole diameter of 22 mm!

• Switch off the drives.

• Move the scoring saw up to its highest position.

• Move the sliding table in the cutting direction.

• Unlock the lock in the middle of the saw blade by pressing the knob on the middle carriage.

• Move the sliding table to the end position in the cutting direction.

• Open the bottom hinged safety cover (orange coloured cover plate).

• Release the nuts with a special wrench by turning counterclockwise.

• Before fitting the new scoring blade, remove any adhering chips from both flanges.

• Place the saw blade and front flange on the saw shaft, and tighten the nut clockwise.

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Attention!

The following must also be observed when using RAPIDO scoring blades with infinitely variable cutting width adjustment:

• Failure to comply with the operating instructions inadmissibly reduces Health and Safety at Work and excludes any claims for liability.

• Incorrect use and use other than that intended is forbidden.

• Permissible cutting widths 2.8 - 3.8 mm

• Take particular caution when unpacking and packing the adjustment unit, danger of injury!

• Only store the adjustment unit in the original packaging!

• Fit the scoring blade outside of the machine.

• Make sure that all connection elements are fitted.

• Only use original spare parts in the case of loss or damage to the connection elements!

Adjusting a two-part scoring blade

The cutting width of the scorer should be set to the cutting width of the main saw blade (+ 0.05 mm). Carry out the adjustment toward the left side of the main saw blade. The cutting width is adjusted with the spacing discs that are supplied.

Adjusting the scoring blade for the RAPIDO scoring tool

Fig. 6-63 Release the clamping screw.

Fig. 6-64 Adjust the spindle.

Note!

Only use the supplied tools for adjustment work!

• Release the clamping screw, approx. 2 turns.

• Turn the spindle until the required dimension is reached. (1 turn = 0.5 mm)

• Tighten the clamping screw.

• Make a test cut and, if necessary, correct the cutting width again as described above.

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Replacing the scoring blade for RAPIDO

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Fig. 6-65 RAPIDO saw blades

Remove the adjustment unit from the machine. It may be necessary to loosen the clamping screw because an excessively tight clamping screw can cause the adjustment unit to jam on the shaft!

Dismantling

Using the Allen wrench:

• Release the clamping screw (1), turn the spindle (2) approx. 3 – 4 turns clockwise until the flange (3) can be removed from the holder (4).

Using the internal torx wrench:

• Undo the screws (5).

• Remove the circular saw blade (6).

• Carefully clean the flange (3) and screws (5). Make sure that the running and flange surfaces are dry and free of dust.

• Fit a new saw blade, paying attention to the rotational direction and hole pattern: The circular saw blade (6) is in full contact with the flange (3) and the shoulder on the circular saw blade must point to the contact surface.

• Turn in the screws (5) and tighten with a torque of 8.6 Nm.

• Proceed in the same manner for the other half of the adjustment unit.

Prohibitory!

Do not apply oil or grease!

Installation

• The clamping screw (1) is released.

• Fit the flange (3) vertically onto the holder (4) so that the spindle (2) engages in the threaded hole (7).

• Turn the spindle (2) counterclockwise with the Allen wrench. The flange (3) is drawn onto the holder (4); the force applied must not increase.

• Continue turning the spindle (2), until the two circular saw blade halves are in contact.

• Install the adjustment unit on the machine.

• Set the cutting width, see above.

• Slightly tighten the clamping screw (1).

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Note!

A red anodised table strip is integrated in the area of the scorer (optionally available with LED lighting).

This strip marks the hazard zone of the scoring tool.

Fig. 6-66 Red table strip (standard)

Fig. 6-67 Red table strip with lighting (optional)

RAPIDO - PLUS

The 3-axis scoring system allows motorised positioning of the cutting height, width and cutting width. All settings can be entered via the keypad while the machine is running, and are shown on the display.

Replacing saw blades

[1] Remove the adjustment unit from the machine.

[2] Undo the screws and remove.

[3] You can now pull the adjustment unit apart

Fig. 6-68 RAPIDO Plus

Fig. 6-69 Disassembled RAPIDO Plus

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Fig. 6-70 RAPIDO-Plus, fitting the saw blade

[1] Undo the screws

[2] Remove circular saw blade

[3] Carefully clean the flange and screws

[4] Fit a new saw blade, paying attention to the rotational direction and hole pattern!

[5] Insert screws and tighten with a torque of 8.6 Nm

[6] Proceed in the same manner for the other half of the adjustment unit

6.6.2 Scorer, tilting to both sides

The following scorer systems are available for machines tilting to both sides:

Scorer diameter: 180 mm!

Duet set

Main saw blade and scorer blade ground to the same width in pairs

RAPIDO-BS

Width-adjustable scoring system with two saw blades, the spacing of which is adjustable

3-axis scorer

In this case, the width and side adjustment is carried out electrically in the control system.

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6.6.3 Mitre fences

Single-sided mitre fence

Fig. 6-71 Single-sided mitre fence

The fence can be fitted quickly and easily to the sliding table with an eccentric clamping system. Dimension scales are inclined in order to stay in the operator's field of vision. Crosscutting to 2500 mm.

Double-sided mitre fence DUPLEX

Fig. 6-72 Double-sided mitre fence DUPLEX

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Operating

The DUPLEX mitre fence can be infinitely adjusted from 0° to 90°. The circular scale with a radius of 350 mm has 0.25° graduation, allowing precise and fast setting of the mitre angle. The DUPLEX mitre fence can be fitted at any position of the sliding table due to its eccentric clamping system.

The stop bar (2 throw-over stops) can be used in both stop profiles. It is possible to crosscut workpieces of up to 1350 mm in length or, when the extended stop fence is used, up to 2150 mm in length.

