Starrett S4220 & S4230 Band Saw Machines Manual by The L.S. Starrett Company Ltd

Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Starrett Call Center: +55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br

Instructions Manual for installation and maintenance band saw machine model:

S4220 & S4230 The Original Manual was written in Portuguese

serial number: date:

Prior to installing or performing any operation, carefully read this Instructions Manual on the use of this machine. For further information or clarifications, please contact Starrett. REV. 3 [1] - AGO/13

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GENERAL INDEX 1. COMPLIANCE CERTIFICATE ..................................................................................... 1 2. WARRANTY............................................................................................................ 5 3. MACHINE IDENTIFICATION ..................................................................................... 7 4. TECHNICAL DATA .................................................................................................... 9 4.1. STANDARD ITEM........................................................................................................................... 10 4.2. PARTS LIST..................................................................................................................................... 10 4.3. APPLICABLE LEGISLATION AND TECHNICAL STANDARDS ........................................................ 13

5. SAFETY RECOMMENDATIONS ............................................................................... 15 6. MACHINE DESCRIPTION ....................................................................................... 21 7. USAGE AND OPERATION INSTRUCTION ................................................................ 29 7.1. ADJUSTMENTS AND CHECKS ...................................................................................................... 29 7.2. MATERIAL TO BE CUT ................................................................................................................... 31 7.3. ADJUSTMENT OF HEIGHT OF CUTTING...................................................................................... 32 7.4. ANGLE CUT PROCEDURE ............................................................................................................. 33 7.5 BAND SAW BLADE REPLECEMENT AND ADJUSTMENT PREOCEDURE .......................................36 7.6 BAND SAW BLADE CONSIDERATION.............................................................................................38 7.7 COOLING OF CUTTING ..................................................................................................................39 7.8 HYDRAULIC SYSTEM ......................................................................................................................41 7.8.1. ADJUSTMENT OF MOBILE VISE PRESSURE ....................................................................... 41 7.8.2. START, NORMAL STOP AND EMERGENCY OF MACHINE .................................................. 41 7.8.2. STOP OF MACHINE .............................................................................................................. 43

8. CRITERIA FOR BAND SAW SELECTION ................................................................... 45 8.1. LIMITS AND RECOMMENDATIONS ............................................................................................. 45 8.2. CRITERIA FOR BAND SAW SELECTION ........................................................................................ 45 8.2.1. TEETH ΈPITCHΉ ..................................................................................................................... 46 8.2.2. CUTTING FEEDING AND BLADE SPEEDS ........................................................................... 46

9. TRANSPORTION INSTRUCTION ............................................................................. 47 9.1. HANDLING ................................................................................................................................... 47

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S4220 & S4230 - ING 10. INSTALLATION INSTRUCTION ............................................................................ 49 10.1. INSTALLATION INSTRUCTION .................................................................................................. 49 10.2. DISASSEMBLY AND DISPOSAL OF THE MACHINE .................................................................... 52 10.2.1. DISPOSAL............................................................................................................................ 52 10.2.2. DISASSEMBLY .................................................................................................................... 52

11. ELETRIC SYSTEMS ............................................................................................... 53 12. HYDRAULIC SYSTEM .......................................................................................... 65 13. MOTOREDUCE ................................................................................................... 69 13.1. OPERATING PRINCIPLE ............................................................................................................. 69 13.2.MAITENANCE INSTRUCTION ...................................................................................................... 69

14. MAINTENANCE AND COTROL ............................................................................ 71 13.1. CLEANING ................................................................................................................................. 71 13.2. GUIDES SET ADJUSTMENT AND MAINTENANCE ................................................................... 71 13.3. CAMBER OF DRIVEN FLYWHEEL ADJUSTMENT ...................................................................... 75 13.4. BOW CYLINDER REPLACEMENT ................................................................................................ 77 13.5. SPRING SET REPLACEMENT ...................................................................................................... 77 13.6. MAINTENANCE TABLE .............................................................................................................. 78 13.7. TROUBLE, CAUSES AND SOLUTION .......................................................................................... 79

15. SPARE PARTS...................................................................................................... 81 15.1. CABINET, ELETRICAL BOX , COOLANT TANK ΈS4220ͳ2Ή ............................................................ 81 15.2. CUTTING TABLE AND VISE SETS ΈS4220ͳ2Ή ............................................................................... 82 15.3. BOW SET, MOTOREDUCER, BOW HYDRAULIC ΈS4220ͳ2Ή ......................................................... 83 15.4. GUIDE SET ΈS4220ͳ2Ή .................................................................................................................. 84 15.5. HYDRAYLIC SYSTEM ΈS4220ͳ2Ή ................................................................................................... 85 15.6. CABINET, ELETRICAL BOX, COOLANT TANK ΈS4220ͳ4Ή ............................................................ 89 15.7. CUTTING TABLE AND VISE SETS ΈS4220ͳ4Ή............................................................................... 90 15.8. BOW SET, MOTOREDUCER, BOW HYDRAULIC ΈS4220ͳ4Ή ........................................................ 91 15.9. GUIDE SET ΈS4220ͳ4Ή ................................................................................................................. 92 15.10. HYDRAULIC SYSTEM ΈS4220ͳ4Ή ................................................................................................ 93 15.11. CABINET, ELETRICAL BOX , COOLANT TANK ΈS4230ͳ4Ή .......................................................... 97

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S4220 & S4230 - ING 15.12. CUTTING TABLE AND VISE SETS ΈS4230ͳ4Ή ............................................................................. 98 15.13. BOW SET, MOTOREDUCER, BOW HYDRAULIC ΈS4230ͳ4Ή ....................................................... 99 15.14. GUIDE SET ΈS4230ͳ4Ή .............................................................................................................. 100 15.15. HYDRAYLIC SYSTEM ΈS4230ͳ4Ή ............................................................................................... 101

ANNEX ...................................................................................................................105 CATALOG - BAND SAW BLADE .................................................................................107 NOTES

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WARNING! •

BEFORE TO START any kind of operation on the machines S4220 & S4230 READ WITH ATTENTION all instructions in this manual, so that the use is familiarize with the equipament;

•

OBSERVE carefully the INSTRUCTIONS for TRANSPORT (Chapter 9);

•

OBSERVE carefully the INSTRUCTIONS for INSTALLATION (Chapter 10). CHECKED the voltage (Volts) of tje machine being delivered;

•

All opetations for transportation, installation, operation, maintenance, assembly, disassembly and repair should be performed by skilled, trained and trained for these types of services. A Starrett will give all assistance and technical support to the user or to the owner of machine, always when requested in writing;

•

Observe and understand all signs contained in the machine;

•

If the standard machine (delivered to the user) was modified or altered their technical characteristics, without the prior knowledge and approval of Starrett, the user or the owner will lose all WARRANTIES, and the civil and criminal liabilities will fall on the owner of the machine.

.Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu • SP • Brazil – CEP 13306-900 Starrett Service Center: +55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br

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1. COMPLIANECE CERTIFICATE: DECLARAÇÃO DE CONFORMIDADE CE DECLARATION EC-CONFORMITY DECLARACIÓN DE CONFORMIDAD CE ATTESTATION DE CONFORMITÉ CE Starrett Indústria e Comércio Ltda. Av. Laroy Starrett, 1880 13306-900 – Itu – SP – Brazil Declara, sob sua exclusiva responsabilidade que o Declara bajo su exclusiva responsabilidad que lo Declare that it is our sole responsibility that the Déclaro sous la seule responsabilité que le produto, producto, produto, produit,

Máquina de serra de fita, Máquina de sierra de cinta, Bandsaw machine, Scie à ruban,

modelo: modelo: modelo: modèle:

S4220 & S4230 O qual se refere a esta declaração está de acordo com as seguintes diretivas: La cual se refiere esta declaración está de acuerdo con las siguientes directivas: Which refers this declaration is in accordance with the following directives: Qui se réfère à cette déclaration est en conformité avec les directives suivantes: DIRECTIVE 2006/42/CE DIRECTIVE 2004/108/CE e que está em conformidade com as normas y que está de acuerdo con las normas and it is in conformity with the standards et qui est conforme aux normes EN 13898:2003+A1:2009 EN ISO 12100-1:2003+A1:2009 EN ISO 12100-2:2003+A1:2009 EN 60204-1:2006+A1:2009 EN ISO 14121-1:2007 EN 61000-6 ED.-2:2005 EN 61000-6 ED.-4:2007

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2. WARRANTY Starrett Indústria e Comércio Ltda. Av. Laroy S. Starrett 1880 Itu - SP - Brazil – CEP 13306-900 Call Center Starrett: +55 11 2118 8000 falecom@starrett.com.br www.starrett.com.br

WARRANTY CERTIFICATE

PRODUCTS S4220 & S4230. The equipments manufactured and marketed by Starrett Ind. e Com. Ltda are covered by 12 months warranty from the issuance of invoice, regardeless or not the use of equipment. During the warranty period, the Technical Support of Starrett provided will loose its free characteristic if the defect allegation is unfounded. The replacement of parts or components, which are proven to have factory defects, shall be free of charge, not including the labor required, except when in reference to: •

Parts with foreseen natural wear caused by usage, such as bearings, protections, sealing, lamps, bearings of guides, etc;

•

Improper and undue handling for the purposes to which the product is intended;

•

Transport, falls, collisions, shocks, or improper storage;

•

Supply or usage of improper electric power;

•

Supply or usage of improper electric power;

•

Lack of observance of the instruction manual;

•

Interventions performed by third parties without Starrett Ind. e Com. Ltda;

•

Extended lack of product usage.

Changes in the technical specifi cations of the machine, structural, electrical or any unauthorized modifi cation written by Starrett Ind. e Com. Ltda will result also in loss of warranty. The warranty does not include regular machine maintenance service, such as adjustments, cleaning, and band replacement. Parts or equipment eventually replaced during the fulfillment of such warranty are the property of Starrett. Starrett Indústria e Comércio Ltda.

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3. MACHINE IDENTIFICATION All Starrett machines are provided with a Identification Plate attached to the Base or Cabinet. The following data in engraved in the ID plate: Model, serial number, code, manufacturing year, weight, power and voltge. Below is showed an ID plate type:

S4220 X 0001-12/TW-S S4220-H4 2012 375 1,5 220

(ILLUSTRATIVE DATA)

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4. TECHNICAL DATA StarreƩ

S4220

S4230

375

475

1,56 x 0,67 x 1,52 (h)

1,86 x 0,73 x 1,56 (h)

Motor Lâmina de Serra (hp/kW) (versão -2)

1,5/1,1

-------------

Motor Lâmina de Serra (hp/kW) (versão -4)

1,5/1,1

2,0/1,5

Coolant Motor (hp / kW)

006/0,05

0,06/0,05

Net Weight (kg) Dimensions (mm)

Blade Speed (m/min) (-2)

35 and 70

Blade Speed (m/min) (-4)

20 - 85

2535 ( ± 2) x 27 x 0,9

3140 ( ± 2) x 27 x 0,9

Dimensões da Lâmina de Serra (mm) Available Voltage - 3 phasis (V)

220 or 380

Motor opera on frequency (Hz)

50 or 60

CUTTING CAPACITY DIMENSIONS (mm)

(*) VOLTAGE according to Customer´s Purchase Order

S4230

S4220 A

0 o 45 60o

230 180 90

AxA 230 x 230 130 x 130 90 x 90

BxA 230 x 270 130 x 180 90 x 90

-45o

160

130 x 130

200 x 115

0o o 45 60o

300 235 140

A AxA 270 x 270 220 x 220 115 x 115

220

150 x 150

-45

A B BxA 250 x 350 200 x 225 115 x 130 115 x 220

3140 x 27 x 0,9

2535 x 27 x 0,9

MOTOR

Noise emmited by the machine Sound Pressure Level= 79,2 dBA Sound Power Level = 74,2 dBA

NOISE DECLARATION (EN 13898:2003+A1:2009(E) – ITEM 7.3): “The figures quoted are emission levels and are not necessarily safe working levels. Whilst there is a correlation between the emission and exposure levels, this cannot be used reliably to determine whether or not further precautions are required. Factors that influence the actual level of exposure of the workforce include characteristics of the work room, the other sources of noise, etc. i.e. the number of machines and other adjacent processes. Also the permissible exposure level can vary from country to country. This information, however, will enable the user of the machine to make a better evaluation of the hazard and risk.” REV. 3 [1] - AGO/13

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4.1. STANDARD ITEM Band Saw Blade

4.2. PARTS LIST

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General View

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4.3. APPLICABLE LEGISLATION AND TECHNICAL STANDARDS

APPLICABLE LEGISLATION (From European Parliament and of the Council): From European Parliament and of the Council: Directive 2006/42 /EC - On Machinery; Directive 2004/108/EC - Electromagnetic Compatibility;

EUROPEAN TECHNICAL STANDARDS: EN 13898:2003+A1:2009 Machine Tools - Safety - Sawing machines for cold metal; EN ISO 12100-1:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design. Basic terminology, methodology EN ISO 12100-2:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design. Technical principles EN 60204-1:2006+A1:2009Safety of machinery - Electrical Equipment of Machines - General Requirements; EN ISO 13857:2008 Safety Distances to Prevent Danger Zones being reached by Upper and Lower Limbs; IEC 61000-6-2: 2005 Electromagnetic compatibility (EMC) - Part 6.2 - Generic standards - Immunity for industrial environments; IEC 61000-6-4: 2007 Electromagnetic compatibility (EMC) - Part 6.4 - Generic standard - Emission standards for industrual environments; EN ISO 14121-1:2007 Safety of machinery - Risk assessment - Part 1: Principles

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5. SAFETY RECOMMENDATIONS

The S4220 and S4230 are equipped with safety protections to operator and to the equipment. However, all safety aspects cannot be summed by this way. Therefore, each user should pay attention to the machine’s confi guration, maintenance, and repair, and also carefully read all parts of this Instructions Manual. In addition, the user or the owner of the machine must observe the conditions and contexts of risk that the equipment will operate through analyzing through mandatory requirements of Laws and Technical Standards of his country. Obligatorily observe the following: •

ONLY qualified personnel with express authorization may operate and maintain this machine. These people must be trained regarding occupational safety standards of each country;

•

Without express authorization, it is strictly forbidden to perform changes or alterations to machine components that may compromise user or machine safety, exposing both to unnecessary risk. For the afore-mentioned changes, it is obligatory to request the authorization and approval of Starrett Technical Support;

•

All machine problems must be immediately communicated to the responsible personnel, that is, Starrett Technical Support;

•

ONLY persons authorized by the company owning the machine may handle, operate, feed material to be cut, prepare for cutting, do the maintenance, remove moving parts, change permanent components, and replace periodic maintenance components, such as: oil, filter, bearings, coolant liquid, etc.;

•

To perform maintenance, changes, and repairs, or replace components of the machine’s electric system, the responsible and authorized person of the owner company must be qualified for such purpose, according to the pertinent law. It is implicit that only qualified persons must connect the machine to the electric power supplier and perform any works for this purpose. This service should be according to the standards and laws valid in the country in which the machine is installed.

