Thomas SAR 460 SA G DIGIT User manual

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SAR 460 SA G
THOMAS S.p.A. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telefono 0444 / 97.61.05 - Fax 0444 / 97.69.34
Registro Imprese n. 4272//VI 116 REA n. 93906/Vicenza
SAR460SAG
DIGIT
USE AND MAINTENANCE MANUAL
2005/SRT

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SAR460SAG
Contents
Contents ........................................................................ " 2
Ordering spare parts .................................................... " 2
Guarantee ...................................................................... " 2
Machine certification and identification marking ...... " 3
CHAPTER 1
Reference to accident-prevention regulations........... " 4
1.1 - Advice for the operator ..........................................." 4
1.2 - Location of shields against accidental contact with
the tool ...................................................................." 4
1.3 - Electrical equipment according to European
Standard "CENELEC EN 60 204-1"......................." 5
1.4 - Emergencies according to European Standard
"CENELEC EN 60 204-1"......................................." 5
CHAPTER 2
Recommendations and advice for use ....................... " 5
2.1 - Recommendations and advice for using the machine." 5
CHAPTER 3
Technical characteristics ............................................. " 6
3.1 - Table of cutting capacity and technical details
standard model......................................................." 6
CHAPTER 4
Machine dimensions -Transport - Installation
Dismantling.................................................................... " 6
4.1 - Machine dimensions .............................................." 6
4.2 - Transport and handling of the machine ................." 7
4.3 - Minimum requirements for the premises
housing the machine.............................................. " 7
4.4 - Anchoring the machine .........................................." 7
4.5 - Instructions for electrical connection ......................" 7
4.6 - Disactivating the machine ......................................" 7
4.7 - Dismantling............................................................." 8
CHAPTER 5
Machine functional parts .............................................. " 8
5.1 - Operating head or sawframe.................................." 8
5.2 - Vice........................................................................." 8
5.3 - Bed ........................................................................." 8
CHAPTER 6
Description of the operating cycle .............................. " 9
6.1 - Starting up .............................................................." 9
6.2 - Cutting speed INVERTER ......................................" 9
6.3 - Piece-counter ........................................................." 10
6.4 - Cutting cycle ..........................................................." 10
6.5 - Sawframe return stroke limit (option) ....................." 10
6.6 - Alarm ......................................................................" 12
Orderingspareparts
- Whenorderingsparepartsyoumuststate:
MACHINE MODEL
SERIAL NUMBER
PART REFERENCE NUMBER
WithoutthesereferencesWEWILLNOTSUPPLYthespares.Seepoint10.1-listofspareparts-
Guarantee
- TheCompanyguaranteesthatthemachine,describedinthismanual,hasbeendesignedtomeetsafetyrequirements.Asformachinefunctionality,inspectionhasbeen
successful.
- Themachineisguaranteedfor12months:theguaranteedoesnotcovertheelectricmotors,electriccomponents,pneumaticcomponentsoranydamageduetodropping
ortobadmachinemanagement,thefailuretoobservemaintenancestandardsorbadhandlingbytheoperator.
- Thebuyerhasonlytherighttoreplacementofthefaultyparts,whiletransportandpackingcostsareathisexpense.
- Theserialnumberonthemachineisaprimaryreferencefortheguarantee,forafter-salesassistanceandforidentifyingthemachineforanynecessity.
CHAPTER 7
Regulating the machine ................................................ " 12
7.1 - Blade tension assembly ........................................." 12
7.2 - Blade-guides .........................................................." 13
7.3 - Vice........................................................................." 14
7.4 - Cutting angle adjustment ......................................." 14
7.5 - Vice pressure regulation ........................................" 14
7.6 - Blade cleaning brush ............................................." 14
7.7 - Changing the blade................................................" 15
CHAPTER 8
Routine and special maintenance ............................... " 15
8.1 - Daily maintenance ................................................." 15
8.2 - Weekly maintenance.............................................." 15
8.3 - Monthly maintenance ............................................." 15
8.4 - Six-monthly maintenance......................................." 15
8.5 - Oils for lubricating coolant......................................" 15
8.6 - Oil disposal ............................................................." 15
8.7 - Special maintenance.............................................." 15
CHAPTER 9
Material classification and choice of tool.................... " 16
9.1 - Definition of materials............................................." 16
9.2 - Selecting blade......................................................." 16
9.3 - Teeth pitch .............................................................." 16
9.4 - Cutting and advance speed ..................................." 17
9.5 - Blade running-in....................................................." 17
9.6 - Blade structure ......................................................." 17
9.7 - Blade type..............................................................." 17
Shape and angle of tooth ......................................." 17
Set..........................................................................." 18
9.7.1 - Table of recommended cutting parameters .............. " 18
CHAPTER 10
Machine components ................................................... " 19
10.1- List of spare parts ................................................... " 19
CHAPTER 11
Three-phase electric diagram...................................... " 30
Hydraulic electric diagram........................................... " 35
CHAPTER 12
Troubleshooting ............................................................. " 37
12.1-Blade and cut diagnosis........................................." 37
CHAPTER 13
Noise tests..................................................................... " 41
Plates and labels ........................................................... " 42