In addition, the DUPLEX and DUPLEX D mitre fence features a length compensation scale with which the length dimension is set in accordance with the mitre angle.

Note!

Separate instructions are enclosed for the selected options DUPLEX,

DUPLEX D or DUPLEX DD.

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Operating

6.6.4 DIGIT L dimension display unit

Fig. 6-73 DIGIT L

The dimensions that have been set are displayed digitally in the 150 mm to

3200 mm range to an accuracy of ± 0.1 mm. The proximity sensor operates wear-free and is not sensitive to dust. A precise adjustment system is used for precision setting in 1/10 mm increments.

Operating the display electronics

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Operating

Fig. 6-74 DIGIT L display unit

Press button 1: switches over the throw-over stop side. Pressing button 2, 3 or

4 changes the measuring range on the display electronics. Throw-over stop 1 is permanently connected to the measuring system and the display unit. The measuring range is from approx. 150 mm to approx. 1630 mm. Throw-over stop 2 is a flip stop and, when it makes contact at the left of throw-over stop 1, it is at a distance of 295.0 mm from throw-over stop 1. This results in a measuring range of approx. 445 mm to approx. 1750 mm. If throw-over stop 2 is pushed onto the length extension, this results in a measuring range of about 1750 mm to 3200 mm; if necessary, the length extension can be connected to throwover stop 1 with the aid of the detent bolt.

Power supply

Power is supplied by a rechargeable battery. The charging state is shown in the bottom right hand corner of the display. The batteries can be recharged using the supplied charger.

Changing the rechargeable battery

Fig. 6-75 Changing the rechargeable battery for DIGIT L , DIGIT LD

Fig. 6-76 Battery charger

Note!

For information on how to handle batteries, see chapter 3.6.4

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Operating

Basic setting / calibration of the display unit

The basic setting of the display unit is needed in order to adapt the measuring system to the machine situation. Check and, if necessary, re-enter the basic settings following each tool change.

How to proceed:

• Push throw-over stop 1 with the display unit to the right against the mechanical stop.

• Fix throw-over stop 1 with a clamping screw.

• Cut a test piece, measure the workpiece width with a calliper and enter the precise value as follows:

• Press key 2; after three seconds the following calibration menu will appear

(only the first throw-over stop can be calibrated).

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Fig. 6-77 Calibration

[1] Press the adjacent function key to select the required decade. If the highest decade has been selected and the function key is reactivated, the lowest decade is automatically selected.

[2] Press the "+" key to increment the display value of the active decade.

[3] Press the "-" key to decrement the display value of the active decade.

[4] Press the adjacent function key to store the new throw-over stop value under parameter L-L1; this value is also automatically calculated with the throw-over stop values displayed on the user interface.

Switching the display unit from mm to inches or inches to mm

• Press the Menu button

• Select inch (or mm) as the measuring unit.

6.6.5 Digital angle and length display DIGIT LD

Fig. 6-78 Crosscut-mitre fence display unit WGA_LD

The angle is shown in the display to an accuracy of 0.01° and the dimensions set in the 150 mm to 3200 mm range are shown in the display to an accuracy of

±0.1 mm. The length dimensions shown are automatically corrected when the angle is changed.

Operating the display electronics

Fig. 6-79 Display unit

Pressing buttons 2, 3, 4 on the right hand side changes the measuring range on the display electronics. The dimension of the current throw-over stop is shown in bold. Throw-over stop 1 is firmly connected to the measuring system and the display unit. Throw-over stop 2 is a flip stop and, when it makes contact at the left of throw-over stop 1, it is at a distance of approx. 200.0 mm from throw-over stop 1. If throw-over stop 2 is pushed onto the length extension, this results in a measuring range of about 1750 mm to 3200 mm; if necessary, the length extension can be connected to throw-over stop 1 with the aid of the detent bolt.

Pressing button 1 (RH side) for more than 3 seconds switches over the degree display.

The fence position is switched over on the cross-slide by pressing the button on the left hand side.

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Power supply

Power is supplied by a rechargeable battery. The charging state is shown in the bottom right hand corner of the display. The batteries can be recharged using the supplied charger.

Changing the rechargeable battery

Fig. 6-80 Changing the rechargeable battery for DIGIT L , DIGIT LD

Fig. 6-81 Changing the rechargeable battery for WGA DIGIT LD

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Operating i

Fig. 6-82 Battery charger

Note!

For information on how to handle batteries, see chapter 3.6.4

Basic setting / calibration of the display unit

The basic setting of the display unit is needed in order to adapt the measuring system to the machine situation. Check and, if necessary, re-enter the basic settings following each tool change.

How to proceed:

• Push throw-over stop 1 with the display unit to the right against the mechanical stop.

• Fix throw-over stop 1 with a clamping screw.

• Cut a test piece, measure the workpiece width with a calliper and enter the precise value as follows:

• Press key 2; after three seconds the following calibration menu will appear

(only the first throw-over stop can be calibrated).

Fig. 6-83 Calibration

[1] Press the adjacent function key to select the required decade. If the highest decade has been selected and the function key is reactivated, the lowest decade is automatically selected.

[2] Press the "+" key to increment the display value of the active decade.

[3] Press the "-" key to decrement the display value of the active decade.

Switching the display unit from mm to inches or inches to mm

• Press the Menu button

• Select inch (or mm) as the measuring unit.

157

Operating

6.6.6 Rip fence with DIGIT X digital dimension display

158

Operating

Fig. 6-84 Rip fence with Digit X

The electronic measuring system with digital display and fine setting system ensures precise and fast setting of the rip fence. The display is always in the field of vision. The touch-free measuring system is not sensitive to dust. When the guide surface of the stop fence is changed, the dimensions are corrected automatically in the measuring system.

