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Thomas ZIP 29 User And Maintenance Manual

Manual metal bandsaw
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MANUAL METAL BANDSAW
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Rev.1 del 15.04.2021 (Added data / wiring diagram for 1PH 230V version)
Information contained in this manual < ORIGINAL INSTRUCTIONS > is produced by the manufacturer.
User's Manual – Mod. ZIP 29 HB (2016)
Thomas Metal Bandsawing Machine - Mod. ZIP 29
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  • Page 1 Thomas Metal Bandsawing Machine - Mod. ZIP 29 ’ ’ MANUAL METAL BANDSAW – – Fig 2 – picture showing Zip 32 DA Figura 1 - picture showing Zip 29 HB Rev.2 del 15.11.2021 (Updated blade speed for 1PH 230V version) Rev.1 del 15.04.2021 (Added data / wiring diagram for 1PH 230V version)

  • Page 2: Table Of Contents

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 CONTENTS INFORMATION ON USER’S MANUAL ......................4 SIGNS ON THE MACHINE ..........................4 MANUFACTURER, MACHINE DETAILS and DECLARATIONS ..............4 MANUFACTURER ............................4 DISTRIBUTOR ..............................5 MACHINE DETAILS ............................5 ‘CE’ PLATE ..............................5 CONTENTS of “CE”...
  • Page 3 Thomas Metal Bandsawing Machine - Mod. ZIP 29 11.1 GENERAL ADVISES ............................ 38 11.2 CHECK EFFICIENCY OF SAFETY DEVICES ................... 39 11.2.1 EMERGENCY PUSH-BUTTON......................40 11.2.2 INTERLOCKING ON THE SAWFRAME COVER ................40 11.3 ADJUSTMENTS ON THE MACHINE ......................41 11.3.1...

  • Page 4: Information On User's Manual

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 INFORMATION ON USER’S MANUAL  This manual is to be regarded as integral part of the Thomas Bandsawing Machine “ZIP 29” (further named “machine”) built by Sthemma Srl (further named “manufacturer”).  The manual is an essential tool for the use and maintenance of the machine. It is law mandatory and for the use and maintenance of the machine.

  • Page 5: Distributor

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 DISTRIBUTOR  Name: _____________________________________________  Address: _____________________________________________  Tel.: _____________________________________________  Fax: _____________________________________________ MACHINE DETAILS  Machine Type: METAL BANDSAWING MACHINE  Model: ZIP 29  Year of Construction: 2016  Weight of the machine: 215 kg These details are to be found on the machine ‘CE’...

  • Page 6: Contents Of "Ce" Certificate Of Conformity

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 CONTENTS of “CE” CERTIFICATE OF CONFORMITY STHEMMA SRL Via Monte Cimone, 1 36010 ZANE’ (VI) - ITALIA Partita I.V.A. IT03753910243 We declare under our own responsibility that the machine Type: Metal Bandsawing Machine...

  • Page 7: Acoustic Emission

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 Place: manufacturer’s factory ACOUSTIC EMISSION According to Regulation EN ISO 4871 e EN ISO 16093 A vuoto (dB) In taglio (dB) Weighted Acoustic Power Level A (Lwa) Weighted Acoustic Pressure Level A at working place (Lpa)

  • Page 8: Maintenance

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  Guarantee includes the replacement or repair of the faulty part (component, machine or part of it) with the exception of dismounting, mounting and shipment costs.  The replacement of such a part does not lead to a renewal of the guarantee of the machine excepted in case of replacement of the complete machine.

  • Page 9: Spare Part Request

    See Chapter SPARE PARTS. GENERAL DESCRIPTION OF THE MACHINE Bandsawing machine THOMAS ZIP 29 is a manual horizontal bandsaw with swing sawframe for easy mitre cutting. Single mitre 0-60° R. Optional ‘DA’ hydraulic controlled sawframe downfeed. The machine is made up of the following assemblies: Sawframe, Vice, Base, Electric Box and Control Panel.