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SAR 460 SA G
via Pasubio, 32 36033 ISOLA VIC. - ITALIA
SAR 460 SA-G
DIGIT
Machine certification and identification marking
MACHINE LABEL
TYPE
SERIAL NUMBER
YEAROFMANUFACTURE
(Space reserved for the NAME and STAMP of the DEALER and/or IMPORTER)

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SAR460SAG
This machine has been built to comply with the national and community accident-prevention regulations in force. Improper use
and/or tampering with the safety devices will relieve the manufacturer of all responsibility.
1.1 - Advice for the operator
- Check that the voltage indicated on the plate, normally fixed to the machine motor, is the same as the line voltage.
- Check the efficiency of your electric supply and earthing system; connect the power cable of the machine to the socket and theearth
lead (yellow-green in colour) to the earthing system.
- When the saw frame is in suspend mode (up) the toothed blade must not move.
- Only the blade section used for cutting must be kept unprotected. Remove guarding by operating on the adjustable head.
- It is forbidden to work on the machine without its shields (these are all white, blue or grey in colour).
- Always disconnect the machine from the power socket before blade change or carrying out any maintenance job, even in the case
of abnormal machine operation.
- Always wear suitable eye protection.
- Never put your hands or arms into the cutting area while the machine is operating.
- Do not shift the machine while it is cutting.
- Do not wear loose clothing with sleeves that are too long, gloves that are too big, bracelets, chains or any other object that could get
caught in the machine during operation; tie back long hair.
- Keep the area free of equipment, tools or any other object.
- Perform only one operation at a time and never have several objects in your hands at the same time. Keep your hands as clean as
possible.
- All internal and/or internal operations, maintenance or repairs, must be performed in a well-lit area or where there is sufficient light
from extra sources so as to avoid the risk of even slight accidents.
1.2 - Location of shields against accidental contact with the tool
- Grey metal guards, fastened with screws onto the mobile blade-guide ensures covering of blade section not used in cutting
operation ( A ).
- Grey metal guards, fastened onto the sawframe, to protect from flywheels ( B ).
- Grey metal guard to protect from driving belts ( C ).
- Grey metal fence around the machine, to protect the operator from cutting area ( D ) .
1
REFERENCE TO ACCIDENT PREVENTION REGULATIONS
B
A
B
D
C
D

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SAR 460 SA G
ited by screws that can only be removed with a special tool; the parts are fed with alternating current at low voltage. The equipment
is protected against splashes of water and dust.
- Protection of the system against short circuits is ensured by means of rapid fuses and earthing; in the event of motor overload,
protection is provided through the inverter.
- The machine has been tested in conformity with point 20 of EN 60204.
1.4 - Emergencies according to European Standard "CENELEC EN 60 204-1"
- In the event of incorrect operation or of danger conditions, the machine may be stopped immediately by pressing the red mushroom
button.
- The casual or voluntary removal of the protection shield of the flywheels causes the stepping-in of a microswitch that automatically
stops all machine functions.
- In case blade breaks, the pressure switch stops all machine functions.
1.5 - OTHER RISKS
- As the machine is running, any intervention from the operator within the “dangerous zone” or cutting area must be considered a
risk for his own safety.
RECOMMENDATIONS AND ADVICE FOR USE
2.1 - Recommendations and advice for using the machine
- The machine has been designed to cut metal building materials, with different shapes and profiles, used in workshops, turner’s
shops and general mechanical structural work.
- Only one operator is needed to use the machine, that must stand as shown in the picture.
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1.3 - Electrical equipment according to Euro-pean Standard "CENELEC EN 60 204-1" which as-similates,
with some integrating modifications, the publication "IEC 204-1"
- The electrical equipment ensures protection against electric shock as a result of direct or indirect contact. The active parts of this
equipment are housed in a box to which access is lim
- Before starting each cutting operation, ensure that the part is firmly gripped in the vice and that the end is suitably supported.
These figures show examples of suitable clamping of different section bars, bearing in mind the cutting capacities of the machine in
order to achieve a good efficiency and blade durability.
- Do not use blades of a different size from those stated in the machine specifications.
- If the blade does not cut through the material, immediately strike the emergency push-button and switch off the machine. Open the
vice with the handwheel, remove part to be cut ad check that the blade teeth are not broken, If they are, replace tool.
- Check saw frame return spring to ensure proper balancing.
- Before carrying out any repairs on the machine, consult the dealer or apply to THOMAS.

