Cassese CS 999 User manual

CS 999
DOUBLE MITRE SAW
09/ 2004
Cassese Communication
Z15009
TECHNICAL AND USER MANUAL
MANUEL D’UTILISATION & TECHNIQUE

User-FriendlyLCDTouchScreen
Digital Stop
AUTOMATIC MEASURING STOPS
CASSESE SMARTSTOP : DIGITAL AUTOMATIC MEASURING STOP
0
Automatic Width Measurer
CS 999
TECHNICAL DATA
Power Supply : 380 – 220V single or three phased connected directly to the double mitre saw.
Measuringcapacity :Outsidedimension: Minimum : 100mm (3'’ 9/10) Maximum : 1966mm (77'’ 4/10)
Insidedimension : Minimum : depends on moulding’s width (from 0mm to 100mm)
Maximum : 1800mm (with a 83mm wide moulding)
Options :to be chosen from the start : Metric or in inches / Extra longer construction for bigger
measure capacity / bar code scanner & wand / Connection to PC
©2004 Cassese Communication
TheCassese Smart Stopis an optionwhich is available forthe CS939, CS939 MA &CS999 Saws. The special«Smart Stop» Saw
willhaveall ofthe featuresof theCS939 orCS999 Saw,butwith acomputerisedautomatic stopmeasuringsystem,availableinMetricor in Inches.
TheSmartStop isdesigned forthehigh volumecontractor chop-serviceframer, wholikesto maximizeproductivity andminimize operatorerrors.
!!
!!
!User-friendlytouchscreen-tells the operator allinformation required to store or retrieve anymoulding profile and/or framesize,
minimisingmistakesandwastage.
!!
!!
!Fastsetuptime- The SmartStop can beeasily programmed to cuteither a smallphoto frame ora large mirror framein a few
seconds.
!!
!!
!Memorizeyour mouldings - The Smart Stop can be programmed to memorize the cutting process for up to 800 different
mouldingprofiles. Justenter theprofile number,and theframe size,and theSmart Stopinstantly adjustsits measuringstop tothe
exactdimension,ready tocut.
!!
!!
!Memorizeyour framesizes - TheSmart Stopcan alsobe programmedto memorize thedimensions ofup to80 differentframe sizes.
Youcan setthis up for all your standard framesizes.
!!
!!
!Automaticwidth measurer-This instantly measures the rebate width of themoulding about to be cut, sothat the cutting stopcan
adjustitself automaticallyto thecorrectdimension required.It avoidsanymistake ofmeasurementand ismuchquicker thanany
manualadjustment.Ideal for ChopService.
!!
!!
!Odometer/ chop counter - shows the total cuts made, and can be reset for use as a chop counter for big production jobs.
!!
!!
!Flexible- theoperatorcanchange between shortand long sizesaccurately,at anytime,atthe touch ofa button.
!!
!!
!Minimiseoperator mistakes - Becauseof its memoryand clear informationreadout onthe touchscreen, operatorerror isreduced to
nil,savingwaste, timeand money.
!!
!!
!Multi-Lingual- TheSmart Stop can operatein 4 differentlanguages - English, French,German & Spanish.
OPTIONS:
!Barcode scanningsystem, includingbarcodeediting software- formanagingyour mouldingprofile database.
!ConnectiontoPC
!Biggermeasure capacityonrequest
CasseseQuickStop: same features thanSmartStop but without theAutomaticWidthMeasurer
FEATURES OF THE CASSESE SMART STOP :

CS 999
Right vertical clamp locking handle
Leftvertical clamp locking handle
Rightverticalclamp
Leftverticalclamp
Bladeprotectionscreen
Pressureregulator
Mainisolatingswitch
Main case
Electricalcabinet Electrical cabinetdoor
Blade height locking handleBlade height adjuster
Mainisolatingswitch
Numeric stop connection
(OPTION)
220V electrical socket
fordustcollectorv
Main case handle
Lefttable Righttable
Offcutoutlet
Left table set square Right table set square
Mouldingguide
Extractionairintakes
Levellingfoot(x4)
Foot locking nut (x4)
A