  • Page 10: Sawframe

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 4.1.2 SAWFRAME Part of the machine holding operating parts (gear-box and flywheels), blade tension and blade guides. Refer to fig. 2-4. 1) Sawframe. 2) Motor and Gear-box. 3) Lock Lever for mobile blade-guide.

  • Page 11: Vice

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 4.1.3 VICE Material clamp during cutting by hand wheel and quick lock lever. The Vice can be moved sideways right and left allowing mitre cutting. Refer to fig. 3-4. 1) Base. 2) Revolving Arm supporting the sawframe.
  • Page 12 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 12...

  • Page 13: Base

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 4.1.4 BASE Metal steel plate base supporting the revolving arm, vice and bar stop. Housing for coolant liquid Tank and Electropump. Refer fig. 4-4. 1) Metal Work. 2) Coolant liquid Outlet. 3) Attachment for material support.

  • Page 14: Electric Box And Control Panel

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 4.1.5 ELECTRIC BOX and CONTROL PANEL Refer to fig. 5-4. 1) Electric Box (plastic). 2) Luminous Push-Button for machine stand-by; when lit up the machine is electric energized and ready for use.

  • Page 15: Technical Details

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 TECHNICAL DETAILS TECHNICAL DATA  Electric Motor controlling blade speed three-phase 400V ..kW 0,55 - 1,1  Electric Motor controlling blade speed single-phase 230V ..kW  Electropump ................kW 0,06 ...

  • Page 16: Interactions Between Machine And Operator

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 Voltage Unbalance for three-phase voltage supply Both inverted sequence and zero sequence should not be over 2% of voltage direct sequence. Voltage Pulsations Voltage pulsations should not last longer than 1,5 ms by up and down time included between 500 ns and 500 µs with peak value not over 200% of the efficient value of nominal voltage supply.

  • Page 17: Machine Working Place

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 Machine Operator Qualified worker properly formed on the machine, capable to operate on the machine and carry out the following operations a) Check safety devices before starting the machine; b) Load and Discharge the stock material;...

  • Page 18: Description Of The Working Place

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 DESCRIPTION OF THE WORKING PLACE 6.3.1 CONTROL PLACE Control place (1 fig. 2-6) is located in front of the control panel (2 fig. 2-6), on the front side of the machine. From this position the operator starts, stops and drives the machine, pulling down the sawframe to cut the material, opens and closes the vice.

  • Page 19: Suitable Use And Unsuitable Use

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 SUITABLE USE and UNSUITABLE USE  The Use of the machine other than prescribed by the manufacturer might lead to dangerous events for people safety and risks of serious accidents. The machine itself can be damaged.

  • Page 20: Technical Data

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  For the machine to be used in a proper and safety way, roller tracks should be provided to support the stock material (these can be delivered from the manufacturer’s optional accessories/equipment sales list).

  • Page 21: General Advises On Safety And Prevention

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  Use contrary to the local or country laws.  Lack of prescribed maintenance.  Modification or intervention non authorized.  Use of non original or non specific parts for the model at hand.

  • Page 22: Guards, Protection Devices And Signs

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  The machine should be used for the purpose which it has been designed for (see chapter SUITABLE USE AND USUITABLE USE).  It is forbidden to eliminate and/or remove the guards and the devices installed on the machine.
  • Page 23 Thomas Metal Bandsawing Machine - Mod. ZIP 29 g) The electric installation makes sure the protection against electric shock, direct and indirect contacts as prescribed by the regulation EN 60204-1; also, it has been tested successfully to the examinations provided by paragraph. 18 of the regulation.

  • Page 24: Safety Signs Attached To The Machine

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 SAFETY SIGNS ATTACHED TO THE MACHINE Labels applied to the machine. 1) Danger : arms crushing. 2) Danger : hands cutting. 3) Danger : electric shock. 4) Attention: do not obstruct coolant liquid top drain hole.

