Tecnodue I.T.S. ST 1200 User manual

I.T.S. by Tecnodue
ST 1200
Operating Manual

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
2
This manual includes technical information onl .
I.T.S. Ital Trade Services srl has the right to make an modifications without an notice

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
3
ST 1200
Workshop hydraulic operated saw machine suitable for PE,PP,PVDF and other thermoplastic pipes
I.T.S. Ital Trade Services S.r.l.
Via Scarsellini 77
1 149 – Genova , Italy
Tel: [phone]
Fax: [phone]
E Mail [email protected]
Web Page: www.its-tecnodue.com

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
4
SAFETY RULES
( To be read carefull and appl while utilizing the ST 1200 )
Due to the specific use , this machine cannot be supplied with all kind of fix and removable
protections suitable to avoid any risk of accident.
The machine, therefore, must be utilized, adjusted and keep in the perfect functioning conditions by
skill operators.
Warning - Rules – Obligations
The use of machines composed by electrical components and movable parts , it's always a
potential danger. In order to avoid any kind of accident caused by electrical or mechanical sources
it' strongly suggested to read and follow carefully the following safety rules before operating the
machine.
TRANSPORT
-. Machine , Keep the maximum care while moving and it's compulsory to utilize
mechanical aids.
All the accessories supplied with the machine must be moved with the maximum care and it’s
compulsory to utilize mechanical aids.
ELECTRIC CONNECTIONS
The machine is operated by 400 Volts therefore be sure that the power supply plug is supplied with
the safety devices according to the standard requirements , also check that the power supply is
on the range of maximum 10% of the machine's nominal tension.
Check regularly the cables and the plug and in case substitute by qualified personnel.
Before carry out a reparation or maintenance all the plugs must with plug out from the power
Supply. Before opening the case wait at least for 3 minutes after unplugging the machine.
ENVIRONMENTAL CONDITIONS
The working area must be clean and duly lighted.
It's very dangerous to utilize the machine in case of rain or in wheat conditions or even close to
flammable liquids.
CLOTHES
Keep the maximum care while utilizing the machine, it's strongly suggested to use suitable gloves.
Avoid long clothes and avoid bracelets , necklaces that might be hooked into the machine.
CORRECT MACHINE'S OPERATION
Remember to check and read carefully the operating manual before utilizing the machine and
The accessories.
KEEP ALWAYS THE MAXIMUN ATTENTION
Be careful to the blades , it's strongly suggested to use suitable gloves.
During the cutting operation it's forbidden to take out the shavings
Avoid utilizing the machine after drinking or drugs use
Take care that all the people around the machine are at safety distance
ACOUSTIC POLLUTION
The acoustic pollution of the drill engine is less than 85 dB ( value measured at 1 meter distance
from the operator)
Due to some particular cases such as too much pressure during the facing the noise should be
increased , therefore it's suggested to utilize acoustic protections.
IMPORTANT !!!!
Keep the maximum care reading and following the above Warning - Rules - Obligations
Ital Trade Services S.r.l. declines all responsibilities if are not followed totall

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
5
Description
The ST 1200 is designed and fabricated in order to cut pipes in different kind of thermoplastic
materials such as: PP, PE, PVC, and PVDF from diameter 500 mm till 1200 mm
The cutting angle could be changed from 30,0° by means of turning the pipe holder to the left , and
8,0° by means of turning the pipe holder to the right.
The special designed hydraulic clamp hold safety the pipe.
a. Pipe clamp
b. Arch
c. Lifting hook to be used during the arch assembl on the machine
d. Arch guide
e. Warning lamp
f. Blade protecting carter
g. Saw blade stretch adjustment nut
h. H draulic unit
i. Blade’s sliding guide
j. Adjusting angle cut s stem
k. Pipe’s roller
Figure 1. ST1200 components description

