Thomas ZIP 22 User manual

Sthemma Srl. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 977980 - Fax 0444 / 977917
THOMAS
Metal-Bandsaw
zip 22
USE AND MAINTENANCE MANUAL

Distributed by:
Trick-Tools
75 Truman Road
Pella, IA 50219
Phone:1-877-VAN-SANT
E-mail: [e-mail]
Here at Trick Tools we believe that our customers deserve the best
value in their tool and equipment purchases. We are constantly at
work searching out a variety of high quality, high performance tools
to oer at the best prices possible. Our commitment to you is that
we will not oer “cheap junk” anywhere on our website. You, the
customer, help us to evaluate our products constantly and as soon as
an ongoing quality issue is uncovered we will correct it or disconnue
that product immediately. We hope to earn your connued trust.

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Certicate of Conformity
We hereby certify that the Metal Sawing Machine described on the frontpage of this manual was manufactured according to the
following directives as far as the safety and health of users is concerned
EC-Directives Harmonised Regulations
EC-Machines Directive (2006/42/EC) DIN EN ISO 12100: 2011-03
EMV-Directive (2004/108/EC), (2002/44/EC) EN 60204, Art 1
Direttiva Comando a Bassa Tensione 2006/95/EC
Sthemma Srl. - Via Pasubio, 32 - 36033 Isola Vicentina (VI) - Telephone 0444 / 977980 - Fax 0444 / 977917

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7.1 - Blade tension assembly .......................................... " 11
7.2 - Blade guides heads................................................. " 11
7.3 - Vice.......................................................................... " 11
7.4 - ................................................................................ " 11
7.5 - Cutting angle adjustment......................................... " 11
7.6 - Changing the blade ................................................. " 12
CHAPTER 8
Routine and special maintenance................................."12
8.1 - Daily maintenance................................................... " 12
8.2 - Weekly maintenance ............................................... " 12
8.3 - Monthly maintenance .............................................. " 12
8.4 - Six-monthly maintenance ........................................ " 12
8.5 - Maintenance of machine operating members ......... " 12
8.6 - Oils for lubricating coolant ....................................... " 12
8.7 - Oil disposal.............................................................. " 12
8.8 - Special maintenance ............................................... " 12
CHAPTER 9
Material classication and choice of tool ...................."13
9.1- Denitionofmaterials.............................................. " 13
9.2 - Selecting blade........................................................ " 13
9.3 - Teeth pitch ............................................................... " 13
9.4 - Cutting and advance speed..................................... " 14
9.5 - Blade running-in ...................................................... " 14
9.6 - Blade structure ........................................................ " 14
9.7 - Blade type ............................................................... " 14
Teeth shape and angle ............................................ " 14
Set ........................................................................... " 15
9.7.1 - Table of recommended cutting parameters .................. " 15
CHAPTER 10
Machine components ...................................................."16
10.1- List of spare parts.................................................... " 16
CHAPTER 11
Wiring diagrams ............................................................."21
CHAPTER 12
Troubleshooting ............................................................."23
12.1- Blade and cutting diagnosis .................................... " 23
12.2- Electrical components diagnosis ............................. " 27
CHAPTER 13
Noise tests ......................................................................"27
Plates and labels ............................................................" 28
Contents
Contents.........................................................................." 2
Ordering spare parts......................................................" 3
Guarantee ........................................................................" 3
Machine certication and identication 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........................."6
2.1 - Recommendations and advice for using the machine "
6
CHAPTER 3
Technical characteristics..............................................." 7
3.1 - Table of cutting capacity and technical details ........ " 7
CHAPTER 4
Machine dimensions - Transport - Installation
Dismantling....................................................................."7
4.1 - Machine dimensions................................................ " 7
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............................................ " 8
4.5 - Instructions for electrical connection ....................... " 8
4.6 - Instructions for assembly of the loose parts and
accessories ............................................................. " 8
4.7 - Disactivating the machine ....................................... " 8
4.8 - Dismantling.............................................................. " 8
CHAPTER 5
Machine functional parts ..............................................."8
5.1 - Operating head or saw frame.................................. " 9
5.2 - Vice.......................................................................... " 9
5.3 - Bed .......................................................................... " 9
CHAPTER 6
Description of the operating cycle................................"9
6.1 - Starting up and cutting cycle ................................... " 9
CHAPTER 7
Ordering spare parts
- When ordering spare parts you must state:
MACHINE MODEL
SERIAL NUMBER
PART REFERENCE NUMBER
Without these references WE WILL NOT SUPPLY the spares. See point 10.1 - list of spare parts -
Guarantee
- The Company guarantees that the machine to which this manual refers has been designed and built to comply with safety regulations
and that it has been tested for functionality in the factory.
- The machine is guaranteed for 12 months: the guarantee does not cover the electric motors, electric components, pneumatic compo-
nents or any damage due to dropping or to bad machine management, the failure to observe maintenance standards or bad handling
by the operator.
- The buyer has only the right to replacement of the faulty parts, while transport and packing costs are at his expense.
- The serial number on the machine is a primary reference for the guarantee, for after-sales assistance and for identifying the machine
for any necessity.

