F45 Elmodrive Manual

Operating manual F45 ElmoDrive
1.5/2016
GB
002
0000010040
Translation of the original operating instructions
Table of contents
Table of contents
1 Foreword
2 Identification
2.1 Machine identification 6

2.2 Certificates 7
2.3 Marks of conformity 15
3 Product description
3.1 Marking, pictographs 16

3.2 Intended use 16
3.3 Dimensions and weights 22
3.4 Auxiliary power/power requirements 23
3.5 Emissions 25
3.5.1 Noise - characteristic values 25
3.5.2 Dust 27
3.5.3 Electromagnetic compatibility 27
3.6 Ambient conditions 28
3.7 Safety information 29
3.7.1 Operational safety 29
3.7.2 Safety devices 32
3.7.3 Top safety hood/riving knife 33
3.7.4 Handling batteries / accumulators 34
4 Definitions
4.1 Description of machine 36

4.2 Terms 38
5 Transport, siting and installation
5.1 Transport 40
5.2 Safety measures before use/installation 41
5.3 Installation 45
5.3.1 Telescopic tube for swinging arm 45
5.3.2 Main table length extension 47
Table of contents 0000010040-002- GB

Table of contents
5.3.3 Rip fence 49

5.3.4 Cross-slide and crosscut fence 51
5.3.5 Sliding table 71
5.3.6 Electrical connection 77
5.3.7 Connecting the extraction system (customer side!) 80
5.4 Basic machine setting 82
5.4.1 Sub rollers on the sliding table 82
5.4.2 Main table 83
5.4.3 Swinging arm 84
5.4.4 Cross-slide height 85
5.4.5 Setting free cut 86
5.4.6 Angle cut 88
5.4.7 0° setting of the saw blade 89
6 Operating
6.1 Working safely with the dimension saw 90

6.1.1 Cross-slide/crosscut fence 90
6.1.2 Rip fence 93
6.1.3 Double roller carriage 95
6.2 Working examples 97
6.3 Machine operation 105
6.3.1 Main switch 105
6.3.2 Switching the saw drives on and off 106
6.3.3 Setting the speed 108
6.3.4 Fitting the main saw blade 109
6.3.5 Saw blade recommendation 113
6.3.6 Table locking 114
6.4 Monitor controls ElmoDrive 115
6.4.1 Calibration 120
6.4.2 Height adjustment 122
6.4.3 Tilt adjustment 123
6.4.4 Motor driven rip fence (option) 127
6.4.5 Infinitely variable speed adjustment (option) 129
6.4.6 Crosscut fences 133
6.4.7 2-axis scoring unit 146
6.4.8 3-axis scoring unit 148
6.4.9 Vacuum clamping in the sliding table 151
6.4.10 Menu 152
6.5 Protection hood 191
6.6 Optional modules 195
6.6.1 Scorer, tilting to one side 195
6.6.2 Scorer, tilting to both sides 204
6.6.3 Mitre fences 205
0000010040-002- GB Table of contents

Table of contents
6.6.4 Dimension display unit DIGIT L 207

6.6.5 Digital angle and length display DIGIT LD 210
6.6.6 Rip fence with DIGIT X digital dimension display 215
6.6.7 Parallel cutting device 219
6.6.8 Workpiece hold-down device 223
6.6.9 Cross-slide width extension 230
6.6.10 Additional cross-slide 231
6.6.11 LASER cutting line display 232
6.6.12 Coolant spray device 234
6.6.13 TIP-SERVO-DRIVE 235
7 Cleaning/care
7.1 Safety measures 236

7.2 Maintenance/cleaning by the user 237
7.3 Maintenance/cleaning by qualified persons 249
7.3.1 Checking the winding shield 249
8 Faults/problems/troubleshooting
8.1 Machine diagnosis 250

8.2 Motor overload protection 251
8.3 Troubleshooting/faults/messages 252
8.4 Electronic brake module 257
9 Technical data
9.1 Standard equipment 258

9.2 Special equipment 262
10 Maintenance and repairs
10.1 General 264

10.2 Customer service addresses 265
Table of contents 0000010040-002- GB

Foreword
1 Foreword
Please read these operating instructions carefully before commissioning

the machine.
No liability will be accepted for any injury, damage or disruption to opera-

tions resulting from failure to comply with these operating instructions!
Persons operating this sliding table saw must have had sufficient instruc-
tion and be suitably qualified!
These operating instructions cannot be regarded as a binding type de-

scription as the manufacturer may have carried out technical modifica-
tions.
The operating instructions must always be available where the machine is

being used. They must be read and heeded by any person performing the fol-
lowing activities at or on the machine:
• Operating including set-up, troubleshooting during operation, elimination of

production waste, care, disposal of operating and auxiliary materials
• Maintenance, repair, inspection
• Transport
It is necessary to comply with national regulations on health and safety at work

and environmental protection, in addition to the operating instructions.
The removal of safety devices, especially safety hoods for the saw blade cover
and riving knives, will endanger the operator and may lead to accidents.
Safe work is only possible with a clean machine and a clean environment!
Reproduction of this document or parts thereof is only allowed with our

permission!
0000010040-002- GB Foreword
Identification
2 Identification
2.1 Machine identification

The type plate fitted to the machine frame serves for identifying the machine
and other important machine data.
Meaning of the stated descriptions:
Fig. 2-1 Type plate
Type: Machine designa-

tion
Number: Machine specific

identification
number
Year of construc- Year of manufac-

tion: ture
Saw blade min Ø Diameter of the

smallest permis-
sible saw blade
Saw blade max Diameter of the

Ø largest permissi-
ble saw blade
Guide slot width Diameter of the

of the riving guide bolts for the
knife: riving knife in the
riving knife hol-
ding fixture
Identification 0000010040-002- GB
Identification
2.2 Certificates
Conformity declaration as defined by the machinery directive, Annex II 1A

-Original / Translation of the original
Manufacturer: Wilhelm Altendorf GmbH & Co. KG

Wettinerallee 43/45
32429 Minden
Germany
Person authorised to Rolf Tweer, Technology Management,

compile the Wilhelm Altendorf GmbH & Co. KG
technical documentation:
Product: Sliding table saw, type F45
Machine number:
Authority named for prototype testing DGUV Test Prüf-und Zertifizierungsstelle Holz
according to annex IX: Fachbereich Holz und Metall
Vollmoellerstraße 11
70563 Stuttgart
Germany
Identification number 0392
We hereby declare that the above-mentioned product conforms with all applicable regulations of machi-
nery directive 2006/42/EC. It fulfils the requirements of the following applicable directives:
- Low-voltage directive 2006/95/EC
- EMC directive 2004/108/EC
The following harmonised standards have been applied:

- DIN EN 1870-18:2007:2013, Safety of woodworking machines - Circular sawing machines - Part 18:
Dimension saws
- DIN EN ISO 12100 :2011-03 Safety of machinery - General principles for design - Risk assessment and
risk reduction
- DIN EN 60204-1:2007:-06, Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
Minden, 20/05/2015
_______________________________________________
Piotr Szablewski, Manager of Development & Construction
0000010040-002- GB Identification
Identification
EC prototype testing certificate
Identification
Identification
GS test certificate
10
Identification
11
Identification
DGUV Test Certificate
12
Identification
13
Identification
C US-Certificate
14
Identification
2.3 Marks of conformity
CE symbol GS symbol Wood dust appro- C US mark

ved
mark
15
Product description
3 Product description
3.1 Marking, pictographs
Danger warning Hand injury warning Laser beam warning
Crushing risk warning Voltage warning Note: Wear ear pro-

tection
3.2 Intended use

The sliding table saw and the workpiece guide equipment supplied with it are
intended to be used for cutting wood and similar materials such as:
• Laminated and unlaminated board materials (e.g. chipboard, coreboard,

MDF board, ...)
• Solid wood
• Veneer with a suitable clamping device
• Gypsum plasterboard
• Cardboard
• Dimensionally stable plastics (thermoset plastics, thermoplastics). Sawing
these materials does not normally involve any risks in respect of dust,
chips, and thermal degradation products.
• Aluminium/aluminium forging alloy in conjunction with the spraying unit
option
16
Product description 0000010040-002- GB

Product description
The sliding table saw and the workpiece guide equipment supplied with it are
not intended to be used for cutting materials such as:
• Sheet steel
• Sheet brass
• Sheet copper
• Round wood without the use of a suitable clamping device
Tools:
• The chosen saw blade must be suitable both for the specific work cycle
(e.g. longitudinal cutting or crosscutting) and for the specific material.
• Only circular blades which are solid chrome vanadium (CV) or tungsten
carbide tipped (TCT) and have a maximum width of 20 mm are permitted
for the main saw and milling/grooving cutter. The middle table strip and the
cushioning disc must be removed when using a milling/grooving cutter.
• Saw blades with a maximum diameter of 120 mm are permissible for the
scoring saw with a machine swivelling to one side.
• Saw blades with a maximum diameter of 180 mm are permissible for the
scoring saw with a machine swivelling to both sides.
• Saw blades made of high-alloy high-speed steel (HSS) may not be
used.
• Wobble units may not be used.
17
0000010040-002- GB Product description

Product description
Usable saw blades:

250 - max. 500 mm diameter with scorer
250 - max. 550 mm diameter without scorer
Site of installation/use:
• The machine is not suitable for use outdoors or in rooms that are subject to
moisture or the risk of explosions.
• The intended use of the machine involves connection to a suitably dimensi-
oned extraction system.
• Intended use also involves compliance with ALTENDORF's specified ope-
rating, maintenance and repair conditions and adherence to the safety
information contained in the operating instructions.
• The sliding table saw may only be used, set up and maintained by persons
who are familiar with the machine and aware of the dangers.
• The pertinent accident prevention regulations as well as any other gene-
rally recognised technical safety and industrial medicine rules must be
observed.
• Repair work must be carried out by our own customer service or by an
organisation that we have authorised. Only original ALTENDORF spare
parts may be used for this. ALTENDORF will assume no warranty for any
damage that is caused by using non-original spare parts.
Coolant spray device: (Option)

A minimum quantity lubrication system is used as a spraying unit. It is required
for cutting plastics and aluminium. When using such a spray device, make sure
you only use coolant that does not impair the function of safety-relevant parts
such as protection hoods! (The transparent parts of the protection hood are
made of polycarbonate, and the grey hood support of polyamide.)
Clamping device:
A suitable clamping device should be used for small workpieces, in particular.
18

Product description
Machine operator positions:

The sliding table saw is intended to be operated from the following operator po-
sitions:
1. On the left of the sliding table at the front of the machine, seen in the feed
direction (main operator position).
2. At the front cross-end of the machine on the right of the sliding table when
working with the rip fence (make sure you do not move your body or parts
of it into the blade rotation area).
3. Any person removing the workpieces must stand at the rear cross-end of
the machine behind the main table length extension (under no circumstan-
ces in the sliding table traverse area)!
Fig. 3-1 Machine operator positions
Warning!
When removing workpieces at the rear of the machine, ensure that you
keep sufficient distance from the extending telescopic tube.
Non-adherence may lead to knee injuries!
Note!
i Any other use is deemed as unintended. ALTENDORF will not be liable
for any kind of injury or damage that may result from such unintended
use; the risk thereof is borne by the user alone.
Unauthorised modifications by users to the machine or its electrical parts
and the use of non-original parts on the machine exclude any liability by
the manufacturer for any resulting injury or damage.
19

Product description
Foreseeable misuse:
• Working with the safety hood swung up

• Working with the safety hood swung away
• Failure to use the push stick or push block for cuts < 120 mm
• Moving the sliding table without using the handle
• Trimming without the trimming shoe
• Touching or manual infeed with automatically moving stops
• Saws without a riving knife
• Incorrect setting of the straight edge on the rip fence
• Use of coolant lubricants containing water
• Insufficient removal of wood and plastic residue prior to machining alumi-
nium
Warning!
Always, under all circumstances avoid the above-mentioned types of

work.
All types of foreseeable misuse can lead to severe injuries!
20

Product description
Residual risk:
Even when the machine is operated in accordance with its intended use and all
pertinent safety regulations, the following residual risks may be encountered
because of design changes caused by the intended use in question:
• Contact with the main saw blade and the scoring blade in the cutting area,
in particular when the saw blade is tilted in the -45° position and the protec-
tion hood is not correctly adjusted.
• Contact with the main saw blade and the scoring blade from beneath the
table level when the sliding table is pushed fully forward or pulled fully
back.
• Kick-back of workpiece or workpiece parts.
• Individual teeth spinning off tungsten carbide tipped blades.
• Breakage and ejection of the saw blade.
• Crushing at the manual or motor-driven sliding table.
• Crushing between the motor-driven tilt movement of the saw blade and the
rip fence or workpieces lying in the tilting area.
• Contact with live parts when the electrical installation area is open.
• Damage to hearing as a result of working for long periods of time without
hearing protection
• Emission of health-endangering dust from operation without extraction.
• Wear suitable gloves due to the risk of cuts when handling saw blades,
grooving tools and pushing the wood into the machine, as well as during
maintenance work.
• Do not remove chips while the saw blades are turning due to the risk of
injuries.
• Do not use the machine unless all protective devices/guards required for
processing have been installed and are in perfect condition due to the risk
of injuries.
Warning!
Avoid the potential dangers posed by these remaining risks by paying

increased attention when setting up, operating and servicing the
machine!
Always adhere to the specified working positions when operating the
machine.
21

Product description
3.3 Dimensions and weights
Dimensions, sliding table box

Gross weight, machine box
Gross weight, sliding table
Gross weight, accessories
Dimensions, machine box

Net weight, machine box
Net weight, sliding table
Net weight, accessories

Sliding table length
[mm] [kg] [kg] [kg] [kg] [kg] [kg] [mm] [mm]

2580x660x330 2060x960x500
2250 855-1282 970-1495 114 175 131-142 203-230
3330x660x330 2060x960x500
3000 855-1282 970-1495 158 234 131-142 203-230
3530x660x330 2060x960x500
3200 855-1282 970-1495 170 250 131-142 203-230
3730x660x330 2060x960x500
3400 855-1282 970-1495 205 289 131-142 203-230
4130x660x330 2060x960x500
3800 855-1282 970-1495 212 304 131-142 203-230
4630x660x330 2060x960x500
4300 855-1282 970-1495 249 350 131-142 203-230
5330x660x330 2060x960x500
5000 855-1282 970-1495 269 385 131-142 203-230
The weights depend on the machine equipment!
22

Product description
3.4 Auxiliary power/power requirements

The permissible tolerance of the specified mainsvoltage is + 5 % and - 10 %.
Greater deviations will impair functionality.
Only connect the machine to a three-phase AC mains with phases L1, L2 and
L3, otherwise the brake module or the frequency converter may be destroyed.
Operating the machine together with phase converters, frequency converters
or transformer-capacitor combinations will destroy the brake module or the fre-
quency converter and power supply unit!
Screw-in fuse links of the type NEOZED D02 (utilisation category gL) should
preferably be used as back-up fuses.
The supply line must be dimensioned such that it cannot be overloaded and a
max. voltage drop < 3% occurs at nominal current.
The loop impedance and suitability of the overcurrent protection device must
be inspected/tested at the machine installation site.
Note!
i Devices for differential protection (to be provided by the customer!)
In 230V400V systems, devices are generally used that detect leakage
currents < 300 mA. For switch-off in the event of a fault, RCDs (residual
current devices) with a rated differential current < 300 mA are normally
used, and for indication, fault current indicators (relays) or RCMs
(residual current monitors) are used.
Mains voltage independent devices for differential protection that also
detect differential currents (leakage currents) with DC components are to
be used.
If leakage current indicators or RCMs are used, ensure that additional
switch-off devices, e.g. circuit breakers, are provided.
(Extract from VDS Directive 2033)
If there are special safety requirements for persons setting up the equip-
ment, then frequency converters complying with EN 50178 must be
replaced by RCMAs with an isolator (preferably) or by type-B RCDs (uni-
versal-current-sensitive residual-current circuit breakers).
The following devices can be used:
Manufacturer: Doepke switching devices; these switching devices can also be
purchased via Altendorf.
• DFS4 040-4/0,30-B NK, release current 300 mA

• DFS4 040-4/0,03-B NK, for personal protection
23

Product description
Auxiliary power/power requirements
Motor Voltage Frequency Nominal current Fusing

Without/with scoring
[kW] [V] [Hz] blade [A]
[A]
4 230 50 12.4 / 15.8 25
4 400 50 7.2 / 8.7 20
5.5 200 - 220 50 19.8 / 23.2 35
7.5 200 - 220 50 26.5 / 29.9 35
5.5 380 - 420 50/60 11.5 / 13.5 20
7.5 380 - 420 50 15.5 / 17.5 25
11 380 - 420 50 22.5 / 24.5 35
VARIO 380 - 420 50/60 36.0 / 38.0 35

tilting to one side
VARIO 5kW 380-420 50/60 36.0 / 38.0 35

tilting to both
sides
VARIO 6.5kW 380-420 50/60 36.0/38.30 35

tilting to both
sides
5.5 200 - 220 60 20.0 / 23.5 35
7.5 200 - 220 60 24.0 / 28.0 35
5.5 600 60 7.5 / 8.5 20
7.5 600 60 9.5 / 10.5 20
24

Product description
3.5 Emissions
3.5.1 Noise - characteristic values
Sound power level Emission Tools

[dB (A)] sound level
at the workplace
[dB (A)]
Idling_____LWA = 87.3 Idling_____LPA =77.4 Circular saw blade

Cutting__LWA = 96.6 Cutting__LPA = 84.0 300x3.2/96 WZ
n = 3987 rpm

n = 3987 rpm

n = 3987 rpm

Cutting__LWA = 99.1 Cutting__LPA = 86.0 303x3.2/60 DH
n = 3987 rpm
LOW NOISE

Cutting__LWA = 96.3 Cutting__L = 84.6 303x3.2/90 WZ
n = 3987 rpm
LOW NOISE
The noise emission values determined according to DIN EN ISO 3746 for the
sound power level or DIN EN ISO 11202 and for the sound pressure level at
the workplace on the basis of the working conditions stated in ISO 7960 Appen-
dix A are as listed in the table.
A measurement uncertainty allowance of K = 4 dB (A) applies to the stated
emission values.
The stated values are emission levels and therefore not necessarily levels for
safe working. Although there is a correlation between emission and immission
levels, it cannot be reliably deduced from this whether or not additional precau-
tionary measures are needed to protect operators.
25

