Hyd-Mech H18 A, H22 A User Manual
H18 A & H22 A
395598
REV G
THANK YOU,
On behalf of everyone at HYD·MECH Group Limited, we would like to thank and congratulate you on your decision to
purchase a HYD·MECH bandsaw.
Your new machine is now ready to play a key role in increasing the eciency of your operation, helping you to reduce cost
while boosting quality and productivity.
To ensure you are maximizing the power and versatility of your new HYD·MECH bandsaw, please take the time to
familiarize yourself and your employees with the correct operation and maintenance procedures as outlined in this
manual. Please keep this instruction manual for future reference in a known location and easily accessible to all users of
the device.
HYD·MECH oers a great variety of options, components, and features for its various models. Therefore, some of the
equipment described in this manual (various illustrations and drawings) may not be applicable to your particular machine.
The information and specications provided in this manual were accurate at the time of printing. HYD·MECH reserves the
right to discontinue or change specications or design at any time without notice and without incurring any obligation.
Thank you.
Hyd·Mech Group Limited
P.O. Box 1659, 1079 Parkinson Road
Woodstock, Ontario, N4S 0A9
Phone : (519) 539-6341
Service : 1-877-237-0914
Sales : 1-877-276-SAWS (7297)
Fax : (519) 539-5126
e-mail : info@hydmech.com
Printed SEPTEMBER 2014
1
TABLE OF CONTENTS
SECTION 0 - SAFETY INSTRUCTIONS
SUMMARY .......................................................................................................................................0.1
BASIC RULES ..................................................................................................................................0.3
RESPONSIBILITIES OF THE OWNER ............................................................................................0.3
RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL ...........................0.4
SAFETY HAZARD LABELS .............................................................................................................0.6
SECTION 1 - INSTALLATION
SAFETY PRECAUTIONS .................................................................................................................1.1
LIFTING INSTRUCTIONS ................................................................................................................1.2
FOUNDATION, LEVELLING AND ANCHORING .............................................................................1.3
WIRING CONNECTIONS .................................................................................................................1.3
EARTH GROUNDING PROCEDURE ..............................................................................................1.4
HYDRAULIC OIL AND CUTTING FLUID .........................................................................................1.4
SECTION 2 - OPERATING INSTRUCTIONS
BLADE BASICS................................................................................................................................2.1
VARIABLE SPEED CONTROL.........................................................................................................2.1
THE CONTROL PANEL ...................................................................................................................2.1
MANUAL OPERATION .....................................................................................................................2.1
PLC 100 CONTROL SYSTEMS .......................................................................................................2.4
OPERATION OVERVIEW ................................................................................................................2.4
FUNCTION KEY DESCRIPTIONS ...................................................................................................2.5
MANUAL MODE FUNCTION KEY DESCRIPTIONS .......................................................................2.5
SINGLE PART CYCLE OPERATION ...............................................................................................2.6
KERF CORRECTION .......................................................................................................................2.6
AUTOMATIC OPERATION ...............................................................................................................2.7
SHUTTLE EMERGENCY STOP ......................................................................................................2.9
HYDRAULIC FEED CONTROL ........................................................................................................2.9
CUTTING PARAMETERS CHART ..................................................................................................2.10
ADDITIONAL CONTROLS ..............................................................................................................2.16
COOLANT FLOW ............................................................................................................................2.16
HEAD UP and DOWN LIMIT SETTING ..........................................................................................2.17
VARIABLE VISE PRESSURE (OPTION) .......................................................................................2.17
BUNDLING OPERATION (OPTION) ..............................................................................................2.18
SECTION 3 – MAINTENANCE
SAFETY DURING MAINTENANCE AND TROUBLESHOOTING ....................................................3.1
LOCK OUT PROCEDURE ...............................................................................................................3.1
BLADE CHANGE MODE PROCEDURE ..........................................................................................3.2
BLADE REMOVAL............................................................................................................................3.3
BLADE INSTALLATION ....................................................................................................................3.3
BLADE BRUSH ADJUSTMENT .......................................................................................................3.4
i
BLADE TRACKING ADJUSTMENT .................................................................................................3.4
