COD: 81091GB_002 Date of printing:

printing: 9/2004

Operating instruction manual

COMBI ELECTRA STAR

Before making any operations on the machine, you have to read and understand
carefully all the parts of this manual

Keep in a safe place and easy to consult

(translation)

The general safety regulations are given in chapter 1

Emmegi S.p.A. via Archimede, 10 - 41010 Limidi di Soliera (MO) - Italy

Tel. +39 059 895411 - Fax +39 059 566286
emmegi@emmegigroup.com - www.emmegigroup.com
 MANUFACTURER: Emmegi S.p.A.

ADDRESS: via Archimede, 10

TYPE OF DOCUMENT: Operating instruction manual

MODEL: COMBI ELECTRA STAR

SERIAL NO.:

CUSTOMER:

YEAR OF MANUFACTURE:

The contents of this document may not be used, reproduced or assigned to third parties without the express consent of Emmegi S.p.A.
Emmegi S.p.A. reserves the right to modify without notice the features of the machine described in this document.
Dear Customer,

Thank you for having opted for the quality associated with the EMMEGI trademark. Our
company bases its organization on customer service; such policy has been developed over the years
to become a real byword distinguishing the Emmegi company style:

accompanying the customer from the purchase to AFTER - sales.

The high level of technology and computerized systems applied to our machines, the constant
commitment to research and training of qualified personnel, are communicated day-by-day into the
service offered by Emmegi to its customers.

In this connection you are kindly requested to contact the Emmegi After-Sales Service nearest
to you, for all technical enquiries or calls for servicing our machines. Emmegi is fully equipped to offer
customized technical solutions for all customers, therefore it can deal with all types of problems
associated with the machine. For any other problem or information you can contact our Sales
Organization which will be at your full disposal to answer your question.

info@emmegigroup.com
Sales department emmegi.italia@emmegigroup.com

Tel. +39 059

059 895411
Fax +39 059 566286
Fax Sales department +39 059 859404

Kind regards

Sole Director
Giuseppe Caiumi

Sole Director
Valter Caiumi

L
 1. INTRODUCTION

4 COMBI ELECTRA STAR

 1. INTRODUCTION

Table of contents

1. INTRODUCTION ......................................................................................................... 3

MACHINE DESCRIPTION ................................................................................................................. 7

SPECIFICATION AND ENVIRONMENTAL DATA .............................................................................. 8
MACHINE OVERALL DIMENSIONS ................................................................................................. 9
STANDARD FEATURES ................................................................................................................. 10
OPTIONAL EXTRAS ...................................................................................................................... 10
CUTTING CHART ............................................................................................................................ 11
SAFETY AND ACCIDENT PREVENTION ........................................................................................ 12
INTENDED AND PROHIBITED USE OF THE MACHINE ......................................................................... 12
GENERAL SAFETY REGULATIONS ......................................................................................................... 12
RECOMMENDATIONS REGARDING ROOM LIGHTING .......................................................................... 13
CONNECTIONS ......................................................................................................................................... 13
EARTHING (GROUNDING) ....................................................................................................................... 13
SAFETY DEVICES ..................................................................................................................................... 14
LAYOUT OF THE SAFETY DEVICES ........................................................................................................ 15
LAYOUT OF RISK ZONE AND RESIDUAL RISK ZONE ........................................................................... 16
LAYOUT OF OPERATOR CONTROL ZONES ............................................................................................ 16
NOISE ......................................................................................................................................................... 17
REFERENCE STANDARDS ............................................................................................................ 18
REFERENCES TO HARMONIZED STANDARDS ............................................................................ 18
DISPOSAL OF HARMFUL SUBSTANCES ..................................................................................... 18
MACHINE DECOMISSIONING ....................................................................................................... 18

2. INSTALLATION ......................................................................................................... 19

TRANSPORT .................................................................................................................................. 19
FORM OF TRANSPORT ............................................................................................................................. 19
CHECK FOR ANY DAMAGE INCURRED ................................................................................................. 19
HOISTING INSTRUCTIONS .......................................................................................................... 20
SITE ............................................................................................................................................... 21
Installation and levelling ............................................................................................................. 22
SWARF EXHAUSTER CONNECTION ....................................................................................................... 23
PREPARATION OF THE MACHINE FOR COMMISSIONING .......................................................... 25
LAYOUT OF THE EQUIPMENT ON BOARD THE MACHINE .................................................................... 25
TO FILL TANKS AND RESERVOIRS ......................................................................................................... 26
CONNECTION OF THE MACHINE TO POWER SUPPLIES ..................................................................... 27

3. MACHINE COMMISSIONING AND OPERATION .................................................... 29

GRAPHIC SYMBOLS AND FUNCTION OF THE CONTROLS ........................................................ 29

LIST AND LAYOUT OF THE CONTROLS ...................................................................................... 30

COMBI ELECTRA STAR 5

 1. INTRODUCTION

PREVENTIVE CHECKS .................................................................................................................. 31

TO CHECK FOR CORRECT DIRECTION OF BLADE ROTATION ........................................................... 32
CHECK FOR BLADE OUTFEED ................................................................................................................ 32
SET-UP AND INITIAL ADJUSTMENTS .......................................................................................... 33
CLAMP ADJUSTMENTS ............................................................................................................................ 33
VERTICAL CLAMPS (OPTIONAL) ............................................................................................................. 34
COOLANT FLOW ADJUSTMENT ............................................................................................................... 35
FEED RATE ADJUSTMENT ....................................................................................................................... 35
WORK CYCLE ................................................................................................................................ 36

