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1.

0 GENERAL INFORMATION
The firm LGF will not be responsible for eventual damages caused by a wrong use of the machine deriving from: use for functions which are not described in this hand-book; bad or wrong maintenance; repairs which are not described in this hand-book; use of the machine in explosive places.

For any necessity or direction, apply to the nearest dealer or to the manufacturer:

Nearest Dealer:

Manufacturer:

LGF s.n.c. Via Togliatti, 81 47827-VILLA VERUCCHIO - ITALY Tel.0541/677315 - Fax.0541/678752 Int. web site: www.lgf.it e-mail: info@ lgf.it

LGF GAMMA DIGIT

EC Declaration of Conformity for Double head cutting machine Model GAMMA DIGIT Model GAMMA DIGIT SWING

The Manufacturer, L.G.F. di Mussoni Walter & C. s.n.c., Via Togliatti 81, 47827 Villa Verucchio (RN) ITALIA Tel. +39 0541 677315 fax +39 0541 678752 e-mail:@lgf.it Declares on its own responsability, that the machine with LGF brand Model GAMMA DIGIT with number.............................. Model GAMMA DIGIT SWING with number..............................

Is in conformity with the following Directives: 98/37/EC Directive (Machines Directives) and following modifications and integrations with the 98/79/EC Directive 73/23EEC Directive (Directive about the low tension) and following modifications and integrations with the 93/68EEC Directive 89/336/EEC Directive (Directive about the electromagnetic compatibility) and following modifications and integrations with the 93/68/EEC Directive

For its design and fabrication the following Rules have been enforced Harmonized rules: EN 292-.1, EN 292-2, EN 294, EN 349, EN 418, EN 1088, EN 60204-1, EN 50081-2, EN 50082-2, EN 23746,EN 31202, EN 1870-9. The machine conformity with the EC Machines Directive is tested by the test certificate of Type n................. Released by the notified Board: Fachausschlu Holz Prf -und Zertifierungsstelle im BG - Prfzert Postfach 80 04 80 D-70504 STUTTGART Villa Verucchio, the......../........./....... The Legal Representative Luciano Canuti

LGF GAMMA DIGIT

INDICE
1.0 GENERAL INFORMATION ....................................................................... Page. 1 CONFORMITY DECLARATION ................................................................ Page. 2 INTRODUCTION ....................................................................................... Page. 5 MACHINE'S IDENTIFICATION .................................................................. Page. 5 SENDING OF CORRESPONDANCE....................................................... Page. 5 OVERALL DIMENSIONS ......................................................................... Page. 6 CONTROL BOARD .................................................................................. Page. 7 TECHNICAL DATA ................................................................................... Page. 8

1.1 1.2 1.3

1.4

1.4bisTECHNICAL DATA .................................................................................. Page.8bis 1.5 1.6 CUTTING CAPACITY ................................................................................ Page 9 NOISE LEVEL .......................................................................................... Page. 9 SONOROUS EMISSION ........................................................................... Page. 10 SAFETY WARNINGS ............................................................................... Page. 11 PERSONAL SAFETY............................................... ..................................... Page. 11 MACHINE'S SAFETY.................................................................................. ...... Page. 11 MAINTENANCE SECURITY ..................................................................... Page. 12 OTHER RISKS ......................................................................................... Page. 12 MACHINE'S INSTALLATION ..................................................................... Page. 13 MACHINE'S UNLOADING ........................................................................ Page. 13

1.7

1.8 1.9 2.0 2.1

2.2 PLACEMENT ........................................................................................... Page. 13 2.3 2.4 2.5 2.6 2.7 3.0 3.1 3.2 WHAT TO DO IF THE MACHINE IS DAMAGED? ..................................... Page. 13 MACHINE'S LEVELLING ......................................................................... Page. 14 ELECTRICAL AND GROUNDING CONNECTIONS ................................. Page. 15 PNEUMATIC CONNECTION .................................................................... Page. 17 COOLING SYSTEM .................................................................................. Page. 18 USE AND ADJUSTMENTS ...................................................................... Page 19 MACHINE'S STARTING............................................................................ Page. 19 CLAMPS ADJUSTMENT ......................................................................... Page. 20
LGF GAMMA DIGIT

INDICE
3.3 PROTECTION OF THE BLADE ................................................................. Page. 22 3.4 CUTTING ADJUSTMENTS 45-90-45 (GAMMA SWING) ........................ Page. 24 3.5 CUTTING ADJUSTMENTS 90-45 (GAMMA) ........................................... Page. 26 3.6 INTERMEDIARY CUTTING ADJUSTMENT ................................................ Page. 27 3.7 BRAKE CHECK ......................................................................................... Page. 28 3.8 SENSOR ADJUSTMENT ........................................................................... Page. 30 3.9 HOW TO PERFORM CUTTINGS ................................................................ Page. 31 3.10 HOW TO PERFORM THE REDUCED CUT ............................................... Page. 31 3.11 DESCRIPTION OF COOLING SYSTEM ..................................................... Page. 32 3.12 BLADE'S ACCESS PROTECTION ............................................................ Page. 33 3.13 BLADE'S SETTING UP .............................................................................. Page. 34 3.14 ADJUSTMENT OF THE BLADE'S WAY OUT SPEED ............................... Page. 35 3.15 ADJUSTMENT OF THE BLADE'S WAY OUT ............................................. Page. 35 3.16 REPLACEMENT BELT MOVABLE HEAD ................................................. Page. 36 3.17 ADJUSTMENT BELT MOVABLE HEAD .................................................... Page. 37 3.18 WORKING TABLE ADJUSTMENT ............................................................. Page. 38 3.19 SUCTION SYSTEM .................................................................................... Page. 39 4.1 CENTRAL MANUAL SUPPORT (ON DEMAND) ........................................ Page. 40 4.2 CENTRAL PNEUMATIC SUPPORT (ON DEMAND) .................................. Page. 41 4.3 RIGHT HEAD SUPPORT WITH ROLLERS (ON DEMAND) ....................... Page. 42 4.4 AUTOMATIC REDUCED CUT MODIFICATION WITH MOVABLE SIDE SUPPORT WITH ROLLERS (ON DEMAND) .............................................. Page. 45 5.0 CHECK SLIDING AXIS .............................................................................. Page. 46 5.1 MAINTENACE CARD ................................................................................ Page. 49 5.2 ELECTRICAL AND PNEUMATIC SCHEMES ............................................ Page. 49
LGF GAMMA DIGIT