IDLER WHEEL TRACKING ..............................................................................................................3.4
DRIVE WHEEL TRACKING .............................................................................................................3.5
GEARBOX LUBRICATION (H-18ASV A503 GEARBOX, H-22ASV A603 GEARBOX) ...................3.5
OUTPUT SHAFT LUBRICATION .....................................................................................................3.5
CAM FOLLOWER ADJUSTMENT ...................................................................................................3.6
LUBRICATION ..................................................................................................................................3.6
HYDRAULIC MAINTENANCE ..........................................................................................................3.7
CLEANLINESS .................................................................................................................................3.7
TROUBLESHOOTING .....................................................................................................................3.8
PROGAMMABLE LOGIC CONTROL ..............................................................................................3.10
PLC PARAMETERS ........................................................................................................................3.11
PLC TROUBLESHOOTING ............................................................................................................3.13
MITSUBISHI FX2N 48MR INPUTS AND OUTPUTS ......................................................................3.18
M12 PIN ASSIGNMENTS FOR I/P & O/P DEVICES .....................................................................3.19
PLC PARAMETER DEFINITIONS & VALUES ................................................................................3.22
SECTION 4 - ELECTRICAL
FOR ELECTRICAL SCHEMATICS SEE PDF ON ATTACHED CD ..................................................4.1
SECTION 5 - HYDRAULIC
HYDRAULIC SCHEMATICS AND PLUMBING DIAGRAMS: SEE PDF ON ATTACHED CD. .........5.1
HYDRAULIC COMPONENT LIST ....................................................................................................5.1
GLAND ASSEMBLIES......................................................................................................................5.2
PISTON ASSEMBLIES .....................................................................................................................5.2
SECTION 6 - MECHANICAL ASSEMBLIES
MECHANICAL ASSEMBLY DRAWINGS AND PARTS LIST: SEE PDF ON ATTACHED CD ...........6.1
SECTION 7 - OPTIONS
FOR OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD ......................................7.1
SECTION 8 - SPECIFICATIONS
H-18 ASV BANDSAW SPECIFICATIONS ........................................................................................8.1
H-22 ASV BANDSAW SPECIFICATIONS ........................................................................................8.2
H18SV & H22SV LIFTING INSTRUCTIONS....................................................................................8.3
H18SV LAYOUT ...............................................................................................................................8.4
H22SV LAYOUT ...............................................................................................................................8.5
WARRANTY .....................................................................................................................................9.1
SECTION 9 - WARRANTY
ii
SECTION 0 - SAFETY INSTRUCTIONS
SUMMARY
All persons operating this machine must have read and understood all of the following sections of this Manual:
Section 0 SAFETY
Section 2 OPERATING INSTRUCTIONS
However, as a memory aid, the following is a summary of the Safety Section.
Put Safety First
Mandatory Information – What operators and maintenance people must have read and understood.
Signatures – Everyone involved with this machine must sign to conrm they have read and understood mandatory
information.
Basic Rules – only use this machine when
• It is in good working order.
• All safety equipment is in place and functional.
• Operations are in compliance with this manual.
• Materials are within designed specications and are non-hazardous.
Owner is responsible to
• Keep Manual accessible at the machine.
• Ensure only reliable, fully trained personnel work with the machine.
• Clearly dene responsibilities of all personnel working with the machine.
• Keep the machine in good working order.
Operator and Maintenance Personnel are responsible to:
• Keep all safety equipment in order, check its function at the beginning of each shift, and report any shortcomings.
• Shut down machine and report any faults or malfunctions that could impair safety.
• Understand and obey safety hazard labels.
• Not to wear un-restrained long hair, loose clothing or jewellery.
• Wear all required personal protective equipment.
• Not to wear gloves within 24 inches of moving blade.
• Maintain a clean working area and machine.
• Always use Lock-out when performing maintenance or repairs.
0.1
FOREWORD
Put Safety First!
This Safety Section contains important information to help you work safely with your machine and describes the dangers
inherent to bandsaws. Some of these dangers are obvious, while others are less evident.
It really is important to PUT SAFETY FIRST. Make it a habit to consider the hazards associated with any action BEFORE
you do it. If you feel any uncertainty, stop and nd a safer approach to the action. If you’re still uncertain, ask for advice
from your supervisor.
The SAFETY FIRST approach is particularly necessary when you do something new, or different, and most people
instinctively recognize this, although impatience may still cause them to take unnecessary risks.
Danger also lurks in the routine task that we have done over and over. Here, familiarity, boredom, or tiredness may lull us
into unthinking, automatic repetition. Be alert for this, and when you feel it happening, stop and take stock of your
situation. Review the safety hazards associated with what you are doing. That should get your brain working again.
Certainly production is important, but if you think you’re too busy to put safety rst, think how much production you’ll lose if
you get hurt.