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AB
C
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xedtothemachinemotor,isthesameasthelinevoltage.
- Checktheefciencyofyourelectricsupplyandearthingsystem;connectthepowercableofthemachinetothesocketandtheearth
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 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sufcient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
- Blue, grey right and left hand metal shields, fastened with screws onto the guide blade stationary head ( REF. A ).
- Blue or grey metal shield fastened with screws onto the blade guide adjustable head, ensures covering of blade section not used in
cutting operation ( REF. B ).
- Greymetalguard,fastenedwithknobsontothesawframe,toprotectfromywheels(REF.C).
1REFERENCE TO ACCIDENT- PREVENTION REGULATIONS

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2
RECCOMENDATIONS 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proles,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.
- Beforestartingeachcuttingoperation,ensurethatthepartisrmlygrippedintheviceandthattheendissuitablysupported.
Theseguresshowexamplesofsuitableclampingofdifferentsectionbars,bearinginmindthecuttingcapacitiesofthemachinein
ordertoachieveagoodefciencyandbladedurability.
- Donotusebladesofadifferentsizefromthosestatedinthemachinespecications.
- If the blade gets stuck in the cut, release the running button immediately, switch off the machine, open the vice slowly, remove the
part and check that the blade or its teeth are not broken. If they are broken, change the tool.
- Check saw frame return spring to ensure proper balancing.
- Before carrying out any repairs on the machine, consult the dealer or apply to Sthemma Srl.

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4
1280 510
1370
TECHNICAL DATA
3.1 - Cutting Capacity and Technical Data
3
Electric Motor ............................................. kW 0,37/0,75
Electropump, Coolant Liquid ...................... kW 0,07
Sawband, Dimensions................................ mm 2095x20x0,9
Flywheel, Diameter..................................... mm 270
Sawband, Cutting Speed............................ m/min 35/70
Vice Opening .............................................. mm 215
Working Table, Heigth ................................ mm 970
Mitre cutting................................................ 45°÷ 60°
Machine-Dimensions.................................. mm 1280x510x1370
Machine-Weight.......................................... kg.180
Voltage........................................................ V 400
Frequency................................................... Hz 50
Max. power Absorption............................... A 2,5
Coolant tank, Capacity ............................... l 16
Technical Data
Round 0° ................................................... ø mm 180
Round 45° ................................................ ø mm 115
Round 60° ................................................. ø mm 70
Square 0° ................................................... mm 180x180
Square 45° ................................................. mm 110x110
Square 60° ................................................. mm 70x70
MACHINE DIMENSIONS
TRANSPORT
INSTALLATION
DISMANTLING
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%.