  • Page 25: Remaining Risks

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 5) Forbidden : maintenance/lubrication while parts in motion. 6) Forbidden : removal of safety devices. 7) Obligation : wear protection gloves. 8) Obligation : wear acoustic protection devices. 9) Obligation : wear protection glasses.
  • Page 26 Thomas Metal Bandsawing Machine - Mod. ZIP 29 DANGEROUS AREA “A” (Vice) 1.3 – Mechanic Danger – Appraoch of a mobile element to a stationary part Possible Consequences Danger: hands crushing as the vice locks the stock material – between mobile and fixed parts of the vice on its movement to lock the stock material –...
  • Page 27 Thomas Metal Bandsawing Machine - Mod. ZIP 29 Loading or Discharge of the stock material on the roller tracks – Stock material moving on the roller tracks. Risk Frequency Risk is there all the time during the use of the roller tracks.
  • Page 28 Thomas Metal Bandsawing Machine - Mod. ZIP 29  Danger : projection of blade parts or material being cut: in case of blade breakage or chips / swarf projection from the stock material.  Danger : hands or fingers contact with hot parts caused by blade stock material overheating.
  • Page 29 Thomas Metal Bandsawing Machine - Mod. ZIP 29 Operator Dangerous event Contact with the steel brush. Risk Frequency Risk is there all the time during the machine use – cleaning or brush replacement. Operator’s Risk Hands injury.  Considerations on Remaining Risk The risk is there just in case of lack of attention or operator’s carelessness, or lack of...

  • Page 30: Personal Protection Devices

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  After the cut is completed, particularly if stock material is a large one, material may fall off the machine or roller tracks.  Risk Frequency Risk is there all the time during machine use.

  • Page 31: Moving

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 Obligation: wear protection helmet During moving and scrap. Obligation: wear acoustic protection plugs During machine use. MOVING GENERAL ADVISES INOBSERVANCE TO THESE ADVISES, WILL RAISE THE MANUFACTURER FROM ANY RESPONSIBILITY IN CASE of ACCIDENT, DAMAGE or MACHINE MALFUNCTIONING.

  • Page 32: Moving The Machine With Fork Lift Truck

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  High Temperature alterations or minus 0° C for more than 72 hours may cause damages to electric equipment. MOVING THE MACHINE WITH FORK LIFT TRUCK Machine Status: Machine ready for moving.
  • Page 33 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 33...

  • Page 34: Installation Of The Machine

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 INSTALLATION OF THE MACHINE 10.1 GENERAL ADVISE INOBSERVANCE TO THESE ADVISES, WILL RAISE THE MANUFACTURER FROM ANY RESPONSIBILITY IN CASE of ACCIDENT, DAMAGE or MACHINE MALFUNCTIONING.  The installation of the machine should be carried out by qualified technicians only and in perfect psycho-physical conditions.

  • Page 35: Anchorage Of The Machine

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 10.4 ANCHORAGE OF THE MACHINE Machine Status: Machine set up on the installation place. Operators: n. 1 mechanic worker a) Referring to the drawing (fig. 1-10), provide fastening and guys to be anchored on the floor.
  • Page 36 Thomas Metal Bandsawing Machine - Mod. ZIP 29  The manufacturer delivers the machine without any current plug: the user should connect a proper plug bearing in mind that the electric circuit of the machine is a three-phase 5 cables with neutral;...

  • Page 37: Mounting Parts And Accessories Separetely Delivered

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 10.6 MOUNTING PARTS AND ACCESSORIES SEPARETELY DELIVERED Machine status: Machine installed. Operator: N. 1 mechanic worker  Mount bar stop Rod (1 fig. 3-10).  Mount and align the stock material support (2 fig. 3-10) to the left side of the base.

  • Page 38: Use Of The Machine

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 USE OF THE MACHINE 11.1 GENERAL ADVISES  The machine working area (area 1 fig. 1-6) is a dangerous area and anybody accessing the area is to be considered “exposed" to risk. Serious risk injury.