5. MAINTENANCE AND REPAIR ................................................................................. 87

PERIODIC CHECKS ....................................................................................................................... 87

OIL CHART .................................................................................................................................... 88

TO DRAIN CONDENSATE .............................................................................................................. 96

TO REPLACE TOOLS .................................................................................................................... 97
TOOL TABLE .............................................................................................................................................. 97
PERIODIC CLEANING .................................................................................................................... 98
WHAT TO DO IF............................................................................................................................. 98
FOREWORD ............................................................................................................................................... 98
... YOU NEED TECHNICAL SERVICE ....................................................................................................... 98
... THE “POWER ON” INDICATOR LAMP FAILS TO LIGHT UP ................................................................ 99
... THE MACHINE DOES NOT START ........................................................................................................ 99
... THE MOVING CUTTING HEAD IS NOT POSITIONED AT THE PRESET POINT ................................. 99
... THE CUTTING HEADS FAIL TO TILT .................................................................................................. 100
... THE “HEAD POSITIONING” MESSAGE FLASHES CONTINUOUSLY. ............................................... 100
... THE BLADE MOTORS FAIL TO START ................................................................................................ 100
... THE CLAMPS FAIL TO CLOSE ............................................................................................................ 100
... THE BLADES FAIL TO FEED OUT DURING THE CUTTING PHASE ................................................. 100
... THERE IS IRREGULARITY IN CUTTING ANGLES ............................................................................ 100
... THE FEED CYLINDER REQUIRES REPLACEMENT ......................................................................... 101
... THE PRESSURE SWITCH IS OFF SETTING ...................................................................................... 101

6 COMBI ELECTRA STAR

 1. INTRODUCTION

MACHINE DESCRIPTION
COMBI ELECTRA STAR model serve exclusively for cutting aluminium profiles.
Machines consist of a steel plate base on which are fastened two high strength steel slideways serving to
guide the moving cutting head in its traverse.
The machine performs an electronically controlled, motorized rotation of the horizontal axis (from 22°30’
on the outside to 45° on the inside) and a pneumatic tilting of the vertical axis (up to 45° on the inside).
The workpiece cutting length is obtained by moving the cutting head with the aid of an industrial computer.

This type of cutting-off machine can support numerous modes of operation, namely:
♦ Execution of single cuts with automatic profile height compensation;
♦ Execution of keyboard-edited cutting lists;
♦ Execution of cutting lists received from Personal Computer via floppy disk or network if installed;
♦ Execution of cleat cutting (optional);
♦ Execution of virtual cuts (cuts whose length is smaller or greater than the minimum or maximum
cutting size of the machine);
♦ Execution of parallel cuts (cuts at angles exceeding machine capacity, performed with aid of the
pusher);
♦ Execution of cuts to remove overhang on mitres (optional);
♦ Label printer control during cutting (optional);
♦ Presetting and execution of formulae for automatic calculation of certain window/door frames.

A hydropneumatic cylinder powers the blade feed. The blade can only be moved from the vertical plane with
the motor started (blade rotating), the clamps locked and the guards down.
Cutting is performed by carbide tipped blades.
Blade cooling, which only takes place during the cutting operation, is through a “LUBRICA” system with
adjustable flow rate.
Just one operator standing at the front of the machine close to the control panel is needed to carry out the
required operations.

COMBI ELECTRA STAR 7

 1. INTRODUCTION

SPECIFICATION AND ENVIRONMENTAL DATA

Characteristics U.M. 500

Minimum cutting lenght mm 475
Maximum cutting lenght mm 4000-5000-6000
Carbide tipped blade diameter mm 500
Blade spindle diameter mm 32
Blade drive motor power kW 2,2
Blade drive r.p.m. (50 Hz) 1/min 2880
D.C. motor power rating (2000 rpm) W 400
Total installed power kW 7
Blade feed rate mm/s 0÷60
Cutting speed m/s 75
Head carriage traversing speed m/min 20
Operating pressure bar 6÷8
Compressed air consumption for cycle at 6 bar Nl 8

Average effective Average effective

Sound power
sound pressure level sound pressure level
ACOUSTIC OUTPUT on the measuring
emitted by the
at the operator
machine
surface position

No-load operation without suction Lp=77,1 [dB(A)] Lw=95,3 [dB(A)] Lop=76,9 [dB(A)]

During cutting with suction Lp=92,0 [dB(A)] Lw=110,2 [dB(A)] Lop=89,1 [dB(A)]
During cutting without suction = = Lop=89,7 [dB(A)]

ENVIRONMENTAL DATA
Ambient air temperature:
Operative: °C 5÷40
No operative: °C -20÷60

Maximum no pressurized altitude:

Operative: m 1000
No operative: m 12000

Relative humidity:
Operative: % 30÷90
No operative: % 5÷95

8 COMBI ELECTRA STAR

 1. INTRODUCTION

MACHINE OVERALL DIMENSIONS

Useful cut A B C D Weight (Kg)

4 m 8000 4620 5480 110 0 1650
5 m 9000 5620 6480 110 0 1800
6 m 1000 0 6620 7480 110 0 2250

COMBI ELECTRA STAR 9

 1. INTRODUCTION

STANDARD FEATURES
Characteristics of the control
• industrial computer MS DOS compatible
• 10,4” TFT color graphic display
• 500 Mb hard disk & 1,44 Mb 3,5” floppy disk drive
• provision for correction to remote PC via disk, network or serial
• provision for connection to industrial label printer
• perform single cuts
• memorization of 500 profile compensations with automatic size calculation for cuts other than 90°
• memorize of 500 cutting lists (1000 instructions per list) via keyboard
• bars optimization