•

When there is intervention of maintenance or any other service, it’s necessary to position the General Switch (09) in OFF, and disconnected from the electrical grid. This way, the machine will not offer risk of electric discharge;

•

To avoid machine operation irregularities, the operator must be well informed and trained on the operation of the machine before putting it into operation;

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OBSERVE and ENSURE that the personnel responsible for handling, operating, feeding material to be cut, preparing for cutting, performing maintenance, repairing, removing moving parts, changing permanent components, replacing machine components, are NOT working under the influence of medicine, alcohol, or drugs that act on the central nervous system;

•

In case of machine problems, do NOT put it in operation before Starrett Technical Support;

•

In case of accidents, problems, or danger, quickly activate the EMERGENCY Button (04);

WARNING: RISK OF AMPUTATION OR SEVERE INJURY!

• NO is authorized to use this machine, UNDER ANY CIRCUMSTANCES, for CHILD(REN) or person(s) NOT qualified; • During the cu ng opera on, MUST NOT BE USED by the operator, UNDER NO CIRCUMSTANCES: short jacket or shirt or any kind of long-sleeved sweater, chain (s) or e or neck scarf, long hair loose, ring (s) in any finger, or any other object in the body that can pull the operator from the machine. • OBSERVE all signaling that are on the Bow (24) of machine. It is very important that the operator is familiarized with these indica ons; • DO NOT DAMAGE the machine´s technical plate; • NEVER touch machine moving parts with your hands or any other part of the body when it is in opera on; • ALWAYS KEEP the machine and the surrounding area clean. This way, it will prevent accidents to operator and also for people who are close to it; • Before to start the cleaning of machine or the maintenance, put the Main Switch (09) in OFF. NEVER remove material chips and other residues with the machine in opera on. DO NOT leave chips , and other residues to accumulate on or around the machine, because this may cause severe accidents or damage; • All the humidity generated by the cooling fluid around the machine must be cleaned and removed to avoid operator or other people accidents. If immediate cleaning is not possible, indicate the risk loca ons; • USE li ing and transport devices to handle the materials to be cut according to appropriate weight and dimension limita ons for a safe and ergonomic work. This opera on must be performed by responsible and qualified persons; 16

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• The operator must USE always the protec ve personal equipment (PPE) legally approved in the country. The operator must use the following PPEs: safety glasses, earplugs and industrial shoes. OBSERVE the Safety Icons Plate (43) placed on the Bow (24). Leather Gloves, must be use ONLY in the replacement of the Band Saw Blade (41), and NEVER use them during cu ng opera on. Besides that, the company owner the machine must guide and train each operator appropriately on how to use and keep each PPE, crea ng or indica ng other individual protec ons especially for the operator;

• Also it is necessary to observe the selec on of the type of band saw blade. Observe: tooth, feeding and cu ng speed, appropriate for the type of material to be cut. This defini on avoids problems during the cu ng opera on ( seer Chapter 8 this Manual); • Long materials to be cut that exceed the Cu ng Table (22) of the machine must be supported by Roller Table (54) in the machine feed posi on; • Before any hydraulic maintenance, keep the Bow (24) completely in the lower posi on so that there is no pressure in the hydraulic system due to the weight of Bow (13.3); • If necessary to remove or replace the springs of rear side of Bow Cylinder (48), use a special device to li the Bow (24) in its highest posi on to eliminate all poten al energy accumulated in the spring, so it avoids the risk of injury (see 13.4); • ALWAYS USE originals and new spare parts. Other spare parts or works not approved by the manufacturer, that present risks or cause accidents and damage are not under StarreƩ responsability; • USE hydraulic oils recommended in this manual. Its disposal should follow the local legisla on; • DO NOT PUT or LEAVE tools or others objects on the machine parts; • ENSURE suﬃ cient free space (1,2m minimum) around the machine, in order to provide work space and for people passage; ► REV. 3 [1] - AGO/13

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DANGER â&#x20AC;&#x201C; risk of electric shock

WARNING - danger of injury or damage to the machine

DANGER - hands crushed

DANGER - RISK OF AMPUTATION

DANGER - projection of chips material

USE LEATHER GLOVES APPROPRIATE FOR THIS PURPOSE, ONLY TO REPLACE THE BAND SAW BLADE USE PROTECTIVE SHOES APPROPRIATE FOR THIS PURPOSE

USE EARPLUGS APPROPRIATE FOR THIS PURPOSE

USE PROTECTIVE EYEWEAR APPROPRIATE FOR THIS PURPOSE

54 Input and Output Roller Table (OPTIONAL)

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WARNING: RISK OF INJURY! DEFINITION OF MACHINE’S WORKSTATION POSITION: During the cu ng process, the operator must be MANDATORILY near Control Panel (20), observing the cu ng parameters, and with his hands free, to access, immediately the EMERGENCY Bu on (04)

DANGER ZONE

WARNING: RISK OF INJURY! The Band Saw Blade (41) has a region that isn´t protected, called de DANGER ZONE. The operator of machine must be aten ve to this area.

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6. MACHINE DESCRIPTION

The models Starrett were developed under quality, safety, modernity, and technology criteria to meet the user’s needs, according to the european harmonized standars and the EC Directives. The purpose of the bandsaw machine is exclusive for cutting parts, mainly metallic materials, and must be used exclusively by qualified persons. Any other form of use is considered incorrect and dangerous, voids warranty, and exempts the manufacturer from responsibility in case of accidents. For correct usage, the usage instructions and maintenance and control conditions must be observed, in order to meet the country’s valid occupational safety standards..

Examples of materials to be cut: • Construc on Steels

• carbon steels

• alloy steels

• cupper

• stainless steels

• brass

• iron cas ng

• other metals

• aluminum alloys

• plas cs

The band saw machine should not be used by peoples with no qualifications and is not intended to cutting operation: Wood, teflon, meat, bones, ceramic materials, etc.

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S4220 & S4230 - ING BASIC CHARACTERISTICS: •

S4220-2 - WORM type gear box with three phases motor of 4/8 poles to 2 speeds;

•

S4220-4 e S4230-4 - WORM type gear box with three phases motor controled by Frequency Inverter (58), to work into cutting speed range from 20 to 85m/´;

•

Hydraulic Pump with three phases motor;

•

Coolant Pump with single phase motor;

•

Safety System with total stop of machine in the case of rupture of Blade (41);

•

Cutting Cycle: close the vise, turn on the blade, move down the bow controlled by Regulator Valve, cut of material, stop the blade, move up the bow and open the vise;

•

Guides combined with carbide plate and bearings;

•

Coolant of cut in the both guides;

•

Band Saw Blade;

•

Dynamometric tension of the blade;

•

Angular Cutting to bothe sides: 0-60° to right and 45° to left;

•

Rod Measuring of 500 mm;

•

Power: 220 or 380V in 50 or 60Hz

•

Manufactered according to EC directives and harmonized standards.

Initially, thes machines consist of a rigid Bow (24) that has two Flywheels: one is Driven Flywheel (33) and the other, Driver Flywheel (34). The Driver Flywheel (34) is engaged with a Gear Box (23) and this with electric Motor (22) three phase. The Driven Wheel (33) is mounted on the shaft of a dynamometric system called Tensioning System (39). A Band Saw Blade (41) is assembled on the two flywheels and properly tensioned by the Tensioning System (39), to keep it correctly tensioned on the Driven Flywheel (33) and the Drive Flywheel (34). The Bow (24) is assembled in the Vise Set (36) by Shaft (44), that enables this tilt in the blade plan, ie, in the cutting plan. The Band Saw Blade (41) and the Flywheels (33) (34) are protected at the Bow (24) rear portion by a Back Cover (25) (figure 01). The Vise Set (36) is basically composed: by a Cutting Table (35) and by Jaws Set (45), responsible to clamp rigidly the material to be cut (figure 02).

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39 41 36

53 Figure 01

The Vise (36) has a longitudinal movement in the direction of clamping of the material, and another movement in the transverse direction of the blade, controlled manually. The clamping or the opening of the vise on the material is commanded manually or hydraulically, by Handlewheel (37) or by Buttons (18) and (19) on the Control Panel (20), respectively (figure 04). According to the machine’s construction, the Bow (24) rotates on a fixed point of the Cutting Table (35), to allow miter cutting (45° to the left, 0°, 45° and 60°to the right) on the material to be cut. A Cabinet (53) constructed of sheet steel, and extremely rigid, maintains all described set, in addition to having inside the Electrical Box (21), the Hydraulic System (47) and the Coolant (76) of cutting.The design of this cabinet makes the operator to work ergonomically correct (figure 05).

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S4220 & S4230 - ING The Band Saw Blade (41) segment that performs the cutting is supported by 2 Guides: the Mobile (27) and the Fixed (30). These Guides are provided with Bearings (31) and Carbide Plates (32) that llow the blade to twist on the rotation plan of Flywheels (33) (34), to create the cutting plane. The Carbide Plates (32) have a function to align and not allow that the Band Saw Blade (41) rotates laterally on the movement axis. The Mobile Guide (27), close the Driven Flywheel (33), can be manually adjusted, to adjust the distance thereof with respect to material to be cut. These models have 2 configurations of Control Panel (20), which perform all movements of the Bow (24), by a simple press of the Buttons (16) and (17) (figures 04A and 04B). With the machine adjusted, electrically connected, the material to be cut duly positioned on the Cutting Table (35), the Switch (03) in the RIGHT side (SEMI AUTOMATIC), press the Button (17) to start the cutting work. With this, the Vise (36) will close automatically, locking the material, and starting the move down of the Bow (24) with the Blade (41) in movement. At the end of the cut, a Micro Switch (13) is triggerer, automatically stopping the movement of the blade in the lower position. In the MANUAL mode (Switch (03) LEFT), the movements to up and down of the Bow (24), opening and closing of Vise (36) can be realize the adjustment of the machine to cutting operation.In this mode, there is NO possibility of the machine perform any cutting operation, ie the Band Saw Blade will not have any movement.

29 87 38

Figure 02 24

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22 33

Figure 03 05

S4220 24V 4

V 1

9 0

REARME RESET

Figure 04A

74 08

S4220 24V

4 3

V (m/min)

6 7

V 1 4

REARME RESET

9 0

8 9

1 0

Figure 04B

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S4220 & S4230 - ING This machine also has operator safety system. The safety systems are: •

EMERGENCY Button (04), in the Control Panel: under any abnormal situation while in operation, in case of problems or risks of accidents, should be pressed.This action will stop instantly the blade movement, the coolant pump and hydraulic system;

•

Safety Micro Switch of Back Cover (12), when the Back Cover (25) is removed, for maintenance or replacement of Blade (41).This micro switch will disable all electrical system, protecting the operator against accidental activations of the machine;

•

Rupture the Band Saw Blade (41): in the case of rupture of Blade (41) during cutting operation, this micro switch installed on the Tensioning System (39) of Blade (41) is pressed, stopping the movement of the tool, the Coolant Pump (76) and Hydraulics (47), protecting the operator against risk of accidents;

•

The model S4220-2 ( 2 speeds ) has thermomagnetic protections (thermal relay) to the motors, respectively: FR1 (86) to Blade Motor (22) and FR2 (69) to Hydraulic Motor (75). The Motor (76) of coolant pump is protected for fast acting fuses type. The models S4220-4 and S4230-4, the Blade Motor (22) is protected by Frequency Inverter (58). The others motors (75) and (76) are protected the same way of S42202 version.

•

The EMERGENCY Button (04) and the Micro Switches (12) and (15) are monitored by Safety Relay ( Safety Mode) (68), in order to quarantee the maximum safety to operator and to the equipment. This component in case of abnormality, will turn off 2 Contactors C1(59) and C2 (60), switching off all electrical system; All details of the systems making up these machines are described in their respective Sections.

WARNING! RISK OF AMPUTATION OR SEVERE INJURY! The length of the Band Saw Blade ) that perform the cu ng opera on between Guides(27)(30), obviously does not count with protec on, therefore: NEVER touch any moving parts of the machine with your hands or any other part of the body while the machine is in opera on, especially the band saw blade .

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75 36

Figure 05

- CONTROLE PRESSÃO - PRESSURE CONTROL - CONTROLE PRESSIÓN - REGULATION DE PRESSION

P - ATENÇÃO - WARNING - ADVERTENCIA - AVERTISSEMENT

2 L 3 4 L1

R1 5 PT

Veja Manual de Instrução

See Instruction Manual

ES FR

Vea el Manual de Instrucciones Voir le Manuel d'Instructions

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7. USAGE AND OPERATION INSTRUCTIONS: Only qualified personnel with expressly authorized may operate and maintain this machine. These people must be trained according to the occupaonal safety standards, use protec ve personal equipment correctly, and be well informed on the contents of this manual.

7.1. ADJUSTMENTS AND CHECKS Before starting any kind of job with the machine, check it: 1.

The volume of coolant (oil + water) in the Tank (84) is approximately 20 liters. The oil concentration in the cutting fluid mixture must follow the instructions as specifications from the oil manufacturer. The level of coolant liquid can be observed in the Indicator (85) (figure 06); The Tap (96) can control the liquid volume during the cutting.

Figure 06

WARNING: Check if the coolant oil to be employed is not obnoxious to the operator, the environment and the machine itself.. Disposal of the coolant oil must be provided in compliance with current environmental regula ons and the product manufacturer standards.

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Check the Band Saw Blade (41) conditions regarding integrity of its teeth and band;

The tension of the Band Saw Blade (41), turning the knobs of the Tensioning Nut (55) until the conditions indicated in the Plate (26) located on the Bow (24) (figure 01) are present, ie, turning the Tensioning Nut (55) until the pointer Tension Indicator Gauge (10) (figure 07B), reaching the GREEN range, as shown below.

< 25000 PSI

= 25000 PSI 55

Figure 07

If the teeth type is the most appropriate for the kind of cuting to be done. Check selection for conformity to item Band Saw Blade Selection Criteria in this Section;

If the cutting speed (m/min) selection is compatible with the characteristics of the material to be cut. . Select the cutting speed through the Speed Control Switch(04) located on the electric panel. As guidance, it can be used the Starrett Cutting Recommendation Table, attached with this Instruction Manual ( Starrett Band Saw Catalog);

If the distance of Band Saw Blade (41) from the material to be cut is suitable as follows below (figure 02A): – Position the Bow (24), as close as possible to the material to be cut; – Release the Lever (29) and slide the Mobile Support (38) of Mobile Guide (27), to decrease the distance between the Guides (27)(28) the maximum possible. Thereafter, lock the Mobile Guide Suport (38) by Lever (29);

If the part to be cut is well positioned on the Cutting Table (35), i.e., properly supported in all surface of table and perfectly flat;

After these adjustment and checking, select the working cutting speed, as follows: In the model S4220-2, by Speed Control Switch (05): ►

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S4220 & S4230 - ING – “ 1 ” (speed = 35 m/ ') to hard materials; – “ 2 ” (speed = 70 m/ ') to soft materials. In the models S4220-4 and S4230-4, by Potentiometer (02), whose speed can range from 20 to 85 m/min (m/´).