1.1 INTRODUCTION This operation and maintenance hand-book concerns the following model of machine:GAMMA DIGIT - GAMMA SWING DIGIT cutting off machine. The model GAMMA DIGIT is different from the model GAMMA DIGIT SWING for the following features: - GAMMA DIGIT has an oscillating movement of the sawhead as regards the working table from 90 to 45 - GAMMA DIGIT SWING has an oscillating movement of the sawhead as regards the working table from90 to 45 and to -45

1.2 MACHINE'S IDENTIFICATION The machine is identified through the wording on the metal plate (Fig.1) set on the base of the machine.

1.2bis APPROPRIATE USE OF THE MACHINE The machine is designed and realised with the aim of performing parallel transversal cuts with the two saws with integrated feed. The piece is loaded an unloaded manually. The machine must be used for working wood an similar materials such as plastics. In case you need to work other materials, you must agree in advance with L.G.F. and with the supplier the matter. For safety reasons all arbitrary transformations on the machine are forbidden. It is also forbidden any other use different from the expected one. LGF declines any responsibility in case of a use not in conformity of the machine. The machine is not suitable to work in the open or in those places where there is the risk of explosion. The environmental temperature admitted is from +5 to +40. The air moisture admitted is from 30% to 95%. The working place of the operator is situated in the front of the machine, where you load the pieces. These machines are designed for only one operator, eventual helpers are considered "exposed people". Maintenance of the instruction manual: it is considered integral part of the machine and therefore must be kept in good conditions until the scraping of the machine.

LGF GAMMA DIGIT

1.3 SENDING OF CORRESPONDANCE For any advice or explanation concerning the machine, please apply to LGF or to the nearest dealer, supplying with: model of the machine; matriculation number; voltage and frequency, purchasing date; name of the dealer where the machine has been purchased; information about the working to carry out; number of employment hours; number of duty hours. For a correct identification of the information concerning the machine, please supply with the data reported on the plate (Fig.1) which is set on the clamps junction-box and describes the data of the electric installation.

Fig.1

LGF GAMMA DIGIT

OVERALL DIMENSIONS

1250

4900 - 5900 - 6900 mm

LGF GAMMA DIGIT

CONTROL BOARD:

A B D

F C

Fig.1A

A B C D E F G

(Fig. 1A) (Fig. 1A) (Fig. 1A) (Fig. 1A) (Fig. 1A) (Fig. 1A) (Fig. 1A)

= PB button: temporary blocking of the clamps = P1 button: permanent blocking of the clamps and guards = P2 button: cutting execution = START button = EMERGENCY button = Three-phase main switch = Single-phase main switch

LGF GAMMA DIGIT

1.4 TECHNICAL DATA T.C.T Saw Blade 530 mm Three-Phase Motor 3HP 2800 rpm Blade Shaft Diameter ............................................................... 30 mm Sliding movable head by ball bearing Radial sliding of the blade unit Min. working pressure ............................................................... 7 bar Heads tilting .............................................................................. 90-45 Overall ................................................................. L. 4000 = (1390x5330x1350) dimensions: ......................................................... L. 5000 = (1390x6330x1350) Weight ................................................................. L. 4000 = 1200 Kg. ............................................................................ L. 5000 = 1350 Kg.

STANDARD EQUIPMENT Nr.2 TCT saw blades mm 530 Kit for TCT saw blades mm 530 Kit horizontal pneumatic clamps Spraying mist units Protection of the blades

OPTIONAL Reduced cut modification Pneumatic central support Right head support with rollers Vee cut modification for PVC Trim cut modification Dust exhaust unit

LGF GAMMA DIGIT

1.4 bis TECHNICAL DATA T.C.T Saw Blade 530 mm Three-Phase Motor 3HP 2800 rpm Blade Shaft Diameter ............................................................... 30 mm Sliding movable head by ball bearing Radial sliding of the blade unit Min. working pressure ............................................................... 7 bar Heads tilting .............................................................................. 45-90-45 Overall ................................................................. L. 4000 = (1390x5330x1350) dimensions: ......................................................... L. 5000 = (1390x6330x1350) Weight ................................................................. L. 4000 = 1200 Kg. ............................................................................ L. 5000 = 1350 Kg.

STANDARD EQUIPMENT Nr.2 TCT saw blades mm 530 Kit for TCT saw blades mm 530 Kit horizontal pneumatic clamps Spraying mist units Protection of the blades

OPTIONAL Reduced cut modification Pneumatic central support Right head support with rollers Vee cut modification for PVC Trim cut modification Dust exhaust unit

LGF GAMMA DIGIT

10 8 bis

1.5 CUTTING CAPACITY

1.5 bis ADMITTED SAWBLADES The machine can only mount blades suitable for working wood and plastic materials of the following size: blade diam. 530 mm, thickness 4,4 with 96 teeth, in HM steel, HOLE DIAM. 30 mm. Make sure that the sawblades are marked with: the name of the constructor the max. speed allowed the diameter and thickness of the blade

and that they are in conformity with the norms EN 847.1

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1.6 LEVELS OF SONOROUS EMISSION

ACOUSTIC EMISSION OF THE GAMMA DIGIT CUTTING OFF MACHINE ACCORDING TO NORMS EN27560

(Leq) Pressione acustica al posto operatore

(Lw) Livello di potenza sonora normalizzata della macchina

(Lmax) Livello sonoro massimo in lavorazione sulla S prescritta

CONDIZIONI DI FUNZIONAMENTO

dBA

dBA

dBC

93,8

109,9

<130

IN LAVORAZ.

