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Stuga Machinery Environmental Considerations + (This section of the manual addresses the environmental considerations relevant to the use of the machine)
TB0421 Balluff OBEAM Sensor Information + (This technical bulletin is for the Balluff BOS01FN sensor. Stuga part number is E0001139. Please see pictures below:)
Standalone Saw Safety Circuit Fault Finding + (This tutorial will guide you through how to find a fault on a safety circuit on all revisions of the Standalone Saw machine.)
Microline Safety Circuit Fault Finding + (This tutorial will guide you through how to find a fault on a safety circuit on all revisions of the Microline machine.)
Flowline Safety Circuit Fault Finding + (This tutorial will guide you through how to find a fault on a safety circuit on all revisions of the Flowline machine.)
Ecoline Safety Circuit Fault Finding + (This tutorial will guide you through how to find a fault on a safety circuit on all revisions of the Ecoline machine.)
Autoflow Safety Circuit Fault Finding + (This tutorial will guide you through how to find a fault on a safety circuit on all revisions of the Autoflow machine.)
Upgrade ZX Machine to Beckhoff Drives and Control + (This tutorial will provide a step by step guide on how to upgrade a ZX style machine to have Beckhoff drives and control system.)
Updating the Touchscreen Driver + (This tutorial will walk you through how to update the touchscreen driver on any machine with either one or two touchscreens.)
Catégorie:Operation + (Tutorials on Machine Operation)
Upgrade Options - Windows 7 Beckhoff Front End + (Upgrade Options for Stuga Machine Type TP431)
WinMulti Software Upgrade - Skip Initialise + (Upgrade to machine control software to allow restart from Emergency Stop without reinitialise)
TB0250 Fault Finding Welding Issues + (Welding Issues - particularly with Y notches - can have a number of root causes outside the Stuga Machine. This checklist identifies a number of potential root causes that have been regularly known to occur)
Autocut Piece Jammed + (What to do if a small offcut is trapped int he machine leading to errors)
Pneumax Valve Bank Recycling + (Which components to send back to Stuga for recycling)
ZX5 Clamp and Gripper Height Changes for Tall Profile + (With the correct model and spec the ZX5 is … With the correct model and spec the ZX5 is able to take some tall profiles above 90-95 mm tall. To be able to take any profile bar above 90mm in height, certain manual mechanical changes and adjustments are required to the saw outfeed clamp and the grippers, by the operator / maintenance engineer, before being able to put a tall profile through the machine. The below guide shows how to carry out these adjustments. shows how to carry out these adjustments.)
Catégorie:Production + (Work Instructions for Machine Assembly)
TB0445 ZX5 Setup - Infeed Measure Sensor Calibration + (ZX5 Setup - Infeed Measure Sensor Calibration)

TB0287 Importance of Outfeed Clear Sensor + (Following an H&S Incident (0005 – Nova … Following an H&S Incident (0005 – Nova Profile Ejecting), all flowlines and ZXs need to be checked to ensure the “Outfeed Clear” sensor is working. The incident proved that if the sensor fails, the outfeed may not be clear and hence the profile can be pushed back through the machine.rofile can be pushed back through the machine.)

TB0436 Creating a Backup Through WinMulti + (A backup zip folder of all necessary files can be created in WinMulti. By pressing the backup button (F11) and navigating to the backup’s folder (C:\multi\backup) a machine backup will be created.)
TB0418 Use of Plastic Reinforcing On Stuga Machines + (As the development of uPVC systems has adv … As the development of uPVC systems has advanced, there is greater and greater use of pre-reinforced profile on Stuga machinery. The profile is often made of a recycled plastic and is inserted into full lengths of profile. It is fixed using a series of staples along the length. The machines were not originally designed with this in mind. We have experienced four serious issues from testing this system in the field.ues from testing this system in the field.)
R0015091 Mount Outfeed Beam Sensor + (Assembly and fitting details for material clear outfeed sensor assembly)
R0015060 Bench Assemble Flapper Beam + (Bench assembly details for sensor rail)
Case Study - Saw Jamming due to Y Notch at End Of Bar Offcut Length + (Case study of profile jamming due to Y notch at the end of the bar)
Stuertz Infeed - Changes made to Version 1-GB Table + (Changes made on Version 1 GB machine to interface with Autoflow Mk4)
RMZX503 ZX5 Guard To Floor Height + (Closing the guard to floor height on a ZX5 machine to prevent users crawling under guard)
Commissioning - Z-Block Calibration + (Commonly used during sawing on Z transoms, the Z block operation is used to fasten the profile, making sure it does not move during sawing.)