Changing the batteries

Fig. 6-85 Release the clamping screws

Fig. 6-86 Remove the housing with the display unit

Note!

For information on how to handle batteries, see chapter 3.6.4

Fig. 6-87 Undo the screws and remove the cover.

Fig. 6-88 Change the batteries, ensuring correct polarity

159

Operating

Basic setting of the display unit

160

Operating

Fig. 6-89 Operating the Digit X

The basic setting of the display unit is needed in order to adapt the measuring system to the machine situation. Check and, if necessary, re-enter the basic setting for each tool change. The basic setting can only be carried out together with the tools used so it cannot be done at the factory.

• Push the rip fence to the left against the mechanical stop

• Hold the F button down and press the Reset button

• Set the rip fence to a cutting width of 130 mm (straight edge in the position of the low guide surface)

• Cut a test piece and measure the workpiece width with a sliding calliper

• Hold the F button down; the right-hand digit of the display starts flashing after approx. 3 seconds

• Pressing the + button increases the flashing digit by 1 each time. When the maximum number value 9 is passed, the numbers start again with 0.

• Pressing the Minus button decreases the flashing digit by 1 in each case.

• Release the F key.

• The dimension that has been set is saved as the basic setting.

Calibrating the display unit

Calibration of the display unit is required when the fence has been moved under the main table.

• Push the rip fence to the left against the mechanical stop

• Hold the F button down and briefly press the Reset button; the display shows the basic setting again.

Switching the display unit from mm to inches or inches to mm

• Hold the + button down for more than 3 seconds; the display shows inches

(or mm).

• Release the + key; the display unit now shows the set dimension in inches

(or mm).

161

Operating

6.6.7 Parallel cutting device

Fig. 6-90 PALIN parallel cutting device

Parallel cutting of long, narrow parts is done to the left of the saw blade. The

PALIN and PALIN_D parallel cutting devices are good for this. In parallel cutting, the flip stop is set to the same dimension at the crosscut fence and at the

PALIN. The workpiece can be placed safely and be guided easily on the left of the saw blade.

Parallel cutting device with digital dimension display and precision setting system

162

Operating

Fig. 6-91 PALIN D parallel cutting device

PALIN_D with digital dimension display and precision setting system A precise adjustment system is used for precision setting in 1/10 mm increments. Both parallel cutting devices can be adjusted to a workpiece width of up to 900 mm.

Alkali manganese batteries have an operating life of approx. 1 year. A battery capacity display provides a timely reminder of a battery change.

We do not recommend the use of rechargeable batteries of any type as their voltage and capacity differ from that of alkaline batteries. As a result, the estimated operating life of approx. 12 months would not be reached, and the symbol in the battery capacity display would not show the battery status correctly.

Note!

For information on how to handle batteries, see chapter 3.6.4

Carefully push out the display unit.

Undo the screws and remove the cover.

Change the batteries, ensuring correct polarity!

Tbl. 6-1 Changing the batteries

Calibrating the display unit

• Push the fence to the right against the mechanical stop.

• Fix the fence with a clamping screw.

• Hold the F button down and briefly press RESET.

• The basic setting value reappears on the display unit.

163

Operating

164

Operating

Basic setting of the display unit

The basic setting of the display unit is needed in order to adapt the measuring system to the machine situation. Check and, if necessary, re-enter the basic settings following each tool change. The basic setting can only be carried out together with the tools used so it cannot be done at the factory.

• Push the fence including the display unit to the right against the mechanical stop and fix with a clamping screw.

• Cut a test piece, measure the workpiece width with a vernier calliper and enter the precise value as follows:

• Press the F button, all digits of the display will light up after 3 seconds.

• Hold the F button down.

• The right-hand digit of the display starts flashing.

• Pressing the + button increases the flashing digit by 1 each time. When the maximum number value 9 is passed, the numbers start again with 0.

• Pressing the - key reduces the flashing digit by 1 each time; when the maximum numeric value (9) is passed, the numbers start again with 0.

• Release the F key.

• The dimension that has been set is saved as the basic setting.

• The display unit is now ready for operation.

Switching the display unit from mm to inches or inches to mm

• Hold the + button down for more than 3 seconds; the display shows inches

(or mm).

• Release the + key; the display unit now shows the set dimension in inches

(or mm).

6.6.8 Workpiece hold-down device

Manual quick-action clamp

Fig. 6-92 Manual quick-action clamp

The manual quick-action clamp fixes the workpiece to the crosscut fence.

Klemmfix

Fig. 6-93 Altendorf Klemmfix

Altendorf Klemmfix consists of two collets for fixing narrow and small workpieces on the sliding table. They securely hold workpieces from 0-70 mm. The collets can be used as required throughout the full length of the sliding table.

165

Operating

Electro-pneumatic hold-down device

166

Operating

Fig. 6-94 Electro-pneumatic hold-down device

The electro-pneumatic hold-down device fixes the workpiece to the crosscut fence and operates with a clamping force of max. 100 kp at a pressure of 6 bar.

The maximum clamping height is 90 mm.

The safety cylinder only clamps the workpiece when the pressure plate is positioned vertically in relation to the cylinder axis. If the pressure plate is offset by more than 2° from the vertical position, e.g. by contact with the back of the hand, no clamping force builds up.

Warning!

Danger of crushing fingers!

• Ensure that the pressure plate can freely move in all directions, otherwise, the safety function will be impaired.

• Never reach beneath the pressure plate on purpose!

• Never use two fingers to reach opposite to, parallel or centred beneath the clamping plate!

Fig. 6-95 Remote control, hold-down device

Movement up and down is controlled wirelessly via a small hand-held radio transmitter.

