Manual - Cassese
Contents
1. 5 1 ec 3 screws V1 V2 V3 VA with a 10 mm Bring th the grooves of table stops B1 and B2 to screws open end spanner V and V2 Slide stop into screws and V4 and against the martyr cube CM Retighten screws V3 and V4 10 mm open end spanner 4 Retighten screws V1 and V2 below the table Remove screw V5 4 mm Allen key from the cylinder of set square E Move set square E below the table and screw the assembly in place with screw V5 5 Fitting the offcut outlet case _SORTIE CHUTE Fit the offcut outlet case using screws Cl and C2 5 mm Allen key ou Electrical connection The user must connect the power supply cable to a source complying with the regulations in force and protect the machine by fitting fuses 10 Amp aM for 380 Volt 3 phase and 16 Amp aM for 220 Volt 3 phase Air line fittings Advised way of fitting USA STANDARD Provide a supply pipe with an inside of 8 that will withstand the maximum pressure of the source which must not be less than 6 bar 76675 7 675 Quick release Q R Source characteristics 749 dry air no lubrication gt Q R US male Standard 7701 Z556 um SOURCE compressor Extraction To conform to hygiene standards the machine must be connected to an extraction air intake producing a maximum flow rate of 28 m second over a diameter of 100 mm The circuit comprises three intake ports 1002. Just enter the profile number and the frame size and the Smart Stop instantly adjusts its measuring stop to the exact dimension ready to cut c Memorize your frame sizes The Smart Stop can also be programmed to memorize the dimensions of up to 80 different frame sizes You can set this up for all your standard frame sizes lt Automatic width measurer This instantly measures the rebate width of the moulding about to be cut so that the cutting stop can adjust itself automatically to the correct dimension required It avoids any mistake of measurement and is much quicker than any manual adjustment Ideal for Chop Service Cc Odometer chop counter shows the total cuts made and can be reset for use as a chop counter for big production jobs lt the operator can change between short and long sizes accurately at any time at the touch of a button c Minimise operator mistakes Because of its memory and clear information readout on the touchscreen operator error is reduced to nil saving waste time and money c Multi Lingual The Smart Stop can operate in 4 different languages English French German amp Spanish OPTIONS Bar code scanning system including barcode editing software for managing your moulding profile database Connection to PC Bigger measure capacity on request Cassese QuickStop same features than SmartStop but without the Automatic Width Measurer TECHNICAL DATA Power Supply 380 22
3. blades Replacing the martyr cube Replacing the offcut support bar Replacing the table edges Maintenance troubleshooting LIST OF WEARING PARTS TECHNICAL DRAWINGS AND PARTS LISTS tA tA MO OO OO OO OO 12 12 13 14 15 16 17 18 18 19 I INTRODUCTION Saw CS 999 is a machine used to cut 45 mitres on all mouldings with solid or reconstituted wood base and with or without coating paint varnish plastic coating paper metal leaf such as gold bronze aluminium etc It cannot be used for Moulding profiles that do not have a 90 heel greater than 5 mm in height Any metal profiles Thin extruded plastic profiles plastic cords trimmings etc Its two circular blades are driven by two electric motors The moulding is held automatically by vertical and horizontal pneumatic cylinders A two hand control actuating both clamping and cutting ensures operator safety by keeping hands out of range of the blades The electrical control equipment is placed in a cabinet in front of the machine The pneumatic equipment is secured in the base of the machine behind the electrical cabinet This machine was built to meet safety and hygiene requirements It 1s therefore forbidden to modify the electrical and pneumatic equipment remove protective equipment installed on delivery or modify the machine safety devices Saw CS 999 cannot be used by more than one operator at a tim