PRODUCT NAME CS 999
Year of build 2004/2005
Cutting dimensions
Max. width 83 mm
Max. height 100 mm
Blade dimensions Ø 350 mm
Bore Ø 30 mm
Rotation speed 3400 rpm/mn at 60 Hz and 2800 rpm/mn at 50 Hz
Maximum cutting length 1500 mm
Electrical power supply 220/380 3-phase, 50-60 Hz
Power supply cable, standard, cross-section 4 x 2.5, H07 RNF, 4G1.5
2 power motors (compliant with standard EN 60204) 1.5 kW
Extraction air inlets, outer Ø2 x 100 mm
Type of extraction compliant with standards 28 m3/s at 4 m for Ø100
Pneumatic power supply 6 bar
Max. power consumption 700 cuts/hour 60 NL/mn at 6 bar
Weight 770 kg
Noise (wearing of earmuffs compulsory) 90 dB
Options: Right extension arm:
- Z14836: 2 metres - Z14835: 0.78 metres
Numeric measurement stop* (on request / factory adaptation):
- Z14432: Smart Stop - Z14431: Quick Stop
TECHNICALSPECIFICATIONS
B
H
E
I
G
H
T
*
100
90
80
70
60
50
40
30
20
10
010 20 30 40 50 60 70 80 90 100
mm
CUTTING CAPACITY (HORS TOUT)
withmax width = 83mm
WIDTH *
* EXTERNAL

DESCRIPTION OF CS 999 A
TECHNICAL SPECIFICATIONS B
I - INTRODUCTION 1
II - CS 999 OVERALL DIMENSIONS 2
III - UNPACKING AND HANDLING 3, 4
IV - SETTING UP THE MACHINE 5
- Setting up the left and right tables 5
- Electrical connections 6
- Pneumatic connections 6
- Extraction 6
V - STARTING UP 7
- Control panel 7
- Two-hand control 7
VI - SAWING 8
- Adjusting the blade height 8
- Adjusting the clamps and cutting 8
- First cut on left 8
- Measuring the first piece 9
- Retractable stop 10
- Cutting the first piece 11
VII - MAINTENANCE AND SERVICING 12
- Opening the main case 12
- Opening the electrical cabinet block 12
- Removing / refitting the blades 13
- Replacing the martyr cube 14
- Replacing the offcut support bar 15
- Replacing the table edges 16
- Maintenance / troubleshooting 17, 18
LIST OF WEARING PARTS 18
TECHNICAL DRAWINGS AND PARTS LISTS 19
Contents

I - INTRODUCTION
Saw CS 999 is a machine used to cut 45° mitres on all mouldings with solid
or reconstituted wood base, and with or without coating (paint, varnish,
plastic coating, paper, metal leaf such as gold, bronze, aluminium, etc.).
It cannot be used for:
. Moulding profiles that do not have a 90° heel greater than 5 mm
in height,
. Any metal profiles,
. Thin extruded plastic profiles:
(plastic cords, trimmings, etc.)
Its two circular blades are driven by two electric motors.
The moulding is held automatically by vertical and horizontal pneumatic
cylinders.
A two-hand control, actuating both clamping and cutting, ensures operator
safety by keeping hands out of range of the blades.
The electrical control equipment is placed in a cabinet in front of the machine.
The pneumatic equipment is secured in the base of the machine behind the
electrical cabinet.
This machine was built to meet safety and hygiene requirements. It is therefore
forbidden to modify the electrical and pneumatic equipment, remove protective
equipment installed on delivery or modify the machine safety devices.
Saw CS 999 cannot be used by more than one operator at a time.
1
Residual risks
Hands must never be inserted inside the beyond the plastic screens of
the top protection cover as this section contains the pressure cylinders
and rotating saw blades in their high idle position.