The operating status of the hold-down device is shown on the switch box of the protection hood support.

Yellow lamp: Cylinder pressurised

White lamp: Cylinder not under tension

If the remote control fails, the hold-down device can be controlled directly by pressing the illuminated push button.

167

Operating

Pneumatic hold-down device

168

Operating

Fig. 6-96 Pneumatic hold-down device

The split hold-down beam can be controlled separately. This ensures optimum adjustment to differing workpiece lengths with one or both hold-down beams.

The hold-down beam stroke is 80 mm; the customer-provided pneumatic connection is 6 bar.

The customer must provide a pneumatic connection of 6 bar.

Sliding table length [mm]

2250

3000

3200

3400

3800

Beam length [mm]

1975

2725

2925

3125

3525

Tbl. 6-1 Beam length

Operation

The pneumatic hold-down beam consists of two segments and can be operated by 2 control levers to ensure optimum holding down of different workpiece lengths.

When valve V1 has been actuated, the two compressed-air cylinders lower the short part of the hold-down beam onto the workpiece.

The entire length of the hold-down beam is controlled via valve V2. After actuation, the two segments of the pressure beam are lowered simultaneously. The rubber coating of the hold-down beam prevents the workpiece from slipping.

Installation

• Place the hold-down beam onto the sliding table.

• Insert the two T-nuts into the sliding table groove.

• Align the hold-down beam in parallel with the protection hood.

• The distance between the hold-down beam and the protection hood should be 15 mm; the length of the slots prevents contact with the protection hood.

• Tighten the M12 nuts.

• Connect the compressed-air supply to the air servicing unit, and set the pressure reducer to 3 bar.

169

Operating

170

Operating

Vacuum fastening in the sliding table

Fig. 6-97 Suction cup rows

A vacuum is generated in one or more suction cup rows via a high-capacity vacuum pump to reliably hold the workpiece on the sliding table. Each suction area can be individually controlled, the workpiece can be released at the press of a button.

Note!

Separate instructions are enclosed for the selected option Vacuum fastening!

6.6.9 Cross-slide width extension

Fig. 6-98 Cross-slide width extension

The cross-slide width extension is intended to facilitate work with large format or long workpieces. It extends the width of the workpiece support surface to max. 700 mm by means of two telescopic tubes. Long boards can be securely loaded and crosscut. The additional horizontal roller allows the workpiece to be easily pushed throughout the entire length.

171

Operating

6.6.10 Additional cross-slide

Fig. 6-99 Additional cross-slide

Optional equipment for optimum support extension for large format or particularly unwieldy boards. The additional cross-slide can be easily fitted at any point of the sliding table due to its quick-action clamping system.

Max. workpiece weight up to 250 kg.

The guide is not supplied as standard with the machine!

172

Operating

6.6.11 LASER cutting line display

Fig. 6-100 Laser cutting line display

The laser beam shows the run of the cutting line over a length of approx. 5000 mm. For trimming or cutting along a marked line (e.g. for stairs/steps) in particular, valuable set-up time and material can be saved.

Warning!

Laser beams!

The laser creates a red luminous beam with a width of approx. 3 mm. The intensity of this laser is sufficiently low that looking into it briefly is harmless. The eye is protected by its natural reflex to close.

Never observe the laser beam using optical aids or instruments, e.g. glasses, binoculars or magnifying glasses etc. which could bundle the light, and then possibly damage the eye.

• Never attach mirror surfaces in the laser area!

• Never carry out any modifications to the laser optics!

• Furthermore, make sure that the warning signs attached to the laser are always legible. They must not be removed!

• Never replace the laser with a laser unit of a different type!

• Defective laser units may only be repaired by the manufacturer!

173

Operating

Aligning the laser beam with the cutting line

174

Operating

Fig. 6-101 Aligning the laser

At the factory the laser is set so that the beam is perpendicular and parallel to the sliding table.

When the hood has been swung away and this has been followed by positioning, it is necessary to check and possibly correct the laser settings.

Setting:

• Place wooden gauges (1) in the sliding table groove, and saw for approx.

15 mm

• Set the laser beam parallel to the cutting line with the left setscrew (2)

• Move the laser in parallel with the right-hand setscrew (3) until the beam aligns with the cutting line

6.6.12 Coolant spray device

Fig. 6-102 Coolant spray device

To improve the cutting quality, we recommend the use of a coolant spray device for plastics with a low melting point and for certain light metal alloys, especially in conjunction with the infinitely variable speed adjustment.

A sensor is fitted in the front table strip to detect the workpiece. It will interrupt the coolant supply when not obstructed by a workpiece.

Note!

Separate instructions are enclosed for the selected option Coolant spray device.

175

Operating

6.6.13 TIP-SERVO-DRIVE

176

Operating i

Fig. 6-103 TIP-SERVO-DRIVE

The drive serves to assist the operator during sawing and is activated as soon as the joystick fitted on the sliding table is actuated (pressing = forward, pulling

= backward). Operation is carried out from the usual workplace of the machine upstream of the sliding table.

Note!

Separate instructions are enclosed for the selected option TIP-SERVO-DRIVE.

7

7.1

Cleaning/care

Safety measures

Attention!

•

Always turn off the main switch and secure it against being turned on again before doing any maintenance work!

•

Before using solvents and cleaning agents, make sure that these substances do not cause damage to the painted, anodised or galvanised surfaces as well as plastic parts. For information on these substances, please refer to the safety data sheets available from the manufacturers of the solvents or cleaning agents.

177

Cleaning/care

7.2 Maintenance/cleaning by the user

Note!

