FOM Blitz Manual

FOM savemaskine Blitz

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MANUALE USO-MANUTENZIONE

USE AND MAINTENANCE MANUAL

BLITZ

ITRONCATRICE Ø 500 MM / Ø 550 MM / Ø 600 MM A DUE TESTE CON CONTROLLO ELETTRONICO

DELLA INCLINAZIONE

I GB

DUAL HEAD Ø 500 mm / Ø 550 mm / Ø 600 mm SAWING MACHINE WITH ELECTRONIC ANGLE SETTING

Vers. 3.0.0

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BLITZ

USE AND MAINTENANCE

MANUAL

SPARES CATALOGUE

TRANSLATION OF

ORIGINAL INSTRUCTIONS

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CONTENTS

1 GENERAL WARNINGS................................................................................................................... 3

1.1 INTRODUCTION ............................................................................................................................. 3

1.2 WARRANTY ................................................................................................................................... 3

2 GENERAL INFORMATION .............................................................................................................. 4

2.1 FOREWORD .................................................................................................................................. 4

2.2 IDENTIFICATION AND CERTIFICATION PLATE ............................................................................ 5

2.3 PLATES ON THE MACHINE .......................................................................................................... 6

3 OVERALL DIMENSIONS ................................................................................................................ 7

3.1 CUTTING DIAGRAM ....................................................................................................................... 8

3.2 TECHNICAL SPECIFICATIONS ..................................................................................................... 9

3.3 BASIC MACHINE VERSION COMPONENTS................................................................................ 10

3.4 SOUND EMISSION OF THE BLITZ SAWING MACHINE ............................................................... 11

4 HEALTH AND SAFETY STANDARDS........................................................................................... 12

4.1 FOREWORD ................................................................................................................................ 12

4.2 INTENDED MACHINE USE .......................................................................................................... 12

4.3 SAFETY WARNINGS ................................................................................................................... 12

4.4 SAFETY DEVICES ....................................................................................................................... 14

4.5 RISK AND RESIDUAL RISK AREAS - 1 ....................................................................................... 15

4.6 RESIDUAL RISK AREAS - 2 ........................................................................................................ 17

5 TRANSPORT AND INSTALLATION ............................................................................................... 19

5.1 HANDLING ................................................................................................................................... 19

5.2 CHECKS ...................................................................................................................................... 20

5.3 MACHINE POSITIONING AND INSTALLATION ............................................................................ 20

5.4 LEVELLING ..........................................................................................................................26

5.5 FIXING TO THE GROUND................................................................................................. ....30

5.7 CHECKING THE ALIGNMENT OF THE MOBILE HEAD ROLLER TABLE ..................................... 31

6 CONTROLS .................................................................................................................................. 32

7 ELECTRICAL AND PNEUMATIC CONNECTION .......................................................................... 35

8 PROCEDURE FOR START UP AND MACHINING ........................................................................ 37

9 ADJUSTMENTS ............................................................................................................................ 39

9.1 BLADES FEED RATE................................................................................................................... 39

9.2 REGULATING THE FLOW OF LUBRICANT TO THE BLADES ...................................................... 40

9.3 VICE - POSITIONING / ADJUSTMENTS ...................................................................................... 41

9.4 MINIMUM CUT .............................................................................................................................. 46

9.5 CUTTING ANGLES ....................................................................................................................... 49

9.6 CUTTING PROCEDURE ............................................................................................................... 49

9.7 SAW BLADE ................................................................................................................................ 49

9.8 PROFILE POSITIONING ............................................................................................................... 50

9.9 CLAMPING PROFILES ................................................................................................................. 51

9.10 ADJUSTING THE PROFILE HEIGHT MEASURER (IF PRESENT) ................................................ 52

9.11 CALCULATING THE CUTTING LENGTH ....................................................................................... 53

9.12 CUTS AT EXTERNAL ANGLES OF LESS THAN 30° - SPECIFIC RULES .................................... 54

9.13 RETRACTABLE MIDDLE PROFILE SUPPORT (OPTIONAL) ........................................................ 55

9.14 CUTS WITH THE STEP-BY-STEP KIT (OPTIONAL) .................................................................... 58

10 MAINTENANCE ............................................................................................................................ 60

10.1 DAILY MAINTENANCE ................................................................................................................. 60

10.2 PERIODIC MAINTENANCE .......................................................................................................... 61

10.3 FITTING A NEW BLADE .............................................................................................................. 63

10.4 FITTING A NEW PRESSURE SWITCH ........................................................................................ 65

10.5 FITTING NEW SOLENOID VALVES ............................................................................................. 66

10.6 FITTING A NEW REMOTE CONTROL SWITCH ........................................................................... 67

10.7 CHANGING THE PADS ON THE VICES ....................................................................................... 68

10.8 FITTING A NEW HORIZONTAL VICE CYLINDER......................................................................... 69

10.9 FITTING A NEW VERTICAL VICE CYLINDER ............................................................................. 70

10.10 CLEANING THE VICE CYLINDER STOP VALVE ......................................................................... 72

10.11 SUBSTITUTING THE CHIPS CONVEYOR BELT........................................................................... 73

11 PROBLEMS - CAUSES - REMEDIES........................................................................................... 79

12 DISPOSAL OF THE MACHINE ..................................................................................................... 82

13 ELECTRICAL AND PNEUMATIC DIAGRAMS............................................................................... 83

14 ORDERING SPARE PARTS.......................................................................................................... 84

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1 GENERAL WARNINGS

Before putting the machine into service all the technical instructions given in this manual must be observed

and all the indications shown must be scrupulously followed.

This manual and all the literature enclosed with it must be kept in an easily accessible place known to all

operators and staff entrusted with maintenance operations.

1.1 INTRODUCTION

The BLITZ has been specifically designed for sawing profiles in aluminium or light alloy.

The machine has been specifically designed to be used by a single operator.

WORKING PRINCIPLE:

- Once a profile is placed on the work tables of the two heads, a pneumatic circuit activates the horizontal

and vertical vices that clamp the profile in place.

- Two motors drive the rotational movement of the respective saw blades. Operated by buttons on the control

console, the blades come out, cut the profile and return automatically.

- Cutting is possible at external angles from 90° to 12° for BLITZ 55 (10° for BLITZ 50, 20° for BLITZ 60L)

and from 90° to 45° internally.

- When cutting is complete the vices open again to allow another profile to be positioned for the next cut.

The instructions for the various pieces of electronic equipment supplied with the models which BLITZ can be

used with are enclosed with this instruction manual as separate publications.

1.2 WARRANTY

The company guarantees that this machine has been tested under peak running conditions with excellent

results. This warranty is valid for a period of 12 months and covers construction materials and defects only.

The customer has only the right to claim for replacement of faulty parts, excluding the cost of carriage and

packaging and complete machine replacement. This warranty does not therefore cover any damage caused

by dropping, tampering or improper machine operation, by disregard of maintenance instructions given in the

instruction manual, or by faulty handling by the operator. No compensation may be claimed for any periods of

machine inactivity. This warranty is not binding unless all payment conditions have been met.

The cost of service assistance, together with the cost of spares used is not covered by the warranty. These

must be paid directly to the service technician who will issue a maintenance slip to be later followed by a regular

invoice.

Maintenance charges and the cost of the spares used are taken from the Price List in force at the time.

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2 GENERAL INFORMATION

2.1 FOREWORD

This manual contains the instructions for use and maintenance as well as the drawings and instructions for

obtaining spare parts for the BLITZ sawing machine manufactured by FOM INDUSTRIE. The manual contains

all the necessary information for correct installation and a description of how the machine works.

All information regarding maintenance procedures and adjustments is also given.

WARNING

- All transport, installation, use, routine and periodic machine maintenance must be carried out solely by

skilled personnel.

- The term “OPERATOR” refers to the person or persons entrusted with installing, operating, adjusting,

performing maintenance, cleaning, repairing and handling the machine.