You owe it to yourself, your family, and your co-workers to PUT SAFETY FIRST.
Mandatory Information
All persons operating this machine must have read and understood all of the following sections of this Manual:
Section 0 SAFETY
Section 2 OPERATING INSTRUCTIONS
Personnel involved in installation and maintenance of the machine must have read and understood all sections of the
manual
Persons who have difculty reading, or for whom English is not their rst language, must receive particularly thorough
instruction.
Signatures
Everyone involved in operation of this machine must sign below to conrm that:
I have read and understood all parts of Section 0 – Safety, and Section 2 – Operating Instructions.
Name Date Signature
Everyone involved in the installation, inspection, maintenance, and repair of this machine must sign below to conrm that:
I have read and understood all parts of this Operation and Maintenance Manual.
Name Date Signature
0.2
BASIC RULES
Intended Use
Exclusion of Misuse
Liability
Our machines are designed and built in line with the state of the art, and specically in accordance with
American National Standards Institute Standard B11.10 Safety Requirements for Metal Sawing Machines.
However, all machines may endanger the safety of their users and/or third parties, and be damaged,
or damage other property, if they are operated incorrectly, used beyond their specied capacity, or for
purposes other than those specied in this Manual.
Misuse includes, for example:
Sawing hazardous materials such as magnesium or lead.
Sawing work pieces which exceed the maximum workload appearing in the Specications.
Operating the machine without all original safety equipment and guards.
The machine may only be operated:
When it is in good working order, and
When the operator has read and understood the Safety and Operating Instructions Sections of the
Manual, and
When all operations and procedures are in compliance with this Manual.
Hyd-Mech Group cannot accept any liability for personal injury or property damage due to operator errors
or non-compliance with the Safety and Operating Instructions contained in this Manual.
RESPONSIBILITIES OF THE OWNER
Organization of work
This Operation and Maintenance Manual must always be kept near the machine so that it is accessible to
all concerned.
The general, statutory and other legal regulations on accident prevention and environmental protection
must also be observed, in addition to the Manual material. The operators and maintenance personnel
must be instructed accordingly. This obligation also includes the handling of dangerous substances and
the provision and use of personal protective equipment.
Choice and qualication of personnel
Ensure that work on the machine is only carried out by reliable persons who have been appropriately
trained for such work.
Training
Everyone working on or with the machine must be duly trained with regard to the correct use of the
machine, the correct use of safety equipment, the foreseeable dangers that may arise during operation of
the machine, and the safety precautions to be taken.
In addition, the personnel must be instructed to check all safety devices at regular intervals.
0.3
Dene responsibilities
Clearly dene exactly who is responsible for operating, setting-up, servicing and repairing the machine.
Dene the responsibilities of the machine operator and authorize him to refuse any instructions by third
parties if they run contrary to the machine’s safety.
Persons being trained on the machine may only work on or with the machine under the constant
supervision of an experienced operator. Observe the minimum age limits required by law.
Condition of Machine and Workplace
Ensure that the machine and its safety equipment are kept in good working order.
Ensure that the work area is well lit, and protected from the elements, such as rain, snow, abrasive dust,
and extremes of temperature.
Ensure that the machine is installed with sufcient clearance around it for the safe loading and unloading
of work pieces.
RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL
Safety equipment
All machines are delivered with safety equipment that must not be removed or bypassed during operation.
The correct functioning of safety equipment on the machine must be checked:
• At the start of every shift.
• After maintenance and repair work
• When starting for the rst time, and after prolonged shutdowns
Emergency Stop Button (E-Stops)
Always be aware of the location of the Emergency Stop Button(s). Do not allow material or objects to
block your access to an Emergency Stop.
Damage
If any changes capable of impairing safety are observed in the machine or its operation, such as damage,
malfunctions, or irregularities, then appropriate steps must be taken immediately, the machine switched
off, locked-out, and the fault reported to the responsible person.
Safe operation
The machine may only be operated when in good working order and when all protective equipment is in
place and operational.
Keep a safe distance from all moving parts – especially the blade and vises.
Stock should not be loaded onto the saw if the blade is running.
Long and heavy stock should always be properly supported in front of and behind the saw.
Faults
The machine must be switched off and locked-out before starting to remedy any faults.
Safety hazard labels
Safety hazard labels and other instructional labels on the machine must be observed. They must be
clearly visible and legible at all times. If they become damaged they must be replaced.
0.4
Clothing, jewellery, protective equipment
Personnel operating or working on the machine must not wear un-restrained long hair, loose-tting
clothes and dangling jewellery.