4. mm in diameter one on each side only one plug must be connected and one at the rear of the machine This installation guarantees effective extraction and must never by dismantled or modified V STARTING UP Open the compressed air source and adjust the machine pressure regulator to obtain compressed air pressure of 6 bar Switch on the machine main isolating switch at bottom right of the machine see drawing on Page A Indicator lamp V Fig 3 Page 6 lights up MAIN ON OFF SWITCH This indicator lamp only lights if the CS 999 15 ener 15 PRESSURE REGULATOR Press button 2 Fig 3 Page 6 and check the rotation direction of one of the blades 1 e clockwise for the left blade anti clockwise for the right blade If the direction is not correct press button 3 Fig 3 Page 6 disconnect the machine and reverse the two phases on the power supply cable CONTROL PANEL NUMERIC STOP OPTION a e MACH BON V wv 7 BLADE VERTICAL STOP 4 SPEED REGULATOR 2 BLADES CANCEL RIGHT The knurled knob controls START CLAMP the blade lowering speed BLADES 6 RESET 5 CANCEL LEFT CLAMP 1 UNLOCK COVER Note The blade lowering speed must set MACHINE READY according to the material to be sawn hardness cross section coating etc the required cutting quality and the characteristics of the blades used BLADE HEIGHT REGULATOR V MACHINE OPERATIONAL V2 V3 CLAMP CANCELLATION LAMPS TWO HA
5. the two hand control Fig 4 Page 6 The rotating blades drop to low position in order to machine the martyr cube When the two hand control is released the blades lift and the indicator lamps go out MARTYR CUBE THE MARTYR CUBE AND OFFCUT SUPPORT BAR CAN BE FITTED AND MACHINED AT THE SAME TIME 14 REPLACING THE OFFCUT SUPPORT BAR Open the main case see Page 11 Open the door of the electrical cabinet using the key provided and remove screws A and B Tilt the cabinet by pulling it towards you Page 11 Next remove screw VTR 5 mm Allen key and lower the setting rod of the offcut support bar Remove screws C and D 4 mm Allen key and remove the worn offcut support bar AS Refit a new bar on the setting rod and then reinstall the assembly bar pressing below the martyr cube Lock the setting rod via screw VTR Close the main case Hook up the 3 spring clips and close their locking levers then switch on the main isolating switch Start up the blades by pressing button 2 on the control panel Fig 3 Page 6 Reduce the blade lowering speed using button 7 on the control panel Press simultaneously buttons 4 and 5 on the control panel Fig 3 Page 6 causing the two clamp cancellation lamps V2 and V3 to light up on the control panel Fig 3 Page 6 for 3 seconds During this time press buttons D and D of the two hand control Fig 4 Page 6 The rotating blades drop to low position in order to machine the offcut s
6. 0 V single or three phased connected directly to the double mitre saw Measuring capacity Outside dimension Minimum 100mm 3 9 10 Maximum 1966mm 77 4 10 Inside dimension Minimum depends on moulding s width from to 100mm Maximum 1800mm with a 83mm wide moulding Options to be chosen from the start Metric or in inches Extra longer construction for bigger measure capacity bar code scanner amp wand Connection to PC 2004 Cassese Communication CS 999 Blade height adjuster Blade height locking handle Main case Left vertical clamp locking handle 1 Right vertical clamp locking handle Left vertical clamp Right vertical clamp Moulding guide Blade protection screen T Right table eit table Right table set square Left table set square Main isolating switch Offcut outlet g Electrical cabinet Electrical cabinet door ee Main case handle Pressure regulator n Main isolating switek Extraction air intakes Numeric stop connection OPTION 220 V electrical socket for dust collectorv Foot locking nut x4 Levelling foot x4 TECHNICAL SPECIFICATIONS PRODUCT NAME CS 999 Year of build 2004 2005 Cutting dimensions Max width 93 mm Max height 100 mm Blade dimensions 0 350 mm Bore 0 30 mm Rotation speed 3400 rpm mn at 60 Hz and 2800 rpm mn at 50 Hz
7. Maximum cutting length 1500 mm Electrical power supply 220 380 3 phase 50 60 Hz Power supply cable standard cross section 4 x 2 5 H07 RNF 4G1 5 2 power motors compliant with standard EN 60204 1 5 kW Extraction air inlets outer 2 x 100 mm Tvpe of extraction compliant with standards 28 m s at 4 m for 0 100 Pneumatic power supply 6 bar Max power consumption 700 cuts hour 60 NL mn at 6 bar Weight 770 kg Noise wearing of earmuffs compulsory 90 dB Options Right extension arm 14836 2 metres 714835 0 78 metres Numeric measurement stop on request factory adaptation 714432 Smart Stop 714431 Quick Stop CUTTING CAPACITY HORS TOUT with max width 83mm 100 90 80 n 4 50 40 EXTERNAL 59 20 10 ane 10 20 30 40 so 60 70180 90 100 WIDTH B Contents DESCRIPTION OF CS 999 TECHNICAL SPECIFICATIONS I INTRODUCTION CS 999 OVERALL DIMENSIONS UNPACKING AND HANDLING IV SETTING UP THE MACHINE Setting up the left and right tables Electrical connections Pneumatic connections Extraction V STARTING UP Control panel Two hand control VI SAWING Adjusting the blade height Adjusting the clamps and cutting First cut on left Measuring the first piece Retractable stop Cutting the first piece MAINTENANCE AND SERVICING Opening the main case Opening the electrical cabinet block Removing refitting the