IMPORTANT

- All the Use and Maintenance operations for the machine which are not described in this manual are contained

in the relative publications enclosed with it.

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2.2 IDENTIFICATION AND CERTIFICATION PLATE

The figure 02-01 shows the ID plate and its location on the machine.

N.B. The type, code and serial number marked on the plate, must be quoted any time the Manufacturer is

contacted for information or when ordering spare parts.

02-01

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2.3 PLATES ON THE MACHINE (Fig. 02-02)

1 - N.2 “Direction of blade rotation” warning plates

2 - N.1 “DANGER. HIGH VOLTAGE” (400 Volts) warning plate

3 - N.1 “GOGGLES/GLOVES/EAR DEFENDERS" safety wear plate

4 - N.2 “Blade exit speed adjustment” plates

5 - N.1 “Indication of instruction manual located inside electrical cabinet” warning plate

02-02

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3 OVERALL DIMENSIONS (Fig. 03-01)

m. 5 7050 2090 2070 2400

m. 6.6 8630 2090 2070 2600

WORKING

CUT WEIGHT

LPH

Total dimensions with mobile head roller table fully out: L + 2200 mm.

03-01

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3.1 CUTTING DIAGRAM

Cutting diagram - BLITZ 55 (FIG. 03-02)

The cutting diagram with the blade Ø 550 mm. illustrates the machine cutting capacity with the blade set at 90°,

with the blade set at 45° internal/external, with the blade set at 22,5° external and with the disc set at 12° external.

03-02

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03-03

Cutting diagram - BLITZ 50 (FIG. 03-03)

The cutting diagram with the blade Ø 500 mm. illustrates the machine cutting capacity with the blade set at 90°,

with the blade set at 45° internal/external, with the blade set at 22,5° external and with the disc set at 10° external.

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03-04

Cutting diagram - BLITZ 60L (FIG. 03-04)

The cutting diagram with the blade Ø 600 mm. illustrates the machine cutting capacity with the blade set

at 90°,

with the blade set at 45° internal/external and with the disc set at 20° external.

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3.2 TECHNICAL SPECIFICATIONS

- Tungsten carbide sawblades Ø 500 mm. (BLITZ 50) - Ø 550 mm. (BLITZ 55) - Ø 600 mm. (BLITZ 60L)

- Hydraulically operated tungsten carbide sawblade feed (adjustable exit speed – quick return)

- Three-phase motors 2.2 kw 2800 r.p.m. - 400V 50Hz

- Direct motor – saw blade transmission

- Sawblade rotation speed: 2800 rpm.

- Blade holding spindle Ø 32 mm.

- Heads tilted by electronic control:

BLITZ 50 : from 45° internal to 10° external

BLITZ 55 : from 45° internal to 12° external

BLITZ 60L : from 45° internal to 20° external

with all intermediate angles electronically programmed

- First head: fixed

- Second head: mobile (automatic positioning)

- Mobile head positioning speed (in automatic mode): <= 25 m/min

- Minimum cutting capacity between the two heads (See Section 9.4)

- Software for undersize cutting

- Max. cutting capacity between the two heads (at 90°): 5000-6600 (depending on the version supplied)

- Double working pressure servo-controlled in low pressure

- Air consumption per work cycle: 53 Nl (normal/litres)

- Total power absorption: 5.9 Kw at 400 V AC

- Total absorbed current: 10 A at 400 V AC

- Electrical switchboard separate from pneumatic one

- Pneumatic horizontal vices (4) and vertical vices (2) with automatic exclusion by program for internally angled

cuts from 70° to 45°

- Microdrop cutting lubrication with pure oil

- Set up to take chips and fumes extraction system (1)

- Working pressure: 7 bar (adjustable)

- Mobile head roller table (2,5 m)

- Integral protective hood around cutting area

- Control console with PC (only on version E)

Upon request:

- Manual kit for undersize cutting

- Mechanical stop for wedge cutting

- Blade rotation inverter kit

- Profile clamping

- Fixed head 3/4.2 m roller table

- Retractable pneumatic middle profile supports

- Retractable external profile support kit

- Profile raising middle roller kit (on mobile head)

- Central swarf conveyor belt

- Kit for conveying chips to centre of machine

- Angled conveyor belt

- Profile height reader + vertical vice (on loading side head)

- External supplementary vertical vice kit

- Remote assistance

- Label printer

- ‘Step-by-step’ cutting program with bi-manual control

- ‘Step-by-step’ cutting program with photocell safety barrier

(1) The exhauster must be installed by the customer under his own responsibility.

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3.3 BASIC MACHINE VERSION COMPONENTS (Fig. 03-03)

1 - Machine bed complete with linear guides

2 - Heads complete with motors, blades and recirculating ball screws for head tilting

3 - Integral guard kit for cutting zone

4 - Pneumatic vices

5 - Sliding console with control panel and PC (only on version E)

6 - Electrical cabinet

7 - Pneumatic circuit at rear of fixed head and mobile head

8 - Air input filter

9 - Microdrop lubrication system

10 - Mobile head roller table

03-03

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3.4 SOUND EMISSION OF THE BLITZ SAWING MACHINE

NOISE VALUES ACCORDING TO ISO 3746/77

Lwa Sound power level dB (A) : 109.1

LpA Sound pressure level at workstation dB (A) : 90.6

N.B: For prolonged machine use personal safety protection against noise is advised.

The sound pressure level has been calculated on the basis of a machining cycle involving the 2 blades cutting

Ø 550 mm. at 90° a 1.5 m length of 80x40 mm and 2 mm thick aluminium profile.

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4 HEALTH AND SAFETY STANDARDS

4.1 FOREWORD

Each machine operator should have a perfect knowledge of the location and working operation of all controls

as well as the machine characteristics. It is therefore essential that they read this manual fully. Furthermore,

the instruction manual must be kept near the machine.

Unauthorised tampering or replacement of machine parts, the use of accessories, tools and consumable

materials other than those recommended by the Manufacturer can lead to accidents for which the Manufacturer

declines responsibility for all penal or civil liabilities.

4.2 INTENDED MACHINE USE

The BLITZ sawing machine has been designed for cutting profiles in aluminium or light alloy.

Any materials other than these are not compatible with the specific machine characteristics.

WARNING

The machine is not suitable for use in environments where there is the risk of fire or explosion.

All combustible and/or flammable materials should be kept as far away from the machine as possible.

The machine has been specifically designed to be used by a single operator.

4.3 SAFETY WARNINGS

The term “OPERATOR” specifically refers to the person or persons entrusted with installing, operating,

adjusting, carrying out maintenance, cleaning, repairing and handling the machine; “DANGEROUS AREAS”

refers to any area inside and/or near the machine in which the presence of an exposed individual constitutes

a risk to the health and safety of that person; “EXPOSED INDIVIDUAL” refers to any person standing fully

or partially in a dangerous area.

Working conditions

- According to the provisions of “lighting in work areas”, the place where the machine is used must have no

areas in shadow, glaring lights (reflections-reverberation), or dangerous strobe effects caused by the lighting

in the workshop. The selected area must be well lit (minimum 300 lux).

- Furthermore, efficient ventilation must be guaranteed in the workplace with the use of a suitable extraction

system where necessary.

- The areas where the operator works should always be kept clear and clean from any oil residue.

Intended machine use

- The machine must be operated by skilled staff only and is designed for machining "NON-TOXIC” “NON

AGGRESSIVE”and“NON EXPLOSIVE” materials; the use of any products other than these absolves the

Manufacturer from any responsibility for damage caused to the machine, persons or property.

- The machine can work at ambient temperatures from 10° to +40°. During storage periods or when the

machine is not working, the ambient temperature must be between -10° and + 60°.

- Before setting to work, the operator must have a perfect knowledge of the location and working operations

of all controls as well as the machine characteristics.

- The machining commands must be given by just one operator; the assistance of more than one operator

is only allowed in the workpiece loading phase.