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SAR460SAG
0° 460 450 760 x 380
30° 450 440 600 x 400
45° 400 380 400 x 360
60° 210 210 210 x 280
TECHNICAL DETAILS
4
A KW
1
2
3
4
DIMENSIONE DELLA LAMA mm
DIAMETRO VOLANI mm
ALTEZZA PIANO DI LAVORO mm
APERTURA DELLA MORSA mm
VELOCITA' DI TAGLIO m/1'
RIDUTTORE Rapp.
PRESSIONE CENTRALINA
IDRAULICA Bar
PRESSIONE TENDINASTRO Bar
PESO Kg
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TECHNICAL CHARACTERISTICS
3.1 - Table of cutting capacity and technical details
standard model
Blade dimension
Flywheel diameter
Working table heigth
Vice opening
Cutting speed
Gear-box
Hydraulic service pressure
Blade tension pressure
Weight
MOTORS
Blade motor
Hydraulic pump motor
Coolant liquid electropump
MACHINE DIMENSIONS
TRANSPORT
INSTALLATION
DISMANTLING
4.1 - Machine dimensions
5500 x 38 x 1,3
560
630
770
20 ÷ 100
INVERTER
35
22
2600
5,5
1,5
0,15
A = 2400
B = 1550
C = 630
D = 2500
E = 2360
F = 2830

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SAR 460 SA G
R = L1
S = L2
T = L3
PE = GND
4.4 - Anchoring the machine
4.2 -Transport and handling of the machine
If the machine has to be shifted in its own packing, use a fork-lift
truck or sling it with straps as illustrated.
4.3 - Minimum requirements for the premises
housing the machine
- Mains voltage and frequency complying with the machine
motor characteristics.
- Environment temperature from -10 °C to +50 °C.
- Relative humidity not over 90%.
- Position the machine on a firm cement floor, maintaining, at
the rear, a minimum distance of 1500 mm from the wall; an-
chor it to the ground as shown in the diagram, using screws
and expansion plugs or tie rods sunk in cement, ensuring that
it is sitting level.
4.5 - Instructions for electrical connection
- The machine is not provided with an electric plug, so the cus-
tomer must fit a suitable one for his own working conditions:
1 - WIRING DIAGRAM FOR 5-WIRE SYSTEM FOR THREE-
PHASE MACHINE - SOCKET FOR A 32A PLUG
4.6 - Disactivating the machine
- If the sawing machine is to be out of use for a long period, it is advisable to
proceed as follows:
1)detach the plug from the electric supply panel
2)loosen blade
3) remove the sawframe return spring
4) empty the coolant liquid tank.