8. ND CONTROL EU LLLA 1 LT Pa A Buttons D and D activate a two hand control The time between pressing the two buttons must not exceed 0 5 seconds This prevents any accidental triggering if one of these 2 buttons is locked Note that when D or D is released during cutting the blades lift immediately To restart the cycle both buttons must be released and pressed again VI SAWING A Adjusting the height of the blades Set key A to blade setting Press D and D Fig 4 Page 6 to bring the blades to low position Place the moulding to be cut on the cutting table Holding rule R by its loop release handle M located on top of the cover Set the blade height using rule R or according to the height of the moulding The rule indicates the maximum clearance height for the moulding Relock handle M Check that the moulding passes correctly below the blade protection screen E Turn key A back to normal operation Note The blade protection screen E 1s set automatically according to the blade height setting The measurement on rule R 15 the height of the moulding to be cut plus approximately 1 centimetre B Setting the clamps and cut First the position of the vertical clamps must be set Place the moulding with the slot side facing the saw blades on the work table feeding it from the left side of the machine Release the handle M set the vertical clamp positioning arms BP accordi
9. Z15009 E Cassese CS 999 DOUBLE MITRE SAW 21 m T a D a 5 5 Bm a TECHNICAL AND USER MANUAL MANUEL D UTILISATION amp TECHNIQUE 09 2004 AUTOMATIC MEASURING STOPS CASSESE SMARTSTOP DIGITAL AUTOMATIC MEASURING STOP CS 999 Digital Stop EL E i 4 ae p d 1 LLL li p 3 25 54 oT T a PA er tL ri ndly LCD Touch Screen User Frie Automatic Width Measurer 4 0 The Cassese Smart Stop is an option which is available for the CS939 CS 939 amp CS999 Saws The special Smart Stop Saw will have all of the features of the CS939 or CS999 Saw but with a computerised automatic stop measuring system available in Metric or in Inches The Smart Stop 1s designed for the high volume contract or chop service framer who likes to maximize productivity and minimize operator errors FEATURES OF THE CASSESE SMART STOP 7 User friendly touch screen tells the operator all information required to store or retrieve any moulding profile and or frame size minimising mistakes and wastage 7 Fast setup time The Smart Stop can be easily programmed to cut either a small photo frame or a large mirror frame in a few seconds c Memorize your mouldings The Smart Stop can be programmed to memorize the cutting process for up to 800 different moulding profiles
10. chine 3 The trimmings case to the left of the machine 3 Remove the suction tip Using cross head screwdriver remove the wedges from the 4 legs of the machine Handling Use a fork lift truck fitted with forks at least 115 cm long taking care to position them correctly below the frame see below Gross weight of machine 770 kg CAUTION TO MOVE THE MACHINE FROM THE PALLET TO THE GROUND SET THE FORKS 330 MM APART FOR THE OTHER HANDLING OPERATIONS SET THE FORKS 550 MM APART CAUTION u SAFETY Position of forks DISTANCE centred on the m 50 MM frame axis m Sr te amp Once the machine i is installed remove mm between the e rotection ground and the base p of the machine 22 330 mm fork lift truck 550 mm IV SETTING UP THE MACHINE There must be sufficient clearance around the machine i QU ud A 4 4 to allow free movement and access maintenance It must be placed on a stable and generally flat floor Before making any electrical or pneumatic connections level the machine by means of the adjustable feet Use a 24 mm open end spanner for locking nut CE and a 12 mm open end spanner for base B Tighten locking nut CE firmly after adjustment and levelling As the work surface is 900 mm from the floor it may be necessary to install a platform for operators of short stature en the left eis tables