  • Page 39: Check Efficiency Of Safety Devices

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  When the machine is working, parts in motion should not be touched in any way, guards should not be removed, cleaning or maintenance operations should not take place. Do not remove swarf...

  • Page 40: Emergency Push-Button

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 Operator: N. 1 operator. ATTENTION Every time, before starting the machine, it is compulsory to check the safety devices as follows: 11.2.1 EMERGENCY PUSH-BUTTON.  Check the efficiency of the emergency push-button (1 fig. 2-11) located on the control panel.

  • Page 41: Adjustments On The Machine

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 luminous push-button <READY> should turn out and and if you press the trigger switch (3 fig. 2-11) the blade should not start. To start again the machine you need to close the sawframe cover and press the button <READY> (2 fig.

  • Page 42: Adjustment Of Blade-Guide Blocks

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  Turn the hand wheel till the index gets to the green area (2 fig. 4-11), or against the mechanical stop (3 fig. 4-11). NOTE If the machine remains unused, it is advised to loosen the blade tension.

  • Page 43: Vice Adjustment

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 NOTE If you need to replace the blade, refer to chapter BLADE REPLACEMENT. a) Raise the sawframe to the top position. b) First adjust the mobile blade-guide pad (1 fig. 6-11) use the key 2 and leave a gap 0.05 mm between the pad and the blade.

  • Page 44: Adjustment Of The Cutting Angle (Mitre)

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 Vice locking Quick lock Lever (2 fig. 7-11) can be pulled to hold firmly the stock material in the vice; first apporach the vice with the hand wheel (3 fig. 7-11) leaving 3 - 4 mm clear from the stock material.

  • Page 45: Blade Replacement

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 11.3.5 BLADE REPLACEMENT a) Raise the sawframe to the top position. b) Release the blade tension by turning the hand wheel (1 fig. 9-11) anti-clockwise. c) Open the sawframe cover (2 fig. 9-11) by releasing the black plastic knobs (3 fig. 9-11).

  • Page 46: Start And Use Of The Machine

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 11.4 START AND USE OF THE MACHINE ADVISE At the beginning of each working shift, before starting the machine, it is compulsory to check the safety devices (see chapter CHECK-UP OF SAFETY DEVICES EFFICIENCY).

  • Page 47: Working Cycle

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 11.4.2 WORKING CYCLE Before using the machine, make sure that all preparation and adjustment of the machine have been completed. See chapter ADJUSTMENT OF THE MACHINE. 11.4.3 DESCRIPTION OF THE CUTTING CYCLE a) Vice close by hand wheel.
  • Page 48 Thomas Metal Bandsawing Machine - Mod. ZIP 29 a) Make sure that the emergency push-button (1 fig. 12-11) is released; if it is still engaged the machine will not start. b) Turn the blade tension hand wheel (2 fig. 12-11) clockwise until the safety micro-switch button is pressed down.

  • Page 49: Cutting Cycle With Option "Hb" Controlled Sawframe Downfeed

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 “HB” 11.4.5 CUTTING CYCLE with OPTION CONTROLLED SAWFRAME DOWNFEED Vice close by hand wheel. Sawframe gravity downfeed hydraulic controlled and cut. Manual sawframe lifting. Vice opening by hand wheel. 1. The hydraulic regulator (1 fig. 13-11) controls the sawframe gravity downfeed speed. The...

  • Page 50: Maintenance Of The Machine

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 Fig. 14-11 MAINTENANCE OF THE MACHINE 12.1 GENERAL ADVISES Maintenance operations are classified in daily, weekly, monthly and biannual. Bear in mind that lack of maintenance determine a poor performance and a shorter machine life.

  • Page 51: Regular Maintenance

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  For all the works which may be dangerous for the eyes, wear protection glasses.  During the maintenance of the machine, the operators should wear personal protection devices (DPI) such as :...

