CRATER-02 A AUTOMATIC 16.5” UPCUT MITER SAW User`s Manual
Contents
1. 02 AUTOMATIC 16 5 UPCUT SAW User s Manual 1 Operating and Safety Instructions CONTENTS 1 General Information 1 1 Introduction 1 2 Manufacturer 2 5 Description and Purpose of Use 2 1 Machine s description 2 2 Technical features 2 3 Cutting diagram 2 4 Overall dimensions 2 5 Part lists and technical drawings 2 6 Electric and pneumatic control panel 3 Safety 3 1 Safety information 3 2 Accident prevention 3 3 General safety information 4 Transport of your machine 5 Installation of your machine 5 1 Preparation 5 2 Electric connection 6 Machine Safety Information 7 Operation 7 1 Operating guide 7 2 Adjusting the air pressure 8 Safe installation of the saw blade 9 Maintenance 9 1 Routine controls and maintenance 9 2 Maintenance at the end of the working day 10 Troubleshooting Guide 11 Electric pneumatic components 11 1 Electric Components 11 2 Pheumatic Components 2 Operating and Safety Instructions Page 9 WW Co 09 1 GENERAL INFORMATION 1 1 INTRODUCTION The user s manual given by the manufacturer contains necessary information about the machine parts Each machine operator should read these instructions carefully and the machine should be operated after fully understanding them Safe and efficient use of the machine for long term depends on understanding2. vertical pneumatic clamps can be adjusted very easily according to the material 7 1 3 The clamp piston of pneumatic clamps moves 55 mm The clamping cylinders have to be outside of the saw blade moving area CORRECT WRONG Illustration 10 Illustration 9 7 1 4 Avoid randomly pressing the buttons on the panel If you feel danger during the cutting operation push the emergency stop button immediately which will terminate the Operation 7 1 5 Close the front cover on the main frame and the control panel and lock it with its key See Illustration 1 For safety reasons the motor will not start unless the main frame front cover is closed NOTE The main frame front cover and the rear panel cover can be open only during maintenance and cleaning of the machine During this work switch the MAIN SWITCH to 0 before opening the cover 7 1 6 If the profile to be cut is broad and high you can move the back fence up to the rear stop pins after loosening the M8 screws The back fence can be moved up to 100 mm 4 to the back See Figure 11 For maximum cutting dimensions and positions see the cutting diagram on page 5 Fix the so called bridge by tightening the M8 hexagonal screws 15 Operating and Safety Instructions Ad ATECH NOTE Ensure that the MAIN SWITCH is on 0 during this operation 7 1 7 Adjust the cutting angle on the scale located on the machine table 15 22 5 30 459 909 To turn the tab
3. J 243 011 65 5610 47 J 1 241 027 MFH 5 1 8 24VAC VALVE 24 Operating and Safety Instructions PNEUMATIC SCHEME iPNUS0000 0001 i 5 oT iPLOT0000 0019 1EL020000 0018 PRESSURE SENSOR T M Peper LUBRIUCATION SYSTEM FP P2 A AI TELTE 8 1 Y1 5 2 AIR INPUT 4 s von Blatt 25 Operating and Safety Instructions WIRING SCHEME JU AMETS PROD NAME CRATER ELECTRICAL 1 ALI DEMIREZEN 13 08 2003 ADNAN 26 Operating and Safety Instructions
4. L DRAWINGS No Part Name Order Number 211 010 Blade Guard 201 005 420 mm Saw blade 33 Angular Back Fence right 2 and Left Pneumatic Clamp Set Square 2 2 kW Electric Motor Hydro Pneumatic Cylinder Table Locking Pin Angle Adjustment Pin Motor Start Stop Cutting Start Cutting Start Speed Adjustment Emergencyst op Clamp Button Main Switch Figure 2 7 Operating and Safety Instructions NO 7 QTY 7 Conveyor Foot Foot 8 Conveyor Profile Profile 9 M8x20Bot x 20 Bolt n Profile Support KN 2 Conveyor 24V Transformer Contactor 24V Coil 4 gt Overload Protection MVH 1 5 Valve Relais Air pressure safety switch Figure 3 Figure 4 8 Operating and Safety Instructions A ATECH 2 6 ELECTRIC AND PNEUMATIC CONTROL PANEL The electric and pneumatic control panel enables you to make adjustments regarding the air pressure The cover of the panel has to be definitely kept closed during operation At servicing works for remedy of defects SWITCH OFF THE ELECTRIC AND PNEUMATIC SUPPLY CONNECTIONS For safety reasons the air pressure safety switch located on the panel deactivates all pneumatic components in case that the air pressure drops below 4 Bar If the air pressure is lower than 4 Bar the saw blade and pneumatic clamps will not operate 3 SAFETY 3 1 SAFETY INFORMATION The symbols shown hereunder are n
