Holzstar BTS Series User manual

Status 23 Nov 2011 | Version 1.02
BTS-SERIE
Operating Instructions
Belt and disk grinder
BTS series
BTS 150 | BTS 250

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Imprint
Product identification
Belt and disk grinder
BTS 150
BTS 250
Manufacturer
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Telephone: [phone] - 0
Fax: [phone] - 55
E-mail: [email protected]
Internet: www.holzstar.de
Information on Operating Instructions
Original operating instructions
Issue: 07/02/2012
Version: 2.01
Language: German
Author: ES
Information on copyright
Copyright © 2012 Stürmer Maschinen GmbH, Hallstadt, Germany.
The contents of these Operating Instructions are under the exclusive ownership of Stürmer Maschinen GmbH.
Distribution and copying of this document, and any usage and communication of its content are prohibited unless
expressly permitted. Any breach commits to damage compensation.
Technical changes and errors reserved.

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Dear customer,
Thank you for buying a HOLZSTAR® product. HOLZSTAR® machines offer a high quality, optimum
technical solution and are excellent value for money. Constant further development and product
innovations are always a guarantee of the latest technological knowledge and safety. It is our great
concern that you enjoy this product which will make your job easier and bring added value to your
business.
For safety reasons and in order to ensure seamless operation, these Operating Instructions should
be carefully studied before first commissioning and kept for possible reference in future.
Information
These Operating Instructions provide all the necessary information for faultless usage of the machines and
adequate maintenance. Such information is essential for any possible warranty claims. Our distribution
network is always available for you and will take care of any difficulties related to client service and/or
spare parts. It will handle any possible demands that can help you with your business processes and
growth.
Your proposals for improvement regarding these Operating Instructions are an important contribution to
the improvement of the service we provide to our clients.
The figures and information contained in this guide may differ from your actual machine. The manufacturer
strives for constant improvement and product upgrades. Therefore, visual and technical changes may be
made without prior notice. We reserve the right to make changes and correct errors.
This guide was written by the manufacturer and is an integral part of the machine equipment. The
information contained in this guide is intended for the user. The guide defines the intended purpose of the
machine and contains all information needed for safe and correct usage of it. Constant observance of the
information contained in this guide guarantees safety for people and the machine, economical operation
and a long service life for the machine.
For easier orientation, this guide is divided into sections, each of which discusses an important topic. The
table of contents gives you a quick overview of the different topics. Important text sections are printed in
bold and are situated under these symbols:
Attention
Reference to situations which can cause damage to persons, the machine and/or its
surroundings or result in financial damage.
Attention! Rotating parts. Danger of injury!
Attention! Use safety goggles. Danger of injury!
Attention! Unplug from the socket before commencing work. Danger of injury
*The designation “machine” replaces the usual business designation of the unit to which these
Operating Instructions refer (see cover sheet).
The designation “expert operators” covers staff who, thanks to their experience, technical
preparation and knowledge of statutory regulations, are able to carry out major works and
identify and avoid possible dangerous situations during operation, installation, usage and
maintenance of the machine.
Should you have any questions, please contact your vendor.

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Table of contents
Page
1. Machine designation 5
2. Designated use 5
3. Technical data 5
3.1 Noise level .................................................................................................................................................6
4. Safety information 6
4.1 Residual risks...........................................................................................................................................7
5. Unpacking and installation 7
6. Scope of delivery and accessories 8
6.1 Scope of delivery ..........................................................................................................................................8
6.2 Special accessories ......................................................................................................................................8
7. Control elements 9
8. Assembly 10
8.1 Safety stop...............................................................................................................................................10
8.2 Work table....................................................................................................................................................10
9. Settings 11
9.1 Pivoting the work table...............................................................................................................................11
9.2 Centring the work desk ..............................................................................................................................11
9.3 Vertical grinding..........................................................................................................................................11
9.4 Work table in vertical ..................................................................................................................................11
grinding position........................................................................................Fehler! Textmarke nicht definiert.
9.5 Replacing grinding disks ...........................................................................................................................12
9.6 Replacing grinding belts ............................................................................................................................12
9.7 Grinding belt run .........................................................................................................................................12
10. Machine control 13
10.1 General.........................................................................................................................................................13
10.2 On / off switch for BTS 250 ........................................................................................................................13
10.3 Surface grinding on the grinding belt .......................................................................................................14
10.4 Edge grinding in vertical grinding position..............................................................................................14
10.5 Grinding bent work pieces .........................................................................................................................14
10.6 Grinding round pieces on the grinding disk............................................................................................15
10.7 Grinding ends on the grinding disk ..........................................................................................................15
10.8 Connecting nozzle for extraction device ..................................................................................................15
11. Notes on the grinding process 15
12. Cleaning, maintenance and repairs 16
12.1 Cleaning .......................................................................................................................................................16
12.2 Maintenance ................................................................................................................................................16
12.3 Repairs .........................................................................................................................................................16
12.4 V-belt replacement ......................................................................................................................................17
13. Warranty information 17
14. Troubleshooting 17
15. EC declaration of conformity 18
16. Spare parts orders 19
17. Explosion drawing BTS 150 20
18. Explosion drawing BTS 250 21