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
6
Electric Data
Voltage 400 V (3ph+1 N.+1Ground)
Frequency 50 Hz
Total Power Installed 5 KW 11A IP 54
Saw Blade Engine (2800 rpm) IP 55 4,00 KW
Hydraulic Unit IP 55 0,75 KW
H draulic & Pneumatic Data
Pump's Capacity ,1 l/min
Hydraulic Oil ISO 4
Oil Tank l
Pneumatic pressure requirement 20 bar
Mechanical data
Saw Blade Transmission System Reducing Gear 1/7
Saw Blade Maximum Speed 900 m/min
Arch down stroke speed range 0-3000mm/min
Maximum Cutting Left Angle 30,0°
Maximum Cutting Right Angle 8,0°
Total saw blade length 11700-11850 mm
Z 10 for hard material and small wall thickness
Z for medium wall thickness
Z 4 for big wall thickness
height 32 mm
Dimensions & Weight
Machine 5,10 x 5,20x 3,50 m , 2590 Kg

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
7
a. Machine's installation
In order to avoid any problems and to achieve the best performances from the machine we strongly
suggest to check the surface where the machine will be located. Check that the ground is solid
(concrete floors or other hard material floor are strongly suggested), otherwise take care to reinforce
the points of contact with the footholds of the machine. Check that the soil has a good flatness and
follow the installation procedures:
1. Position on a plane surface the central foot of the
machine
2. Assemble the columns
3. Assemble the crosspiece
4. Assemble the arch
Place two spacers under the arch extremity to maintain a
perfect parallelism of the arch with the ground.
5. Assemble the pipe’s roller
Check that roller is in a flat position, you can act on the
appropriate regulations you can adjust the flatness
. Connect the hydraulic hoses of the machine to the
couplers under the handwheel adjusting the arch down
stroke
Warning: concerning the above steps, the screw must be not too tighten in view to let the
settlement of the various components of the machine

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
8
7. Connect the cable to the power supply, taking care that the two black wires and the
brown one are the phases, the blue wires is the Neutral and the yellow – green is the
ground (Warning: the differential switch connected to the power suppl main switch could
grant a sensitivit of 300Ma)
8. Connect the power supply cable keeping care that the two black wires and the brown
wire are the phases and the yellow green wire is the ground
9. Switch on the machine by means of acting the main switch
10. Push the Reset push button
11. Push the Reset button
12. By acting on the selectors “Clamp locked” and “Clamp unlocked” , if the engine turn
but the clamp is not moving it’s necessary invert the two phases on the control board
power cable in order to change the engine rotation
13. By acting on the selectors “Arch Up Stroke” lift the saw arch
14. After making different movement with the arch in view to settle the machine, tighten all
the screws
15. Mount the blade
Unwind the blade (using protecting gloves, keeping care to
avoid any contact with sharp side of the blade) remove the
protecting plates of the arch and position the blade
respecting the direction indicated by the stickers.
Apply the correct tension to the idler pulley.
Manually rotate the main pulley for at least 20 revolutions
checking the tension and that the blade is inside the guide
After checking that there is any person close to the machine, start the engine of the blade
at the minimum speed and check that the blade is running properly.
To better understand this operation check out the chapter e – Blade replacement.
Execute some complete movements with the locking clamp to flush out the air.
The installation of the saw machine 0214 0191 will be done by our technicians. Therefore
the instructions contained in this manual must to be considered as approximate
instructions.

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
9
b. Controls description
All the controls are located on the control panel
1. White light line light
2. Yellow light Blade engine overheating light
3. Yellow light Hydraulic unit engine overheating light
4. Green light Broken or slack blade light
5. Green light Blade case door open light
. Ke selector To select the different sawing mode
7. The blue Light Push Button Safety switches on (Once pushed does not permit the
unsafe start of the saw blade)
8. The White light push button This button resets the machine
9. The Blue Push Button this button locks the clamp
10.The Blue Push Button this button controlling the arch up stroke
11.The Green Light Push Button this button starts the saw blade
12.The Emergenc Push Button this button stops the machine
13.The Black Push Button this button unlocks the clamp
14.The Black Push Button this button controlling the arch down stroke
15.The Red Push Button this button stops the saw blade
1 .Wheel Controlling the blade rotation speed
17.Wheel Controlling the arch down stroke speed
Figure 2. Control panel