5. allation electric pneumatic maintenance of the machine should be carried out by qualified personnel only 6 8 4 Routine maintenance and scheduled maintenance should be carried out by qualified personnel after unplugging the machine and disconnecting the air supply first 6 8 5 Ensure that the machine has been cleaned tested and maintain before starting to operate 6 8 6 Check the safety devices power cable and moving parts regularly Don t operate the machine before having replaced defective safety devices or faulty parts 6 8 7 Never replace the saw blade before unplugging first 6 8 8 Keep foreign materials away from the working area of the machine keep away from the machine s moving parts he safety data have been defined above In order to prevent physical damage or damage to the equipment please read the safety information carefully and keep the manual always in an easy accessible place 7 OPERATION 14 Operating and Safety Instructions automatic upcut saw model CRATER 02 A cuts non ferrous aluminum PVC profiles and PVC materials The operator adjusts manually via knob the cutting speed of the saw blade according to the material type to be cut Inner and outer sharp edges of the carbide tipped circular saw blade ensures high quality clean cutting results 7 1 1 Start the machine only after proper clamping of the work piece to be cut 7 1 2 The machine is equipped with vertical clamps These
6. and following the instructions contained in this manual The technical drawings and details contained in this manual constitute a guide for the operator 1 2 DISTRIBUTOR ATech Machine Inc 10752 A Tucker Street Beltsville MD 20705 USA Phone 1 301 595 1816 gt Fax 1 301 560 6627 Website www ATechMachinery com E mail info ATechMachinery com In case of any technical problem please contact your nearest ATECH dealer or ATECH head office through the above mentioned phone fax or e mail address Technical labels with the model description of the machine are fixed onto the front side of each machine machine s serial number and manufacturing year are stipulated on the technical label 2 MACHINE S DESCRIPTION AND PURPOSE OF USE 2 1 MACHINE S DESCRIPTION Automatic upcut saw with circular saw blade for serial cutting of PVC aluminum and wooden profiles in desired angles The operator has the possibility to adjust the cutting speed of the saw blade via knob according to material type and size Cutting at fixed angles of 15 22 5 30 45 90 and at intermediate angles via fixing arm Machine has been designed according to CE Safety Directives movable back fence enables straight and angle cutting of broad profiles cutting speed can be adjusted manually according to material type If the protection cover is opened during the cutting operation the saw blade moves down to its start
7. clamped appropriately by the machine s clamp Or vice 3 3 11 Ensure safe working position always keep your balance 3 3 12 Keep your machine always clean for safe operation Follow the instructions at maintenance and replacement of accessories Check the plug and cable regularly It damaged let it replace by a qualified electrician Keep handles and grips free of any oil and grease 3 3 13 Unplug first before conducting and maintenance works 3 3 14 Ensure that any keys or adjustment tools have been removed before operating the machine 3 3 15 If you are required to operate the machine outside use only appropriate extension cables 3 3 16 Repairs should be carried out by qualified technicians only Otherwise accidents may occur 3 3 17 Before starting new operation check the appropriate function of protective devices and tools ensure that they work properly All conditions have to be fulfilled in order to ensure proper operation of your machine Damaged protective parts and equipment have to be replaced or repaired properly by the manufacturer or dealer 11 Operating and Safety Instructions 3 3 18 Don t use machines with improper functioning buttons and switches 3 3 19 Don t keep flammable combustive liquids and materials next to the machine and electric connections 4 TRANSPORT OF THE MACHINE The transport should be done by qualified personnel only The machine should be t
8. contained in this manual have to be observed fully The machine cannot be operated in any way for purposes other than those described herein Otherwise the manufacturer shall not be deemed responsible for any damages or injuries And such circumstances would lead to the termination of the warranty 3 3 GENERAL SAFETY INFORMATION 3 3 1 power cable should be led such a way that nobody can step on it or nothing can be placed on it Special care has to be taken regarding the inlet and outlet sockets 3 3 2 If the power cable should be damaged during operation don t touch and Unplug it Never use damaged power cables 3 3 3 Don t overload machines for drilling and cutting Your machine will operate more safely with power supply in accordance with the stipulated values 3 3 4 Don t place your hands between parts in motion 10 Operating and Safety Instructions 3 3 5 Use protective eye glasses and ear plugs Don t wear oversize clothes and jewels These can be caught by moving parts 3 3 6 Keep your working place always clean dry and tidy for accident prevention and safe operation 3 3 7 Use correct illumination for the safety of the operator ISO 8995 89 The Lighting of Indoor Work Systems 3 3 8 Don t leave anything on the machine 3 3 9 Don t use any materials other than those recommended by the manufacturer for cutting operations on the machine 3 3 10 Ensure that the work piece is