Level of acoustic pressure at the operator working place ............. Leq 93,8.....dB(A) Level of acoustic power in working ............................................... Lw 109,9......dB(A) Max. value of instantaneous and pondered acoustic pressure at the operator working place in working inferior to ............................................................ 130 dB(C) The observations have been made with suction, in accordance with the norms: EN 1870.9 as far as the test material, the measurement conditions and the instruments EN ISO 11202 for the calculation of the values at the operator working place; EN ISO 3746 for the calculation of the sonorous power Additional safety margin: 4 dB(A).

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SONOROUS EMISSION Carrying out many activities together with the use of the machine can sometimes involve physical uneasiness and weariness . For example, being engaged with extra-working activities which require sonorous exposures involves higher risks and a lower health's defence. Working conditions like, for example, the loudness of the working environment play an important role for the health and personal comfort. Some factors which influence the real exposure level are: - the period of exposure. - the adjacent working machines - the type and characteristics of the buildings. Moreover, noise emission can be contained by: reducing the number of the machine's revolutions, a low advancing, a correct fastening of the piece, a good condition of the tools. and , above all, using the appropriate acoustic protections.

A protracted exposure over 85 dB (A) could cause health troubles. In any case, it is advisable to employ some appropriate protection systems (ex: casings, plugs)

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1.7 SAFETY WARNINGS While drawing up this hand-book, we considered all the necessary functions for a correct maintenance of the machine, getting the best use of it. Therefore read carefully through these directions before starting up the machine. This machine was built to offer the highest possible safety together with the best performances. The greatest security is in your hands. It must be kept in mind that the use of every kind of machine-tool involves some risks. PERSONAL SAFETY 1) The operator must have reached the legal age, according to the law, and must not be lacking knowledge of manufactures of aluminium machines. 2) Experience teaches that there are several objects which could cause you accidents. Take off rings, watches and eventual bracelets; fasten the sleeves round your wrists, buttoning them accurately; take off neckties which, hanging down could get entangled in the most disparate places; put up your hair with proper accessories (caps, rubber bands). Make use of suitable footwear which antiaccident regulations in all countries of the world prescribe and recommend. 3) Always make use of glasses or protective screens for your eyes. 4) Always make use of working gloves 5) Always make use of anti accident shoes MACHINE'S SAFETY 1) Pay the utmost attention before starting any work. 2) Never start the machine without controlling that all the protection coverings of cutters, betts, ecc. are properly set up. 3) Work only with all appropriate protections at their place and in perfect efficiency. 4) Make sure that the tools are perfectly balanced, sharped and accurately keyed and tight; never make use of bigger tools than the ones indicated in the technical data. 5) Never employ cracked, warped cutters. 6) The machine must be overhauled by specialized staff, acquainted with safety regulations. 7) The machine must not be left unguarded when working. Shutters and protections must be disassembled strictly when the machine is stalled and it is not working. 8) All shutters and protections provided with keys must be closed and the key is to be kept by responsible staff in suitable places. 9) Never employ benzine, solvents or other inflammables for the cleaning. Make use of commercial solvents which are not inflammable or toxic. 10)The manufacturing firm declines all responsability for the inobservance of these regulations. N.B. All disassembly and repairing operations must be carried out exclusively by authorized and qualified staff. Moreover, it is to be racommended not to carry out reparations or others which are not written in this hand-book.
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14

There are particular operations for which you must pay attention, i.e.: Do not try remove with your hands the offcuts inserted in the blade gap, when the blade has just lowered. Do not try to adjust the blocking pistons after the Start but wait until the guards ore open Arrange in a proper way the offcuts Use gloves when handling the piece for the loading and unloading.

There are particular operations in the maintenance for which you must pay attention. i.e.: Replacing the blade. Before opening the second guard, check that the blade is fully stopped. Do not make testing of the blade rotation with the guards opened. This operation must be carried out only by skilled personnel. Completely stop the machine when estracting the chips and offcuts. Do not carry out any maintenance with the machine in movement. Adjustment of the blade way out: follow the instructions at chapter 3.15 of the instruction manual. This operation must be carried out only by skilled personnel. Adjustment of the blade way out speed: follow the instructions at chapter 3.14 of the instruction manual. This operation must be carried out only by skilled personnel. Cutting adjustments, chapter 3.4: pay attention to the head body. If this is badly adjusted it comes down very quickly with the risk of crushing. This operation must becarried out only by skilled personnel. Protection of the blade: see chapter 3.3. If this is badly adjusted it comes down very quickly with the risk of crushing. This operation must be carried out only by skilled personnel Adjustment belt movable head, chapter 3.17: do not perform any testing on the belt rotation with the guard opened. This operation must be carried out only by skilled personnel.

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1.8 MAINTENANCE SECURITY Maintenance must be carried out by qualified staff. The various operations for the ordinary and extra ordinary maintenance are indicated in the last pages of this hand-book. It is compulsory to switch off the general electrical equipment, when it is necessary to adjust the machine or to disassemble any protection, by pointing out such operation through a clearly visible plaquard. An important security factor is the cleaning of the machine, of the working tables, of the floor and the surrounding places. It is very useful to read carefully through this hand-book before starting the machine: in this way you will realize that the machine has been concerned to offer the best performances together with the highest security. Encumbering and mobile objects, which could come into contact with the moving organs, are very dangerous. A certain risk factor, which is eliminable with a good technique and with a constant attention by your side, exists in every work. Before starting the machine, make sure that there are no other people carrying at maintenance operations. 1.8 bis SPECIFIC PROTECTIONS The machine is equipped with mechanical and electrical protections which fulfil to the safety and technical norms: - IP54 Electric equipment pannel with main switch with padlock - Emergency button with self-retain - Safety device for stopping the autonomous starting of the machine after a power cut. - Thermic protections at the spindle motors - Heads enclosure in plate thickness 2 mm. and window in plycarbonate - Blocking clamps with double pressure device. - Spindle motor self-braking. - Blades guards which lower before the blade goes out - Two-hands control for the cutting - Last 500 mm between the two heads to be made only keeping pressed a button. 1.9 OTHER RISKS The machine has been designed bearing in mind the safety prescriptions of various Countries. Anyway there are some risks left: - Injuries due to the contact with the tools, in the maintenance - Injuries due to the handling of the pieces during their motion - Injuries due to electric shock inside the electrical panel placed on the feeding terminal box - Injuries due to electric shock on the inverters also after having switched off the current - Dangers for the hearing due to a prolonged exposure at the machine.