Characteristics of the machine

• automatic setting of any intermediate angles
• couple of TCT widia blades 500 mm dia.
• 2 full pneumatic guards, cutting area
• vertical clamping system with horizontal clamp
• couple of horizontal pneumatic clamps
• profile support roller conveyor
• profile support and millimeter scale
• provision for swarf exhauster MG4
• LUBRICA, pure oil blade coolant system

OPTIONAL EXTRAS
Description
• graphic software Frame Project for industrial computer
• EXTRA (software extending cutting capacity, short cuts, cleat cuts also at angles other than 90°,
automatic, bevels, parallel and bar-code printing)
• software for control through macros with 500 styles other than 90°
• additional clamp for profile holding on the roller conveyor
• couple of vertical pneumatic clamps
• intermediate profile support pneumatically swivelling (not applicable with swarf drawers)
• swarf drawers
• clamp and support for automatic cutting and cleat cutting software
• industrial label printer (thermal printing) and BAR CODE software
• uninterruptible power supply 550-VA (no break)

10 COMBI ELECTRA STAR

 1. INTRODUCTION

CUTTING CHART

COMBI ELECTRA STAR 11

 1. INTRODUCTION

SAFETY AND ACCIDENT PREVENTION

FOREWORD
It is the employer’s duty to instruct the personnel as regards risks of accidents, as well as devices provided
for the operator’s safety, risks in exposure to noise and general accident prevention regulations laid down by
international directives and by legislation of the country of destination for the machines.
Before starting work, the operator should be perfectly familiar with the position and operation of all machine
controls as well as with the machine characteristics.
The machine must only be used by operators trained in its use, who have fully read and understood the
instructions contained in this manual.
The instructions, recommendations and general safety rules contained in this manual must be fully observed.
Tampering/non authorized replacement of one or more machine parts or units, or the use of accessories,
tools, consumables differing from the ones recommended by the manufacturer, could represent risk of
accident; moreover they exonerate the manufacturer from civil and criminal liability, and cause the immediate
ceasing of all forms of warranty.
In accordance with ECC DIRECTIVE 89/392 FOR MACHINES the following definitions are given:
“Danger zones”: any zone within and/or in the vicinity of a machine in which the presence of an exposed
person represents a risk for the safety and health of such person;
“Exposed person”: any person who is located fully or partly in a danger zone;
“Operator”: the person/persons assigned to install, operate, adjust, carry out maintenance, clean, repair and
handle the machine.

INTENDED AND PROHIBITED USE OF THE MACHINE

The machine model COMBI ELECTRA STAR has been designed and built for cutting ALUMINIUM
profiles. Hence it is not allowed to use the machine to cut other types of material. A use differing from the
intended one could cause damage to the work facility and represent a hazard for the operator.
As regards the foreseeable misuse, it is recommended:
to consider that the consistency in section of the aluminium profile is linked to the power rating of the blade
drive motor installed.
never to use the machine for cutting profiles not falling within the maximum cutting capacities given in the
cutting chart.

GENERAL SAFETY REGULATIONS

♦ Routine and unscheduled maintenance should only be performed with the machine stationary and
disconnected from the electric and pneumatic power sources;
♦ Any work on the hydraulic or pneumatic equipment should only be performed after discharging the
pressure from inside said equipment;
♦ Repairs to the electrical equipment must only be carried out with the power switched off and with the
emergency push button pressed;
♦ Never change tools with the machine operating or in movement;
♦ Never place foreign matter, hands or otherwise on moving parts and never place containers of liquids
close to the electrical parts;
♦ The workplace should always be kept clean and tidy;
♦ The operator should avoid carrying out any uncertain operations or operations not prescribed by the
current job that could impair his balance;
♦ It is strictly forbidden to remove safety devices and/or barrier guards;
♦ The operator is recommended to use personal protective aids against noise;
♦ The operator is recommended to wear clothing suitable for the workplace and the situation in which he
finds himself;
♦ Machine operator or maintenance personnel should refrain from wearing chains, bracelets, rings; hair
nets should be worn when necessary.

12 COMBI ELECTRA STAR

 1. INTRODUCTION

RECOMMENDATIONS REGARDING ROOM LIGHTING

The customer should ensure that the workplace be provided with suitable lighting (natural or artificial) in order
to safeguard the operator’s safety and health.
(See ISO 8995-89 standard “Lighting in the wrkplace”).

CONNECTIONS

Make sure that the conductors or hoses of the various supply systems (electrical, water, pneumatic,
hydraulic) be of adequate size to withstand the maximum levels drawn by the machine as indicated on the
nameplate in Fig. 1-1.
When making the connections, it is good practice to observe the general installation rules for the preparation
and installation of electrical equipment. See IEC 64-8 standard.
Installation and electrical connections should be carried out by qualified personnel

Fig. 1-1

EARTHING (GROUNDING)

The earthing system must correspond to precise characteristics laid down by relative standard IEC 64-8
(IEC64; IEC364).
Connection to earth (ground) should also be made for low voltage equipment if the voltage exceeds 25 V to
earth for alternating current and 50 V to earth for current current.