When operating or working on the machine, always wear suitable, ofcially tested personal protective
equipment such as safety glasses and safety boots and any other equipment required by plant
regulations.
Gloves
Experience has shown that careless use of gloves around machinery is a major factor in serious hand
injuries.
Gloves should not be worn when operating or adjusting the machine, except:
Wear protective gloves when handling bandsaw blades at blade changes.
Gloves may be worn when handling work pieces, only if the machine is in Manual Mode and the
bandsaw blade is not running.
If the machine is running in Auto Mode, and only if the cut parts are greater than 24 inches
long, it may be possible to safely wear gloves for handling the cut parts, but the wearer of the
gloves must never put his hands near the blade for any reason. If the cut parts are less than 24
inches long, it is required to arrange their automatic ow into a parts bucket or other suitable
arrangement to avoid the necessity to pick them off the machine by hand.
Hearing protection
Ear protection must be worn whenever necessary.
The level and duration of noise emission requiring hearing protection depends upon the national
regulations in the country in which the machine is being used.
The actual level of noise emission by band sawing machines depends upon work piece size, shape and
material, blade type, blade speed and feed rate.
The only practical course of action is to measure the actual noise emission levels for the type of work that
is typically done. With reference to national standards, decide upon the necessary hearing protection
required.
In the absence of such measurements, it is advisable for anyone exposed to long periods of moderate to
loud noise to wear hearing protection. It is important to understand that hearing loss is gradual and easily
goes un-noticed until it is serious and irreversible.
Workplace
A clear working area without any obstructions is essential for safe operation of the machine. The oor
must be level and clean, without any build-up of chips, off-cuts, coolant, or hydraulic oil.
The workplace must be well lit, and protected from the elements, such as rain, snow, abrasive dust, and
extremes of temperature
Nothing may ever be placed on, or leaned against the machine, with the obvious exception of the work
piece on the table and conveyor of the machine.
0.5
Master Disconnect
Lock-out the machine before undertaking any maintenance or repair work on it. ‘Lock-out’ refers switching
off the master electrical disconnect switch, and locking it out so that it cannot be switched on again
without authorization.
On Hyd-Mech machines the Master Disconnect Switch will be of one of four types:
• Rotary switch mounted in electrical control cabinet door and inter-locked with door.
• Rotary switch mounted on the side of the operator interface console.
• Lever switch mounted in separate box mounted on the machine.
• Supply disconnect switch supplied by user at installation and usually wall-mounted within sight of
the machine, depending upon local regulations.
In almost all jurisdictions, it is required that owners of industrial equipment establish and post
lock-out procedures. Know and use the lock-out procedures of your company or organization.
Residual Risks
The machine is still not completely de-energized if an electrical cabinet door type switch is
locked-out.
The line side of the disconnect switch itself remains energized.
Variable speed blade drives store dangerous voltage in their capacitors, and this requires time to
dissipate. After locking out power, wait 3 minutes before beginning to work on machine electrical
circuits.
If compressed air is supplied to the machine to power a mist lubrication system or other devices,
it should be disconnected, and any stored air pressure released before working on the machine.
The weight of individual machine components represents stored potential energy that can be
released if they fall when disconnected. Secure these components with adequate hoisting gear
before disassembly.
SAFETY HAZARD LABELS
The safety hazard labels attached to your machine represent important safety information to help you avoid personal injury
or death.
All supervisors, operators, and maintenance personnel must locate and understand the safety information associated with
each hazard label prior to operating or servicing the machine.
The safety hazard labels shown below are located at various positions on the machine to indicate possible safety hazards.
The location and re-order part number of all the safety labels associated with this particular model of bandsaw are indicated
at the end of this section of the manual. It is important to replace any safety hazard label that becomes damaged or illegible.
HAZARDOUS VOLTAGE INSIDE
Contact with high voltage may cause death or serious injury. Never perform
maintenance on, or near, electrical components until the machine’s electrical
power source has been disconnected. Lock-out power in accordance with your
company’s lock-out procedures before any such maintenance. The “Stop” or
“Emergency Stop” push button does not disconnect the machine’s power supply.
Hazardous voltage is still present in the machines electrical circuits.
The machine’s Electrical Disconnect Switch does disconnect voltage from the
machine’s circuits; however hazardous voltage is still present inside the main electrical cabinet, on the infeed (line) side of
the main fuses. Therefore keep hands and tools away from the infeed side of the control panel main fuses. If these fuses
need to be replaced, use a fuse puller.
