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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB ’ ’ MANUAL METAL BANDSAW – – Figura 1 – picture showing Zip 22 HB Vers. 1.0 del 16.02.2016 <ORIGINAL INSTRUCTIONS> Information contained in this manual < ORIGINAL INSTRUCTIONS > is produced by the manufacturer.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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’...
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 11.1 GENERAL ADVISES ............................ 39 11.2 CHECK EFFICIENCY OF SAFETY DEVICES ................... 41 11.2.1 EMERGENCY PUSH-BUTTON......................41 11.2.2 INTERLOCKING ON THE SAWFRAME COVER ................42 11.3 ADJUSTMENTS ON THE MACHINE ......................42 11.3.1...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB INFORMATION ON USER’S MANUAL This manual is to be regarded as integral part of the Thomas Bandsawing Machine “ZIP 22” (further named “machine”) built by Sthemma Srl (further named “manufacturer”).
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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)
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
See Chapter SPARE PARTS. GENERAL DESCRIPTION OF THE MACHINE Bandsawing machine THOMAS ZIP 22 is a manual horizontal bandsaw with swing sawframe for easy mitre cutting. Single mitre 0-60° R. Optional ‘HB’ hydraulic controlled sawframe downfeed. The machine is made up of the following assemblies: Sawframe, Vice, Base, Electric Box and Control Panel.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 4.1.1 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 4.1.2 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.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB User’s Manual – Mod. Zip 22 (2016) Page 12...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 4.1.3 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 4.1.4 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB TECHNICAL DETAILS TECHNICAL DATA Electric Motor controlling blade speed 3/400V...... kW 0,37 – 0,75 Electric Motor controlling blade speed 1/230V...... kW Electropump ................kW 0,06 ...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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;...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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).
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB User’s Manual – Mod. Zip 22 (2016) Page 23...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB The list below shows some danger and remaining risks on the machine with the identification of dangerous areas in which some activities are associated with dangerous situations. As far as the area “I” is concerned (the complete machine), the remaining risk refers to the noise and vibrations which are to be evaluated when the machine is running.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Operative Cycle Stock material moving on the roller tracks. Employed Operator Dangerous Event Loading or Discharge of the stock material on the roller tracks – Stock material moving on the roller tracks.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Danger : hands or fingers amputation between the blade (at stop or running) the working table, between the blade (at stop or running) and the vice jaws.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Danger: hands abrasion in case of contact with the steel brush as it turns. perforation of hands/fingers during brush handling. Operative Cycle Machine use – maintenance.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Employed Operator Dangerous event The stock material may have burrs or cutting edges before and after the cut. After the cut is completed, particularly if stock material is a large one, material may fall off the machine or roller tracks.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Obligation: wear protection shoes During moving, use, maintenance and scrap. 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB DELIVERY OF THE MACHINE Upon delivery, check the machine in all its parts: in case of damages during transportation, these are to be notified to the manufacturer immediately and within the day after. Deviations from the delivery note should be notified too.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB a) Release the machine from the straps and fixtures which held the machine during transportation. b) Lift and discharge the machine from the truck floor as prescribed by chapter 9.3 MOVING.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB The user should provide electric supply socket at handy spots allowing easy electric connection. Provide free floor space 1000 mm alla around the machine. The machine should be set up on a floor having 1000 kg/m2 capacity, without any depression and built according to the regulations suitable for the current activity.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB c) If the cable supplied with the machine should not be suitable to the installation requirements, replace it with one of correct section to the power in use (see label placed on the electric board), local temperature, conditions and length of the cable.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB User’s Manual – Mod. Zip 22 (2016) Page 37...