7.2. MATERIAL TO BE CUT; WARNING: ALL cu ng opera on must be performance ONLY by qualified operators to this purpose. In ALL cu ng opera on use PPEs duly approved for this purpose.

Before starting any operation, move up the Bow (24) until the upper position by Button (16), closing completely the Feeding Regulator Valve (50). Then, place the General Switch (09) on position OFF and the EMERGENCY Button (04) pressed (figures 01, 04A and 04B). So, the machine will be safe before handling or adjustment of the same. With the Handle (37), approach the Vise (36) until the material to be cut. Touch the jaws against the material and turn the Handle (37) ¼ turn back. With this, it will have a small clearance enough to move longitudinally the part by operator. The clamping and the releasing of the vise on the material will be performed hydraulically, when the MODE Selector Switch of operation is in the SEMI-AUTOMATIC (left side). Make sure that the material is well adjusted and supported in equilibrium on the Cutting Table (35), and verifying the conditions of clamping below.

RECOMMENDATIONS OF BEST WAY TO CLAMP THE MATERIAL:

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7.3. ADJUSTMENT OF HEIGHT OF CUTTING: WARNING: ALL cu ng opera on must be performance ONLY by qualified operators to this purpose. In ALL cu ng opera on use PPEs duly approved for this purpose.

Before starting any operation, move up the Bow (24) until the upper position by Button (16), closing completely the Feeding Regulator Valve (50). Then, place the General Switch (09) on position OFF and the EMERGENCY Button (04) pressed (figures 01, 04A and 04B). So, the machine will be safe before handling or adjustment of the same. Behind the Cover (87) (figure 02), are located the two Micro Switches (13) and (14) for positioning the Bow (24), in the below and above positions, respectively (figure 08). By Lever (89) can adjust the upper height desired, ie the Blade ( 41) should be between 10 to 20mm above the material to be cut.

ADJUSTMENT OF UPPER POSITION: 1. Place the Bow (24) in the desired position; 2. Loosen the clamping of the Lever (89) so that the Bow Down Stop (90) to lightly touch the Micro Switch (14) in this position Bow (24), without removing the Cover (87); 3. Next, tighten the Lock Levers (89). 4. With the machine switched on, check if the desired height was reached, moving the Bow (24) by Buttons (16) and (17), in the MANUAL mode (Switch (03) to RIGHT side).

ADJUSTMENT OF LOWER POSITION: There will be circumstances that the position should be adjusted to that the Blade (41) to stop above the surface of the Cutting Table (35). With appropriate tools and without removing the Cover (87); 1. Loosen the screw that fix the Cover (87); 2. Place the Bow in the desired upper position; 3. Lightly touch the Micro Switch (13) with Bow Up Stop (88) locking in this position;

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4. With the machine switched on, check if the desired height was reached, moving the Bow (24) by Buttons (16) and (17), in the MANUAL mode (Switch (03) to RIGHT side). With these procedures the machine will have heights adjusted, which may result in increased productivity and / or reduce the total time of each cutting process.

90 Figure 08

7.4. ANGLE CUT PROCEDURE To perform this procedure the Bow (24) should be at its maximum upper posi on. A er, the operator must press the EMERGENCY Bu on (04) and the General Switch (09) in the OFF posi on, un l the end of this adjustment item. To cut in angle, above all, the operator should choose the correct value of the degree and the desired side of the cut. RIGHT SIDE ( from 0 to +60o ): With the Bow (24) at its maximum upper position, position Bow Rotation Lock Lever (42) forward to unlock the clamp system (figure 09A). Turn the Bow (24) to right until desired angle viewed in the Angular Scale (83) according to Pointer 0o (92) (figure 09C). Next, lock the Bow (24), positioning the Lever (42) to right.

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. MAKE SURE if the Bow (24) is locked forcing its rota on. . CHECK if the Vise Set (36) is the LEFT side and locked by Lock Levers (42) and (91) (figures 09A and B);

LEFT SIDE ( from 0 to -45o ): With the Bow (24) at its maximum upper position, position Bow Rotation Lock Lever (42) forward to unlock the clamp system (figure 09A). Then, release the Lock Pin (93) of the position 0o , to allow the Bow (24) rotate to the left side (figure 09C). Next, lock the Bow (24), positioning the Lever (42) to right. Turn the Bow (24) to right until desired angle viewed in the Angular Scale (83) according to Pointer 0o (92) (figure 09C). Next, unlock by Levers of Lock Vise (42) and (91), positioning the Vise Set (36) to the right side, as viewed in the figure 09C. Lock by Levers (42) and (91) of Vise Set (36). Electrically switch on the machine and start it to operate.

. MAKE SURE if the Bow (24) is locked forcing its rota on. . CHECK if the Vise Set (36) is the LEFT side and locked by Lock Levers (42) and (91) (figures 09A and B);

91 42 83

35 Figure 09A

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Figure 09B 35

Figure 09C CUTTING AT RIGHT SIDE

Figure 09D CUTTING AT LEFT SIDE

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7.5. BAND SAW BLADE REPLACEMENT AND ADJUSTMENT PROCEDURE: To replace or change the Band Saw Blade (41) correctly, it´s necessary to keep the Bow (24) on highest position and at 0º angle; thereafter: 1.

Disable electrically the machine keeping the General Switch (09) in the OFF position, the EMERGENCY (04) pressed (locked);

Remove the Back Cover (25) protection tightening the 4 Toggle Latches (94) located in the rear part of the bow (figure 10B);

Remove the Protection (28) , installed in the Support (38) of Mobile Guide (27) (figure 10);

Removing the Back Cover (25) the protection automatically disable the electric system through Micro-Switch (12) attached in the Bow (24), installed to protect user against possible accidents with the machine (figure 10) – UNDER NO CIRCUMSTANCES NEVER ACTUATE THE MICRO SWITCH (12) IN THIS SITUATION;;

Turn the Tensioning Handle (40) to reduce (loosening) the tension of Band Saw Blade (41), in order to reduce the distance between centerlines of Flywheels (33) (34);(figura 03);

Remove the Blade with care, wearing leather gloves, only this situation;

Before to install a new blade, clean thoroughly the area touched by the blade of the two Flywheels (33)(34) and also inside the Guides (27)(30) by injecting Micro-Oil M1 between the Lateral (31) and Plates (32) Bearings;

Assemble the new Band Saw Blade (41) making sure that the teeth are intacts and compatible with the material to be cut, observing if the teeth are towards the direction indicated on Plate (26)(figure 02). First, put in the gap of the Guides (27) (30) (between the Bearings (31) and after in the Driver Flywheel (34) and, then, in the Driven Flywheel (33). (figura 03);

Make the pre-tensioning turning the Levers (40) of Tensioning Nut (55) towards to tension the blade (stretch);

10. Assemble the Back Cover (25) clamp it by Toggle Latches (94) and reset the Micro Switch (12) (figure 10); 11. Assemble the Mobile Guide Protection (28) with their respective screws;

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S4220 & S4230 - ING 12. Unlock the EMERGENCY Switch (04) and place the General Switch (09) in ON. With the Selector Switch (03) in the SEMI AUTOMATIC mode, select the lowest cutting speed by Speed Control Switch (05) (to S-4220-2) or by Potentiometer (02) (to S4220-4 and S4230-4). Keep the Feeding Regulator Valve (50) closed. Trigger momentarily the Motor (22) by Start Button (07). Then, press the Stop Button (08). Repeat this operation for 4 to 5 times to seat the blade on the flywheels and the guides. 13.

Make the tensioning permanent of Band Saw Blade (41), turning the handles of Tensioning Nut (40) as described in the section 7.1 point 3. 46

12 Figure 10

40 10

24 Figure 11

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WARNING: The recommended limit is 20,000 PSI -pounds sq.inches (20kSI) or 1400 Kgf/cm2. However, it is advisable to use a Saw Tension Gage Starre 682 EMZ (EDP 57075 – SAW TENSION GAGE), as seen below, to check and to adjust the tensioning set from supplier.

7.6. BAND SAW BLADE CONSIDERATIONS: Some advices to keep the good performance of the band saw blade 1.

Properly tension the band saw blade, as instruction of item 7.1., point 3.

Know very well the material to be cut, mainly the hardness and homogeneity;

Choose a speed cutting that is compatible with the geometry, dimensions and physical characteristics (hardness) of the material to be cut;

Use blade with good quality, with correct teeth type and íntact (no broken teeth);

Use the recommendations above for the first cuts;

Frequently clean the Guides (27)(30) – with the machine stopped and use Micro-Oil Starrett M1, to clean the Lateral (32) and Rear(31) Bearings;

Check the conditions of Bearings (31)(95), and the Carbide Plates (32);

Check periodically the clearances between the Bearings (31) (0.95 mm) and the distance between the back of band saw blade and the Rear Bearing (95) as showed in the figures 14A and 14B.

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OBSERVATION: The cu ng opera on must be realized with force and speed perfectly suited to teeth type of Blade (41), the thickness of the material to be cut and the blade wear.

It´s vey important to try to keep the cutting conditions within the parameters established by Starrett. Thus, the efficiency and the lifetime it will be larger. For a good use of the machine is important to keep The Guides (27) (30) cleans and make sure that the both receive abundant coolant liquid. Increase or decrease the flow of coolant liquid just open or close the tap located in the Oil Distributor (46), installed on the Bow (24).

OBSERVATION: For be er performance of the Band Saw Blade, it´s recommended to make the break-in while the blade is new upon its installa on on the machine. This break-in is a prac ce that purpose an arrangement of the tooth cu ng edge before the blade will be put into full opera on. The break-in consists to make that the Band Saw Blade works for a period with twice the me required for cu ng and at a suitable speed cu ng, as intruc on of the Starre ´s Cu ng Recommenda ons Table. AVOID THAT THE BLADE SLIDE ON THE MATERIALWITHOUT REMOVING THE CHIPS. (PREVENT VIBRATION)

7.7. COOLING OF CUTTING The coolant system consists of a Motor,(76), an aspiration pump, and a Tank (84), placed inside of machine´s cabinet. The pump sends the coolant liquid through a hose to the distributor, which by some connections send it to the both guides.The quantity of coolant liquid that leaves the connections can be regulated by valves. The emulsion coolant (coolant liquid + water + cutting oil) ensures the cooling of blade, a disposal correct of waste and avoid the oxidation of cut material. The pump is switched on and switched off with start and the stop of blade motor.In the tank of coolant liquid there is a deposit of sediment that must be cleaned regularly.

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(30) FIXED GUIDE

(27) MOBILE GUIDE

CARBIDE PLATE (32)

LATERAL BEARING (31)

COOLANT PUMP MOTOR (M3)

COLLECTOR SCREEN ON THE CABINET

TANK OF COOLANT LIQUID (84) VENT RETURN LINE

SEDIMENTS

Use oils cutting indicated for machineries that work with circulating fluid generally with base of water. There are a wide variety of oil cooling, but must be chosen by the company owning of the machine, according to the type of material to be cut, the use conditions, the ambient, the environmental standards established by the company etc. The oil cooling must be handle by qualified person.

WARNING! Do not ingest! Prevent contact with eyes! Handle using appropriate protec ve gloves! Observe the environmental standards of disposal this product! Keep away from children and animals!

WARNING! ALWAYS CHECK THE MANUFACTURERÂ´S RECOMMENDATIONS! 40

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7.8. HYDRAULIC SYSTEM The Hydraulic System (47) is placed inside of Cabinet (53) of machine to allow perform all movements of the Bow (24) and the opening and clamping of the Vise (36) in the SEMI AUTOMÁTIC mode.

7.8.1. ADJUSTMENT OF MOBILE VISE PRESSURE The Hydraulic System (47) is adjusted from manufacturer with 30 kg/cm2, but is equipped with a Pressure Regulator Valve (82) allowing the reduction of clamping force of Jaws (45) on the material to be cut. This allow to cut tubes or profiles with thickness very small, without deformation of material, due the pressure exercised by vise (figure 06). The range of pressure adjustment of Vise (36) will be from 15 to 30kg/cm2. Turning the Regulator Valve (82) COUNTERCLOCKWISE thepressure decrease. Turning the Regulator Valve (82) CLOCKWISE the pressure increase. The Pressure Gauge (81) allows to see the pressure in the vise.

7.8.2. START, NORMAL STOP AND EMERGENCY OF MACHINE

WARNING: ALL cu ng opera on must be performance ONLY by qualified operators to this purpose. In ALL cu ng opera on use PPEs duly approved for this purpose. •

Place the General Switchl (09) in ON, and check if the EMERGENCY Button (04) is unlocked and press the Start Button (06) to start the hydraulic system in operation;

•

Adjust the upper height of the bow, considering the height of material to be cut (See item 7.3);

•

Position the bow in the desired angle (See item 7.4);

•

Introduce the material to be cut on the vise and position it, according to required length. (It is possible move the vise to right or to left) (See item 7.4);

•

Adjust the Mobile Guide (27) closest possible distance of material to be cut (See item 7.1 point 6);

•

Close fully the Feeding Regulator Valve (50);

•

Select the cutting speed of blade by Speed Control Switch (05) (to S4220-2) or by Potentiometer (02) (to S4220-4 and S4230-4);

•

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Operation Mode Selector Switch (03) in MANUAL( place to LEFT);

•

Press the Start Button (06) (green) to start the hidraulic system;

•

Press the Buttons (16) or (17) to move the Bow (24), and (18) or (19) to open or close the Vise (36);

•

By Regulator Valve (50) adjust the feeding speed of the Bow (24);

•

Make necessary adjustments to the beginning of cutting process.

SEMI AUTOMATIC MODE: •

Operation Mode Selector Switch (03) in SEMI AUTOMATIC (place to RIGHT);

•

Position the material to be cut on the Cutting Table (35);

•

Press the Start Button (06) (green) to start the hidraulic system;

•

Press the Start Button (07) to start the cycle: the vise will be closed, the blade will rotate, and the bow will begin to lower;

•

Select the cutting speed of blade by Speed Control Switch (05) (to S4220-2) or by Potentiometer (02) (to S4220-4 and S4230-4);

•

Select a correct descent speed of bow (feeding cutting) with Feeding Regulator Valve to get a good compromise between cutting quality and tool life. The blade will cut the material;

•

After finish the cut, the bow will moved up to start position and the vise will open.