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5
R = L1
S = L2
T = L3
PE = GND
600mm
385mm
740mm
ø 10,5mm
OuterProle
4.4 - Anchoring the machine
- Positionthemachineon armcementoor,maintaining,at
therear,aminimumdistanceof800mmfromthewall;anchor
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tasuitableoneforhisownworkingconditions:
1 - WIRING DIAGRAM FOR 4-WIRE SYSTEM FOR THREE-
PHASE MACHINE - SOCKET FOR A 16A PLUG
4.6 - Instructions for assembly of the loose parts
and accessories
See following picture
1) Mount Bar-Stop n.1.
2) Material-Support n.2 should be set according to working table
levelandxedtotheposition.
3) Splash-Guard n.3 should be set in place to avoid coolant liquid
droppingdowntotheoor.
4.7 - 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) release the arch return spring
4) empty the coolant tank
5) carefully clean and grease the machine
6) if necessary, cover the machine.
4.8 - Dismantling
(because of deterioration and/or obsolescence)
General rules
ATTENTION: This symbol indicates that this product shall not be
treated as household waste. Instead it should be handed over
to the applicable collection point for the recycling of electrical
equipment. For more detailed information about recycling of this
product,pleasecontactyourlocalCivicOfce,yourhousehold
waste disposal service or the shop where you purchased the
product.
MACHINE FUNCTIONAL
PARTS
5.1 - Operating head or sawframe
- Machine part consisting of the members that transfer the motion
(gearmotor,ywheels),andtension/guide(blade-guides,blade
tension slide) and sawframe dowfeed control.

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DESCRIPTION OF THE
OPERATING CYCLE
Before operating, all the main organs of the machine
must be set in optimum conditions (see the chapter on
Regulating the machine
5.2 - Machine Bed
- Support structure for the OPERATING HEAD OR SAW FRAME
(rotating arm for gradual cutting, with respective blocking system),
the ELECTRIC BOX, the VICE, the BAR STOP, the material sup-
port PLATE and the housing for the coolant liquid TANK and pump.
The coolant liquid consisting of 8-10% emulsion oil diluted
inwatercontainedinthetank(C)lleduptothelevelshown
through the sight glass (B). CAUTION:donotoverllforthe
electropump (A) could fail. Liquid can be drained by removing
the plug (D).
6
6.1 - Start-up and Cutting Cycle
- Make sure that the emergency Stop has been released. Rel-
evant red button ( 5) should be turned anti-clockwise to get
the electric connection on stand-by mode.
- Turn clockwise the handwheel to put the blade under
tension according to the scale ( 10 ) showing 20, 30
and 35.000 psi (pounds per square inch). Bi-metal M42
blades need to be tensioned to 30-35.000 psi, whilst
for Carbon blades the tension should be 20.000 psi.
Select desired blade rotation speed on the Commutator ( 4) :
Position 1 (turtle) = 33 m/min.
Position 2 (rabbit) = 66 m/min.
- Grab the Lever ( 8) and raise the sawframe manually to the top
position. Usually, the sawframe is held up by a special return
spring.
- Load the material to cut on the vice and appraoch the vice jaw
to3-4mmfromthematerial;lockthematerialsafelybymeans
of the quick lock lever.
- Press the Push-button ( 1) and the READY Pilot Light will illuminate.
Press GRIPSWITCH ( 6) to start both bla-
de rotation and coolant liquid flow making the motor
running as long as your finger keeps pressing on it.
Release your finger off the switch to stop the motor.
Keep pressing your finger on the switch and
pull down the sawframe to cut your material.
Once the cut is completed release your finger off the
switch and gently move the sawframe to the top position.
CAUTION: In case of danger or trouble, press the red
emergency Push-button ( 5) to stop any function.
5.2 - Vice
- System for clamping the material during the cutting operation,
operated with approach handwheel and quick locking lever.
1
4
5
A
B
C
D