9. ctions have to be made by a qualified electrician the rotation direction of the saw blade has to be observed by starting the machine If the saw blade rotates in reverse direction the socket connections have to be checked and re connected properly If the saw blade rotates in reverse direction it will cause danger for the operator and the equipment Saw Blade Rotation Direction To correct the rotation direction of the saw blade insert the electric power socket of the machine to the 3 phase slot which has been prepared before and folow these instructions 1 Press the Motor Start Button operate the saw blade 2 Monitor the rotation direction of the saw blade through the blade slot 3 The correct direction is shown with an arrow on the machine table See Figure 7 13 Operating and Safety Instructions The electric socket connections to be checked and corrected by a qualified electrician The rotation direction of the saw blade should not be defined before testing Saw Blade Guard 50 160 Cylinder Hydro pull Hydro Pneumatic cylinder System Group Hydro pull depot cylinder 6 MACHINE SAFETY INFORMATION 6 8 1 1 is not allowed to operate the machine with the protective cover and other protective equipment removed 6 8 2 Your machine operates with 400V 440V 3 Phase 50Hz 60Hz Let the electric installation of your machine carry out by a qualified electrician only 6 8 3 Lifting inst
10. ecessary to be read with special attention Not reading or observing of them may cause damage to the equipment or personal injury The IMPORTANT symbol above is one telling to apply special care and to be careful at carrying out the specified operation CAUTION Symbol above warns you against specific dangers and requires to read the text Not observing may cause damage to the equipment DANGER WARNING above symbol DANGER WARNING warns you against specific dangers and you have definitely to read them Negligence may cause damage to the equipment and bodily injury Read the user s manual carefully before using the machine or carrying out maintenance works 9 Operating and Safety Instructions 3 2 ACCIDENT PREVENTION 3 2 1 Our machines are manufactured in accordance with EN 60204 1 and EN 292 2 CE safety directives which cover national and international safety directives 3 2 2 It is the task of the employer to warn his staff against accident risks to train them on prevention of accidents provide for necessary safety equipment and devices for the operator s safety 3 2 3 Before starting to work with the machine the operator should check the features of the machine learn all details of the machine s operation 3 2 4 Machine should be operated only by staff members who have read and understood the contents of this manual 3 2 5 All directives recommendations and general safety rules
11. er of the blade washer is 30 and 32 mm 8 4 Nuts Blade Bracket I Saw Blade Protection Front Cover Blade Washer Online Na Washer i MIO x20 Blade Bracket II 7 Hex Screw 30x8x7 Washer 420 mm Saw Blade Figure 14 20 Operating and Safety Instructions 17 mm Wrench Key blade shaft Figure 15 9 MAINTENANCE 9 1 ROUTINE CONTROLS and MAINTENANCE 9 1 1 BEGINNING OF THE WORK 9 1 1 Ensure that the table and all kind of parts are clean and dry Degrease and dry the table Especially ensure that the holding grips are clean and 9 1 2 Remove all burr chip and foreign materials from all surfaces of the machine Use protective eye glasses 9 1 3 Check the saw blade before each use Turn the saw blade carefully after removing the blade guard to see the teeth of the saw blade Replace the saw blade if it is damaged 9 1 4 Check the pressure of the air pressure system If necessary adjust the air pressure between 7 8 Bar See Page 22 No 7 2 9 1 5 Check the air pressure filters and the oil level of the conditioner Fill up if the oil level islow See Page 22 No 7 2 Unplug and disconnect the air pressure connections first before carrying out these works 9 2 MAINTENANCE AT THE END OF THE WORKING DAY 9 2 1 Disconnect electric and pneumatic connections Main Switch must be on 0 position 21 Operating and Safety Instructions Ad ATECH 9 2 2 Remove all burr c