TB0247 Safety Gate Distances on Autoflow + (Confusion surrounds the parameter values needed to ensure the end of a bar length does not clash with the safety gate)
R0015293 Install Flap Sensor Beam + (Correct installation , setting and quality checks for installation of material sensor beam)
Adding a new machine on Monday + (Correct procedure to add a new machine on Monday and creating the associated Contract for the warranty)
Ecoline Refurb SubStore Instructions + (Correct procedures for efficient working of the Ecoline Sub Store Stock)
TB0394 Fitting Ultrasonic Sensor to Flowline OCLEAR + (Currently, the Flowlines have an m12 barre … Currently, the Flowlines have an m12 barrel sensor fitted for the OCLEAR sensor. After research and updates to new machines, we have found that fitting an ultrasonic sensor is much more reliable and effective at picking up different profile colours. For this reason, we have created an upgrade kit to enhance the functionality of the OCLEAR sensor.ce the functionality of the OCLEAR sensor.)
Autocut Daily Maintenance + (Daily maintenance tasks on a Stuga Autocut machine)
TB0315 Fitting Autoflow Dark Profile Sensor + (Dark windows profiles were sometimes not picked up by the photoelectric sensors, resulting in incorrect length measurements, and errors on the machine.)
Training Ultrasonic Sensor + (Describing a common problem with setting the ultrasonic sensor where the minimum range is set less than 30mm - the sensor will not work)
TB0390 Fitting SR Datum Sensor + (Due to the SR Axis losing its datum position an additional datum sensor is to be fitted.)
TB0331 Idle Time Overrun Message + (Error message appears on screen to operator. “Idle Time Overrun – Contact Stuga”. It is not clear what this message means or what could be the root causes.)
TB0238 Fault Finding 300Hz Spindles + (Faults on the 300Hz spindle circuit have p … Faults on the 300Hz spindle circuit have proved to be very difficult to trace. There symptoms are quite straight forward, but failing to find the real root cause has created huge costs in revisits and destroyed components. It is vital that all root causes are examined and eliminated, as there is often more than one root cause and very often they are intermittent.ause and very often they are intermittent.)
R0015332 Mount Backfences and Align + (Fitting and setting details for back fences)
TB0287 Importance of Outfeed Clear Sensor +
Reducing Saw Cut Height for Lower Profiles + (For sawing modules running from winMulti ( … For sawing modules running from winMulti (including flowlines with integrated control), there is an option to reduce the cut height. This is managed through an additional sensor on the saw cut stroke cylinder. This is particularly useful on saws with a 500mm blade (to cut wide or tall profiles) but a reduced cycle time can be gained by reducing the saw cut stoke time by limiting its travel on shorter profilesby limiting its travel on shorter profiles)
RMZX502 Infeed Protection + (Guard panel modifications to prevent access to dangerous areas of machine)
VM Upgrade Hardware + (Hardware Upgrade for Virtual Machine)
Adding Machine Build Number to Label + (How to add the machine build number to a label created by 3rd Party Software company)
Back Polish Stuga Saw Blades + (How to back polish a Stuga saw blade)
Troubleshoot - Permanent IP Address - Windows 8 + (How to change or create a permanent IP address on a Windows 8 machine.)
ZX5 Adjusting V Notch Depth and Position + (How to change the depth and position of the V notch on a ZX5 machine)
Changing Main Saw Blade + (How to change the main saw blade on a Stuga machine)
ZX5 Alignment Check + (How to check and correct the alignment of a ZX5 machine)
Autoflow PC Cleanup + (How to clear up any temporary or historical files that may slow the PC down)
Create a TwinCAT Project from Existing Project + (How to create a TwinCAT project from an existing project on a similar machine)
Device Magic - Adding a Device Email Address + (How to ensure an email address is in place for an engineer's device)
Monday - Emails to Updates + (How to ensure supplier / customer emails are automatically recorded on Monday Jobs / Items)
Increasing Waste Amount for Specific Profiles + (How to ensure the optimiser wastes a set amount of profile from the end of every bar)
Accessing Machine Location from a job + (How to find a machine / customer location from an assigned job)
Z Transom Width Measurement + (How to measure the width of a Z section profile)