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CAUTION:
Keep away both Hands and Arms from the cutting area !
6) Dead man's Switch
A dead man's switch is a switch that is automatically operated
if the human operator becomes incapacitated, such as though
death, loss of consciousness or being bodily removed from
control. This switch merely brings back the machine to a safe
state while leaving the machine ready to resume normal ope-
ration once control is reestablished.
7) Sawframe holder Spring
This is a set of of one or two springs to hold up the sawframe
to the top position before introducing the material to cut into
the vice. Successively, once the preliminary operations have
been completed such as:
- The Blade has been tensioned
- The Blade rotation speed has been selected
- The Material to cut has been loaded and clamped in the vice
- The Motor has been started to run the blade and the coolant
liquid.
The operator can pull down the sawframe at the recommended
feed rate and cut the material.
Once the cut is completed, the sawframe raises to the top
position through the spring pull.
-
- Make sure that the blade rotates in the sense shown by the
arrow ( 9) located on the sawframe and that the electropumps
delivers the coolant liquid properly. The coolant liquid should
be consisting of water and 8-10% emulsion oil.
Now the machine is ready to use. Pay attention to the following
CUTTING PARAMETERS:
- BLADE SPEED, SAWFRAME DOWNFEED SPEED and
BLADE TOOTH PITCH. These are fundamentals which guar-
antee proper cutting quality and machine performance.
For more information see Chapter:
MATERIAL CLASSIFICATION and TOOL CHOICE
- In case of danger or trouble, press the red emergency push-
button to stop any function.
89
10
6
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7.2 - Blade guide blocks
The blade is guided by means of adjustable rollers set in place
during inspection as per the thickness of the blade with minimum
playasshowninthegure.
In case the blade needs to be replaced, make sure to always
install 0.9 mm thick blades for which the blade guide rollers have
been adjusted. In the case of toothed blades with different thick-
nesses adjustment should be carried out as follows:
- Loosen the nuts ( 1 ) and rotate the pin ( 2 ) widening the pas-
sage between the rollers.
- Mount the new blade, place the rollers and rotate the pin ( 2 ) leaving
0,04mmcleartoallowthebladeslidingsmoothely.SecuretheNut(1).
- Make sure that 0,2-0,3mm clear between the blade back and
theroller(4);Justincase,loosenthescrewsthatfastensthe
heads(5)andcarryoutnaladjustment.
7.3 - Vice
- Thedevicedoesnotrequireanyparticularadjustment;incase
of excess play of the sliding guide, tighten slide screw more.
- Place material to be cut in the vice. Close jaws against piece,
keeping a distance of approx. 3 - 4 mm then clamp with lever.
REGULATING
THE MACHINE
7.1 - Blade tension assembly
-Turn clockwise the handwheel to put the blade under tension ac-
cording to the scale ( 10 ) showing 20, 30 and 35.000 psi (pounds
per square inch). Bi-metal M42 blades need to be tensioned to
30-35.000 psi, whilst for Carbon blades the tension should be
20.000 psi. At the end of each working day, it is reccomended
to loose the blade tension to a minimum. This will preserve the
exibilityofthebladeandguaranteelongerdurability.
7
6
7.5 - Cutting angle adjustment
-Unlock lever (6) and rotate the saw frame arm until you
reach mechanical stop and check if the index corres-
pondsto60°;ifnotoperateonthesetscrewstomake
measures meet.