Allow three minutes after locking-out power before opening any electrical enclosures. Your machine may be equipped with a
variable frequency drive that stores high voltage within its capacitors. Three minutes will allow sufcient time for this voltage
to safely discharge.
Never spray coolant directly at electrical components or cabinets.
0.6
PINCH POINT
MOVING BANDSAW BLADE WILL CUT
Do NOT operate with guard removed.
Do NOT place hands or ngers near moving bandsaw blade.
For blade changing, always follow the proper Blade Changing Procedure, as given in
Section 3 of this manual.
Machine parts may move without warning, either because the machine is operating automatically, or because another
person initiates the motion. Keep hands clear of all labelled pinch points, whenever the machine is running. Machine vises
can exert great force and cause severe injury. Keep hands clear of vises and work piece when vises are opened or closed.
Be aware that vise closing or opening may result in potentially dangerous work piece movement. Be aware also that the
opening motion of a vise may create potential pinch points.
MOVING PARTS CAN CRUSH AND CUT
Keep hands clear of chip auger. Lock-out power in accordance with your company’s lock-out procedures before attempting
to clear a jam in the chip auger.
Be aware that the chip auger may start unexpectedly, either because the machine is operating automatically, or because
another person initiates the motion.
If the chip auger is stalled because of a jam, it may start without warning when the jam is cleared, unless the machine power
is locked out.
0.7
Chip Augar
Item #: 391335
Item #: 391938
Item #: 391340
0.8
Fixed Vise
Item #: 392801
Item #: 391397
Shuttle Vise
Item #: 392801
0.9
SECTION 1 - INSTALLATION
Upon delivery of your new H-18/22 SV saw, it is imperative that a thorough inspection be undertaken to check for any
damage that could have been sustained during shipping. Special attention should be paid to the electrical and hydraulic
systems to check for damaged cords, hoses and uid leaks. In the event of damage caused during shipping, contact your
carrier to le a damage claim.
SAFETY PRECAUTIONS
The machine has been designed to give years of reliable service. It is essential that operators be alerted to the safe
operation of this saw and the practices to avoid that could lead to injury. The following safety rules are at the minimum
necessary for the safe installation, operation, and maintenance of the saw. Take every precaution for the protection of
operators and maintenance personnel.
• POWER HOOK-UPS AND REPAIRS SHOULD ONLY BE ATTEMPTED BY QUALIFIED TRADESMEN.
• THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK INTO
THE SAW. SECURE THE SAW TO THE FLOOR.
• THE AREA AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID
OBSTACLES OPERATORS COULD TRIP OVER.
• THE H-18/22 SV SHOULD ONLY BE OPERATED ACCORDING TO THE SPECIFICATIONS OF THE SAW.
AVOID UNSAFE USAGE PRACTICES.
• IF AT ANY TIME THE SAW DOES NOT APPEAR TO BE OPERATING PROPERLY IT SHOULD BE
STOPPED IMMEDIATELY AND REPAIRED.
OPERATOR :
• THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE IN PLACE AND
CLOSED.
• KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE AND VISES.
• LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING THE SAW. COVER LONG
HAIR.
• STOCK SHOULD NOT BE LOADED ONTO THE SAW IF THE BLADE IS RUNNING.
• LONG AND HEAVY STOCK SHOULD ALWAYS BE PROPERLY SUPPORTED IN FRONT OF AND BEHIND THE
SAW.
• NEVER ATTEMPT TO DISLODGE OR MOVE STOCK WHILE THE BLADE IS MOVING. TAKE THE TIME TO
STOP THE SAW BLADE, REMOVE OBSTRUCTIONS, AND START THE BLADE.
• MUST WEAR EYE PROTECTION.
• MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION, BLADE GUIDES, AND BEARINGS
• HOLD WORKPIECE FIRMLY AGAINST TABLE.
• DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED.
NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROM
HYD-MECH. ANY APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.
1.1
LIFTING INSTRUCTIONS
1.2
FOUNDATION, LEVELLING AND ANCHORING
The machine location should be carefully selected. A at
concrete oor area should be chosen. It should have enough
free space surrounding the machine to enable free access for
safe operation and maintenance.
Machine should be leveled in both directions i.e. along and
across its in-feed conveyor especially when machine is to be
inserted into a larger conveyor system.
Six leveling screws are provided, one in each corner of the
machine base plus one in the hydraulic cabinet. Steel plates
are to be placed under each screw to prevent their sinking
into the concrete oor. In cases where the machine is to be
anchored permanently, anchoring holes are provided. They
are located next to the leveling screws.