Product description
Factors that influence the immission level at the workplace include the duration
of exposure, room characteristics, other sources of noise such as the type and
number of neighbouring machines, and other working processes involving noi-
se emission.
26

Product description
3.5.2 Dust
The dust emission values – measured in accordance with the “Principles for
Testing Dust Emission (Concentration Parameters) from Woodworking Machi-
nes” issued by the German trade association's technical committee for wood –
are below 2 mg/m3.
When the machine is attached to a correctly functioning extraction system with
an air speed of at least 20 m/s (measured after joining the two extraction con-
nections) you can assume it is and will stay compliant with the technical refe-
rence concentration (TRK) limit for wood dust that is in force in Germany.
The machines are tested concerning wood dust in accordance with the BGI
739-1. The machines bear the DGUV mark with the additional wood dust mark
"holzstaubgeprüft". Consequently, a company operating the machine in Ger-
many is exempt from the obligation to perform measurements at the workplace
in accordance with TRGS 553.
Note!
i Metal dust does not usually occur when cutting aluminium.
3.5.3 Electromagnetic compatibility
EMC (Electromagnetic Compatibility) is the ability of an electrical device to

function in its electromagnetic environment without disruptively influencing this
environment, which also includes other devices, or being disturbed by it.
The machine complies with the requirements set out in the European electro-
magnetic compatibility directive 2004/108/EC (EMC directive).
27

Product description
3.6 Ambient conditions

Transport and storage
The machine must not be used in an environment with explosive or corrosive
gases.
The ambient temperatures for transport and storage range from - 25° C to +
55° C, and + 70° C is permissible for a short time.
The maximum air humidity must not exceed 90%, and condensation must be
avoided in all cases.
28

Product description
3.7 Safety information
3.7.1 Operational safety

The operation of woodworking machines with a manual feed involves a high
risk in the event of incorrect handling. Therefore always observe the safety in-
formation that is summarised in this chapter as well as government and other
industrial safety regulations (e.g. accident prevention regulations)!
Note!
i Ensure that the operators are suitably trained in the use, setting and ope-
ration of the machine!
• Never operate the machine without the protective devices intended for the
specific work cycle (also refer to “Working safely with the sliding table saw
– working examples”), and do not make any changes that could impair
safety.
• Before all work, make sure that the protective and working devices are
securely fitted and are not damaged.
• Before changing a tool, rectifying any faults and carrying out repairs, make
sure that the machine cannot be turned on accidentally, for example by
padlocking the main switch.
• Only use correctly sharpened tools designed to conform with the require-
ments of the European standard EN 847-1:2005+A1:2007.
• When grooving with milling tools, only use milling tools for manual feeding
with a groove width less than or equal to 20 mm (5 mm for machines with
the option "Saw blade tilting to both sides"), marked with MAN according to
the European standard EN 847-1:2005+A1:2007.
• Only fit saw blades with the dimensions described in the technical data.
The diameter of the mounting hole must always measure 30 mm. Loose
intermediate rings are not allowed to be used.
• Select the rotational speed so that the maximum permissible rotational
speed specified for the tool is not exceeded when using tungsten carbide
tipped saw blades or grooving cutters.
• HSS saw blades and cracked or deformed saw blades may not be used.
• Always wear tight-fitting work clothes and do not wear rings, bracelets or
watches.
• Make sure that the workplace is uncluttered, slip-proof and well lit.
• Do not cut workpieces that are too large or too small for the machine to
handle.
• When working at the machine, always stand to the side of the saw blade
outside a possible kick-back area.
29

Product description
• Remove any loose parts from the vicinity of the saw blade before switching
on the machine.
• Only start cutting when the saw blade has reached its full rotational speed.
• Always use the top protection hood!
• Adjust the height of the top protection hood to the thickness of the workpi-
ece to be cut. When operating with a tilted saw blade, exchange the narrow
hood for a wide hood. For machines with the option "Saw blade tilting to
both sides", move the protective hood to the respective work position by
pushing it to the correct side!
• Always guide the workpiece safely and use the appropriate stops/fences.
• Use a push stick when cutting narrow workpieces (< 120 mm) at the rip
fence.
• Crosscuts and longitudinal cuts in round wood are not permitted with the
standard feeding aids or fences/stops.
• Always use the riving knife except for insert cuts. The riving knife must not
be thicker than the cutting line width or thinner than the main blade. Adjust
it so that it is at a distance of least 3 mm and at most 8 mm from the gear
rim. The guide slot must be 13 + 0.5 mm wide. The riving knives supplied
with the machine cover the entire range of permitted saw blade diameters –
from 250 mm to 550 mm. With respect to their thickness, they match the
cutting line widths of commercially available tungsten carbide tipped saw
blades. If other saw blades, e.g. made of chrome vanadium (CV), are used,
select a riving knife thickness that lies between the cutting line width and
the main blade thickness. Such riving knifes can be obtained from the trade
or directly from ALTENDORF.
• Use an anti-kick device for insert cuts, e.g. the front of the clamping shoe.
Fix this in the sliding table groove, ensuring that the sliding table is locked
with its interlock to prevent movement. Following insert cutting, immedia-
tely refit the riving knife and the top protection hood immediately!
• Only do angle cuts when the cross-slide is fixed to the sliding table. Make
sure that small cut-off workpieces cannot be taken up by the gear rim and
kick out, for example by using a deflection wedge.
• For trimming, use the clamping shoe fixed to the sliding table to hold down
the workpiece.
• When using a feeding unit, use at least the riving knife as an anti-kick
device.
• Replace worn-out table strips immediately.
• Wobble units or wobble cutting devices are not allowed to be used.
• The sound pressure level at the workplace generally exceeds 85 dB(A).
For this reason, wear hearing protection when working.
• Only qualified electricians are permitted to work on the electrical equipment
of the machine.
30

Product description
• Regular cleaning of the machine and, in particular, the main table, sliding
table and guides (e.g. rip fence) is an important safety factor. Before star-
ting this work, make sure that the machine cannot be switched on uninten-
tionally.
• Prior to cutting aluminium, thoroughly clean the machine and remove all
remaining chips and dust to prevent ignition of remaining chips/dust.
• The sawdust generated during cutting not only impairs visibility but is also
partially hazardous to health. Therefore, the machine must be connected to
a chip extraction system with both extraction sockets. The minimum air
speed at the lower extraction socket must be at least 20 m/s. When the
machine is switched on, the extraction system must switch on at the same
time.
Warning!
Always use a deflector wedge fastened to the table top when small waste
pieces are produced during cutting that could be kicked out by the saw
blade.
Fig. 3-2 Deflector wedge
31

Product description
3.7.2 Safety devices

Altendorf's sliding table saws have been developed in compliance with Euro-
pean standard DIN EN 1870-18 "Safety of woodworking machines – circular
sawing machines –: circular saw benches (with and without sliding table) and
dimension saws”.
During the design stages great importance was attached to creating optimum
working conditions, ranging from numerous mechanical and electrical safety
devices to noise insulation and reduction of dust emission.
The machine is equipped with all the necessary safety devices to protect
against operating risks that could not be eliminated by its design. These safety
devices include, in particular:
• Rip fence with straight edge adjustable in cutting direction: Can be pulled
back to prevent parts of crosscut workpieces from jamming between the
fence and the rising gear rim, or can be switched over to a low guide sur-
face for cutting narrow and flat workpieces, allowing adequate space for
the guide hand together with the possibility of lowering the top safety hood
onto the workpiece here, too.
• Trimming hold-down to clamp and hold down untrimmed solid wood to
secure against slippage in the course of trimming.
• Electrical interlocking of the door in the machine frame to change over the
belt to change the rotational speed (only with three-speed model). It is not
possible to switch on the machine when the door is open, and if the door is
opened while the machine is running, the drives will switch off.
• Sliding table arresting device to prevent workpiece kick-back for insert cuts
together with the cross-stop.
• Automatic brake which, after switching off, brings the main saw blade to a
standstill in less than 10 seconds, regardless of the saw blade diameter
and rotational speed.
• Ergonomic arrangement of the operating elements at readily accessible
positions.
32

Product description
3.7.3 Top safety hood/riving knife

For a max. tool diameter of 450/500/550 mm:
• Top safety hood fitted separately from the riving knife for max. saw blade
diameter of 450/500/550 mm, available in a narrow and a wide format
made of polycarbonate to optimally cover the section of the blade not requi-
red for sawing above the machine table with a safeguard against lifting
beyond the maximum cutting height of + 5 mm. Rollers integrated in the
safety hoods at the leading and trailing ends facilitate both feeding workpi-
eces and pulling back workpieces if workpieces have a slightly different
thickness.
• Laterally displaceable protective hood for machines with the option "Saw
blade tilting to both sides"
• 3 riving knives for saw blades between 250 and 450/500 (550) mm diame-
ter to avoid workpiece kick-back as a result of jamming in the cutting line.
33

Product description
3.7.4 Handling batteries / accumulators

Information on battery regulations
Note!
i Dispose of used batteries according to the applicable laws and regulati-
ons at a communal collection point or return them to your retailer free of
charge.
Danger caused by lithium batteries
If lithium batteries are used or stored outside of their specification, they may be
dangerous. Dangers result primarily from incorrect handling and improper use.
Examples of improper use:
• mechanical damage (internal short-circuit)

• thermal stress (internal short-circuit)
• overloading (strong temperature increase due to exothermic processes).
In Germany:
According to § 5 ArbSchG (German Occupational Safety and Health Law), § 3
BetrSichV (German Industrial Safety Law), the owner/user must create a risk
assessment to assess the dangers caused by technical equipment and de-
vices.
Measures for damage prevention

The risk potential of lithium batteries is, in addition to the product design, prima-
rily determined by the module or system capacity. The types used by Altendorf
are low-capacity lithium batteries (batteries > 1 kg). The information for dama-
ge prevention applies to both new and used batteries.
General safety regulations
Always observe the following safety regulations:
• Adhere to all specifications by manufacturers and on safety data sheets

• Prevent external short-circuits
• Prevent internal short-circuits (protect from mechanical damage)
• Immediately and properly dispose of damaged products (even in case of
slight damage)
• Do not expose directly and permanently to high temperatures or sources of
heat (e.g. direct sunlight)
• Train employees in the proper handling of lithium batteries (as with hazar-
dous materials)
34

Product description
Source: VdS 3103 : 2012-06 (01)

Lithium batteries - Excerpt of the GDV leaflet for damage prevention
35

Definitions
4 Definitions
4.1 Description of machine
Fig. 4-1 Description of the sliding table saw
36
Definitions 0000010040-002- GB
Definitions
1. Riving knife
2. Saw blade, protective hood
3. Protective hood support
4. Fixed guards beneath the table
5. Rip fence
6. Trimming hold-down device (clamping shoe)
7. Table insert
8. Machine table
9. Table length extension
10. Fixing elements
11. Protective hood holding fixture
12. Push stick
13. Sliding table
14. Crosscut fence
15. Sliding table handle
16. Movable operating terminal
17. Additional fixing elements on the rear end of the sliding table (optional)
37
0000010040-002- GB Definitions
Definitions
4.2 Terms
Scoring
Creation of a shallow cut in the surface of a workpiece, deep enough to pass
through any coating on the workpiece, so as to prevent damage to the undersi-
de when the main saw blade makes its cut.
Scoring blade
A blade that is located in front of the sawing blade, used to score the workpiece
and rotate along with the feed direction.
Grooves
Creation of cuts in the surface of the workpiece not deep enough to pass
through using the saw blade or a milling tool.
Machine drive
Power driven device to effect a machine movement
Hand feed
Holding and/or guiding the workpiece manually.
Removable feeding device
Feeding mechanism fastened to the machine such that it can be tilted out of the
work position without tools or similar equipment
Safety appliance
Additional device that is not an integral part of the machine but helps the opera-
tor to feed the workpiece safely, e.g. a push block or push stick.
Kick-back
Unexpected sudden movement of the workpiece or parts of it opposite to the di-
rection of feed in the course of sawing.
Riving knife
Protection against workpiece kick-backs and unintentional contact with the ri-
sing gear rim.
Spraying unit (minimum quantity lubrication)
The reduction of the lubricant quantity compared with the circulation quantity of
standard coolant lubricant systems is the main feature of minimum quantity lub-
rication. Unlike conventional overflow lubrication, a minimum quantity lubrica-
tion system only requires a few millilitres (ml) per hour of lubricant for the
chipping process.
38
Definitions 0000010040-002- GB
Definitions
39
0000010040-002- GB Definitions
Transport, siting and installation
5 Transport, siting and installation
5.1 Transport
When transporting the sliding table saw by elevating truck or fork lift truck (forks
only with unchangeable length), only lift the machine up slightly and secure it
against tipping!
Packaging
The type of packaging depends on the type of transport. Unless otherwise con-
tractually agreed, the packaging corresponds to the HPE guidelines establis-
hed by Bundesverband Holzmittel, Paletten, Exportverpackungen e.V. (the
German Association for Wooden Materials, Pellets, Export Packaging) and the
VDMA.Observe the symbols on the outside of the packaging!
Degree of dismantling
The degree of dismantling of the sliding table saw depends on the transport
conditions and the options supplied with the machine.The sliding table is al-
ways shipped dismantled into several installation assemblies.
Sensitivity
Particular care must be taken when transporting the sliding table saw in order
to avoid damage from force or poor loading and unloading.Knocks and conden-
sation due to extreme temperature fluctuations must be avoided during trans-
port.
Intermediate storage
If the sliding table saw or its assemblies are not installed immediately after deli-
very, make sure that they are stored in a protected location.They must be cor-
rectly covered to prevent any ingress of dust or moisture.Bare, non-surface-
treated parts of the sliding table saw are protected with a conserving agent
which will protect them for approx. 1 year. Reconservation is necessary if sto-
rage is to last longer than this period.
40
Transport, siting and installation 0000010040-002- GB

5.2 Safety measures before use/installation

Installation site
No special foundations are required at the installation site for the sliding table
saw. The floor must have a load bearing strength suitable for the machine
weight and should be flat and level.
Select an installation site that provides enough clearance around the sliding ta-
ble saw, allowing for the space requirements shown in the figure and the size of
the workpieces to be cut. In addition, observe the safety clearances to parts of
the building and other machines in order to eliminate the risk of crushing the
operator or other personnel.
Fig. 5-1 Foundation plan
41
0000010040-002- GB Transport, siting and installation

Danger!
Danger of crushing!
• For operation with the max. workpiece weight, secure the machine
against tilting!
• Ensure that there is sufficient safety clearance from building parts
and other machines!
42

Fig. 5-2 Space requirement
Key
Dimension A:
Manual adjustment PA: Cutting width + 280 mm
Motor-driven adjustment PA: Cutting width + 360 mm
Dimension B: Sliding table length + 360 mm
Dimension C: Sliding table length + 290 mm; sliding table length + 30 mm with
TSD
Dimension D:
Crosscut fence: 1890 - max. 3420 mm
Crosscut mitre fence and PQS: 1960 - max.3690 mm
CNC crosscut fence UNO/DUO: 2200 - max.3670 mm
43

Fixing
A fixing element is provided on the side of the machine frame to ensure the ma-
chine stays in position. Once the sliding table saw has been set up, loosen the
screws and lower the fixing down to the floor. Then retighten the two screws.
44

5.3 Installation
5.3.1 Telescopic tube for swinging arm
Assembly, telescopic tube Standard/Compact
Fig. 5-3 Installing the telescopic tube

[1] Undo the cheese head screw
[2] Push in the telescopic tube from the front through the housing for the swinging arm
[3] Insert and tighten the cheese head screw
45

Installing the telescopic tube, 4th axis
Fig. 5-4 Swivelling arm, 4th axis

[1] Support bolt
[2] Plug-type connection plate, telescopic tube
[3] Plug-type connection plate, swivelling arm housing
Note!
i • The two plug-type connections have a different number of pins!
• The number of pins is 3 and 5.
• The 5-pole connection is marked red!
Fig. 5-5 Plug-type connections
46

5.3.2 Main table length extension
Assembly of TPL 840
Fig. 5-6 Installing the main table length extension

[1] TPL board
[2] Support arm
[3] Fastening screw M10
[4] Support screw
[5] Stationary installed, adjusted bracket on the cast table top
[6] Fastening screws for TPL on bracket
Assembly steps:
• Place the TPL onto the brackets on the table top and insert the fastening
screws of the support arms into the holes on the table top face end.
• Loosely secure to the table top with two M10 nuts and U-shaped washers
• Screw-fit the TPL to the aluminium brackets (6)
• Tighten the M10 nuts.
• If necessary, correct the alignment and flushness by readjusting the sup-
port screws (4).
47

Table top expansion 1600/2000 with base support:
Fig. 5-7 TPL 1600/2000

[1] Support screws
[2] Fastening screws
[3] Adjustable feet
Assembly steps:
• Place the TPL onto the brackets on the table top and insert the fastening
• Screw-fit the TPL to the aluminium brackets
• If necessary, correct the alignment and flushness by readjusting the adjus-
table feet (3) and/or the support screws (1).
48

5.3.3 Rip fence
Fig. 5-8 Installing the measuring bar

[1] Fit the measuring bar easily with M6x30 countersunk screws (1)
[2] Knock a 6x45 clamping pin (2) through
[3] Tighten the countersunk screws(1)
Assembly of TPV
Fig. 5-9 Installing the main table width extension

[1] TPV board
[2] Support arm
[3] Fastening screw M10
[4] Support screw
[5] Stationary installed, adjusted bracket on the cast table top
[6] Fastening screws for TPV on bracket
49

Assembly steps:
• Carefully push the rip fence onto the round bar

• Place the TPV onto the brackets on the table top and insert the fastening
• Screw-fit the TPV to the aluminium brackets (6)
• If necessary, correct the alignment and flushness by readjusting the sup-
port screws (4).
50