Regular cleaning of the machine and the machine environment prolongs the life of the machine, is prerequisite for perfect cutting results and reduces the risk of accidents.

Pay attention to the following:

• Machine table

• Sliding table

• Sliding table guides

• Tilt segments

• Stop bar of rip fence

• Machine interior

• Machine environment

Carry out cleaning/care measures as follows:

Regularly:

Fig. 7-1 Remove chips and dust from the sliding table + machine table with a brush

Fig. 7-2 Remove chips from the bottom carriage of the sliding table

178

Cleaning/care

Once a month:

Sliding table

Fig. 7-3 Remove dirt and resin residue from the guide of the sliding table using a cloth soaked in spirit

Fig. 7-4 Remove dirt from the bottom of the guide of the sliding table

Fig. 7-5 Dirt from the bottom of the sliding table guide

179

Cleaning/care

180

Cleaning/care

Swinging arm

Fig. 7-6 Cleaning of the sub-rollers of the sliding table

Fig. 7-7 Open the swinging arm compartment

Fig. 7-8 Clean the roller

Fig. 7-9 Clean the roller from below

Note!

DO NOT APPLY OIL TO THE SWINGING ARM, just clean (dry)!

Segments

Fig. 7-10 Remove chips/dirt from the tilt segments (right and left-hand side) and spray with universal oil

Fig. 7-11 Spray round bar. Subsequently move the block up and down.

181

Cleaning/care

Every 6 months

Sliding table

Fig. 7-12 Spray guides with universal oil

Note!

Remove the oil from all lubricated points using a cloth!

Note!

Clean the monitor controls/screen using screen cleaning equipment such as a microfibre cloth, cleaning spray or cleaning pad (available from PC or mobile phone shops).

Type of soiling

Chips and dust

On the monitor

Remove/clean with

Vacuum cleaner, brush, cleaning cloth

Resin residue Nitro thinner

Resin residue on the sliding table guide Cleaning cloth, petroleum, spirit

Microfibre cloth, display cleaning spray or pad

Avoidance of

Rust formation

Necessary subsequent treatment

Universal oil

182

Cleaning/care

Warning!

NEVER APPLY RESIN REMOVER TO ANODIZED SURFACES!

• Do not allow resin removing cleaning agents to corrode the aluminium surfaces!

• It is very important to adhere to the manufacturer's specifications!

183

Cleaning/care

Quantity of lubricant

When lubricating, max. 5 strokes are required for applying the required 7 g of lubricant.

The filled grease gun is included in the scope of delivery.

Attention!

• Adhere to the precise lubricant quantity and time interval specified for each relubrication cycle.

• Excessive lubrication as a result of shorter intervals and/or too much lubricant will lead to malfunctions!

Note!

If you want to save time and money, sign up for the annual Altendorf inspection, the "check-up" for your sliding table saw.

The lubrication measures will be carried out by our maintenance staff within the framework of the professional maintenance.

Motor driven rip fence (X axis)

The rail guide is lubricated via lubricating nipples on the carriage.

Time interval :

After travel of 1500 m a message is shown on the display indicating that relubrication is necessary.

Lubrication is necessary every 12 months, irrespective of the distance travelled.

Clearing the message

To temporarily clear the message: Actuate the STOP button.

After 10 adjustments or an interruption to the power, the message reappears!

To clear the message after lubrication: Press the START button 3x

184

Cleaning/care

Remove the protective cover and relubricate the lubricating nipples with the provided grease gun.

Warning!

Turn off the main switch before removing the cover plate!

Fig. 7-13 Lubricating nipple, linear guide X axis

Fig. 7-14 Lubricating nipple, spindle drive F45

185

Cleaning/care

186

Cleaning/care

Lubrication of the main saw

Time interval:

After a travel path of 100 m has been reached, a message is shown on the display indicating that relubrication of the height adjustment unit is necessary.

Lubrication is necessary once a year, irrespective of the distance travelled.

How to proceed:

To relubricate, set the tilt of the saw blade to 45° and the cutting height to 0 mm. Open the machine door or remove the protective cover plate (VARIO).

This allows optimum access to the lubricating nipples.

Fig. 7-15 Lubricating nipple (1) height adjustment

Remove any emerging grease and chips from the guides (2).

Fig. 7-16 Lubricating nipples, saw unit tilting to both sides

Lubricating the scorer

Note!

Lubricating the scorer is only required for machines tilting to both sides (option).

Note!

No relubrication of the saw shaft is necessary!

Fig. 7-17 Lubricating nipple, scorer

187

Cleaning/care

188

Cleaning/care

Choice of lubricants

Lubricant

Aralub HL 2

BEACON 2

BP Energrease LS 2

ELF ROLEXA 2

Gulfcrown Grease No. 2

Marson EPL 2

Shell Alvania grease R 2

Extreme pressure-bearing grease

LGEP 2

Way Lubricant 220

Manufacturer

Aral

Esso

Elf

Gulf

Wintershall

Shell

SKF

Texaco

Tbl. 7-1 Choice of lubricants

Attention!

Lubricants containing graphite or MoS2 additives are not allowed to be used!

7.3 Maintenance/cleaning by qualified persons

7.3.1 Checking the winding shield

The resistance of the PTC resistors must be checked in the motor terminal box by an electrician at least once a year. Resistance must be measured with a cold motor, and should be 750 ohms ± 200 ohms.

189

Cleaning/care

8

8.1

Faults/problems/troubleshooting

Machine diagnosis

The display shows when limit switches have been actuated at protective devices and so on. There are two function groups.