LGF GAMMA DIGIT

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2.0 MACHINE'S INSTALLATION


Your cutting off machine mod. GAMMA DIGIT, will be delivered by one of your authorized carriers or directly by the dealer. Verify the conformity of your goods and their good repair.

2.1 MACHINE'S UNLOADING Before unloading the machine, free it from all those parts which, for transport or packing exigences are put on it. Therefore the machine's unloading from the transporting vehicle can be effected in the following way: 1) The machine is equipped with a special frame, which raises it from the ground. Therefore it can be easily lifted by an elevator by inserting the forks under the pedestal and balancing the weight which is totally of 1200 Kg. (Version L. = 4000) (Fig.2A) 1350 Kg.(Version L.= 5000)

2.1bis MACHINE'S UNLOADING AND MOTION

The unloading and motion operations of the machine must be carried out only by skilled personnel, trained for this kind of manoeuvres (people carrying trolleys, sling men, etc.......)

The machine must be lifter and moved in only one way (a pictogram on the machine self shows the lifting system): it is necessary the equipment as per picture 2a composed by a fork lifter min. length 1200mm) with appropriate lifting power: see the plate on the machine self. It is of absolute importance that the lifting means used have appropriate lifting power according to the weight of the machines to be moved. Move sideways and with caution avoiding oscillations and place the machine in the working area previously established. THE WEIGHT OF THE MACHINE IS: THE WEIGHT OF THE MACHINE IS: 1200 kos (4000 mm version) 1350 kos (5000 mm version)

DO NOT USE OTHER LIFTING AND TRANSPORT SYSTEMS: the timber cart or other rope systems are forbidden. Before any motion the machine must be free of whatever is not well fixed to the machine self for packaging or shipment reasons.

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17

2.2 PLACEMENT Choose the most favourable position, according to the length of the pieces to work and to the connections of the eletric and compressed air installations, for an easy maintenance. Verify the solidity of the floor surface (preferably a material that cannot be deformed, like cement) so that the frame can find a solid support. Insert the 4 antivibration feet (which are included with the machine) in the special holes on the frame of the machine. For levelling, screw or unscrew the feet (Fig.2). N.B.The machine is greased and oiled for transport. Therefore, take the grease off the working tables and the protections accurately.

2.3 WHAT TO DO IF THE MACHINE IS DAMAGED?

1) Of course, the carrier is covered by an insurance, which will fairly refund you the damages. 2) After questioning the damages, you will have to communicate it within two days by registered letter to the carrier and the dealer. 3) Make to the manufacturer a request for eventual pieces to substitute as well. Those will be forwarded to you by cash on delivery. The invoice of such pieces, together with eventual assembly expenses, must be reimbursed by the insurance company. Attention: the goods travel at the customer's exclusive risk.

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2.4 MACHINE'S LEVELLING Level the machine, controlling that it has been perfecty placed horizontally and transversally, using a spirit-level placed on the working table. Eventual level adjustments are carried out by operating on the adjusting screws A (Fig.2). Then fasten the machine at the floor by means of two expansion plugs inserted in the convenable B( Fig.2)holes which are on the pedestal back shutter (Fig.2).

Fig. 2

Fig. 2A
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19

2.5 ELECTRICAL AND GROUNDING CONNECTIONS

The electrical connection and the necessary inspections must always be carried out by a specialized electrician according to norms EN 60204-1. Make sure that the electrical installation in the factory is able to support the power of the machine and control that the main supply voltage corresponds to that of the machine. Note: the best working condition for the machine is providing with the same voltage reported on the plate in Fig.1. Yet it can also adopt itself to higher or lower working voltages in a range of endurance of +/- 5% (ex: a machine with working voltage V=380 has a range of endurance which runs from 360 to 400 volts). Out of this range, provide for the adjustment of the feeding voltage. Read the value of the total absorbed current (Amp) on the identification plate of the machine. Consult the following table to use the right wire section and to install on the machine "DELAYED INTERVENTION FUSES". Absorbed Ampere from 3 to 6 from 6 to 10 from 10 to 14 Wire Section 2,5 mm 2,5 mm 4,0 mm Delayed Fuses 10A AM 10A AM 16A AM

The machine has one external electrical connection, three phase (380 V) for the feeding of the saw motors of the drive unit. In order to connect it to the line, act as follows: Insultate electrically the machine and connect to the electric cable on the rear of the fix head a release plug for industrial tension type CE, (phases L1, L2, L3, as per picture3). Connect the green-yellow cable (ground) to the terminal (PE or marked with the symbol). Tighten accurately the presscable; check that the rotation sense of the blade is the correct one, turning on the machine as described later on. If the blades is not turning in the correct sense, you must: take off the tension to the line invert two phases try again the rotation sense that must be anti clockwise
LGF GAMMA DIGIT

20

L1 L2 L3 PE P

Fig. 3

LGF GAMMA DIGIT

21

2.6 PNEUMATIC CONNECTION

The pneumatic connection is effected by engaging in connection A (Fig.4) a flexible pipe ( mm.8) Pressure can be adjusted from O to 12 ATM, operating on grip B (Fig.4) and reading the value on pressure gauge C (Fig.4). N.B. The air pressure of the machine has to be 6/7 ATM. PAY ATTENTION: The pneumatic energy must be easily sectioned whenever you do the maintenance

Fig. 4

LGF GAMMA DIGIT

22

2.7 COOLING SYSTEM - Insert cutting oil in the suitable tank A (Fig.5). - Insert oil for cooling the pneumatic installation in the proper tank B (Fig.5), (use MOBIL ALMA 525 or similar).