5.3.4 Cross-slide and crosscut fence
Cross-slide
Installing the cross-slide

The cross-slide must be attached to every point of the outer-lying round bar of
the sliding table, and must be clamped.
Assembly steps:
- Place the supporting pipe of the cross-slide [1] onto the bolt [8] of the telesco-
pic tube
- Tilt the cross-slide to the sliding table, suspend and clamp using the eccentric
lever [2]; for the operation of the eccentric lever, refer to the following pages.
Fig. 5-10 Installing the cross-slide

[1] Support pipe
[2] Eccentric clamping lever
[3] Workpiece support
[4] Crosscut fence
[5] Crosscut fence clamping
[6] Extendable crosscut fence extension
[7] Extendable cross-slide width extension (option)
[8] Support bolt, telescopic tube
51

Cross-slide clamping mechanism WA/WGA/CNC crosscut fence UNO 90
Fig. 5-11 Clamping lever

[1] Clamping lever
[2] Safety locking mechanism
[3] Stop, safety locking mechanism for displacing the cross-slide
[4] Drill hole, safety locking mechanism for removing the cross-slide
To push the cross-slide to other positions on the sliding table, undo the clam-
ping lever [1] up to the stop of the safety locking mechanism. It is now possible
to displace the cross-slide without a risk of the cross-slide falling down.
To remove the cross-slide, pull out the safety locking mechanism and push up
the clamping lever. The safety mechanism engages in the hole [4]. The cross-
slide can now be removed completely.
When assembling the cross-slide, first hook it in, pull out the safety locking me-
chanism, push the clamping lever all the way to the fixed stop. Release the sa-
fety locking mechanism.
52

Cross-slide clamping, CNC crosscut fence DUO 90/DUO Flex
Fig. 5-12 Cross-slide clamping, CNC crosscut fence DUO

[1] Eccentric clamping lever
[2] Safety locking mechanism
To push the cross-slide to other positions on the sliding table, undo the clam-
ping lever [1]. It is now possible to displace the cross-slide without a risk of the
cross-slide falling down.
To remove the cross-slide, pull out the safety locking mechanisms and turn
them. The safety locking mechanisms engage. The cross-slide can now be re-
moved completely.
When assembling the cross-slide, first hook it in and push the clamping lever all
the way to the fixed stop. Undo the safety locking mechanism and turn to enga-
ge.
53

Crosscut fence, 90° only
Fig. 5-13 Installing the 90° crosscut fence
1. Place the crosscut fence on the cross-slide such that the clamping bolts [1]
can be inserted in the grooves [2]
2. Tighten the clamping bolts [1], positioning is carried out by means of the
tapered surfaces
Changing the 90° crosscut fence
1. Undo the clamping bolts [1]

2. Move the crosscut fence to a new position; ensure that the clamping bolts
are inserted into the grooves
3. Tighten the clamping bolts [1], positioning is carried out by means of the
tapered surfaces
Warning!
In the case of the "tilting to both sides" option, only use the crosscut fen-
ces supplied with this machine!
Non-observance can lead to injuries and/or damage of machine compo-
nents.
54

Crosscut-mitre fence
Fig. 5-14 Crosscut-mitre fence operating elements

[1] Clamping lever 90° position
[2] Clamping degree scale
[3] Clamping pivot point
[4] Clamping lever, cross-slide / sliding table
[5] Clamping, C profile
Installing the standard crosscut-mitre fence / with DIGIT L + LD:
• Place the WGA on the rear fence surface

• Push the ball bearing over the groove in the sliding table
• Unscrew the handle of the degree scale clamping
• Carefully turn the crosscut-mitre fence by 90° so that the ball bearing can
be inserted in the groove of the sliding table and the threaded bolt of the
clamping degree scale in the groove of the profile
• Fasten the handle of the clamping degree scale
55

Fig. 5-15 Installing the WGA

[3] Ball bearing
56

90° clamping
Fig. 5-16 90° clamping

[1] Support roller
[2] Clamping lever
[3] 90° stop
[4] Pressure piece on the clamping lever
[5] Guide bolt(s)
Fig. 5-17 Crosscut-mitre fence left-hand side

[1] Clamping screw, telescopic extension
[2] Guide groove for 90° position
[3] Clamping piece, 90° position
57

Crosscut-mitre fence WGA_LD

Crosscut-mitre fence with digital angle and length measurement
Fig. 5-18 WGA_LD

[1] Clamping lever 90° position
[2] Indexing bolt, angle measurement
[4] Clamping lever
[5] Clamping, angle measurement
Assembly of the crosscut fence
• Place the WGA_LD on the rear fence surface

• Push the bolt for the degree setting clamp over the groove in the degree
scale, and push the guide carriage into the middle.
• Position the T-nut for pivot clamping so that there is enough clearance to
the pivot
• Push the ball bearing over the groove in the sliding table
• Carefully turn the crosscut-mitre fence 90° and raise it so that the bolt
enters the degree scale groove and the ball bearing enters the sliding table
groove
58

• Lower the crosscut-mitre fence so that the bolt enters the guide carriage
hole
• Turn in clamping screw [5] loosely
• Push the T-nut with clamping screw [3] into the pivot
• Swivel the WGA to its 90° position and clamp with clamping lever [1].
• Tighten the clamping screws
Operating elements
Fig. 5-19 WGA_LD

[1] Telescopic extension
[2] Clamping, telescopic extension
[3] 90° stop
[4] Guide groove, 90° position
[7] Guide roller, sliding table
[8] Clamping lever, 90° position
[9] Indexing bolt, angle measurement
59

Fig. 5-20 90° clamping

[1] Support roller
[2] Clamping lever
[3] 90° stop
[4] Pressure piece on the clamping lever
[5] Guide bolt(s)
Fig. 5-21 WGA_LD, LH side

[1] Clamping screw, telescopic extension
[2] Guide groove, 90° position
[3] Clamping piece, 90° position
60

CNC crosscut fence

Operating elements, CNC crosscut fence UNO 90
Fig. 5-22 CNC crosscut fence UNO 90

[1] Stop fence
[2] Axis drive
[3] Axis extension
[4] Electrical connection
[5] Clamping screws
[6] Indexing bolt, extension
[7] Clamping screw, extension
[8] Clamping lever, cross-slide
61

Extension
Fig. 5-23 Extension, CNC crosscut fence UNO 90

[1] 1000 mm extension piece
[2] Indexing bolt
[3] Clamping screw
Extension installation
• Insert the extension into the guide until the indexing bolt engages
• Tighten the clamping screw.
• When using the second throw-over stop, the adjustable dimension increa-
ses by 1000 mm
62

Fig. 5-24 Extension installation

[1] Locking hole, extension
[2] Indexing bolt
[3] Clamping, extension
63

Operating elements, 4th axis DUO 90
Fig. 5-25 Operating elements, 4th axis DUO 90

[1] 4th axis DUO 90
[2] 90° stop
[3] Safety frame
[4] Clamping
[5] Drive unit
[6] Cross-slide, clamping
[7] Cross-slide, locking mechanism
64

Fig. 5-26 Operating elements

[1] 4th axis DUO 90
[2] Drive unit
[3] 90° stop
[4] 90° clamping screw
[5] Handle for guide plate
[6] Clamping
[7] Extension
[8] Throw-over stop 2
[9] Throw-over stop 1
[10]Cross-slide clamping
[11]90° mounting
[12]Cross-slide locking mechanism
The cross-slide can be hooked in and clamped at any position on the sliding ta-
ble as follows:
• Place the supporting pipe of the cross-slide on the bolt of the telescopic
tube.
• Swing the cross-slide to the sliding table, hook it in and clamp it with the
clamping mechanism.
• Engage cross-slide locking mechanism
65

Installing the 4th axis:
Fig. 5-27 Installing the 4th axis

[1] 4th axis DUO 90
[2] Safety frame
[3] Cross-slide
• Place the safety frame and fix it with screws

• Place 4th axis DUO 90
• Push the guide plate into the mounting
• Swivel and tighten 90° clamping screw into the 90° stop
• Tighten the guide plate clamp
• Insert the plug connectors of the 4th axis underneath the telescopic tube.
Note!
i If the safety frame is not installed, adjustment movements are only pos-
sible in HOLD TO RUN mode!
66

Fig. 5-28 Electrical connection

[1] Socket 1
[2] Socket 2
Warning!
The plug connectors have 3 and 5 poles, are marked in different

colours and must only be connected or disconnected when the
main switch is switched off.
Non-adherence can lead to destruction of the plug connectors or the
electronics.
67

Operating elements, 4th axis DUO Flex
Fig. 5-29 Operating elements, 4th axis DUO Flex

[1] 4th axis DUO Flex
[2] 90° stop
[3] Angle measuring unit
[5] Clamping, cross-slide
[6] Cross-slide, locking mechanism
[7] Drive unit
[9] 90° clamping

The cross-slide can be hooked in and clamped at any position on the sliding ta-
ble as follows:
• Place the supporting pipe of the cross-slide on the bolt of the telescopic
tube.
• Swing the cross-slide to the sliding table, hook it in and clamp it with the
clamping mechanism.
• Engage cross-slide locking mechanism
68

Installing the 4th axis DUO Flex
Fig. 5-30 Installing the 4th axis DUO Flex

[1] Guide roller
Prior to assembly, unscrew the handle of the clamping, degree scale [3].
• Place the 4th axis on the rear fence surface

• Position the guide roller over the groove in the sliding table
• Position the degree scale clamping over the groove in the degree scale
• Position the guide carriage such that the distance between the stop fence
and the hole in the guide carriage is 100 mm
• Turn the clamps 90° in the longitudinal direction
• Turn the 4th axis by 90°
• Check the guide roller in the roller carriage groove
• Push the pivot clamp to the right into the clamping plate and tighten the
bolts
• Fasten the handle of the 'Degree scale clamping'
• Insert the plug connectors of the 4th axis underneath the telescopic tube.
69

Fig. 5-31 Electrical connection

[1] Socket 1
[2] Socket 2
[3] 90° clamping
Warning!
The plug connectors have 3 and 5 poles, are marked in different

colours and must only be connected or disconnected when the
main switch is switched off.
Non-adherence can lead to destruction of the plug connectors or the
electronics.
70

5.3.5 Sliding table
Fig. 5-32 Bottom carriage stop

[1] Place the bottom carriage on the machine frame and push against the stop screws.
[2] Screw on the bottom carriage using the outer fixing screws.
[3] Only tighten the middle fixing screw loosely.
Fig. 5-33 Installing the middle carriage

[1] Place the middle carriage on the bottom carriage so that the interlock is pointing to
the right.
[2] Push the middle carriage to the right until the 1st double roller is still just resting on
the round bars. If this is not observed, in the case of the TIP-SERVO-DRIVE the
end position sensors could be destroyed when the top carriage is pushed on!
71

Fig. 5-34 Installing the top carriage

[1] Carefully push on the top carriage making sure it is not skewed, watch the e-chain.
[2] Carefully push the guide rails onto the double rollers.
[3] Push the top carriage towards the left, all the way to the stop.
Fig. 5-35 Back stop

[1] Back stop
[2] Clamping piece for rear stop
The rear stop is fastened with two screws in the clamping piece.
72

Fig. 5-36 Central fixing

[1] Tighten the central fixing screw.
[2] Check that the sub-rollers are correctly adjusted.
Fig. 5-37 Bracket on the bottom carriage

[1] Fix the bracket to the bottom carriage with 3 screws.
73

Fig. 5-38 Bracket on the bottom carriage
Fig. 5-39 Position of e-chain

[1] Place the bottom e-chain on the bracket on the bottom carriage.
[2] Run the cable into the machine frame through the opening in the bottom carriage.
74

Fig. 5-40 Fastening the e-chain

[1] Screw the first link of the e-chain onto the bracket using 2 screws.
Fig. 5-41 Switch cabinet

[1] Connect the plug to the switch cabinet.
[2] Tighten the cap nut.
Warning!
The connectors have 3 and 5 poles.

Ensure you plug the 3-pole connector into the 3-pole socket, otherwise
the connector will be destroyed!
Observe the colour marking.
75

Fig. 5-42 Fastening the e-chain / cable

[1] Remove all the packing tape.
[2] Screw on the cover profile.
76

5.3.6 Electrical connection
Warning!
Dangerous electric voltage!
All work on the electrical equipment, including connection to the mains
supply, may only be performed by a qualified electrician. Disconnect the
machine from the mains supply before working on the electrical equip-
ment.
• After connecting the supply line, check the rotationaldirection of the
main saw motor by briefly starting up and, if necessary, correct it by
interchanging the two outer conductors in the mains connection box.
Pay attention to the rotational direction arrow on the saw blade cover!
• As far as machines with a VARIO drive are concerned, check the
rotational direction of the scoring saw motor, because the frequency
converter ensures that the directional rotation of the main saw motor
is always correct, regardless of the phase position.
• Only connect or disconnect plug-in connectors when the main switch
has been turned off or disconnected!
Fig. 5-43 Mains connection
The mains connection is in the RH switch cabinet on the right-hand side. The
terminals for the supply line are marked L1, L2, L3, N and PE, the terminals for
the potential-free contact for the control of an extraction system are marked
POT. The supply line cross-section and the fuses to be fitted by the user de-
pend on the installed motor rating.
If the machine is connected via a flexible supply line, a rubber-sheathed cable
(wire marking H07RN-F) must be used. Required plug-in device: Round con-
nector in accordance with DIN 49463.
77

Fig. 5-44 Circuit diagram
78

Designation Designation
GL 1 Rectifier
Q1 Main switch
S 26 LASER option switch
M1 Main saw motor
M2 Scoring saw motor
MR 1 Temperature monitor for main saw motor
S1 Sliding table safety switch
S2 EMERGENCY STOP button
S3 Temperature monitor for scoring saw motor
S1 Machine door/cover plate safety switch
E1 Multifunction module
F1-F2 Control fuses (primary)
F4-F6 Scorer motor (option)
F7-F9 Control fuses (secondary)
F 10 - F11 SPRAY / LASER control fuse (option)
F 12 - F 14 CEKON (option)
K1M-K5M Motor contactors
K5E Supply voltage contactor for adjustment drives
K 14 M CEKON contactor (option)
79

5.3.7 Connecting the extraction system (customer side!)
Fig. 5-45 Bottom extraction connection
Total extraction system connection D = 140 mm

Vmin = 1150 m3/h at 20 m/s
Bottom extraction connection D =120 mm
The hoses and Y-tube are not supplied as standard with the machine.
The dust emission values – measured in accordance with the “Principles for
Testing Dust Emission (Workplace-Related Dust Concentration) from Wood-
working Machines” issued by the German trade association's technical commit-
tee for wood – are under 2 mg/m3. When the machine is attached to a correctly
functioning extraction system with an air speed of at least 20 m/s (measured at
the connection socket) you can assume it is and will stay compliant with the
technical reference concentration (TRK) value for wood dust that is in force in
Germany. For perfect and safe operation, the machine must be connected to
the extraction system at the extraction sockets (rear of machine frame and pro-
tection hood support). The minimum air speed at the extraction sockets must
be 20 m/s.
The 80 mm extraction hose from the hood to the connection socket on the sup-
port tube is not supplied as standard. The extraction socket and hoses are not
supplied as standard!
80

Note!
i Observe the following:
• Make sure that the extraction system is switched on together with the
machine. For this, you can use the existing potential-free contact
(POT - refer to circuit diagram) or a current transformer installed in
the supply line.
• When using spray device (SPRAY), make sure that you use a suita-
ble moisture extraction system in order to avoid faults.
• Check the function of the extraction system at regular intervals!
• A spark-extinguishing system should be installed as a precaution to
prevent fires and explosions in filter systems, silos and other produc-
tion environments.
• Ensure that the extraction system is suitable for extracting aluminium
chips!
• Always collect wood, aluminium and plastic chips separately!
• Prior to cutting aluminium, thoroughly clean the machine and remove
all remaining dust and chips!
81

5.4 Basic machine setting

Basic machine setting is carried out at our factory during final assembly. It may
be necessary to correct the machine's basic settings due to removal of various
assembly groups, and transport and installation on site. The machine elements
to be checked are described below.
5.4.1 Sub rollers on the sliding table

Check the sub-rollers
Fig. 5-46 Sub-rollers
The sub-rollers must run smoothly against the start slope at the start and end of
the raceway. They should be set so that they can be held by hand with noticea-
ble force and that they slip while the sliding table is moved.
Setting of the sub-rollers

The sub-rollers have eccentric bearings and can be adjusted.
The sub-rollers are set so that they can be held by hand with noticeable force
and that they slip while the sliding table is moved. Adjusting them too tightly will
result in stiff movement of the sliding table, and can lead to unwanted cutting
results.
Repeat this process for all sub-rollers.
82

5.4.2 Main table

Checking the main table
Place a rip fence straight edge on the sliding table, and move the table into the
middle position. Move the sliding table forward and backward; the main table
must be approx. 1/10 mm lower.
Adjusting the main table

Release the lock nuts (1) of the 4 stay-bolts, adjust the main table, and tighten
the lock nuts.
Fig. 5-47 Adjusting the main table
83

5.4.3 Swinging arm

Check
Fig. 5-48 Swivelling arm, check
Rest the swinging arm against the machine frame, fully extend the telescopic
tube of the swinging arm and check dimensions A and B. Set dimensions A and
B with a tolerance of 0.5 mm; if necessary correct the setting with EX 1 and EX
2.
The dimension between the bottom edge of the crosscut fence profile and the
top edge of the top carriage profile (see fig. 2) is a feature for the tolerance of
the swivel arm setting. The dimension must not exceed the cut length possible
with the cross-slide between 0.1 and 0.9 mm (check with feeler gauge).
Fig. 5-49 Crosscut fence setting
84

5.4.4 Cross-slide height

Check
Fig. 5-50 Checking the cross-slide height
Push a piece of cardboard of approx. 0.5 mm thickness between the crosscut

fence and the sliding table; it must be possible to move the cardboard freely in
every position. The crosscut fence must be parallel to the surface of the sliding
table!
Setting
Fig. 5-51 Adjusting the cross-slide height
Adjust the height of the swinging arm bolt and fix it with a lock nut. Check that
the swinging arm is parallel if the gap changes in accordance with the position
of the sliding table!
85