Function group 1:

• Motor temperature

• Machine door

• Lower saw blade cover

• EMERGENCY STOP button

• Sliding table limit switch

Function group 2:

• Brake unit

Response by function group 1:

Machine drives are switched off or cannot be started

Response by function group 2:

Machines will not start

Indication to request a service technician to check the functioning

190

Faults/problems/troubleshooting

8.2 Motor overload protection

Fig. 8-1 Motor overload protection

The drive motors are protected against overload by a winding shield. This switches a motor off automatically if it overheats. In the case of machines equipped with a scorer, the scorer drive is also switched off even if this motor was not overloaded. The motor can only be switched on again when it has cooled down. It may take several minutes (max. 10) for the motor to cool down!

191

Faults/problems/troubleshooting

8.3 Troubleshooting/faults/messages

Fault Cause

The machine cannot be switched on.

The main switch is not turned on.

Power failure or phase failure

Overload protection has responded.

Troubleshooting

Turn the main switch to switch position “I”.

Wait for power to be reinstated, or eliminate cause for loss of power, check factory fuses.

Allow motor to cool down, also refer to machine diagnosis display.

Sliding table moved over saw blade centre line.

EMERGENCY STOP button pressed.

Control circuit fuses defective

Move the sliding table back to the saw blade centre line; also refer to machine diagnosis display.

Rearm the EMERGENCY STOP button again by pulling, also refer to machine diagnosis display.

Door in machine frame or lower base plate in front of saw blades opened.

Close the machine door or cover plate; also refer to machine diagnosis display.

Turn off the main switch, open the switch cabinet and identify which of the fuses F1, F2, F8 is defective. Find and eliminate the cause. Replace defective fuses, only using fuses of the same rating!

The machine switches off automatically during operation.

Power failure in one or several phases due to responding factory fuses.

Overload protection has responded due to blunt saw blade or excessive feed speed.

Eliminate cause of phase failure.

Change saw blade or reduce feed speed. Allow motor to cool down, also refer to machine diagnosis display.

Control circuit fuses defective

Turn off the main switch, open the switch cabinet and identify which of the fuses F1, F2, F8 is defective. Find and eliminate the cause. Replace defective fuses, only using fuses of the same rating!

Workpiece jammed while feeding forward.

Blunt saw blade Fit a sharp saw blade.

Riving knife thickness does not match the saw blade used.

Fit the correct riving knife; it must be thicker than or equal to the thickness of the main saw blade.

192

Faults/problems/troubleshooting

Fault Cause

The finished size of the cut workpiece does not match the cutting width set on the rip fence.

Dimension scale for cutting width display is misadjusted.

Troubleshooting

Reset the dimension scale: Cut a workpiece at the rip fence, precisely measure the cut width and position the measuring scale so that the measured cutting width is displayed on the fence edge.

Incorrect calibration for

DIGIT_X,

CONTROL

Recalibrate

The finished size of the cut workpiece does not match the cutting width set on the crosscut stop.

Dimension scale for cutting width display is misadjusted.

Reset the dimension scale: Cut a workpiece at the crosscut stop, precisely measure the cut width and position the measuring scale so that the magnifying glass display matches the measured cut width.

Incorrect calibration for

DIGIT_X,

CONTROL

Recalibrate

Swinging arm does not move smoothly.

Soiled telescopic tube or track rollers

Sliding table has lateral play.

Sub-rollers incorrectly set.

In its end positions, the sliding table is higher than the machine table.

Sub-rollers incorrectly set.

Clean telescopic tube or track rollers; check wiper.

Set the sub-rollers.

Saw blade burns on the sliding table side.

Insufficient free cut on sliding table

Excessive free cut on the rip fence

Saw blade burns on the rip fence side.

Insufficient free cut on rip fence

Saw blade burns on both sides.

Incorrect free cut setting.

Readjust the free cut.

Readjust the rip fence.

Readjust the free cut.

Readjust the free cuts.

Workpiece jammed.

Operating error

Insert a riving knife in the cutting line or use a wider riving knife.

Guide the workpiece either at the LH or the RH fence. Do not guide the workpiece on the rip fence when cutting with the sliding table.

Workpiece has burn marks.

Blunt saw blade Change the saw blade.

193

Faults/problems/troubleshooting

Fault

Break-outs in spite of scorer

Cause

Feed too low

Troubleshooting

Increase the feed rate.

Saw blade has too many teeth.

Incorrect free cut

Change the saw blade.

Scoring blade too narrow

Readjust the free cut.

Scorer not aligned with main saw blade

Readjust free cuts; the free cut should be almost “0”.

Adjust saw width.

Workpiece rises when cut with the scorer.

Blunt scoring blade

Cutting height too low

Exchange the sawing blade.

Set the scoring blade higher.

Tbl. 8-1 Fault

Fault message

B000 - B063

E01

E02

E03

E06

E07

E08

E18

E21

E22

E40

E41

Cause

Internal faults

Limit switch ES_MIN1 reached

Limit switch ES_MIN2 reached

Limit switch ES_MAX reached

Fault, collision, fast shutdown

Drive positioning fault

Axis reference run error

Fresh oil lubricator empty

Error during update:

File error on the USB stick

Error during update:

File errors on the USB stick (various)

20VAC control voltage missing

24VAC control voltage missing

Troubleshooting

Request a service technician to check the function.

Perform new reference run

Change cartridge

Check fuse F9

Check fuse F8

194

Faults/problems/troubleshooting

Fault message

E42

E43

E44

E45

E46

E47

E48

E49

E51

E53

E54

E55

E56

E57

E58

E59

E61

Cause

Scoring saw motor overheated

Main saw motor overheated

Sliding table limit switch

Saw blade cover open

Machine door open

EMERGENCY STOP button 1 pressed

EMERGENCY STOP button 2 pressed

Troubleshooting

Allow motor to cool down.