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8.1 - Daily maintenance
- General cleaning of the machine to remove accumulated chips.
- Cleanthelubricatingcoolantdrainholetoavoidexcessuid.
- Top up the level of lubricating coolant.
- Check blade for wear.
- Rise of saw frame to top position and partial slackening of the
blade to avoid useless yield stress.
- Check functionality of the shields and emergency stops.
8.2 - Weekly maintenance
- More accurate general cleaning of the machine to remove chips,
especiallyfromthelubricantuidtank.
- Removalofpumpfromitshousing,cleaningofthesuctionlter
and suction zone.
- Clean the lter of the pump suction head and the suction
area.
- Cleaning with compressed air the blade guide heads (guide
bearings and drain hole of the lubricating cooling).
- Cleaning ywheel housings and blade sliding surfaces on
ywheels.
8.3 - Monthly maintenance
- Checkthetighteningofthemotorywheelscrews.
- Check that the blade guide bearings on the heads are perfect
running condition.
- Check the tightening of the screws of the gearmotor, pump and
accident protection guarding.
8.4 - Six-monthly maintenance
- Continuity test of the equipotential protection circuit.
8.5 - Maintenance of the operating machine
members
The worm drive gear box mounted on the machine is mainte-
nance-free guaranteed by its manufacture.
8.6 - Oils for lubricating coolant
Considering the vast range of products on the market, the user
can choose the one most suited to his own requirements, using
as reference the type SHELL LUTEM OIL ECO.
THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER
IS 8 - 10 %.
8.7 - Oil disposal
The disposal of these products is controlled by
strict regulations. Please see the Chapter on
Machine dimensions - Transport - Installation
BEFORE PERFORMING THE FOLLOWING OPERATIONS,
THE ELECTRIC POWER SUPPLY AND THE POWER CABLE
MUST BE COMPLETELY DISCONNECTED.
7.6 - Changing the blade
To change the blade:
- Lift the saw frame.
- Loosen the blade with the handwheel, remove the mobile
blade-guardcover,opentheywheelguardsandremovethe
oldbladefromtheywheelsandthebladeguideheads.
- Assemblethenewbladebyplacingitrstbetweenthebear-
ingsoftheheadsandthenontheseatoftheywheels,paying
particular attention to the cutting direction of the teeth (page
10).
- Tensionthebladeandmakesureitperfectlytsinsidetheseat
oftheywheels.
- Assemble the mobile blade-guide and the fly-
wheel guard and fasten it with the relative knobs.
WARNING: always assemble blades having dimensions speci-
edinthismanualandforwhichthebladeguide
heads have be set: otherwise, see chapter on
“Description of the operating cycle” in the section
Starting-up.
ROUTINE
AND SPECIAL
MAINTENANCE
THEMAINTENANCEJOBSARELISTEDBELOW,DIVIDED
INTO DAILY, WEEKLY, MONTHLY AND SIX-MONTHLY
INTERVALS. IF THE FOLLOWING OPERATIONS ARE
NEGLECTED, THE RESULT WILL BE PREMATURE WEAR
OF THE MACHINE AND POOR PERFORMANCE.
8.1 - Daily maintenance
- General cleaning of the machine to remove accumulated chips.
- Cleanthelubricatingcoolantdrainholetoavoidexcessuid.
- Top up the level of lubricating coolant.
- Check blade for wear.
- Rise of saw frame to top position and partial slackening of the
blade to avoid useless yield stress.
- Check functionality of the shields and emergency stops.
8.2 - Weekly maintenance
- More accurate general cleaning of the machine to remove chips,
especiallyfromthelubricantuidtank.
- Removalofpumpfromitshousing,cleaningofthesuctionlter
and suction zone.
- Clean the lter of the pump suction head and the suction
area.
- Cleaning with compressed air the blade guide heads (guide
bearings and drain hole of the lubricating cooling).
- Cleaning ywheel housings and blade sliding surfaces on
ywheels.
8.3 - Monthly maintenance
- Checkthetighteningofthemotorywheelscrews.
- Check that the blade guide bearings on the heads are perfect
running condition.
- Check the tightening of the screws of the gearmotor, pump and
accident protection guarding.
8.4 - Six-monthly maintenance
- Continuity test of the equipotential protection circuit.
8.5 - Maintenance of the operating machine
members
The worm drive gear box mounted on the machine is mainte-
nance-free guaranteed by its manufacture.
8.6 - Oils for lubricating coolant
Considering the vast range of products on the market, the user
can choose the one most suited to his own requirements, using
as reference the type SHELL LUTEM OIL ECO.
THE MINIMUM PERCENTAGE OF OIL DILUTED IN WATER
IS 8 - 10 %.
8.7 - Oil disposal
The disposal of these products is controlled by
strict regulations. Please see the Chapter on
Machine dimensions - Transport - Installation
8