WARNING! RISK OF DAMAGE TO THE EQUIPMENT AND ACCIDENT: Before begin any cu ng opera on, check the posi on of Vise Set (36) according tothe Bow (24). If the cut will be of the right side,ie, the Bow (24) turned to right, the Vise Set (36) should be to le side. If the Bow (24) is at le , the Vise Set (36) should be at right. ALWAYS check if the Bow (24) is locked by Lever (42) and the Vise (36) by Lever (91).

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S4220 & S4230 - ING 7.8.3. STOP OF MACHINE: When it is necessary to stop the machine, either in a NORMAL or EMERGENCY way, the following procedure should be followed:

NORMAL STOP: There are 2 situations that the machine will stop in the NORMAL way. The first is in the final cut, which the Micro Switch (13) will pressed, switching off the Motor (22) and the Coolant Pump (76). The second case is by operator action when the Stop Button (08) is pressed. Also in this case, the Motors (22) and (76) are switched off and the bow (24) will stop the feeding, keeping in the static position. In both cases, the Hydraulic System (47) will not stop to work.

EMERGENCY STOP: In emergency cases, the EMERGENCY Button (04) should be pressed. In this caso, all systems of machine will be switched off, totally disabled, waiting for a RESET. Analyzed the emergency situation in which the machine finds itself, the operator can put in operation so as follows: - Unlock the EMERGENCY Button (04); - Place the Mode Selector Switch ( 03) in MANUAL (to right); - Press the Button (06) ( RESET ) to start the Hydraulic System; - By decision of operator, press the Buttons (16)(17) to move the Bow (24) or the Buttons (18)(19) to open or close the Vise (36). The cases of EMERGENCY always should be analyzed and the removal of this condition must be careful and executed by authorized persons.

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8. CRITERIA FOR BAND SAW SELECTION 8.1. LIMITS AND RECOMMENDATIONS: Prior to beginning any kind of work with the machine, see that the job to be carried out is within the limits specified in table TECHNICAL DATA. If not, it is recommended to communicate in written to Starrett on the possibility of changing of some technical specification. The Starrett will reply in written regarding the best solution to be adopted.

WARNING! The StarreĆŠ is not responsible for damages caused to persons or objects, being forced the user's machine to check with a en on the characteris cs of the material to be cut in order to avoid any risk to the operator and / or third par es.

Being specified within the capabilities of the machine, the correct choose of band saw blade will be another important factor to improve the cutting performance.

8.2. CRITERIA FOR BAND SAW BLADE SELECTION: The proper selection of a saw band for a given application must consider some factors: Type of material, hardness, cutting section, capability of the machine itself, etc. There are 4 basics variables to choose a band saw blade: 1.

- Blade Type;

teeth shapes

Teeth (Pitch):

Cutting Feeding and Blade Speeds.

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S4220 & S4230 - ING 8.2.1. TEETH (PITCH): The pitch is number of teeth per inch (25,4 mm), that operator must be choose in function of material cutting section. The normal or annealed materials require at least 3 teeth inside cross section to be cut. It is ideal between 6-12 teeth. In general, materials with thin section require a band saw blade with a larger number of teeth per inch (25,4mm), or a band saw blade with “teeth thinner” being this opposite for materials with larger section.

8.2.2. CUTTING FEEDING AND BLADE SPEEDS. It´s important that the feed and cutting speed will be corrects. Starrett can to send a table “slide chart” type, to fast and easy selection of band saw blade, with specification of feeding and cutting speed for each kind of material. The same information are available in the Starrett Band Saw Catalog attached.

OBSERVATION: The best condi ons to cut are 3 to 12 teeth inside in the cross sec on to be cut, in the same me.

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9. TRANSPORTION INSTRUCTIONS: 9.1. HANDLING:

WARNING: To install correctly this machine it´s necessary, a er removing it from packaging, CAREFULLY READ this Instruc on Manual, during the machine opera on and on maintenance ac ons.

When the machine leaves the factory, it´s fixed on a wooden pallet, which allows it to be carried by a lift truck or other moving system. Also, in case of transportation by traveling crane, it can lifted by steel cables fastened along with it, as showed in the figure below. To lift the machine will be necessary to use appropriate cables with resistance to support 490Kg (Gross Weight) of it. Thereafter, the machine must be lifted just the minimum required to move it. During this operation, must be regarded the safety conditions that the traveling offer, in function of characteristics (distances, maximum height and load-lifting capacity). The same care should be taken in case that lift trucks are employed.

OBSERVATION: 1. Use steel cables (mininum diamenter = ø 8 mm) with enough resistance to support 490kg , and pass by hook eye, as indicated in the following figure; 2. The user must make sure that the steel cable or rope are intacts, before to start the li ing opera on; 3.

Make sure that the 4 hooks are intacts before li the machine;

Make sure that the machine is well balanced during the li ing opera on;

Li the machine the minimum required to enable moving the same;

Do not permit to shake the machine during movement of traveling crane.

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10. INSTALLATION INSTRUCTION 10.1. INSTALLATION INSTRUCTION: The machine must be installed in a normally lighted working environment on an industrial type floor having the strength required to hold up the weight of the machine itself plus the weight of the material to be cut.

WARNING: The machine may not be installed in environments where the risk of explosion or fire exists.

It is advisable that the machine be fixed by screws "anchor" in the floor according to the type illustrated below, especially when to handle the long and heavy materials. These attachments must be through the points of support.

Also, in this case, it´s recommended to install supports devices and/or roller tables to support the material. When the installation has been completed, the installer or whoever shall have carried out the same will check if all parts of the machine: –

Perfectly intacts (free from cracks or any other defects, in particular the EMERGENCY Button (04), the Moto Reducer(22)(23), the Coolant Pump (76), the Vise (36) and the Handle (37).Check also for the condition of theCabinet (53), Mobile Guide (27), Control Panel (20), etc.;

–

In conformity with what is specified in the manual and on its order (optional items).

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OBSERVATION: In case that some parts are not intact or fail to conform to the order and/or the manual, customer (installer) shall promptly no fy Starre , in wriƟng to obtain clarifi caƟons, also in wriƟng, on what is to be done to solve the problem. However, a er the problem is detected, the installer must not proceed with the installa on un l such me as the problem has been solved and clarified. ENVIRONMENTAL CONDITIONS: - Environmental temperature: from -10 to +50 oC.; - Relative humidity: cannot be over 90% The installation of machine in the electric line supplier must be done by individuals qualified for this kind of service. Also, must be observed the electrical diagram, in this Manual, that electrical connection to be properly made. The Control Panel (20) is on the Bow (24) of machine. The Cooling Pump (76) is located inside the Cabinet (53), it is ready for operation.. Before connecting the machine in the electric line supplier, check: 1.

If the power cable provided with the machine is intact in all extension;

If user’s main electric line has the same voltage (V) and frequency (Hz) as required by machine.

OBSERVATION: In case that the voltage and/or frequency is not compa ble with user’s electrical grid, due the mistake of the client, immediately, the Starre must be advised of it, so that components can be replaced, by its decision, under warranty or not, the Motor (22), the Cooling Pump (76), the transformer and the overload fuses by appropriate values. User’s electrical grid shall use cables or wires whose cross sec on area is equal to or larger than 2.5mm2.

In the extremity of electric cable must be installed a plug with 4-pins, being 3 used for phases R, S and T, and the fourth pin for Grounding (Earth), always conform specifications and recommendations of manufacter of plug. When the installation of plug is ready, connect in the user´s electric line. Immediately, a Pilot Lamp (11) (WHITE) in the command panel will light indicating that machine is switch on. 50

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S4220 & S4230 - ING After, position the Switch (03) to right side (SEMI AUTOMATIC mode) to start the Motor (22). Then, momentarily press the Start Button (07), to check if the Blade (41) is turning in the direction indicated on Plate (26), placed in the Bow (24) (figure 02).

OBSERVATION: Make sure if the Band Saw Blade (41) is running in the same direc on indicated in the Plate (26), located on the Bow (24) (figure 02). If the blade direc ons is opposite as indicated, exchange 2 or 3 phases (cables) in the plug that is connected in the machine ot user´s electrical line.

WARNING: – For the electric installa on, use the following color codes or numbering:

–

OPTION 1

OPTION 2

Cables funcƟon

GREEN / YELLOW

GREEN/YELLOW

Ground

BROWN

BLACK 1

BLUE

BLACK 2

BLACK

BLACK 3

Always check if the Ground connec ng cable is well connected and that no connecon in common exists with user’s electrical grid Neutral.

– Connect the machine electrical cables on an output of an independent panel board with a three-pole thermomagne c switch of 16A and a diﬀeren al of 40A with a 0.3A sensi vity at 220V.

WARNING (IMPORTANT INFORMATION): NEVER perform any welding opera on (common electric weld type, MIG or TIG) with the machine switched on, or connected to electrical grid, with General Switch (09) in ON, the Pilot Lamp (WHITE) (11) ligthed. NO use the machine itself as a point of grounding welding equipment. Even with the machine without the above condi ons, NO PERFORM ANY OPERATION of welding on the machine. NEVER WELD in any material that will be cut on the machine, even if it is necessary to repair the same, because it may cause irreparable damage to electrical, machine and this will not be covered under warranty.

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S4220 & S4230 - ING

10.2 DISASSEMBLY AND DISPOSAL OF THE MACHINE: 10.2.1. DISPOSAL In the case, if itÂ´s necessary to disposal the machine for some reason, some cares should be taken: 1.

Power off and remove the machine are tasks that should be carried out by a person duly qualified and authorized to do it and having experience and expertise to do that job;

Correctly disconnect it from userâ&#x20AC;&#x2122;s power line in a safe way, making sure that the same is totally powered off;

Clean the machine completely, removing the coolant liquid (oil + water) from the cooling system contained in Tank (84). Drain all liquid and do not dispose of it in the environment;

Remove completely all chips contained in the Tank (84) and on Cabinet (53);

Parts susceptible to oxidation and that have been exposed to weather for long time must be smeared with oil for protection.

10.2.2. DISASSEMBLY

OBSERVATION: Before star ng the disassembly or decommissioning opera on of the machine or its components, INQUIRE Starre for all instruc ons required in respect of the subject. If need to disassembly the machine, follow these instructions: : 1.

Avoid direct contact with cutting oil and other lubricants.

Wear appropriate SAFETY GLASSES.

Avoid and pay a attention to do not to discard any type of oil in the environment;

For the step involving moving the machine and/or parts, observe the instructions contained in the item9.1 - Handling this Section;

When disassembly the machine or part of it, follow a sequence that will later on enable you to properly re-assemble it. To that end, take down notes on this manual on the operations carried out.

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S4220 & S4230 - ING

11. ELECTRIC SYSTEM The Electric Systems of models S4220 and S4230 were developed accordind to european standards EN. S4220-2: For this model, the electric system was dimensioned to receive a Blade Motor (22) of double polarity, ie 4/8 poles. So this model has 2 cutting speeds (35 and 70 m/ min) controlled by Speed Control Switch (05) localed in the Control Panel (20). Basically the is composed of: BLADE MOTOR (22) (M1) - (75) - M2 - Hydraulic System Motor; - (76) - M3 - Coolant Pump Motor; In the Control Panel (20): - (04) - SB1 EMERGENCY BUTTON - (05) - SA1 Speed Control Switch - (06) - SB2 - Start Button of Hydraulic System - RESET; - (07) - SB3 ON - Start Button of Blade; - (08) - SB3 ON - Stop Button of Blade; - (11) - HL1 - Pilot 24V PILOT LAMP - (16) - SB6 - Bow Up Button; - (17) - SB7 - Bow Down Button; - (18) - SB5 - Open Vise Button; - (19) - SB4 - Close Vise Button; - (73) - HL2 - PILOT Lamp of Hydraulic System (GREEN); - (74) - HL3 - PILOT Lamp of Start of Blade Motor (GREEN) In the Electrical Box (21): - (09) - Q1 General Switch - (57) - KM3 - Contactor of Coolant Pump Motor; - (86) - FR1 - Thermal Relay of Blade Motor; - (56) - KM2 - Contactor of Hydraulic System Motor; - (69) - FR2 - Thermal Relay of Hydraulic System Motor; - (71) - KT1 - Timer of Hydraulic System; - (72) - KT2 - Timer of Bow feeding Start; - (59) - C1 - Contactor Safety Mode - Safety Relay;

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S4220 & S4230 - ING - (60) - C2 - Safety Mode - Safety Relay; - (70) - TC - Transformer 220/380V - 24V; - (61) - FU1 - Fuse - Protection of Transformer Input (1A); - (62) - FU2 - Fuse - Protection of Transformer Input (1A); - (63) - FU3 - Fuse - Protection of Transformer Output (3A); - (64) - FU4 - Fuse - Protection of Command Line (3A); - (65) - FU5 - Fuse - Protection od Directional Valves (5A); - (66) - FU T1 - Fuse - Coolant Pump Protection (1A); - (67) - FU T2 - Fuse - Coolant Pump Protection (1A); In the Bow (24): - (12) - SQ1 - Safety Micro Switch - Opening of Back Cover; - (13) - SQ4 - Limit Micro Switch - Bow DOWN; - (14) - SQ5 - Limit Micro Switch - Bow UP; - (15) - SQ2 - Safety Micro Switch - Blade Rupture. In the Blade Motor (M1) (22): - (98) - FRM - Internal Thermal Protection to the coils of Motor (M1). The EMERGENCY Switch (04) and the Safety Micro Switch (12) of Back CoverÂ´s opening are monitored by a Safety Relay (68), for purposes of ensuring full stop, secure and guaranteed the machine in case of emergency and maintenance or replacement of the saw blade.Moreover, all commands of machines working in extra low voltage, ie 24VAC. To ensure the stopping of machine, and especially of the Blade Motor M1 (22) are installed 2 contactors C1 (59) and C2 (60) in series, which are also the monitored by the Safety Relay (68).So in case of emergency the system will switched off safely.