COMBI ELECTRA STAR 13

 1. INTRODUCTION

SAFETY DEVICES

The COMBI 5 ELECTRA STAR cutting-off machine is fitted with various “SAFETY DEVICES”:

Description of the devices Function of the devices

A. blade drive motor guard
Fixed guards
B. blade guard

Moving guards C. blade cover during cutting phase

D. positioned on the control panel, after pressing

Emergency stop device
it stops all machine functions instantaneously

E. one microswitch checks that electrical panel

doors are closed; after opening, it stops all
machine functions instantaneously
F. two microswitches protect against any
Electromechanical limit switches
accidental opening of the moving blade guard
during cutting
G. two microswitches indicate which cutting
heads are in rest position

H. minimum pressure switch: interrupts all work

functions when the pressure drops below 4 bar
I. low pressure valve: allows having a pressure of
2 bar on the profile clamp until the operator
starts using the two-hand control
Safety devices of electropneumatic
L. pneumatic equipment provided with device for
type
discharging pressure before carrying out
maintenance
M. unidirectional solenoid valves mounted on the
cylinders: they keep the profile gripped in the
event of insufficient pressure

N. Two-hand control, type 2 (CEI EN 60204-

1.9.2.5.7):
- both hands must be used at the same time to
Controle devices activate the work cycle;
- continous actuation during the cutting phase;
- interruption of the work cycle if one of the two
push buttons is released.

14 COMBI ELECTRA STAR

 1. INTRODUCTION

LAYOUT OF THE SAFETY DEVICES

F C F

A A
B B

M G M

I H

L D

N N

COMBI ELECTRA STAR 15

 1. INTRODUCTION

LAYOUT OF RISK ZONE AND RESIDUAL RISK ZONE

Despite the barriers and safety devices installed on the machine, the machine can have zones defined
as “RISK and RESIDUAL RISK” due to a possible incorrect use of the machine by its operator.

LAYOUT OF OPERATOR CONTROL ZONES

Under normal operating conditions the control and operation of the COMBI 5 ASSI STAR machine
should be confined to areas assigned for its operation.
These areas are free from risk for the machine operators and are designated “CONTROL ZONES”.

1. Control zone
2. Operating zone

16 COMBI ELECTRA STAR

 1. INTRODUCTION

NOISE

The machine is designed and built so as to reduce the pressure power level at the source. Its sound
characteristics regarding:

♦ average effective sound pressure level on the measuring surface;

♦ sound power level emitted by the machine;
♦ average effective sound pressure level at the Operator’s place.

They are reported in the SPECIFICATION AND ENVIRONMENTAL DATA chart, and have been determined
according to ISO 3476.

Test environment: semi-anechoic chamber conforming to ISO 3745/77

Instumentation: all instruments are of class 1

Test method: the test piece is placed at the centre of the chamber.
The measuring surface is that of a parallelepiped whose sides lie at one
metre from the most projecting point of the two cutting heads spaced apart by
1000 mm; 10 measuring points are placed on the parallelepiped.
The operator’s place is situated at 1.5 m from the floor and 0.5 m from the most
projecting vertical plane of the machine front.
A tee-shaped aluminium profile, size 90x45 mm, was used during the cutting
phase.

The employer should see that the necessary steps are taken to reduce the noise level and make sure that the
operators are provided with personal protective equipment (ear plugs, ear muffs). Moreover the notices
affixed to the machine (Fig. 1-2) should be duly observed.
As regards personal protection equipment, we refer to EEC directives 89/686 “PERSONAL PROTECTIVE
EQUIPMENT” and 89/391 “SAFETY AND HEALTH IN THE WORKPLACE”.
When requested, EMMEGI S.p.A. will be glad to offer their services in examining and finding solution to
problems associated with such risk.

Fig. 1-2

COMBI ELECTRA STAR 17

 1. INTRODUCTION

REFERENCE STANDARDS

DIRECTIVES REGARDING MACHINE SAFETY

♦ EEC directive 89/392 “Machines”;

♦ EEC directive 73/23 “Low voltage”;
♦ EEC directive 89/336 “Electromagnetic compatibility”;

DIRECTIVES CONCERNING SAFETY IN THE WORKPLACE

♦ EEC directives N° 80/1107; 83/477; 86/188; 88/642 concerning protection of workers against risks
derived from exposure to chemical, physical and biological agents during work;
♦ EEC directive N° 89/391 concerning improvement of safety and health of the operators during work,
with special allied EEC directives N° 89/654 and N° 89/655;
♦ EEC directive N° 90/394 concerning protection of workers against risks derived from exposure to
carcinogenic agents during work;
♦ EEC directives N° 77/576 and N° 79/640 regarding safety notices in the workplace;

DIRECTIVES CONCERNING PERSONAL PROTECTION

♦ EEC directive N° 89/656 and N° 89/686 concerning the use of personal protective equipment;

REFERENCES TO HARMONIZED STANDARDS

General: UNI EN 292-1; UNI ENA 292-2; ENV 1070;

Safety aspects: UNI EN 294; UNI EN 349; CEI EN 60204-1; EN 60439-1; CEI EN 60445;
CEI EN 60073; CEI EN 60529; CEI EN 61082-1; ISO 7000;

Safety devices: UNI EN 418; UNI EN 457.

DISPOSAL OF HARMFUL SUBSTANCES

When the machine lies idle for more than three months, the coolant loses its properties and should be
disposed of.
The spent emulsifed oil should be handed over to firms authorized for its disposal in accordance with current
legislation in the country of destination of the machine.

MACHINE DECOMISSIONING
The machine is not equipped with instrumentation involving risks to persons. Therefore it can be sent to a
centre equipped for collecting industrial products for subsequent scrapping and differential collection of the
various materials of construction of the machine.