B Fig. 5

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23

2.8 CHIPS EXTRACTION Dust and chips cause by the saw cut create dust clouds which can cause danger of fires or of skin deseases of brathing tract. The machine is equipped with 4 circular pipe unions to be connected to the suction installation Pipe unions: 2 80 mm 100 M3/h 1000Pa 2 60 mm air consumption depression The air speed must be at least 20m/sec. In order to assure that the dust and the chips are extracted. For the connection, if a flexible pipe is used, use antistatic and uninflammable material When you start the machine, the suction installation must compulsory activate To do that, the machine is equipped with contacts predisposed to the connection (see also electric diagram)

80

LGF GAMMA DIGIT

24

60

3.0 USE AND ADJUSTMENTS

3.1 MACHINE'S STARTING - Turn the main switch A (Fig.6) (three phase) ON. - Turn the main switch B (Fig.6) (single phase) ON. - Screen C (Fig.6) will light on automatically. Start the procedure described on instruction manual for programmer EM 22 page 10: you will have two options: ESC - (If you press this button, you enter the main menu, the test machine and the fix parameters) START - (If you press this button, the machine makes the zero procedure)

A B

Fig. 6

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25

3.2 CLAMPS ADJUSTMENT Clamps have to be adjusted accordingly to the profile to be cut operating as follows: (Mod. GAMMA SWING) - For vertical adjustment loosen release handle A (fig. 7) lifting or lowering the support C (fig.7) of piston D (fig.7) till you reach the desired position, then block the release handle A (fig.7). (Mod. GAMMA SWING) - In case of a reduced section profile loosen screw E (fig.7) and push the profile closer to piston D (fig.7) then tighten screw E (fig.7). (Mod. GAMMA SWING) - In case of a bigger section profile, loosen screw E (fig.7) and push away piston D (fig.7) to the outside of the machine till it will be possible to block the profile, lastly fix again screw E (fig.7). (Mod. GAMMA) - In case of a reduced section profile loosen release handle E (fig.7/a) and push the profile closer to piston D (fig.7/a) then tighten release handle E (fig.7/a). (Mod. GAMMA) - In case of a bigger section profile, loosen release handle E (fig.7/a) and push away piston D (Fig. 7/a) to the outside of the machine till it will be possible to block the profile, lastly fix again release handle E (fig.7/a). The machine Mod. GAMMA SWING MX is equipped with 2 horizontal clamps for each cutting unit. N.B. Make sure that during positioning of the clamps the end parts G (fig.7) once opened skill the profile.

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26

E G

C A Fig. 7

E G

C A Fig. 7a

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27

3.3 PROTECTION OF THE BLADE - The protection of the blade A (Fig.8a) is operating by blocking the profile that is by pressing the button PB "TEMPORARY BLOCKING" (Fig.8), by pressing the button P1 "PERMANENT BLOCKING" (Fig.8) the motors will start automatically. In order to lift the protection A (Fig.8a), after the working cycle press the button PB (Fig.8). - The speed of descent of the protection can be adjusted by operating on valve E (Fig.8b), using a screw driver and turning it anticlockwise to increase the speed or clockwise to decrease the speed. - The speed of rise of the protection can be adjusted by operating on valve G (Fig.8b), using a screwdriver and turning it anticlockwise to increase the speed or clockwise to decrease the speed.

PAY ATTENTION ! If the protections are not closed, the blades do not come out.

PB P1

Fig. 8

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Fig. 8 a

Fig. 8 b

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3.4 CUTTING ADJUSTMENTS 45-90-45(GAMMA SWING) It may happen that due to some shocks, vibrations, you may miss the perfect alignment. In this case it is recommended to operate as follows (fix head): 45 INNER CUTTING Take off head's rear protection Loosen nut B (Fig.9) which fixes grub screw A (Fig.9) by means of correspondent spanner. Turn bolt A (Fig.9) to clockwise direction to decrease cutting angle or to anticlockwise direction to increase cutting angle. Cut a fragment of profile and place it against the inside of a 45steel precision square. 45 EXTERNAL CUTTING Take off head's rear protection Loosen nut C (Fig.9a) which fixes bolt D (Fig.9a) by means of correspondant service spanner. Turn bolt D (Fig.9a) to clockwise direction to reduce cutting angle or turn the screw to anti-clockwise direction to increase cutting angle. Cut a fragment of profile and place it against the inside of a 45steel precision square to check perfection of the cutting. 90 CUTTING Take off head's rear protection Insert spanner A (Fig. 9a) in the appropriate place situated on shaft B (Fig. 9a) of piston C (Fig. 9a). Insert spanner D (Fig. 9a) inside nut E(Fig. 9a) situated on shaft B (Fig.9a) of piston C (Fig. 9a) by loosening it. Turn shaft B (Fig.9a) to the left to move the cutting angle to the right, or turn shaft B (Fig. 9a) to the right, in order to move the cutting angle to the left. Cut a fragment of profile and place it against the inside of a 90 steel precision square to check perfection of the cutting. Block nut E (Fig.9a) with the spanner D (Fig.9a) Assemble the head's rear protection. The piston E (Fig. 9) is equipped with speed adjusters F and G,H and I (Fig.9).

