Hyd-Mech M-16A PLC 500 E600, M-20A PLC 100 E200, M-16A PLC 100 E200, M-20A PLC 500 E600 User Manual
M-16A & M-20A PLC 500 E600 & PLC 100 E200
2003 Revision C
393060 December 2003
Effective T0503338
THANK YOU,
On behalf of everyone at HYD.MECH, I would like to thank and congratulate you on your decision to purchase a
HYD.MECH band saw.
Your new machine is now ready to play a key role in increasing the efciency of your operation, helping you to reduce cutting costs while boosting quality and productivity.
To ensure you are maximizing the power and versatility of your new HYD.MECH band saw, please take the time to familiarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual.
We sincerely appreciate the condence you have demonstrated in purchasing our product and look forward to building a
long and mutually benecial relationship.
Thank-you.
HYD.MECH GROUP LIMITED
P.O. BOX 1030, 1079 Parkinson Road
Woodstock, Ontario Canada, N4S 8A4
Phone: (519) 539-6341
Service 1-877-237-0914
Sales 1-877-276-SAWS(7297)
Fax (519) 539-5126
e-mail, info@hydmech.com
01
Table of Contents
SECTION 0, SAFETY
M-16A & M-20A PLC 500 E600 & PLC 100 E200 ......................................................................................................01
SECTION 0 - SAFETY INSTRUCTIONS .................................................................................................................... 0.1
SUMMARY..................................................................................................................................................................0.1
OWNER IS RESPONSIBLE TO..................................................................................................................................0.1
OPERATOR AND MAINTENANCE PERSONNEL ARE RESPONSIBLE TO: .......................................................... 0.1
SECTION 0, SAFETY INSTRUCTIONS .....................................................................................................................0.2
BASIC RULES ............................................................................................................................................................ 0.3
RESPONSIBILITIES OF THE OWNER ...................................................................................................................... 0.5
RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL .................................................... 0.6
SECTION 1, INSTALLATION
LIFTING INSTRUCTION.............................................................................................................................................1.1
FOUNDATION, LEVELLING AND ANCHORING.......................................................................................................1.2
BLADE TENSION CHECK ......................................................................................................................................... 1.3
WIRING CONNECTIONS............................................................................................................................................1.3
CUTTING FLUID.........................................................................................................................................................1.4
HYDRAULIC OIL ........................................................................................................................................................ 1.4
HEAD HEIGHT CHECK..............................................................................................................................................1.5
SECTION 2, OPERATING INSTRUCTIONS
BLADE BASICS..........................................................................................................................................................2.1
VARIABLE SPEED CONTROL ..................................................................................................................................2.1
THE CONTROL CONSOLE........................................................................................................................................ 2.2
PANEL SWITCHES SPECIFIC TO PLC 100, E200 INTERFACE ..............................................................................2.4
CONTROL SYSTEM, MITSUBISHI PLC 500.............................................................................................................2.5
OPERATION OVERVIEW ........................................................................................................................................... 2.5
PLC CONTROL DESCRIPTION.................................................................................................................................2.6
FUNCTION BUTTON DESCRIPTION ........................................................................................................................2.7
ONE CUT MODE.........................................................................................................................................................2.9
AUTOMATIC OPERATION .........................................................................................................................................2.10
PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE ...........................................................2.10
WORKING WITH A QUEUE .......................................................................................................................................2.12
PLC CONTROL SYSTEM E200 ................................................................................................................................. 2.13
OPERATION OVERVIEW ........................................................................................................................................... 2.13
ACTIVATING THE INTERFACE ................................................................................................................................. 2.14
FUNCTION KEY DESCRIPTIONS..............................................................................................................................2.14
SINGLE PART CYCLE OPERATION ......................................................................................................................... 2.15
AUTOMATIC OPERATION .........................................................................................................................................2.15
PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE ...........................................................2.16
KERF CORRECTION FOR ANGLE CUTTING ..........................................................................................................2.18
HYDRAULIC FEED CONTROL..................................................................................................................................2.19