11. e Residual risks Hands must never be inserted inside the beyond the plastic screens of the top protection cover as this section contains the pressure cylinders and rotating saw blades in their high idle position STANDARD CS 999 OVERALL DIMENSIONS 958717 00 2 uoisua x 14614 68712 ul 97 0 1 14 1 1I03N83A 06624 9 13 11 3 12 HJ 892 OSI sgjeJauel 5 sexueJa 101 a L Th Wa 5 CE 7 4 ro 0609 ZH 09 09 eseud e A 082 022 SUOI DBUUOD 6211199 3 10 099 09 101 194205 e211199 3 9 NO INDO 8SS1 9 Ajddns UNPACKING AND HANDLING This machine is packaged in a crate containing 1 left extension arm 1 box containing one 10 mm Allen key to remove blades one 6 mm Allen key to assembly tables one 3 mm Allen key triangular key quick fit coupling fitted on the machine 1 barbed connector 1 USA connector 1 quick fit coupling see page 6 1 blade steadying handle Fuses 1 25 Amp aM 2 Amp aM 4 Amp aM with numeric stop option ig 5 7 L 1 E 3 he i E E H 7 v 2 4 E E hu Remove 1 The left and right hand arms to the right of the machine 2 Accessories box to the rear of the ma
12. lectrical cabinet and check on the electronic card to see which item in the chain is faulty LED red lit COVER SAFETY DEVICE THERMAL CIRCUIT BREAKER 2 THERMAL CIRCUIT BREAKER 1 Check that the coveris Reset the thermal safety device If it Reset the thermal safety device If it closed correctly trips again call the After Sales trips again call the After Sales service service STOP BLADES Check the red STOP BLADES button COMPRESSED AIR Check the air supply THERMAL CIRCUIT BREAKERS LIST OF WEARING PARTS ZCODE PARTNAME ZCODE PARTNAME 2 2843 FLEXIBLE STOP 20x8 5 M6x15 1 214376 OFFCUTSUPPORTROD 1 214070 SHAFT 2 211257 VENTILATIONFILTER GRILL 1 214830 CUTTINGSQUARE 1 2555 FUSE 2A10x38 aM i1 214831 RIGHTTABLEEDGE 1 2145 FUSE 4A 10x38 aM 1 214832 LEFTTABLEEDGE 3 21688 RULEO 500mm 2 21570 BLADE 350 108 TEETHLR 3 21676 RULEO 1000mm 2 211476 BELTXPZ710 3 172942 RULE1000 2000mm 1 2674 GLASS FUSE 1 5A 5x20 18
13. ng to the profile and width of the moulding Start up the right clamp for example via button D Fig 4 Page 6 and check that the clamp pressor does not tilt the moulding 4 The back of the moulding must be pressed firmly against the stops and the bottom against the work table To be sure of obtaining good cutting quality and the essential safety conditions the moulding must be immobilised and completely stable Repeat the test under the same conditions for the left clamp using button D C First cut on the left The right clamps vertical and horizontal must be cancelled by pressing button 4 on the control panel Fig 3 Page 6 After the first cut these clamps will be reactivated If this precaution is not taken the clamps may push the moun against the instead of immobilising it Place the moulding with the slot side facing the saw blades on the work table feeding it from the left side of the machine Slide the moulding against the moulding guide and towards the cutting table keeping the B offcut minimising knob MC pressed 4 When the moulding comes to stop ES position against the offcut minimiser MC it will be in the best position for cutting with minimum offcut Start up the blade motors via button 2 of the control panel Fig 3 Page 6 then use buttons D and D Fig 4 Page 6 to actuate clamping followed by blade lowering The first cut 15 then produced Buttons D and D Fig 4 Page 6 activate a
14. rol buttons are kept pressed after cutting the corresponding clamps will not be released and the moulding ends or offcut can be retrieved without being extracted to the offcut case If the offcut or piece of moulding does not drop under gravity after a cut and cannot be retrieved from outside the cover it must be cleared by pushing with the next moulding Or a stick It is strictly forbidden to cut several lengths of moulding at the same time by lining them up one in front of the other The operator must never put his hands inside the case When the machine 18 in use there must be no more than one person at the workstation This person is responsible for the controls The sawing operation blade lowering is only possible with the horizontal and vertical pneumatic clamps engaged and the saw blades rotating If one of the buttons 15 released during cutting the blades are withdrawn but the clamps remain engaged The cycle can be restarted by pressing buttons D and D Fig 4 Page 6 or the cycle can be reset via key 6 of the control panel Fig 3 Page 6 If the electrical circuit 1s accidentally broken the blades are withdrawn immediately When power 15 restored the motors will only start up when button 2 15 pressed on the control panel Fig 3 Page 6 In the event of an operating problem immediately press button 3 STOP BLADES red thrust button on the control panel Fig 3 Page 6 and before taking any further action s