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Operators

- Use only skilled and competent personnel. Establish clearly personnel duties for handling, setting up, use,

maintenance and repair of the machine.

- Electrical installation and connections must only be made by a qualified technician.

NOTE: A qualified technician is defined as anyone who has completed a specialised training course

and has experience in the field of installation, putting into service and maintenance of systems.

- The qualified technician must also be familiar with first-aid techniques in the event of accident.

- Staff involved in operating, maintenance, cleaning, inspection etc. will in any case have to carefully observe

the safety rules in force in the country where the machine is to be used.

- All operators should dress in a suitable manner for the work place and for the job to be carried out.

For example: wear clothes that are not too loose (which could be caught in the moving machine parts), wear

safety shoes, gloves and, where necessary, other safety wear such as sound insulating ear plugs, goggles

and a mask.

The machine operator or maintenance technician must not wear neck chains, bracelets or rings, and long

hair should be tied back.

- If long pieces that protrude significantly beyond the machine are machined, the areas must be made off

limits and marked as such (e.g. floor markings) and if necessary access limited by mobile barriers.

- When using any cooling-lubricating liquids (which may contain active chemical additives harmful to health)

the regulations that govern the treatment and disposal must be observed (see the technical safety sheet

enclosed with this manual).

- Routine and extraordinary maintenance operations must take place with the machine stopped and

disconnected from the mains and pneumatic power supply . To cut off the power supplies to the machine

a padlock must be put on the main switch and the pneumatic supply quick connector has to be detached,

or, if present, fit a padlock to the pneumatic master switch. If the machine is out of service for any reason

make this known by putting up a sign.

- Any work on the pneumatic systems must only be performed after having discharged the pressure inside

the circuit.

- Removal of the safety guards and tampering with the safety devices is absolutely forbidden. Furthermore,

if it is noticed that one or more of the safety devices are not working, the machine must be stopped

immediately.

- It is absolutely forbidden to climb onto the machine to carry out any type of operation when it is being supplied

with electrical and pneumatic power.

- Electrical connections should be made according to the general installation rules for the preparation and

operation of electrical systems.

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4.4 SAFETY DEVICES (Fig. 04-01)

List of safety devices

1 - Pressure switch which cuts in to stop the machine in the event of anomalous air pressures

2 - Vices non return valves (4)

3 - Microswitch for controlling blade return to rest position with enabling signal for hood opening

4 - Integral safety hoods around cutting area with guard closing microswitch (2)

5 - Electronic safety relays for 2 handed control

6 - Blade braking circuit board (2)

7 - Access prevention bands (4)

8 - Acoustic/light signal: cutting – head tilting – mobile head roller table automatic positioning

9 - Light signal: cutting – head tilting – mobile head roller table automatic positioning

04-01

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4.5 RISK AND RESIDUAL RISK AREAS - 1

Despite the safety guard and the devices provided on the machine, there are still some areas designated as

“risk and residual risk” due to the fact that certain machine risks cannot be eliminated for constructional reasons.

The figure shows the area where the machine is controlled and operated under normal working conditions.

This area is free of risk for operators and is defined as the “Operator command and control area”.

As the machine is too large for the operator to have full control over every area [length: from 6763 mm (min)

to 8400 mm (max)] as well as the safety devices and signals fitted to the machine, the machine perimeter must

also be delimited.

The procedure for delimiting the machine perimeter can be one of two basic situations.

1st - The machine is positioned with the rear part next to a wall.

In this case a sturdy barrier must be fitted and fixed to the ground as shown in Fig. 04-02 and in Fig. 04-04.

2nd - The machine is placed in the centre of the workshop or in any case not near a wall.

In this case a sturdy barrier must be fitted and fixed to the ground as shown in Fig. 04-03 and in Fig. 04-05.

04-02

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04-04

04-03

04-05

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04-06

4.6 RESIDUAL RISK AREAS - 2

The BLITZ can be supplied (optional) with 1 belt for the removal of chips and offcuts created during cutting.

The belt can “discharge” into a container (Fig. 04-06).

The “discharge” area of the mobile belt, both in Fig. 04-06 and Fig. 04-07 is not exactly considered a “RESIDUAL

RISK AREA”; but the “mobile head roller table” may also come within this area (see residual risk areas - 1)

and so it is advisable to adopt certain measures described in the paragraph “RESIDUAL RISK AREAS -

CONCLUSIONS”.

In any case, the chips removal belt is only in motion during the cutting phase, when both cutting buttons are

pressed and up to roughly 5 seconds after the bi-manual control has been released, to allow the swarf to be

evacuated from around the head.

WARNING

Clean away the swarf only once the belt has stopped.

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RESIDUAL RISK AREAS - CONCLUSIONS

The BLITZ, according to the contents of the paragraph “RESIDUAL RISK AREAS 1-2” could be represented

as in Fig. 04-07:

1 - Fixed head roller table

2 - Mobile head roller table (may “protrude” from the machine by a max. of 2195 mm)

3 - Mobile belt

5 - Conveyor belt

6 - Container

Taking into account the sizes shown in the figure, the barriers should therefore be arranged as in Fig. 04-04

and 04-05.

N.B: In all drawings contained in the chapter “RESIDUAL RISK AREAS” the BLITZ is not shown with the

barriers fitted at the front, in both the “OPERATOR AREA” and the installation and/or operating areas

of the “ROLLER TABLES”. In fact at the front of the machine the operator will have to handle manually

the profile bars to be cut which are originally approx. 6/7 m long. The whole of the front of the machine

(including the roller table area) must therefore be free of obstacles, to allow “LOADING”the bars which

the operator feeds into the machine from Left to Right and/or Right to Left.

Furthermore, a free space of at least 1000 mm. must be left to the Right of the mobile head roller table

(positioned as in Fig. 04-07)

04-07

List of the dangerous and residual risk areas

1. Rear area for the forced extraction of chips and fumes: It is FORBIDDEN to use the machine without

a working exhauster connected; it is in any case prohibited for anyone to stand in this area.

2. Front part: risk of trapping the arms between the mobile head in motion and the retractable profile

supports.

2. Front part: risk of arms becoming crushed between each head and relative upright - seat when the head

is tilted.

3. Risks due to the presence of electrical power.

4. Risks of being cut by accidental contact with the blade at rest and while handling workpieces that may

have sharp edges

5. Risks of being crushed due to machine movement and installation and also while handling heavy

workpieces.

6. Risks due to noise generated in the work area.

7. Risks due to inhaling smoke or fumes during machining if the extraction system provided is inadequate.

8. Risks due to machining chips being projected

With reference to that previously indicated in paragraphs 4.5 and 4.6, FOM Industrie supplies a “post and chain

barrier kit” with the machine: the assembly and installation instructions for the kit can be found in the relative

instruction manual attached to this publication.

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5.2 CHECKS

- Check that the place where the machine is installed does not have any areas in shade, that there are no

glaring lights, or dangerous strobe effects (reflections-reverberation) due to the type of lighting used in the

workshop where the machine is to be used.

- Check that the machine has not been damaged during transit.

- Check that the machine rests evenly on the floor.

- Check that there is enough free space around the machine to completely open all the doors and in order to

carry out all maintenance operations easily.

5.3 MACHINE POSITIONING AND INSTALLATION

Having selected the location, the machine can then be installed.

5.3.1 RELEASING THE HEADS

To release the hoods on the heads, remove the relative fixing brackets “A” - Fig. 05-03.

To remove each of the 2 brackets undo the relative 4 fixing nuts “B” - Fig. 05-03. The 4 brackets removed

(2 on each head) will later be used for fixing the machine to the ground.

05-03

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5.3.2 INSTALLING THE CONSOLE

Proceed as follows:

- Remove the 2 lower fixing screws ‘A’ - Fig. 05-04.

- Manually rotate the console to the working position.

- Tighten the 2 lower fixing screws ‘A’ - Fig. 05-05 and use the 2 upper screws ‘B’ - Fig. 05-05 to adjust the

height of the console.