EMERGENCY STOP button 3 pressed

Brake unit fault: Phase failure/rotational direction

Brake unit fault: Mains contactor not in neutral position.

Check fusing in the factory and fuses F15 /

F16.

Request a service technician to perform a repair.

Operating error, incorrect riving knife position or speed setting, e.g. too fast for 450 mm saw blade. Drives cannot be started!

Check rotational speed and riving knife position.

Brake unit fault: Communication problem with machine control unit - brake unit is operating in default mode, 450 mm saw blade / 4000 rpm.

Request a service technician to check the function.

Frequency converter phase failure/ overvoltage

Press any button on the control unit.

Frequency converter excessive speed

Restart the machine.

If this does not remedy the fault, request a service technician.

Frequency converter communication fault

Request a service technician to check the function.

Emergency running block 3500 rpm Switch the main saw blade off and on again.

Malfunction, drive positioning, current consumption evaluation

Lubricate the axle

195

Faults/problems/troubleshooting

Fault message

E81

E91K

E92

E93K

E94

E99

Cause

Malfunction, shaft encoder

A/B channel evaluation error

K contact error of the STOP button

K-n stop signal missing

Check the AC stop circuit

K contact error of the START button

K free signal missing

Excess temperature of the control electronics

Troubleshooting

Request a service technician to check the function.

If the fault occurs repeatedly, request a service technician to check the function.

Request a service technician to check the function.

If the fault occurs repeatedly, request a service technician to check the function.

Request a service technician to check the function.

Switch off machine and allow to cool down before restarting. If fault occurs again, request a service technician to check the function.

Tbl. 8-2 Fault messages

196

Faults/problems/troubleshooting

8.4 Electronic brake module

The main saw shaft is braked with an electronic brake module. This brake module is located in the contractor control housing, and is accessible when the rear panels have been removed.Braking is controlled in such a way that there is a high brake current at the beginning of braking. This is reduced over time to ensure smooth braking. In addition, a standstill monitoring facility switches off the brake current if the motor is standing still. The brake module contains various function blocks for control and monitoring tasks. There is also a communications connection for machine control.

197

Faults/problems/troubleshooting

9

9.1

Technical data

Standard equipment

Saw blade heights: Standard up to 450 mm

Features

Electromotive height and tilt adjustment 0 - 46 ° for the main saw blade, for tilting in both directions from -46° to +46°, with automatic correction of the cutting height when tilting the saw unit, and with display of tilt angle and cutting height.

F45 display control system with dimension input via the keypad

Saving of 99 programs

Sliding table incl. infinitely variable top carriage locking

Sliding table length 3000 mm

Rip fence

Cutting width 1000 mm, table width extension, aluminium anodised

• Manual adjustment with precision setting

Crosscut fence

• manual adjustment, crosscutting up to 3200 mm, 2 operating positions on the cross-slide frame

Drive power / rotational speed of main saw shaft

With automatic brake and display of rotational speed

• 4kW (5.5 PS) with a rotational speed of 4200 rpm

Tool clamping system

for main saw blade

Max. cutting height 150 mm, max. saw blade diameter 450 mm

Cutting heights: see table

Table length extension

840 mm, aluminium anodised

USB-A port for data and program transfer

Machine diagnosis and operating hours meter

Aluminium parts in anodised finish

Clamping shoe, push stick, push block handle and pull-back handle

198

Technical data

450

500

550

250

300

350

400

Saw blade diameter [mm]

---

0°

0 - 55

0 - 80

0 - 105

0 - 130

25 - 155

-----

Standard

+ 45°

0 -30

0 - 47

0 - 64

0 - 81

16 - 98

-----

- 45°

0 -1

0 - 18

0 - 35

2 - 52

20 - 69

-----

0°

0 - 55

Option:

Extended cutting height

+ 45°

0 - 30

- 45°

0 - 1

0 - 80

0 - 105

25 - 130

50 - 155

75 - 180

100 - 205

0 - 47

0 - 64

17,5 - 81

35,5 - 98

53 - 115

70,5 - 132

0 - 18

2,5 - 35

20,5 - 52

38 - 69

56 - 86

73,5 - 103

Note!

1) For machines with a scoring unit, the scoring blade, including the front and rear flange, or RAPIDO must be removed.

199

Technical data

Main saw

Technical data:

Tool holder diameter

Saw blade tilting range

Idling speed

Tool edge width

30 mm

0-46°

4000 rpm max.20 mm

Sliding table

Crosscut fence

Rip fence

Extraction

Sliding table cutting length

Crosscutting at 90° crosscut fence

Cutting width at rip fence

Connection socket diameter below table

See table

3200 mm

1000

120 mm

Connection socket diameter at top safety hood 80 mm

Overall vacuum connection

∅ 140 mm

1500 PA

Air speed

Minimum air volume

Operating temperature

Ambient conditions

Max. relative humidity

Do not expose the machine to a gaseous environment which is explosive or may cause corrosion!

20 m/s

1150 m

10 - 40 °C

90 %, no condensation

200

Technical data

Weight

Machine weight, dependent upon equipment

Lockable main switch

Approx. 1100 kg

Contactor control with pushbutton operation

Adjustment of tilt and cutting height for the main saw

Control voltage 24 VAC

Electrical equipment

Rotational speed, tilt angle, cutting height

Braking of main motor, monitoring of winding temperature

Digital display

Electronic multifunction module/frequency converter

CNC-controlled

Sliding table length [mm]

Cutting length [mm] for WA,WGA,PQS, UNO

Cutting length [mm] for DUO and DUO Flex

TIP-SERVO-DRIVE

Cutting length [mm]

without scoring blade

Cutting length [mm] with scoring blade

Sliding table cutting lengths

Maximum cutting length with use of clamping shoe or crosscut-mitre fence

Does not apply to crosscut fence, crosscutting up to 2500 mm.