5.4.5 Setting free cut
Sliding table
Definition:
The sliding table, the saw blade and the rip fence are not parallel to each other,
so the crosscut fence and the rip fence do not form a 90° angle. The sliding ta-
ble runs to the left out of the direction, by a fraction of a millimetre. in the same
way, the rip fence points slightly to the right so that a gap is created behind the
saw blade.
The rising saw blade tooth must not recut, but free cut should be set as small
as possible. When using a scorer, make sure that both free cuts are of an equal
size.
Check:
Set the saw blade to maximum cutting height, and cut off an approx.100 mm pi-
ece from an MDF test piece at the cross-cut fence. The noise difference bet-
ween the cutting and non-cutting teeth lets you identify whether the sliding
table is set correctly. When the rising teeth pass, only a slight fluttering should
be heard compared to the noise of the cutting teeth.
Setting:
Release the sliding table mounting components at both ends and in the centre
(if installed). Release the lock nuts of the stop screws. Adjust them as required
and fix them with lock nuts again. Then push the sliding table against the stop
screws and re-tighten all fastening screws.
Rip fence
Check:
Set the saw blade to maximum cutting height, and cut off a test piece of about
300 x 450 mm (if possible MDF) at the rip fence. The sound of the rising teeth
must be the same as when cutting free on the left, with the sliding table correct-
ly set.
Cross-check:
Move the rip fence approx. 0.5 mm closer to the saw blade, push the riving kni-
fe with the workpiece slightly to the side and cut in backward approx. 50 – 80
mm. Pull out again in the normal direction, turn it once around the cross-axis,
and cut in approx. 20 mm deep in the normal way. The difference between the-
se two cuts should be almost invisible but easily felt.
When using a scorer, make sure that both free cuts are set as equal as possib-
le!
86

Setting: Manually adjustable rip fence
Fig. 5-52 Setting free cuts, standard rip fence
• Undo the nuts on the bolts connecting the round bar and the table width
extension
• The degree of free cut on the rip fence can be altered by adjusting the
middle lock nuts
• Tighten the nuts on the bolts connecting the round bar and the table width
extension
Setting: Electromotive rip fence
Fig. 5-53 Free cut setting, electromotive PA
• Release clamping screws 1

• Set the free cut by adjusting setscrews 2
• Tighten clamping screws 1
87

5.4.6 Angle cut

Checking the angle cut
Before checking the angle cut, check the settings of the sliding table and of the
swinging arm, and correct them if necessary.
Carry out the check as follows:
Fig. 5-54 Angle cut
As the tool, use a sharp saw blade, D = 350 mm/ 3.5/2.5/72 teeth alternate be-
vel at n = 5000 rpm. Take a 1000 x 1000 mm chipboard or MDF board, mini-
mum board thickness 19 mm. Perform 5 cuts (see fig.), laying the last cut side
at the crosscut fence for the next cut (turn the board counterclockwise). For the
5th cut, cut off a strip with a width of approx. 10 mm. Measure the thickness at
both ends of the strip with a vernier caliper. The difference between the two di-
mensions divided by 4 gives the angular error per metre cut length.
Check:
The angle cut must be checked at a minimum of 2 different positions on the
cross-slide of the sliding table.
Factory setting:
The cross-slide is clamped to positions of approx. 300 mm and 1300 mm from
the sliding table end. In these two positions, the angle cut is checked and ad-
justed as described above. Ensure that the setting does not exceed the maxi-
mum permissible tolerance of < 0.2 mm (for the 5th cut (dimension 1 -
dimension 2)).
88

5.4.7 0° setting of the saw blade

Check:
• Set the tilt adjustment to 0°.

• Position 2 strips (approx. 100 mm wide) vertically in front of the crosscut
fence, cut in this position and butt the cut surfaces against each other.
• If the setting is correct, the cut surfaces should be parallel, i.e. no gap can
be seen between the cut surfaces.
Fig. 5-55 Cutting a test piece
Fig. 5-56 Checking the 0° -setting
Setting:
Recalibrate the machine if a gap is detectable!
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6 Operating
6.1 Working safely with the dimension saw
6.1.1 Cross-slide/crosscut fence
Fig. 6-1 Cutting boards
The crosscut fence can be installed at two positions on the cross-slide.

Position 1: Cutting boards
The operator presses the workpiece against the fence in the cutting direction.
Fig. 6-2 Cutting solid wood
Position 2: Cutting solid wood and boards up to 600 mm wide

The operator pulls the workpiece along the fence against the cutting direction.
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Function description of the crosscut-mitre fence
• The crosscut-mitre fence can be swung by 49° (angle indicated on scale),

plus angle-dependent adjustable length compensation via a scale.
• Ball bearings run in the sliding table groove, preventing the stop fence
coming into the cutting plane when swung
• Clamping of the stop profile at the pivot and on the degree scale
• Additional clamping at the 90° position
• Movable, fixable C profile as an additional workpiece support
Operating elements
Fig. 6-3 Position of clamping screws

[1] Clamping screw 1
[2] Clamping screw 2
Adjusting the angle
• Release the clamping screws

• Set the crosscut-mitre fence to the desired angle
• Carry out length compensation
• Tighten clamping screw 1
• Set and tighten clamping screw 2
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Length compensation
Fig. 6-4 Length compensation scale
By shifting the crosscut-mitre fence, the length dimension can be adjusted for
the set angle.
Changing the crosscut-mitre fence
• Release the clamping screw and clamping lever

• Push the crosscut-mitre fence to the 2nd position
• Push the guide piece of the eccentric clamping system into the pivot
groove as far as it will go and clamp it
• Tighten the clamping screws
Note!
i When dimensions need to be adjusted with the stop bar, make sure that
the flip stop is against the fence of the extension!
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6.1.2 Rip fence
Fig. 6-5 Position of the clamping screw
For cutting parallel, the rip fence is pushed up to the required dimension. The
set dimension is read off from the edge of the aluminium profile.
The dimension scale can be adjusted to the individual tool thickness after re-
leasing the knurled screw.
Stop fences
Fig. 6-6 Upright position of the stop fence
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The stop fence of the rip fence can be adjusted in the cutting direction and to
the profile height. Clamp it in the required position with the top eccentric lever.
For crosscutting short workpieces and for recessing or other work cycles during
which offcuts can become jammed between the stop and the saw blade, the
stop fence is moved forward until its rear end is in front of the saw blade.
Fig. 6-7 Flat position of the stop fence
The stop fence is moved into the flat position when cutting flat and narrow
workpieces. This means there is more space for workpiece guidance and the
fence can be moved closer to the saw blade, in particular when the saw blade
is tilted, without hitting the protection hood.
Warning!
Danger of injury!
When cutting widths of less than 120 mm, make sure that the material is
fed with a push stick and that the stop fence is laid flat.
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6.1.3 Double roller carriage

Sliding table operating elements:
Fig. 6-8 Sliding table operating elements, manual
Fig. 6-9 Sliding table operating elements, TIP SERVO
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Fig. 6-10 Sliding table operating elements, vacuum suction cups
The vacuum suction cups are exclusively operated by means of the operating
panel.
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6.2 Working examples

General information
The Altendorf sliding table saw is a universal machine that can be used for va-
rious saw cuts. However, the machine must be set up appropriately.
Tools
First, make sure that you only use saws in perfect condition, that the riving knife
is correctly set and that the top protection hood is lowered close above the
workpiece to be cut. The latter is also particularly important for ensuring perfect
functioning of the top extraction system.
Rotational speed
Note!
i Make sure that the correct rotational speed is set and, after the machine
has been switched on, do not start pushing the workpiece forward until
the saw blade has reached its full rotational speed.
Position of the hands
Lay your hands flat on the workpiece with fingers and thumbs close together,
and with sufficient safety clearance from the saw blade.
For further information about safe working, refer to the following description of
the individual work steps.
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Edge cutting (trimming)
Fig. 6-11 Edge cutting
Tool: Circular saw blade for longitudinal cuts

Work cycle: Fit the clamping shoe on the sliding table. Lay the workpiece with
the hollow side down, and press underneath the clamping shoe. Push the
workpiece forward by applying pressure with the ball of your right hand on the
workpiece edge. Place your hands with sufficient safety clearance from the
tool.
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Longitudinal cutting of narrow workpieces
Fig. 6-12 Longitudinal cutting
Workpiece width < 120 mm

Tool: Circular saw blade for longitudinal cuts
Work cycle: Set the rip fence to the required cutting width. Lower the top pro-
tection hood according to the workpiece height. Push the workpiece (aligned
along the fence) and sliding table forward, using the push stick in the vicinity of
the saw blade, and push the parted workpiece beyond the riving knife. Use the
push stick from the very beginning when cutting short workpieces.
Cutting strips
Fig. 6-13 Cutting strips
Tool: Circular saw blade for fine cuts
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Work cycle: Set the aluminium straight edge of the rip fence to the low guide
surface. Lay the workpiece on the sliding table and press against the rip fence
with your left hand. Push the workpiece forward with the sliding table; use the
push stick in the vicinity of the saw blade to push the strip beyond the riving kni-
fe.
Crosscutting wide workpieces
Fig. 6-14 Crosscutting
Tool: Circular saw blade for crosscuts

Work cycle: Lay the workpiece against the crosscut fence; when pushing for-
ward, push firmly against the fence with your left hand. When using the throw-
over stop, raise the stop and remove the workpiece from the saw blade before
pulling back after the cut, or remove the workpiece behind the rising gear rim.
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Concealed cutting, rebating
Fig. 6-15 Concealed cutting

Work cycle: When rebating, select the cutting sequence so that the cut-out strip
is produced on the side of the blade opposite the fence. Lower the protection
hood onto the workpiece and ensure good workpiece guidance (left hand pres-
ses the workpiece against the rip fence).
Concealed cutting, grooves
Fig. 6-16 Grooves
Tool: Grooving tool permitted for manual feeding (max. width 20 mm)
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Work cycle: Close the table opening with a table strip matched to the grooving
tool. Set the tool to the required groove depth. Leave the riving knife in as a
rear tool cover. When pushing forward, firmly press the workpiece onto the tab-
le (otherwise danger of unintentional insert operation.).
Note!
i Always use the crosscut fence when cross-grooving narrow workpieces.
Crosscutting against the rip fence
Lay the material against the crosscut fence of the cross-slide. Set the required
dimension at the rip fence, pulling back the stop fence to the front of the saw
blade after releasing the clamping, and guide the workpiece with the sliding ta-
ble. When the stop fence is pulled back, the workpiece cannot jam between the
saw blade and fence.
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Crosscutting short and narrow workpieces

Work cycle: Adjust the deflector wedge featuring a magnet (not part of the
scope of supply) such that the workpiece cuts cannot touch the rising section of
the saw blade. Only feed workpieces using the crosscut fence. Never remove
off-cuts by hand from the vicinity of the tool.
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Dividing large boards
Fig. 6-19 Dividing
For this work cycle, the dimension can be set both on the rip fence and on the
crosscut fence. If several pieces of the same size are to be cut from a large
board, it is best to first cut off parallel strips at the rip fence and then cut them to
the required dimension. However, if the workpieces exceed the cutting width of
the machine, the dimension is set at the machine's crosscut fence.
Cutting with a negative cutting angle
Fig. 6-20 Cutting with a negative angle
For this work cycle only the crosscut fence or crosscut-mitre fence is used.
Do not use a DUPLEX fence!
Do not use a clamping shoe as the saw blade is tilted above the sliding table for
a negative cutting angle.
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6.3 Machine operation
6.3.1 Main switch
Fig. 6-21 Main switch
The main switch is located on the outside of the RH switch cabinet.

Before turning on the saw drives, the main switch must be moved to setting I.
The machine control unit carries out a self-test, after which the available axes
and their current values are displayed.
Grey/black main switch

The main switch does not have an EMERGENCY STOP function! When the
machine is turned off with the main switch, the saw drives run down unbraked!
Red/yellow main switch

The main switch has an EMERGENCY STOP function! When the machine is
turned off at the main switch, the main saw drive is braked.
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6.3.2 Switching the saw drives on and off
Fig. 6-22 Switches for saw drives
Warning!
• Before switching on the machine, make sure that all protective

devices required for the respective work cycle are attached and ope-
rative. In addition, check that the saw blades are correctly fitted and
that there are no workpieces or other objects in their vicinity. Check
whether the correct rotational speed has been preselected to match
the saw blade and the work cycle to be performed. Check that the cir-
cular saw blade is running in the correct direction by briefly switching
on.
• Make sure that the extraction system switches on at the same time
as the saw drives.
Press the white push button I with the main saw symbol in the operating panel
to start the main saw drive. After switching on the main saw, this button is lit.
The scoring saw can only be started when the main saw has reached its opera-
ting speed. To do so, press the white push button I with the symbol of the sco-
ring saw. This button lights up when the scoring saw has been switched on.
To switch off, press the black button marked “0”.
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Fig. 6-23 Switches for sliding table saw drives
The drives can also be turned on and off with the switches on the sliding table
(option).
In addition, the machine can be switched off with one of the EMERGENCY
STOP buttons. However, this possibility should only be used in case of an
emergency.
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6.3.3 Setting the speed

Three rotational speeds can be set for the main saw drive by moving over the
V-ribbed belt:
• 3000 / 4000 / 5000 rpm
Changing the rotational speed
Fig. 6-24 Changing the rotational speed

[1] Switch off the drive.
[2] Open the machine door.
[3] Turn screw 1 counterclockwise until it engages.
[4] Set belt guide 2 to the required rotational speed.
[5] Place the V-ribbed belt so that it runs in the recess of the belt guide and into the
vertical opposite grooves of the belt pulley.
[6] Turn screw 1 clockwise.
The belt tension is automatically set when the screw is turned back!
A rotational speed of only 3000 rpm is permissible with a saw blade dia-
meter of D = 550 mm (only for machines without scoring unit), for VARIO
3500 rpm.
Optimum position for changing speed/belt: Tilt saw unit to 25°!
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6.3.4 Fitting the main saw blade

AKE clamping system
Warning!
The following points must always be observed:

Non-adherence may lead to severe injuries!
• Do not fit any saw blades that are cracked or damaged in any way.
• Only fit saw blades with a diameter between 250 and 550 mm.
Machines with a scoring unit have a maximum saw blade diameter of
only 500 mm!
• The maximum rotational speed n max stated on the tool must not be
exceeded.
Fig. 6-25 Front flange
Fig. 6-26 Lock on the middle carriage
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1. Switch off the drive.

2. Set the saw blade to the maximum cutting height and tilt to 0°.
3. Turn off the main switch.
4. Move the top carriage to the middle of the saw shaft, and unlock the lock at
the saw blade centre by pressing the knob on the middle carriage.
5. Move the top carriage to the end position in the cutting direction.
6. Raise the red cover plate.
7. Use the wrench to release the screw in the expansion-head screw.
8. Undo the expansion-head screw by turning it counterclockwise with the
flange.
9. Before fitting the new saw blade, remove any adhering chips and dust from
both flanges.
10. Place the saw blade and front flange onto the saw shaft, turn in the expan-
sion-head screw by hand and tighten it with the wrench.
11. Check the riving knife for strength and distance from the saw blade.
12. Close the red protective cover and perform a short test run to see whether
the saw blade is running freely. Do this by lowering the top protection hood
down to the table so that the saw blade is completely covered.
Warning!
Check that saw blade clamping system is tight before operating the
machine!
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Fitting a milling tool

In order to use a milling tool (max. cutting width 20mm), first proceed as descri-
bed in point 1-8 in the previous section.
Then proceed as follows:
1. Remove the riving knife, cushioning disc and screws in the centre table
strip
Fig. 6-27 See point 1
2. Remove the front part of the centre table strip

3. Place the milling cutter and front flange onto the saw shaft, turn in the
expansion-head screw by hand and tighten it with the wrench.
4. Retract the riving knife block completely and tighten the clamping screw of
the riving knife holding fixture
5. Close the red protective cover and perform a short test run to see whether
the milling cutter is running freely. Do this by lowering the top protection
hood down to the table so that the milling cutter is completely covered.
Warning!
When returning to normal processing with a saw blade, adhere to the fol-
lowing:
Non-adherence to these points may lead to severe injuries of the opera-
tor!
• Reinsert the disassembled centre table strip; only use original brass
screws for fastening
• Reinstall the cushioning disc
• Reinstall and correctly adjust the riving knife
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Warning!
After changing a saw blade, always check that the riving knife is correctly
set.
Non-adherence to these points may lead to severe injuries of the opera-
tor!
• Select the riving knife according to the saw blade size and main
blade thickness
• Ensure that the riving knife thickness is min. 0.2 mm larger than the
main blade thickness
• The distance of the riving knife from the gear rim must be between 3
mm and 8 mm.
• The highest point of the riving knife must be set to between 0 and -2
mm beneath the topmost tooth.
• The riving knife must be at least 0.2 mm thicker than the main saw
blade.
Fig. 6-28 Adjusting the riving knife
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6.3.5 Saw blade recommendation
Warning!
Please note that only main saw blades with side holes can be fitted.
This is necessary to prevent loosening of the saw blade mounting in the
course of braking!
• Do not use high-speed steel (HSS) saw blades!
• The tools require a hole diameter of 30 mm and carrier holes of 10
mm diameter on a pitch circle diameter of 60 mm!
• The scoring blades have different diameters and are described in the
respective chapters of this manual.
Choosing the correct saw blade in accordance with the material to be cut and
its thickness, alongside the correct cutting speed, is very important for a clean
cut and low stress for the operator. For a selection of saw blades for ALTEN-
DORF sliding table saws, refer to the tool manufacturers' documentation. As
some of the stated cutting speeds cover large ranges, it is indispensable to em-
pirically determine the best speed for optimum cutting results!
Cutting speed in m/sec. for the adjustable rotational speeds and saw blade dia-
meters:
Diameter 3000 rpm 4000 rpm 5000 rpm

[mm]
250 39 52 65
300 47 63 79
350 55 73 92
400 63 84 105
450 71 94 118
500 80 106 132
550 86 115 144
Tbl. 6-1 Cutting speed
The areas marked grey may not be adjusted!
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6.3.6 Table locking