STANDARD CS 999 OVERALL DIMENSIONS
2
Electrical socket for dust collector
Electrical connections, 220 / 380 V, 3-phase, 50-60 Hz
Air supply at 6 bar
Extraction air intakes, dia. 100 mm
Identification label
Offcut outlet
Electrical cabinet
Clearance area
Right extension arm 0.78 m Right extension arm 2.00 m
CS999OVERALLDIMENSIONS

This machine is packaged in a crate containing
1 right extension arm with Slot base measuring system
+ Fixed stop + Retractable stop (Option: CS 999> S/N 68).
· 1 left extension arm
· 1 box containing
- one 10-mm Allen key (to remove blades)
- one 6-mm Allen key (to assembly tables)
- one 3-mm Allen key
- 1 triangular key
- 1 quick-fit coupling (fitted on the machine) / 1 barbed connector / 1 USA
connector / 1 quick-fit coupling (see page 6)
. 1 blade steadying handle
. Fuses: 1.25 Amp aM - (2 Amp aM - 4 Amp aM with numeric stop option)
3
III - UNPACKING AND HANDLING
EXCEPT FOR NUMERIC
STOP OPTION
Using a screwdriver open the fasteners on the crate then remove the cover and its 4 sides.
Remove:
1) The left and right - hand arms (to the right of the machine)
2) Accessories box (to the rear of the machine)
3) The trimmings case (to the left of the machine).

Handling: Use a fork-lift truck fitted with forks at least 115 cm long, taking care to position
them correctly below the frame: see below. Gross weight of machine: 770 kg.
Remove the suction tip. Using a cross-head screwdriver remove the wedges from the 4 legs of
the machine.
CAUTION:
SAFETY
DISTANCE =
50 MM
Fork insertion area:
80 mm between the
ground and the base
of the machine
Once the machine
is installed, remove
protection.
550 mm
Position of forks
centred on the
frameaxis
330 mm
CAUTION: TO MOVE THE MACHINE FROM THE PALLET TO THE
GROUND SET THE FORKS 330 MM APART. FOR THE OTHER
HANDLING OPERATIONS SET THE FORKS 550 MM APART.
fork-lift truck
4

IV - SETTING UP THE MACHINE
5
Assembling the left and right tables
There must be sufficient clearance around the machine
to allow free movement and access for maintenance.
It must be placed on a stable and generally flat floor.
Before making any electrical or pneumatic
connections, level the machine by means of the
adjustable feet. Use a 24-mm open-end spanner for
locking nut CE and a 12-mm open-end spanner for
base B. Tighten locking nut CE firmly after adjustment
and levelling. As the work surface is 900 mm from
the floor, it may be necessary to install a platform for
operators of short stature.
V1
V2
V3 V4
Loosen screws V1, V2,V3, V4 with a 10-mm
open-end spanner. Bringthe grooves of table stopsB1 and B2 toscrews
V1 and V2.
V1
V2
B1
B2
Slide stop B1 into screwsV3 andV4 and against
the martyr cube CM. Retighten screws V3 and
V4 (10-mm open-end spanner)
V3 V4 CM
B1
B1
V3
V4
Retighten screwsV1 and V2 below the table.
V5
Remove screw V5 (4-mm Allen key) from the
cylinderof setsquare E. Moveset squareE below
the table and screw the assembly in place with
screw V5.
E
B
CE
V1 V2

6
Electrical connection
The user must connect the power supply cable to a source complying with the regulations in
force and protect the machine by fitting fuses: 10 Amp aM for 380 Volt 3-phase and 16 Amp
aM for 220 Volt 3-phase.
Extraction
To conform to hygiene standards the machine must be connected to an extraction air intake
producing a maximum flow rate of 28 m3/second over a diameter of 100 mm. The circuit
comprises three intake ports 100 mm in diameter: one on each side (only one plug must be
connected) and one at the rear of the machine. This installation guarantees effective extraction
and must never by dismantled or modified.
Fitting the offcut outlet case
Fit the offcut outlet case using screws C1
and C2 (5-mm Allen key).
C1 C2
SORTIE CHUTE
Air line fittings
USA
AIR SOURCE (compressor)
Q/R US male
Quick release (Q/R)
Standard
Z675 Z675
Z749
Z701 Z556
STANDARD
Advised way of fitting :
Provide a supply pipe with an
inside Ø of 8 that will withstand
the maximum pressure of the
source, which must not be less
than 6 bar.
Source characteristics:
dry air, no lubrication