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1. Machine designation
A nameplate is fitted onto the machine which identifies the machine, article number and
important technical data. Always keep the nameplate clean and in legible condition.
2. Designated use
The belt grinder and disk grinder of said type is designed only for grinding wood or wood-like
materials.
Grinding of any other material can lead to fire, injuries or damage. Refer to the notes in the
Operating Instructions and signs and labels on the machine.
The machine is intended for universal usage in schools and workshops as well as at home.
Attention:
Certain wood types and products produce dust emissions, hazardous to health, during
processing. Therefore, use the machine only in a well-ventilated room and use an
extraction device where possible.
Note:
The machine may be operated only if it is in excellent technical condition. Any possible
defects must be repaired without delay.
Any unauthorised changes to the machine or non-designated use and/or failure to
observe the safety rules or Operating Instructions waive any liability of the manufacturer
for resulting damage to health or property and invalidate the warranty claim!
3. Technical data
Model BTS 150 BTS 250
Motor 400W / 230V~50 Hz 800W / 230V~50 Hz
Grinding belt speed 490 rpm 517 rpm
Grinding disk diameter 150 mm 250 mm
Grinding belt dimensions 100 x 915 mm 1220 x 150 mm
Grinding unit pivoting 0–90° 0–90°
Table dimensions 230 x 150 mm 360 x 200 mm
Table pivoting 0–45° 0–45°
Dimensions 560 x 270 x 300 mm 720 x 410 x 440 mm
Weight 17 kg 47 kg
Article number 5904150 5904250

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3.1 Noise level
This machine emits noise (sound pressure level) which can exceed 82 dB(A) in the workplace.
For this reason the operator should take noise and hearing protection measures.
Note:
It must be noted that the duration of exposure to noise, the type and nature of the work
area and other machines in simultaneous operation can affect the noise level in the
workplace.
4. Safety information
Note:
Before start-up, usage, maintenance and other action on the machine, the Operating and
Maintenance Instructions must be studied with great care. Handling and working with the
machine is permitted only to those who are familiar with the handling and functionality of
the machine.
Attention:
Any repairs, maintenance or upgrades may only be carried out by expert staff and with
the machine shut down (unplugged from the socket)!
Never place your hands close to rotating parts when the machine is in operation!
Use protective gear and fix the gear in place safely. Never work without protective gear and
keep the gear in working condition. Check the machine for functionality prior to commencing
work.
Always keep the machine and its work environment clean. Ensure sufficient lighting.
Ensure a sufficient supporting surface.
The concept of the machine must not be altered and the machine may only be used for the
work processes intended by the manufacturer.
Never work under the influence of concentration-disturbing illnesses, overfatigue, drugs,
alcohol and/or medication.
Remove wrenches and other loose parts after assembly or repair of the machine before
switching the machine on.
All safety instructions and risk warnings on the machine must be maintained complete and
legible.
Keep children and other persons not familiar with the machine away from your workspace,
the machine and tools.
The machine may only be used, equipped and maintained by users who are familiar with
these tasks and are aware of the dangers.
In general, switch the machine off for maintenance, upgrades and repairs! Also, unplug the
cable supplying power to the machine from the socket!
Do not pull the mains cable when unplugging the cable from the socket. Protect the cable
from heat, oil and sharp edges.
Ensure that the main switch is in the “OFF” position when connecting the machine to the
power supply, so that any unintended activation can be prevented.