- Fix the upper plate ‘C’ - Fig. 05-05 using the 4 fixing screws.

05-04

05-05

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- Use the lateral screw ‘A’ - Fig. 05-06 to adjust the inclination of the console monitor. When adjustment is

complete, use the 3 rear screws ‘B’ - Fig. 05-07 to reposition the monitor table on the underlying gasket.

05-06

05-07

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05-08

- Version E only: open the PC housing panel and check that the cables are connected correctly (power supply,

video, mouse, keyboard, network, serial, USB extension) as shown in Fig. 05-08.

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5.4 LEVELLING

The machine sits on the ground on adjustable feet (see Fig. 05-12). These feet can vary in number depending

on the length of the machine.

BLITZ m. 5 = 8 feet

BLITZ m. 6.6 = 10 feet

The machine is shipped with the adjustable feet fully screwed in, concealed inside the “U”-shaped cross member

housing.

Remove the 2 brackets “A” - Fig. 05-12A that secure the mobile head to the machine bed.

Use a centesimal spirit level with tolerance of between 0.02 and 0.05 mm per metre. Levelling must take place

crosswise (where maximum precision is required) and lengthwise (where the machine does not need to be

perfectly level but the error should however be constant over the whole of the machine length).

N.B. The spirit level should always be placed on the worktable of the MH.

Rest the machine feet on the ground using the screw adjusters “1” - Fig. 05-12 and with the relative lock nuts

“2” - Fig. 05-12 loose.

1st PHASE

With the MH next to the FH, level lengthwise, placing the spirit level as in Fig. 05-13.

Move the MH manually to the mid position between the feet up to the position between the penultimate and last

foot and then level lengthwise in each of these positions (see Fig. 05-14) making sure the error is constant.

Move the MH manually to the RIGHT up to the end of the bench and then level crosswise, placing the spirit

level as in Fig. 05-15; if necessary use the RIGHT front and rear adjusters to make it perfectly level.

Move the MH manually to the FH and level crosswise placing the spirit level as in Fig. 05-16; if necessary use

the LEFT front and rear adjusters to make it perfectly level.

Move the MH manually to the centre of the machine where the centre feet are and level crosswise placing the

spirit level as in Fig. 05-17; if necessary use the centre front and rear adjusters to make it perfectly level.

2nd PHASE

Move the MH manually to the FH and carry out the operations again in the same sequence as described in the

1st phase in order to obtain more precise levelling.

Once the levelling operations are complete, tighten all the lock nuts of the foot adjusters (see Fig. 05-12).

Switch on the power and air to the machine (see chap. 7 - ELECTRICAL AND PNEUMATIC CONNECTION),

then enable it by pressing “1” - Fig. 06-02in order to raise the safety hoods. Once the hoods are raised, cutoff

power and air to the machine again.

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1 Screw Adjuster

2 Adjuster lock nut

3 Foot

4 U”-shaped cross member”

05-12 05-12A

05-13

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05-16

05-17

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5.5 FIXING TO THE GROUND (FIG. 05-18)

Once the levelling operations are complete, proceed with fixing the machine to the ground.

The machine comes supplied with. 4 brackets (these are the same brackets that were used to secure the heads

in transit). The brackets “A” are fixed to the front (2) and rear (2) sides of the machine (see Ref. “B”) and to

the floor as shown in the figure.

- Make the two holes for fixing to the ground through points “C”.

- Insert the two “STOP plugs” in the holes”D” just made.

05-18

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5.7 CHECKING THE ALIGNMENT OF THE MOBILE HEAD ROLLER TABLE (Fig. 05-19)

Check the alignment of the mobile head roller table with the machine worktable using, for example, a straight

bar and making sure it rests properly on the worktable and on the rollers.

If it is not, open guard “A”, then adjust the 4 screws “B” to align the 1st roller vertically with the head table (the

screws should be loosened and then tightened).

With a no. 10 spanner turn the 2 screws “C” to align the roller table crosswise and vertically.

With a no. 17 spanner turn the screws “D” (2 at the front and 2 at the rear) for longitudinal alignment.

After making the adjustments, tighten all the screws and secure guard “A”.

If the roller table alignment proves especially difficult, contact FOM service assistance.

05-19

BLITZ G BG B

G BG B

G B

105-20

5.7 CHIPS AND FUMES EXTRACTION

At the rear of each head, the machine is fitted with a connection for an extractor to take chips and fumes

generated by the cutting operation away from the area (see Ref. “1” Fig. 05-20).

If a type of exhauster is used which is different from those proposed by FOM Industrie, check that the system

has an adequate volumetric flow rate (min. flow rate. 500 m3/h at 150 mbar).

N.B. The extractor is installed by the user on his own sole responsibility.

CAUTION

It is forbidden to use the machine without a properly working exhauster connected.

G BG B

G B BLITZ

05-21

The heavier chips can instead be conveyed to the collection tank (or onto the central conveyor belt, if fitted),

by the hoses “2” and “3” (Fig. 05-21) (OPTIONAL).

BLITZ G BG B

G BG B

G B

406-01

CONSOLE (Fig. 06-01)

1 - Monitor with touch screen

2 - PC (version E only)

3 - Mouse (version E only)

4 - Alphanumeric keyboard (version E only)

5 - Input for USB connection (Version E only)

6 CONTROLS

G BG B

G B BLITZ

CONTROL PANEL (Fig. 06-02)

1 - Button to enable machining

2 - Vices open/close button

3 - Bi-manual cutting buttons

4 - Selector giving consent to allow mobile head positioning within the ‘SAFETY ZONE’ (mobile head

approaching fixed head) and/or to tilt one or both heads

5 - EMERGENCY-STOP button

6 - Photocell reset button for optional ‘step-by-step’ program (optional)

N.B: Buttons 3 also provide a bi-manual synchronous command when continuously held down to execute

the (optional) ‘step-by-step’ program

06-02

G BG B

G B BLITZ

OPERATING NOTE - 2

- TILTING one or both heads to the set measurement, while the mobile head is inside the SAFETY ZONE,

can pose safety risks (despite the fact that the acoustic-light signals are working).

- The danger risk when tilting the heads in AUTOMATIC mode is that of BEING CRUSHED between the two

heads.

- For this reason the machine has been constructed to respond as follows: The tilting movement starts at a

“reduced” speed and can be increased to normal speed by turning (and holding in place) selector “4” - Fig.

06-02: the head or both heads carry out the tilting movement stopping automatically at the final measurement

set. If the selector is released before the final set measurement, tilting of one or both heads takes place at

a “reduced” speed for safety reasons.

OPERATING NOTE - 1

- The POSITIONING movement of the mobile head to the set measurement when moving away from the fixed

head causes no safety problems (in this phase the 2 lights on the fixed head and on the mobile head roller

table flash and the acoustic-light signal activates on the mobile head).

- The POSITIONING movement of the mobile head to the set measurement when “APPROACHING” the fixed

head can cause safety problems (even though the flashing lights/acoustic signals are working).

- The danger risk when the mobile head approaches the fixed one in AUTOMATIC mode is that of BEING

CRUSHED between the two heads.

- For this reason the machine has been constructed to respond as follows:

1 - If the measurement set is less than (or equal to) 1250 mm (which defines the SAFETY ZONE), the mobile

head moves quickly towards the fixed one and “STOPS” at the safety distance.

2 - When the mobile head enters the SAFETY ZONE, the LED on selector “4” - Fig. 06-02 comes on.

3 - By turning (and holding in position) selector “4” - Fig. 06-02 the mobile head approaches the fixed head

and only stops if released or when the final set measurement is reached.

OPERATING NOTE - 3

When POSITIONING the mobile head as well as tilting one or both heads is necessary, the following situations

can occur:

- If tilting one or both heads takes place with the mobile head which, even if initially inside the SAFETY ZONE,

moves away from the fixed head, then the TILTING movement starts at the same time as MH positioning

but at “reduced” speed and can be increased to normal speed by turning (and holding in position) selector

“4” - Fig. 06-02. The POSITIONING movement when moving away however always takes place at normal

speed.