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SAR460SAG
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5.2 -Vice
- Material clamping system during the cutting operation by
means of a special stop pawl and hydraulic locking.
5.3 - Bed
4.7 - Dismantling
(because of deterioration and/or obsolescence)
General rules
Ifthemachine is tobepermanentlydemolished and/or scrapped,
divide the material to be disposed of according to type and
composition, as follows:
1)Cast iron or ferrous materials, composed of metal alone, are
secondary raw materials, so they may be taken to an iron
foundry for re-smelting after having removed the contents
(classified in point 3);
2)electrical components, including the cable and electronic ma-
terial (magnetic cards, etc.), fall within the category of mate-
rial classified as being assimilable to urban waste accord-
ing to the laws of the European community, so they may be
set aside for collection by the public waste disposal service;
3)old mineral and synthetic and/or mixed oils, emulsified oils
and greases are special refuse, so they must be collected,
transported and subsequently disposed of by the old oil dis-
posal service.
NOTE: since standards and legislation concerning refuse in
generalisin astateof continuous evolutionandtherefore
subject to changes and variations, the user must keep
informed of the regulations in force at the time of dis-
posing of the machine tool, as these may differ from
those described above, which are to be considered as
a general guide line.
MACHINE FUNCTIONAL
PARTS
5.1 - Operating head or saw frame
- Part of the machine consisting of drive members (gearmotor
orvariablespeed motor,flywheels),tightening andguide(blade
tightening slide, blade guide head) of tool.
- Structure supporting the SAWFRAME OPERATING HEAD
(revolving arm for degree cutting along with clamping sys-
tem), the VICE; the bedplate houses the cooling liquid TANK,
the CONTROL BOARD, ELECTRICAL and HYDRAULIC
SYSTEMSandtheDEVICECONTROLLINGtheAUTOMATIC
HYDRAULIC LOWERING AND RISE of the SAWFRAME.

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SAR 460 SA G
DESCRIPTION OF THE
OPERATING CYCLE
Before operating, all the main organs of the machine must
be set in optimum conditions (see the chapter on “Regulat-
ing the machine”).
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- Ensure that the machine is not in emergency stop condition; if
it is, release the red mushroom button ( 1).
- Make sure that the flywheel metal Cover is closed as well as
the relevant Microswitch.
- Rotate the main switch ( 3) towards the right to
position 1 .
- Press start button ( 2).
- Close the regulator ( 4 ) completely (turn it clockwise).
- Press the key activating the hydraulic pump (see legenda at
page 10) as well as the keys moving the sawframe and the
vice to verify if these work properly; if they doesn’t attempt to
swap one of the electric power supply wires (only during
installation).
-
ATTENTION: having started the hydraulic unit motor, make
sure that the blade is under tension (eventually the blade
tension lever is released), so that the relevant microswitch
won't break the electrical circuit. Please refer to
para. 7.1 Blade
tension assembly
for more details.
- Press the key lifting the sawframe.
- Check the index showing the cutting angle; refer to para. 7.4
Cutting angle adjustment if you want to perform mitre cutting.
6.1 - Starting up and cutting cycle
1
1
34
2
- Display shows the following information soon after you switch
on the machine:
-START = start of the cutting cycle.
-PZ. I = programmed cutting cycles. The machines stops
automatically once the programmed number has been
completed; reset the piece-counter to start the machine again.
-PZ. T = programmed cutting cycles completed.
-VEL . LAMA or BLADE SPEED = current blade speed
expressed in meters per minute.
-F1: corrisponding to the sign 'PZ' goes to the programming of
the piece-counter.
-F2 : corrisponding to the sign 'STATO' goes to the visualization
checking up the machine functions.
-F4 : corrisponding to the sign 'VEL' goes to the adjustment of
the blade speed.
START = BUTTON
PC. I = PC.T =
Blade speed Mt /m= ___
PC STATO VEL

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SAR460SAG
SAWFRAME DOWNFEED
SAWFRAME LIFT
VICE LOCK
LEGENDA CONTROLLER
CYCLE START
CYCLE STOP
ALARM WARNING LIGHT
K4 VICE OPEN
K1
K2
K5 CYCLE START SELECTION:
FOOT CONTROL SWITCH, OR
KEY ON THE CONTROLLER
HYDRAULIC PUMP ON
PROG
K6
K3
F3
F1
F2
F4
ACCESS TO THE CONTROLLER
CONFIGURATION ( ACCESS PROTECTED BY
PASSWORD ).
ACTIVATES THE FUNCTION SHOWN RIGHT
ABOVE ON THE DISPLAY
ACTIVATES THE FUNCTION SHOWN RIGHT
ABOVE ON THE DISPLAY
ACTIVATES THE FUNCTION SHOWN RIGHT
ABOVE ON THE DISPLAY
ACTIVATES THE FUNCTION SHOWN RIGHT
ABOVE ON THE DISPLAY