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Wear tight working clothes, safety goggles and protective shoes and use hearing protection.
Tie up long hair. Do not wear watches, wristbands, chains, rings or gloves (rotating parts!).
Repair immediately any defect which can compromise safety.
Never step on the machine. Heavy injuries can occur should the machine tilt over.

Never keep the machine in operation without supervision and stay at the machine until the
tool has come to a complete standstill. Then, unplug the power supply cable from the socket,
so that unintended activation can be prevented.
Protect the machine from humidity (danger of short circuit!).
Never use electrical tools and machines in the vicinity of combustible liquids and gases
(danger of explosion!).

Before each use of the machine, ensure that no components are damaged. Immediately
replace damaged components to eliminate any source of danger!
Do not overload the machine! You will work better and more safely in the defined output
range. Use correct tools! Ensure that the tools are not blunt or damaged.
Only use original spare parts and accessories to prevent any possible risk of accident.
4.1 Residual risks
Even when all safety regulations are followed and the machine is used in accordance with
instructions, the following residual risks are still present:
injury through flying work pieces or work piece parts
risk of fire if insufficient ventilation is provided for the motor
electrical current risk if wiring is not properly connected
risk of noise and dust (use hearing protection and a suitable extraction device).
Note:
Please note that every machine represents residual risks. During all work processes
(even the simplest ones) always take maximum care. Safe work depends on you!
5. Unpacking and installation
Take the machine out of the packaging and remove all protective wrapping. Ensure that the
machine is not installed or put into operation in a wet or humid environment. Air humidity should
not exceed 60% and room temperature should be between 0 °C and 40 °C.
To ensure firm footing, the machine should be fixed on a stable surface (e.g. a work
bench) by using the bores on the machine leg.
Optional accessories for BTS 250 include a base:
-base BTS 250 / Art. No. 5914250

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6. Scope of delivery and accessories
6.1 Scope of delivery
Check the machine immediately after delivery for transportation damage and incorrect amounts.
To do so, take all spare parts from the box and compare them those listed below.
Machine
Work table
Angle stop
Work table support
Allen wrench
Safety stop
Operating instructions
Standard grinding belt and grinding disk
Operator’s tools
Set of screws
6.2 Special accessories
We recommend using only high-quality original Holzstar accessories. Faultless operation and
optimal work results can be guaranteed only with original accessories.
Identification article number
Grinding belt Korn 60 (pack of 10) 5911006
Grinding belt Korn 80 (pack of 10) 5911008
Grinding belt Korn 100 (pack of 10) 5911010
Grinding belt Korn 120 (pack of 10) 5911012
Grinding belt Korn 150 (pack of 10) 5911015
Velcro holder Ø 150 mm f. disk grinding disk with velcro fastener 5911001
Grinding disk Ø 150 Korn 60 (pack of 10) 5911506
Grinding disk Ø 150 Korn 80 (pack of 10) 5911508
Grinding disk Ø 150 Korn 100 (pack of 10) 5911510
Grinding disk Ø 150 Korn 120 (pack of 10) 5911512
Grinding disk Ø 150 Korn 150 (pack of 10) 5911515
Grinding belt 1220 x150 mm Korn 60 (pack of 10) 5911206
Grinding belt 1220 x150 mm Korn 80 (pack of 10) 5911208
Grinding belt 1220 x150 mm Korn 100 (pack of 10) 5911210
Grinding belt 1220 x150 mm Korn 120 (pack of 10) 5911212
Grinding belt 1220 x150 mm Korn 150 (pack of 10) 5911215
Grinding belt 1220 x150 mm Korn 180 (pack of 10) 5911218
Velcro holder Ø 250 mm for grinding disk 5912501
Grinding disk Ø 250 Korn 60 (pack of 10) 5912506
Grinding disk Ø 250 Korn 80 (pack of 10) 5912508
Grinding disk Ø 250 Korn 100 (pack of 10) 5912510
Grinding disk Ø 250 Korn 120 (pack of 10) 5912512
Grinding disk Ø 250 Korn 150 (pack of 10) 5912515
Base BTS 250 5914250