NOTE:
In some cases leveling the saw in-feed and auxiliary conveyor
with a slight slope towards blade is recommended. This will prevent coolant from running down the raw stock. (This is
especially true when cutting tubing or bundles).
WIRING CONNECTIONS
After the machine is leveled and anchored the necessary power hook-up needs to be performed. In order to provide safe
operation as well as to prevent potential damage to the machine, only qualied personnel should make the connections.
BEFORE START-UP THE FOLLOWING TWO POINTS SHOULD BE
CHECKED:
1. Signs of damage that may have occurred during shipping to the
electrical cables, conduits and the hydraulic hoses.
2. The hydraulic oil level is between the upper and lower lines on
the level gauge.
As supplied, the machine is set to run on three phase voltage as indicated on the serial plate and voltage label.
Power connection to the machine is made to L1, L2, L3 at the
disconnect switch and Ground terminals in the main electrical box found
beside the conveyor on the drive side. For machines equipped with a
variable frequency drive unit, an earth ground is also recommended.
During the initial hook-up it is very important to check that the phase order is correct. This is indicated by the hydraulic pressure gauge registering a pressure rise and the blade running in a counter clockwise direction. If the hydraulics do not register an immediate pressure rise, shut
the hydraulics off and change the phase order.
ATTENTION: Running the hydraulics “backwards” can damage the hydraulic pump.
1.3
EARTH GROUNDING PROCEDURE
1. The customer is to provide and install a ground rod approximately .60 (15mm) diameter, copper clad steel, to be
driven no less than 8’ (2.5m) into the ground, no more than 10’ (3m) away from control enclosure.
2. The ground rod is to be connected to customer’s in plant ground system. This connection shall be made directly
at the ground rod. (If applicable).
3. It is desirable that the overall resistance to ground measured at the ground rod does not exceed 3 ohms.
Customer is advised to consult local power company for further information on grounding.
4. The ground rod is to be connected to the ground terminal in the control enclosure using insulated, stranded
copper wire. The wire gauge size is to be determined according to the electrical code of the customer’s local
electrical authority.
5. An additional point to check is to ensure continuity of all ground within the control enclosure. Start with the main
power entrance ground terminal where the internal ground conductors should originate and then connect to, the
DIN terminal strip, control transformer, and the lid of control enclosure. Also, the PLC and Interface units should
have their own ground conductors connected to one of the main ground terminals.
6. A properly functioning ground system will:
- provide safety for personnel.
- ensure correct operation of electrical/electronic apparatus.
- prevent damage to electrical/electronic apparatus.
- help dissipate lightning strikes.
- divert stray radio frequency (RF) energy from electronic/control equipment.
HYDRAULIC OIL AND CUTTING FLUID
The H-18/22 SV bandsaw is supplied with Texaco Rando HD46 hydraulic oil. If it is necessary to change the oil to a
different brand see the HYDRAULIC SECTION for equivalent grade oil.
No cutting uid is supplied with the machine. There are two types of coolant available:
• Oil based; dilute 1:10 ratio (one part concentrated coolant to 10 parts water)
• Synthetic; dilute as recommended by the manufacturer.
1.4
SECTION 2 - OPERATING INSTRUCTIONS
This section has been prepared to give the operator the ability to set up the saw for most cutting situations. Before cutting
any material, the operator should be familiar with all operations and controls as well as the basic cutting theory described
below. The saw is equipped with variable blade speed and hydraulic feed control, as well as an extensive door chart to
guide the operator to the correct setting of these controls.
BLADE BASICS
Technology is rapidly changing all aspects of production machining. Metal cutoff is no exception. The advances made
in the bandsaw blade industry have denitely brought down the cost per cut, despite the three fold higher price of high
technology blades. Variable pitch, bi-metal blades (like the 4/6 or 3/4 bi-metal blade supplied with the machine) last much
longer, cut faster, and more accurately than conventional carbon steel blades. In order to take advantage of the superiority
of bi-metal blades, it is critical to properly “break-in” a new blade. This is accomplished by taking two or three cuts through
solid four or ve inch diameter mild steel at an extremely slow feed rate. (It is also advisable to utilize a slow blade speed)
These two or three slow cuts sufciently lap (polish) the teeth on the new blade so that it does not snag the material being
cut. Proper break-in will alleviate blade vibration; improve surface nish, accuracy, and blade life.