The sliding table interlock can lock the sliding table in any position, so that the
workpiece can be pushed against the crosscut fence without the easy-running
sliding table being set in motion unintentionally. It is actuated by means of a
handle at the end of the top carriage.
Fig. 6-29 Sliding table unlocked
Fig. 6-30 Sliding table locked
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6.4 Monitor controls ElmoDrive
Fig. 6-31 Monitor controls P-terminal
The buttons for the saw motor controls and the EMERGENCY STOP button
are located on the LH side beneath the touch screen.
A key block containing with 4 keys for the axes is arranged on the RH side. The
start/stop key can be used to start or interrupt positioning. The start button is
also required for positioning in the safety area in the inching mode. A selected
axis can be moved to any position using the - or + keys. During this, the axis
moves at slow speed for 3 seconds and automatically changes over to a faster
traverse speed afterwards. Touching the keys causes an adjustment of 0.1 mm
or 0.1°.
A USB interfacefor data transfer is fitted above the keypad.
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Fig. 6-32 ELMO II start screen
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Fig. 6-33 Start screen
Fig. 6-34 Start screen / tilting in both directions
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Fig. 6-35 Start screen / CNC crosscut fence DUO
The menu bar with fixed programmed buttons and freely programmable but-
tons is located in the bottom screen section.
The following buttons are programmed fixed:
• Rotational speed
• Menu
• Scorer (if present)
• Back
• Prog
When the machine has been switched on, the basic mask appears after ap-
prox. 10 seconds. The middle part of the display shows the outline of the sliding
table saw. The adjustable axes are highlighted. On the top screen margin, but-
tons containing axis symbols and the respective axis values are located. The
colours of the axis values have the following meaning:
• Green <> Axis in position

• Red <> Axis not in Position
• Yellow <> Axis being positioned
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Note!
i It is also possible to change several axes in their dimension and then
pressing the start button to displace them simultaneously. Positioning is
completed once the dimension display changes over from yellow to
green.
Safety area / Inching mode
In the safety area, the operator is told to press the Start button to conti-
nue positioning. For clarity, a flashing start symbol is displayed in the bot-
tom right-hand corner of the screen and, in this case, the START key is
lit.
Description of numeric keypad functions

After pressing an axis selection button, a window opens showing a numeric
keypad for entering dimensions.
Fig. 6-36 Numeric keypad

[1] Exit the numeric keypad
[2] Prevents automatic closing of the input window after the Enter or Start button is
pressed.
[3] Calculator
[4] Delete input
[5] Cal button
[6] Input confirmation
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6.4.1 Calibration
Fig. 6-37 Calibration
The dimensions of the axes must be checked and possibly calibrated every
time the saw blade is changed.
Select the axis to be calibrated by touching and press the Cal button in the
right-hand window for more than 1 seconds. Enter the dimension that was as-
certained via a test cut and confirm this by pressing Enter.
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Fig. 6-38 Tool Management
If, for example, you change the value of the cutting height and select a saw bla-
de in Tool management, a tool management window opens. The new saw bla-
de diameter calculated by the calibration process (after calibrating the cutting
height) is displayed and can be applied by pressing (green background) Save.
It then changes the saw blade diameter in tool management.
If the corrected saw blade diameter is not to be applied, press the top button
with the original diameter and press Exit to close the window.
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6.4.2 Height adjustment
Fig. 6-39 Height adjustment (ElmoDrive)
• Touch the Height Adjustment button, the numeric keypad and a separate
input window appear next to the axis in the RH section of the screen.
• Enter the desired figure and confirm with Enter, or press the START button
immediately for positioning
• You can also use the + / - buttons (above the START button) to make fine
adjustments
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6.4.3 Tilt adjustment
Fig. 6-40 Tilt adjustment_ElmoDrive, tilting to one side
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Fig. 6-41 Tilt adjustment_ElmoDrive, tilting to both sides
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Fig. 6-42 Tilt adjustment_ElmoDrive, tilting to both sides
• Touch the Tilt Adjustment button in the RH section of the screen, the
numeric keypad and a separate input window appear next to the axis.
• Enter the required dimension and confirm it with Enter
• Press the START button for positioning
adjustments
Attention!
It is imperative to ensure the following before tilting:

• Use the wide safety hood!
• When tilting to negative angles, observe the correct lateral position of
the wide protective hood
• Clear the main table of any workpieces in the tilting area
• When cutting widths less than 180 mm, set the rip fence straight
edge in the flat position
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Note!
i When the tilt angle is changed, the position control automatically adjusts
the cutting height that has been set.
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6.4.4 Motor driven rip fence (option)
Fig. 6-43 Rip fence adjustment
• Touch the Rip fence button, the numeric keypad and a separate input win-
dow appear next to the axis in the RH section of the screen.
adjustments
Note!
i The low guide surface of the fence is used when sawing thin and narrow
workpieces.
In the case of cuts less than 120 mm wide, the material must be fed with
a push stick and the low guide surface of the fence must be used.
For work cycles in which cut-offs can get jammed between the saw blade
and the fence, the stop fence must be adjusted so that the rear end is in
front of the saw blade
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Flat guide surface High guide surface
Fig. 6-44 ElmoDrive monitor with man. Rip fence
When the saw blade is tilted, the rip fence and crosscut fence is mapped in and
the correction values for the setting are displayed.
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6.4.5 Infinitely variable speed adjustment (option)
Fig. 6-45 Selecting the rotational speed for the main saw blade
The VARIO drive supports infinite adjustment of the speed so that the cutting
speed can be set optimally for the different materials.
Pressing the Rotational Speed button on the menu bar takes you to the Rotati-
onal Speed Selection function.
The circumferential speed of the saw blade is shown in addition to the rotatio-
nal speed. The saw blade diameter obtained from the position of the riving knife
is used to calculate the speed.
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Set/change speed
Fig. 6-46 Entering the rotational speed for the main saw blade
The speed can be influenced in the following ways:
• Press the Plus or Minus symbol in the middle of the screen to increase or
reduce the rotational speed (within the permitted limits) by 50 rpm or to the
next 50 increment.
• Press the button with the current speed display at the top right of the
screen (green font) to map in a numerical keypad on the right side of the
screen. You can enter the speed here in increments of 5, and confirm by
pressing the Enter button.
• Select one of the 5 stored speeds displayed on the left-hand side of the
screen.
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Selecting a stored speed
Fig. 6-47 Selecting a stored speed
• Press the desired speed button on the left of the screen; the button is dis-
played with a yellow background
• Press the START button and the stored speed will be set.
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Storing a rotational speed
Fig. 6-48 Edit button (editing / changing)
• Press the Edit button

• Actuate the desired rotational speed button
Fig. 6-49 Storing a rotational speed
• Enter a value and press Enter

• The value is accepted and stored
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6.4.6 Crosscut fences

Manual crosscut fence
Fig. 6-50 Screen displayed for tilt angle 0°
If the machine does not feature motorised adjustment of the crosscut-mitre

fence's throw-over stops, the temporary sizes for setting the crosscut-mitre
fence are displayed, provided the tilt angle is ¹ 0°.
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Fig. 6-51 Screen after entry of tilt angle 22.5°
Once the saw blade has been tilted, 2 new buttons each appear at the top left
and bottom of the screen.
The two bottom buttons specify the material thickness and saw blade width.
These values must be entered to allow effective use of the top functions.
These buttons can be hidden by pressing ExitExtras (which can be used for
opening the window again) then appears under the buttons at the top left of the
screen.
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Fig. 6-52 Screen after entry of tilt angle 45°
Fig. 6-53 Entry of the acute angle
To specify the finished size, press the top left-hand button and enter the acute
angle.
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Fig. 6-54 Correction dimension
The dimension to be set manually will be calculated and displayed. This dimen-
sion not only depends on the tilt angle but also on the cutting width and material
thickness.
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CNC crosscut fence UNO 90
Fig. 6-55 CNC crosscut fence UNO
• Actuate CNC crosscut fence. A red input window and the numeric keypad
appear.
• Enter the required dimension via the numeric keypad; the new dimension is
shown in red.
• Press the START button to carry out positioning.
• The dimension depending on the tilting angle is automatically corrected.
Infinitely variable fine adjustment is possible by pressing the Plus or Minus

button. Adjustment takes place in creep speed mode. Pressing the button for
more than 3 seconds switches adjustment to rapid speed mode. Briefly tou-
ching the Plus or Minus button causes adjustment of 0.1 mm.
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CNC crosscut fence DUO 90
Fig. 6-56 CNC crosscut fence DUO
• Actuate the CNC crosscut fence button. A red input window and the nume-
ric keypad appear.
• Enter the required dimension via the numeric keypad; the new dimension is
shown in red.
• Press the START button to carry out positioning.
• The dimension depending on the tilting angle is automatically corrected.
Infinitely variable fine adjustment is possible by pressing the Plus or Minus

button. Adjustment takes place in creep speed mode. Pressing the button for
more than 3 seconds switches adjustment to rapid speed mode. Briefly tou-
ching the Plus or Minus button causes adjustment of 0.1 mm.
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Fig. 6-57 0° position
Setting the dimension for the throw-over stops
Fig. 6-58 Setting the dimension for the throw-over stop
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• Touch the Crosscut-Mitre Fence button (throw-over stop 1 or 2), the nume-
ric keypad and a separate input window are shown next to the axis on the
right of the display.
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CNC crosscut-mitre fence DUO FLEX

The crosscut-mitre fence can be swung from 0.00 to ± 47.00°. The angle can
be set and calibrated manually.
The entire crosscut fence can be moved by about 260 mm to get closer to the
saw blade when the fence has been swung.
Fig. 6-59 Crosscut-mitre fence 0° position
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Fig. 6-60 Screen after pressing the EXTRAS field
Pressing the Extras button opens a window at the bottom left which shows the
additional fields for the crosscut-mitre fence.
The following settings are possible:
• Parking position for 2nd throw-over stop (1900 mm)

• Material thickness
• Saw blade cutting width
• Acute or obtuse angle
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Calibrating the crosscut-mitre fence
Fig. 6-61 Calibrating the crosscut-mitre fence
Once you have pressed the Crosscut-Mitre Fence button (outlined in red), you
can calibrate the angle of the straight edge. This is carried out at 90°.
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Fig. 6-62 .
• Press the Cal button for > 3 seconds
Fig. 6-63 .
• Enter the new value
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Fig. 6-64 .
• Press the Cal button and the new value will be accepted
Fig. 6-65 .
• Press the START button
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6.4.7 2-axis scoring unit
Fig. 6-66 Scorer menu button
Press the Scorer menu button to display the "Adjust Rapido scorer system"
function.
Fig. 6-67 2-axis scoring saw
When the scorer motor is switched on, the scorer is in its top position. Otherwi-
se it is raised when the function is selected.
The cutting height of the scorer and its lateral position can now be defined by
means of the arrow buttons.
When leaving this function (press Exit button), the scorer lowers once the mo-
tor is switched off.
Otherwise it lowers when the scorer motor is switched off, on returning from an
EMERGENCY STOP, and when the machine is switched on. The set height
position is saved.
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Fig. 6-68 Switches for saw drives
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6.4.8 3-axis scoring unit

RAPIDO Plus is a 3-axis scoring system with motorised adjustment of the cut-
ting height and the right and left-hand side of the scoring saw blade. All settings
can be made while the machine is running, so they can be done very quickly.
Fig. 6-69 RAPIDO Plus
Fig. 6-70 Scoring saw setting
Pressing the Scorer menu button calls up the Adjust Rapido Plus Scorer Sys-
tem function.
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Function of the axis position buttons:
• Top button <> Sets the position of the right-hand saw blade side
• Middle button <> Sets the cutting height
• Bottom button <> Sets the position of the left-hand saw blade side
Note!
i The positions given for the saw blade sides are guide figures only.
Adjustment:
The arrow keys can be used to position the 3 axes of the scorer. If you press
the button with the axis position, the numeric keypad will appear on the right of
the screen and you can enter position values. Briefly pressing the side arrow
buttons causes movement of 0.02 mm each time. Briefly pressing the height ar-
row buttons results in movement of 0.1 mm.
Calibrating the scoring saw
• Press the Axis Position button to select the position of the saw blade to be
calibrated.
• Press the Cal button in the numeric keypad for > 1 second. C appears in
the red input field.
• Enter a value and press the Cal button. The entered value is shown on the
display.
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Setting the scoring saw blade
• Setting the cutting height

• Set the blade protrusion
• Set the position of the right saw blade side
• such that both cutting edges are congruent when a test cut is made.
• Enter + 0.05 so that the scorer cuts wider than the main saw blade.
• Set the position of the left saw blade side.
• Set the scoring blade to the thickness of the main saw blade.
• If a test cut is OK, increase the cutting width by + 0.05.
When you exit the menu, the electronics saves the last values set. When the
scoring saw is switched on, the scoring blade is automatically moved to the
previously set values. When the saw drives are switched off, the scoring blade
is automatically moved to its lowest position.
If you select this menu item when the scoring saw is running, the scorer will not
travel down to its lowest position when the saw drives are switched off!
Reference
The reference is the 2nd way of storing the scoring saw blade positions.
• Pressing the Save Reference button saves the currently set values. The
button briefly flashes red during the storage process. These positions are
moved to when the START key is pressed.
• Pressing the Load Reference button loads the previously saved reference.
The field briefly flashes red. These positions are moved to when the
START key is pressed.
Saving the reference with the active saw blade of the tool management
• If the tool management is activated, the scorer position is saved for the saw
blade currently active.
Loading the reference with the active saw blade of the tool management
• If the tool management is activated, the scorer position is read out for the
saw blade currently active.
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6.4.9 Vacuum clamping in the sliding table
Vacuum clamping in the sliding table (vacuum table)
Note!
i If the option Vacuum clamping in the sliding table is selected,
separate instructions are enclosed!
Fig. 6-71 Monitor for vacuum table
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6.4.10 Menu
Fig. 6-72 Main menu
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Applications
Grooves
Fig. 6-73 Grooves
It is possible with all saw blade thicknesses to cut grooves that are wider than
the saw blade thickness.
Pressing the Grooves button under Main Menu/Application Technology takes
you to the Grooves function.
Enter the start, width and spacing of the grooves, the number of the grooves as
well as the height of the saw blade. The current position of the rip fence is
shown on the right, as is the number of the current cut.
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Fig. 6-74 Groove_display Cut...of...cuts
“Cut .. of ..” only appears if a setting has actually been positioned. Otherwise
the flashing start symbol is shown, apart from during value entry. The Start
symbol is also hidden for step z of z (after final positioning).
Fig. 6-75 Grooves_after last cut
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Pressing the Back button takes you back to cut 1. This also happens if you exit
the menu and call it up again.
The values in this menu are also retained when the machine is switched off.
When you return to the normal display, the old actual values are retained there
as setpoints, and positioning can take place again with the Start button.
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Incremental dimensions
Fig. 6-76 Incremental dimension
The Incremental Dimensions function supports cutting sequences at an identi-

cal distance on the rip fence in both directions.
Pressing the Incremental Dimensions button in the Main Menu/Applications
field takes you to the Incremental Dimensions function.
The current position of the rip fence is displayed. The incremental dimension is
retained in storage. Every time the Start button is pressed, the fence moves by
the increment entered and the current actual position is shown in the left dis-
play.
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Angle cut with oversize
Fig. 6-77 Angle cut with oversize
This function enables you to cut mitres using the motorised rip fence, finished
size F, with or without an oversize. Pressing the "Angle Cut With Oversize" but-
ton in the Main Menu/Applications button takes you to the Angle Cut With Over-
size function.
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The following values have to be entered after the respective function key is
pressed:
• Workpiece oversize
• Workpiece thickness (measured)
• Cutting height
• Tilt angle
Note!
i You must enter the saw blade thickness, otherwise the dimensions will
be wrong!
Note that saw blades generally cut wider than the blade thickness indica-
ted on the saw blade.
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Shifter cut
Once the Shifter cut button is pressed, the following screen appears:
Fig. 6-78 Shifter cuts
Enter the respective values here, missing values are calculated and displayed
in blue.
When the green key with arrow is pressed, the following screen appears:
Fig. 6-79 Workpiece positioning
The workpiece infeed is described and the setting values for tilting and fences/
stops are displayed here.
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“False” Mitre function
Fig. 6-80 “False” mitre
Pressing the False Mitre function key under Main Menu/Applications takes you
to the "False" Mitre function.
This function can be used to calculate "false" mitres of any angle.
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Fig. 6-81 “False” mitre with axis display
This menu consists of 2 basic components, the graphic with the 5 assigned di-
mension windows, and the axis positions that can be mapped in or out with the
Show Axis Positions or Hide Axis Positions button.
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Press the Clear button to delete the false mitre values entered. A green "?" is
written to the 3 dimension windows.
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For this graphic, it is necessary to enter 3 values (buttons with question marks).
They are shown in green. The missing angles are calculated automatically and
are shown in blue. The green numbers can be changed repeatedly later. Recal-
culation takes place.
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Press the Show Axis Positions button to display the current axis positions at the
top right of the screen. The axes can now be positioned.
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Programs function
Fig. 6-86 Programs
Pressing the Programs function button under Main Menu/Applications takes

you to the Programs function.
The program used last is displayed.
Press the START button to start the positioning process.
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Program selec- Edit/change pro- Create new pro- Save

tion list gram gram
EDIT button
Delete program Scroll through programs Exit page
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Changing or creating programs
Fig. 6-87 Selecting a program
Pressing the Program Selection List button opens the selection window with
the list of assigned programs.
The currently selected program is marked in this window.
Press the button EDIT to display the program marked in the program list.
This program can be changed by entering new axis values.
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Proceed as follows to create a new program:
Fig. 6-88 Creating a program
Press the Create Program button to open the screen shown.
After pressing the Name button, a window with a keypad for entering letters
and digits opens. Once the program name has been entered, close the window
by pressing the EXIT button.
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You can now press an axis selection button to enter the desired dimensions.
No value is assigned to axes that are not required.
Save the newly created program by pressing the Save button.
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Geometric shapes
Fig. 6-91 Geometric shapes
Pressing the Geometric Shapes function button under Main Menu/Applications

takes you to the Geometric Shapes function. 3 geometric shapes, triangle, tra-
pezoid and pentagon, can be selected here.
Select a geometric shape by pressing it.