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
10
c. Machine’s operation
01. Turn the pipe’s roller to the required cutting angle (for more details go to page 17)
02. Block the pipe holder by tightening the locking bolt (for more details go to page 13)
03. Insert the pipe into the pipe holder.
04. Block the clamp by pushing the relative push button
05. Adjust the blade’s sliding guide, please be sure that only the blade track used for the cut is
outside the blade’s protection (for more details go to page 17)
0 . Please carefull check that an person is outside the working perimeter of the machine.
07. By acting on the sliding potentiometer adjust the blade rotation speed. This speed depends on
the pipe to be cut.
08. By acting on the wheel adjust the arch down stroke to the minimum.
09. Push the black button for the arch down stroke. The arch will down stroke until when the blade
will be at few centimetres to the upper part of the pipe.
10. Push the blue light button for a safety start of the saw blade. For 5 seconds the machine gave
out an acoustic and light warning to advice that a new cutting cycle is starting.
11. Push the green light button to start the saw blade
Warning: It could happen that during this phase the arch up strikes for a little while before going
down. This is due to the state of the engine.
12. Adjust the down stroke speed by acting on the wheel (no.1 )
13. Once reached the limit stop of the arch the machine automatically stops the saw blade
rotation
14. Remove the cut pipe
15. Push the blue light button to completely lift the saw arch. Please kindly note that If you do not
remove the left pipe from the pipe holder, the photoelectric cells will stop the arch few
centimetres above the pipe.
Some suggestions
• Keep the blade guides close the external profile of the pipe: this will assure a longer
life to the blade because you will avoid a strong torsion.
• Keep the clamp in the correspondence of the axis of the pipe.
• Keep the moveable trolley and auxiliary side rail close to the cutting area
With some cutting angle the trolle s, side rail and blade guide, could collide one against
other. Therefore, during the preparation of the cut, kindl check that on the blade there is
an component of the machine.

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
11
d. Adjustments
1. Rollers
Rollers are bench equipped with rollers that let
the pipe slide.
The picture shows the moveable trolley.
The arrows indicate the pin to remove the
clamp set and the screw locking the trolley
movement.
With the machine is supplied an auxiliary roller,
that can be placed on different positions. This
additional roller is useful to avoid accidental
fall of the pipe on the right side of the
machine.
There is a moveable side rail in view to contain
the cut pipe.
The screw, indicated by the arrow, locks the
side rail.
Note: it is always suggested, for each type of
cut and type of pipe, to use the side rail. The
pipe must always lean on side rail you can
achieve this goal by using the clamp.
The front and back part or the trolley are
equipped with a self-levelling system to
compensate possible height differences of the
floor.
The adjustment must be done by the brass nut
shown by the arrow only during the installation
procedure.

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
12
2. Clamp pressure adjustment
Working with different pipe diameter and
pipe material it could be necessary to
adjust clamp locking pressure.
To adjust this pressure by pushing the blue
button no. 9 (see page 8) act on the wheel
marked as b in the picture on the left.
You can read the pressure on the pressure
gauge a. On the pressure gauge c you can
check the working pressure of the hydraulic
unit.
3. Clamp position adjustment
You can adjust the horizontal
position of the pipe’s clamp by
slacking on the handwheel a to
translate the position of the clamp
and on the handwheel b to rotate
the clamp. Once achieved the
correct position of the clamp
close again the handwheels
Figure 3. H draulic unit
Figure 4. Adjusting the pipe’s clamp

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
13
The pipe’s clamp must work in two
different positions accordingly with the
OD of the pipe to be cut
You must fix the cylinder of the pipe’s
clamp in the hole A to cut pipes in the
range 500-800mm
You must fix the cylinder of the pipe’s
clamp in the hole A to cut pipes in the
range 800-1200mm
In the Figure 5 you can see the holes a
and b to be used to fix the cylinder
To change configuration of the pipe’s clamp cylinder follow this procedure:
Support the pipe’s clamp by using a piece of
pipe as shown in figure
Figure 5. Holes a and b to fix the c linder
Figure 6 .Supporting the pipe’s clamps

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
14
Remove the split pin (see figure 7)
Remove the pin blocking the cylinder’s sliding (see
figure 8). Now the cylinder is free to slide (as per figure
5)
If you need help to move the pipe’s clamp simply push the button no. 9 for locking the clamp. The
cylinder stem will be moved down and centring the hole b will be easier.
Figure 7. Removing the split pin
Figure 8.Removing the pin