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7. Control elements
1 Track adjustment screw
9 Safety stop
2 Grinding belt bedding
10 Grinding belt
3 Clamping lever
11 Attachment bore
4 Work table holding bore
12 ON / OFF switch
5 Attachment bore
13 Grinding disk guard
6 Grinding unit adjustment screw
14 Work table
7 Clamping screw table pivoting
15 Grinding disk
8 Machine footing
16 Grinding disk
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

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8. Assembly
8.1 Safety stop
Take the safety stop as shown in the figure
and attach it by using the
hexagon screw M6 x 1.0-14 and toothed washer.
When tightening the screw, ensure that the
safety stop is attached approx. 3 mm above the grinding belt.
Do not tighten the screw entirely,
otherwise you may strip the thread.
8.2 Work table
Take the work desk as shown in the figure alongside this text
and attach the table support to the table with
three hexagon screws M6 x 1.0-14 and the washers.
Then place and hold the pre-assembled work desk
on the grinding machine and fix it with the clamping screw and
washer, as shown in the figure.
The table edge must be positioned as to ensure a maximum
distance of 2 mm.
This will eliminate the risk of tools and fingers being trapped
between the table and the grinding disk.

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9. Settings
Note:
Before taking any action on the machine,
the power supply must be disconnected.
Only persons familiar with the handling and functionality
of the machine
may handle and work with the machine.
9.1 Pivoting the work table
Loosen the clamping screw and place the work desk
in the desired position. Then, tighten the clamping screw again.
9.2 Centring the work desk
To centre the work desk to exactly 90°, take a right angle
and hold it on the table as shown in the figure.
Loosen the clamping screw for table pivoting
and centre the table.
Then, tighten the clamping screw again.
Note:
You can repeat this procedure for centring the work desk
on the grinding belt unit in vertical position.
9.3 Vertical grinding
Loosen the fixing screw with the Allen Wrench.
Place the grinding unit in the desired position and
tighten the fixing screw again.
9.4 Work table in vertical grinding position
For grinding on the grinding belt in vertical position
you can mount the work table on the grinding unit.
To do so, remove the safety stop.
Place the grinding unit in a vertical position
by following the procedure described. Then, mount the work table
on the fixing bores of the safety stop.

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9.5 Replacing grinding disks
Disassemble the work desk. Loosen both grinding unit guard
screws and remove them.
Replace the grinding disk with a new one and fix the guard
again.
9.6 Replacing grinding belts
Reduce tension of the grinding belt
by using the clamping lever. Now carefully pull the old grinding
belt off.
Pull the new grinding belt on and centre it.
Finally, clamp the grinding belt via the clamping lever.
Note:
For easier replacement of the grinding belt
the grinding unit can be easily pivoted upwards.
For easier pull-out and pull-on of the grinding belt, move the
grinding unit back and forth.
9.7 Grinding belt run
The run of the grinding belt can be changed by means of the
track setting screw. As the grinding belt moves towards
the grinding disk, turn the setting screw clockwise. As the
grinding belt moves from
the grinding disk, turn the setting screw counter-clockwise.
Finally, move the grinding belt manually in a direction and
check its run. You can re-adjust the run if necessary.

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10. Machine control
10.1 General
Follow the instructions below to ensure that the results of your work are successful as expected.
ATTENTION!
Rotating parts! Work carefully and use common sense. Pay attention to what you are doing. Especially
beware of the rotating parts. Wear tight clothes. Make sure that your hair or clothes are not caught by
rotating parts! Wear a hair net.
You must not wear any jewellery when working with the machine.
Beware flying chips and other objects ejected from the machine! You must wear safety goggles! Protect your
eyes from flying chips and other fragments.
Always check the following prior to commencing work:
Check all cables and plugs.
Check that the work table is firmly tightened.
Remember the different granulation of grinding disks for different works.
Before starting the machine, keep in mind that the grinding disk and grinding belt run freely
and are not obstructed, retarded or blocked by attached work pieces.
Apply grease as required in the maintenance checklist.
Always push the grinding belt forward manually to test whether it runs in the centre before
starting the machine!
10.2 On / off switch for BTS 250
To start the machine, open the switch lid, press the green
switch
(marked with the symbol ( | ) ) and hold it pressed for about one
second.
To shut down the machine, press
the switch marked with the symbol ( O ) or press the switch lid
as shown in the figure on the right.
You can always press the switch lid downwards every time
you wish to shut down the machine.