BLADEVERTICAL
SPEEDREGULATOR
The knurled knob controls
the blade lowering speed.
(Voir page 9)
MAINON/OFFSWITCH
- Open the compressed air source and adjust the
machine pressure regulator to obtain compressed
air pressure of 6 bar.
- Switch on the machine: main isolating switch at
bottomright of the machine (seedrawing on Page
A). Indicator lamp V (Fig. 3, Page 6) lights up.
This indicator lamp only lights if the CS 999 is
energised. PRESSUREREGULATOR
Press button 2 (Fig. 3, Page 6) and check the rotation direction of one of the blades, i.e.:
- clockwise for the left blade,
- anti-clockwise for the right blade.
Ifthe direction is not correct, press button 3(Fig. 3, Page 6), disconnect the machineand reverse the two phases on
the power supply cable.
MD
START
BLADES
MACHINE ON STOP
BLADES
CANCELLEFT CLAMP
CANCELRIGHT
CLAMP
RESET
UNLOCKCOVER
MACHINE READY
BLADEHEIGHTREGULATOR
Note : The blade lowering speed must be set
according to the material to be sawn (hardness,
cross-section,coating,etc.),therequiredcutting
qualityandthecharacteristics oftheblades used.
V - STARTING UP
CONTROL PANEL
V2 V3
V2-V3 = CLAMP CANCELLATION LAMPS
NUMERICSTOPOPTION
TWO-HAND CONTROL
Buttons D and D’ activate a two-hand control. The time between pressing the two buttons must not exceed
0.5 seconds. This prevents any accidental triggering if one of these 2 buttons is locked. Note that when D
or D’ is released during cutting, the blades lift immediately. To restart the cycle, both buttons must be
released and pressed again.
7
DD’
V
2
34
5
6
7
V1
12
3
4
OFF
V1 = MACHINE OPERATIONAL
ON

Set keyA to “blade setting”.
Press D and D’ (Fig. 4, Page 6) to bring the blades to low position. Place the
moulding to be cut on the cutting table. Holding rule R by its loop, release handle
Mlocated on top of the cover. Set the blade height using rule R or according to the
height of the moulding. The rule indicates the maximum clearance height for the
moulding. Relock handle M. Check that the moulding passes correctly below the
blade protection screen E.
Turn keyA back to “normal operation”.
Note : The blade protection screen (E) is set automatically according to the blade
height setting. The measurement on rule R is the height of the moulding to be cut
plus approximately 1 centimetre.
8
VI - SAWING
Reglet β
A- Adjusting the height of the blades
B- Setting the clamps and cut
First the position of the vertical clamps must be set:
Place the moulding with the slot side facing the saw blades on the
work table, feeding it from the left side of the machine. Release
the handle (M), set the vertical clamp positioning arms (BP)
according to the profile and width of the moulding. Start up the
right clamp (for example) via button D (Fig. 4, Page 6) and check
that the clamp pressor does not tilt the moulding.
E
M
R
MC MC’
M
BP
C- First cut on the left: The right clamps (vertical and horizontal) must be cancelled by
pressing button 4 on the control panel (Fig. 3, Page 6). After the first cut, these clamps will be
reactivated. If this precaution is not taken, the clamps may push the moulding against the blade
insteadof immobilising it. Place the mouldingwith the slot side facingthe saw
blades on the work table, feeding it from the left side of the machine. Slide the
mouldingagainstthe mouldingguideand
towards the cutting table, keeping the
offcut minimising knob MC pressed.
When the moulding comes to stop
position against the offcut minimiser
(MC’) it will be in the best position for
cutting with minimum offcut.
The back of the moulding must be pressed firmly against the stops and the bottom against the work
table. To be sure of obtaining good cutting quality and the essential safety conditions, the moulding
must be immobilised and completely stable. Repeatthe test under thesameconditionsfortheleft
clamp using button D’.