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 11.2 CHECK EFFICIENCY OF SAFETY DEVICES Machine status: Machine energized (stand-by) ready to start. Operator: N. 1 operator. ATTENTION Every time, before starting the machine, it is compulsory to check the safety devices as follows: 11.2.1...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 11.2.2 INTERLOCKING ON THE SAWFRAME COVER Make sure that the switch (2 fig. 3-11) located on the sawframe cover (1 fig. 3-1) is perfectly working. The machine energized and ready to start (luminous push-button <READY> lit up - 2 fig. 2-11) but not working (blade at stop) slightly open the sawframe cover: luminous push-button <READY>...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 11.3.1 BLADE TENSION Blade tension is obtained by turning the hand wheel (1 fig. 4-11) clockwise. Turn the hand wheel till the index gets to the green area (2 fig. 4-11), or against the mechanical stop (3 fig.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB NOTE Bearings should rest on the blade just providing a light pressure against it; thus, the blade should be gently twisted. e) Once the adjustment has been effected, tight both screws and nuts.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Fig. 7-11 11.3.4 ADJUSTMENT OF THE CUTTING ANGLE (MITRE) Release the Lever (1 fig. 8-11) and turn the sawframe to the desired cutting angle with reference to special degree scale punched under the vice.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB h) Mount the mobile blade-guide protection (4 fig. 9-11) and close the sawframe cover with the knobs (3 fig. 9-11). Doing so, the relevant interlock switch is activated, otherwise the machine could not start.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB See table here below (fig. 10-11) showing some clamping methods on different profiles. Always make sure that the stock material is not too large for the machine cutting capacity.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Fig. 11-11 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) as instructed on Paragraph 11.3.1 BLADE TENSION.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Fig. 12-11 “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.
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Fig. 13-11 Fig. 14-11 User’s Manual – Mod. Zip 22 (2016) Page 50...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 12.2 REGULAR MAINTENANCE Machine status: Machine at stop and plug disconnected from the socket (1 fig. 1-12). Operators: N. 1 operator Personal protection devices: Protection Gloves Work blue overalls Protection shoes.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Check drain plug (1 fig. 4-12) for the coolant liquid in excess. Refill coolant liquid in the tank (2 fig. 4-12). Check blade teeth wear.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Clean the sawframe internal part, the flywheels in particular the tracks where the blade run (8 fig. 4-12). Check wear of blade clearing brush. 12.2.5 MONTHLY MAINTENANCE ...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB b) Lubricate the machine. c) Make the machine running idle. d) Test all the functional parts separately. e) Check the safety devices, the control panel and the efficiency of the electric components.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 13.2.2 ELETCTRIC OPERATIONS Machine status: Machine at stop and disconnected electric plug (1 fig. 1-12). Operators: N. 1 electrician. a) Remove the plug from the power cable and remove the cable from the electric board.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB These specifications 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 14.6 BLADE STRUCTURE Bi-metal blades are the most commonly used. They consist in a spring-steel blade backing with electron beam or laser welded high speed steel (HSS) cutting edge. The type of stocks are classified 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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 22 (2016)
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB 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.
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB ELECTRIC DIAGRAMS Figura 2 – Single-phase for Mod Zip 22 manual pull down User’s Manual – Mod. Zip 22 (2016) Page 65...
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Figura 3 – three-phase for Zip 22 manual pull down User’s Manual – Mod. Zip 22 (2016) Page 66...
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Figura 4 – single-phase for Zip 22 HB User’s Manual – Mod. Zip 22 (2016) Page 67...
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Figura 5 – three-phase for Zip 22 HB User’s Manual – Mod. Zip 22 (2016) Page 68...
Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB SPARE PARTS Electric Box Button START for ‘HB’ version Luminous Button Emergency Button Switch 2 blade speeds Main Switch Hydraulic System for ‘HB’ version User’s Manual – Mod. Zip 22 (2016)
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Note : _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ User’s Manual – Mod. Zip 22 (2016) Page 73...
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Note : _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ User’s Manual – Mod. Zip 22 (2016) Page 74...
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Thomas Metal Bandsawing Machine - Mod. ZIP 22 / ZIP 22 HB Note : _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ User’s Manual – Mod. Zip 22 (2016) Page 75...
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