18 COMBI ELECTRA STAR

 2. INSTALLATION

2. INSTALLATION

TRANSPORT

FORM OF TRANSPORT

Depending on the type, weight and size of the machine to be shipped, EMMEGI S.p.A. will use appropriate
packing to ensure its intactness and preservation of the machine during transit up to delivery to the customer.
For shipment within the domestic territory and EEC countries, EMMEGI S.p.A. adopts road haulage via lorry;
in such case the machine is shipped complete with all its parts and reaches the Customer ready assembled
(apart from certain optional accessories specified in the machine delivery documents).
For international and intercontinental shipments (depending on requirements or conditions stipulated in the
sales contract) EMMEGI S.p.A. uses sea transport; in such case the machine is shipped inside a “container”
or “flat”.
In the event of prolonged stays outdoors or in especially aggressive environments, it is recommended to
protect the machine after reaching its destination at the Customer’s premises.
Lubricate the moving parts and unpainted metal parts or else treat the latter with a corrosion preventing
product.
Protect the machine, if necessary, with tarpaulin to safeguard against dust, rain and humidity.

CHECK FOR ANY DAMAGE INCURRED

The Customer’s attention is drawn to the need to carry out a careful preliminary check and duly notify any
damage incurred during transport and handling.

COMBI ELECTRA STAR 19

 2. INSTALLATION

HOISTING INSTRUCTIONS
Always use suitable means according to the dimensions and weight of the
machine when unloading, loading and moving it.

Before proceeding, make sure that the machine is balanced as regards weight.
For such purpose two yellow arrows (fig. 2-1) are marked on the machine: one
on the moving cutting head and one on the base. These arrows should coinci-
de when hoisting the machine.

When using an overhead travelling crane or similar means, use the 4

anchoring rings A located inside the base, which should be securely fastened
via relative screws.

Fig. 2-1

Fig. 2-2

20 COMBI ELECTRA STAR

 2. INSTALLATION

SITE
The machine should be sited with a distance of at least 800 mm from any rear wall in order to allow access
for the operator or service engineer to carry out any necessary maintenance or repair work.

A cable entry hole for electrical connection to the mains;

B compressed air connector;

C suction intake on fixed cutting head;

D suction intake on moving cutting head.

COMBI ELECTRA STAR 21

 2. INSTALLATION

INSTALLATION AND LEVELLING

♦ The machine does not require anchoring to the floor. However, at least in the bearing points, it
requires a flat surface at the same level.
♦ Rest the machine on the levelling screws A.
♦ Carefully clean the slideways with a petrol-soaked rag.
♦ With a spirit level B resting on the slideways, proceed to level the machine accurately in the longitudinal
and cross directions by adjusting relative levelling screws.
♦ After levelling, tighten relative nuts.

Fig. 2-3

22 COMBI ELECTRA STAR

 2. INSTALLATION

SWARF EXHAUSTER CONNECTION

The machine is provided with 2 suction intakes, ∅ 70 mm, on the rear side of each cutting head serving for
connection to the silenced swarf exhauster model MG4 through relative suction hose. Secure the hose on
the suction intakes of the machine with hose clips A.

Fig. 2-4

The swarf exhauster is provided with its own on/off switch and plug. Provide a main switch with thermal
magnetic trip according to the total installed power and supply voltage.

If automatic switching on of the swarf exhauster is required during the work cycle, connect it to socket B
mounted on side of the electrical cabinet.

Fig. 2-5

COMBI ELECTRA STAR 23

 2. INSTALLATION

The swarf exhauster can be connected in central rear position and to the left of the machine using suction
hoses of length according to the max. cutting length of the cutting-off machine.

Position Cutting lenght Hose 1 Hose 2 Clam ps

4 m 4000 mm 4000 mm 4
back 5 m 4500 mm 4500 mm 4
6 m 5000 mm 5000 mm 4

4 m 3500 mm 7000 mm 4
left 5 m 3500 mm 8000 mm 4
6 m 3500 mm 9000 mm 4

Table 2-1

24 COMBI ELECTRA STAR

 2. INSTALLATION

PREPARATION OF THE MACHINE FOR COMMISSIONING

LAYOUT OF THE EQUIPMENT ON BOARD THE MACHINE

B E

Fig. 2-6

A electrical and pneumatic cabinet

B control panel;
C computer;
D optical scale reader;
E clamp adjustments.

COMBI ELECTRA STAR 25

 2. INSTALLATION

TO FILL TANKS AND RESERVOIRS

Before starting to use the cutting-off machine, check that the reservoirs of the compressed air preparation
unit (FRL) and coolant tank (LUBRICA system) are full. If not, proceed to top up using the grade
recommended in THE OIL CHART (chapter 4), following the instructions given below:

COOLANT TANK:
LUBRICA system
To top up coolant level of LUBRICA system, take off the cap A, unscrew fill plug on the reservoir and, when
filling, make sure that no dirt enters as this could impair the flow of coolant.
Handling of coolant is subject to regulations regarding PROFESSIONAL USE.
The quantity of oil can be adjusted or shut off by turning knob B.

N.B. NEVER ALLOW THE TANK TO REMAIN WITHOUT OIL SO AS TO AVOID RISK OF DAMAGING
THE PUMP.

Fig. 2-7

F.R.L.:
Before proceeding to top up the oil in the compressed air preparation unit, discharge air from the supply line.
It is now possible to act in two different ways:
- empty reservoir C using a pin spanner dia. 3 and fill it up to 3/4
- unscrew plug F and top up level to 3/4.