D- Measuring the first piece (mobile stop)
9
Keeping the moulding in
position, bring the MOBILE
STOP into contact with the
moulding and lock it. Remove
the cursor below the moulding.
Slot base measurement is now
complete.
MEASURING THE SLOT BASE (INTERNAL)
Slide the CURSOR along the rule and lock it at the required dimension by tightening the locking
screw. Bring the moulding to the cursor so that the edge of the slot base coincides with the 45°
angle.
EXTERNAL
MEASUREMENT
CURSOR
RULE LOCKING SCREW
READING
POINT
CURSOR
MOBILESTOP READING POINT
LOCKING
HANDLE PUNCH MARK
Release the MOBILE STOP
locking handle. Slide it on the
rule until it reaches the required
measurement.
Be sure to measure using the
external rule in relation to the
punch mark on the mobile stop
Start up the blade motors via button 2 of the control panel (Fig. 3, Page 6), then use
buttons D and D’ (Fig. 4, Page 6) to actuate clamping followed by blade lowering. The
first cut is then produced.
Buttons D and D’ (Fig. 4, Page 6) activate a two-hand control. The time between
pressing the two buttons must not exceed 0.5 seconds. This prevents any accidental
triggering if one of these 2 buttons is locked. Note that when D or D’ is released
during cutting, the blades lift immediately. To restart the cycle, both buttons must be
released and pressed again.
block. The external measurement is complete.

RETRACTABLE STOP
(Storing a second cutting point in the memory)
10
FOR THE SLOT BASE MEASUREMENT, USE THE SAME PROCEDURE
AS FOR THE MOBILE STOP (PAGE 9).
FOR THE EXTERNAL MEASUREMENT, USE THE SAME PROCEDURE
AS FOR THE MOBILE STOP (PAGE 9) BUT USE THE INTERNAL RULE.
The Cassese removable stop is a positive stop, easy to retract, by a simple action on lever L.
It remains stable and without play both in engaged and retracted positions.
I1
I2
Fig A Fig B
R1
R2 L
Allows the measuring and cutting of two dimensions of the frame, at any time.
The special design of the removable stop makes all mouldings to be placed in the best
way against the measuring system of the machine, even if the moulding is twisted.
L
Measuring Scale
Each measuring stop is indexed (red mark Il 8c I2) which indicate which one of the two scales
(rules) is to be used with this stop.These scales are for direct read-off of outside measurements of
the frame. Sliding Removable Stop: R1 with I1 // Sliding Fixed Stop: R2 with I2. Figure A.

If the two-hand control buttons are kept pressed after cutting, the corresponding clamps
will not be released and the moulding ends or offcut can be retrieved without being
extracted to the offcut case.
If the offcut or piece of moulding does not drop under gravity after a cut, and cannot be
retrieved from outside the cover, it must be cleared by pushing with the next moulding
or a stick.
It is strictly forbidden to cut several lengths of moulding at the same time by lining them
up one in front of the other.
When the machine is in use, there must be no more than one person at the workstation.
This person is responsible for the controls.
The sawing operation (blade lowering) is only possible with the horizontal and vertical
pneumatic clamps engaged and the saw blades rotating.
If one of the buttons is released during cutting, the blades are withdrawn but the clamps
remain engaged. The cycle can be restarted by pressing buttons D and D’ (Fig. 4, Page
6) or the cycle can be reset via key 6 of the control panel (Fig. 3, Page 6).
If the electrical circuit is accidentally broken, the blades are withdrawn immediately.
When power is restored, the motors will only start up when button 2 is pressed on the
control panel (Fig. 3, Page 6).
In the event of an operating problem, immediately press button 3 STOP BLADES (red
thrust button) on the control panel (Fig. 3, Page 6) and before taking any further action,
switch off the power supply at the main isolating switch (Fig. 1, Page 6).
11
The operator must never put
his hands inside the case
E- Cutting the first piece
The moulding is in contact with either the mobile stop or the retractable stop.
Press buttons D and D’ (Fig. 4, Page 6) for left and right clamping followed by blade
lowering.
END OF MOULDING
Clamping and cutting are visible to the operator. He must therefore check that the
horizontal clamp on the left is properly engaged in the moulding slot and does not create
pressure on the end of the moulding.
If it does, the operator can only continue with clamping on the right once the left clamp
has been cancelled via button 5 on the control panel (Fig. 3, Page 6).
Note: The left clamp will be automatically reactivated at the next cycle.
!