Autocut Open Guard Doors + (How to open the doors on a Stuga Autocut machine)
Reporting Faults On Stuga Machines - Best Practice + (How to report machine issues to Stuga to enable fast and efficient resolution of a fault)
Common Issue - Critical Saw File AQS is corrupt + (How to restart machine after "Critical Saw Queue File ..... is Corrupt. Please check the saw queue carefully")
Decommissioning - Autoflow Mk4 1 + (How to safely decommission and load a Stuga Autoflow Mk4.1 machine)
Autocut Startup Procedure + (How to safely switch on and startup a Stuga Autocut Machine)
Setting Ultrasonic Sensor - Vertical + (How to set ultrasonic sensor to detect profile)
Flush Sash Compatibility additions + (How to set up a Stuga Flowline / ZX machine for Flush Sash modification)
Disabling a Tool Home or Tool Out Sensor + (How to temporarily disable a tool out or tool home sensor in the winMulti control software)
Upgrading To Version 5 Software 64 bit + (How to upgrade a Nextmove / TwinCAT 3 machine to the latest Version 5 software (64 bit))
WinMulti - Changing The Colour Identification Box + (How to use the colour identification box to indicate profile colour and loading orientation)
Viewing Camera Footage from Hikvision Cameras + (How to view the live footage and stored data from a Hikvision camera on a Stuga machine)
Stuga Gripper Insert Identification + (Identification aid for Stuga Machine Grippers)
TB0399 Fitting Spindle Plunge End Stop on ZX + (If the plunge cylinder fails on the spindle, the entire assembly can come off the end of the bearing rail and fall into the centre of the spindle ring, causing more damage)
R0000712F Rotary Trunking + (Installation of rotary energy chain and back plates)
R0000712E Rotary Trunking + (Installation of rotary energy chain and back plates)
R0015082B fencing and guards + (Instruction for assembly and mounting of machine guarding)
R0015080 Bench Assemble Sensor Rail + (Instructions for bench assembly of sensor rail components)
R0002794E Mount Width sensor + (Instructions for correct mounting and set up of width sensor assembly)
TB0387 Windows 10 to Windows 8 Connection Issues + (Issue connecting to the Windows XP machine on F060.)
TB0269 Proving Accuracy Variation due to Ambient Temperature + (It has long been known that profile lengths grow and shrink with thermal expansion. This bulletin explains a method used to visually prove that this is a root cause of accuracy issues)
Recommended Lubricants + (Lubrication is essential for reliability and extended life of your Stuga machine)
ZX4 Machine Centre Outfeed + (Machine centre outfeed operation)
Install markings and measurements ZX5 + (Markings and measurements required by the … Markings and measurements required by the Install team, after a machine commission. This helps towards a smoother install process, getting the machine module positions and fencing to be in the same place (or close to) as they were during the commission at stuga base. were during the commission at stuga base.)
90mm Z Profile Modifications + (Modification necessary to allow 90mm tall profile Z sections to be handles by Stuga Machines Liniar LCW9022)
R0015085 Mount SR Datum Sensor and Flag + (Mounting details for SR axis flag and sensor)
Move SR Datum Sensor to Higher Level R0019217 + (Moving the SR axis datum sensor to a higher level to prevent damage and improve reliability Autoflow Mk4 only)
PC Configuration - ZX E + (PC network configuration of the ZX3 / 4 following using a Windows Front End Pc and Beckhoff TwinCAT2 system running the back end on machining centre side. Windows PC with Nextmove ESB on Saw side)
PC Configuration - ZX F + (PC network configuration of the ZX3 / 4 following using a Windows Front End Pc and Beckhoff TwinCAT3 system running the back end for the whole machine.)
Outfeed Support Roller - Flowline + (Part code R0010276 - Extra support roller upgrade added to replace single roller on outfeed rear clamp.)
R0015279 Align Backfences + (Procedure for correct alignment of module E back fences and channel bar)
Autoflow Maintenance - Outfeed Table + (Procedures for Daily, Weekly and monthly maintenance on Autoflow Outfeed Table)
Saje uPVC Unloading Process + (Process for unloading and locating Autoflow Mk4 machine in Saje upvc)
R0015028D MC Outfeed X-axis Assembly ZX5 - 2021 + (R0015028D MC Outfeed X-axis Assembly ZX5 (2021))
CX5120 Replacement + (Replacement of a CX5120 on a customers machine.)