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FR2

KM2

FU T1

KM3

FU T2

FU2

FU1

SA1

FR1

TC FU5

FU4

FU3

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

HL1

FU3

FU4

KT1

FRM

SQ2

SQ1

FR2

FR1

KM2

HL2

SB2

KT1

SB3 ON

HL3

SA3 OFF

KA1

KT2

SA3 ON

KM3

SB4

SA1

KA2

SB5

SB6

KA3

SQ4

KA4

SQ5 KT2

SB7

KA5

YV1

YV2

YV3

YV4

S4220 & S4230 - ING

S4220 & S4230 - ING SUBTITLE OF ELECTRIC SYSTEM:

EN 6162 ED.63:64

65, 66

Figure 12

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S4220 & S4230 - ING ELECTRIC COMPONENTS LIST OF S4220-2:

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S4220 & S4230 - ING S4220-4 e S4230-4: For these models, the electric system was dimensioned to receive a three phase Blade Motor (22) of 220 or 380V and in 50 ou 60Hz. Thus these models have multiple cutting speeds (20 to 85 m / min) driven by a Frequency Inverter (58).The speed variation is performed by Potentiometer (02) located in the Control Panel (20). Basically the system is composed of: BLADE MOTOR (22) (M1) - (75) - M2 - Hydraulic System Motor; - (76) - M3 - Coolant Pump Motor; In the Control Panel (20) (figura 04A): - (01) - DIS - Cutting Speed Display; - (02) - VR - Potentiometer - Speed Selector; - (04) - SB1 EMERGENCY BUTTON - (06) - SB2 - Start Button of Hydraulic System - RESET; - (07) - SB3 ON Start Button of Blade; - (08) - SB3 OFF - Stop Button of Blade; - (11) - HL1 24V PILOT LAMP - (16) - SB6 - Bow Up Button; - (17) - SB7 - Bow Down Button; - (18) - SB5 - Open Vise Button; - (19) - SB4 - Close Vise Button; - (73) - HL2 - PILOT Lamp of Hydraulic System (GREEN); - (74) - HL3 - PILOT Lamp of Start of Blade Motor (GREEN) In the Electrical Box (21): - (09) - Q1 General Switch - (57) - KM3 - Contactor of Coolant Pump Motor; - (58) - A1 - Frequency Inverter of Blade Motor; - (56) - KM2 - Contactor of Hydraulic System Motor; - (69) - FR2 - Hydraulic System Motor- Thermal Relay Protection (FR2); - (71) - KT1 - Timer of Hydraulic System; - (72) - KT2 - Timer Bow Feeding Start; - (59) - C1 - Safety Mode - Safety Relay; - (60) - C2 - Safety Mode - Safety Relay; - (70) - TC - Transformer 220/380V - 24V; - (61) - FU1 - Fuse - Protection of Transformer Input (1A); - (62) - FU2 - Fuse - Protection of Transformer Input (1A); - (63) - FU3 - Fuse - Protection of Transformer Output (3A); REV. 3 [1] - AGO/13

S4220 & S4230 - ING - (64) - FU4 - Fuse - Protection of Command Line (3A); - (65) - FU5 - Fuse - Protection od Directional Valves (5A); - (66) - FU T1 - Fuse - Coolant Pump Protection (1A); - (67) - FU T2 - Fuse - Coolant Pump Protection (1A); In the Bow (24): - (12) - SQ1 - Safety Micro Switch - Opening of Back Cover; - (13) - SQ4 - Limit Micro Switch - Bow DOWN; - (14) - SQ5 - Limit Micro Switch - Bow UP; - (15) - SQ2 - Safety Micro Switch - Blade Rupture. In the Blade Motor (M1) (22): - (98) - FRM - Internal Thermal Protection to the coils of Motor (M1). The EMERGENCY Switch (04) and the Safety Micro Switch (12) of Back CoverÂ´s opening are monitored by a Safety Relay (68), for purposes of ensuring full stop, secure and guaranteed the machine in case of emergency and maintenance or replacement of the saw blade.Moreover, all commands of machines working in extra low voltage, ie 24VAC. To ensure the stopping of machine, and especially of the Blade Motor M1 (22) are installed 2 contactors C1 (59) and C2 (60) in series, which are also the monitored by the Safety Relay (68).Thus in case of emergency, the system will switched off safely, by sending a signal to the Frequency Inverter A1 (58).

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MOTOR SISTEMA HIDRÁULICO MOTOR SISTEMA HIDRAULICO HYDRAULIC SYSTEM MOTOR

FR2

KM2

FU T1

KM3

MOTOR BOMBA REFRIGERACIÓN COOLANT PUMP MOTOR

M3 MOTOR BOMBA REFRIGERAÇÃO

FU T2

FU2

FU1

MOTOR LÂMINA DE SERRA MOTOR HOJA DE SIERRA BLADE MOTOR

FU5

FU4

FU3

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

HL1

KT1

KM2

FRM

SQ2

SQ1

FR1

FU3

FU4

HL2

SB2

KT1

SB3 ON

HL3

KA1

KT2

SA3 OFF

SA3 ON

KM3

SB4

KA2

SB5

KA3

SQ4

KA4

SQ5

SA4 KT2

SB7

KA5

YV1

YV2

YV3

YV4

S4220 & S4230 - ING

S4220 & S4230 - ING SUBTITLE OF ELECTRIC SYSTEM:

61,62, 63, 64 and 65

56 Figure 13

69 71

REV. 3 [1] - AGO/13

66, 67

S4220 & S4230 - ING

ELECTRIC COMPONENTS LIST OF S4220-4 and S4230-4:

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S4220 & S4230 - ING

12. HYDRAULIC SYSTEM

The Hydraulic System (47) of models S4220 andS4230 have the same components and function, according to observed un the table following. This system is composed by 2 Cylinders (48) (51). The Bow Cylinder (48) is responsible by vertical movement, by force and speed of feeding. The control of feeding speed of the Bow (24) is made by Feeding Regulator Valve (50) localized in the Control Panel (20). The Buttons (16) and (17) installed in the Control Panel (20) has the function to perform this movement, to down and to up. The Vise Cylinder (51) is responsible by opening and clamping of Vise Set (36). In the MANUAL mode, this movement, opening and clamping is performed by Buttons (18) and (19), which have the function of adjusting the cutting process.In AUTOMATIC mode, when triggered the Start Button (07) of the blade, the Vise Set (36) will close, clamping the material to be cut. At the end of the cut, the system also automatically opens this set, releasing the material. The hydraulic unit is installed inside of Cabinet (53), as figure 05. Inside, there is the Pressure Regulator Valve of Vise (82), which allow the regulation of pressure of vise according to the type of material to be cut. There. also it is installed 2 Directional Valves (77)(78) responsibles by movements of the Vise (36) and the Bow (24). Under these components above, has the Tank (79) hydraulic oil.Also, it is installed an Indicator (80) to visualize the hydraulic level in the maintenance cases. Hydralic Hoses (52) make the connections between the Cylinders (48) and (51) with hydraulic unit. Attached is a table of hydraulic oils that can be used in this system.

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AJUSTE PRESSÃO DA MORSA

FAIXA DE PRESSÃO: 15 a 30 kg/cm 2

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CILINDRO DA MORSA VISE CYLINDER CILINDRO DO ARCO BOW CYLINDER

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13. MOTOREDUCER: The machines S4220 and S4230 were developed with a motoreducer system composed by a Gear Box (23) engaged with a Motor M1 (22) of three phase. This motor allow vary the rotation in the output shaft of Gear Box (23), ie, in the Driver Flywheel (34). In the model S4220-2, the Motor M1 (22) has double polarity, ie, 2 cutting speed (35 and 70 m/min). To models S4220-4 and S4230-4 the Motor M1 (22), three phase is controlled by a Frequency Inverter (58), according to observed in the electric diagram.

13.1. OPERATING PRINCIPLE: The Gear Box (23) is the WORM type, with permanent lubrication. The Motor M1 (22) can be of 4/8 poles, three phase of double polarity, with voltages: 220 or 380V and the frequencies of 50 and 60 Hz. This caonfiguration equip the model S4220-2. The models equipped with frequency inverter, the Motor M1 (22) is three phase, 4 poles, with voltages 220 or 380V. In cases of long period of operation in hot environments, the gear box of WORM type, for these characteristics, can operate in temperatures between 60 and 80 ยบ C.Within this range, neither its performance nor that of the motor will be impaired.

13.2. MAINTENANCE INSTRUCTIONS: Assembling and Disassembling the Gear Box Reducer For assembly and disassembly of the motoreducer should follow these instructions (Observe figure 14): 1.

Before any maintenance operation, make sure that the machine is switched off with the General Switch (09) in OFF position and the EMERGENCY Button (04) locked;

Disconnect the cables of Motor (22), observing and noting the wiring diagram to avoid mistakes of assembly later;

Release the screws that attach the Motor (22) in the Gear Box (23), to remove them to maintenance if necessary;

On the inner side of the Bow (24), remove the Driver Flywheel (34), releasing it by removal of the central bolt;

Without the Driver Flywheel (23), release the screws that fix the Gear Box (23);

With care, remove the Gear Box (23) of the Bow Set (24);

REV. 3 [1] - AGO/13

S4220 & S4230 - ING 7.

Make the maintenance necessary, and if to drain the oil contained in the gear box, avoid to drop it in the envioronment;

After the maintenance necessary, remake the assembly of the Gear Box (23), following the opposite steps of the disassembly;

Assemble the Driver Flywheel (34) in the tip of Reducer (23) shaft. Check the tighten of the bolt;

10. Assemble the Motor (22) in the Gear Box (23), making sure the tightening of the respective screws; 11. Remake the original electric connection; 12. Turn the motor in the two directions for approximately 20 times, through the Fan, avoiding excess efforts on the shafts; 13. Check if the Motoreducer set is running without any abnormal noise. If happen this, contact the Starrett Technical Support.

OBSERVATION: User is advised to inquiry Starretâ&#x20AC;&#x2122;s Technical Support before performing any ac on.

Figure 14

Bolt of Gear Box in the Bow

Bolt of Driver Flywheel

Bolt of Motor in the Reducer

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S4220 & S4230 - ING

14. MAINTENANCE AND CONTROL This Section provides a description of the main systems that make up this machine,in addition to the main periodic maintenance procedures. Keepng the periodic inspections to date, certainly the machine will always get a good overall performance.

14.1. CLEANING It is very important: –

To clean and remove chips from Flywheels (33) (34) and from the Guide set (27)(30) on daily basis;

–

Periodically (at least each 2 continuous days of work) clean the Tank (84) of coolant liquid.Complete or change, if necessary, the coolant emulsion in the Tank (84) and keep the level;

–

At given intervals during the day, remove chips from Vise Set (36) and Cabinet (53);

–

- Clean periodically the electrical cables ("whips") conservation status.

WARNING: In the case the operator u lizes compressed air or equivalent cleaning systems, he shall USE SAFETY GLASSES, to avoid needless accidents.

14.2. GUIDES SETS ADJUSTMENT AND MAINTENANCE WARNING: Only qualified persons authorized by the owner of machine can perform this opera on.

The Guides Set should periodically be adjusted, so cutting performance is the most appropriate. Cleaning Daily, clear these two sets with its own coolant (water + oil cut), with the Bow (24) in the lower position, without material to be cut on the Cutting Table (35)

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S4220 & S4230 - ING Run the machine for 5 minutes, at the end of the period of machine use, in order to that the coolant liquid wash the inside of the guides sets with abundance. Other way to clean these sets every day is washing under pressure with Micro Oil M1 of Starrett. Monthly, it is advisable to remove the Band Saw Blade (41), the machine completely disabled electrically, the Bow (24) in the lower position and to wash under pressure with Micro-Oil. With the aid of a clean brush remove all kinds of dirt on these Guides Sets (27)(30). Lateral Bearings Adjustments: (figures 14A and 14B)

WARNING: INJURIES DANGER! All repairs and adjustments required a qualified and trained person to perform any opera on on the machine, and necessarilly must be pressed the EMERGENCY Bu on (04) and the General Switch (09) in OFF. It is recommended to use the Technical Suppor Starre , to specialized repair.

MONTLY, during cleaning of Guide Sets (27)(30), the Laterals Bearing (31) should be adjusted, in order to improve the performance of cutting process. With the machine switched off electrically, as observed above, place the Bow (24) in the upper position.Relieve the tension of Band Saw Blade (41), as item 7.1.5. Adjustment Procedure for Carbide Plates (32): 1. After the cleaning procedure of Guides (27)(30), loosen the Lock Nut (99). 2. With the help of a hex allen wrench tighten the Screw (100), in order to touch the Carbide Plate (32) against the side of Band Saw (41); 3. After, lock the Screw (100) with Lock Nut (99). Adjustment Procedure of Lateral Bearings (31): 1. Loosen the Lock Nut (101) and release the Screws (102); 2. With help of fixed wrench, turn the Eccentric Shaft (103) ALWAYS clockwise as showed in figure 14A. The Lateral Bearings (31) should touch completely in the lateral of the Blade (41). The gap between the lateral bearings must be from 0.90 to 0.95mm. The pressure of Lateral Bearing (31) on the Blade (41) NOT can be excessive, as this will cause premature wear of bearings. Also, these bearings can NOT be too far away from side of the blade, which can cause cutting desviations. 3. Then, tighten the Screw (100) and Nut (99), otherwise will get the chance to loose and leave the Lateral Bearing (31) free, may be generating future problems. 72

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S4220 & S4230 - ING

Figure - 14A - LATERAL BEARING Adjustment

Fixed Wrench

18 or 19

27 or 30

Adjustment Nut 31 Adjustment Nut

103

WARNING: INJURIES DANGER! For this adjustmen requires a qualified and trained person to perform this opera on on the machine. Necessarily it must have the EMERGENCY Bu on (04) pressed and the General Switch (09) in OFF.

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Adjustment Procedure of Rear Bearings (95): It should be observedDAILY the position of the Rear Bearing (95) against the back of the Band Saw Blade (41). The distance must be between 0.5 to 1.0mm of clearance. If the blade is outside these limits, adjust the guides by loosening the Screws (102) (figure 14C), moving up or down the Guide Sets (27) or (30), installed in the Guides Support (38) and (105), respectively. Also check the height of Protection of Fixed Guide (104) in relation to the teeth of the Band Saw Blade (41), ie, the protection to cover the teeth, not to be exposed.

Figure 14B 27

100 89 99 88

90 101

37 38

91 102

87 31

95 87

32 92

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S4220 & S4230 - ING

14.3. CAMBER OF DRIVEN FLYWHEEL ADJUSTMENT WARNING: Only qualified persons authorized by the owner of machine can perform this opera on. The life of a blade will depend of the adjustment with Driver and Driven Flywheels. The Band Saw Blade (41) running on the Driven (33) and Driver Flywheel (34) should touch lightly in the ledge these flywheels. For this, the camber adjustment of Driven Flywheel (33) can relieve the pressure of the blade on the ledge. PROCEDURE: 1. Disconnect the machine from the power grid, keep the Bow (24) in lower position; 2. Position the General Switch (09) in OFF and the EMERGENCY Button (04) pressed; 3. With Allen screwdriver, loosen ( relieve the tighting ) the Screws A, B e C, without removal them from Tensioning System (39); 4. By screw D, adjust the camber of Driven Flywheel (33), this way: - in clockwise the back of the blade touches the ledge; - in counterclockwise the back of the blade away from the ledge; The intensity of the turn of the screw D should be small, around 1/4 to 1/3 turning to each setting,until you reach the ideal condition, as illustrated in the figures below; 5. After adjustment, tighten again the Screws A,B and C, and connect the machine on the electrical grid, place the Mode Selector Switch (03) in SEMI AUTOMATIC mode. Then, switch on the machine, position in ON the General Switch (09) and pull the EMERGENCY (04) Button; 6. Check if the tension of the blade is correct; 7. With light touches on the Trigger (07), run the Motor (22) of band saw blade; 8. Remove the Back Cover (25) of the Bow (24) and check the position of the blade's back against the ledges of the Flywheels (33)(34);

REV. 3 [1] - AGO/13

S4220 & S4230 - ING 9. As reference measure the back of the blade should be 0.2 to 0.5 mm from the ledges of the flywheels; 10. If it maintain beyond these measures, reinstall the Back Cover (25) and repeat the procedure from 1 to 8; 11. Reaching the measure according to item 9, enable it electrically and put in operation; 12. Perform this procedure MONTHLY or when there is a problem of breaking the blade or wear on the ledge of the flywheels.