13
ZIP 22
Thickness in mm (S) Continuous Toothing Alternate Toothing
up to 1,5mm Z=14 Z=10/14
from 1 to 2 Z=8 Z=8/12
from 2 to 3 Z=6 Z=6/10
from 3 to 5 Z=6 Z=5/8
from 4 to 6 Z=6 Z=4/6
more than 6 Z=4 Z=4/6
Standard /
Materialien
(I)
UNI
(D)
DIN
(F)
AFNOR
(GB)
SB
USA
AISI-SAE
Brinell
Härte HB
Rockwell
Härte HRB
R=N/mm2
Construction
steel
Fe360 Fe430
Fe510
St37 St44
St52
E24 E28
E36
43 50 116 148 180 67 80 88 360÷480
430÷560
510÷660
Non Alloy Steel C20 C40 C50
C60
CK20 CK40
CK50 CK60
XC20
XC42H1
XC55
060 A 20 060
A 40 060
A 62
1020 1040
1050 1060
198 198
202 202
93 93 94 94 540÷690
700÷840
760÷900
830÷980
Spring Steel 50CrV4
60SiCr8
50CrV4
60SiCr7
50CV4 735 A 50 6150 9262 207 224 95 98 1140÷1330
1220÷1400
Alloy Steel for
Hardening
35CrMo4
39NiCrMo4
41CrAlMo7
34CrMo4
36CrNiMo4
41CrAlMo7
35CD4
39NCD4
40CADG12
708 A 37 905
M 39
4135 9840 220 228
232
98 99 100 780÷930
880÷1080
930÷1130
Alloy Einsatzstahl 18NiCrMo7
20NiCrMo2
21NiCrMo2 20NCD7
20NCD2
En 325 805
H 20
4320 4315 232 224 100 98 760÷1030
690÷980
Steel for Bea-
rings
100Cr6 100Cr6 100C6 534 A 99 52100 207 95 690÷980
Tool Steel 52NiCrMo-
KU C100KU
X210Cr13KU
58SiMo8KU
56NiCrMo
C100W1
X2210Cr12
Z200C12
Y60SC7
BS 1 BD2 -
BD3
S-1 D6 - D3
S5
244 212
252 244
102 96 103
102
800÷1030
710÷980
820÷1060
800÷1030
Stainless Steel X12Cr13
X5CrNi1810
X8CrNi1910
X8CrNiMo171
4001 4301
4401
Z5CN18.09
Z6CDN17.1
304 C 12
316 S 16
410 304 316 202 94 670÷885
590÷685
540÷685
490÷685
Kupferlegierung
Spezialmessing
Bronze
Aluminium-Kupferlegierungen G-CuAl11Fe4Ni4 UNI 5275 Spezialmessing
mit Mangan/Silizium G-CuZn36Si1Pb1 UNI 5038 Manganbronze SAE43 -
SAE430 Phosphorbronze G-CuSn12 UNI 7013/2a
220 140
120 100
98 77 69 56,5 620÷885
375÷440
320÷410
265÷314
Since the aim is to obtain excellent cutting quality, the various
parameters such as hardness of the material, shape and
thickness, transverse cutting section of the part to be cut,
selection of the type of cutting blade, cutting speed and
control of saw frame lowering.Thesespecicationsmust
therefore be harmoniously combined in a single operating
condition according to practical considerations and common
sense, so as to achieve an optimum condition that does
not require countless operations to prepare the machine
when there are many variations in the job to be performed.
The various problems that crop up from time to time will be
solved more easily if the operator has a good knoledge of
thesespecications.
WE THEREFORE RECOMMEND YOU TO ALWAYS USE
GENUINE "THOMAS" SPARE BLADES THAT GUARANTEE
SUPERIOR QUALITY AND PERFORMANCE.
9.1 - Denition of materials
The table at the foot of the page lists the characteristics of the
materials to be cut, so as to choose the right tool to use.
9.2 - Selecting blade
First of all the pitch of the teeth must be chosen, in the other
words, the number of teeth per inch (25,4 mm) suitable for the
9MATERIAL
CLASSIFICATION AND
CHOICE OF TOOL
material to be cut, according to these criteria:
- partswithathinand/orvariablesectionsuchasproles,pipes
and plate, need close toothing, so that the number of teeth used
simultaneouslyincuttingisfrom3to6;
- parts with large transverse sections and solid sections need
widely spaced toothing to allow for the greater volume of the
chipsandbettertoothpenetration;
- parts made of soft material or plastic (light alloys, mild bronze,
teon,wood,etc.)alsorequirewidelyspacedtoothing;
- pieces cut in bundles require combo tooth design.
9.3 - Teeth pitch
As already stated, this depends on the following factors:
- hardness of the material
- dimensions of the section
- thickness of the wall.