  • Page 52: Blade Cleaning Brush

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 12.2.1 BLADE CLEANING BRUSH  Blade cleaning brush (1 fig. 2-12) is a very important device for the proper blade cleaning as the swarf should not stick to the blade teeth during the cutting operation.

  • Page 53: Weekly Maintenance

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 12.2.4 WEEKLY MAINTENANCE  Clean and remove the chips/swarf from the coolant liquid tank (1 fig. 4-12).  Remove the electro-pump (2 fig. 4-12) from its housing, clean the draught filter (3 fig. 4-12).

  • Page 54: Monthly Maintenance

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 12.2.5 MONTHLY MAINTENANCE  Check and tight the screw (1 fig. 5-12) holding motor flywheel.  Check and tight the ring nut (2 fig. 5-12) of the return flywheel.  Check wear blade-guide carbide pads (3 fig. 5-12).

  • Page 55: Biannual Maintenance

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 12.2.6 BIANNUAL MAINTENANCE (every 2000 hours) Provide electric continuity test for the circuit of the equipotential protection. 12.2.7 OIL COOLANT LIQUID  We advise to use SHELL LUTEM OIL ECO or any equivalent oil from any other reliable make.

  • Page 56: Machine Disposal

    Thomas Metal Bandsawing Machine - Mod. ZIP 29  During the de-installation and machine disposal, people not involved should keep away at safety distance.  The floor around the machine should be kept clean and clear as much as possible.

  • Page 57: Modifications

    The various problems that crop up from time to time will be solved more easily if the operator has a good knowledge of these specifications. WE THEREFORE RECOMMEND YOU TO ALWAYS USE GENUINE "THOMAS" SPARE BLADES THAT GUARANTEE SUPERIOR QUALITY AND PERFORMANCE.

  • Page 58: Teeth Pitch

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 variable section such as profiles, 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;...

  • Page 59: Blades Type

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 14.7 BLADES TYPE 14.7.1 TEETH FORM and GEOMETRY User’s Manual – Mod. ZIP 29 HB (2016) Page 59...
  • Page 60 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 60...

  • Page 61: Trouble-Shooting

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 TROUBLE-SHOOTING This chapter lists the probable faults and malfunctions that could occur while the machine is being used and suggests possible remedies for solving them. User’s Manual – Mod. ZIP 29 HB (2016)

  • Page 62: Blades And Cuts

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 15.1 BLADES AND CUTS TOOTH BREAK 1. Too fast sawframe downfeed speed 2. Wrong cutting speed 3. Wrong tooth pitch 4. Chips sticking onto teeth and in the gullets or material that gums 5.

  • Page 63: Electric Problems

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 27. Ineffective gripping of the part in the vice 28. Blade touching material at beginning of cut 29. Blade guide blocks not regulated or dirty because of lack of maintenance 30. Blade too slack 31.

  • Page 64: Electric Diagrams

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 ELECTRIC DIAGRAMS User’s Manual – Mod. ZIP 29 HB (2016) Page 64...
  • Page 65 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 65...
  • Page 66 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 66...

  • Page 67: Spare Parts

    Thomas Metal Bandsawing Machine - Mod. ZIP 29 SPARE PARTS Plastic box Light Button to energize the Start button for HB machine Emergency button Main Switch Blade speed Switch Figura 3 Hydraulic CONTROL for HB Figura 4 User’s Manual – Mod. ZIP 29 HB (2016)
  • Page 68 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 68...
  • Page 69 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 69...
  • Page 70 Thomas Metal Bandsawing Machine - Mod. ZIP 29 User’s Manual – Mod. ZIP 29 HB (2016) Page 70...
  • Page 71 Thomas Metal Bandsawing Machine - Mod. ZIP 29 Note : _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ User’s Manual – Mod. ZIP 29 HB (2016) Page 71...
  • Page 72 Thomas Metal Bandsawing Machine - Mod. ZIP 29 è è User’s Manual – Mod. ZIP 29 HB (2016) Page 72...

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