2250 3000 3200 3400 3800 4300 5000

2155

2100

1840

1725

2905

2850

2590

2475

3105

3050

2790

2675

3305

3250

2990

2875

3705

3650

3390

3275

3705

3650

3870

3775

3705

3650

3870

3775

201

Technical data

9.2 Special equipment

Available special equipment

Main saw drive

Heavy-duty motors up to 11 kW (for machines tilting to one side)

Infinite rotational speed adjustment (VARIO, adjustable in increments of 5, power for machines tilting to one side: 5.5kW, 7.5kW , power for machines tilting to both sides:

5kW and 6.5 kW)

Sliding table

Sliding table lengths from 2250 mm to 5000 mm

Second support (STEG), support width extension by 400 mm

On/Off switch at the end of the sliding table

Crosscut-mitre fence

Length dimension adjustable via digital display with fine adjustment (DIGIT L), setting accuracy 0.1 mm, crosscutting up to 3200 mm

Length dimension, angle, length compensation via digital display (DIGIT LD), setting accuracy 0.1 mm / 0.1°, crosscutting up to 3200 mm

Mitre fences

One-sided mitre fence, angle adjustable via scale from - 30° to 45°, crosscutting up to 2500 mm

Double-sided mitre fence (DUPLEX), angle adjustable via scale from 0° to 90°, crosscutting up to 1350 mm or 2150 mm, length compensation

Double-sided mitre fence (DUPLEX D), angle digitally adjustable, setting accuracy

0.01°, crosscutting up to 1350 mm or 2150 mm, length compensation

Double-sided mitre fence (DUPLEX DD), angle and length digitally adjustable, setting accuracy 0.01° / 0.1 mm, length display is adapted automatically in accordance with the angle that is set, crosscutting up to 1350 mm or 2150 mm

Rip fence

With digital dimension display and fine adjustment, setting accuracy 0.1 mm

Parallel cutting device

Parallel cutting device (PALIN), crosscutting up to 900 mm, adjustable via scale

Parallel cutting device (PALIN_D), crosscutting up to 900 mm, digitally adjustable, setting accuracy 0.1 mm

202

Technical data

Available special equipment

Pneumatic hold-down beam

For sliding table length 2250 mm, clamping length 1975 mm

For sliding table length 3000 mm, clamping length 2725 mm

For sliding table length 3200 mm, clamping length 2925 mm

For sliding table length 3400 mm, clamping length 3125 mm

For sliding table length 3800 mm, clamping length 3525 mm

Max. clamping height 80 mm, min. pneumatic connection 6 bars

Electro-pneumatic hold-down device

with 1 cylinder with 2 cylinders

Max. workpiece height 0 – 90 mm or 80 – 170 mm, min. pneumatic connection 6 bar, wireless remote control

Manual quick-action clamp

Max. clamping height 175 mm

Cross-slide

Telescopic cross-slide width extension for up to 700 mm extra

Additional cross-slide with floor supporting roller, max. workpiece weight 250 kg

LASER cutting line display

Light beam width approx. 3 mm, light beam length approx. 5 m

Three-phase A/C socket

In European standard version, fuses 10 A, can be switched via the main switch

Coolant spray device

Minimal cooling lubrication, operating pressure 0.5 – 5 bars

Support roller, tilting

Positioned on the sliding table in front of the machine table

Parallelogram cross-slide

Additional cross-slide with digital display

Vacuum suction cup in sliding table

5 individually selectable suction areas for all table lengths

203

Technical data

10 Maintenance and repairs

10 Maintenance and repairs

10.1 General

Keeping a supply of the most important spare and wear parts on site is an important prerequisite for the constant functioning and operating capability of the sliding table saw. We only accept a guarantee for original spare parts supplied by us. We expressly point out that original spare parts and accessories not supplied by us have not been checked and released by us. Therefore, the fitting and/or use of such products may negatively influence the properties of the sliding table saw and thus impair its active and/or passive safety. Wilhelm Altendorf GmbH&Co. KG will not accept any liability or guarantee for damage resulting from the use of non-original spare parts and accessories.

Please note that special production and delivery specifications exist for our own and our suppliers' parts, and that we always supply spare parts that meet the latest state of the art and comply with the latest statutory regulations.

Please refer to the spare parts list when ordering spare parts.

For further information please refer to the spare parts drawings included in the spare parts list.

When ordering spare parts, please state the following information:

• Machine no.

• Article no.

204

Maintenance and repairs

10.2 Customer service addresses

Wilhelm Altendorf GmbH & Co KG

Service department

Wettinerallee 43/45

D-32429 Minden

Post office box

D-32377

Phone: +49 571 9550222

Telefax: +49 571 9550111 e-Mail: [email protected]

www.altendorf.com

10 Maintenance and repairs

205

Maintenance and repairs

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Key features

Riving knife
Top safety hood
Automatic brake
Adjustable cutting height
Tilt adjustment
Optional scoring saw
CNC crosscut fence

Frequently asked questions

The F45 ProDrive is intended for cutting wood and similar materials, such as laminated and unlaminated board materials, solid wood, veneer, gypsum plasterboard, cardboard, dimensionally stable plastics, aluminum, and aluminium alloys.

The F45 ProDrive is equipped with a riving knife to prevent workpiece kick-backs, a top safety hood to protect the operator from contact with the saw blade, and an automatic brake to quickly stop the saw blade after switching off.

The F45 ProDrive comes in various sliding table lengths, ranging from 3000 mm to 5000 mm. The weights depend on the machine equipment.