14
ZIP 22
Full Material ø Continuous Toothing Alternate Toothing
up to 30mm Z=8 Z=5/8
from 30 to 60 Z=6 Z=4/6
from 60 to 80 Z=4 Z=4/6
more than 90 Z=3 Z=3/4
9.4 - Cutting and advance speed
The cutting speed (m/min) and the advance speed (cm2/min =
area travelled by the disk teeth when removing shavings) are
limited by the development of heat close to the tips of the teeth.
- The cutting speed is subordinate to the resistance of the mate-
rial (R = N/mm2), to its hardness (HRC) and to the dimensions
of the widest section.
- Too high an advance speed (= lowering of the saw frame) tends
to cause the disk to deviate from the ideal cutting path, produc-
ing non rectilinear cuts on both the vertical and the horizontal
plane.
The best combination of these two parameters can be seen
directly examining the chips.
Long spiral-shaped chips indicate ideal
cutting.
Veryneorpulverizedchipsindicatelack
of feed and/or cutting pressure.
Thick and/or blue chips indicate overload
of the blade.
9.5 - Blade running-in
When cutting for the rst time, it is good practice to run
in the tool making a series of cuts at a low advance speed
(= 30-35 cm2/min on material of average dimensions with respect
to the cutting capacity and solid section of normal steel with R =
410-510 N/mm2), generously spraying the cutting area with
lubricating coolant.
9.6 - Blade structure
Bi-metal blades are the most commonly used. They consist in a
silicon-steel blade backing with electron beam or laser welded
high speed steel (HHS) cutting edge. The type of stocks are clas-
siedinM2,M42,M51anddifferfromeachotherbecauseoftheir
major hardness due to the increasing percentage of Cobalt (Co)
and molybdenum (Mo) contained in the metal alloy.
9.7 - Blade type
They differ essentially in their constructive characteristics, such
as:
- shape and cutting angle of tooth
- pitch
- set
Shape and angle of tooth
REGULAR TOOTH: 0° rake and constant pitch.
Most common form for transversal or inclined cutting of solid small
and average cross-sections or pipes, in laminated mild steel and
grey iron or general metal.
POSITIVE RAKE TOOTH: 9° - 10° positive rake and constant
pitch.
positive
Particular use for crosswise or inclined cuts in solid sections or
large pipes, but above all harder materials (highly alloyed and
stainless steels, special bronze and forge pig).
COMBO TOOTH: pitch varies between teeth and consequently
varying teeth size and varying gullet depths. Pitch varies between
teeth which ensures a smoother, quieter cut and longer blade life
owing to the lack of vibration.
Another advantage offered in the use of this type of blade in the
fact that with an only blade it is possible to cut a wide range of
different materials in size and type.
COMBO TOOTH: 9° - 10° positive rake.
positive
This type of blade is the most suitable for the cutting of section
bars and large and thick pipes as well as for the cutting of solid
bars at maximum machine capacity. Available pitches: 3-4/4-6.

15
ZIP 22
Set
Saw teeth bent out of the plane of the saw body, resulting in a
wide cut in the workpiece.
REGULAR OR RAKER SET: Cutting teeth right and left, alter-
nated by a straight tooth.
Of general use for materials with dimensions superior to 5 mm.
Used for the cutting of steel, castings and hard nonferrous ma-
terials.
WAVY SET: Set in smooth waves.
Thissetisassociatedwithveryneteethanditismainlyused
for the cutting of pipes and thin section bars (from 1 to 3 mm).
ALTERNATE SET (IN GROUPS): Groups of cutting teeth right
and left, alternated by a straight tooth.
Thissetisassociatedwithveryneteethanditisusedforex-
tremely thin materials (less than 1 mm).
ALTERNATE SET (INDIVIDUAL TEETH): Cutting teeth right
and left.
This set is used for the cutting of nonferrous soft materials,
plastics and wood.
9.7.1 - CUTTING PARAMETERS
Steel Type Cutting Speed m/min. Coolant Liquid
Construction Steel 60÷80 m/min Oil Emulsion
Einsatzstahl 40÷50 m/min Oil Emulsion
Non Alloy Steel 40÷60 m/min Oil Emulsion
Vergüteter Stahl 40÷50 m/min Oil Emulsion
Steel for Bearings 40÷60 m/min Oil Emulsion
Steel for Springs 40÷60 m/min Oil Emulsion
Tool Steel 30÷40 m/min Oil Emulsion
Steel for Valves 35÷50 m/min Oil Emulsion
Stainless Steel 30÷40 m/min Oil Emulsion
Cast-Iron 20÷40 m/min Oil Emulsion
Stahleisen 40÷60 m/min Oil Emulsion
Aluminium 80÷600 m/min Kerosene
Bronze 70÷120 m/min Oil Emulsion
Hartbronze 30÷60 m/min Oil Emulsion
Messing 70÷350 m/min Oil Emulsion
Kupfer 50÷720 m/min Oil Emulsion