- If tilting one or both heads takes place with the mobile head which, initially being outside the SAFETY ZONE,

moves towards the fixed head with a destination measurement inside the SAFETY ZONE, then the

TILTING movement starts at the same time as positioning the MH but at “reduced” speed and can be

increased to normal speed by turning (and holding in position) selector “4” - Fig. 06-02. The POSITIONING

movement when approaching however always takes place in the same way as described in NOTE 1.

- If tilting one or both heads takes place with the mobile head which, initially being inside the SAFETY

ZONE,moves towards the fixed head, then both TILTING and POSITIONING movements can be started

by turning (and holding in position) selector “4” - Fig. 06-02. If the selector is released, the TILTING

movement takes place at “reduced” speed; on the contrary, POSITIONING the mobile head only takes place

by turning (and holding in position) selector “4” - Fig. 06-02.

G BG B

G B BLITZ

If the direction of tool rotation is not the same as that indicated by the arrow on the machine, two of the three

poles of the electrical power supply must be inverted.

Insert the incoming air hose (with 12 mm. internal diameter) into the input filter connection “1” and fix it in place

with a metal clip; turn the pneumatic master switch “A1” to position “I” and check on gauge “2”that the pressure

is 7 bar; If it is not, adjust using knob “3”.

This adjustment is necessary because at pressure values lower than 5 BAR a pressure switch is triggered that

stops the machine from working.

N.B. If any pneumatic connections are made other than those provided for by the constructor, an easy

and intuitive type of quick connector must still be used.

07-02

BLITZ G BG B

G BG B

G B

8 PROCEDURE FOR START UP AND MACHINING

- Turn the main power switch to position “I”.

WARNING

The machine is now being supplied with electrical power

- Enable the machine for work by pressing button “1” - Fig. 06-02 located on the control console.

WARNING

Before carrying out any operations, check the direction of rotation of the blades by starting one of the 2 motors

(see attached software manual). Immediately after, press the emergency stop button to stop the motor. The

direction of rotation of the blade can be seen through the front blade exit slot.

If the blades are seen to rotate in the opposite direction, then two of the three electrical power phases of the

BLITZ must be inverted.

N.B: The correct direction of blade rotation can be seen from the plate with an arrow “1” - Fig. 02-02 affixed

to the head guards.

After enabling the machine, carry out the zeroing procedure (see attached software manual); this must be done

every time the machine is switched on or when the mobile head position has been changed by a non electrical

means.

Start the fixed head and mobile head blade motors by pressing the F1 and F5 buttons

MANUAL CUTTING

Turn selector “1” - Fig. 06-03 (where present) to activate the ‘MANUAL’ cutting mode.

Set the required cutting measurements on the equipment (see the enclosed manual).

Position the profile on the worktable and clamp it in place with the vices by pressing button “2” - Fig. 06-02.

WARNING

When handling any profile the wearing of safety gloves is mandatory.

IMPORTANT

In this condition of the machine being enabled for work, the vices clamp the profile in “low pressure” (~ 0.8 bar

working pressure) to allow positioning and to avoid fingers or hands being crushed.

However, if any re-positioning is needed to clamp the profile perfectly, press again the open vices button “2”

- Fig. 06-02, then follow the indications given in Paragraphs. 9.1 and 9.2.

By pressing together (and keeping pressed down) the cutting buttons “3” -Fig. 06-02 the hoods are closed

and, once the hoods are completely closed, the blades come out to cut.

IMPORTANT

Before the sawblade comes out to cut, the vices clamp the profile on the worktable in high pressure.

Under normal conditions of use, after making the cut, the blade goes back in immediately, the mobile safety

hoods will raise, the vices open automatically to allow the cut profile to be removed and another profile to be

put in position for cutting.

G BG B

G B BLITZ

SEMI-AUTOMATIC CUTTING (‘STEP-BY-STEP’ CYCLE) (OPTIONAL)

Turn selector “1” - Fig. 06-03 to activate the ‘SEMI-AUTOMATIC’ cutting mode’.

Set the required cutting measurements on the equipment (see the enclosed manual).

Once the vices have been clamped, consent to start the ‘step-by-step’ cutting program is given by pressing

at the same time (and keeping them pressed down for the whole duration of the program) buttons ‘3’ - Fig. 06-

02.

If one or both the buttons are released, the ‘step-by-step’ cycle stops and starts again (from the point where

it was interrupted) only when both buttons are pressed again.

N.B. ‘Step-by-step’ cutting can be done in the automatic cycle mode (the program starts with an impulse

command), instead of the bi-manual control with continuous action, using a photocell barrier (OPTIONAL)

to protect the front of the machine (for further information, refer to the booklet “Photocell kit for step-by-

step program” enclosed with this manual).

BLITZ G BG B

G BG B

G B

9 ADJUSTMENTS

N.B: The “BLADES FEED RATE” and “REGULATING THE BLADE LUBRICATION FLOW” adjustments are

normally set to standard values during testing in the assembly workshop. If any adjustments to the

above settings are necessary, proceed as described below.

9.1 BLADES FEED RATE (Fig. 09-01)

Turning knob “A” clockwise decreases the blade exit speed, while turning knob “A” counter clockwise

increases the blade exit speed.

09-01

BLITZ G BG B

G BG B

G B

09-03

09-04

09-05

9.3 VICE - POSITIONING / ADJUSTMENTS

There are 3 threaded holes on the machine heads for

positioning the vices (“1-2-3” - Fig. 09-03).

When positioning the vices the following factors must

be taken into consideration:

- Blade exit.

- Diameter and configuration of the profile to be cut

(the operation described below)

PLEASE NOTE

The vices MUST NEVER come within the cutting range

of the blades (as shown in Figs. 09-04 and 09-05).

G BG B

G B BLITZ

IMPORTANT!

The clamping pads of the 4 vices are patented.

The vice clamping pads (“4” - Fig. 09-07) have special

innovative technical features that will be described

below.

When positioning the vices, it is important that the

arrow printed on the pad is always facing upwards

(perpendicular to the worktable).

09-07

HORIZONTAL VICES

Undo release handle “1” - Fig. 09-06 to adjust vertically and rotate the vice cylinder.

Undo release handle “2” - Fig. 09-06 to adjust the vice cylinder horizontally.

N.B. Each horizontal vice is fitted with a safety valve defined as the non return valve. If the air pressure in the

circuit fails for any reason, this valve keeps the vices closed.

When the compressed air supply returns all the machine functions are restored.

WARNING

Before every cutting operation, the profiles must ALWAYS be clamped using the vices on the left and

right of the blade

Tap “3” excludes (as required) the external horizontal vice.

09-06

BLITZ G BG B

G BG B

G B

To make very inclined external cuts (near to 12°), the fixing point of the external horizontal vice must be moved

so that it will not collide with the blade when it comes out.

To do this, undo release handle ‘1’ - Fig. 09-08 to remove the vice and fix it over hole ‘2’ - Fig. 09-08 in order

to obtain the configuration as in Fig. 09-09.

09-08

09-09

G BG B

G B BLITZ

09-10

SUPPLEMENTARY VERTICAL VICE (OPTIONAL) (Fig. 09-10)

The supplementary vertical vice is used on the piece loading side (on the mobile head and/or on the fixed head)

and next to the profile height measurer (if present).

Turn screw “1” to adjust the vertical vice height positioning.

Turn screw “2” to adjust the vice horizontally.

Tap “3” excludes (as required) the supplementary vertical vice.

G BG B

G B BLITZ

9.4 MINIMUM CUT

The minimum cut between the two heads varies depending on how the actual heads are inclined.

Fig. 09-12 / 09-13 / 09-14 / 09-15 / 09-16 show the basic situations in which the two heads can be arranged

are shown.

NOTE 1:

The machines are equipped with safety devices that prevent INCORRECT MANOEUVRES to make sure that

below the minimum cutting measurements shown in the figures the heads cannot tilt and collide with each other.