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H D C F G I A

E B Fig. 9

A D

C E Fig. 9a

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3.5 CUTTING ADJUSTMENTS 90- 45 (GAMMA) It may happen that due to some shocks, vibrations, you may miss the perfect alignment. In this case it is recommended to operate as follows: 90 CUTTING Take off head's rear protection Loosen nut B (Fig.10) which fixes screw A (Fig.10) by menas of correspondent spanner. Turn screw A (Fig.10) to clockwise direction to increase cutting angle or turn the screw to anticlockwise direction to reduce cutting angle. Cut a fragment of profile and place it against the inside of a steel precision square. Lock nut B (Fig.10) by means of a key C (Fig.10) 45 CUTTING Take off head's rear protection Loosen nut C (Fig.10) which fixes screw D (Fig.10) by means of correspondant service spanner. Turn screw D (Fig.10) to clockwise direction to reduce cutting angle or turn screw to anti-clockwise direction to increase cutting angle. Cut a fragment of profile and place it against the inside of a steel precision square to check perfection of the cutting. Lock nut C (Fig.10) by means of correspondent spanner. The piston E (Fig.10) is equipped with speed adjusters F e G (Fig.10). A D B C F

E G

Fig. 10

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3.6 INTERMEDIARY CUTTING ADJUSTMENT The machine is equipped with a graduated sector A (Fig.11) on wich are reported all cutting angles that machine can perform. In order to perform intermediate cuts operate as follows: - Loosen screw B (Fig. 11) which locks pointer C (Fig.11) by means of service spanner D (Fig.11). Usually the pointer is in rest position pointed to the left on the movable head and pointed to the right on the fixed head. - Move pointer C (Fig.11) to the expected position. - Lock screw B (Fig.11) by means of correspondent service spanner and make the positioning.

B Fig. 11

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3.7 BRAKE CHECK

In case the mobile head brake doesn't block perfectly act as follows: - Remove the guard A (Fig.12). 1st SOLUTION - Take off screw B (Fig.13) with key C (Fig.13), setting free the unibol E (Fig.13) from the support F (Fig.13). - Loosen screw D (Fig.13) and turn to anti-clockwise direction the unibol E (Fig.13) untill desired position. - Block screw D (Fig.13) and fix again the unibol E (Fig.13) with key B (Fig.13), to the support F (Fig.13). 2st SOLUTION - Take off screw B (Fig.13) with key C (Fig.13), blocking the unibol E (Fig.13) to the support F (Fig.13). - Fix screw B (Fig.13) that found it self in position 1(Fig.13), of the support F (Fig.13), in position 2. If not enough, move it till position 3. - Tighten screw B (Fig.13) blocking the unibol E (Fig.13) to the support F (Fig.13). 3rd SOLUTION - Loosen screw B (Fig.13) with key C (Fig.13), setting free the unibol E (Fig.13) from support F (Fig.13). - Loosen screw H (Fig.14) fixing the support F(Fig.13). - Take off the support F (Fig.13) from hexagon G (Fig.14), where it is fixed. - Fix the support F (Fig.13) in the new position of hexagon, G (Fig.14), giving to it more tilting to the bottom, by tightening screw H (Fig.14). - Tighten screw B (Fig.13) blocking the unibol E (Fig.13) to the support F (Fig.13). - Fit the guard again.

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Fig. 12

1 2

D B C E

3 F

Fig. 13

G H

Fig. 14
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3.8 SENSOR ADJUSTMENT For a correct reading of sensor A (Fig.15) on the magnetic band B (Fig.15) make sure that the distance between them is not lower than 0,5 mm nor more than 1,5 mm and that the sensor is perfectly aligned to the magnetic band. In case this do not happen, act as follows: Adjustment of the distance between sensor and magnetic band: - Loosen the screws C (Fig.15) Lift or lower the support D (Fig.15) until you reach a distance included in the a/m values - Tighten the screws C (Fig.15) Alignment sensor-magnetic band: - Loosen the screws F (Fig.15) - Adjust the bracket sensor holder E (Fig.15) so that it is aligned with the magnetic band - Tighten the screws F (Fig.15).

C D

B A

E F Fig.15

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3.9 HOW TO PERFORM CUTTINGS SEE INSTRUCTION MANUAL FOR "PROGRAMMER EM 22" Page 15.

3.10 HOW TO PERFORM THE REDUCED CUT SEE INSTRUCTION MANUAL FOR "PROGRAMMER EM22" Page15.

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3.11 DESCRIPTION OF THE COOLING SYSTEM The machine, when cutting, has a cooling system through spray mist unit A (Fig.16) which automatically comes into function when the blade comes out. Lubrication oil is placed in the tank B (Fig.16) previously described. Check regularly (every 24 working hours) that oil is to right level (use only coolant of the type: emulsifying lubricating coolant ( atoxic and biodegradable) exclusively cutting oil).

B P1

P2

Fig. 16

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3.12 BLADE'S ACCESS PROTECTION To reach the blades, operate as follows: Check that main switch A (Fig.17) is in on off position. Remove screws B (Fig.17a) holding carter C (Fig.17a). N.B. Before removing carter C (Fig.17a) make sure that the blade is steady.

Fig. 17

Fig. 17a

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3.13 BLADE'S SETTING UP To set up the blade A (Fig.18) operate with the two service spanners B and C (Fig18). - Insert spanner B (Fig.18) in the appropriate seat placed on the top of the motor shaft. - Put spanner C (Fig.18) in the appropriate slot of nut D (Fig.18), then keep steady spanner B (Fig.18), loosen nut D (Fig.18) turning it to clockwise direction for the mobile head (right), to anticlockwise direction for the fix head (left), through spanner C (Fig.18). - Take off nut D (Fig.18) and flange E (Fig.18). - Mount the blade A (Fig.18) making sure that the parts in contact are perfectly cleaned, in order to avoid dangerous vibrations. - Assemble flange E (Fig.18) and nut D (Fig.18) again, blocking through spanners B and C (Fig.18). - Make sure that blades are sharpened and in good order.

Fig. 18

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3.14 ADJUSTMENT OF THE BLADE'S WAY OUT SPEED To adjust speed of the blade's way out operate as follows: - Turn knob A (Fig.19) situated on valve B (Fig.19) to clockwise direction to reduce the speed or to anticlock wise direction to increase blade's speed.