16
ZIP 22
Figure 1 - Base

17
ZIP 22
Figure 1 - BASE Qty
1) Sawframe Support, revolving.......................................... 1
2) Screw TE M10x45 .......................................................... 2
3) Nut M10, exagonal ......................................................... 2
4) Bearing 32007X .............................................................. 2
5) Sleeve .............................................................................. 2
6) Bushing ........................................................................... 1
7) Screw TBEI M5x16 ........................................................ 2
8) Nut GUK M35 ................................................................ 1
9) Splash Guard ................................................................... 1
10) Material Support, infeed ............................................... 1
11) Screw TCEI M8x25 ...................................................... 3
12) Round Plate ................................................................... 1
13) O-ring ID195X5.7W ..................................................... 1
14) Filter, coolant liquid ...................................................... 1
15) Tube .............................................................................. 1
16) Screw TBEI M6x20 ...................................................... 1
17) Connection 3/8”, coolant liquid .................................... 1
18) Electropump, coolant liquid ......................................... 1
19) Glass 3/8”, coolant liquid level ..................................... 1
20) Plug, coolant liquid drain .............................................. 1
21) Screw M10x20 .............................................................. 4
22) Washer M10 .................................................................. 4
23) Lever, Sawframe miter lock/unlock ............................ 1
24) Screw TCEI M8x25 ...................................................... 1
25) Washer d.18-8,5x1,6 ..................................................... 2
26) Screw TCEI M6x15 ...................................................... 1
27) Washer M6 .................................................................... 1
28) Nut M6, exagonal ......................................................... 1
29) Vice Support ................................................................. 1
30) Screw TBEI M6x10 ...................................................... 1
31) Screw TE M8x20 .......................................................... 12
32) Washer M8 .................................................................... 24
33) Nut M8, exagonal ......................................................... 12
34) Pedestal ......................................................................... 1
35) Bench/Reservoir, coolant liquid ................................... 1

18
ZIP 22
Figure 2 - Sawframe

19
ZIP 22
Figure 2 - SAWFRAME Qty
101) Sawframe .................................................................... 1
103) Bar, attachment for return spring ................................ 1
104) Shaft, sawframe articulation ....................................... 1
105) Screw TCEI M10x25 .................................................. 2
106) Screw TCEI M10x40 .................................................. 2
107) Screw TCEI M8x30 .................................................... 2
108) Screw TCEI M6x20 .................................................... 4
109) Washer M6 .................................................................. 2
110) Ring Nilos 32006X AV ............................................... 2
111) Bearing 32006X .......................................................... 2
112) Flywheel, return .......................................................... 1
113) Nut GUK M30 ............................................................ 1
114) Flywheel, motor .......................................................... 1
115) Washer, Large ............................................................. 1
116) Screw TE M12x20 ...................................................... 1
117) Screw TCEI M6x10 .................................................... 2
118) Valve 1/8” ................................................................... 2
119) Block, blade tension .................................................... 2
120) Screw M6x6 ................................................................ 2
121) Screw TBEI M5x12 .................................................... 2
122) Washer 12-5,5x0,8 ...................................................... 3
123) Blade Guard, blade-guide xed .................................. 1
124) Screw TBEI M6x30 .................................................... 4
125) Pin, short eccentric ..................................................... 2
126) Bearing 608 2RS ......................................................... 4
127) Ring S10 ..................................................................... 4
129) Sawframe Cover ......................................................... 1
130) Washer ........................................................................ 1
131) Blade ........................................................................... 1
132) Screw M6x10 .............................................................. 4
133) Bar, mobile blade-gurad ............................................. 1
134) Screw M6x15 .............................................................. 1
135) Screw TCEI M8x20 .................................................... 1
136) Block, mobile blade-guide .......................................... 1
137) Blade Guard, blade-guide mobile ............................... 1
138) Screw TBEI M6x10 .................................................... 1
139) Support, electric box ................................................... 1
140) Electric Box ................................................................ 1
141) Spring, sawframe return ............................................. 1
142) Pin, spring attachment ................................................. 1