Ring Support under Pressure Loss + (Report of a near miss on an Autoflow machine when servicing)
TB0266 Grip released Sensor Upgrade + (Retrofitting Grip Released sensor on Autoflow)
Setting Ultrasonic Sensor - Horizontal + (Setting an ultrasonic sensor mounted horizontally)
X252 Forward Clamp Out Sensor Setup Stuertz Infeed + (Setting the laser distance sensor for the forward clamp out input (Vorlaufwagen))
Setting Profile Detection Laser Sensor + (Setting the laser sensor used on Flowline / ZX offcut sensors and Autoflow measurement sensors)
IP Camera Viewer exe Setup + (Setting up the freeware 4 camera viewer system IP Camera Viewer.exe for simple multiple camera views on a machine)
ZX4 Sensors + (Showing all major sensors on the ZX4 Machine)
Upgrade Autoflow to Windows 11 + (Steps to upgrading an Autoflow to Windows 10, replacing both the front end and back end PCs)
Hotswap Beckhoff PLC with Licence Slice Installed + (Swapping a Beckhoff PC on an machine with EL6070 Licence Slice installed)
TB165 C0001 Stepper Motor Obsolescence + (The C0001 stepper motor used on the G axis of flowlines and on all motors on the router has become obsolete. A replacement will be available using the same Stuga part number)
TB0407 Replacing Infeed Belt with Joined Belt + (The infeed belts on Flowlines and Ecolines require the disassembly of the infeed tables to replace the belts. Jointed belts will now be supplied when replacement required. These belts are cut and use threaded pins to join the ends into a continuous belt.)
Training Laser on Ecoline + (The laser on an Ecoline needs to be specially set up to measure the profile accurately)
TB0420 Obsolescence Note - Flowline Spindle Motors + (The original motor is no longer available, and a replacement has proved impossible to find due to the physical size of the motor)
TB0161 Fitting Outfeed Clear Sensor on ZX Machine + (The outfeed clear sensor that existed on Mk3 flowlines was not repeated on ZX machines. This leaves the machine vulnerable to crash.)
Throwaway Chutewidth and SmallestGrip + (The parameters work together to define the … The parameters work together to define the process that happens with the final offcut at the end of a bar when it is too small to be ejected onto the outfeed table. It is surprisingly complicated, particularly on an Autoflow machine where the final piece is gripped. machine where the final piece is gripped.)
TB0428 Phase Detection Relay + (The phase detection relay shuts the power down to the machine if one phase is missing, or if the voltage drops or exceeds a set threshold.)
TB0434 Setting Up Deep Y notches on ZX5 + (The saw “Y drive” on a ZX5 is limited in i … The saw “Y drive” on a ZX5 is limited in its depth range to +/- 20mm from the centreline of the profile, and 20mm from the backfence. This is fine for most normal Y notching, but there are combinations when a particularly deep Y notch is required. This process is also useful on an Autoflow where the SY axis distance is limited by the backfence / top clamp interference by the backfence / top clamp interference)
Understanding Output Timings Tab + (The winMulti software contains a system to monitor machine performance and a screen to view the details. It is accessed by tapping the service button, then selecting “Output Timings”.)
Specialised Settings for Beckhoff Drives + (There are a number of specialised settings that need to take place on the Beckhoff setup for a new machine.)
TB0411 Spindle Home Sensor Position + (There have been instances where the cylind … There have been instances where the cylinder rod on a spindle has sheared, dropping the spindle down into the path of the gripper. Because the cylinder is still sensed in the home position the machine head will continue to operate causing damage to the gripper. to operate causing damage to the gripper.)
ZX5 Gripper Energy Chain & Tray Setup + (Things to look out for and check when setting up ZX5 energy chains on the ZX5 MH Outfeed or Saw Infeed)
ZX5 Improvements and Upgrades + (This document is intended for existing users and owners of Stuga Flowlines to help explain the improvements and enhancements made to the flowline / ZX3 / ZX4 range of machines into out latest flagship product - the ZX5)
Installation Guide - ZX5 Electrical + (This guide is to be used for all of the electrical connections when installing a ZX5 machine.)
General Accuracy Guidelines for Engineers - Start Here + (This is the launch page for starting an accuracy journey on any Stuga machine. It contains general principles to follow and signposts further procedures and pages to investigate further)
Important Information - Stuga Machinery + (This maintenance log is designed to be used in conjunction with the Stuga Daily, Weekly and Monthly maintenance procedures. These maintenance procedures are essential to the function of the machine and must be carried out.)
TM016 Arrow Head Adjustment on Saw + (This module guides the engineer on how to correctly adjust the centralising mechanism on Stuga saws. The engineer will need a reasonable mechanical knowledge, and a working knowledge of the operation of the machine.)
TM003 Flowline Overview + (This module should give the trainee a gene … This module should give the trainee a general understanding of the concepts behind the original "Flowline" and "ZX4" and how the machine is broken down into simple sub-systems. The module is aimed at anyone who wishes to know the machine in more depth than an operator, and is the basis for further modules.tor, and is the basis for further modules.)
WinMulti - Postest + (This page will describe how to generate a Postest (operation position test), and is used to set the distance relationship between the routed holes and the saw blade so that routed pieces line up correctly back to back.)
WinMulti - Adding Cuts to the Manual Input Piece + (This page will instruct the operator in the correct Procedure to add cuts to the manual input profile.)