After “break-in”, the following six points must be closely monitored to ensure long blade life:
1. Proper blade tension should be maintained. (See Section 3, Maintenance and Troubleshooting)
2. Generous coolant application is essential with most materials. A high quality and well mixed coolant will extend
blade life, and also increase cutting rate and quality. On those materials where coolant is undesirable for cutting,
a slight coolant ow or periodic oiling of the blade is necessary to prevent the blade from being scored by the
carbide guides.
3. The stock being cut must be securely clamped in the vises.
4. The proper feed force should be chosen. (see Saw Cutting Parameters: Step 2)
5. The proper blade speed must be selected. (see Saw Cutting parameters: Step 4)
6. The proper feed rate must be applied. (see Saw Cutting Parameters: Step 5)
VARIABLE SPEED CONTROL
Blade speed can be adjusted for the H18 innitely between 50 to 350 SFM(Surface Feet/Minute) (15 to 107m/min) and
for the H22, 40 to 300 SFM(Surface Feet/Minute) (12 to 92m/min). Adjustment should be made only when the blade is
running. Clockwise rotation of the knob increases blade speed while counter clockwise rotation decreases blade speed.
THE CONTROL PANEL
START-UP
The control console has been designed to simplify the operation of the saw, to give the operator the ability to stop any
function at any time, and to be able to control all the functions remotely. We cannot overstress the importance of
familiarizing yourself with the controls prior to star ting the machine.
NOTE:
1. ALL SWITCHES MUST BE IN THE CENTER NEUTRAL POSITION TO START THE MACHINE!
2. WHEN STARTING THE MACHINE FOR THE FIRST TIME MAKE SURE THAT BLADE IS MOVING IN A
COUNTERCLOCKWISE DIRECTION, AND THAT THE HYDRAULIC PRESSURE IS 1000 PSI (6890kP). IF
THERE IS NO IMMEDIATE PRESSURE, SHUT THE SAW DOWN AND CHANGE THE PHASE ORDER.
MANUAL OPERATION
Manual Operations can be performed when the PLC 100 controller is set to MAN (AUTO is active when a RED light is on
above the AUTO/MAN button). All functions are self-explanatory. Specic control button functions are described on the
following pages.
2.1
FRONT VISE
This switch has three positions, OPEN, HOLD and CLOSE. With the switch held in the
OPEN position the vise will open all the way or until the switch is released. With the switch in
the HOLD position, the vise will stay where it is and will not move freely
although it will not resist a large force indenitely without creeping. In CLOSE, the vise will
close all the way, or until it encounters enough resistance to stop it.
HEAD CONTROL
This switch has three positions: UP, HOLD and DOWN. The switch is inactive unless the
PLC is in manual mode. In the UP position, the head will rise until it trips the head up limit,
which is adjustable. In the HOLD position the head will stay still. In the DOWN position the
head will descend until it reaches the bottom of the stroke. The speed of descent is
controlled by the Head Feed and Head Force Limit controls.
BLADE START
The blade can be started only when the hydraulics are running in either manual or auto
mode.
NOTE: In automatic Mode the head will not descend until the blade has been started, which
the PLC will prompt the operator to do so.
HYDRAULIC START
To start the hydraulic system, the switches for the head and both vises must be in the
“NEUTRAL” position. The “HYDRAULIC START” button must be depressed and held in
momentarily until the PLC display becomes active.
CYCLE START / PAUSE
This button starts the cutting cycle and will stay illuminated until the cycle is completed. The
PLC control system will prompt you to start the blade if it is not running. The
machine will then begin the automatic cycle until completed when it will shut itself off. The
current cycle can be PAUSED by pressing this button at any time during a cycle and
restarted by pressing it again.
2.2
COOLANT
This switch has three positions, AUTO, OFF, and ON. In the ON position, the coolant system
will operate when there is power to the machine; this allows using the wash gun to clean
the machine. In the OFF position, the coolant system is inactive. In the AUTO position the
coolant system will only run when the blade is on. The coolant system can also be run only
when both the blade is on and the head is descending by selecting this option in the PLC
parameters.
SHUTTLE VISE
This switch has three positions, OPEN, HOLD and CLOSE. With the switch held in the
OPEN position the vise will open all the way or until the switch is released. With the switch
in the HOLD position, the vise will stay where it is and will not move freely although it will not
resist a large force indenitely without creeping. In CLOSE, the vise will close all the way, or
until it encounters enough resistance to stop it.