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10.3 Surface grinding on the grinding belt
Check if the safety stop is correctly mounted
and properly tightened. Carefully push the work piece
as shown in the figure with both hands
against the grinding belt and safety stop.
For better material collection,
the work piece can easily be moved back and forth.
Attention:
Do not apply too much force when working,
otherwise the grinding belt can wear quickly. Never touch
the grinding belt with your fingers.
10.4 Edge grinding in vertical grinding
position
Place the grinding unit in a vertical position as described
and mount the work table.
Hold the work piece firmly with both hands and apply slight
force to the grinding belt.
Move work piece slightly back and forth.
10.5 Grinding bent work pieces
Hold the work piece firmly with both hands and proceed
as shown in the figure above.
Only grind inside bends on the front return pulley.

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10.6 Grinding round pieces on the grinding
disk
Hold the work piece firmly with both hands and
proceed as shown in the figure above.
Attention:
Grind round pieces only on the left side,
on the side running downwards,
otherwise the work pieces may be thrown off.
10.7 Grinding ends on the grinding disk
If you need to grind the ends of a narrow work piece,
it is easier to use the grinding disk with the mitre stop,
as shown in the figure.
When grinding, move the work piece from the centre to the left
side of the wheel outwards.
Attention:
Always grind on the left side of the grinding disk running downwards, as shown in the figure. Grinding on
the right side of the grinding disk running upward can cause the work piece to be ejected upwards.
The edge of the work table must be positioned as to ensure that the maximum distance between the table
and the grinding disk is 2 mm, so that no work piece or finger can be caught between the table and grinding
disk.
10.8 Connecting nozzle for extraction device
A connecting nozzle with Ø 60 mm for connection of an extraction device is located on the right side below the work
desk.
11. Notes on the grinding process
When grinding, follow the safety notes and use the protective gear on the machine and personal protective
equipment (safety goggles, hearing protection, protective shoes, etc.).
Special reference for situations which can cause damage to persons, the machine and/or its surroundings or
result in financial damage:
Never apply too much force when pressing material onto the grinding disk during grinding.
Remember that the slit between the work table and the grinding disk must not be set too large. Particularly for thin
work pieces there is a danger that the work pieces will get caught in the slit!
As the machine lacks any clamping possibility, it is essential that the work pieces stick to the work table with as much
of its surface as possible and can be held firmly!
Ensure that the grinding disk is in good shape and replace worn grinding disks in due course. Good grinding quality
can only be achieved with faultless tools!

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12. Cleaning, maintenance and repairs
Prior to commencement of any cleaning, maintenance and/or repair work, always disconnect the machine
from the power supply!
Note:
Oil, grease and cleaning agents are harmful to the environment and must not be disposed of in waste water
or standard refuse. Dispose of these substances in an environmentally friendly way. Cleaning cloths soaked
in oil, grease and/or cleaning agents can easily catch fire. Collect the cleaning cloths or cleaning wool in a
suitable, closed container and dispose of them in an environmentally friendly way –do not add them to
house waste!
12.1 Cleaning
The machine should be generally cleaned after each usage. Remove chips and dust when the machine is off with a
hand brush or paint brush.
Refer to local regulations governing chip disposal.
Attention:
Do not remove chips with bare hands. You may suffer a cut injury through chips and tools!
12.2 Maintenance
Lubricate the bearings and return pulleys
with high-quality oil on a regular basis, but at the latest
after 10 hours of operation.
Loosen the grinding tension and add two drops of oil
to the designated opening (see figure).
Do not use too much oil, as the V-belt can slip
or oil can leak onto the work piece.
Finally, clamp the grinding belt again
and set the run.
12.3 Repairs
As a result of wear, repair of the machine may be necessary.
Attention:
Any repair work may only be carried out by qualified personnel with a good knowledge of mechanics.