CUTTING PARAMETERS CHART ............................................................................................................................. 2.19
COOLANT FLOW ....................................................................................................................................................... 2.24
HEAD UP AND DOWN LIMIT SETTING .................................................................................................................... 2.24
SECTION 3, MAINTENANCE AND TROUBLESHOOTING
LOCK -OUT.................................................................................................................................................................3.1
LOCK OUT PROCEDURE.......................................................................................................................................... 3.1
BLADE CHANGING....................................................................................................................................................3.2
BLADE TRACKING .................................................................................................................................................... 3.3
DRIVE WHEEL ADJUSTMENT..................................................................................................................................3.3
IDLER WHEEL ADJUSTMENT .................................................................................................................................. 3.3
BLADE BRUSH ADJUSTMENT................................................................................................................................. 3.3
TOC.1
TOC.3
BLADE GUIDE ADJUSTMENT .................................................................................................................................. 3.4
BLADE HEIGHT ADJUSTMENT................................................................................................................................3.4
WORK LAMP ...........................................................................................................................................................3.4
LUBRICATION ............................................................................................................................................................ 3.5
HYDRAULIC MAINTENANCE.................................................................................................................................... 3.6
HEAD FEED RATE CALIBRATION...........................................................................................................................3.11
ANGLE CALIBRATION ..............................................................................................................................................3.11
PLC 500 E600 INPUT / OUTPUT TERMINAL............................................................................................................ 3.12
INFORMATION ...........................................................................................................................................................3.12
PLC 500 TROUBLESHOOTING EXAMPLES............................................................................................................3.15
PROGRAMMABLE LOGIC CONTROL, (E200, 2100 V1.0).......................................................................................3.17
PLC PARAMETERS (DESCRIPTIONS, E200 INTERFACE, 2100 SOFTWARE)...................................................... 3.17
PLC TROUBLESHOOTING........................................................................................................................................ 3.19
INCONSISTENT INACCURACY.................................................................................................................................3.21
CONSISTENT INACCURACY .................................................................................................................................... 3.21
LINEAR INACCURACY..............................................................................................................................................3.21
AUTO CYCLE NOT BEING COMPLETED.................................................................................................................3.22
AUTO CYCLE SEQUENCE:....................................................................................................................................... 3.22
FUSES E200 ............................................................................................................................................................... 3.23
MITSUBISHI FX2N 48MR INPUTS & OUTPUTS.......................................................................................................3.24
ENCODER AND PROXIMITY SENSOR CONNECTIONS ......................................................................................... 3.25
CALIBRATION PROCEDURE .................................................................................................................................... 3.26
SECTION 4, ELECTRICAL SYSTEM
GENERAL INFORMATION .........................................................................................................................................4.1
INITIAL START-UP ..................................................................................................................................................... 4.1
EARTH GROUNDING PROCEDURE......................................................................................................................... 4.1
M16A PLC500 COMPONENT LIST: NO OPTIONS ................................................................................................... 4.4
M16A PLC500 COMPONENT LIST: 208V .................................................................................................................4.8
M16A PLC500 COMPONENT LIST: 240V .................................................................................................................4.9
M16A PLC500 COMPONENT LIST: 480V .................................................................................................................4.10
M16A PLC500 COMPONENT LIST: 575V .................................................................................................................4.11
M20A PLC500 COMPONENT LIST: NO OPTIONS ................................................................................................... 4.12
M20A PLC500 COMPONENT LIST: 208V .................................................................................................................4.16
M20A PLC500 COMPONENT LIST: 240V .................................................................................................................4.17
M20A PLC500 COMPONENT LIST: 480V .................................................................................................................4.18