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
15
4. Saw Blade Stretch Adjustment
In order to stretch the saw blade it’s
necessary to act on the nut located
on the left side of the arch A. You
can read the stretch value on the
scale B
The machine is supplied with an
alloy blade and you must adjust the
stretch blade between 250 and 300
kgs. Please ask to your supplier the
right stretch to apply to the
purchased blades!
Manually rotate the main pulley for at least 20 revolutions checking the tension and that
the blade is inside the guide.
Close the protecting plates and after checking that there is any person close to the
machine, start the engine of the blade at the minimum speed and check that the blade is
running properly.
Figure 9. Nut regulating the blade stretch
Figure 10. Scale with blade stretch values in kgs

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
16
5. Pulle adjustment
To adjust the idler pulley A act on the screw B. This operation is useful to avoid the coming out of
the blade from the housing. HOWEVER IS STRONGLY DISCOURAGED TO PROCEED WITH THIS KIND
OF ADJUSTMENT, due to the fact that is operation must be carried out during the test by our
technicians.

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
17
6. Adjusting angle cut
The cutting angle could be changed from 30,0° by
means of turning the pipe holder to the left , and 8,0°
by means of turning the pipe holder to the right.
To adjust the cutting angle follows the points here
below:
1) Release the bolt on the graduated scale
2) Turn the pipe holder to the desired position
3) Tighten the bolt on the graduated scale
7. Blade’s Guide and blade protection
Adjustment
In order to maintain the saw blade into the correct
position during the cutting , it’s necessary that the
blade’s guide is adjusted according to the pipe’s
diameter to be cut, therefore the operator to
adjust should act on the screws A and B by loosen
and tighten them.
Figure 11. The blade’s guide

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
18
e. Blade Replacement
In order to replace the blade, the following operations must be carried out:
Disconnect the machine from the power supply
Open the protecting plates
Remove the old blade by loosing the stretch adjusting nut
A and pull out the blade from the housings
Mount the blade into the pulleys respecting the sense
indicted by stickers . Use appropriate garments and gloves.
Rotate the blade and insert it into the blade housing
(check that the broken and slack blade led is switched
off)
Close the protecting plates.
Important!
During this operation ou must wear protective gloves.
The blade’s guides are supplied with two small
wheels to keep the blade in the correct cutting
position. One of the wheels (see X on drawing) is
mounted on an eccentric screw to adjust the beam
of the blade.
Every time you change the blade is better to slack
the screw and after tighten it again to reduce or
eliminate the beam.

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
19
g. Tools to ease the cutting procedure
The machine is supplied with two
tools (see picture and drawings)
to reduce the pipe deformation
during the cutting procedure.
Both tools can be adjusted to
different diameters and cutting
conditions.
Warning: After placing the tools,
double check that the blade will
not interfere with the blade run
inside the pipe.

I.T.S. Ital Trade Services srl ST 1200 Operating Manual
20
h. Maintenance
BASIC MACHINE - ROLLERS
It's strongly suggested to keep always the machine clean with particular care of the cylinder's
stems and sliding bars .
Keep attention while insert pipes on the rollers avoiding to damage the machine's slide bars.
Keep always clean the machine by using compressed air in order to remove material shavings
ARCH
Check weekly the wearing state of the blade and controlling if there are cracks at the base of the
teeth
Monthly, open the protecting plates and remove the shavings.
Grease the trolley of the idler pulley when necessary.
HYDRAULIC UNIT
Check periodically the oil level. If the oil level is under 5 cm from the upper edge of the tank, add oil
by using oil type: EESSO NUTO H 8, MOBIL DTE 2 , SHELL TELLUS 8, AGIP OSO 4 0, ISO 4 .
Keep the hydraulic unit clean.
CONTROL BOARD
Clean the control board only with detergents for electric/electronics components
Keep always clean the electrical part of the machine by using compressed air in order to blow
away dust and dirt. Keep care to gently blow, to avoid any damage to the devices.
Each six months clean the filters of the fans.
GENERAL CONTROL
In case something will happen on the machine or in one component, kindly contact our technical
assistance department.
Warning: Do not use water to clean the machine!!!