The following applies to all geometric shapes:
• Enter known dimensions (these are displayed in green)

• Calculated dimensions are shown in blue
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Fig. 6-92 Geometric shapes, triangle
Fig. 6-93 Axis function mapped in
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Fig. 6-94 Geometric shapes, trapezoid
Fig. 6-95 Geometric shapes, pentagon
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Vacuum clamping in the sliding table (vacuum table)
Note!
i If the option Vacuum clamping in the sliding table is selected,
separate instructions are enclosed!
Fig. 6-96 Monitor for vacuum table
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Utilities
Optimisation/Cutting Lists function
Fig. 6-97 Optimisation / cutting points
Pressing the Optimisation/Cutting Lists function button under Main Menu/Utili-

ties takes you to the Optimisation/Cutting Lists function.
There is an additional operating manual which is supplied along with the option.
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Total process time
Fig. 6-98 Total process time
Pressing the Total Process Time function button under Main Menu/Utilities
takes you to the Total Process Time function.
Time date capture is started by pressing the START button and stopped by
pressing the STOP button. Pressing the Clear button resets the time in the 3 li-
nes to 0 min.
The running time of the main saw blade is displayed at the bottom left (opera-
ting hours counter). It is not possible to reset this time.
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Tool Management
Note!
i It is essential to use the Tool Management to ensure malfunction-free
machine operation.
It is important to observe the following:
• Select the tool (saw blade) used and the attendant storage space in
the Tool Management. This ensures that different operators are infor-
med about the current tool.
• Calibrate the cutting height (e.g. after sharpening)
Pressing the Tool Management function button under Main Menu/Utilities takes
you to the Tool Management function.
Fig. 6-99 Tool Management deactivated
Actuate the Activate function button to use the tool management.
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Fig. 6-100 Tool Management activated
The tool management is shut down by pressing the Deactivate function button.
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Create tool:
• Select the tool number with the arrow button.

• Touch and a new window will open.
Fig. 6-101 Creating/changing a tool
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Various input fields are mapped in that can be used to enter the name/designa-
tion and values. Inputs for the cutting width and the saw blade diameter are ob-
ligatory.
Fig. 6-102 Entering designation
Fig. 6-103 Entering diameter
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Fig. 6-104 Entering saw blade thickness
Fig. 6-105 Input of a rotational speed
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Fig. 6-106 Input of the main blade width
• The name/designation and value have been entered but not yet saved.
• Exit by pressing Exit
The following display appears:
Fig. 6-107 Inquiry when the tool management is left
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• Actuate the START button to apply the rotational speed

• Actuate the EXIT button, if the rotational speed is to be discarded
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For option 3-axes scorer RAPIDO-Plus:
The scorer is saved with in the field with the green frame.
Fig. 6-108 Storing the scorer
Use the symbol to delete the scorer position for this saw blade.
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Adjusting dimensions following a tool change
After changing a saw blade it is necessary to calibrate the cutting height to the
actual value.
How to proceed:
1. Fit the saw blade

2. Enter the cutting height in the field, e.g. 70 mm
3. then measure the cutting height precisely.
4. Keep the Cal button pressed for approx. 1 seconds until a C appears.
5. Enter the measured value.
6. Press the Cal button.
The following window will open:
Fig. 6-109 Screen after calibration of the cutting height
As the value of the cutting height has been changed, this also changes the dia-
meter which then has to be adjusted. If the saw blade diameter is identical,
keep the original diameter.
• Confirm actual diameter
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Fig. 6-110 Actual diameter confirmed
• with and saved.
The height automatically appears in the field. The new, changed saw blade dia-
meter is displayed in the Tool Management.
Fig. 6-111 Actual diameter saved
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• Exit the Tool Management by pressing EXIT.
The actual values of the fences are adjusted in line with the saw blade diameter
and the saw blade thickness. The actual values in question are shown in red.
Press the Start button and the fences will travel to the new dimensions.
Note!
i Tool Management is deactivated if an empty tool location is selected.
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Basic settings
Fig. 6-112 Language
Pressing the Language button under Main Menu/Basic Settings takes you to
the Language function.
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Fig. 6-113 Setting of mm/inch
Pressing the Millimetre/Inch button under Main Menu/Basic Settings takes you
to the mm/inch function.
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Fig. 6-114 Setting of mm/inch
Pressing the Data export/import button under Main Menu/Basic Settings takes
you to the data transmission function.
Programs, tools, machine parameters can be written (exported) to a USB stick

here.
This data can also be read in (imported) from a USB stick here.
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Fig. 6-115 Technician level
Pressing the Technician level button under Main Menu/Basic Settings takes
you to the technician level function.
The technician level is password protected and is not required for operating the
machine.
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6.5 Protection hood
Fig. 6-116 Protection hood swung away
Swing away the protection hood as follows:
• Turn off the main switch and secure against turning on again
• Actuate the release lever
• Swing the protection hood away
Warning!
You may only work with the protection hood swung away in special cases
and with increased caution, e.g. for bulky workpieces.
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Fig. 6-117 Normal working position

[1] Unlocking/locking lever
Note!
i After completing the work cycle, immediately swing the protection hood
back into the normal working position and lock it with the lever.
Pull the lever forward until it noticeably engages.
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Changing the protection hood sections
Fig. 6-118 Swivel out the hood section
When changing between wide and narrow, it is not necessary to completely ex-
change the hood but only the respective hood section by means of a snap fit.
For exchanging the hood section, press the red pusher down and swivel out the
hood section. Suspend the other hood section and swivel in until the snap fit
engages.
Fig. 6-119 Large protection hood with wide hood section
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Protection hood, machine tilting to both sides
Installing the wide protection hood, see photo and text on previous page.
For tilting in the negative range (-), the protection hood is pulled out after unlo-
cking the lever at the rail guide.
Fig. 6-120 Lateral displacement, protection hood
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6.6 Optional modules
6.6.1 Scorer, tilting to one side

When processing boards coated on both faces, the scoring unit makes it possi-
ble to cut without breakouts on the underside of the board. The scorer cuts into
the material from below approx. 1-2 mm; then the main saw blade cuts through
it. Make sure that the scoring blade is exactly in line with the main blade and is
set to the corresponding width. To achieve optimum cutting results, the scoring
blade runs in the workpiece advance direction, i.e. the opposite direction to the
main saw blade.
The scoring saw can only be started once the main saw has reached its opera-
ting speed (after approx. 5 sec.). It is started by pressing push-button I labelled
with the scoring saw symbol on the panels.
Saw blades
Fig. 6-121 Two-part scoring blade
We recommend using two-part scoring blades which can be set to the required
blade thickness by inserting spacer discs. The cutting line of the scoring blade
should be approx. 1/10 mm wider than the main saw blade, i.e., 5/100 mm to
each side. In addition, the two scoring blades should have carrier pins and their
thickness should be marked on the spacer discs.
The RAPIDO scoring tool facilitates and accelerates cutting width adjust-
ment. Compared with two-part scoring blades, this represents a potential sa-
ving of up to 30 minutes since the cutting width can (without removing the saw
blades) be adjusted infinitely to the cutting width of the main saw blade.
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Fig. 6-122 RAPIDO scoring tool
Fitting the saw blade

The description for fitting the saw blade applies both to two-part scoring blades
and to RAPIDO scoring tools.
Only use saw blades with a diameter of 120 mm and a hole diameter of 22 mm!
• Switch off the drives.

• Move the scoring saw up to its highest position.
• Move the sliding table in the cutting direction.
• Unlock the lock in the middle of the saw blade by pressing the knob on the
middle carriage.
• Move the sliding table to the end position in the cutting direction.
• Open the bottom hinged safety cover (orange coloured cover plate).
• Release the nuts with a special wrench by turning counterclockwise.
• Before fitting the new scoring blade, remove any adhering chips from both
flanges.
• Place the saw blade and front flange on the saw shaft, and tighten the nut
clockwise.
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Attention!
The following must also be observed when using RAPIDO scoring blades
with infinitely variable cutting width adjustment:
• Failure to comply with the operating instructions inadmissibly redu-

ces Health and Safety at Work and excludes any claims for liability.
• Incorrect use and use other than that intended is forbidden.
• Permissible cutting widths 2.8 - 3.8 mm
• Take particular caution when unpacking and packing the adjustment
unit, danger of injury!
• Only store the adjustment unit in the original packaging!
• Fit the scoring blade outside of the machine.
• Make sure that all connection elements are fitted.
• Only use original spare parts in the case of loss or damage to the
connection elements!
Adjusting a two-part scoring blade

The cutting width of the scorer should be set to the cutting width of the main
saw blade (+ 0.05 mm). Carry out the adjustment toward the left side of the
main saw blade. The cutting width is adjusted with the spacing discs that are
supplied.
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Adjusting the scoring blade for the RAPIDO scoring tool
Fig. 6-123 Release the clamping screw.
Fig. 6-124 Adjust the spindle.
Note!
i Only use the supplied tools for adjustment work!
• Release the clamping screw, approx. 2 turns.

• Turn the spindle until the required dimension is reached. (1 turn = 0.5 mm)
• Tighten the clamping screw.
• Make a test cut and, if necessary, correct the cutting width again as descri-
bed above.
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Replacing the scoring blade for RAPIDO
Fig. 6-125 RAPIDO saw blades
Remove the adjustment unit from the machine. It may be necessary to loosen
the clamping screw because an excessively tight clamping screw can cause
the adjustment unit to jam on the shaft!
Dismantling
Using the Allen wrench:
• Release the clamping screw (1), turn the spindle (2) approx. 3 – 4 turns
clockwise until the flange (3) can be removed from the holder (4).
Using the internal torx wrench:
• Undo the screws (5).

• Remove the circular saw blade (6).
• Carefully clean the flange (3) and screws (5). Make sure that the running
and flange surfaces are dry and free of dust.
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• Fit a new saw blade, paying attention to the rotational direction and hole
pattern: The circular saw blade (6) is in full contact with the flange (3) and
the shoulder on the circular saw blade must point to the contact surface.
• Turn in the screws (5) and tighten with a torque of 8.6 Nm.
• Proceed in the same manner for the other half of the adjustment unit.
Prohibitory!
Do not apply oil or grease!
Installation
• The clamping screw (1) is released.

• Fit the flange (3) vertically onto the holder (4) so that the spindle (2) enga-
ges in the threaded hole (7).
• Turn the spindle (2) counterclockwise with the Allen wrench. The flange (3)
is drawn onto the holder (4); the force applied must not increase.
• Continue turning the spindle (2), until the two circular saw blade halves are
in contact.
• Install the adjustment unit on the machine.
• Set the cutting width, see above.
• Slightly tighten the clamping screw (1).
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Note!
i A red anodised table strip is integrated in the area of the scorer (optio-
nally available with LED lighting).
This strip marks the hazard zone of the scoring tool.
Fig. 6-126 Red table strip (standard)
Fig. 6-127 Red table strip with lighting (optional)
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RAPIDO - PLUS
The 3-axis scoring system allows motorised positioning of the cutting height,
width and cutting width. All settings can be entered via the keypad while the
machine is running, and are shown on the display.
Replacing saw blades
Fig. 6-128 RAPIDO Plus

[1] Remove the adjustment unit from the machine.
[2] Undo the screws and remove.
[3] You can now pull the adjustment unit apart
Fig. 6-129 Disassembled RAPIDO Plus
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Fig. 6-130 RAPIDO-Plus, fitting the saw blade

[1] Undo the screws
[2] Remove circular saw blade
[3] Carefully clean the flange and screws
[4] Fit a new saw blade, paying attention to the rotational direction and hole pattern!
[5] Insert screws and tighten with a torque of 8.6 Nm
[6] Proceed in the same manner for the other half of the adjustment unit
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6.6.2 Scorer, tilting to both sides

The following scorer systems are available for machines tilting to both sides:
Scorer diameter: 180 mm!
Duet set
Main saw blade and scorer blade ground to the same width in pairs
RAPIDO-BS
Width-adjustable scoring system with two saw blades, the spacing of which is
adjustable
3-axis scorer
In this case, the width and side adjustment is carried out electrically in the con-
trol system.
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6.6.3 Mitre fences

Single-sided mitre fence
Fig. 6-131 Single-sided mitre fence
The fence can be fitted quickly and easily to the sliding table with an eccentric
clamping system. Dimension scales are inclined in order to stay in the opera-
tor's field of vision. Crosscutting to 2500 mm.
Double-sided mitre fence DUPLEX
Fig. 6-132 Double-sided mitre fence DUPLEX
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The DUPLEX mitre fence can be infinitely adjusted from 0° to 90°. The circular
scale with a radius of 350 mm has 0.25° graduation, allowing precise and fast
setting of the mitre angle. The DUPLEX mitre fence can be fitted at any position
of the sliding table due to its eccentric clamping system.
The stop bar (2 throw-over stops) can be used in both stop profiles. It is possib-
le to crosscut workpieces of up to 1350 mm in length or, when the extended
stop fence is used, up to 2150 mm in length.
In addition, the DUPLEX and DUPLEX D mitre fence features a length com-
pensation scale with which the length dimension is set in accordance with the
mitre angle.
Note!
i Separate instructions are enclosed for the selected options DUP-
LEX, DUPLEX D or DUPLEX DD.
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6.6.4 Dimension display unit DIGIT L
Fig. 6-133 DIGIT L
The dimensions that have been set are displayed digitally in the 150 mm to
3200 mm range to an accuracy of ± 0.1 mm. The proximity sensor operates
wear-free and is not sensitive to dust. A precise adjustment system is used for
precision setting in 1/10 mm increments.
Operating the display electronics
Fig. 6-134 DIGIT L display unit
Press button 1: switches over the throw-over stop side. Pressing button 2, 3 or
4 changes the measuring range on the display electronics. Throw-over stop 1
is permanently connected to the measuring system and the display unit. The
measuring range is from approx. 150 mm to approx. 1630 mm. Throw-over
stop 2 is a flip stop and, when it makes contact at the left of throw-over stop 1,
it is at a distance of 295.0 mm from throw-over stop 1. This results in a measu-
ring range of approx. 445 mm to approx. 1750 mm. If throw-over stop 2 is pu-
shed onto the length extension, this results in a measuring range of about 1750
mm to 3200 mm; if necessary, the length extension can be connected to throw-
over stop 1 with the aid of the detent bolt.
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Power supply
Power is supplied by a rechargeable battery. The charging state is shown in the
bottom right hand corner of the display. The batteries can be recharged using
the supplied charger.
Changing the rechargeable battery
Fig. 6-135 Changing the rechargeable battery for DIGIT L , DIGIT LD
Fig. 6-136 Battery charger
Note!
i For information on how to handle batteries, see chapter 3.6.4
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Basic setting / calibration of the display unit

The basic setting of the display unit is needed in order to adapt the measuring
system to the machine situation. Check and, if necessary, re-enter the basic
settings following each tool change.
How to proceed:
• Push throw-over stop 1 with the display unit to the right against the mecha-
nical stop.
• Fix throw-over stop 1 with a clamping screw.
• Cut a test piece, measure the workpiece width with a calliper and enter the
precise value as follows:
• Press key 2; after three seconds the following calibration menu will appear
(only the first throw-over stop can be calibrated).

[1] Press the adjacent function key to select the required decade. If the highest decade
has been selected and the function key is reactivated, the lowest decade is auto-
matically selected.
[2] Press the "+" key to increment the display value of the active decade.
[3] Press the "-" key to decrement the display value of the active decade.
[4] Press the adjacent function key to store the new throw-over stop value under para-
meter L-L1; this value is also automatically calculated with the throw-over stop
values displayed on the user interface.
Switching the display unit from mm to inches or inches to mm
• Press the Menu button

• Select inch (or mm) as the measuring unit.
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6.6.5 Digital angle and length display DIGIT LD
Fig. 6-138 Crosscut-mitre fence display unit WGA_LD
The angle is shown in the display to an accuracy of 0.01° and the dimensions
set in the 150 mm to 3200 mm range are shown in the display to an accuracy of
±0.1 mm. The length dimensions shown are automatically corrected when the
angle is changed.
Operating the display electronics
Fig. 6-139 Display unit
Pressing buttons 2, 3, 4 on the right hand side changes the measuring range
on the display electronics. The dimension of the current throw-over stop is
shown in bold. Throw-over stop 1 is firmly connected to the measuring system
and the display unit. Throw-over stop 2 is a flip stop and, when it makes contact
at the left of throw-over stop 1, it is at a distance of approx. 200.0 mm from th-
row-over stop 1. If throw-over stop 2 is pushed onto the length extension, this
results in a measuring range of about 1750 mm to 3200 mm; if necessary, the
length extension can be connected to throw-over stop 1 with the aid of the de-
tent bolt.
Pressing button 1 (RH side) for more than 3 seconds switches over the degree
display.
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The fence position is switched over on the cross-slide by pressing the button on
the left hand side.
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Power supply
Power is supplied by a rechargeable battery. The charging state is shown in the
bottom right hand corner of the display. The batteries can be recharged using
the supplied charger.
Changing the rechargeable battery
Fig. 6-140 Changing the rechargeable battery for DIGIT L , DIGIT LD
Fig. 6-141 Changing the rechargeable battery for WGA DIGIT LD
Fig. 6-142 Battery charger
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Note!
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Basic setting / calibration of the display unit

settings following each tool change.
How to proceed:
• Push throw-over stop 1 with the display unit to the right against the mecha-
nical stop.
• Fix throw-over stop 1 with a clamping screw.
• Cut a test piece, measure the workpiece width with a calliper and enter the
precise value as follows:
• Press key 2; after three seconds the following calibration menu will appear
(only the first throw-over stop can be calibrated).