M20A PLC500 COMPONENT LIST: 575V .................................................................................................................4.19
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................ 4.20
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................ 4.22
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................ 4.24
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................ 4.26
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................ 4.28
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................ 4.30
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH OPTIONS ......................................................................4.32
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH OPTIONS ......................................................................4.34
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH OPTIONS ......................................................................4.36
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH OPTIONS ......................................................................4.38
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH OPTIONS ......................................................................4.40
M16/20 A 480V / 575V ELECTRICAL SCHEMATIC WITH OPTIONS ......................................................................4.42
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................. 4.44
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................. 4.46
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................. 4.48
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................. 4.50
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................. 4.52
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH NO OPTIONS................................................................. 4.54
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH OPTIONS .......................................................................4.56
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH OPTIONS .......................................................................4.58
TOC.2
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH OPTIONS .......................................................................4.60
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH OPTIONS .......................................................................4.62
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH OPTIONS .......................................................................4.64
M16/20 A 240V / 208V ELECTRICAL SCHEMATIC WITH OPTIONS .......................................................................4.66
M-16/20 A PLC 100, E200, 208/240V, WITH OPTIONS............................................................................................. 4.80
M-16/20 A PLC 100, E200, 208/240V, WITH OPTIONS............................................................................................. 4.82
M-16/20 A PLC 100, E200, 208/240V, WITH OPTIONS............................................................................................. 4.84
M-16/20 A PLC 100, E200, 208/240V, WITH OPTIONS............................................................................................. 4.86
M-16/20 A PLC 100, E200, 208/240V, WITH OPTIONS............................................................................................. 4.88
M-16/20 A PLC 100, E200, 208/240V, WITH OPTIONS............................................................................................. 4.90
M-16/20 A PLC 100, E200, 480/575V, WITH OPTIONS............................................................................................. 4.92
M-16/20 A PLC 100, E200, 480/575V, WITH OPTIONS............................................................................................. 4.94
M-16/20 A PLC 100, E200, 480/575V, WITH OPTIONS............................................................................................. 4.96
M-16/20 A PLC 100, E200, 480/575V, WITH OPTIONS............................................................................................. 4.98
M-16/20 A PLC 100, E200, 480/575V, WITH OPTIONS............................................................................................. 4.100
M-16/20 A PLC 100, E200, 480/575V, WITH OPTIONS............................................................................................. 4.102
SECTION 5, HYDRAULIC SYSTEM
M20 HYDRAULIC ASSEMBLY COMPONENT LIST.................................................................................................. 5.1
M16 HYDRAULIC ASSEMBLY COMPONENT LIST.................................................................................................. 5.2
M-16/20 HYDRAULIC PLUMBING DIAGRAM........................................................................................................... 5.4
M-16/20 HYDRAULIC SCHEMATIC ........................................................................................................................... 5.6
SECTION 6, MECHANICAL SYSTEM
BLADE BRUSH ASSEMBLY...................................................................................................................................... 6.1
GUIDE ARM ASSEMBLY............................................................................................................................................6.2
M-16 GUIDE ARM ASSEMBLY COMPONENT LIST .................................................................................................6.3
M-20 GUIDE ARM ASSEMBLY COMPONENT LIST .................................................................................................6.4
BLADE TENSION ASSEMBLY...................................................................................................................................6.5
BLADE TENSION ASSEMBLY COMPONENT LIST .................................................................................................6.6
PIVOT LINK ASSEMBLY............................................................................................................................................ 6.7
HYDRAULIC TANK ASSEMBLY ................................................................................................................................ 6.8
HYDRAULIC PUMP ASSEMBLY................................................................................................................................6.9
CONVEYOR ASSEMBLY ...........................................................................................................................................6.10
CONVEYOR ASSEMBLY COMPONENT LIST .......................................................................................................... 6.11
SHUTTLE VISE ASSEMBLY ...................................................................................................................................... 6.12
DATUM VISE JAW ASSEMBLY ................................................................................................................................. 6.13
ENCODER LENGTH CONTROL ASSEMBLY............................................................................................................6.14
ENCODER COVER ASSEMBLY ................................................................................................................................ 6.15
HYDRAULIC CHIP AUGER ASSEMBLY ................................................................................................................... 6.16
DOOR AND COVER ASSEMBLIES ........................................................................................................................... 6.17
DIRECT DRIVE ASSEMBLY.......................................................................................................................................6.18
GEARBOX ASSEMBLY.............................................................................................................................................. 6.20
SECTION 7, OPTIONAL EQUIPMENT
BUNDLING ASSEMBLY .............................................................................................................................................7.1
BUNDLING ASSEMBLY .............................................................................................................................................7.2
BUNDLING ASSEMBLY COMPONENT LIST............................................................................................................7.3
VERTICAL ROLLER ASSEMBLY .............................................................................................................................. 7.4
CUT LINE LASER SIGHT........................................................................................................................................... 7.6
OUTBOARD VISE ASSEMBLY OPTION ................................................................................................................... 7.7
MIST BLADE LUBRICATION SYSTEM .....................................................................................................................7.9
M16/20 A REMOTE CONSOLE .................................................................................................................................. 7.10
TOC.3
SECTION 8, SPECIFICATIONS
M-16 SPECIFICATIONS .............................................................................................................................................8.2
M20 LAYOUT .............................................................................................................................................................. 8.3
M16 LAYOUT .............................................................................................................................................................. 8.4
SECTION 9, WARRANTY
WARRANTY................................................................................................................................................................9.1
TOC.4
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 infor-
mation.
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 which 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
0.3
SECTION 0, SAFETY INSTRUCTIONS
FOREWORD
Put Safety First!
This Safety Section contains important information to help you work safely with your machine and describes the dangers
inherent in our machines. 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.
0.2
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
BASIC RULES
Intended Use
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.
0.3
0.5
Exclusion of Misuse
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
Liability
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.
0.4
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.
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.
0.5
0.7
Condition of Machine and Workplace
Ensure that the machine and its safety equipment is 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 correction 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.
Never attempt to dislodge or move stock while the blade is moving. Take the time to stop the saw blade,
remove obstructions and restart the blade.
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.
0.6
Clothing, jewellery, protective equipment
Personnel operating or working on the machine must not wear un-restrained long hair, loosetting 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
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.
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 typically done, and 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.
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.
0.7
On Hyd-Mech machines the Master Disconnect Switch will be of one of three types:
• Rotary switch mounted in electrical control cabinet door and inter-locked with door
• 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.
0.8
SECTION 1 INSTALLATION
Upon delivery of your new M-16/20 bandsaw, 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.
• POWER HOOK-UPS AND REPAIRS SHOULD BE ATTEMPTED ONLY BY QUALIFIED TRADESPEOPLE.
• THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK INTO
THE SAW. SECURE THE SAW TO THE FLOOR.
NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROM HYD·MECH. ANY
APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.
LIFTING INSTRUCTION
This machine is designed to be lifted in one, fully assembled piece. In order to lift the machine it needs to be in following
condition.
- Saw head in its bottom position at 90O.
- Shuttle vise fully forward.
- Coolant tank emptied.
There is a large lifting eye (shown below) at the top of the machine. The machine may be lifted with an overhead hoist and
chain, both being rated for 7400 lbs (3356 kg) for M-16A or 7700lbs (3465kg) for M-20A. For “P” models the weight is less,
6400lbs (2880kg) for M-16P and 6800lbs (3060kg) for M-20P.
Lifting hook
M-16A being lifted.
1.1
1.3
FOUNDATION, LEVELLING AND ANCHORING
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.
The 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. Four leveling screws are provided, one in each corner of the machine base.
Steel plates are to be placed under each screw to prevent their sinking into the concrete oor. In cases when 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 conveyors with a slight slope towards the blade is recommended.
This will prevent coolant from running down the raw stock. (This is especially true when cutting tubing or bundles).
Use Precision Level
on Outfeed Table in
both directions
2 leveling bolts at the idler side of the machine are shown.
Level saw from front to rear and from side to side
1.2
BLADE TENSION CHECK
When the machine is rst started, the head must be swung to the 45O position so the blade position
can be checked. Open the door at the idler end of the head and see that the blade has not moved off
of the wheel. Correct tracking of the blade would see the teeth overhang the rim of the wheel by .260”
to .300”. If it has stayed in its correct position, then turn the blade tension switch to the “+” and close
the door, if not, please refer to section 3 of the manual to correct this.
Blade tension
switch, behind
WIRING CONNECTIONS
After the machine is leveled and anchored the necessary power hook-up needs to be performed.
In order to provide a safe operation as well as to prevent potential damage to the machine, only qualied personnel
should be allowed to do the work.
The rst two areas that need to be checked are:
• There are no signs of shipping damage to electrical conduits, cords or hydraulic hoses.
• Hydraulic oil level is between the upper and lower lines on the level gauge.
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 counterclockwise direction. If the hydraulics do not
register an immediate pressure rise,
the idler door.
- SHUT THE HYDRAULICS OFF -
and change the phase order. As supplied, the machine is set to run on the three phase voltage as indicated on the serial
plate and voltage label. Power connection to the machine is made to the main disconnect switch and the Ll, L2, L3 and
Ground terminals. The disconnect switch box is located on right side of the Operator Control Panel.
The Power Terminal Block is shown below. We also recommend that an earth ground be attached to the machine.
To gain access to the disconnect box, follow these steps:
1. Ensure the switch is in the OFF position and power is disconnected.
2. Push the lockout tab to the right and pull the door open.
To close the door properly, reverse the above steps.
1.3
1.5
ON/OFF SWITCH SHOW
IN “OFF” POSITION
L1 L2 L3
SAFETY LOCKOUT HOLE
GROUND
Disconnect Box
Main Power Connections
CUTTING FLUID
The M16/20 uses a pump and reservoir to circulate the necessary cutting uid to the blade for
maximum blade life. Your saw blade supplier will be able to provide information on the cutting
uid products that are available for your needs. No cutting uid (coolant) 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 manufacturer.
Coolant wash down gun
on the front of the saw
HYDRAULIC OIL
As shipped, the saw oil tank is lled with Texaco Rando HD 46 hydraulic oil. If you want to change the hydraulic oil or the
brand of oil, see HYDRAULIC MAINTENANCE in Section 3.
Oil Level Gauge on the power pack door
1.4
Oil Filler Cap found inside power pack door.
HEAD HEIGHT CHECK
The head height is carefully checked at the factory prior to shipping and should not change, however there may be a possibility that either through lifting or when the machine is in transit, the position changes slightly. This should be checked at
the time of installation.
If adjustment is required, the blade should be 1/8” below the top surface of the infeed table.
Blade teeth 1/8” below the top
surface of the Infeed Table
Blade
Outfeed Table
Head Height Adjustment
1.5
SECTION 2, OPERATION INSTRUCTIONS
This section has been prepared to give the operator the ability to set up the saw for most cutting situations. The saw is
equipped with variable blade speed control 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 M-16/20) 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 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, Blade Changing)
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.
5. The proper blade speed must be selected.
6. The proper feed rate must be applied.
VARIABLE SPEED CONTROL
Blade speed can be adjusted innitely between 60 to 350 SFM (Surface Feet/Minute) (18 to 105 meters/min). The blade
speed is controlled with dial on the control panel.
Blade speed adjuster.
2.1
2.3
THE CONTROL CONSOLE
START-UP
The M-16A and M-20A 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 of the M-16A and M-20A prior to starting the machine.
NOTES:
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 900 PSI (6200kP). IF
THERE IS NO IMMEDIATE PRESSURE, SHUT THE SAW DOWN AND CHANGE THE PHASE ORDER AS
STATED IN SECTION 1 .
Operator Control Console TOP ROW
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 switch. In the HOLD position the head will stay still. In the DOWN position the
head will descend until it reaches the head down limit switch. 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.
2.2
CENTER ROW
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 cycles and will stay illuminated white until
the cycles are 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.
COOLANT - This switch has three positions, ON, OFF, and AUTO. 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 head is descending. This
minimizes coolant carry over on the stock.
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.
EMERGENCY
BOTTOM ROW
BLADE SPEED - This dial will increase or decrease the speed at any time while the blade is run-
ning.
BLADE STOP BUTTON - 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.
STOP - This mushroom button stops the blade and hydraulic motors. Both vises will hold their po-
sition 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.
AUXILLARY 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.
2.3
2.5
GUIDE ARM - This switch controls the position of the idler (left) guide arm.
WORK LAMP - This switch has two positions, OFF and ON.
LASER GUIDE - This option switch has two positions, OFF and ON.
PANEL SWITCHES SPECIFIC TO PLC 100, E200 INTERFACE
HEAD SWING 90°
This is a two position push button. By pressing the button in partially, the head will slowly swing
towards the 90° position until it reaches 90° or the button is released. This allows for a ne adjustment in the cut angle, If pressed fully in, the head will swing at a fast rate
Note:
The head control switch must be in the “HOLD” position for this button to operate.
HEAD SWING 30°
This is a two position push button. By pressing the button in partially, the head will slowly swing
towards the 30° position until it reaches 30° or the button is released. This allows for a nd adjustment in the cut angle. If pressed fully in, the head will swing at a fast rate.
Note:
The head control switch must be in the “HOLD” position for this button to operate.
2.4
CONTROL SYSTEM, MITSUBISHI PLC 500
OPERATION OVERVIEW
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 “ONE CUT
MODE”.
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). Piece lengths from 0.1” to 220” (5588mm) and cut angles from 900 through
to 300. Jobs can be run individually or in a QUEUE which allows a maximum of 5 jobs to run consecutively.
NOTE: If an emergency situation arises during any operation, use the large red mushroom “emergency stop” button
located on the control panel to shut down the machine.
2.5
2.7
PLC CONTROL DESCRIPTION
ACTIVATING THE PLC
The PLC control will become active when all selector switches are in the neutral position and the HYDRAULIC START
button is depressed and “held in” momentarily. If the head is not in the 900 position, the display will prompt you to “SWING
THE HEAD TO 90 DEGREES”, press and hold the 900 key until the display returns to “MANUAL MODE”. When the head
is at 900, the AUTO/MAN indicator light will be green, all MANUAL controls as described previously are enabled, and the
“MANUAL MODE STATUS” screen will appear as shown below. The PLC controls are described on the following pages.
The length value (shuttle vise position) will display the previous positions. To reset or clear the length value, press the F8
key.
PLC 500 CONTROL PANEL
All key functions are explained in detail on the following pages.
2.6
FUNCTION BUTTON DESCRIPTION
On the dual function buttons, if a green indicator light is illuminated, it means that the function printed in green on the top
of the button is enabled. A red light indicates the function printed in red at the bottom of that button is enabled.
•
•
•
•
AUTO
MAN
FWD
REV
90
MANUAL MODE (Green light)
Enables all control switches and PLC function buttons. Also stops an automatic job in
progress by switching to MANUAL.
AUTO MODE (Red light)
Puts the machine in AUTO MODE and disables all manual functions. The front vise selector switch must be in the closed position.
MANUAL MODE
This key will advance the shuttle toward the head (home position).
AUTO MODE
Key is disabled.
MANUAL MODE
This key will retract the shuttle away from the head.
AUTO MODE
Key is disabled.
MANUAL MODE
This key will swing the head toward 90 degrees.
•
•
•
30
SLOW
FAST
INCH
METRIC
AUTO MODE
Key is disabled.
MANUAL MODE
This key will swing the head toward 30 degrees.
AUTO MODE
Key is disabled.
MANUAL MODE
Green light indicates that the shuttle movement and head swing will move at a slow
speed.
Red light indicates that the same movements will be at a fast speed.
AUTO MODE
Key is disabled.
MANUAL MODE/AUTO MODE
Green light indicates Imperial values.
Red light indicates Metric values.
2.7
2.9
F5
•
AUTO MODE
Energizes CYCLE START button.
MANUAL MODE
No function
F6
•
F16
•
F7
•
F8
•
MANUAL MODE
After entering an angle value, pressing F2 will cause the screen to read “TO INTIATE
MOVEMENT TO XX.X DEGREES PRESS CYCLE START”. Upon pressing “CYCLE
START” the head will swing to the programmed angle.
AUTO MODE
Used to scroll up through job information.
MANUAL MODE
Used for accessing the PARAMETERS screen which will then require a pass word before
entering the parameters.
MANUAL MODE
Used for accessing the KERF screen. The KERF screen cannot be accessed while in
METRIC mode and any change made to the KERF value will not be accepted by the controller until it has been shut down and restarted. (The standard kerf values are .066 for 1
1/4” blade & .074 for 1 1/2” blade at 90O.)
AUTO MODE
Used to scroll down through job information.
MANUAL MODE
Used to clear the length display (shuttle vise position) value.
AUTO MODE
Used to CLEAR the jobs from the queue or job values for whichever job the cursor is at.
CURSOR KEY PAD
The cursor keys are used to navigate the cursor box on the screen. If the display
has columns, only the UP and DOWN keys are activated. If the display has both
rows and columns, then all four cursor keys are activated.
2.8
ONE CUT MODE
In MAN mode, switching the front vise to closed position changes the PLC to “One Cut Mode “ to cut one piece at a desired length. To accomplish this, follow the procedure below.
1. In “MAN MODE” position the head for the required angle by using the 900 or 300 function keys. You can also
accomplish this by moving the cursor to the “Angle Go” feature, input desired angle, press ENTER. Then press
F6. The screen will display “ TO INITIATE ANGLE MOVEMENT TO __.__ DEGREES PRESS CYCLE START”.
Press CYCLE START and the head will travel to the displayed angle.
2. A trim cut should be made in “MAN MODE” before initiating the “ONE CUT MODE” operation. This will ensure a
clean inital cut and that the head is above the material height so no damage is caused when the shuttle moves
the material forward.
As the head up limit switch must be tripped in order for the cycle to continue, set the head height using this procedure;
a) Raise the head up limit switch (located behind the console).
b) Move the head with the HEAD switch so the blade is just above the material.
c) Loosen the grip knob on the limit switch block, move the block so the trip plate is almost touching the
limit switch roller and tighten the grip knob.
d) Turn the head switch to “UP”. When the head trips the limit switch, the head will stop.
3. To enable the “ONE CUT MODE”, turn the front vise switch to the CLOSED position.
4. To the left of the F5 button, the display will be ashing. Move the cursor to the rectangular box
and key in the desired length using the numeric key pad and press “ENTER”.
5. If the blade is not running, “BLADE” will be ashing beside the length value, press the “BLADE START” button.
Adjust the blade speed as required, then press the “CYCLE START / PAUSE” button to continue the cycle. When
the “CYCLE START” button is pressed, the shuttle vise will move to the forward home position before executing
the length movement.
6. When the cut is completed, the head will retract, the blade will stop and the display will reset for the next cut.
7. To make another cut, repeat steps 5 through step 6.
NOTE: To cut multiple pieces, load and position the material and head up limit for a trim cut and follow the automatic
procedures on the following pages.
2.9
2.11
AUTOMATIC OPERATION
To enter AUTO MODE, the front vise switch must be in the closed position. When the AUTO/MAN button is pressed, the
red indicator above it will come on, the screen will change to the PICK LIST display as shown on the following page and
be ready for editing or starting a new job. The VISE and HEAD switches on the control panel will be disabled.
PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE
Each job is dened by two angles and two lengths. Angle 1 (A1) is the rst angle to be cut (this will be the trim cut). Length
1 (L1) is the length of the material to be cut as measured between the two intersection points of the blade axis and the
saw table datum line. Angle 2 (A2) is the second angle to be cut and length 2 (L2) again is the length of material as measured between the two intersection points of the blade axis and the vise datum line.
2.10
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