12. f the main frame with its key 8 1 2 Remove the four bolts on the saw blade guard with an appropriate key by turning clockwise 8 1 3 Remove the front cover of the saw blade guard by holding its handle 8 1 4 Remove the screw In Figure 14 by turning it counter clockwise with 8 mm hexagonal key Hold the saw blade shaft at the opposite end with a 17 mm wrench key and prevent so that the shaft turns Figure 15 8 1 5 Remove the 30x8x mm washer outer nut washer and the saw blade bracket in an order See Figure 14 8 1 6 Remove the saw blade carefully 8 1 7 Insert the new saw blade on the saw blade shaft ensuring correct rotation direction See Figure 7 8 1 8 Insert the other parts washer outer nut washer and saw blade bracket in reverse order as removal 8 1 9 Tighten the M10 screw with a 8 mm hexagonal key by turning in clockwise direction Prevent the saw blade shaft from turning by holding it with a 17 mm wrench key 18 Operating and Safety Instructions 8 1 10 It is necessary to sharpen replace the saw blade in certain intervals depending on the cutting material If the cut material leaves burr after the cutting operation or if the saw blade is strained it needs to be sharpened replaced 19 Operating and Safety Instructions 8 1 7 When replacing the saw blade use the part of the saw blade washer 48 which is in accordance with the saw blade shaft diameter The outer diamet
13. hip and foreign materials from the machine surfaces If it is necessary to clean the inside of the blade guard remove the front cover use gloves to protect your hands from the sharp edges of the blade 9 2 3 If water or water based liquids were used during cutting dry the machine with a dry cloth after the operation is finished 9 2 4 Apply a thin layer of machine oil to protect the table against corrosion If the machine will not be used for a long time lubricate with a protective oil 9 2 5 Don t use materials for cleaning the machine which could damage its paint 9 2 6 Lubricate both surfaces of the saw blade with machine oil in order to protect it against corrosion 10 TROUBLESHOOTING GUIDE are some recommendations for solving urgent problems If the trouble cannot be solved or if you have a problem other than those described hereunder please contact our technical service or your nearest dealer TROUBLE CAUSES REMEDY Low surface quality at Not cooling the saw blade Lubricating the saw blade cutting aluminum and similar surfaces surfaces materials Using of cooling liquid Rough surface Large chip Check the saw blade teeth Not homogenous surface saw blade Replace if necessary oaw blade traces visible Saw blade moves to quick The cutting speed is too high for the material Decrease the cutting speed Motor does not work Start No power supply to the Check the electric cable button is pressed
14. ing point automatically due to safety reasons After the cutting operation is finished the saw blade moves down automatically from the top rising point Please include the below mentioned data in all your correspondence regarding the machine with the manufacturer and or your ATECH dealer 3 Operating and Safety Instructions Machine model Machine s serial number Voltage and frequency Name of dealer where machine was purchased Date of purchase Description of the machine fault Average daily operation period Protective Upper Cover Control Panel Control panel Lock General Key Frame Cover Cover Lock CRATER 02 A Illustration 1 Note for safety reasons the motor does not start unless the upper protective cover is closed 4 Operating and Safety Instructions 2 2 TECHNICAL FEATURES Technical Features FF Metric EL La 2 2kW D 420 mm 02 400V 50Hz TEE A 6 8 35 l min 90x85x130 cm Technical ra Features immi J Een ur WL XH ale 3000 rpm Er 35 x34 x51 CRATER 02 Phase 220V 440V 60Hz 4 30 32 mm 2 3 CUTTING DIAGRAM L1 1 1 L H HHHHHHHHHHHHHHHHH I mm 0 450 150 Th 730 290 ge 48 5 Operating and Safety Instructions 2 4 OVERALL DIMENSIONS Figure 1 6 Operating and Safety Instructions 2 5 PARTS LIST AND TECHNICA
15. le release the table locking pin by turning counter clockwise Fix the desired intermediate angle with the angle adjustment lever Figure 3 Fix the turning table by tightening the table locking pin Figure 3 NOTE WHILE CARRYING OUT ANGLE CUTTING OPERATIONS ON THE MACHINE ENSURE THAT THE CLAMP CYLINDERS AND RIGHT LEFT MOVING FENCES REMAIN OUTSIDE OF THE CUTTING AREA Figure 9 10 7 1 8 Adjust the cutting length of the material using the metric system with length stop units on the conveyor See Figure 4 After adjusting the cutting length fix the profile support fence by tightening the handle No 11 in Figure 4 7 1 9 Ensure clamping of the work piece by the vertical pneumatic clamps pressing the clamp button on the machine See Figure 3 7 1 10 Start the saw blade by pressing the Motor Start Button Figure 3 7 1 11 Press both Cutting Start Buttons simultaneously Figure 3 to move the saw blade 7 1 12 The circular saw blade will rise and cut the work piece and will move down automatically after cutting the work piece It will continue to turn inside the guard until the Cutting Start Buttons pressed again 7 1 13 The rising speed of the saw blade can be adjusted manually Figure 3 7 1 14 Press the clamp button to release the work piece and take it out 16 Operating and Safety Instructions Figure 12 Figure 11 17 Operating and Safety Instructions A ATECH NOTE Adjust the air pre