NOTE 2:

Below 685 mm (Fig. 09-15) it is only possible to tilt to 45° internally THE FIXED HEAD as shown in Fig. 09-

16 to a minimum cutting measurement of 492 mm.

NOTE 3:

When in contact, the safety hoods around the cutting area move along the machine axis to allow the minimum

cutting conditions and return to their position by means of gas springs.

09-12

90°

350 mm

BLITZ G BG B

G BG B

G B

45° EXT

09-14

352 mm

09-13

MAX EXT.

DEG.

CUTTING LENGHT MIN

MAX EXT.

DEG.

MAX EXT. DEGREE CUT. LENGHT MIN MODEL

10° 485 mm. BLITZ 50

12° 478 mm. BLITZ 55

20° 485 mm. BLITZ 60L

G BG B

G B BLITZ

45°

INT

45°

INT

09-15

90°

492 mm

09-16

45°

INT

685 mm

BLITZ G BG B

G BG B

G B

Minimum cut at 45° EXT made in 2 phases by means of an undersize cutting program

1st PHASE: 45° cut with the fixed head only (see Fig. 09-17)

2nd PHASE: The mobile head clamps the piece and moves it back by a few mm, then the fixed head locks it

in that position. The mobile head moves back to the minimum measurement and makes the cut (see Fig. 09-

18).

09-17

09-18

G BG B

G B BLITZ

9.5 CUTTING ANGLES

To make cuts at fixed angles (45° external, 90°, 45° internal) and at intermediate angles, the electronic

control must be used following the instructions given in the documentation enclosed with this manual for

the electronic equipment fitted to the machine.

9.6 CUTTING PROCEDURE

To proceed correctly with cutting operations certain basic rules must be followed.

Check

- Start the motors (just one impulse – stop immediately ) and check that the blades are rotating in the correct

direction.

- Check that the atomising flow is sufficient, if not adjust it following the instructions given in the specific

paragraph.

- Check that the profile bars show no evident signs of twists along their length, as the clamping tends to

straighten them. In actual fact the profiles remain defective and the twist returns as soon as the vices are

released after cutting, so the pieces obtained cannot subsequently be used for assembly.

- Check that the thickness of the profiles is within the tolerance, as in angled cuts in excess of 90° the

differences in thickness create errors in determining the length of the piece to be cut.

9.7 SAW BLADE

One last but very important piece of advice on cutting is the choice of blades. The machine is actually calibrated

for a blade thickness of 3.4 mm. and a tooth thickness of 4.1 mm. (Ø 550), for a blade thickness of 3.2 mm.

and a tooth thickness of 4 mm. (Ø 500), for a blade thickness of 4 mm. and a tooth thickness of 4.7 mm. (Ø

600).

If these thicknesses are changed, automatically the fulcrum of the heads is altered and therefore the cutting

measurement. Non sharpened blades can also vary the fulcrum of the heads. These points must obviously

therefore be borne in mind.

For these reasons we recommend that only our blades are used as they offer guarantees of quality control,

balance, choice of materials used and design.

Furthermore the use of adapter rings applied to the blade hole is PROHIBITED. Only blades with a hole diameter

as shown on the machine ID plate must be used (Ø 32 mm. for blades Ø 500 and Ø 550, Ø 40 mm. for blades

Ø 600).

N.B. Use only blades that conform to EN 847-1 standard.

BLITZ G BG B

G BG B

G B

09-19

9.8 PROFILE POSITIONING

(Fig. 09-19)

For correct profile positioning on the work table, first of

all the vice jaws must be suitable for the profile to be

cut. For this reason the specifications are requested at

the time of ordering and it is in any case sufficient to

make requests according to the needs (even later on

if necessary).

The vice jaws are easily positioned on the worktable

because their only reference is a cylindrical pin.

Before positioning the vice jaws a thin film of grease

must be smeared over the contact surfaces to prevent

any swarf from entering.

The cutting quality does also in fact depend on the level

of cleanliness of the work table under the vice jaws.

Correct use of the vice jaw is illustrated in figure

09-20.

Vice jaw Vice jaw Vice jaw

09-20

CORRECT

12 3

CAUTION - IMPORTANT

The horizontal work tables are aligned during the machine assembly phase and MUST NEVER BE

DISMANTLED unless by qualified technicians and only in the event of specific necessity, as disassembly

by the user could compromise the correct work table alignment and consequently the cutting precision

of the machine.

G BG B

G B BLITZ

9.9 CLAMPING PROFILES

Efficient profile clamping is obtained (given the precise positioning, see previous paragraph) by checking the

clamping position of the pads - vice cylinders.

With reference to the main drawing (Fig .09-21) it should be noted that the height and crossways adjustment

of the vices is carried out in such a way as to clamp the profile in the way shown or in any case in the areas

with most ribbing on the profiles.

The profile must make perfect contact with the work table and the vice jaw.

Nevertheless, for cutting lengths over 2 metres, the use of the intermediate profile support is

recommended (OPTIONAL). This is to prevent the profile bowing downwards in the middle with consequent

measurement errors that may arise.

NOTE: As already described in the Chap.VICE - POSITIONING/ADJUSTING the vice pad (B - Fig. 09-21) is

worthy of a separate description. The pad has a special kind of articulation with a movement that tends

to adapt itself to the shape of the profile to be cut and which distributes part of the horizontal clamping

force in the direction of the worktable (downwards). For this reason it must be checked that the arrow

printed on the pad is always facing upwards (perpendicular to the worktable)..

09-21

A Vice cylinders

BLITZ G BG B

G BG B

G B

9.10 ADJUSTING THE PROFILE HEIGHT MEASURER (if present) (Fig. 09-22)

To exclude the profile height measurer, located on the mobile head, lower lever “A” completely.

WARNING

Before taking any readings with the profile height measurer, check that the surface “B” on which the piece rests

is higher than the rollers “C” on the mobile head roller table so that the profile lies perfectly on the table “B”.

NOTE

The use of the supplementary vertical vice kit is recommended to be placed near the measurer so as to allow

the profile to lie perfectly on the table “B”.

09-22

G BG B

G B BLITZ

09-23

9.11 CALCULATING THE CUTTING LENGTH (FIG. 09-23)

The following situations are three basic examples of calculating the cutting length.

1) To cut profile “1” read length “X” on the program

display

2) To obtain the reading “X” (same length as 1) for

profile cutting “2” (Right and/or Left) move the

head subtracting from the previous measurement

once the h value.

3) To obtain reading “X” (same length as “1 and 2”)

to cut profile “3” move the head subtracting from

the previous measurement “1” twice h.

4) To cut profile “4” read length “X” on the program

display.

Of course the important variable in determining the

length of the piece to be cut is always “h” which

changes depending on the profile used.

2) h

3) h

45°

45°45°

G BG B

G B BLITZ

09-25

9.13 RETRACTABLE MIDDLE PROFILE SUPPORT (OPTIONAL)

To fit one of the retractable middle profile supports (supplied AS AN OPTIONAL EXTRA) to the machine proceed

as follows (the machine is in any case supplied with the necessary mechanical and pneumatic connections

to allow easy fitting).

Fit the support over the 2 holes on the front of the base using the 2 screws “A” - Fig. 09-25.

Make the pneumatic connection by connecting hose “B” - Fig. 09-25 as represented in figure.

Adjust, the height of the support, if necessary, using cam “C” - Fig. 09-26.

If necessary, adjust the support horizontally using screw “D” - Fig. 09-26 making sure that the horizontal roller

at rest is parallel with the machine base.

09-26

WARNING

The LH profile support should be fitted to the first or second pair of holes on the machine base.

The RH profile support, for the 6.6 m version only, should be fitted to the third pair of holes on the machine base.