LEDGE

D 24

B 33

D 39

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

14.4. BOW CYLINDER REPLACEMENT WARNING: Only qualified persons authorized by the owner of machine can perform this opera on.

The replace and repair the Bow Cylinder (48) is necessary some recommendations so that the replacement of the item is held securely. PROCEDURE: 1. Disconnect the machine from the power grid, keep the Bow (24) in lower position; 2. Position the General Switch (09) in OFF and the EMERGENCY Button (04) pressed; 3. With the Cylinder (48) fully retracted, remove and replace it, loosening their respective bolts that fix it; 4. NEVER try work with machine without the Cylinder (48) properly installed, as this can cause risks and damages to the operator or to the equipment; 5. With the Cylinder (48) installed, connect electrically the machine and test it if it is performing properly.

14.5. SPRING SET REPLACEMENT WARNING: Only qualified persons authorized by the owner of machine can perform this opera on. The replace and repair the Spring Set (49) (figure 10) is necessary some recommendations so that the replacement of the item is held securely. PROCEDURE: 1. Lift the Bow (24) until the maximum upper position; 2. Disconnect the machine from electrical grid; 3. Position the General Switch (09) in OFF and the EMERGENCY Button (04) pressed; 4. Using any device, lock the Bow (24) in the maximum upper position, REV. 3 [1] - AGO/13

S4220 & S4230 - ING because if there is any loss of pressure within the Bow Cylinder (48), the bow set will remain safe on the high; 5. Relieve completely the tension of the Spring (49) by nuts which tension; 6. Disassemble the set and replace the items necessaries; 7. Assemble again the Spring Set (49) and tension them; 8. Remove the safety device from the bow; 9. Connect the electrically the machine and test it to check if it is performing properly.

14.6. MAINTENANCE TABLE

DescripĆ&#x;on

Frequency

AcĆ&#x;on

Guide cleaning (bearings and carbide plates)

Daily

Clean with M1 micro-oil, or cooling fluid and/or compressed air

Check the wear of the carbide plate guides (gaps)

Monthly

Measure with a feeler gauge

Check the reducer lubricant

Half-yearly

Refill

Check the reducer lubricant

Daily

Fill-up

Check coolant liquid and the level

Daily

Clean

Clean Back Cover and Flywheels

Daily

Clean

Weekly

Lubricate flywheel axles with grease

Daily

Adjust

Check Band Saw Blade tension

Clean the surface of the cu ng table, Daily vise, and other machine surfaces

Clean

Check springs

Monthly

Replace, if required

Tensioning System

Monthly

Grease and adjust

Band Saw Blade

Daily

Replace, if required

Check hydraulic oil reservoir

Monthly

Fill-up

Hydraulic oil

Annual

Replace

Check oil filter

Half-yearly

Replace, if required

Monthly

Replace, if required

Check hydraulic hoses

Every 3 years

Replace

Check cylinder sealing

Monthly

Lubricate and/or replace, if required

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S4220 & S4230 - ING

14.7. TROUBLE, CAUSES AND SOLUTIONS

PROBLEMS 24 V pilot lamp not light Blade does not rotate when START is pressed Blade Motor rotates, but he blade does not No cooling fluid arrives at the guides

CAUSES • General switch in the OFF posi on • Fuses burnst • General switch in the OFF posi on • Emergency Switch pressed • Back cover not fully inserted • Bow lowered pressing at course end • Broken the blade • Sliding in flywheel • Trac on flywheel axle broken • Empty or low level reservoir • Dirty circuit • Coolant Pump broken

Teeth rupture

• No wheelwork performed • Excessive cu ng feed • Incorret serrulate

Cracks appear on top of the Blade

• Blade poorly posi oned on the flywheel • Excessive upper hard metal plate pressure • Mobile guide support too close to the flywheel • Blade tension too high • Material to be cut fastened poorly • Mobile guide support too close to the flywheel • Blade tension too high

Blade upper part rupture

Cracks appear in • Blade too worn for the sec on to be cut teeth thro les • Excessive cu ng feed

REV. 3 [1] - AGO/13

SOLUTIONS • Place in the ON posi on • Replace • Put in the ON posi on • Unlock • Insert correctly • Li Bow • Replace • Apply correct tension • Replace • Fill-up • Clean circuit • Check and replace if required • Always perform wheelwork • Reduce cu ng feed • Choose the appropriate saw for the sec on to be cut • Correct posi on • Posi on guides correctly in the ver cal plane • Posi on as close as possible to the material to be cut • Fasten correctly • Posi on as close as possible to the material to be cut • Apply tension according to the recommended values • Choose an appropriate saw for the sec on to be cut • Reduce cu ng feed

►

S4220 & S4230 - ING

► PROBLEMS Cut devia on

The bow move irregularly The bow move with the flow regulator closed The bow does not li

CAUSES • Insuficient blade tension • Mobile guide support too close to the flywheel • Excessive cu ng feed • Angular limiters adjusted poorly • Lack of oil in the circuit

SOLUTIONS • Increase blade tension • Posi on as close as possible to the material to be cut • Reduce limiter posi on • Correct limiter posi on • Fill-up the circuit

• Cable posi oned poorly

• Posi on the cable and fasten correctly with M5 bolts • Replace • Replace the flow regulator • Disassemble and clean • Put in the ON posi on • Disconnect • Insert correctly

• Internal o-ring damaged • Cone or cone housing damaged • Impuri es inside the valve • General switch in the OFF posi on • Emergency stop pressed • Back cover not fully inserted

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15. SPARE PARTS 15.1. CABINET, ELECTRICAL BOX, COOLANT TANK (S4220-2)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.2. CUTTING TABLE AND VISE SETS (S4220-2)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.3. BOW SET, MOTOREDUCER, BOW HYDRAULIC (S4220-2)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.4. GUIDES SET (S4220-2)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.5. HYDRAULIC SYSTEM (S4220-2)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.6. CABINET, ELECTRICAL BOX, COOLANT TANK (S4220-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.7. CUTTING TABLE AND VISE SETS (S4220-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.8. BOW SET, MOTOREDUCER, BOW HYDRAULIC (S4220-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.9. GUIDES SET (S4220-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.10. HYDRAULIC SYSTEM (S4220-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.11. CABINET, ELECTRICAL BOX, COOLANT TANK (S4230-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.12. CUTTING TABLE AND VISE SETS (S4230-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.13. BOW SET, MOTO REDUCER, BOW HYDRAULIC (S4230-4)

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.14. GUIDES SET (S4230-4)

100

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

15.15. HYDRAULIC SYSTEM (S4230-4)

REV. 3 [1] - AGO/13

101

S4220 & S4230 - ING

102

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

REV. 3 [1] - AGO/13

103

S4220 & S4230 - ING

104

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

ANNEX: OIL TO LUBRICAT AND CLEANING THE GUIDES Product: Micro-Oil Prevents Rust M1

Manufacter: Starrett

SpecificaĆ&#x;on: Color

Amber (clear)

Odor

pleasant

Specific Gravity

0,788 to 60 oF (15,5C)

Viscosity

2,2 cSt (cen Stokes) connverts to 10,5 SUS

Lubrifica on

680Kg (1500 lb) of pressure (independent tes ng)

Flash Point

Minimum 53 oC Toledo open cup

Percent Non-Vola le

15% by weight

Percent vola le maximum

85% by weight petroleum dis late

Pour Point

-73 oC Excelent low temperature stability

Evapora on Rate

0,7 (water = 1 )

Coverage

85 to 100 m2 / liter = 3500 to 4000 sq. per U.S Gal. (4,5 liters)

Bolling Point, Ini al

173 oC

Weight, Applied Coa ng

8 x 10 -3 Kg/m2

Film Tickness

0,010 mm average

Humity

According with ASTM-D 655. Zero rust a er 1000 hours

Salt Spray

According with ASTM-B 117. Zero rust a er 48 hours

Indoor Protec on

at lasts up to a year

Outdoor Protec on

reapply as needed

Packages Types

No catalogs

No EDP

Case of 12 / 12 oz. (0.3 liter) Aerosol Cans

M1.95173

95173

1 Gallon (3.8 liters) Containers

M1.01 - 5

93221

5 Gallons (19 liters) Pall

M1.05

93227

53 Gallons (200liters) Drum

M1.53

93233

REV. 3 [1] - AGO/13

105

S4220 & S4230 - ING TYPES OF HYDRAULIC OIL Use hydraulic oils according to the recommendations herein. The maintenance operation of the hydraulic system and oil changes must be performed by qualified professionals. Starrett uses PARAMOL HM 46 oil, and recommends replacement before 5,000 hours of operation. Safety conditions must be observed when handling hydraulic oils.

ATTENTION! Do not ingest! Avoid contact with the eyes! Handle using appropriate protec on gloves! Respect the environmental laws for the disposal of this product! Keep away from children and animals!

ATTENTION! CHECK THE MANUFACTURER’S RECOMMENDATIONS

SpecificaƟon CETOP RP 91 H ISO VG Manufacturers AGENA CASTROL ELF ESSO FUCHS GULF HOUGHTON IPIRANGA MARIS MICROQUÍMICA MOBIL PETROBRÁS ROCOL SHELL TEXACO TIRRENO UNI VALVOLINE REPSOL

HM 32

HM 46

AGEFLUID AW 785/32 HYSPIN AWS 32 ELFONA 32 NUTO H32 RENOLIN B10 GULF HARMONY AW 32 HYDRODRIVE HP 32 IPITUR AW 32 HILLUS AW32 MICROFLUID AW32 MOBIL DTE 24 LUBRAX INDUSTRIAL HR-32-EP HO 32 TELLUS 32 RANDO HD32 TIRROIL AWSE 32 HIDRAMAX AW 32 HYDRAULIC AW 32 HIDRAULICO BP 32

AGEFLUID AW 785/46 HYSPIN AWS 46 ELFONA 46 NUTO H 46 RENOLIN B10 GULF HARMONY AW 46 HYDRODRIVE HP 46 IPITUR AW 46 HILLUS AW 46 MICROFLUID AW 46 MOBIL DTE 25 LUBRAX INDUSTRIAL HR-46-EP HO 46 TELLUS 46 RANDO HD46 TIRROIL AWSE 46 HIDRAMAX AW 46 HYDRAULIC AW 46 HIDRAULICO BP 46

With temperatures below +5 ° C should replace the oil type: PARAMOL H 46 by PARAMOL H 32. 106

REV. 3 [1] - AGO/13

S4220 & S4230 - ING

CATALOG - BAND SAW BLADE

NOV.2011

REV. 3 [1] - AGO/13

107

170% MORE WELD CONTACT AREA

A - WIDTH Tip of the cutting edge to the back of the blade. B - LENGTH Measurement along the back edge of the blade.

MULTIPLE CUTTING EDGES

C - THICKNESS Measurement of the body of the blade. D - BACK EDGE Opposite side of the blade from the teeth. E - TOOTH PITCH Distance from the tip of one tooth to the next tip. F - TEETH PER INCH/25MM Number of teeth per inch/25mm. G - GULLET The curved area between two teeth. H - TOOTH FACE Surface of the tooth where the chip is formed. The tooth can have a positive or straight angle when measured against a line perpendicular from the back of the blade.

SPLIT CHIP ADVANTAGE

Â®

I - TOOTH SET The bending of the teeth, right and left, to allow blade clearance through the cut.

starrett.com

Constant Pitch

INTENSS

.8-1.3 to 14-18

INTENSS PRO-VTH

VERSATIX MP

REGULAR

HOOK

SKIP

Variable Pitch

6 to 32

1-2 to 4-6

Positive rake (up to 12º) product with a patented surging cutting action. Use with nickel alloys, stainless steels, and heat treated steels (up to HRc 45).

2-3 to 6-10

Computer designed product with a resultant robust positive rake tooth aimed specifically for intercept cuts on beams, channels, and tubes. Works well for all general cutting. M-42 - 8% cobalt teeth.

8-12 to 14-18

A standard 0º rake tooth form good for general and light duty cutting applications.

2 to 6

A 10º rake angle available in the carbon line. Good for fast cutting of hardwoods and nonferrous materials.

3 to 6

0º rake tooth with expanded gullet area. Works well in soft woods, nonferrous and non-metallics.

1 to 3

CNC ground triple chip tooth form. Excellent for high production rates on hard metallic and abrasive nonmetallics. Advanz™ FS is for shock, foundry applications. Advanz™ TS is for heat treated, difficult to machine materials.

ADVANZ FS & TS (Carbide Tipped)

Aggressive positive rake (up to 12º). Use for high production cutting of solids or heavy wall profiles. M-42 high speed edge with 8% cobalt.

.9-1.1 to 3-4

TOOTH CONSTANT PITCH

All teeth on the blade have uniform spacing, gullet depth and rake angle throughout the full length. Typically for general purpose cutting. Identified by one pitch number.

VARIABLE PITCH

Size of tooth and depth of gullet varies to substantially reduce noise levels and vibrations. Cuts all structurals, tubing and solids smoothly and quickly. Identified by two pitch numbers.

SETS RAKER SET

A recurring sequence of teeth set left and right, followed by one tooth unset. Frequency of unset teeth on variable pitch blades varies depends on the tooth configurations.

WAVY SET

Groups of teeth set to each side of the blade, with varying amounts of set in a controlled pattern.

ALTERNATE SET

A recurring sequence of teeth set alternately left and right.

TRAPEZOIDAL

Special carbide cylinder welded in the tooth edge, being slightly thicker than the blade, and triple chip grind.

starrett.com

BLADE TYPE Use this guide to choose the blade that will work best for the material to be cut, or provide an acceptable result, as necessary.