16. not machine Main Switch is in connections working 0 position Check the electric power sockets The upper protective cover Switch the Main Switch to or the front cover is open Close the upper cover and the front cover Motor is working but the The air supply connections Check the air compressor pneumatic clamp pistons do are missing or the air connections not work pressure is below 4 Bar Adjust the air pressure between 6 8 Bar on the conditioner The saw blade rotates in The electric connection Let the electric connections carry reverse direction the power cable or the out by a qualified electrician connection at the panel is wrong 22 Operating and Safety Instructions A ATECH 11 ELECTRIC PNEUMATIC COMPONENTS 11 1 ELECTRIC COMPONENTS STOCK CODE PART NAME 161 006 MAIN SWITCH 162 011 HERMAL SWITCH LR2 0312 1 162 012 RANSFORMER 61504 1 162 037 K 0610 B7 163 002 2 2 kW ELECTR MOTOR 3 Phase 164 009 D 0 75 CABLE SPECIAL HO5W F 4 CABLE 164 013 4 1 5 TTR CABLE HO 7RN F 164 016 4 1 5 TTR CABLE 164 022 7 0 75mm CONTROL CABLE 164 023 2 9 mm NYAF CABLE YELLOW 0 65 GREEN 2 165 043 FUSE CONNECTOR UK 5 HS WSI 6 23 Operating and Safety Instructions Ad ATECH 11 2 PNEUMATIC COMPONENTS PART NAME QTY FKV 1 4 HYDRAULIC LIMITER 6mm AIR HOSE 9 45 2 5 _ 241 008 H 228W SELECTIONKEY _ 241 016 l 8EXHAUST SC SINTER
17. ransported by lifting with proper equipment not touching the ground during the transport Don t the machine before ensuring that lifting devices or other equipment is placed properly under the machine 5 INSTALLATION OF THE MACHINE he machine should be located at least 50 cm away from the back wall in order to enable full opening of the upper cover to the back and to carry out maintenance and cleaning works on the machine For the distance to be left on the left and right side of the machine see Figure 6 and Dimensions 5 1 PREPARATION 5 1 1 The outer dimensions of the machine are stipulated in the Dimensions page Page 7 The ground where the machine will be placed should be even solid enough to bear the weight of the machine 5 1 2 At our upcut saw CRATER 02 A all parts are delivered by the manufacturer ready for Use 5 1 3 Assemble the KN 2 conveyor which is delivered as standard accessory to the right side of the machine as shown in Figure 3 12 Operating and Safety Instructions 5 2 ELECTRIC CONNECTION 5 2 1 The three phase power cable socket has to be in accordance with the socket on the machine 5 2 2 Use a connection cable socket in accordance with the CE Safety Directives 5 2 3 Check the inlet power supply before powering the machine See Page 18 Item 3 8 3 5 2 4 Make the electric socket connections after switching the MAIN SWITCH on the machine to O The socket conne
18. ssure between 7 8 Bar The air pressure is read in Bar from the manometer If the value read on the manometer is the lower or higher than the desired pressure adjust the pressure between 7 8 Bar by turning the air pressure adjustment key to the right or to the left accordingly Figure 12 If the air pressure drops below 4 Bar the saw blade and the clamps will not operate due to safety reasons 7 1 15 The conditioner unit collects the water within the air system in a receptacle in order to prevent damage to the pneumatic system components Discharge this water periodically at the end of the working day by pressing or opening the button under the conditioner 7 2 ADJUSTING THE AIR PRESSURE 7 2 1 Pull the adjustment button of the conditioner upwards See Figure 12 a Turning the adjustment button in clockwise direction increases the pressure b Turning the adjustment button in counter clockwise direction decreases the pressure 7 2 2 Once you read 6 8 Bar on the manometer push the adjustment button of the conditioner down and lock it in that position See Figure 12 7 1 3 Ihe manufacturer recommends to use the following oils with the conditioner TELLUS C 10 BP ENERGOL HLP 10 MOBIL DTE LIGHT PETROL OFISI SPINDURA 10 8 SAFE INSTALLATION OF THE SAW BLADE 8 1 To remove the circular saw blade from the blade shaft follow the instructions below 8 1 1 Switch the MAIN SWITCH on the machine to Open the front cover o
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