3.15 ADJUSTMENT OF THE BLADE'S WAY OUT To adjust the cutting capacity ( blade's way out) operate as follows: - Loosen screw C (Fig.19) by means of spanner D (Fig.19), blocking the micron support E (Fig.19). - Move manually the micron E (Fig.19) to the right in order to increase the cutting capacity, or to the left in order to decrease the cutting capacity. You can read the measure on the metric ruler F (Fig.19).

A B

Fig. 19

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3.16 REPLACEMENT BELT MOVABLE HEAD To replace the belt A (Fig.20) act as follows: - Unscrew the screws B (Fig.20) with spanner C (Fig.20) - Drill the two ends of the belt A (Fig.20) - Insert the two ends of the belt between the support D (Fig.20) and shagreened plate E (Fig.20) - Insert the two screws B (Fig.20) and block with spanner C (Fig.20).

C Fig. 20

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3.17 ADJUSTMENT BELT MOVABLE HEAD The adjustment of the belt it comes by positioning the free pulley which is placed on the rear part of the machine (right side). To obtain the adjustment pls; follow those operations: - Remove the protection cover by unscrewing the screws which are placed on the lateral side. - Unloose the nut A (Fig.21) by a convenable key B (Fig.21). - Insert the key C (Fig.21) in the hole D (Fig.21). - By unloosing the screw E (Fig.21) you will get the loosening of the belt F (Fig.21). - By tighteening the screw E (Fig.21) you will get the tensioning of the belt.

C A E B

Fig. 21

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3.18 WORKING TABLE ADJUSTMENT Whenever blade's rotation centre is not perfect pls operate as follows: - Loosen nr. 3 screw B (Fig.22) by means of correspondent spanner - Then lower or lift working table D (Fig.22) operate by means of spanner A (Fig.22) by turning screw C (Fig.22) to anticlockwise direction to lower the working table or to clockwise direction to lift working table.

B Fig. 22

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3.19 SUCTION SYSTEM The machine is featured in order to be connected with a vacuum for chips and smokes.

Fig. 23

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4.1 CENTRAL MANUAL SUPPORT (ON DEMAND) The machine can be equipped with the manual central support with nr. 1roll A (Fig.24).

Fig. 24

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4.2 PNEUMATIC CENTRAL SUPPORT (ON DEMAND) The machine can be equipped with the pneumatic central support. It may happen that due to shocks or vibrations you loose the perfect alignment with the support tables of the profile, in this case act as follows: - Loosen grain A (Fig. 25) by spanner B (Fig.25), placed in the support C (Fig.25) of piston D (Fig.25). - Place a square over the two tables F (Fig.25) of the machine. - Lift piston D (Fig.25) untill the support table E (Fig.25) touch the square. - Block the grains A (Fig.25) with the appropriate spanner. - The central support comes into function normally when you perform cutting superior to 3 mtrs. NB. Pay attention that during its movement, the mobile head does not damage the manual central support

A B

C Fig. 25

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4.3 RIGHT HEAD SUPPORT WITH ROLLERS (ON DEMAND) The machine can be equipped with side support with rollers, to assemble it operate as follows: 1- Fix the support A (Fig.26) with the appropriate screws B (Fig.26) on the right side of the mobile head. 2- Fix the connection C (Fig.26a) to the extension guide D (Fig.26a) blocking the screws with the spanner. 3- Fix the connection C (Fig.26b) to the guide E (Fig.26b) of the machine, blocking the screws F (Fig.26b) with the spanner G (Fig.26b). 4- Place a square over the two guides, checking their linearity, then blocking the support H (Fig.26c) of the mobile guide D (Fig.26b) with spanner I (Fig.26c). 5- Align the fence L (Fig.26d)and the vertical rollers M (Fig.26e) to the front plan profile support of the mobile head, checking through a precision square. If not aligned, operate as follows: FENCE - Loosen screw O (Fig.26d) with spanner P(Fig.26d) - Move forward or backward the fence L (Fig.26d) until it is perfectly aligned - Block the screw O (Fig.26d) with the appropriate spanner. VERTICAL ROLLERS Loosen nut Q (Fig.26e) of the roller M (Fig.26e) with the appropriate spanner. Move forward or backward the roller M (Fig.26e) until its perfect alignment. Block nut Q (Fig.26e) with its spanners. Align the horizontal rollers N (Fig.26e) to the support profile of the mobile head, checking through a precision square. If not aligned, operate as follows: Loosen grains R (Fig.26e) with the appropriate spanners. Turn the grain S (Fig.26e) with the appropriate spanner T (Fig.26e) to clockwise direction in order to lift the roller, to anticlockwise direction to lower the roller. Block the grains R (Fig.26e) with the appropriate spanner.

6-

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Fig. 26

Fig. 26a E C

G D F Fig. 26b

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Fig. 26c

L Fig. 26d N T M

Q R Fig. 26e

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4.4 AUTOMATIC REDUCED CUT MODIFICATION WITH MOVABLE SIDE SUPPORT WITH ROLLERS ( ON DEMAND ) The machine can be equipped with the automatic reduced cut modification c/w movable side support with rollers. For its adjustment and assembling, operate as per par.5.3 page 42 (Fig.27). The engine is equipped with a piston A (Fig.27a) for the movement of the aluminium profile. The piston A (Fig.27a) is equipped with speed adjusters B and C (Fig.27b).