BLADE WIDTH Use the widest blade your machine will take except for contour cutting. Use this chart for cutting radii:

EXOTIC & NICKEL-BASED ALLOYS Intenss™ PRO or Intenss™ VTH TOOL & STAINLESS STEEL Intenss™ PRO or Intenss™ VTH ALLOY & HIGH CARBON STEEL Intenss™ PRO GENERAL PURPOSE Intenss™ PRO CARBON STEEL Intenss™ PRO-DIE STRUCTURAL STEEL Intenss™ PRO-ST or Versatix™ MP ALUMINUM Intenss™ PRO or Intenss™ PRO-DIE or Duratec™ FB CAST ALUMINUM Advanz™ FS THIN FERROUS SECTIONS Duratec™ FC COMPOSITES, FIBERGLASS, GRAPHITE & CERAMICS Advanz™ CG or Advanz™ DG WOOD & PLASTIC Woodpecker™ Premium or Woodpecker XF™ FOAM, PAPER PRODUCTS & RUBBER Band Knives FRESH OR FROZEN MEAT OR FISH (WITH OR WITHOUT BONES) Meatkutter™ Premium or Meatkutter™ Stainless

TOOTH SHAPE Regular - A conventional tooth used for general purpose sawing, straight or zero rake. Intenss™ PRO - Large teeth, up to 12º positive rake angle, for optimum production cutting of steels up to HRc 45, stainless, nickel based and nonferrous alloys. Hook - A positive rake for fast cutting of nonferrous metals and non-metallics. Skip - Zero rake and shallow gullets for cutting large sections of soft, nonferrous material.

BLADE LENGTH The blade length varies according to the band saw machine type and specifications. Please find the correct blade length on your band saw machine user manual.

PITCH Pitch is the number of teeth per inch or 25mm. Cutting thinner sections requires a finer pitch (more teeth per inch/25mm). Thick sections require coarser pitches (fewer teeth per inch/25mm). The charts are good guidelines. Because the cross section limits in the chart are broad and overlap, choose a coarser pitch if the speed of cut is most important. Choose a finer pitch if finish is most important. Section Size (Inch)

Constant Pitch (TPI)

Variable Pitch (TPI)

5/32 - 3/8

32 or 24

14-18

1/4 - 1/2

18 or 14

10-14

1/2 - 3/4

14 or 10

8-12

3/4 - 1

10 or 8

6-10

1 - 1-1/2

8 or 6

5-8

1-1/2 - 3-1/2

6 or 4

4-6

3-1/2 - 7

4 or 3

3-4

7 - 10

2-3

10 - 16

1.4-2

14 - 20

1-2

16 - 32

1-1.2

Over 30

.8-1.3

Wall Thickness

Outside diameter of tube or maximum profile section length (Inch)

(Inch)

3/8

3/4

1-5/8

2-3/8

3-1/4

4-3/4

3/32

14-18

10-14

8-12

6-10

5-8

1/8

10-14

8-12

6-10

5-8

5/32

8-12

6-10

5-8

4-6

3/16

6-10

5-8

4-6

1/4

5-8

4-6

3-4

5/16

4-6

3-4

3/8

4-6

3-4

2-3

1/2

4-6

3-4

2-3

5/8

4-6

3-4

2-3

3/4

4-6

3-4

2-3

3-4

2-3

1.4-2

1-1/4

3-4

2-3

1.4-2

1-5/8 2 2-3/8

starrett.com

3-4

2-3

1.4-2

3-4

2-3

1.4-2

1-2

2-3

1.4-2

1-2

Intenssâ&#x201E;˘ Pro Blade Width x Thickness

Blade Pitch with Material Numbers (all are Positive Rake)

Inch

.8-1.3/P

3/4 x .035

19 x 0.90mm

1 x .035

25 x 0.90mm

1-1/4 x .042

32 x 1.10mm

1-1/2 x .050

38 x 1.30mm

2 x .063

50 x 1.60mm

99928

2-5/8 x .063

67 x 1.60mm

3-1/8 x .063

79 x 1.60mm

1-1.2/P

1-2/P

1.4-2/P

2-3/P

3-4/P

4-6/P

5-8/P

6-10/P

8-12/P

10-14/P

99191

99902

99903

99206

99222

99234

99905

99906

99907

99908

99318

99329

99334

99500

99911

99096

99912

99913

99914

99915

99917

99919

99921

99923

99924

99926

99927

99929

99930

99931

99932

99933

99962

99934

99937

99939

99941

99942

99943

99945

99947

3/4 to 1-1/4 sizes available in 250 (76m) coils. 1-1/2 to 2 sizes available in 150 (45m) coils. 2-5/8 and larger available in welded bands only.

POCKET LASER TACHOMETER KIT WITH CASE Cat. No. S7793Z • EDP No. 68930 The Pocket Laser Tachometer is a digital, battery-powered portable optical tachometer that can operate up to 25 feet from a reflective target using a laser light source. This powerful 32 function Tachometer/ Ratemeter, Totalizer/Counter and Timer is programmable in both inch and metric rates. It has TTL compatible pulse output to trigger devices such as data collectors or strobocopes. Ergonomic design makes measurement of speed and RPM simple.

RANGE Optical: 5 to 200,000 RPM Contact: 0.5 to 20,000 RPM Accuracy: Optical: ±0.01% of reading Contact: ±0.05% of reading Kit includes: Tachometer, RCA, contact tips,10cm linear contact wheel, 5 of T-5 reflective tape, (2) AA batteries, carrying case

SAW TENSION GAGE Cat. No. 682EMZ • EDP No. 57075 The Saw Tension Gage will check for proper blade tension in either English or metric, and is graduated both in pounds and kilograms. The tension gage can be read directly on either band saws of any type, or power hacksaws. It is graduated to read up to 60,000 PSI or 4,000kg per cm2 and is furnished with instructions, including suggested tensions.

BAND SAW BLADE ALIGNMENT GAGE Cat. No. PT92925 • EDP No. 65049 The alignment of your band saw blade is a key factor to guarantee blade life and accuracy with Starrett Band Saw Blades. This gage enables you to make sure your blade is running square to the cut.

187 SLIDE CHART FOR BAND SAW SELECTION AND OPERATING GUIDE Our popular band saw slide chart selection and operating guide includes a wealth of useful information printed on both sides. This slide chart recommends the pitch suitable for the cross section to be cut as well as surface feet per minute speed plus the optimum cutting rate. This tool was developed by our R & D group from actual tests.

193 CUTTING RATE SELECTION CHART This cutting rate selection chart is a heavy-weight, laminated, two sided sheet with a chain for easy attachment to a band saw machine. It also includes recommended tension for Starrett band saw blades and a quick reference troubleshooting table.

121 CRESCENT STREET ATHOL, MA 01331 978 249 3551

starrett.com M1, M2, M7, M10, M50 M3, M4, M30-M47 High Speed Steels

T1, T2, T6 T4, T5 T15

Free Machining Stainless Steels

303 416, 420F, 430F

Austenitic Stainless Steels

201, 202, 301-304 305, 308, 321, 347, 348

Ferritic

Monel K500 Hastelloy, Rene 41 99% Titanium

Molybdenum Refractory Metal

Tantalum

405, 409, 430, 434, 436, 442, 446

99% Copper

403, 410, 420, 422, 501, 502 440A-C, 414, 431

Cast Iron

15-5PH, 17-4PH, 17-7PH

INSTRUCTIONS: Set ARROW on slide at material to be cut. Check ARROW in lower right corner for correct blade type. For Intenss™ PRO-VTH increase scale speed/feed by 15%. For Advanz™ carbide tipped, increase scale speed/feed by 25%-30%. Use Versatix™ MP for structurals, pipe, tube, channel and small diameters. Instructions on reverse side. CUTTING STRUCTURALS SPEEDS: 250-325 wet; 200-250 dry NOTE: Break in blade at about 1/2 normal cutting rate for the ﬁrst 50-100 square inches on easy to cut material. Tough work hardening material, break in at about 3/4 normal cutting rate for the ﬁrst 25 square inches, gradually increasing feed to reach maximum cutting rate after 50 square inches. Always remove a chip and maintain recommended band speed. (Avoid vibration.)

Free Cutting Brass Yellow/Red Brass Copper Alloys

Phosphor Bronze

Class 20

Aluminum Bronze

Class 40

Aluminum Bronze (Hardened)

Free Machining Carbon Steels

Beryllium Copper

Ductile 80-55-06, 225HB

Beryllium Copper (Hardened)

Medium Carbon Steels

Most Aluminums

High Carbon Steels

1/2"-1"

1"-2"

320 5-7

300 6-8

270 8-10

10-14

8-12 6-10

5-8 4-6

TEETH PER INCH

SPEED ft./min. sq. in./min. CUTTING RATE

1211-1215

5040-5060

1110, 1117-1118

5115-5120

1137-1151

5130-5160

1005-1012

50100, 51100, 52100

Low Carbon Steels

Ductile 60-40-18, 150HB

MATERIAL WIDTH <1/2"

Titanium Alloys

Alpha, Alpha-Beta, Beta

Columbium

Prec. Hardening

Nickel Alloys

Monel 400, 401

A286, 309, 310, 314, 316, 317, 330

Martensitic Stainless Steels

Front

Inconel 625, 718, X-750 Waspaloy Inconel 600, 601

1015-1026

6118

1030-1055, A36

6150

MATERIAL WIDTH 2"-5"

5"-10"

250 8-10

250 6-7

4-6 3-4

3-4 2-3

>10"

Intenss™ PRO

PREFERRED 180 BAND TYPE 4-6 Intenss™ 1-2 3/4 - 1-1/4 PRO-VTH

TEETH PER INCH

Manganese Steels

8115, 8615-8622

1330-1345

8720, 8822

1513-1527

8145, 8625-8637

1536-1552

8640-8660, 8740

1561-1572

9310

4012-4024

9430-9445

4030-4042

9255-9262

4047-4068

A2-A6, A8-A10

or Advanz™

Molybdenum Steels Intenss™ PRO-VTH recommended for cutting these materials GENERAL INFORMATION Consult our technical dept. for appropriate Advanz™ carbide style 1) When cutting materials of various hardness other than normal listing on speed chart, multiply speed or cutting rate given on chart by these factors to arrive at speeds and cutting rates for hardened material. CUTTING RATE FACTOR Rockwell Brinell SPEED FACTOR 0 0 225Bhn Up to 20Rc .75 .75 225-275Bhn 20-28Rc HARDNESS .54 .60 275-325Bhn 28-35Rc .40 .50 325-375Bhn 35-40Rc 2) Cutting normal or annealed materials requires at least 3 teeth to be in contact with the work, with the optimum being 6-12 teeth, and 24 teeth being too many. 3) When using Duratec™ PH or Duratec™ FB, reduce speed by 50% and cutting rate by 85%. 4) When cutting dry, reduce band speed 40-50%, and cutting rate 40-50%. Blade life will also be shorter by approximately 40-50%. 5) To choose correct Versatix™ MP for cutting tubing, pipe and structurals, first find the total square inches and divide by the distance the saw blade must travel to finish cut. This figure can be used as material width to determine Teeth Per Inch (Pitch). 6) To find estimated cutting rate for pipe, tubing and structurals, multiply factor for minimum wall thickness of section to be cut by the cutting rate shown for the same size solid material. 7) For foundry applications (aluminum, non-ferrous) use Advanz™ FS carbide tipped at 1000-5000FPM 8) For case hardened & hardened steels, use Advanz™ CS. (+) Up to 3/16 .4

3/16 - 3/8 .5

3/8 - 5/8 .6

5/8 - 1 .7

1 and Over .8

1/2 3/4 1 1-1/4 1-1/2 1-3/4 2 2-1/4 2-1/2 2-3/4 3 3-1/4 3-1/2 3-3/4 4

.20 .44 .79 1.22 1.76 2.40 3.14 3.97 4.90 5.93 7.06 8.25 9.62 11.04 12.56

4-1/4 4-1/2 4-3/4 5 5-1/4 5-1/2 5-3/4 6 6-1/2 7 7-1/2 8 8-1/2 9 9-1/2

14.18 15.90 17.72 19.63 21.64 23.75 25.96 28.27 33.18 38.48 44.17 50.26 56.74 63.61 71.00

10 10-1/2 11 11-1/2 12 12-1/2 13 13-1/2 14 14-1/2 15 15-1/2 16 16-1/2 17

78.53 86.60 95.00 104.00 113.00 122.75 132.00 143.06 153.86 165.04 176.62 188.59 200.96 213.71 226.86

17-1/2 18 18-1/2 19 19-1/2 20 20-1/2 21 21-1/2 22 22-1/2 23 23-1/2 24 24-1/2

240.40 254.36 268.66 283.43 298.49 314.00 330.09 346.18 362.86 379.94 397.40 415.26 433.51 452.16 471.19

4142-4161

L2, L6 S1-S7

4815-4820

1/2"-1"

1"-2"

Tool Steels (Air and Oil Hardening)

D2, D3, A7 W1-W5

4340

MATERIAL WIDTH <1/2"

Nickel Chrome Moly Steels

Silicone Steels

O1, O2, O6, O7, P20

4320

4615-4626

Intenss™ PRO-VTH recommended for cutting these materials

Carbon Tool Steel

Special Purpose Shock Resistant Hot Work Steel

H10-H19 H21-H42

SPEED

MATERIAL WIDTH 2"-5"

5"-10"

4-6 3-4

3-4 2-3

>10"

Intenss™ PRO

ft./min. sq. in./min. 10-14

WALL THICKNESS FACTOR

Diameter Area in Diameter Area in Diameter Area in Diameter Area in in inches Sq. Inches in inches Sq. Inches in inches Sq. Inches in inches Sq. Inches

4130-4140

Chrome Moly Steels

Nickel Chrome Moly Steels

Nickel Moly Steels

Chrome Steels

Chrome Vanadium Steels

1060-1095

8-12 6-10

TEETH PER INCH

5-8 4-6

CUTTING RATE

PREFERRED BAND TYPE Intenss™ 1-2 3/4 - 1-1/4 PRO-VTH

TEETH PER INCH

starrett.com

or Advanz™

SPECIFICATIONS SUBJECT TO CHANGE BULLETIN 110-25M/PG-04/09

No Varnish Area

BLADE BREAK-IN Using the right break-in procedures for a bimetal blade assures longer blade life, faster cuts for a longer period of time and consistent performance. Conversely, blade life can be significantly compromised if the proper break-in procedures are not followed.

LONGER BLADE LIFE

NEW BLADE WITH RAZOR SHARP TEETH

TOOTH CORRECTLY BROKEN IN

The teeth on a new band saw blade are razor sharp. To withstand the cutting pressures of band sawing, the tip of each tooth should be honed to create an extremely small radius on its tip. Easy-to-cut material such as carbon steel and aluminum: A. Run the normal surface feet per minute (SFPM). B. Adjust the feed pressure to about one-half the normal cutting rate for the first few cuts or for 50-100 square inches (323-645 sq.cm). C. Increase to the normal cutting rate. D. Avoid vibration. Hard-to-cut materials such as nickel-based alloys like inconel, hardened steels,tool steels and stainless steels: A. Run the normal surface feet per minute (SFPM). B. Adjust the feed pressure to about threequarters of the normal cutting rate for the first few cuts or for 25-75 square inches (161-484 sq.cm). C. Then increase the cutting rate part way to normal for the next few cuts. D. Then increase to the normal cutting rate. E. Avoid vibration.