BLITZ G BG B

G BG B

G B

09-27

1ST LEFT SUPPORT PLATE

2ND LEFT SUPPORT PLATE

1ST LEFT SUPPORT SOLENOID VALVE

III

After opening the fixed head rear guard, fit the relative solenoid valve in place of the closing plate (see Fig. 09-

27) following the directions given in Chap. 10.5 CHANGING SOLENOID VALVES and in the electrical wiring

and pneumatic diagrams (N.B. the 1st Left support solenoid valve is the one for the lower closing plate, the 2nd

Left support is the one for the upper closing plate).

Connect one of the air hoses “E” - Fig. 09-27 already made available (to make sure the hose to be connected

is the right one, first blow air into the hose with the gun and check that it comes out of hose “B” - Fig. 09-25).

G BG B

G B BLITZ

The RH profile support for the 5 m version only, should be fitted externally (see Fig. 09-28). It can be fitted up

to a max. distance of 4 m from the end of the base.

Once the support has been levelled on the relative foot using the 4 screws ‘A’ - Fig. Fig. 09-28, a check must

be made to see that it is aligned horizontally and vertically with the other profile supports on the machine.

To adjust the height, turn the 4 screws ‘B’ - Fig. 09-28 so that the support can run along extrusion ‘C’ - Fig.

09-28 up to the set height.

Lastly, it must be fixed to the ground by inserting 2 STOP plugs at points ‘D’ - Fig. 09-28.

09-28

To enable from the program the retractable support that has been fitted, proceed as follows:

- Press the emergency button.

- From the program’s main menu, press ‘Parameters’ and then ‘Machine Configuration’.

- Type in the password (0546) and press Enter.

- Move to the relevant ‘Profile support’ field and select the ‘YES’ option, pressing the left or right arrow keys

as necessary.

- Press the following keys in the order given: HOME => HOME => HOME to return to the main menu.

NOTE: For an explanation of the significance of the touch-screen buttons, press key ‘i’.

- Reset the emergency button

BLITZ G BG B

G BG B

G B

9.14 CUTS WITH THE STEP-BY-STEP KIT (OPTIONAL)

To make cuts using the (OPTIONAL) STEP-BY-STEP mode a supplementary profile support table must be

used on the fixed head work table.

First of all, support ‘A’ - Fig. 09-29 must be fitted using the 2 screws below the support.

Then, fit pin ‘B’ - Fig. 09-30 (push-fit): once the pin has been height adjusted using cam ‘C’ - Fig. 09-30, secure

the pin in place by tightening grub screw ‘D’ - Fig. 09-30.

09-29

DC09-30

G BG B

G B BLITZ

Now table ‘E’ - Fig. 09-31 can be fitted for making 90° step-by-step cuts.

The table is inserted over support ‘A’ - Fig. 09-29 and rests up against pin ‘B’ - Fig. 09-30

The table is secured in place by tightening the 2 fixing screws ‘F’ - Fig. 09-31.

CAUTION - IMPORTANT

Table ‘E’ - Fig.09-31 must ONLY be used when making 09° step-by-step cuts with the fixed head blade.

For non 90° cuts using the fixed head blade, the table must ALWAYS be removed otherwise it could be cut by

the blade.

09-31

If the ‘step-by-step’ program is used with a safety photocell barrier, for fitting the photocells see the leaflet

“Photocell kits for step-by-step program” enclosed with this manual

BLITZ G BG B

G BG B

G B

10 MAINTENANCE

GENERAL ADVICE

Before carrying out any type of operations, read carefully the instructions given in this manual.

WARNING

These operations must only be carried out by skilled and competent personnel.

- All maintenance operations must be carried out with the machine disconnected from the electrical power

and compressed air supplies, using padlocks to block the relative switches.

-When the electrical equipment is supplied with power, certain parts of the machine can be dangerous.

- Non compliance with the safety rules set out here can therefore lead to damage being caused to persons

or things.

- All the instructions given in chapter 10.1 of this manual must therefore be followed, as well as the warning

notices affixed to the machine itself.

- Once maintenance operations are complete, before putting the machine back into service, make sure that:

1 - any parts replaced and/or tools used for the maintenance operations have been removed from the

machine.

2- all safety devices are in proper working order.

10.1 DAILY MAINTENANCE

The maintenance operations for the BLITZ are very simple and are listed in the following order:

- Check the cutting lubrication oil level “A” - Fig.10-01 (a lack of oil is in any case signalled by the equipment).

CAUTION - IMPORTANT

Top up using only “Oil for cutting aluminium” with a viscosity no greater than 40 cSt.

- Check on gauge “B” - Fig. 10-02 the incoming air pressure level.

- Check through the slits “C” - Fig. 10-02 for any condensation in the cup. If there is condensation in the

vessel, press knob “D” - Fig. 10-02 upwards until it is drained (this operation must be carried out without

disconnecting BLITZ from the air supply). The condensation is in any case drained automatically (with

the ring open) each time the air supply hose is disconnected.

- Using the compressed air gun supplied if necessary, clean all traces of dust or chips from the work contact

surfaces.

WARNING

Protective eye goggles and a face mask must be worn whenever the compressed air gun is used; make sure

also that there is no one in the area where cleaning is taking place.

- Keep the area around the machine clear of offcuts, chips and all other machining residue.

10-01 10-02

BLITZ G BG B

G BG B

G B

10-04B

10-04A

Approx every 900 work cycles each retractable profile support must be greased (if present) by the following

procedure:

1) move the mobile head away from the fixed head and take it to the end of the bench so that the profile supports

can be raised;

2) remove the support cover using screw “3” - Fig. 10-04C

3) apply grease inside race “4” - Fig. 10-04D;

4) put the cover back on the profile support using screw “3” - Fig. 10-04C making sure that the support is set

perpendicularly to the bench.

For each lubrication, pump just once with average force during the operation.

The specifications of the grease to use are given in Table 10-02.

GREASE SPECIFICATIONS

Table 10-02

FOM spare part code for grease: ET-77460 in 1 Kg. packs.

Type of soap Semi-synthetic

Active component Liquilon PTFE

NLGI consistency 0

Working temperature -20 +178 °C

Flash point 276 °C

Density at 40°C 0.904 g/cm3

Consistency ASTM D217 25°C 285

Evaporation ASTM D972 99°C None

Rust protection ASTM D 1743 Passed

G BG B

G B BLITZ

- Periodically check the cleanliness of the filters inside the cabinet ventilation grilles. The ventilation grilles

are dismantled manually.

If the filters are black and therefore saturated they must then be cleaned or if necessary replaced.

When fitting new filters, use a filtering material in heat bound synthetic fibre with the following specifications:

Type: 350 g/m2

Filtering efficiency: 83%

Filter category (DIN 24 185): EU 3

10-04D10-04C

-Cleaning the keyboard and touch screen

It is recommended to not use sharp objects to operate the keyboard or the touch screen.

In particular, use the pen provided to activate the touch-screen.

Clean with a soft cloth in a neutral detergent, you can use for this purpose also ethanol.

Never use chemical solvents, acids or alkaline solutions.

The cleaning liquid should not drain between the film and the glass surface of the display.

BLITZ G BG B

G BG B

G B

10.3 FITTING A NEW BLADE

The saw blade should be changed when it is noticed that the cutting quality is not optimal because of wear or

because some teeth are broken. To do this carry out the following procedure.

Wear gloves.

Position the head to 90°.

Turn the pneumatic disconnecting switch to “0” and padlock it; open the main switch locking it in place with

a padlock.

WARNING - IMPORTANT

After switching off the compressed air supply, wait at least 10 sec. before cutting off power to the machine,

to make sure, for safety reasons, that the blades have stopped completely in braked mode (with a time of less

than 10 sec.). Otherwise, if this rule is not followed, when power to the machine is cut off, it will be necessary

to wait at least 3 min. before gaining access to the blade.

Take away blade safety guard “A” by undoing the 3 screws “B” (Fig. 10-05).

With one of the tools supplied “C” secure the flange by inserting the 2 pins of the tool in the relative holes and

with the other tool “D” remove fixing screw “E” turning counter clockwise for the fixed head and clockwise for

the mobile head (Fig. 10-06).