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12.4 V-belt replacement
Prior to commencement of any
cleaning, maintenance and/or repair work,
always disconnect the machine from the power supply!
Remove the belt casing guard by
loosening the cross-head screw. Loosen the three fixing screws
which hold the belt tight.
Put the new belt in place and clamp it by placing
a slotted screwdriver into the bore
and pushing the belt casing upwards.
Tighten the fixing screw (see p. 14).
13. Warranty information
We assume warranty for our products under our warranty terms and conditions for faultless functionality. The
warranty period of 24 months starts at machine takeover and is subject to statutory and country-specific provisions.
Please provide a proof of purchase as evidence of the date (receipt, invoice, delivery note, etc.). Please keep these
documents safely.
Any damage due to natural wear, transportation, overloading and/or improper operation or handling is exempt from
our warranty. Any damage caused by material or manufacturing errors will be repaired free of charge in the form of a
replacement delivery.
In the event of a warranty claim or repair, please contact your vendor.
14. Troubleshooting
Fault
Possible cause
Remedy
Motor does not run
Damaged ON / OFF switch
Damaged ON / OFF switch line
Damaged relay
Motor is defective
Fuses are defective
Have the machine checked and
damaged components replaced by
an electrical engineer
Machine gets slower when running
Too much force is applied
Apply less force on the work piece
Poor service life of grinding tools
Grinding tools’ (belt or wheel)
granulation is too fine
Use grinding disk with rougher
granulation
Poor look of ground surface
Grinding tools’ granulation is too
rough
Use grinding disk with finer
granulation
Grinding angle does not fit
Angles set on work table or stop
angle do not fit
Check angle and adjust if necessary
Grinding disk does not rotate
symmetrically by look
Grinding disk does not stick properly
Adjust grinding belt track
Grinding disk runs off driving wheels
Grinding disk does not stick properly
Adjust grinding belt track
Wood burns during grinding
Grinding disk or belt is covered with
lubricants
Too much force is applied onto the
work pieces
Replace the grinding belt or wheel
Reduce force on the work piece

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15. EC declaration of conformity
Pursuant to machinery directive 2006/42/EC appendix II 1.A
Manufacturer/distributor Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Product group: Metallkraft® Metal processing machines
Machine identification: BTS 150 / BTS 250
Machine type: Belt and disk grinder
Article number: 5904150 / 5904250
Serial number: ___________________
Year of manufacture: 20____
Meets all respective provisions of the above directive as well as other applicable directives (listed below) –including
amendments thereto effective as of the declaration date.
Applicable EU directives: 2006/95/EC Low voltage directive
2006/42/EC Machinery directive
The following harmonised standards were applied:
Safety of machinery –Electrical equipment of machines –Part 1:
General requirements; German issue EN 60204-1:2006
EN ISO 12100-1:2003 Safety of machinery –Basic concepts, general principles for design –
Part 1: Basic terminology, methodology (ISO 12100-1:2003)
EN ISO 12100-2:2003 Safety of machinery –Basic concepts, general principles for design –
Part 2: Technical principles (ISO 12100-2:2003)
Person responsible for documentation: Kilian Stürmer, Dr.-Robert-Pfleger-Str. 26, D-96103 Hallstadt
Hallstadt, 01/12/2009
______________________
Kilian Stürmer
Executive

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16. Spare parts orders
Spare parts can be ordered via vendors or directly from the manufacturer. The following key data must be reported when requesting
or ordering a spare part:
- device type
- article number
- position number
- year of manufacture
- amount
- required mode of shipment (post, freight, sea, air, express)
- shipping address
Spare part orders lacking the information listed above will be disregarded. Should information on the mode of shipment be missing,
the supplier will decide at its own discretion.
You can find information on the device type, article number and year of manufacture on the nameplate.
Example
A grinding belt is to be ordered for belt and disk grinder BTS 150.
Device type: Belt and disk grinder BTS 150
Article number: 5904150
Position number: 04
The order number is: 0-5904150-04
The order number consists of the article number and position number and a position before the article number.
•Always write a 0 before the article number.
•Always write a 0 also before the position numbers 1–9.

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17. Explosion drawing BTS 150