15. ronic cards and PLC to operate correctly The filters ref Z11258 placed each side of the cabinet must be replaced at regular intervals 16 MAINTENANCE Depending on the frequency of use On the basis of 8 hours work a day Cleaning clean the plexiglass screen with a soft cloth Belt inspection every 3 months Blade sharpening good cutting is the result of good sharpening We recommend contacting your dealer for this service Type of blade recommended for multi purpose cutting Teeth Number of teeth Body thickness Dia 350 3 positive LR FAULT POSSIBLE CAUSES Check the electrical power supply Indicator lamp V on control panel Main isolating switch not engaged Fig 3 Page 6 1s off Fuses need to be changed The blades have not been started up The clamps operate but the blades Buttons D and D not pressed simultaneously do not lower Fig 4 Page 6 Blades turning in wrong direction Poor quality cut Blades need to be sharpened Moulding in unstable position and moves during cutting Blade lowering speed not suitable for the type of wood being cut An offcut may be preventing the blades from Right clamp cancellation lamp V3 lifting fully flashes on the control panel Fig Check the condition of the high position sensor 3 Page 6 and its distance from the blade block BL 1 5 mm MAX 17 FAULT POSSIBLE CAUSES Indicator lamp V1 is off Safety chain broken Open the e
16. ts always pull the key towards you and remove the flange and blade USING THE Steadying handle STEADYING HANDLE 10 mm Allen ke REFITTING THE BLADES Clean the blades and flanges Fit the blade teeth pointing in cutting direction Check the cutting direction carefully it is marked on the support Refit the flange and screw then tighten the screw while holding the steadying handle to immobilise the shaft Close the main case Hook up the 3 spring clips and close their locking levers then switch on the main isolating switch Lock the cover by setting the key to Normal operation position 13 REPLACING THE MARTYR Open the main case Page 11 Loosen screw V1 using a 5 mm Allen key and remove the worn martyr cube by sliding it towards the inside of the machine Refit the martyr cube so that a sound side is facing the blades and secure it with screw V1 Close the main case Hook up the 3 spring clips and close their locking levers then switch on the main isolating switch Lock the cover by setting the key to NORMAL OPERATION POSITION Start up the blades by pressing button 2 on the control panel Fig 3 Page 6 Reduce the blade lowering speed using button 7 on the control panel Press simultaneously buttons 4 and 5 on the control panel Fig 3 Page 6 causing the two cancellation lamps V2 and V3 to light up on the control panel Fig 3 Page 6 for 3 seconds During this time press buttons D and D of
17. two dimensions of the frame at any time Fig A Fig B The Cassese removable stop is a positive stop easy to retract by a simple action on lever L It remains stable and without play both in engaged and retracted positions Measuring Scale Each measuring stop is indexed red mark 8c I2 which indicate which one of the two scales rules is to be used with this stop These scales are for direct read off of outside measurements of the frame Sliding Removable Stop RI with Fixed R2 lin I2 Figure A The special design of the removable stop makes all mouldings to be placed in the best Way the system of the machine even if the moulding is twisted Cutting the first piece The moulding is in contact with either the mobile stop or the retractable stop Press buttons D and D Fig 4 Page 6 for left and right clamping followed by blade lowering END OF MOULDING Clamping and cutting are visible to the operator He must therefore check that the horizontal clamp on the left is properly engaged in the moulding slot and does not create pressure on the end of the moulding If it does the operator can only continue with clamping on the right once the left clamp has been cancelled via button 5 on the control panel Fig 3 Page 6 Note The left clamp will be automatically reactivated at the next cycle If the two hand cont