Pull out by hand flange “F” of the motor shaft (Fig. 10-07).

Remove the blade carefully, slipping it off the motor shaft.

WARNING

When refitting the new blade, make sure that the teeth are pointing in the right direction.

After positioning the sawblade on the shaft, fit flange “F” - Fig. 10-07 by hand after greasing it suitably, then

refit fixing nut “E” - Fig. 10-06 (clamping torque = 35 Nm).

Lastly, refit safety guard “A” securing the 3 fixing screws “B” (Fig. 10-05).

Release and turn the pneumatic disconnecting switch to “I”, remove the padlock from the main switch, then

restore power to the machine using the same switch.

Carry out a few test runs of the blade (to check for any vibrations).

10-05

G BG B

G B BLITZ

10-07

10-06

BLITZ G BG B

G BG B

G B

10.4 FITTING A NEW PRESSURE SWITCH

To fit a new pressure switch proceed as follows:

1) Turn the pneumatic master switch to “0” and

secure it with a padlock. Then open the main switch

and secure that too with a padlock.

2) Open the fixed head rear guard “A” - Fig. 10-08

using the relative 4 fixing screws.

3) After removing cap “B” - Fig. 10-09, disconnect

the two electrical wires “C” - Fig. 10-09 1coming

out of the pressure switch.

4) Undo the pressure switch by using an Allen key to

turn block “D” - Fig. 10-09

5) Fit the new pressure switch by screwing it into

connection “E” - Fig. 10-09.

6) Connect the two wires “C” - Fig. 10-09 (it does not

matter to which terminals, there is no specific

polarity)

7) Replace the pressure switch cap “B” - Fig. 10-09.

8) Close safety guard “A” - Fig. 10-08.

9) Release the pneumatic master switch and set it to

“I”, remove the padlock from the main switch,

then restore power to the machine using the same

switch.

10) Carry out a few test runs.

10-09

10-08

G BG B

G B BLITZ

10.5 FITTING NEW SOLENOID VALVES (FIG. 10-10)

The need to fit a new solenoid valve may arise each time one of the electro-pneumatically governed operations

cannot be performed; for example, closing the vices, blade exit, etc.

In this case substitute the relevant solenoid valve by the following procedure:

1) Turn the pneumatic master switch to “0” and secure it with a padlock. Then open the main switch and

secure that too with a padlock.

2) Open the rear safety guard “A” - Fig. 10-09 of the FH or MH (depending on which solenoid valve needs

replacing) using the 4 fixing screws.

3) Disconnect the air tubes.

4) Undo screw “C” and then pull out the solenoid valve by turning it through 90°.

5) Fit the new solenoid valve to the sub-base (turning it through 90°) and fix it in place with screw “C” (there

is only one way round to fit it).

6) Disconnect the air tubes “B”.

7) Refit and secure the rear safety guard.

8) Release the pneumatic master switch and set it to “I”, remove the padlock from the main switch, then

restore power to the machine using the same switch.

9) Carry out a few test runs.

10-10

BLITZ G BG B

G BG B

G B

10-12

10.6 FITTING A NEW REMOTE CONTROL SWITCH

If the motor does not start, even though power is being supplied to the machine and the compressed air

connection has been made properly, it means that the remote control switch is faulty, and so it needs to be

replaced by the following procedure:

1) Turn the pneumatic master switch to “0” and secure it with a padlock. Then open the main switch and

secure that too with a padlock.

2) Open the door of the electrical cabinet “A” - Fig. 10-11 using the triangular spanner supplied.

3) Using a screwdriver as a lever, prise the remote control switch “B” - Fig. 10-12 from the omega bar which

it is fixed to.

4) Disconnect the auxiliary connections fixed to the sides of the remote control switch, undoing the two

corresponding screws without having to disconnect the electrical wires from these contacts.

5) Disconnect the wires from the old remote control switch and connect them to the new one being careful

to attach the wires in the same point.

6) Hook up the auxiliary contacts again with the relative screws.

7) Fix the remote control switch to the omega bar again

8) Close the door of the electrical cabinet “A” - Fig. 10-11.

9) Release the pneumatic master switch and set it to “I”, remove the padlock from the main switch, then

restore power to the machine using the same switch.

10) Carry out a few test runs.

10-11

G BG B

G B BLITZ

10-13

10.7 CHANGING THE PADS ON THE VICES (Fig. 10-13)

Turn the top grub screw “A” to remove special pad “B”.

BLITZ G BG B

G BG B

G B

10-15

10.8 FITTING A NEW HORIZONTAL VICE CYLINDER

1) Turn the pneumatic master switch to “0” and padlock it, then turn the main switch to “0”.

2) Remove the vice pad.

3) Undo the release handle “A” - Fig. 10-14 and remove the cylinder.

4) Disconnect the air tubes “B” - Fig. 10-14.

5) Fit the pad to the new cylinder, replacing it with a new one if necessary.

6) Position the new cylinder inside its housing, securing it with the release handle “A”.

7) Connect the air tubes “B” to the union on the new cylinder.

8) Release the pneumatic master switch and turn it to “I” then turn the main switch to “I”.

9) Carry out a few test runs.

10-14

BLITZ G BG B

G BG B

G B

10-17

Internal vertical vice (Fig. 10-17)

1) Turn the master switch to “0” and secure it with a padlock, then turn the main switch (400 V - three-phase)

to “0”.

2) Remove the PVC pad.

3) Disconnect tube “A”.

4) Undo grub screw “B” and screw “C” of the reed in order to remove the reed and its cylindrical support.

5) Undo release handle “D”and take out cylinder “E”.

6) Remove ring “F” from the old cylinder by undoing the grub screw and fit it to the new cylinder making sure

it goes in exactly the same position as before (see measurement in the figure).

7) Replace the cylinder in its housing and tighten release handle “A”.

8) Refit the PVC pad (or fit a new one if necessary).

9) Fix the reed (making sure the position of the cylindrical support is perfectly level with the cylinder) tightening

grub screw “B” and screw “C”.

10) Connect up tube “A”.

11) Release the pneumatic master switch and turn it to “I” then turn the main switch to “I”.

12) Carry out a few test runs (e.g. to check the reed is on with the vice raised).

90 mm.

G BG B

G B BLITZ

10-18

10.10 CLEANING THE VICE CYLINDER STOP VALVE (Fig. 10-18)

Remove the metal ring “A” with a screwdriver ; take out the stop valve end cap “B”; Take out the shutter “C”

and clean it being careful of the springs fitted to the shutter, then refit all the components.

N.B. Do not unscrew the valve body “D” from the cylinder body “E”, because there is a preloaded spring

inside which would push the piston out.

BLITZ G BG B

G BG B

G B

10.12FITTING A NEW SWARF CONVEYOR BELT

- Turn the master switch to “0” and secure it with a padlock, then turn the main switch (400 V - three-phase)

to “0”.

- Remove the chips-protection brush “A” next to the fixed head using the relative fixing screws “A1” (Fig.

10-19)

- Remove the 4/6 top metal panels “B” (2/3 on each side) by undoing the relative fixing screws “B1” (Fig.

10-20).

- Undo the fixing screws on plates ‘C1’ and ‘C2’ (Fig. 10-20).

- Remove the conveyor belt from the base of the machine by undoing the fixing screws “D1” for the brackets

“D” (1 on each side) (Fig. 10-21): the nuts “D2” on the screw adjusters are loosened in order to tighten

screw “D1” on the belt leaving enough space to remove it.

- Open safety guard “E” around the motor using the 4 fixing screws “E1” so that the cable can be disconnected

from the motor (Fig. 10-22).

10-19

A1 A1

G BG B

G B BLITZ

10-20

10-21

Produkt Specifikationer

Mærke:	FOM
Kategori:	savemaskine
Model:	Blitz

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savemaskine FOM Manualer

FOM Blitz Manual

7 August 2024

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