[1] Press the adjacent function key to select the required decade. If the highest decade
has been selected and the function key is reactivated, the lowest decade is auto-
matically selected.
[2] Press the "+" key to increment the display value of the active decade.
[3] Press the "-" key to decrement the display value of the active decade.
[4] Press the adjacent function key to store the new throw-over stop value under para-
meter L-L1; this value is also automatically calculated with the throw-over stop
values displayed on the user interface.
• Press the Menu button

• Select inch (or mm) as the measuring unit.
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6.6.6 Rip fence with DIGIT X digital dimension display
Fig. 6-144 Rip fence with Digit X
The electronic measuring system with digital display and fine setting system
ensures precise and fast setting of the rip fence. The display is always in the
field of vision. The touch-free measuring system is not sensitive to dust. When
the guide surface of the stop fence is changed, the dimensions are corrected
automatically in the measuring system.
Changing the batteries
Fig. 6-145 Release the clamping screws
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Fig. 6-146 Remove the housing with the display unit
Note!
Fig. 6-147 Undo the screws and remove the cover.
Fig. 6-148 Change the batteries, ensuring correct polarity
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Basic setting of the display unit
Fig. 6-149 Operating the Digit X
setting for each tool change. The basic setting can only be carried out together
with the tools used so it cannot be done at the factory.
• Push the rip fence to the left against the mechanical stop
• Hold the F button down and press the Reset button
• Set the rip fence to a cutting width of 130 mm (straight edge in the position
of the low guide surface)
• Cut a test piece and measure the workpiece width with a sliding calliper
• Hold the F button down; the right-hand digit of the display starts flashing
after approx. 3 seconds
• Pressing the + button increases the flashing digit by 1 each time. When the
maximum number value 9 is passed, the numbers start again with 0.
• Pressing the Minus button decreases the flashing digit by 1 in each case.
• Release the F key.
• The dimension that has been set is saved as the basic setting.
Calibrating the display unit

Calibration of the display unit is required when the fence has been moved un-
der the main table.
• Push the rip fence to the left against the mechanical stop
• Hold the F button down and briefly press the Reset button; the display
shows the basic setting again.
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• Hold the + button down for more than 3 seconds; the display shows inches
(or mm).
• Release the + key; the display unit now shows the set dimension in inches
(or mm).
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6.6.7 Parallel cutting device
Parallel cutting device
Fig. 6-150 PALIN parallel cutting device
Parallel cutting of long, narrow parts is done to the left of the saw blade. The
PALIN and PALIN_D parallel cutting devices are good for this. In parallel cut-
ting, the flip stop is set to the same dimension at the crosscut fence and at the
PALIN. The workpiece can be placed safely and be guided easily on the left of
the saw blade.
Parallel cutting device with digital dimension display and precision set-
ting system
Fig. 6-151 PALIN D parallel cutting device
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PALIN_D with digital dimension display and precision setting system A precise
adjustment system is used for precision setting in 1/10 mm increments. Both
parallel cutting devices can be adjusted to a workpiece width of up to 900 mm.
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Alkali manganese batteries have an operating life of approx. 1 year. A battery

capacity display provides a timely reminder of a battery change.
We do not recommend the use of rechargeable batteries of any type as their
voltage and capacity differ from that of alkaline batteries. As a result, the esti-
mated operating life of approx. 12 months would not be reached, and the sym-
bol in the battery capacity display would not show the battery status correctly.
Note!
Carefully push out the Undo the screws and Change the batteries,
display unit. remove the cover. ensuring correct polarity!
Tbl. 6-2 Changing the batteries
Calibrating the display unit
• Push the fence to the right against the mechanical stop.

• Fix the fence with a clamping screw.
• Hold the F button down and briefly press RESET.
• The basic setting value reappears on the display unit.
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Basic setting of the display unit

settings following each tool change. The basic setting can only be carried out
together with the tools used so it cannot be done at the factory.
• Push the fence including the display unit to the right against the mechanical
stop and fix with a clamping screw.
• Cut a test piece, measure the workpiece width with a vernier calliper and
enter the precise value as follows:
• Press the F button, all digits of the display will light up after 3 seconds.
• Hold the F button down.
• The right-hand digit of the display starts flashing.
• Pressing the + button increases the flashing digit by 1 each time. When the
maximum number value 9 is passed, the numbers start again with 0.
• Pressing the - key reduces the flashing digit by 1 each time; when the
maximum numeric value (9) is passed, the numbers start again with 0.
• Release the F key.
• The dimension that has been set is saved as the basic setting.
• The display unit is now ready for operation.
• Hold the + button down for more than 3 seconds; the display shows inches
(or mm).
• Release the + key; the display unit now shows the set dimension in inches
(or mm).
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6.6.8 Workpiece hold-down device

Manual quick-action clamp
Fig. 6-152 Manual quick-action clamp
The manual quick-action clamp fastens the workpiece to the crosscut fence
can be fastened along the groove on the sliding table top at any point. For this
purpose, use the handle on the top end of the round bar to open the mecha-
nism until the sliding block can be pushed laterally into the carriage groove.
Use the handle to fasten the quick-action clamp to the desired position applying
slight force. Undo the lateral handle and set the quick-action clamp to a suitable
height, subsequently fasten by means of the handle. Now the workpiece is
clamped by means of the threaded rod on the extension arm. Use the clamp
handle to clamp or unclamp the workpiece.
Klemmfix
Fig. 6-153 Altendorf Klemmfix
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Altendorf Klemmfix consists of two collets for fixing narrow and small workpie-
ces on the sliding table. They securely hold workpieces from 0-70 mm. The col-
lets can be used as required throughout the full length of the sliding table.
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Electro-pneumatic hold-down device
Fig. 6-154 Electro-pneumatic hold-down device
The electro-pneumatic hold-down device fixes the workpiece to the crosscut

fence and operates with a clamping force of max. 1000 N at a pressure of 6
bar. The maximum clamping height is 90 mm.
The safety cylinder only clamps the workpiece when the pressure plate is posi-
tioned vertically in relation to the cylinder axis. If the pressure plate is offset by
more than 2° from the vertical position, e.g. by contact with the back of the
hand, no clamping force builds up.
Warning!
Danger of crushing fingers!
• Ensure that the pressure plate can freely move in all directions,
otherwise, the safety function will be impaired.
• Never reach beneath the pressure plate on purpose!
• Never use two fingers to reach opposite to, parallel or centred
beneath the clamping plate!
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Fig. 6-155 Remote control, hold-down device
Movement up and down is controlled wirelessly via a small hand-held radio

transmitter.
The operating status of the hold-down device is shown on the switch box of the
protection hood support.
Yellow lamp: Cylinder pressurised
White lamp: Cylinder not under tension
If the remote control fails, the hold-down device can be controlled directly by
pressing the illuminated push button.
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Pneumatic hold-down device
Fig. 6-156 Pneumatic hold-down device
The split hold-down beam can be controlled separately. This ensures optimum
adjustment to differing workpiece lengths with one or both hold-down beams.
The hold-down beam stroke is 80 mm; the customer-provided pneumatic con-
nection is 6 bar.
The customer must provide a pneumatic connection of 6 bar.
Sliding table length [mm] Beam length [mm]
2250 1975
3000 2725
3200 2925
3400 3125
3800 3525
Tbl. 6-3 Beam length
Operation
The pneumatic hold-down beam consists of two segments and can be opera-
ted by 2 control levers to ensure optimum holding down of different workpiece
lengths.
When valve V1 (in the centre) has been actuated, the two compressed-air cy-
linders lower the short part of the hold-down beam onto the workpiece.
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The entire length of the pressure beam is controlled via valve V2 (at the end).
After actuation, the two segments of the pressure beam are lowered simultane-
ously. The rubber coating of the hold-down beam prevents the workpiece from
slipping.
Installation
• Fit the hold-down beam onto the sliding table.

• Insert the two T-nuts into the sliding table groove.
• Align the hold-down beam in parallel with the protection hood.
• The distance between the hold-down beam and the protection hood should
be 15 mm; the length of the slots prevents contact with the protection hood.
• Connect the compressed-air supply to the air servicing unit, and set the
pressure reducer to 3 bar.
Note!
i Pressures exceeding 3 bar can lead to inadmissible holding forces and
cause damage to the workpiece and/or change the cutting quality!
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Vacuum fastening in the sliding table
Fig. 6-157 Suction cup rows
A vacuum is generated in one or more suction cup rows via a high-capacity va-
cuum pump to reliably hold the workpiece on the sliding table. Each suction
area can be individually controlled, the workpiece can be released at the press
of a button.
Note!
i Separate instructions are enclosed for the selected option Vacuum
fastening!
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6.6.9 Cross-slide width extension
Fig. 6-158 Cross-slide width extension
The cross-slide width extension is intended to facilitate work with large format
or long workpieces. It extends the width of the workpiece support surface to
max. 650 mm by means of two telescopic tubes. Long boards can be securely
loaded and crosscut. The additional horizontal roller allows the workpiece to be
easily pushed throughout the entire length.
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6.6.10 Additional cross-slide
Fig. 6-159 Additional cross-slide
Optional equipment for optimum support extension for large format or particu-
larly unwieldy boards. The additional cross-slide can be easily fitted at any
point of the sliding table due to its quick-action clamping system.
Max. workpiece weight up to 250 kg.
The guide is not supplied as standard with the machine!
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6.6.11 LASER cutting line display
Fig. 6-160 Laser cutting line display
The laser beam shows the run of the cutting line over a length of approx. 5000
mm. For trimming or cutting along a marked line (e.g. for stairs/steps) in parti-
cular, valuable set-up time and material can be saved.
Warning!
Laser beams!
The laser creates a red luminous beam with a width of approx. 3 mm. The
intensity of this laser is sufficiently low that looking into it briefly is harm-
less. The eye is protected by its natural reflex to close.
Never observe the laser beam using optical aids or instruments, e.g.
glasses, binoculars or magnifying glasses etc. which could bundle the
light, and then possibly damage the eye.
• Never attach mirror surfaces in the laser area!
• Never carry out any modifications to the laser optics!
• Furthermore, make sure that the warning signs attached to the laser
are always legible. They must not be removed!
• Never replace the laser with a laser unit of a different type!
• Defective laser units may only be repaired by the manufacturer!
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Aligning the laser beam with the cutting line
Fig. 6-161 Aligning the laser
At the factory the laser is set so that the beam is perpendicular and parallel to
the sliding table.
When the hood has been swung away and this has been followed by positio-
ning, it is necessary to check and possibly correct the laser settings.
Setting:
• Place wooden gauges (1) in the sliding table groove, and saw for approx.
15 mm
• Set the laser beam parallel to the cutting line with the left setscrew (2)
• Move the laser in parallel with the right-hand setscrew (3) until the beam
aligns with the cutting line
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6.6.12 Coolant spray device
Fig. 6-162 Coolant spray device
To improve the cutting quality, we recommend the use of a coolant spray de-
vice for plastics with a low melting point and for certain light metal alloys, espe-
cially in conjunction with the infinitely variable speed adjustment.
A sensor is fitted in the front table strip to detect the workpiece. It will interrupt
the coolant supply when not obstructed by a workpiece.
Note!
i Separate instructions are enclosed for the selected option Coolant
spray device.
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6.6.13 TIP-SERVO-DRIVE
Fig. 6-163 TIP-SERVO-DRIVE
The drive serves to assist the operator during sawing and is activated as soon
as the joystick fitted on the sliding table is actuated (pressing = forward, pulling
= backward). Operation is carried out from the usual workplace of the machine
upstream of the sliding table.
Note!
i Separate instructions are enclosed for the selected option TIP-SERVO-
DRIVE.
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Cleaning/care
7 Cleaning/care
7.1 Safety measures
Warning!
Please observe:
• Always turn off the main switch and secure it against being turned on
again before doing any maintenance work!
Non-observance can lead to severe injuries!
Note!
i
Before using solvents and cleaning agents, make sure that these
substances do not cause damage to the painted, anodised or galvanised
surfaces as well as plastic parts. For information on these substances,
please refer to the safety data sheets (available from the manufacturers
of the solvents or cleaning agents.)
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Cleaning/care
7.2 Maintenance/cleaning by the user
Note!
i Regular cleaning of the machine and the machine environment pro-
longs the life of the machine, is prerequisite for perfect cutting results and
reduces the risk of accidents.
Pay attention to the following:
• Machine table
• Sliding table
• Sliding table guides
• Tilt segments
• Stop bar of rip fence
• Machine interior
• Machine environment
Carry out cleaning/care measures as follows:

Regularly:
Fig. 7-1 Remove chips and dust from the sliding table + machine table with a brush
Fig. 7-2 Remove chips from the bottom carriage of the sliding table
237
0000010040-002- GB Cleaning/care
Cleaning/care
Once a month:
Sliding table
Fig. 7-3 Remove dirt and resin residue from the guide of the sliding table using a cloth soaked in spirit
Fig. 7-4 Remove dirt from the bottom of the guide of the sliding table
Fig. 7-5 Dirt from the bottom of the sliding table guide
238
Cleaning/care
Fig. 7-6 Cleaning of the sub-rollers of the sliding table
Swinging arm
Fig. 7-7 Open the swinging arm compartment
Fig. 7-8 Clean the roller
239
Cleaning/care
Fig. 7-9 Clean the roller from below
Note!
i DO NOT APPLY OIL TO THE SWINGING ARM, just clean (dry)!
Segments
Fig. 7-10 Remove chips/dirt from the tilt segments (right and left-hand side) and spray with universal oil
240
Cleaning/care
Fig. 7-11 Spray round bar. Subsequently move the block up and down.
Every 6 months
Sliding table
Fig. 7-12 Spray guides with universal oil
Note!
i Remove the oil from all lubricated points using a cloth!
Note!
i Clean the monitor controls/screen using screen cleaning equipment such
as a microfibre cloth, cleaning spray or cleaning pad (available from PC
or mobile phone shops).
241
Cleaning/care
Type of soiling Remove/clean with
Chips and dust Vacuum cleaner, brush, cleaning cloth
Resin residue Nitro thinner
Resin residue on the sliding table guide Cleaning cloth, petroleum, spirit
On the monitor Microfibre cloth, display cleaning spray

or pad
Avoidance of Necessary subsequent treatment
Rust formation Universal oil
Warning!
NEVER APPLY RESIN REMOVER TO ANODIZED SURFACES!

• Do not allow resin removing cleaning agents to corrode the alumi-
nium surfaces!
• It is very important to adhere to the manufacturer's specifications!
242
Cleaning/care
Lubrication, CNC rip fence

Quantity of lubricant
When lubricating, max. 5 strokes are required for applying the required 7 g of
lubricant.
The filled grease gun is included in the scope of delivery.
Attention!
Please observe:
• Adhere to the precise lubricant quantity and time interval specified for
each relubrication cycle.
• Excessive lubrication due to short intervals and/or by too much lubri-
cant will lead to failures!
Note!
i If you want to save time and money,
sign up for the annual Altendorf inspection, the "check-up" for your sliding
table saw.
The lubrication measures will be carried out by our maintenance staff
within the framework of the professional maintenance.
Motor driven rip fence (X axis)

The rail guide is relubricated via 2 lubricating nipples on the carriage.
The spindle for the X axis drive is lubricated via an additional lubricating nipple,
see figure!
Time interval :
After travel of 1500 m a message is shown on the display indicating that relub-
rication is necessary.
Lubrication is necessary every 12 months, irrespective of the distance tra-
velled.
Clearing the message

To temporarily clear the message: Actuate the STOP button.
After 10 adjustments or an interruption to the power, the message reappears!
To clear the message after lubrication: Press the START button 3x
243
Cleaning/care
Lubricating process:
• Move the rip fence to the position ~ 800 mm (in this position, it is also pos-
sible to access the lubricating nipple for the drive spindle).
• Turn off the main switch and secure against turning on again.
• Remove the protective cover and relubricate the lubricating nipples with the
provided grease gun.
• After lubrication, fit the cover plate!
• The machine is operational again after the error message is deleted.
Warning!
Danger of injury!
• Turn off the main switch before removing the cover plate!
Fig. 7-13 Lubricating nipple, X axis

[1] Lubricating nipple, rail guide
[2] Lubricating nipple, spindle drive
244
Cleaning/care
Lubricating nipple, saw unit
Time interval:
After travel of 100 m, a message is shown on the display indicating that relubri-
cation of the height adjustment unit is necessary.
Lubrication is necessary once a year, irrespective of the distance travelled.
How to proceed:
To relubricate, set the tilt of the saw blade to 45° and the cutting height to 0
mm. Open the machine door or remove the protective cover plate (VARIO).
This allows optimum access to the lubricating nipples.
Fig. 7-14 Lubricating nipple (1), height adjustment of the saw unit tilting to one side
[1] Lubricating nipple, height adjustment
[2] Shaft sealing rings, height adjustment
Remove any emerging grease and chips from the guide rods (2).
245
Cleaning/care
Fig. 7-15 Lubricating nipples (arrows), saw unit tilting to both sides
Lubricating the scorer
Note!
i Lubricating the scorer is only required for machines tilting to both sides
(option).
Fig. 7-16 Lubricating nipple (arrow), scorer
246
Cleaning/care
Note!
i No relubrication of the saw shaft is necessary!
247
Cleaning/care
Choice of lubricants
Lubricant Manufacturer
Aralub HL 2 Aral
BEACON 2 Esso
BP Energrease LS 2 BP
ELF ROLEXA 2 Elf
Gulfcrown Grease No. 2 Gulf
Marson EPL 2 Wintershall
Shell Alvania grease R 2 Shell
Extreme pressure-bearing grease SKF

LGEP 2
Way Lubricant 220 Texaco
Tbl. 7-1 Choice of lubricants
Attention!
Lubricants containing graphite or MoS2 additives are not allowed to

be used!
248
Cleaning/care
7.3 Maintenance/cleaning by qualified persons
7.3.1 Checking the winding shield

Checking the winding shield
The resistance of the PTC resistors must be checked in the motor terminal box
by an electrician at least once a year. Resistance must be measured with a
cold motor, and should be 750 ohms ± 200 ohms.
249
Faults/problems/troubleshooting
8 Faults/problems/troubleshooting
8.1 Machine diagnosis

The display shows when limit switches have been actuated at protective de-
vices and so on. There are two function groups.
Function group 1:
• Motor temperature
• Machine door
• Lower saw blade cover
• EMERGENCY STOP button
• Sliding table limit switch
Function group 2:
• Brake unit
Response by function group 1:

Machine drives are switched off or cannot be started
Response by function group 2:

Machines will not start
Indication to request a service technician to check the functioning
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8.2 Motor overload protection
Fig. 8-1 Motor overload protection
The drive motors are protected against overload by a winding shield. This swit-
ches a motor off automatically if it overheats. In the case of machines equipped
with a scorer, the scorer drive is also switched off even if this motor was not
overloaded. The motor can only be switched on again when it has cooled
down. It may take several minutes (max. 10) for the motor to cool down!
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8.3 Troubleshooting/faults/messages
Fault Cause Troubleshooting
The machine cannot be The main switch is not Turn the main switch to switch position “I”.
switched on. turned on.
Power failure or phase Wait for power to be reinstated, or eliminate cause

failure for loss of power, check factory fuses.
Overload protection Allow motor to cool down, also refer to machine dia-
has responded. gnosis display.
Sliding table moved Move the sliding table back to the saw blade centre
over saw blade centre line; also refer to machine diagnosis display.
line.
EMERGENCY STOP Rearm the EMERGENCY STOP button again by

button pressed. pulling, also refer to machine diagnosis display.
Door in machine frame Close the machine door or cover plate; also refer to
or lower base plate in machine diagnosis display.
front of saw blades
opened.
Control circuit fuses Turn off the main switch, open the switch cabinet
defective and identify which of the fuses F1, F2, F8 is defec-
tive. Find and eliminate the cause. Replace defec-
tive fuses, only using fuses of the same rating!
The machine switches Power failure in one or Eliminate cause of phase failure.
off automatically during several phases due to
operation. responding factory
fuses.
Overload protection Change saw blade or reduce feed speed. Allow

has responded due to motor to cool down, also refer to machine diagnosis
blunt saw blade or display.
excessive feed speed.
Control circuit fuses Turn off the main switch, open the switch cabinet
defective and identify which of the fuses F1, F2, F8 is defec-
tive. Find and eliminate the cause. Replace defec-
tive fuses, only using fuses of the same rating!
Workpiece jammed Blunt saw blade Fit a sharp saw blade.

while feeding forward.
Riving knife thickness Fit the correct riving knife; it must be thicker than or
does not match the equal to the thickness of the main saw blade.
saw blade used.
252
The finished size of the Dimension scale for Reset the dimension scale: Cut a workpiece at the
cut workpiece does not cutting width display is rip fence, precisely measure the cut width and posi-
match the cutting width misadjusted. tion the measuring scale so that the measured cut-
set on the rip fence. ting width is displayed on the fence edge.
Incorrect calibration for Recalibrate

DIGIT_X,
CONTROL
The finished size of the Dimension scale for Reset the dimension scale: Cut a workpiece at the
cut workpiece does not cutting width display is crosscut stop, precisely measure the cut width and
match the cutting width misadjusted. position the measuring scale so that the magnifying
set on the crosscut glass display matches the measured cut width.
stop.
Incorrect calibration for Recalibrate

DIGIT_X,
CONTROL
Swinging arm does not Soiled telescopic tube Clean telescopic tube or track rollers; check wiper.
move smoothly. or track rollers
Sliding table has late- Sub-rollers incorrectly Set the sub-rollers.

ral play. set.
In its end positions, the Sub-rollers incorrectly Set the sub-rollers.

sliding table is higher set.
than the machine table.
Saw blade burns on the Insufficient free cut on Readjust the free cut.
sliding table side. sliding table
Excessive free cut on Readjust the rip fence.

the rip fence
Saw blade burns on the Insufficient free cut on Readjust the free cut.
rip fence side. rip fence
Saw blade burns on Incorrect free cut set- Readjust the free cuts.
both sides. ting.
Workpiece jammed. Insert a riving knife in the cutting line or use a wider
riving knife.
Operating error Guide the workpiece either at the LH or the RH

fence. Do not guide the workpiece on the rip fence
when cutting with the sliding table.
Workpiece has burn Blunt saw blade Change the saw blade.
marks.
253
Feed too low Increase the feed rate.
Saw blade has too Change the saw blade.

many teeth.
Incorrect free cut Readjust the free cut.
Break-outs in spite of Scorer not aligned with Readjust free cuts; the free cut should be almost “0”.
scorer main saw blade
Scoring blade too nar- Adjust saw width.

row
Workpiece rises when Blunt scoring blade Exchange the sawing blade.
cut with the scorer.
Cutting height too low Set the scoring blade higher.
Tbl. 8-1 Fault
254
Fault message Cause Troubleshooting
B000 - B063 Internal faults Request a service technician to check the

function.
E01 Limit switch ES_MIN1 reached
E02 Limit switch ES_MIN2 reached
E03 Limit switch ES_MAX reached
E06 Fault, collision, fast shutdown
E07 Drive positioning fault
E08 Axis reference run error Perform new reference run
E18 Fresh oil lubricator empty Change cartridge
E21 Error during update:

File error on the USB stick
E22 Error during update:

File errors on the USB stick (vari-
ous)
E40 20VAC control voltage missing Check fuse F9
E41 24VAC control voltage missing Check fuse F8
E42 Scoring saw motor overheated Allow motor to cool down.
E43 Main saw motor overheated Allow motor to cool down.
E44 Sliding table limit switch
E45 Saw blade cover open
E46 Machine door open
E47 EMERGENCY STOP button 1

pressed

pressed

pressed
E51 Brake unit fault: Phase failure/rota- Check fusing in the factory and fuses F15 /
tional direction F16.
255
Fault message Cause Troubleshooting
E53 Brake unit fault: Mains contactor Request a service technician to perform a
not in neutral position. repair.
E54 Operating error, incorrect riving Check rotational speed and riving knife posi-
knife position or speed setting, e.g. tion.
too fast for 450 mm saw blade. Dri-
ves cannot be started!
E55 Brake unit fault: Communication Request a service technician to check the
problem with machine control unit - function.
brake unit is operating in default
mode, 450 mm saw blade / 4000
rpm.
E56 Frequency converter phase failure/ Press any button on the control unit.
overvoltage
E57 Frequency converter excessive Restart the machine.

speed If this does not remedy the fault, request a
service technician.
E58 Frequency converter communica- Request a service technician to check the

tion fault function.
E59 Emergency running block 3500 rpm Switch the main saw blade off and on again.
E61 Malfunction, drive positioning, cur- Lubricate the axle

rent consumption evaluation
E81 Malfunction, shaft encoder Request a service technician to check the

Evaluation faulty, A/B channel function.
E91K K contact error of the STOP button If the fault occurs repeatedly, request a ser-
vice technician to check the function.
E92 K-n stop signal missing Request a service technician to check the
Check the AC stop circuit function.
E93K K contact error of the START but- If the fault occurs repeatedly, request a ser-
ton vice technician to check the function.
E94 K free signal missing Request a service technician to check the

function.
E99 Excess temperature of the control Switch off machine and allow to cool down
electronics before restarting. If fault occurs again, request
a service technician to check the function.
Tbl. 8-2 Fault messages
256
8.4 Electronic brake module

The main saw shaft is braked with an electronic brake module. This brake mo-
dule is located in the contractor control housing, and is accessible when the
rear panels have been removed.Braking is controlled in such a way that there
is a high brake current at the beginning of braking. This is reduced over time to
ensure smooth braking. In addition, a standstill monitoring facility switches off
the brake current if the motor is standing still. The brake module contains vari-
ous function blocks for control and monitoring tasks. There is also a communi-
cations connection for machine control.
257
Technical data
9 Technical data
9.1 Standard equipment

Saw blade heights: Standard up to 450 mm
Features
Electromotive height and tilt adjustment 0 - 46 ° for the main saw blade, for til-
ting in both directions from -46° to +46°,
with automatic correction of the cutting height when tilting the saw unit, and with dis-
play of tilt angle and cutting height.
F45 display control system with dimension input via the keypad
Saving of 99 programs
Sliding table incl. infinitely variable top carriage locking

Sliding table length 3000 mm
Rip fence
Cutting width 1000 mm, table width extension, aluminium anodised
• Manual adjustment with precision setting
Crosscut fence
• manual adjustment, crosscutting up to 3200 mm, 2 operating positions on the
cross-slide frame
Drive power / rotational speed of main saw shaft

With automatic brake and display of rotational speed
• 4kW (5.5 PS) with a rotational speed of 4000 rpm
Tool clamping system AKE

for main saw blade
Max. cutting height 150 mm, max. saw blade diameter 450 mm
Cutting heights: see table
Table length extension

840 mm, aluminium anodised
USB-A port for data and program transfer
Machine diagnosis and operating hours meter
Aluminium parts in anodised finish
Clamping shoe, push stick, push block handle and pull-back handle
258
Technical data 0000010040-002- GB

Technical data
Saw blade dia- Standard Option:

---
meter [mm] Extended cutting height
0° + 45° - 45° 0° + 45° - 45°
250 0 - 55 0 -30 0 -1 0 - 55 0 - 30 0-1
300 0 - 80 0 - 47 0 - 18 0 - 80 0 - 47 0 - 18
350 0 - 105 0 - 64 0 - 35 0 - 105 0 - 64 2,5 - 35
400 0 - 130 0 - 81 2 - 52 25 - 130 17,5 - 81 20,5 - 52
450* 25 - 155 16 - 98 20 - 69 50 - 155 35,5 - 98 38 - 69
500* ----- ----- ----- 75 - 180 53 - 115 56 - 86
550* ----- ----- ----- 100 - 205 70,5 - 132 73,5 - 103
Note!
i * For machines with a scoring unit, the scoring blade, including the front
and rear flange, or RAPIDO must be removed.
259
0000010040-002- GB Technical data

Technical data
Technical data:
Main saw Tool holder diameter 30 mm
Saw blade tilting range 0-46°
Idling speed 4000 rpm
Tool edge width max.20 mm
Sliding table Sliding table cutting length See table
Crosscut fence Crosscutting at 90° crosscut fence 3200 mm
Rip fence Cutting width at rip fence 1000
Extraction Connection socket diameter below table 120 mm
Connection socket diameter at top safety hood 80 mm
Overall vacuum connection ∅ 140 mm 1200 PA
Air speed 20 m/s
Minimum air volume 1110 m3/h
Ambient conditions Operating temperature 10 - 40 °C
Max. relative humidity 90 %, no condensation

Do not expose the machine to a gaseous
environment which is explosive or may
cause corrosion!
260

Technical data
Weight Machine weight, dependent upon equipment Approx. 1100 kg
Electrical equipment Lockable main switch
Contactor control with pushbutton operation Control voltage 24 VAC
Rotational speed, tilt angle, cutting height Digital display
Braking of main motor, monitoring of winding Electronic multifunction

temperature module/frequency converter
Adjustment of tilt and cutting height for the CNC-controlled

main saw
Sliding table cutting lengths

Maximum cutting length with use of clamping shoe or crosscut-mitre fence
Does not apply to crosscut fence, crosscutting up to 2500 mm.
Sliding table length [mm] 2250 3000 3200 3400 3800 4300 5000
Cutting length [mm] 2155 2905 3105 3305 3705 3705 3705
for WA,WGA,PQS, UNO
for DUO and DUO Flex
TIP-SERVO-DRIVE
without scoring blade
with scoring blade
261

Technical data
9.2 Special equipment
Available special equipment
Main saw drive

Heavy-duty motors up to 11 kW (for machines tilting to one side)
Infinite rotational speed adjustment (VARIO, adjustable in increments of 5, power for
machines tilting to one side: 5.5kW, 7.5kW , power for machines tilting to both sides:
5kW and 6.5 kW)
Sliding table
Sliding table lengths from 2250 mm to 5000 mm
Second support (STEG), support width extension by 400 mm
On/Off switch at the end of the sliding table
Crosscut-mitre fence
Length dimension adjustable via digital display with fine adjustment (DIGIT L), set-
ting accuracy 0.1 mm, crosscutting up to 3200 mm
Length dimension, angle, length compensation via digital display (DIGIT LD), setting
accuracy 0.1 mm / 0.1°, crosscutting up to 3200 mm
Mitre fences
One-sided mitre fence, angle adjustable via scale from - 30° to 45°, crosscutting up
to 2500 mm
Double-sided mitre fence (DUPLEX), angle adjustable via scale from 0° to 90°, cros-
scutting up to 1350 mm or 2150 mm, length compensation
Double-sided mitre fence (DUPLEX D), angle digitally adjustable, setting accuracy
0.01°, crosscutting up to 1350 mm or 2150 mm, length compensation
Double-sided mitre fence (DUPLEX DD), angle and length digitally adjustable, set-
ting accuracy 0.01° / 0.1 mm, length display is adapted automatically in accordance
with the angle that is set, crosscutting up to 1350 mm or 2150 mm
Rip fence
With digital dimension display and fine adjustment, setting accuracy 0.1 mm
Parallel cutting device

Parallel cutting device (PALIN), crosscutting up to 900 mm, adjustable via scale
Parallel cutting device (PALIN_D), crosscutting up to 900 mm, digitally adjustable,
setting accuracy 0.1 mm
262

Technical data
Available special equipment
Pneumatic hold-down beam

For sliding table length 2250 mm, clamping length 1975 mm
Max. clamping height 80 mm, min. pneumatic connection 6 bars
Electro-pneumatic hold-down device

with 1 cylinder
with 2 cylinders
Max. workpiece height 0 – 90 mm or 80 – 170 mm, min. pneumatic connection 6
bar, wireless remote control
Manual quick-action clamp

Max. clamping height 200 mm
Cross-slide
Telescopic cross-slide width extension for up to 650 mm extra
Additional cross-slide with floor supporting roller, max. workpiece weight 250 kg
LASER cutting line display

Light beam width approx. 3 mm, light beam length approx. 5 m
Three-phase A/C socket

In European standard version, fuses 10 A, can be switched via the main switch
Coolant spray device

Minimal cooling lubrication, operating pressure 0.5 – 5 bars
Support roller, tilting

Positioned on the sliding table in front of the machine table
Parallelogram cross-slide
Additional cross-slide with digital display
Vacuum suction cup in sliding table

5 individually selectable suction areas for all table lengths
263

Maintenance and repairs
10 Maintenance and repairs
10.1 General
Keeping a supply of the most important spare and wear parts on site is an im-
portant prerequisite for the constant functioning and operating capability of the
sliding table saw. We only accept a guarantee for original spare parts supplied
by us. We expressly point out that original spare parts and accessories not sup-
plied by us have not been checked and released by us. Therefore, the fitting
and/or use of such products may negatively influence the properties of the sli-
ding table saw and thus impair its active and/or passive safety. Wilhelm Alten-
dorf GmbH&Co. KG will not accept any liability or guarantee for damage
resulting from the use of non-original spare parts and accessories.
Please note that special production and delivery specifications exist for our own
and our suppliers' parts, and that we always supply spare parts that meet the
latest state of the art and comply with the latest statutory regulations.
Please refer to the spare parts list when ordering spare parts.
For further information please refer to the spare parts drawings included in the
spare parts list.
When ordering spare parts, please state the following information:
• Machine no.
• Article no.
264
Maintenance and repairs 0000010040-002- GB

Maintenance and repairs
10.2 Customer service addresses

Wilhelm Altendorf GmbH & Co KG
Service department
Wettinerallee 43/45
D-32429 Minden
Post office box

D-32377
Phone: +49 571 9550222

Telefax: +49 571 9550111
e-Mail: service@altendorf.de
www.altendorf.com
265
0000010040-002- GB Maintenance and repairs

F45 Elmodrive Manual

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Operating manual F45 ElmoDrive

2.1 Machine identification 6

3.1 Marking, pictographs 16

4.1 Description of machine 36

5 Transport, siting and installation

Table of contents 0000010040-002- GB

5.3.3 Rip fence 49

6.1 Working safely with the dimension saw 90

0000010040-002- GB Table of contents

6.6.4 Dimension display unit DIGIT L 207

7.1 Safety measures 236

8.1 Machine diagnosis 250

9.1 Standard equipment 258

10 Maintenance and repairs

10.1 General 264

Table of contents 0000010040-002- GB

Please read these operating instructions carefully before commissioning

No liability will be accepted for any injury, damage or disruption to opera-

These operating instructions cannot be regarded as a binding type de-

The operating instructions must always be available where the machine is

• Operating including set-up, troubleshooting during operation, elimination of

It is necessary to comply with national regulations on health and safety at work

Reproduction of this document or parts thereof is only allowed with our

2.1 Machine identification

Type: Machine designa-

Number: Machine specific

Year of construc- Year of manufac-

Saw blade min Ø Diameter of the

Saw blade max Diameter of the

Guide slot width Diameter of the

Conformity declaration as defined by the machinery directive, Annex II 1A

Manufacturer: Wilhelm Altendorf GmbH & Co. KG

Person authorised to Rolf Tweer, Technology Management,

Product: Sliding table saw, type F45

The following harmonised standards have been applied:

EC prototype testing certificate

DGUV Test Certificate

2.3 Marks of conformity

CE symbol GS symbol Wood dust appro- C US mark

3.1 Marking, pictographs

Danger warning Hand injury warning Laser beam warning

Crushing risk warning Voltage warning Note: Wear ear pro-

3.2 Intended use

• Laminated and unlaminated board materials (e.g. chipboard, coreboard,

Product description 0000010040-002- GB

0000010040-002- GB Product description

Usable saw blades:

Coolant spray device: (Option)

Product description 0000010040-002- GB

Machine operator positions:

Fig. 3-1 Machine operator positions

0000010040-002- GB Product description

• Working with the safety hood swung up

Always, under all circumstances avoid the above-mentioned types of

Product description 0000010040-002- GB

Avoid the potential dangers posed by these remaining risks by paying

0000010040-002- GB Product description

3.3 Dimensions and weights

Dimensions, sliding table box

Idling_LWA = 87.3 Idling_LPA =77.4 Circular saw blade

Idling_LWA = 101.3 Idling_LPA =95.7 Circular saw blade

Idling_LWA = 93.9 Idling_LPA =84.1 Circular saw blade

Idling_LWA = 93.9 Idling_LPA =84.5 Circular saw blade

Idling_LWA = 87.7 Idling_LPA =78.1 Circular saw blade