Next check the oil flow via sight D: there should be one drop every 3/5 cuts. Use screw E to adjust oil flow,
turning it clockwise to decrease flow or anti-clockwise to increase flow.

F E D

Fig. 2-8

26 COMBI ELECTRA STAR

 2. INSTALLATION

CONNECTION OF THE MACHINE TO POWER SUPPLIES

Before starting the machine, it is necessary to connect it to power supplies which allow its normal
operation.

The COMBI ELECTRA STAR requires connection to two power supplies: electric and pneumatic.

ELECTRIC CONNECTION
Make sure that main switch B is in position “0” and that the nameplate voltage D matches that of the mains
to which the machine is to be connected. Using the standard key, open door C and pass the mains cable
through cable entry fitting A.
B C

Fig. 2-10 D

Fig. 2-9

Connect the four-pole cable to the main switch as illustrated below..

R S T

GRD

Fig. 2-11

COMBI ELECTRA STAR 27

 2. INSTALLATION

After connection, refit the protective cap E on the main switch.

Fig. 2-12

PNEUMATIC CONNECTION
Insert compressed air hose A, inner diameter 12 mm, in fitting B and secure it with a metal hose clip.
The machine operates at a pressure of 6 bar. In the event of insufficient pressure, relative pressure switch is
tripped thus switching off the controls.
Check for exact pressure on pressure gauge C. If pressure requires adjusting, raise knob D, then turn it
clockwise to increase pressure, or viceversa to decrease pressure.

D
C

A
Fig. 2-13

28 COMBI ELECTRA STAR

 3. MACHINE COMMISSIONING AND OPERATION

3. MACHINE COMMISSIONING AND OPERATION

GRAPHIC SYMBOLS AND FUNCTION OF THE CONTROLS

SYMBOL NAME FUNCTION

Power on indicator lamp lights up when the machine is switched on

when key is turned to right and the alarm reset push

Overtravel alarm disable
button pressed, the overtravel alarm is disabled

Limit stop disable push button used after disabling the overtravel alarm

when this push button is pressed, the machine is fully

Emergency push button
stopped and placed in emergency condition

determines general operating status of the machine;

switches off if an automatic alarm is given or the
Illuminated main start push button
emergency push button is pressed; when pressed, it
allows the machine to resume operation

when actuated it informs the machine that the

User attendance switch
operator is present

when actuated together with the user attendance

Cycle START switch
switch, it allows the cutting cycle to start

when turned to right, the clamps are closed, vice-

Clamp open/close selector switch
versa, clamps are opened

COMBI ELECTRA STAR 29

 3. MACHINE COMMISSIONING AND OPERATION

LIST AND LAYOUT OF THE CONTROLS

A B C D E

F G H

A power on indicator lamp;

B illuminated main start push button;
C limit stop disable push button;
D overtravel alarm disable key;
E emergency push button;
F cycle start switch;
G clamp open/close selector switch;
H user attendance switch.

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PREVENTIVE CHECKS
Turn main switch to position “1”: the power on indicator lamp should light up.

♦ Check that indicator lamp A lights up.

♦ Check compressed air pressure.

♦ Check coolant level.

♦ Reset the machine and check that the size indicated by the computer corresponds to the actual position
of the cutting head given by B on metric scale C;

♦ Then check the clamps: close the ON/OFF valves (see CLAMP ADJUSTMENTS) of the vertical clamps
and actuate selector switch D: the horizontal clamps are closed.

A D

Fig. 3-1

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TO CHECK FOR CORRECT DIRECTION OF BLADE ROTATION

1. Release emergency push button A;

2. start the machine by pressing push button B;
3. select a single cut;
4. preset the workpiece length at “500” and angular setting of the cutting heads at 90° (confirm each data
entry with ENTER);
5. start the cutting cycle;
6. actuate selector switches C and D; the guards are closed and the cutting head is positioned according
to the preset cutting size;
7. after positioning, the blade motors start: release the selector switches and press ESC;
8. look through the blade feed opening and check that the blade rotates in correct direction (from top to
bottom). If direction of rotation is incorrect, switch off the machine and invert the position of two of the
phase wires on the terminal board (see section ELECTRICAL CONNECTION) and try again.

CHECK FOR BLADE OUTFEED

1. Proceed as described previously until point 6;

2. actuate selector switch E, when prompted by the positioner, to close the clamps;
3. again actuate selector switches C and D; check that the blades move out correctly. Even if just one of
the selector switches is released, the cutting cycle is stopped.

B A

D E C

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SET-UP AND INITIAL ADJUSTMENTS

CLAMP ADJUSTMENTS

The machine is equipped with 2 horizontal pneumatic clamps as standard.

For accurate cutting of the profile, the clamps should grip the workpiece securely during cutting. If the clamp
position requires correction, use the following adjustments:

A locking lever for horizontal adjustment of the clamp;

B locking lever for vertical adjustment of the clamp;
C ON/OFF valve, clamp pressure.

For efficient clamping of the profile, adjust the clamps to a distance of about 10 mm from the profile.

A C

Fig. 3-2

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VERTICAL CLAMPS (OPTIONAL)

Optionally 2 vertical pneumatic clamps can be supplied.

To mount the vertical clamp, fasten mounting bracket A as shown in Fig. 3-3, by tightening screw B and knob
C. When introducing the clamp, remember to trip the microswitch of Fig. 3-5 detecting the presence of
clamps.
Then remove the quick connect from its parking position (Fig. 3-4) and attach it to the clamp by inserting it in
D.
Follow this procedure for both vertical clamps: they will now work together with the horizontal clamps.