18. two hand control The time between pressing the two buttons must not exceed 0 5 seconds This prevents any accidental triggering if one of these 2 buttons is locked Note that when D or D is released during cutting the blades lift immediately To restart the cycle both buttons must be released and pressed again D Measuring the first piece mobile stop MEASURING THE SLOT BASE INTERNAL required dimension by tightening the locking M i slide the CURSOR along the rule and lock it at the screw Bring the moulding to the cursor so that the edge of the slot base coincides with the 45 angle Keeping the moulding in position bring the MOBILE STOP into contact with the moulding and lock it Remove the cursor below the moulding Slot base measurement is now 4 complete READING POINT EXTERNAL ey MEASUREMENT wa LOCKING B Release the MOBILE STOP PUNCH MARK HANDLE lE locking handle Slide it on the rule until it reaches the required measurement Be sure to measure using the external rule in relation to the punch mark on the mobile stop block The external measurement 15 complete RETRACTABLE STOP Storing a second cutting point in the memory FOR THE SLOT BASE MEASUREMENT USE THE SAME PROCEDURE AS FOR THE MOBILE STOP PAGE 9 FOR THE EXTERNAL MEASUREMENT USE THE SAME PROCEDURE AS FOR THE MOBILE STOP PAGE 9 BUT USE THE INTERNAL RULE Allows the measuring and cutting of
19. upport bar When the two hand control is released the blades lift and the clamp indicator lamps go out THE MARTYR CUBE AND OFFCUT SUPPORT BAR CAN BE FITTED AND MACHINED AT THE SAME TIME LIf the cut has defects such as tears of the paper coating covered mouldings or splintering of the base below the moulding you must REPLACE THE TABLE EDGES Open the main case see procedure on Page 11 Switch off the machine at the main isolating switch located on the right side of the machine and lock the switch by padlocking the tab Open the door of the electrical cabinet using the key provided and remove screws A and B see Page 11 Tilt the cabinet Remove screws 1 Vb2 and Vb3 from worn table edges using a 4 mm Allen key Fit the new table edges on the cutting table Close the main case Page 13 MACHINING THE TABLE EDGES Start up the blades by pressing button 2 on the control panel Fig 3 Page 6 Reduce the blade lowering speed using the knurled screw Press simultaneously buttons 4 and 5 of the control panel Fig 3 Page 6 This causes lamps V2 and V3 to light up on the control panel Fig 3 Page 6 for 3 seconds During this time press buttons D and D of the two hand control The rotating blades drop to low position in order to machine the table edges When the two hand control 15 released the blades lift and the indicator lamps go out Internal ventilation of the electrical cabinet 15 required for the elect
20. witch off the power supply at the main isolating switch Fig 1 Page 6 11 VIL MAINTENANCE AND SERVICING When the cover is open motor start up and blade lowering are disabled by the safety unit PROCEDURE FOR ACCESS INSIDE THE MACHINE Opening the main case Press button 3 on the control panel Fig 3 Page 6 if necessary Position the control panel key to unlock cover Wait during the 20 second time out until green lamp V1 Fig 3 Page 6 goes out indicating that the blades have stopped completely Lift the locking levers of the 3 spring clips S1 S2 and 53 and release the hooking mechanism Using handle P pivot the cover upwards and let it rest on the flexible stud at the top of the machine For all maintenance adjustment or repair operations prevent unintentional operation of electrical and pneumatic circuits on the machine by padlocking the main isolating switch cabinet using the key provided and remove screws and B Tilt the cabinet by pulling it IESU 2 2 towards you 12 REMOVING THE BLADES IMPORTANT Switch off the machine at the main isolating switch Page 6 located on the right of the machine and lock the switch by padlocking the tab During this operation gloves should be worn to handle the blades and to avoid getting yours hands caught Use the steadying handle provided to immobilise the shaft loosen the nut when loosening the blade securing nu
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