Fig. 27

Fig. 27a

Fig. 27b

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5.0 CHECK SLIDING AXIS In case of uncorrect positioning of the mobile head, the anomaly can be caused by different components, that must be checked as follows, in order to restore or replace the same. DRIVE UNIT 1Check that the drive unit A (Fig.28) is fed, looking at the display which must show the symbol if it does not appear, check that connectors C (Fig.28) and D (Fig.28) are well connected. Check that the programmer A (Fig.28) starts the drive unit by pressing F6 from the main menu in order to enter the test machine. In the screen "outputs description" go with the cursor on line 9 and press START. On the display of the drive unit B (Fig.28) must appear the symbol if it does not appear check that connectors C (Fig.28) and D (Fig.28) are well connected and repeat the whole procedure. If during the positioning the machine blocks itself, check on the display B (Fig.28) the number which appears. If it is different from turn off the machine

2-

3-

and wait approx 10 min and then turn the machine on. 4- In case on the screen appears the message EMERGENCY, in order to verify that the damage is due from the driver unit, disconnect the wires 9 and 10 of the "inputs connectionscheme" and join them. If the message of EMERGENCY doesn't disappear, this means that the damage is in the drive unit. If after all the a/m checks you have seen some anomaly in the drive unit you must replace it as follows: disconnect the connectors C (Fig.28) and D (Fig.28), connector C (Fig.28) by pressure and connector D (Fig.28) by unscrewing the two screws by screwer E (Fig.28). take off the screws F (Fig.28) with spanner G (Fig.28). E B D C

F
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CONVERTER Check if during the movement of the head, you see on the video the measure changing according to the position, if this does not happen, this may mean that the converter is faulty and therefore you should replace it. In order to replace it take off connectors B (Fig.29) and C (Fig.29) and the screw D (Fig.29)

A D

Fig. 29

MAGNETIC STRIP Check the correct positioning between the magnetic strip and the sensor (see page.30).

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PROGRAMMER If the programmer stops working,check the fuses B (Fig.30) and C (Fig.30). The fuse C (Fig.30) is situated inside the pannel on the rear re: D (Fig.30) near to the plug socket E (Fig.30). Check that connectors F- G -H (Fig.30) are well connected, check that the leds I (Fig.30) placed on the pannel D (Fig.30) of the programmer are all lighted on. In case the problem continues also after all this checks, replace the programmer by extracting it from its seat after having taken off the connectors F-G-H- (Fig.30) and unscrewed the screws L (Fig.30).

L A D

H G F MOTOR In case of damage at the motoreducer and replacement, take off the screws from the plate A (Fig.31) and take off all the motoreducer group along the axis of shaft B (Fig.31), then disconnect electrically it by opening the terminal box C (Fig.31). Fig. 30

A B C

Fig. 31
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5.1 MAINTENANCE CARD


PAY ATTENTION! before any maintenance operation cut the electric an pneumatic power. Read carefully the instruction manual at chapter 1.7 (safety warnings). The under mentioned operations must be carried out only by skilled personnel. Check every morning the tank in case of condensate deposit D (Fig.32) (To let out the condensate press the botton situated on the bottom of the tank). Check every day all the safety devices, like the emergency control an the working sequence: blocking of the piece-guards lowering. Check regularly the level of the oil in the tank E (Fig.32).

Fig. 32

PAY ATTENTION: Before making any cleaning operation take off the electric and pneumatic energy. Clean periodically (every 15/20 days) the sliding bars ank keep them lubricated with grease or oil, to avoid that scrapers placed to protect the ball bush bearing run on areas of the bar without lubrication.

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5.1 bis SELF-BRAKING MOTOR The machine is equipped with a special self braking motor on the head motors. The tool is braked soon after having activated the motor switch or the emergency switch. The asyncronic motor with external ventilation, type of protection IP 54, is equipped with electromagnetic brake with disc. Also the bearings are at watertight seal lubricated forever. Any intervention on the motor must be carried out by skilled personnel. Aircore of the electromagnet picture 4.2 Restore the distance (4) between the electromagnet body an the mobile core in case the braking power decreases. The wear limit of the friction material is 3 mm. (5). The braking efficiency reduction can be noticed from the increase of the time needed by the shaft to fully stop. The braking couple can be restored as follows: take off the protection cover insert an hexagonal spanner in the seat, on the end of the shaft (1) to avoid the rotation. screw progressively the nut (8) until you annul the aircore without forcing unscrew the nut (8) by half round check that the distance (4) (aircore) is within the limits indicated: 0,1 - 0,3 mm. Make some testing to verify the correct functioning The mechanical release is obtained by unscrewing the nut (8), increasing the aircore by 1 mm. more or less.

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5.2 ELECTRICAL AND PNEUMATIC SCHEMES

PNEUMATIC INSTALLATION: Check the oil level and, if necessary, replace it with the following oils: AGIP, OSO15 ROL OIL, LR10 ESSO, NUTO H15 MOBIL, ALMO 525

5.2 bis MACHINE SCRAPING At the end of the machine life do not disperse any part of it in the environment. In case you decide not to use anymore this machine because obsolete or irreparably broken, proceed with the off duty, so that it cannot be used anymore and does not represent a anger. Disconnect the machine from the electric an pneumatic net. Seal the machine with a hardy packaging and operate in conformity with the Country norms. In any case take off the coolant, block the movable parts and take off the tools an the cutting parts as well as the electric cables.

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LEFT HEAD

A =Blocking valve B = Material support (OPT) C = Guard D = Clamps E = Blades way out F = Tilting G = Double pressure device H = Adjustment screw low pressure clamps

C D

E F

H G

A RIGHT HEAD B C A =Tilting B = Blade way out D C = Brake (OPT) D = Clamps E = Guard E F = Blocking valves G = Double pressure device H = Adjustment screw low pressure clamps F G
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LEFT HEAD GAMMA SWING G

E D C B A A= B= C= D= E= F= G= Left Head Material Support Left Head Left Guard Left Head Left Clamps Blade Way Out Int. Tilting Ext. Tilting Double Pressure Device

RIGHT HEAD GAMMA SWING G A= B= C= D= E= F= G= Guard Clamps Brake Blade Way Out Int. Tilting Est. Tilting Double Pressure Device

B C F E D

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G = Blocking valve

G D E

B A C A = Reactivation Button B = Thermic Adjustment Motor Protector C = Screwdriver for Thermic Adjustment D = Fuse Holder E = Remote Control Switches
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ENGLISH

GAMMA DIGIT GAMMA DIGIT-SW


INSTRUCTIONDIGIT LGF GAMMA MANUAL
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