If an internal cut (angle >90°) is programmed when the vertical clamps are installed, the message:
“VERTICAL CLAMPS INSERTED” appears and the machine will not perform the positioning.
The vertical clamps must be removed before making an internal cut; to do so: disengage the quick connects
and return them to their parking posiiton (Fig. 3-4), then pull out screw B, loosen knob C and remove the
clamp support.

Fig. 3-3

Fig. 3-4 Fig. 3-5

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COOLANT FLOW ADJUSTMENT

The blade is cooled through a Lubrica system which starts operating during the cutting cycle. The amount of
coolant can be adjusted by means of screw A: turn clockwise to decrease coolant, anti-clockwise to increase
it. Coolant flow can be shut-off by turning the screw fully: just the compressed air flow remains.

N.B. NEVER ALLOW THE TANK TO REMAIN WITHOUT OIL SO AS TO AVOID RISK OF DAMAGING
THE PUMP.

Fig. 3-6

FEED RATE ADJUSTMENT

Feed rate is factory set. However it can be varied if necessary by turning the graduated knob B: it is advisable
to set the feed rate of both the cutting heads in the same way with the fixed blade slightly ahead.

Fig. 3-7

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WORK CYCLE
Phases to be followed for normal cutting operations are as follows:

1. preset the type of cutting to be carried out on the computer;

2. actuate selector switch A, then switch B to position the moving cutting head (after reaching the preset
position, the cutting head stops and the blade motors start);
3. actuate selector switch C to clamp the profile;
4. again actuate selector switches A and B to allow the guards to lower and the blades to feed out; release
the selector switches (one or both) to retract the blades;
5. make all the cuts required;
6. repeat the above described sequence for a new length.

B A

CAUTION: For internal cuts (angles >90°), leave a sufficient margin for head and end
waste (profile outside the blades) in order to allow correct ejection of this scrap. Failure
to observe this rule could cause damage to the machine as well as risks for the operator.

NO

YES

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5. MAINTENANCE AND REPAIR

PERIODIC CHECKS
After every 40 running hours or at least once a week, proceed to the following checks in order to ensure
perfect efficiency of the cutting-off machine:

♦ check oil level in the lubricator reservoir A of compressed air preparation unit (to top up, see section TO
FILL TANKS AND RESERVOIRS chapter 2);
♦ check level of condensate in the bowl of compressed air preparation unit (see section TO DRAIN
CONDENSATE in this chapter);
♦ check level of emulsifed oil for blade cooling in the rear cans B (to top up, see section TO FILL
TANKS AND RESERVOIRS chapter 2);

At least once a week perform a few idle cuts with the blade fully out in order to avoid risk of air bubbles
forming in the feed cylinder brake.

B
A

Fig. 5-1

Fig. 5-2

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OIL CHART

SYSTEM R EC O M M EN D ED O IL

FR L A IR PR ESS 32*

LU B R IC A System LB 200*

Table 5-1

*Oil distributed by Emmegi: the Material Safety Data Sheet is given in the following pages

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TO DRAIN CONDENSATE
The condensate drain valve can be used in manual or automatic mode:
1 During rest condition, the valve is semi-automatic. This position allows draining of condensate when
pressure is missing; when pressure returns, the valve is closed automatically.
2 However, if necessary, the condensate can also be drained in the presence of pressure. To do so, press
the button on the valve up.
3 Lastly, when the button is turned to the right, the valve is locked; in this position, there is no drainage.
4 When it is necessary to clean, merely unscrew the bowl, then the guard of the cartridge unit. Now
proceed to clean or replace the cartridge.

1 2

3 4

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TO REPLACE TOOLS
MAKE SURE THAT THE BLADE TO BE REPLACED IS STATIONARY!

This operation should be performed with the cutting heads at 45° and the machine switched off (main switch
turned to “0”):

1 remove cover A;
2 keeping the blade spindle still with allen key B, turn nut D with spacer C in the direction of blade rotation;
3 refit the blade, carefully clean the spindle, mounting flange and front flange;
4 before starting the machine, make sure that the blades are securely fastened, the guard closed and cover
fixed.

A
C

Fig. 5-3 Fig. 5-4

TOOL TABLE

Standard blade types for light alloys:

N° OF
MATERIAL DIAMETER THICKNESS BORE
TEETH

Aluminium 500 4,0 32 120

Table 5-2

For cutting solid material, the blade characteristics will depend on the section to be cut; hence it is always
necessary to contact the manufacturer.

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PERIODIC CLEANING
At the end of each shift, after switching the machine off, proceed to clean it carefully following the
instructions given below:
♦ clean the slideways with a petrol-soaked rag, then lubricate them with gear oil.
♦ Remove the chips or flakes of profile from the head tilting zone in order to ensure consistently
accurate tilting.
♦ Remove the covers from the cutting heads and clean inside the guards with compressed air to
remove any foreign matters. Make sure the blade be stationary!
♦ Carefully clean the microswitches and all control members on board the machine.
In order to avoid risk of building up of scale and residual machining deposits which in the long run could create
problems in machine operation, it is important to pay particular attention to cleaning at the end of each shift,
including the area surrounding the machine.

CAUTION: never use water in order to avoid risk of infiltration inside mechanical and electronic
components.

WHAT TO DO IF...

FOREWORD

N.B. The operations to be performed in the various sections must always be carried out with the
machine SWITCHED OFF and DISCONNECTED from the power sources (electrical and pneumatic).