12
When the cover is open, motor start-up and blade lowering are
disabled by the safety unit
For all maintenance, adjustment or repair operations, prevent unintentional
operation of electrical and pneumatic circuits on the machine by padlocking
the main isolating switch.
VII - MAINTENANCEAND SERVICING
Opening the main case
- Press button 3 on the control panel (Fig. 3, Page 6) if necessary.
- Position the control panel key to “unlock cover”.
- Wait during the 20 second time-out until green lamp V1 (Fig. 3, Page 6)
goes out, indicating that the blades have stopped completely.
- Lift the locking levers of the 3 spring clips S1, S2 and S3 and release the
hooking mechanism.
- Using handle P, pivot the cover upwards and let it rest on the flexible stud at
the top of the machine.
PROCEDURE FOR ACCESS INSIDE THE MACHINE
P
S1 S2
S3
A
B
Opening the electrical cabinet block
Open the door of the electrical
cabinet using the key provided
and remove screws A and B.
Tilt the cabinet by pulling it
towards you.
!

REMOVING THE BLADES
IMPORTANT
Switch off the machine at the main isolating switch (Page 6) located on the
right of the machine and lock the switch by padlocking the tab.
During this operation gloves should be worn to handle the blades and to
avoid getting yours hands caught.
Use the steadying handle provided to immobilise the shaft, loosen the nut (when
loosening the blade securing nuts always pull the key towards you), and remove
the flange and blade.
13
10-mmAllen key
Steadying handle USING THE
STEADYING HANDLE
Clean the blades and flanges.
Fit the blade (teeth pointing in cutting direction). Check the cutting
direction carefully: it is marked on the support.
Refit the flange and screw then tighten the screw while holding the
steadying handle to immobilise the shaft.
Close the main case. Hook up the 3 spring clips and close their locking
levers, then switch on the main isolating switch.
Lock the cover by setting the key to Normal operation position.
REFITTING THE BLADES

Open the main case (Page 11).
Loosen screw V1 using a 5-mm Allen key and remove the worn martyr cube by sliding it
towards the inside of the machine.
Refit the martyr cube so that a sound side is facing the blades and secure it with screw V1.
Close the main case. Hook up the 3 spring clips and close their locking levers, then
switch on the main isolating switch.
Lock the cover by setting the key to NORMAL OPERATION POSITION.
Start up the blades by pressing button 2 on the control panel (Fig. 3, Page 6).
Reduce the blade lowering speed using button 7 on the control panel.
Press simultaneously buttons 4 and 5 on the control panel (Fig. 3, Page 6), causing the
two cancellation lamps V2 and V3 to light up on the control panel (Fig. 3, Page 6) for 3
seconds. During this time, press buttons D and D’ of the two-hand control (Fig. 4, Page
6). The rotating blades drop to low position in order to machine the martyr cube. When
the two-hand control is released, the blades lift and the indicator lamps go out.
V1
MARTYR CUBE
REPLACING THE MARTYR CUBE
14
THE MARTYR CUBE AND OFFCUT SUPPORT BAR CAN BE FITTED AND
MACHINED AT THE SAME TIME

15
Open the main case (see Page 11).
Open the door of the electrical cabinet using the key provided and remove screws A and B. Tilt
the cabinet by pulling it towards you. (Page 11).
Next remove screw VTR (5-mm Allen key) and lower the setting rod of the offcut support bar.
Remove screws C and D (4-mm Allen key) and remove the worn offcut support bar (AS).
Refit a new bar on the setting rod and then reinstall the assembly (bar pressing below the martyr
cube). Lock the setting rod via screw VTR. Close the main case.
Hook up the 3 spring clips and close their locking levers, then switch on the main isolating
switch.
Start up the blades by pressing button 2 on the control panel (Fig. 3, Page 6).
Reduce the blade lowering speed using button 7 on the control panel.
Press simultaneously buttons 4 and 5 on the control panel (Fig. 3, Page 6), causing the two
clamp cancellation lamps V2 and V3 to light up on the control panel (Fig. 3, Page 6) for
3 seconds. During this time, press buttons D and D’ of the two-hand control (Fig. 4, Page 6). The
rotating blades drop to low position in order to machine the offcut support bar. When the two-
hand control is released, the blades lift and the clamp indicator lamps go out.
REPLACING THE OFFCUT SUPPORT BAR
VTR
C
D
AS
AS
A
B
THE MARTYR CUBE AND OFFCUT SUPPORT BAR CAN BE FITTED
AND MACHINED AT THE SAME TIME