BAND SAW SERVICE & SUPPORT Starrett service technicians are available to tune up and perform preventative maintenance on your production sawing machine using Starrett Band Saw Blades, at no additional cost. They fully review machine condition, blade mounting and operation in detail, making adjustments, as required, to help maintain good sawing and long life for both the machine and blades.

TRAINING

TOOTH INCORRECTLY BROKEN IN

START TO CUT MATERIAL AT REDUCED CUTTING RATE

Starrett service technicians can also instruct saw operators on achieving the best performance of blade and machine for your applications. Contact your Starrett Band Saw distributor about arranging a visit to your workplace by a Starrett service technician.

AFTER BREAK-IN WHEN THE BLADE HAS FULLY ENTERED THE WORKPIECE, INCREASE THE FEED RATE OVER A SERIES OF CUTS UNTIL THE RECOMMENDED CUTTING RATE IS ACHIEVED

BAND SAW BLADE INSTALLATION GUIDELINES Always follow the machine manufacturer’s instructions and recommendations for blade changes and the safe operation for the band saw machine. The guidelines are not intended to replace the machine manufacturer’s instructions or recommendations. The general information contained in the guidelines is intended to assist in the proper installation of band saw blades. Proper blade installation achieves more efficient blade performance. Please contact your machine manufacturer for appropriate procedures for blade changes for your specific machine and your saw blade manufacturer for appropriate cutting recommendations. The L. S. Starrett Co. nor its employees, shall not be held responsible for the accuracy or completeness of these guidelines. Wear gloves when handling band saw blades.

Wear eye protection, safety shoes, and hearing protection.

FOLLOW INSTRUCTIONS CAREFULLY Follow all the safety instructions shown in the band saw machine operator’s manual and on the machine labels. Recognize and read safety and warning signs such as Danger, Warning and Caution. Follow the saw blade installation instructions for the make and model of the band saw machine.

BASIC BLADE CHANGE GUIDELINES Position saw head to appropriate location to facilitate ease of blade change. Follow required lock out tag out procedures. Position chip brush away from saw blade. Relieve saw blade tension and remove blade. Remove any chips from saw guides and band wheels. Select appropriate blade for cutting application. (Refer to saw blade selection chart) Unfold blade properly. Do Not Throw. Throwing the blade will result in tooth damage that will reduce saw blade performance. (Refer to unfolding procedure) Install blade with saw teeth pointing in proper direction.

Apply appropriate tension to the blade. Be aware of pinch points and keep hands and clothing clear of rotating blade.

Adjust guide arms to appropriate positions to workpiece. Adjust blade guides for proper blade support. Adjust chip brush to fully engage saw blade teeth to ensure proper chip removal. Check hydraulic fluid levels if applicable. Ensure appropriate cutting fluid placement and mix ratios as applicable per machine, cutting fluid, and blade manufacturer’s recommendations. Break in blade properly before reaching desired cutting rates.

Steel Specification USA (AISI)

Feet per Minute

Meters per Minute

Sq Inch per Minute

Sq cm per Minute

1211-1215

230 - 310

69 - 93

12 - 18

78 - 117

1110, 1117-1118

220 - 300

66 - 90

9 - 15

58 - 97

1137-1151

165 - 245

50 - 74

5 - 11

32 - 71

1005-1012

220 - 300

66 - 90

9 - 14

58 - 97

1015-1026

210 - 290

63 - 87

8 - 13

52 - 91

1030-1055, A36

140 - 220

42 - 66

5-9

32 - 58

1060-1095

120 - 200

36 - 60

5-8

32 - 52

1330-1345

140 - 220

42 - 66

4-8

26 - 52

1513-1527

220 - 300

66 - 90

8 - 12

52 - 91

1536-1552

165 - 245

50 - 74

6 - 10

39 - 65

1561-1572

120 - 200

36 - 60

5-8

32 - 52

4012-4024

150 - 230

45 - 69

4-9

26 - 58

4030-4042

140 - 220

42 - 66

4-8

26 - 52

4047-4068

130 - 210

39 - 63

4-8

26 - 52

4130-4140

130 - 210

39 - 63

4-8

26 - 58

4142-4161

120 - 200

36 - 60

3-7

20 - 45

4320

130 - 210

39 - 63

4-8

26 - 52

4340

120 - 200

36 - 60

3-7

20 - 45

4615-4626

140 - 220

42 - 66

4-8

26 - 52

4815-4820

130 - 210

39 - 63

4-8

26 - 52

5040-5060

130 - 210

39 - 63

4-8

26 - 52

5115-5120

150 - 230

45 - 69

5-9

32 - 56

5130-5160

130 - 210

39 - 63

4-8

26 - 52

50100, 51100, 52100

90 - 160

27 - 48

3-5

20 - 32

6118

150 - 230

45 - 69

5-9

32 - 58

6150

130 - 210

39 - 63

4-8

26 - 52

8115, 8615-8622, 8720, 8820

130 - 210

39 - 63

5-9

32 - 58

8145, 8625-8637

130 - 210

39 - 63

5-9

32 - 58

8640-8660, 8740, 9430-9445

130 - 210

39 - 63

4-8

26 - 52

9310

110 - 190

33 - 57

2-4

13 - 26

Work Material Type

Free Machining Carbon Steels

Low Carbon Steels Medium Carbon Steels High Carbon Steels

Manganese Steels

Molybdenum Steels

Chrome Moly Steels

Nickel Chrome Moly Steels

Nickel Moly Steels

Chrome Steels

Chrome Vanadium Steels

Nickel Chrome Moly Steels

Steel Specification USA (AISI)

Feet per Minute

Meters per Minute

Sq Inch per Minute

Sq cm per Minute

130 - 210

39 - 63

4-8

26 - 52

140 - 220

42 - 66

3-6

20 - 39

A2-A6, A8-A10

130 - 210

39 - 63

2-4

13 - 26

01, 02, 06, 07

130 - 210

39 - 63

2-6

13 - 29

D2, D3, D7 (CUT DRY)

50 - 100

15 - 30

2-3

13 - 20

W1-W5

130 - 210

39 - 63

2-6

13 - 39

L2, L6

120 - 200

36 - 60

2-6

13 - 39

S1 - S7

90 - 160

27 - 48

2-4

13 - 26

H10 - H19

130 - 210

39 - 63

2-5

13 - 32

H21 - H42

90 - 160

27 - 48

2-4

13 - 26

M1, M2, M7, M10

75 - 130

22 - 39

2-4

13 - 26

M3, M4, M30 - M47

50 - 100

15 - 30

1-3

7 - 20

T1, T2, T6

75 - 130

22 - 39

2-4

13 - 26

T4, T5

60 - 120

18 - 36

1-3

7 - 20

T15

50 - 90

15 - 27

1-3

7 - 20

303

75 - 140

22 - 42

2-5

13 - 32

416, 420F, 430F

100 - 180

30 - 54

3-6

20 - 39

201, 202, 301-304, 305, 308

70 - 120

21 - 36

2-4

13 - 26

321, 347, 348

70 - 120

21 - 36

2-4

13 - 26

A286, 309, 310, 314

50 - 80

15 - 24

1-2

7 - 13

316, 317, 330

50 - 80

15 - 24

1-2

7 - 13

405, 409, 430, 434

60 - 100

18 - 30

1-3

7 - 20

436, 422, 446

60 - 100

18 - 30

1-3

7 - 20

403, 410, 420, 422, 501, 502

70 - 130

21 - 39

2-4

13 - 26

440A-C, 414, 431

60 - 100

18 - 30

1-3

7 - 20

15-5PH, 17-4PH, 17-7PH

50 - 90

15 - 27

1-3

7 - 20

CLASS 30

120 - 200

36 - 60

8 - 14

52 - 91

CLASS 40

80 - 160

24 - 48

5 - 11

32 - 71

DUCTILE 60-40-18 150HB

160 - 240

48 - 72

4 - 10

26 - 65

DUCTILE 80-55-06 225HB

80 - 160

24 - 48

2-7

13 - 45

Work Material Type Silicon Steels

9255-9262

Nitriding Steels

Tool Steels (Air & Oil Hardening)

Carbon Tool Steel

Special Purpose Shock Resistant Hot Work Steel

High Speed Steels

Free Machining Stainless Steels

Austenitic Stainless Steels

Ferritic Stainless Steels

Martensitic Stainless Steels Precision Hardening Stainless Steels

Cast Iron

Diameter

AREA CALCULATION

Area

Inches

Centimeters

Square Inches

Square Centimeters

1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 14.5 15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 24

2.5 3.8 5.1 6.4 7.6 8.9 10.2 11.4 12.7 14 15.2 16.5 17.8 19.1 20.3 21.6 22.9 24.1 25.4 26.7 27.9 29.2 30.5 31.8 33.0 34.3 35.6 36.8 38.1 39.4 40.6 41.9 43.2 44.5 45.7 47.0 48.3 49.5 50.8 52.1 53.3 54.6 55.9 57.2 58.4 61.0

0.8 1.8 3.1 4.9 7.1 9.6 12.6 15.9 19.6 23.8 28.3 33.2 38.5 44.2 50.3 56.7 63.6 70.9 78.5 86.6 95.0 104.0 113 123 133 143 154 165 177 189 201 214 227 241 254 269 284 299 314 330 346 363 380 398 415 452

4.9 11.3 20 32 45 62 82 102 127 154 186 214 249 287 324 366 412 456 507 560 611 670 731 794 855 924 995 1064 1140 1219 1295 1379 1466 1555 1640 1735 1832 1924 2029 2132 2231 2341 2454 2570 2679 2922

In order to calculate the best cutting progress, you can select an option from the charts below.

ATTENTION Make all the measurements in centimeters to get the area in cm2

SQUARE area = L2

ROUND area = D2 x 0,7854

ROUND TUBE area = (De2 - Di2) x 0,7854

SQUARE TUBE area = = Le2 - Li2

RECTANGULAR area = E x L

HEXAGONAL area = L2 x 2,598 E2 x 0,866

Blade Effect

Blade Breakage

Straight break indicates fatigue.

Prematurely Dull Teeth

Inaccurate Cut

Band Leading in Cut

Chip Welding

Teeth Fracturing - Back

Probable Cause

Solution

Incorrect blade

Check tooth selection

Band tension too high

Reduce band tension, refer to operator’s manual

Excessive feed

Reduce feed pressure

Incorrect cutting fluid

Check coolant recommendations

Wheel diameter too small for blade width

Use narrower blade

Worn or chipped pressure block

Replace worn pressure blocks

Blade rubbing on wheel flange

Adjust wheel alignment

Teeth in contact with work before starting saw

Allow blade clearance above work

Side guides too tight

Refer to operator’s manual

Blade on machine backwards

Install blade correctly

Improper blade break-in procedure

Refer to recommended procedures

Hard material or heavy surface scale

Check material hardness and surface condition

Material is work-hardening

Increase feed pressure

Improper cutting fluid or mix ratio

Follow coolant mixing procedures

Speed or feed too high

Check cutting recommendations

Guide arms too far apart

Adjust guide arms closer to material

Blade worn out

Replace blade

Over or under feeding

Check cutting recommendations

Improper tooth pitch

Use proper tooth selection

Cutting fluid not applied properly

Adjust coolant nozzles

Too many teeth for material cross section

Use proper tooth selection

Guides worn or loose

Tighten or replace guides

Over feeding

Check cutting recommendations

Low band tension

Refer to operator’s manual

Tooth set damaged

Check material hardness

Guide arms loose or space too wide

Adjust guides and guide arms

Worn or missing chip brush

Replace or adjust chip brush

Improper or lack of cutting fluid

Check coolant flow and fluid type

Wrong coolant ratio

Check coolant type and ratio

Excessive feed or speed

Reduce feed or speed

Incorrect blade pitch

Use proper tooth selection

Saw guides not properly adjusted

Align or adjust saw guides

Incorrect feed or speed

Refer to cutting recommendations

Incorrect blade

Use proper blade type and pitch

Material moved in vise

Inspect and adjust vise

Indexing while blade in work

Adjust index sequence

Blade not high enough before index

Adjust height selector

Saw head drifts into work while neutral

Check hydraulic cylinder

Back of tooth indicates spinning in vise.

Irregular Break

Indicates material movement.

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Blade Effect

Teeth Stripping

Wear on Back of Blade

Rough Cut

Washboard surface, vibration and/or chatter

Wear Lines - Loss of Set

Twisted Blade

Contour sawing

Blade Wear

Teeth blued.

Teeth Fracturing - Front

Front of tooth indicates work spinning in vise.

Probable Cause

Solution

Improper blade break-in procedure

Follow proper break-in procedure

Speed too slow

Refer to cutting recommendations

Feed pressure too high

Reduce feed pressure

Tooth jammed in cut

Do not enter new blade in that cut

Poor cutting fluid application or ratio

Adjust coolant flow and ratio

Hard material or heavy scale

Check material or surface hardness

Wrong blade pitch

Use proper tooth selection

Work spinning or loose nested bundles

Tighten vises or use nesting clamps

Blade on backwards

Install blade correctly

Excessive back-up guide preload

Adjust pressure blocks

Low blade tension

Refer to operator’s manual

Incorrect blade (carbon steel type)

Switch to a bi-metal blade

Excessive feed rate or pressure

Reduce feed rate or pressure

Damaged or worn pressure block

Replace pressure block

Guide arms spaced too far apart

Adjust guide arms closer to work

Blade rubbing band wheel flanges

Adjust wheel alignment

Dull or damaged blade

Install new blade

Incorrect feed or speed

Refer to cutting recommendations

Blade not supported properly

Adjust or tighten guide arms

Low blade tension

Refer to operator’s manual

Incorrect tooth pitch

Use proper tooth selection

Guide arms too far apart

Adjust guide arms closer to material

Saw side guides too tight

Adjust guides properly

Blade riding too high in guide

Adjust rollers or pressure blocks

Blade teeth riding on band wheel surface

Adjust tracking or replace wheel

Wrong blade width for machine

Refer to operator’s manual

Chips being carried back into cut

Replace or adjust chip brush

Worn or damaged pressure block

Replace pressure block

Insufficient coolant flow

Adjust coolant flow

Blade binding in cut

Adjust feed or use heavy set blades

Side guides are too tight

Adjust guides

Work loose in vise

Adjust vise

Feed too heavy

Reduce feed pressure

Guide arms too far apart

Adjust guide arms closer to material

Incorrect blade

Use proper tooth selection

Heavy feed or too fast speed

Refer to cutting recommendations

Lack of cutting fluid

Adjust coolant flow or ratio

Blade installed backwards

Install blade correctly

Material loose in vise

Adjust vise

Incorrect tooth pitch

Use proper tooth selection

Feed too heavy

Reduce feed rate

Speed too fast

Refer to cutting recommendations

NOTAS: