ZAF 250 Vario - Milling machine Mafell - Free user manual and instructions

USER MANUAL ZAF 250 Vario Mafell

ZAF 250 VARIO Translation of the original operating instructions

These Operating Instructions are intended to help you getting to know the machine and using it as intended. They comprise important information on how to operate the machine safely, correctly and economically. Observing them helps you to avoid risks, reduce repair costs and downti- me, and increase the reliability and useful life of the machine. These Operating Instruc- tions were drawn up under consideration of Directive 2006/42/EC (Machine Directive) and the requirements pursuant to the European standard EN 292. The Operating Instructions must always be available at the site of installation of the ma- chine. They must be made known to all persons coming into contact with this machine. This applies in particular to persons who are commissioned to – operate the machine, including tooling, troubleshooting in the process of regular work, placement and removal of workpieces, clearing away process waste – maintain the machine (cleaning, servicing, inspection, repair) – transport the machine (during conveyance to its final location, installation, and connec- tion). In addition to the notes on occupational safety in these Operating Instructions, the health and safety regulations mandatory in the operating company's country must be observed. Furthermore, MAFELL points out that these Operating Instructions may not necessarily be modified immediately to reflect any technical improvements implemented in the machi- ne design. However, this does not apply to any modifications to the technical safety equipment of the machine. All notes concerning your safety are characterised by this symbol. Non-compliance with the regulations specified in these notes may result in serious injury. Notes referring to situations that will potentially cause damage are characterised by this symbol. If you do not avoid these situations, the product or objects in its vicinity may be damaged. This symbol characterises user tips and other useful information.– 25 – 1 Information on the product on the machine with art. no. 991201

1.1 Information on the manufacturer

All data required for identification of the tenon cutting machine are located on the type la- bel at the machine base.

Maximum timber dimension (width x height) for – tenon cutting at right angle 500 x 250 mm (19 11/16 x 9 27/32 in.) – tenon cutting with maximum inclination of 60° 220 x 250 mm (8 21/32 x 9 27/32 in.) – flattening at right angle and maximum tilt angle of 45° 340 x 250 mm (13 25/64 x 9 27/32 in.) Maximum tendon length 110 mm (4 3/8 in.) Maximum flattening in one process step 110 mm (4 3/8 in.) Maximum flattening depth 80 mm (3 1/8 in.) 3-phase alternating current motor 400 V ~, 50 Hz – rated input power (regular load) 6000 W – rated output power (regular load) 4500 W – rated current (regular load) 10.4 A CE sign for documentation of the conformance with the basic safety and health requirements according to Annex I of the Machine Directive. Read the Operating Instructions carefully to reduce the risk of injury.– 26 – Tool (cutter head with cutter ring) – cutter head diameter 100 mm (3 15/16 in.) – cutter ring diameter 165 mm (6 1/2 in.) – cutter ring width 40 mm (1 9/16 in.) – cutter head width (cutting width) 110 mm (4 5/16 in.) – tool holding fixture diameter 30 mm (1 3/16 in.) – rated idling speed 6670 rpm – speed at regular load 6260 rpm – cutting rate at regular load speed 32.8 m/s (108 ft/s) – feed rate 0.9-2.2 m/min. (2.9 - 7.2 ft/min) – feed force approx. 800 N – cutting length 320 mm (12 5/8 in.) – tilt range of tool assembly 0–60° Machine dimensions and weight – width x length x height 1400 x 1400 x 1450 mm (55 x 55 x 57 3/32 in.) – working height 780 mm (30 45/64 in.) – dimensions of infeed table (W x L x H) 350 x 3000 x 900 mm (13 3/4 x 118 7/64 x 35 1/2 in.) – weight without infeed table 380 kg (836 lbs) – weight of infeed table 83 kg (182.6 lbs) – diameter of extraction connection pipe 2 x 100 mm(3 15/16 in.)

1.4 Scope of delivery

Tenon cutting machine ZAF 250 Vario complete with: – 3 m (9.9 ft) infeed table – device for transport by fork-lift truck – special milling tool – operating tool – push-type grease gun – Operating Instructions

1.4.1 Special accessories

– extraction kit Order no. 202 320

1.5 Noise emission data

The average noise values over the total machining cycle are as follows: An additional K = 4 dB must be allowed on the above emission values for measuring in- accuracy. Tenon cutting Flattening Noise level 108 dB (A) 108 dB (A) workplace-related emission 93 dB (A) 94 dB (A)The sound power level is measured pursuant to EN ISO 3746 with the following deviati- ons: – the correction factor for the background noise is max. 4 dB, – at each measuring point, the balance between the noise level of the background noise and the machine noise level is greater than 6 dB, – the distance between the surface area of the machine and the measuring area is 1 m, – there are 9 measuring points, – the measuring duration is equivalent to one machining cycle. The sound power level of the workplace-related emission value is measured pursuant to EN ISO 11202 with the following deviations: – the correction factor for the background at the measuring area as well as at the work- place is max. 4 dB, – the balance between the noise level of the background noise and the noise level at the workplace is greater than 6 dB, – the correction factor at the workplace is calculated pursuant to Annex 2 of EN ISO

Measurement on the basis of the following operating conditions: Tenon cutting: Cutting of a straight tenon with a thickness of 40 mm (1 9/16 in.) and a length of 40 mm (1 9/16 in.) at a 180 x 160 mm (7 x 6 1/4 in.) workpiece of fir wood with the serial tool and the specified speed of 6260 rpm (load speed). Flattening: Flattening at a 180 x 160 mm (7 x 6 1/4 in.) fir wood workpiece at half the workpiece height (i.e. 80 mm) to a depth of 70 mm (2 3/4 in) with the serial tool (with cutter ring re- moved) and the specified speed of 6260 rpm (load speed). The specified values are emission levels and not necessarily levels for safe operation. Ir- respective of the existence of a correlation between the emission and the immission le- vels, these values cannot be used as a reliable decision basis regarding the need for ad- ditional precautions. The factors affecting the immission level at a workplace at a given time comprise the duration of the exposure, the properties of the premises, other noise sources etc., such as for instance the number of machines and other adjacent proces- sing operations. Furthermore, the permissible immission level may differ from country to country. Nevertheless, this data gives the machine operator valuable information for a better estimation of the risks and dangers of the tenon cutting machine. – 27 –1.6 Machine description The tenon cutting machine ZAF 250 makes it possible to manufacture straight and angled (max. 60°) tenons fast, accurately, efficiently, and with exact tolerances, com- plete with an all-round chamfer and auto- matic face-grinding for angled tenons. The tooling change for the manufacture of flat- tenings is fast and simple. For all kinds of machining operations and for straight as well as for angled tenons, the workpiece always remains in the same position and does not require labour- and time-consu- ming moving. This is made possible by the integrated tilt position of the entire machi- ning unit. The 3 m (9.9 ft) long infeed table safely supports the workpiece to be machined and can accommodate workpieces of up to 500 x 250 mm (19 11/16 x 9 27/32 in.) for straight tenons, and up to 220 x 250 mm ( 8 21/32 x 9 27/32 in.) for maximum tilt angle. The integrated double stop plate and the accurate scale allow for exact length measurement even in case of ma- chining at both ends of the workpiece. The combination cutting tool developed specifically for ZAF can be set easily and quickly to different tenon length and, after removal of the cutter ring, switched to flat- tening operation. It is equipped with repla- ceable hard metal reversible knifes that can be reversed three times. Thus, a long operating life of the tool is guaranteed be- fore the reversible knifes need to be repla- ced. The machine has easily accessible setting elements. Together with the clearly reada- ble scales and the easily visible line laser, these elements allow for accurate setting of the desired geometry of tenon or flat- tening. All electrical switches for controlling the machine are arranged at the clearly struc- tured operating panel located directly at the workplace. Use the operating mode selec- tion switch to preselect the operating mo- des Curtain closed, Setting, Manual milling, Tenon, and Flattening. In the operating mode Tenon and Flattening, all functions will run automatically after the start com- mand has been given: Closing the protection curtain, starting the drive motor for the cutting tool, tracing the tenon contour with face grinding, setting and chamfering, returning the tool to home position, switching off the drive motor, and opening the protection curtain. The ZAF 250 Vario allows reduction of the feed to 50%. At this setting, the powerful drive unit relia- bly meets the high requirements of the chip removal processes commonly applicable in a carpentry. The chips resulting from machining are eit- her ejected downwards through adjustable shutters, or - in case of stationary operati- on in a joining shop - may alternatively be disposed of into the extraction system via the standard hose connectors.

Already during the development of this new machine, optimum working conditions were one of our key concerns, from a num- ber of mechanical and electrical safety fea- tures up to the consideration of ergonomic principles and measures to reduce the emission of noise and dust. The machine is equipped with all protective devices required during its intended use to protect the operator and others from those risks that could not be eliminated by the machine design. This protective equipment comprises in particular:

Designed pursuant to EN 847-1, with chip – 28 – The equipment described her- ein is necessary for the safe operation of the machine. It must not be removed or ren- dered ineffective.– 29 – thickness restriction, suitable for mechani- cal feed. Locking feature to prevent loose- ning during startup and shutdown by positi- ve connection of the tool with the rear abutment flange by means of 2 driving pins.

2. Protection against touching the tool:

Housing fully closed with the exception of the opening for feeding the workpiece. The door in the housing providing access to the setting elements for adjusting the tenon thickness is guarded by means of a safety limit switch that is connected to the drive motor for the milling tool and the feed dri- ve. When the door is opened, both drives are switched off, and the automatic brake shuts the tool down in approx. 3 seconds. The safety circuit of the control is designed to meet performance level PL=c pursuant to EN ISO 13849 (PL).

3. Safety feature of the opening for work-

piece feed-in: The feed-in opening is adjusted to the di- mensions of the respective workpiece by an automatically closing protection curtain pursuant to EN 1870-13.

4. Clamping the workpiece:

The workpiece positioned in the machine is protected against accidental shifting by a manual clamping device.

5. Protection against tool damage:

When the machine is set to cut angled te- nons, a collision with the workpiece is pre- vented by automatic correction of the start position via retraction of the tool.

Setup mode, selected by means of the operating mode selection switch, is only available when the milling tool is in stand- still. Then, the setting of milling unit can be changed in every direction by means of the inching control key.

The chips are guided through the integra- ted chip deflection channel either to 2 ejec- tion chutes or 2 hose connectors.

The noise is reduced thanks to the almost circular shape of the milling tool and the closed housing. The duration of the emissi- on is limited by automatic shutdown of the tool at the end of the machining cycle.

9. Electrical safety:

The electrical equipment of the machine in in accordance with the European standard EN 60204-1. It is immune to interference by electromagnetic fields. There is no emit- tance of electromagnetic interference pul- ses.

The MAFELL tenon cutting machine ZAF 250 is exclusively intended for cutting straight and angled tenons and to machine flattenings in solid timber with a maximum cross-section of 500 x 250 mm (19 11/16 x 9 27/16 in.) for straight tenons or 220 x 250 mm (8 21/32 x 9 27/32 in.) for tenons with a tilt angle of 60°. To this end, only the assembled milling tool comprised in the delivery with the dimensions Ø 100 mm x 110 mm (3 15/16 Ø x 4 5/16 in.) or Ø 165 mm x 40 mm (6 1/2 Ø x 1 9/16 in.) may be used. The operator station of the machine is in front of the control panel that holds the switches for all machine functions. Any use beyond the above is not conside- red intended use. The manufacturer wai- ves any and all liability for resulting dama- ge of any kind; the risk is exclusively borne by the user. Likewise, the machine is not suitable for outdoor operation in rainy weather, or in hazardous areas. To meet the requirements for 'intended use', the operating company must further-– 30 – more observe the conditions for operation, maintenance and repair as specified by MAFELL, and the safety information in the Operating Instructions. The tenon cutting machine ZAF 250 must only be used, tooled and maintained by in- dividuals who are familiar with the machine and have been informed of its hazards. All repairs must be done by MAFELL repre- sentatives or MAFELL service agencies. The applicable accident prevention regula- tions and other generally acknowledged stipulations in respect of safety technology and occupational health must be observed. The manufacturer waives all liability for da- mage resulting from unauthorized modifi- cations to the machine.

Also when the machine is used as inten- ded and all applicable safety regulations are observed, there may occur residual risks that are attributable to the design of the machine for its intended purpose, for example: – Touching the tool blades during tool change. – Rupture of the tool and parts thrown from the machine. – Sudden violent shifting of the tool when it is not clamped fast. – Touching of live parts when the control cabinet is open and the main switch is not switched off, or the connecting cable not unplugged. – Adverse effect on hearing in case of pro- longed working without ear protection. – Emission of hazardous wood dusts in case of prolonged operation in closed rooms without sufficient ventilation.

1.9.1 Information in respect of the laser

– The laser is switched on and off with the main switch that is located on the side of the control cabinet. – The laser opening is located in the top of the protective cover, to the left of the sa- fety curtain. The laser radiates obliquely downwards (cut edge of the milling tool) onto the workpiece. – Do not attach any additional optical in- struments in front of the laser.

Do not repair defects on the laser yours- elf.

The built-in laser corresponds to class 2M and is thus safe for the human eye in case of brief exposure by eye lid closing reflex (looking into the beam for up to 0.25s)

1.10 Safety information

General: – Before starting to work, always check the safety devices for correct functions. Do not modify the machine in any way that might impair its safety. – Children and teenagers are not allowed to operate this machine, with the excepti- ons of underage apprentices for training purposes under supervision of an expert. – When working outdoors, only use rubber- insulated extension cables (for example If used improperly, woodworking machines may be dangerous. For this reason, always observe the safety information in this sec- tion, the accident prevention re- gulations of your Employer's Lia- bility Insurance Association, and the safety regulations applicable in your country! Do not look directly into the laser beam!H07 RN-F) with a cross-section of no less than 5 x 2.5 mm². Take care not to pull the cable over sharp edges. – Take the environmental influences into consideration. Do not expose the machi- ne to rain. Avoid operating it in a moist or wet environment and close to combu- stible liquids or gases. – When operating the machine out of do- ors, we recommend that you use a resi- dual-current circuit breaker. – Switch the main switch off before chan- ging the milling tool and before troubles- hooting. – Only use the milling tools comprised in the delivery. Be sure never to use a blunt tool. – When the machine is shut down for a longer period of time, secure the swit- ched-off main switch against accidental activation by locking it with a padlock. Information on the use of personal sa- fety equipment – Always wear closely fitting work clothes and remove rings, bracelets and wrist- watches before starting to work. – Always wear suitable gloves when ope- rating the tenon cutting machine and changing tools. – To protect your eyes from injury, wear eye protection (goggles) or face protec- tion when operating the machine.

The noise level at the ear is greater than 85 dB (A). For this reason, wear ear pro- tection when operating the machine. Information on operation – Always lead the electrical connecting ca- ble away from the machine and lay it in such a way that there is no tripping ha- zard at the operator station. – Make sure that the operator station is fre- ely accessible, sufficiently lighted, and slip-proof. – Ensure that there are no other individuals in the working space, in particular no children. – Protect the workpiece from slipping or dropping by clamping it fast by means of the screw clamp provided for this purpo- se. – Only switch the machine on if there is a workpiece in machining position. – Check the workpiece for foreign particles. Do not cut into metal parts, for example nails, as this might damage the sensitive hard metal knifes. – Do not machine any workpieces that are too small or too big for the performance range of the machine. – On no account change the angle position of the milling unit during an ongoing mil- ling operation. Information on maintenance and repair – Before doing any maintenance or repair, always unplug the connecting cable from the socket at the machine, or switch off the main switch and protect it from acci- dental activation, for example by secu- ring it with a padlock. – Only use original MAFELL spares and accessories. The manufacturer does not accept any warranty claim and liability beyond the above. – Regular checks of the machine, in parti- cular of the guides of the milling unit and the smooth running of the protection cur- tain, are of major importance. – Careful maintenance of the milling tool is significant as well. Keep it sharp and cle- an to allow for safe operation and good results. Observe the maintenance in- structions and the notes for tool change. – 31 –2 Startup

2.1 Delivery and transport

Always use a fork-lift truck for unloading the machine and conveying it to its final in- stallation location. Make sure that you al- ways lift the machine from the operator side (the side with the control panel). It is imperative that both forks reach under the transport device bolted to the frame and marked in blue (no. 1 - Fig. 1). When moving the machine, lift it just a few centimetres. Check the machine for any transport da- mage immediately after unloading. Dama- ged packaging material may be an indicati- on of improper transport. It is imperative that the forwarder confirm any transport damage in the bill of lading; otherwise, the forwarder's insurance will not cover the da- mage. If the machine is not set up immediately af- ter receipt, it must be stored in a dry place at temperatures between +5° and +40° C. For prolonged storage, it is advisable to check the rust-proofing of the uncoated parts occasionally and replace the coating if necessary.

Choose the place of installation of the ma- chine in such a way that there is sufficient free space around it, considering the space taken up by the tenon cutting machine and the size of the workpieces to be machined. The footprint of the machine is shown in Fig. 3. The machine does not need to be fa- stened. It must be placed on a floor capa- ble of bearing its weight. By means of the adjustment screws at the machine base, horizontally align the tenon cutting machine with a spirit level placed on the workpiece support. Then, screw down the 2 feet at the work- piece support table. Attach this table with the two provided hexagonal screws SW 13 to the machine, arranging it so that both support surfaces are aligned in height with each other, and the two vertical feed edges fall in line.

2.3 Electrical connection

The machine is delivered fully wired and operative. The wiring diagrams are to the be found in the control cabinet. It is connected to the electrical power sup- ply via the 16A-CEE socket at the right of the control cabinet. As a minimum require- ment, the supply line must comply with H07 RN-F and have a cross-section of 5 x

When connecting the machine, make sure that the operating voltage is 400 V and the frequency between 50 and 60 Hz. The ac- tual voltage may be somewhat above or below the above operating voltage as long as a tolerance range of ± 10 % is not ex- ceeded. Slow 16-A fuses must be provided as operative backup fuses by the custo- mer. – 32 – When operated out of doors, the machine must be protected from the rain. It must not be operated in an hazardous environment. All work to the electrical system must only be done by a qualified electrician. Caution: After installing the machine, it is imperative that you loosen the two 1 - Abb. screws (no. 2 - Fig. 1) to remo- ve the transport device (no.

Abb. 1). Otherwise, the milling unit will collide with this part in the course of its stroke! The machine must not be lifted or transported with a crane or other hoisting gear, but only with a fork-lift truck.– 33 – Furthermore, observe the correct sense of rotation of the milling tool. To check it, look through the workpiece feed-in opening: the tool must rotate anti-clockwise. If it does not, disconnect the connecting cable and change 2 phases in the socket (for example L1 and L2).

2.4 Dust extractor connection

The tenon cutting machine is intended for operation without dust extraction as well as for connection to an in-plant dust extractor system. To this end, it has 2 connection nozzles of 100 mm (3 15/16 in.) diameter each (no. 3 - Fig. 2). In case of operation in closed rooms, the machine must be connected to a dust ex- tractor system that allows for air speeds of no less than 20 m/s (65.6 ft/s) at both connection nozzles. The resulting vacuum amounts to 258 Pa. Flame retardant, fle- xible extraction hoses must be used whose cross-section up to the point of junction must be at least equal to that of the connection nozzles. After the junction, the cross-section of the hose must be at least 140 mm (5 1/2 in.). For outdoor operation or working briefly in closed rooms, the machine can be retrofit- ted so that the chips fall beneath it. To this end, the screws provided on both sides (no. 5 - Fig. 4) are loosened, and the shut- ters (no. 4 - Fig. 4) are opened. Retighten the screws afterwards. 3 Operation

– These Operating Instructions must be made known to all individuals commis- sioned to operate the machine. In parti- cular, their attention must be drawn to the section "Safety information". – You must check that all protection devi- ces have been installed and are operati- ve. – When operated in closed rooms, the ma- chine must be connected to an in-plant dust extractor system, and the air speeds at the connection nozzles must be at least 20 m/s (65.6 ft/s). The resulting va- cuum amounts to 258 Pa. Furthermore, ensure that the dust extractor system is automatically activated when the machi- ne is switched on. – The air speed must be checked on initial commissioning and after significant modi- fications. – The suction devices must be checked prior to initial commissioning, daily for obvious defects and monthly for their ef- fectiveness. – Ensure that the individual reversible kni- fes of the milling tool are tightened cor- rectly, and that the tool is fastened safely on the drive shaft. (See the section "Tool change" for the tightening torques.) – With the machine idling, check the milling tool for correct sense of rotation (see section "Electrical connection").

All setting elements of the electrical switch- gear of the machine are provided in the control cabinet at the operator station (see Fig. 5). The individual switches shown in Fig. 5 have the following functions: 6: Main switch: Disconnects the entire el- ectrical equipment from the mains. In position 0, it can be secured with a padlock. It has 2 switch positions: : 0: off (machine disconnected from the mains). Never reach into the running ma- chine via the open shutters, for example to removed a buildup of chips. Danger of touching the running milling tool! Before initial startup of the tenon cutting machine, it is imperative that you observe the following no- tes:: 1: on (machine is live and operative). 7: Operating mode selector switch: Is used to preselect an operating mode. The in- dividual switch positions have the follo- wing significance: : 0: Close curtain: The protection curtain closes. : 1: Setup mode: To check the preset pa- ths, the individual feed movements of the milling unit can be tested by means of the 4 pushbuttons (10). The movement continues as long as you keep the respective pushbutton pressed. It is not possible to switch on the drive of the milling tool. The protection curtain remains open. 2: Manual milling: Press the Start key and keep it pressed to close the pro- tection curtain and start up the mil- ling motor. Press the 4 pushbuttons to execute the individual feed movements of the milling unit. The unit only moves as long as you keep the respective pus- hbutton and the Start key pressed. When you release the Start key, the milling motor switches off immediate- ly, the feed movement is aborted, and the protection curtain opens au- tomatically. 3: Preselection for tenon cutting: All 4 feed movements are activated. 4: Preselection for flattening: Only the horizontal feed is activated. 8: Start pushbutton for enabling the mil- ling process: Depending on the selected operating mode (tenon or flattening), the process runs automatically. The milling tool dri- ve is switched off after it has returned to home position. When the positions "0" or "1" are selected at the operating mode selection switch, this start push- button is not active. 9: EMERGENCY STOP pushbutton: Aborts the milling process in case of danger, and aborts all movements. 10: Pushbutton for moving the milling unit in setup mode and during manual mil- ling: Press the respective pushbutton for each of the 4 feed movements X+, X-, Z+, Z+. The selected movement only continues as long as you keep the pushbutton pressed. 11: : Stop button for interrupting the mil- ling operation

3.3 Switching on and off

To switch the machine on, first set the main switch to position "1" and the opera- ting mode selection switch to the desired operating mode. Then, initiate the entire milling process by pressing the Start push- button. After completion of the process, the milling unit returns to home position where it is switched off automatically. The auto- matic brake reduces the slowing time to approx. 3 seconds. After that, the protec- tion curtain opens. That is to say that the machine switches off automatically. Use the EMERGENCY STOP pushbutton only for fast shutdown in an emergency.

3.4 Cutting straight tenons

Before machining, roughly cut off the work- piece. When cutting straight tenons, make sure that the pointer (no. 13 - Fig. 9) points to the value "0" at the indicator scale (no. 14) at the segment for tilting. If this is not the case, loosen the handle lever (no. 15). Now, you can tilt the entire milling unit with the housing to point to this value. After til- ting, re-tighten the handle lever. To set the tenon dimensions and for subse- quent machining, proceed as follows: – 34 – Never tilt the milling unit with the protection curtain closed!1. Set the operating mode selection switch (no. 7 - Fig. 5) to position "1" and fold open the lid of the machine housing.

2. Check or set tenon length "t" (see Fig.

6) at the milling tool (see section 4.1,

3. Press the pushbuttons "Z-" and "X-"

(no. 10 - Fig. 5) to move the milling unit to home position.

4. Set the tenon thickness "Z2" (see Fig.

6) by shifting the clamping ring (no. 19

- Fig. 11). To do so, first loosen the clamping lever (no. 43 - Fig. 11). The pointer must point to the value for the desired tenon thickness on the scale (no. 20). Then, re-tighten the clamping lever (43).

5. By pressing the pushbutton "Z+",

move the milling unit up until the spiral dowel sleeve (no. 16 - Fig. 10) no longer bears down on it. Then, loosen the clamping lever (no.

on "Z1" (Fig. 6) is indicated on the scale (no. 18) between the lower edge of the tenon and the lower edge of the workpiece. Then, re-tighten the clam- ping lever (no. 15).

6. To ensure that the tenon starts at the

edge of the workpiece, check that the value "0" is indicated at the edge of the housing on the scale (no. 12 - Fig. 8). If this is not the case, adjust the va- lue accordingly with the hand wheel (no. 11).

7. By turning the hand wheel (no. 21 -

Fig. 12), adjust the horizontal path of the milling unit in such a way that the position indicator shows at least the width of the workpiece. We recom- mend to add a safety margin of some mm to this value.

8. Press the pushbutton "Z-" to return the

and close the lid of the machine housing.

9. For one-sided tenons, loosen the

handle lever (no. 27 – Fig. 15) to set the double stop plate in such a way that the pointer (no. 28) points to the finished timber length without tenon length "t" (see Fig. 6) on the scale (no. 29). Re-tighten the handle lever. Lay the workpiece against the contact edge of the workpiece support and in- sert it into the slide-in opening. Fold down the front stop shutter (no. 30 - Fig. 15) and push the workpiece against it. Then, fix the workpiece with the screw clamp (no. 26 - Fig. 14). Press the Start pushbutton (no. 8 - Fig. 5). The protection curtain closes. The milling head automatically follows the preset tenon contour. Simultaneously, the te- non is chamfered. After completion of the cycle, the mil- ling motor returns to home position and is switched off. The protection cur- tain opens automatically.

10. For double-sided tenons, set the work-

piece length as described above in

section 9. Additionally, set the knurling

screw (raw timber stop) in the rear shutter to the tenon length pursuant to the scale at the double stop. Lock it with the clamping screw (no. 32). Lay the workpiece against the contact edge of the workpiece support and in- sert it into the slide-in opening until it hits the raw timber stop. Clamp down the workpiece and cut the first tenon. After the milling tool has come to a standstill, loosen the clamp, reverse the workpiece until it touches the front stop with the base surface (not the te- non), and clamp it down. Then, cut the second tenon. – 35 –3.5 Cutting straight shouldered tenons Also with this type of tenon, it is important to check that the pointer (no. 13 - Fig. 9) points to the value "0" at the indicator scale (no. 14) at the segment for tilting. To set the tenon dimensions and for subse- quent machining, proceed as follows:

1. Perform the steps 1 to 5 described in

2. By turning the hand wheel (no. 11 - Fig.

8) at the edge of dimension "X1" (see

12), set the horizontal path of the mil- ling unit in such a way that the position indicator shows the width of the tenon + the shoulder dimension "X1". Example: For a desired tenon width of 10 cm and a shoulder dimension of 3 cm, set the pointer to a dimension of 13 cm.

4. Perform the steps 8 to 10 described in

To set the tenon dimensions and for subse- quent machining, proceed as follows:

Loosen the handle lever (no. 15 - Fig. 9) and tilt the milling unit until the pointer (no. 13) points to the finished angle on the scale (no. 14). Then, re-tighten the handle lever.

2. Set the operating mode selection switch

(no. 7 - Fig. 5) to position "1" and fold open the lid of the machine housing.

3. To set the tenon dimensions "t" and

"Z2" and the distance "Z1" (see Fig. 6) between lower edge of tenon and lower edge of workpiece, follow the steps de- scribed in paragraph 2 to 6 of section

ling unit by means of the hand wheels (no. 11 - Fig. 8) and (no. milling unit 12). First, use the hand wheel (no. 11 - Fig.

8) to set the face-grinding dimension "0"

or the shoulder dimension "X1" as de- scribed under 3.5.2. Now, using the handwheel (no. 21 - Fig. 12) set the ho- rizontal path as described in 3.5.3

5. Press the pushbutton "Z-" to return the

milling unit to the lower end position. Then, set the operating mode selection switch (no. 7 - Fig. 5) to position "3" and close the lid of the machine housing.

6. Lay the marked workpiece against the

contact edge of the workpiece support und insert it into the slide-in opening un- til the mark is aligned with the 0 position (Fig. 14), which correspond to the line projection of the laser. Then, fix the workpiece with the screw clamp (no. 26 - Fig. 14).

7. Press the Start pushbutton (no. 8 - Fig.

5). The protection curtain closes. The milling head automatically follows the preset tenon contour, including face- grinding and producing a shoulder. Si- multaneously, the tenon is chamfered. After completion of the cycle, the milling motor returns to home position and is switched off. The protection curtain opens automatically.

3.7 Cutting vertical tenons

The machine design also allows for cutting vertical tenons (see Fig. 17). Note that this type of machining is only suitable for maxi- – 36 – Never tilt the milling unit with the protection curtain closed! Important: Before machining, the workpiece must be cut diagonally in accordance with the desired angle! Never tilt the milling unit with the protection curtain closed!– 37 – mum workpiece heights of 160 mm (6 1/4 in.). Also with this type of tenon, it is impor- tant to check that the pointer (no. 13 - Fig.

9) points to the value "0" at the indicator

scale (no. 14) at the segment for tilting. To set the tenon dimensions and for subse- quent machining, proceed as follows:

1. Set the operating mode selection switch

(no. 7 - Fig. 5) to position "1" and fold open the lid of the machine housing.

2. Check or set tenon length "t" (see Fig.

17) at the milling tool (see section 4.1,

3. Press the pushbuttons "Z-" and "X-"

(no. 10 - Fig. 5) to move the milling unit to home position.

4. To ensure that the tenon extends over

the whole height of the workpiece, ad- just the clamping ring (no. 19 - Fig. 11) so that the pointer attached to the clam- ping ring points to the workpiece height on the scale (no. 20).

5. Press the pushbutton "Z+" to move the

milling unit up until the spiral dowel sleeve (no. 16 - Fig. 10) no longer be- ars down on it. To have the tenon start at the bottom workpiece surface, loosen the clamping lever (no. 15) and shift the adjustment disk (no. 17) until the value “0“ is indicated on the scale (no. 18). Then, re-tighten the clamping lever (no. 15).

6. By turning the hand wheel (no. 11 - Fig.

8, set the dimension "X1" (see Fig. 17) at the edge of the housing pursuant to the scale (no. 12).

7. By turning the hand wheel (no. 21 - Fig.

12), set the horizontal path of the mil- ling unit in such a way that the position indicator shows the width of the tenon "d" + the dimension "X1" (see Fig. 17). Example: For a desired tenon width of 4 cm and an edge distance of 8 cm, set the pointer to a dimension of 12 cm.

8. Perform the steps 8 to 10 described in

Cut the workpiece to the exact angle and length. During flattening (see Fig. 7), the path of the milling unit is limited to the hori- zontal movement required for this type of machining. This speeds up machining and saves time. To set the flattening dimensions and for subsequent machining, proceed as follows:

1. Check whether the indicator (no. 13 -

Fig. 9) points to the value "0" at the indi- cator scale (no. 14) at the segment for tilting. If this is not the case, loosen the handle lever (no. 15) to correct the posi- tion of the segment for tilting accordingly.

2. Set the operating mode selection switch

(no. 7 - Fig. 5) to position "1" and fold open the lid of the machine housing.

4. Press the pushbuttons "Z-" and "X-"

(no. 10 - Fig. 5) to move the milling unit to home position.

5. Press the pushbutton "Z+" to move the

milling unit up until the spiral dowel sleeve (no. 16 - Fig. 10) no longer be- ars down on it. Then, loosen the clam- ping lever (no. 15) and shift the adjust- ment disk (no. 17) until the desired flat- tening dimension "Z1" is indicated on the scale (no. 18) (see Fig. 7). Then, re- tighten the clamping lever (no. 15).

6. To ensure that the flattening starts at

the edge of the workpiece, check that the value "0" is indicated at the edge of Never tilt the milling unit with the protection curtain closed! Never tilt the milling unit with the protection curtain closed!the housing on the scale (no. 12 - Fig. 8). If this is not the case, adjust the va- lue accordingly with the hand wheel (no. 11).

7. By turning the hand wheel (no. 21 - Fig.

12), set the horizontal path of the mil- ling unit in such a way that the position indicator shows at least the width of the workpiece. We recommend to add a sa- fety margin of some mm to this value.

8. Press the pushbutton "Z-" to return the

milling unit to the lower end position. Then, set the operating mode selection switch (no. 7 - Fig. 5) to position "4" and close the lid of the machine housing.

9. For flattenings, loosen the handle lever

(no.27 - Fig. 15) and set the double stop plate in such a way that the pointer (no. 28) points to the finished timber length without flattening length "t" on the scale (no. 29) (see Fig. 7). Re-tigh- ten the handle lever. Lay the workpiece against the contact edge of the workpie- ce support and insert it into the slide-in opening until it hits the front shutter of the double stop plate. Then, fix the workpiece with the screw clamp (no. 26 - Fig. 14).

10. Press the Start pushbutton (no. 8 - Fig.

5). The protection curtain closes. The milling head automatically follows the preset flattening contour. After comple- tion of the cycle, the milling motor re- turns to home position and is switched off. The protection curtain opens auto- matically.

11. Lay the marked workpiece against the

contact edge of the workpiece support and insert it into the slide-in opening until the mark "t" is aligned with the 0 position (corresponds to the line pro- jection of the laser). Observe the maxi- mum machining length of 110 mm (4 3/8 in.) per work step. Now, fix the workpiece with the screw clamp (no.

The ZAF 250 Vario has the option to redu- ce the feed rate of the feed motors to 50% of the regular rate. To select this setting, turn the potentiome- ter on the top left of the control panel. 4 Tooling and maintenance

The milling tool delivered with the tenon cutting machine has been developed spe- cifically for this machine. It consists of the cutter head (no. 37 - Fig. 18) and the cut- ter ring (no. 38) fitted with replaceable hard metal reversible knifes. This eliminates the need for labour- and time-intensive sharpe- ning of the tool: When the hard metal re- versible knifes are dull, they only require reversing or replacing. Proceed as follows:

1. Check whether the indicator (no. 13 -

Fig. 9) points to the value "0" at the indi- cator scale (no. 14) at the segment for tilting. If this is not the case, loosen the handle lever (no. 15) to correct the posi- tion of the segment for tilting accordingly.

2. Set the operating mode selection switch

(no. 7 - Fig. 5) to position "1". – 38 – Before starting to do any mainte- nance work, either switch off the main switch and protect it against accidental re-activation, or dis- connect the power plug! Never tilt the milling unit with the protection curtain closed! Per work step, the blade length "t" can be max. 110 mm (4 3/8 in.). For longer blades, machining must be divided into several steps. (The rear shutter of the double stop plate may possibly be used).3. By pressing the pushbuttons (no. 10 - Fig. 5), to move the milling unit so that it is positioned in the centre of the slide-in opening.

4. To hold up, insert the pin (no. 39 - Fig.

18) into the provided bore of the cutter

head. With the Allen key SW 10 (no. 40), unscrew the clamping screw (no.

5. Loosen the bolted hard metal reversible

knifes with the provided Allen key, turn them by 90°, and re-tighten them to 4 Nm. After three reversals, replace them by new reversible knifes.

6. For tenon cutting, loosen the cutter ring

(no. 38) and shift it on the cutter head (no. 37) until the front edge of the cutter ring points to the desired tenon length "t" on the scale provided on the cutter head (see Fig. 6). Then, re-tighten the cutter ring to 15 Nm. For flattening, re- move the cutter ring completely. Thanks to the distortion lock between the two parts, it can only be removed in one direction.

7. Remove any clinging chips and dust

from the tool spindle and the clamping surfaces and position the tool. Ensure that the two driving pins at the spindle engage with the two bores of the tool. Screw in the clamping screw (no. 41) with the clamping disk (no. 42) and tighten it.

8. Press the pushbuttons "Z-" and "X-"

(no. 10 - Fig. 5) to move the milling unit to home position.

4.2 Machine servicing

Clean the machine regularly to extend its useful life, avoid unnecessary repairs, and meet the requirements for excelling cutting and milling quality. The MAFELL tenon cut- ting machine is designed to require little maintenance and care. Depending on the degree of soiling, it should be cleaned at least once per week. This goes in particu- lar for the guides of the milling unit and the spindles for the dimensions setting func- tions. Remove any clinging chips and dust with a vacuum cleaner. To remove any residual resin, it is advisable to use a resin-solving detergent. It is imperative that you wipe all parts treated in this way with an oil-moi- stened rag to avoid the formation of rust. To prevent excessive motor heating, regu- larly check that the ventilation slots are not clogged by dust. Always use a vacuum cle- aner for dust removal; blowing off the dust would direct it into the interior of the motor. Use a grease gun to grease the feed spindle nuts with acid-free grease at the two provided nipples when necessary. The provided ball-bearings have a lifetime lubrication and normally do not require any maintenance. For all grease point, only use our special grease, order no. 049040 (1 kg tin). After a long period of operation, we recom- mend to have the machine checked by MAFELL service technicians.

All resin should be regularly cleaned off the milling tool as clean tools help to improve the quality of the cuts. Do not use heavily alkaline agents. Only clean the tool with acid-free detergents. To remove the resin from the milling tool, deposit it for 24 hours in petroleum or another commercially avai- lable deresinification agent.