BLADE SPEED
H18, 50 to 350 SFM(Surface Feet/Minute) (15 to 107m/min)
H22, 40 to 300 SFM(Surface Feet/Minute) (12 to 92m/min)
Adjustment should be made only when the blade is running. Clockwise rotation of the knob
increases blade speed while counter clockwise rotation decreases blade speed.
BLADE STOP
Stops the blade. If the blade is stopped during a cycle, the cycle will continue but will not let
the head descend until the blade is started.
EMERGENCY STOP
This mushroom button stops the blade and hydraulic motors. Both vises will hold their
position but, pressure will begin to fall off. Long pieces of work should always be supported
so they will not become loose over time and fall while the machine is shut down. This is a
latched button and must be pulled out to start the machine.
WORK LAMP
This switch has two positions, OFF and ON.
BLADE CHANGE MODE
This lock is provided for the safety of the operator during the blade changing procedure.
When the lock is in the “ON” (I) position, the door interlocks are disabled and the only functions that are active are the HEAD and BLADE TENSION controls. All other controls are
inactive. After the blade has been changed the lock must be switched to “OFF” (O) in order
to operate the machine.
LASER (OPTION)
This switch has two positions, OFF and ON.
2.3
PLC 100 CONTROL SYSTEMS
NOTE: This instruction manual is applicable to the H-18/22 SV equipped with a MITSUBISHI PLC.
OPERATION OVERVIEW
DISPLAY WINDOW
F4
F3
F5
F2
NAVIGATION
KEYS
ENTER KEY
The PLC is a programmable logic controller which allows the operator to run the machine in both manual and automatic
modes.
In manual mode, all functions can be operated by using a combination of selector switches on the control console and
the PLC function buttons. Also the operator has the ability to execute a single cut utilizing a preprogrammed “Single Part
Cycle”.
In automatic mode, the PLC has the capacity to program and store 99 jobs. Designated job numbers can be programmed
for quantity required (maximum of 999 pieces) and lengths from 0.1” to 220” (5588mm).
Jobs can be run individually or in a QUEUE which allows a maximum of 5 jobs to run consecutively and the queue can be
repeated automatically as well up to 99 times.
All machine operators should be familiar with the entire operation instructions prior to operating the machine.
NOTE: If an emergency situation arises during any operation, use the large red mushroom “STOP” button located on the
control panel to shut down the machine. To operate the machine, the “STOP” button must be pulled out.
2.4
ACTIVATING THE PLC
Position the head, xed vise, and shuttle vise switches to the NEUTRAL (center) positions. If any of these switches are
not in the NEUTRAL position, the hydraulics will not start. The PLC control will become active when the HYDRAULIC
START button is depressed and “held in” momentarily. First, the HMI and PLC’s current revision number will be shown on
the display window and nally the MANUAL MODE display window will appear as shown below. The AUTO/MAN green
indicator light will be on and all MANUAL controls are enabled. The “LTH” value (shuttle vise position) will always display
zero at start up. The “LTH” value can be reset or cleared at any time in MANUAL mode by pressing the CLEAR function
button.
FUNCTION KEY DESCRIPTIONS
If a red indicator light above a function button is illuminated, it means that the function printed in red is enabled. If a green
indicator light above a function button is illuminated, it means that the function printed in green is enabled.
The following are the function keys for AUTO and MAN modes:
AUTO / MAN MODE
- This key will toggle between MAN and AUTO modes. Auto mode cannot be accessed unless the front vise is
closed.
- Also used to stop an automatic job in progress by switching to MANUAL mode.
UNLABELLED
- The function of these keys are displayed directly above them. The function will change as the PLC is
switched from one mode to another and as the process of each mode is changed.
INCH/MM
- While depressed momentarily, it resets the displayed length value to zero. If held depressed for a few
seconds, the displayed length will toggle between millimeters and inches and the blade speed in either surface
feet per minute or meters per minute. It becomes disabled once any cycle is initiated.
MANUAL MODE FUNCTION KEY DESCRIPTIONS
While in manual mode, the display will show the current function of the unlabelled key. They are shown below.
FWD: FORWARD - This key will advance the shuttle vise toward the head (home position). If pressed simultaneously with
the REV key, (the front vise must be closed and a password is required) the parameters will be displayed.
REV: REVERSE - This key will retract the shuttle vise away from the head (home position). If pressed simultaneously with
the FWD key, (the front vise must be closed and a password is required) the parameters will be displayed.
S/F : SLOW / FAST - This key will toggle between slow and fast shuttle speed.
2.5
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