ATTENTION: The cases described below are listed in a precise order (on a chronological basis according to
when they could occur). Hence before proceeding with the various operations described in the specific
section, make sure that all the previous cases have been checked.

... YOU NEED TECHNICAL SERVICE

Contact your EMMEGI dealer or our Technical Service Department directly giving the necessary data
stamped on nameplate a affixed to the machine:

♦ type of machine
♦ serial N°
♦ date of purchase
♦ electrical connection

Also give exact full details as regards the problem encountered.

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... THE “POWER ON” INDICATOR LAMP FAILS TO LIGHT UP

Check that:
♦ the machine is connected to the mains;
♦ the main switch is turned to position “1”;
♦ the bulb of the indicator lamp is not burnt out; otherwise replace
it;
♦ the fuses of the wall socket;
♦ the fuses A of the main switch and replace them if necessary.
A

Fig. 5-4
... THE MACHINE DOES NOT START

Check that:
♦ the “power on” indicator lamp is lit up;
C
♦ the emergency stop mushroom push button is not
pressed;
♦ electrical panel doors are closed (microswitch
pressed);
♦ the message signalling OVERTRAVEL of the moving B
cutting head is not appearing on the computer screen;
in this case, proceed to another AUTOMATIC MACHINE
Fig. 5-5
RESET operation, turn the overtravel disable key- Fig. 5-6
operated selector switch and at the same time press the alarm reset push
button, lastly press the push button for disabling the limit switch;
♦ the air pressure is the required one;
♦ magnetic circuit breakers with thermal overload B are reset (black buttons pressed); if not, proceed to
reset them;
♦ using a voltmeter, test fuses FU2, FU3 and FU4 C; if not OK, proceed to replace them;

... THE MOVING CUTTING HEAD IS NOT POSITIONED AT THE PRESET POINT

3 distinct cases can occur:

1. the cutting head does not start:
♦ repeat the AUTOMATIC MACHINE RESET;
♦ check that the preset length is neither too long or too short (the message “software limit switch” appears);
♦ using a voltmeter, test fuses FU4, FU5 and FU7; replace them if necessary;
♦ make sure that the parameters preset on the machine correspond to those given in the PARAMETER
TABLE;
♦ if the “DRIVER KO!” message appears, contact our Technical Service Department.
2. the cutting head stops during its traverse and the message “tracking error” appears:
♦ check for correct connection of the optical scale connector D and
also that the cable has not been sheared; D
♦ check for presence of foreign bodies on the slideways which
would impede head movement;
♦ release the selector switches and re-actuate them immediately.
3. the cutting head stops closed to the preset point and the message Fig. 5-7
“positioning error” appears:
♦ increase parameter KI2 by one unit;
♦ adjust the OFFSET (contact our Technical Service Department).

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 5. MAINTENANCE & REPAIR

... THE CUTTING HEADS FAIL TO TILT

♦ Make sure that the blades are in rest position;

♦ check that the guards are lowered;

... THE “HEAD POSITIONING” MESSAGE FLASHES CONTINUOUSLY.

This message appears when one or both cutting heads fail to reach the preset angle:
♦ make sure that the stops for the intermediate angles do not prevent reaching of the required position;
♦ carry out the HEAD RESET and BLADE RESET procedures (contact our Technical Service Department).

... THE BLADE MOTORS FAIL TO START

♦ Make sure that the blade angles are not set to “0”;
♦ check whether the cutting head has reached its preset position.

... THE CLAMPS FAIL TO CLOSE

Check that:
♦ the message “close clamps” appears on the screen;
♦ check whether the clamp valves are open.

... THE BLADES FAIL TO FEED OUT DURING THE CUTTING PHASE

Make sure that:

♦ the blade drive motors are switched on;
♦ the microswitches detecting guard position has not been tripped;
♦ clean the surrounding area and press the microswitch to try and
release it.

Fig. 5-8

... THERE IS IRREGULARITY IN CUTTING ANGLES

As these adjustments are electronic, in the event of irregular operation, please contact the EMMEGI
TECHNICAL SERVICE DEPARTMENT.

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... THE FEED CYLINDER REQUIRES REPLACEMENT

1 Remove the yellow guard from inside the cutting head;

2 manually raise the blade arm, and insert a block of wood as shown in the figure;

3 remove the feed control knob after backing off the screw on its top;
4 loosen the set screw at the end of the piston rod of the cylinder;
5 loosen the lock nut;

6 remove the pins from the bottom of the cylinder (inside and outside);
7 lift out the feed cylinder by turning it anti-clockwise.
8 mount the new feed cylinder following the same procedure but from point 7 to point 1.
9 perform a few cutting cycles on the cutting-off machine with the blade fully out and
adjust the feed rate.

... THE PRESSURE SWITCH IS OFF SETTING

Check that the pressure on the pressure gauge of the compressed

air preparation unit is greater than 4 atm. Adjust it if necessary
(see section PNEUMATIC CONNECTION).
If the motors still fail to start, it could be necessary to adjust the
pressure switch:

♦ remove mounting screw a and anti-unscrewing plate b;

♦ using a screw driver, turn screw c until pointer d
coincides with a pressure of 5 bar (this corresponds to
the minimum permissible machine operating pressure);
♦ pointer e corresponds to the decrease in pressure
beyond which the machine does not operate. Its value is
1.5 bar. This means that if the mains pressure drops to 3.5
bar, the machine enters the emergency condition. If
necessary, adjust this pointer with screw f;
♦ the incoming electrical leads to the pressure switch
should be connected to terminals g and h.

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