1316S-Auto Operating Manual
1316S - Auto
MODEL
Fully Automatic Bandsawing
with Conversational Set-Up,
Active Hydraulic Cutting
Force Control, True Swivel
Head for Miter Angles
Operating Manual
Fully Automatic
Bandsaw with Miter Head
Built better to work stronger and last longer
Shown with Optional
Bundle Clamp System
REV 130610
File Name: S:\Master Parts Manuals\New scanned manuals MLS\1316S-Auto Operating Manual.indd
2829 N. Burdick
ick St. Kalamazoo, MI 49004
Phone: 269-345-1132
345-1132 Fax: 269-345-0095
www.wellsaw.com
TABLE OF CONTENTS
Auto Quick Start Guide .............................................12
Review of Control Panel Buttons & Operation..........13
The Six Control Screens...........................................15
Manual Operation .....................................................18
Automatic Operation .................................................18
Electrical Maintenance Notes ...................................19
General Operating Information .................................20
Blade Selection Guide ..............................................22
1316S-Auto Specifications ........................................2
1316S-Auto Components ..........................................2
Safety Instructions .....................................................3
Warranty Information .................................................5
Receiving and Installation..........................................5
Machine Overview .....................................................6
Trouble Shooting .......................................................8
Cutting Force Feature...............................................10
Specifications
Capacity
@ 0° (90°)
@ 45°
@ 60°
Blade Size
Blade Speeds
Blade Guides
Blade Tension
Round | Rectangular
13" | 13"H x 16"W
12" | 13"H x 12"W
7-1/2" | 8-1/2"H x 7-1/2"W
1" x .035" x 12'6" (150")
Infinitely Variable 60-420 SFPM
Carbide Guides with Rollers
Double Die Spring with Indicator
Electrical Options
230/3 (See Options for Other Voltages)
Tank Capacity 8 Gallons
Submersible Pump 115V/.6 Amp/3
GPM
Quick Positioning/Air Powered
Variable Positive Hydraulic with
Sawing Force Control
30-120 Lbs.
Coolant System
Vise Control
Feed Rate Control
Cutting Force
Control
Jobs Storage
Band Wheels
Barfeed Projection
Barfeed Accuracy
Barfeed Remnant
Barfeed Length
Weight Capacity
Bed Height
Floor Area
Shipping Weight
1316S-Auto Components
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99
15" Diameter Cast Iron
25" Unlimited Indexes
+/- .002"
10"
5'
3,000 Lbs.
35"
90"W x 120"L
3,100 Lbs.
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Square D® Programmable Machine Controller with
Membrane Keypad and LCD display
Square D® Vector Type Frequency Motor Controller
Baldor® 5hp TEFC Blade Drive
Baldor® 3/4hp Hydraulic Motor
Textron/Cone Drive® Double Enveloping Gearbox
Vickers® Hydraulic Valves
Wellsaw Tiger-Tooth® Bi-Metal Blade
Active Hydraulic Cutting Force Control
Encoder Type Barfeed
Blade Break/Stall Proximity Switch
Working Light with Transformer
Unitized Base Design (Saw and Barfeed) with Integral
Fork Pockets
Out of Stock Shutdown
Self Centering Shuttle Carriage with Anti-Climbing
Vises
Discharge Table & Shute
Spring-Loaded Carbide Guides with Rollers
8 Gallon Flood Coolants System with Sample/Start-Up
Coolant
Full Surround Chip Pan
Powered Blade Brush
110 Volts at Controls
Overload and Undervoltage Protection
Precision Ground Beds and Discharge Table
Auto Shut-Off at End of Cut
OSHA Blade Guarding
Low Air Pressure Safety Switch
NFPA Electrics (with Fused Disconnect)
Flush Hose
Key Features
Available Factory Options
Fully Automatic Bandsawing | Conversational
Set-Up | Encoder Type Barfeed | Quick Set-Up
and Multiple Job Programing | Automatic Kerf
Compensation | Machine Diagnostics | Hydraulic
Cutting Force Control System
Overhead/Bundle Clamping | Transformer for
460 Volt Operation | Chip Conveyor | Variable
Vise Pressure | Laser Line Pointer | 5' and 10'
Non-Powered Conveyors | Oil Injection Type
Lubrication Systems | Hour Meter
Wellsaw® | 2829 N. Burdick Street | Kalamazoo, MI 49004 | Phone: 269-345-1132 | Fax: 269-345-0095 | Web: www.wellsaw.com
2
Safety Instructions
1.
Always wear protective eye wear when operating machinery.
Eye wear shall be impact resistant, protective safety glasses
with side shields which comply with ANSI Z87.1 specifications.
Use of eye wear which does not comply with ANSI Z87.1 specifications could result in severe injury from breakage of eye
protection.
2.
Keep hands in sight and clear of all moving parts and cutting
surfaces.
3.
Wear proper apparel. No loose clothing or jewelry which can
be caught in moving parts. Rubber soled footwear is recommended for best footing.
4.
Do not overreach. Failure to maintain proper working position
can cause you to fall into the machine or cause your clothing to
get caught - pulling you into the machine.
5.
Keep guards in place and in proper working order. Do not operate the machine with guards removed.
6.
Avoid dangerous working environments. Do not use stationary machine tools in wet or damp locations. Keep work areas
clean and well lit. Special electrics should be used when working on flammable materials.
7.
Avoid accidental starts by being sure the start switch is “OFF”
before plugging in the machine.
8.
Never leave the machine running while unattended. Machine
shall be shut off whenever it is not in operation.
9.
Disconnect electrical power before servicing. Whenever
changing accessories or general maintenance is done on the
machine, electrical power to the machine must be disconnected before work is done.
10. Maintain all machine tools with care. Follow all maintenance
instructions for lubricating and the changing of accessories.
No attempt shall be made to modify or have makeshift repairs
done to the machine. This not only voids the warranty but also
renders the machine unsafe.
11. Secure work. Use clamps or a vise to hold work when practical. It is safer than using your hands and it frees both hands to
operate the machine.
15. Use the right tool. Don’t force a tool or attachment to do a job
it was not designed for.
16. Use only recommended accessories and follow manufacturer’s
instructions pertaining to them.
17. All visitors should be kept at a safe distance from the work
area. Make workshop completely safe by using padlocks,
master switches, or by removing starter keys.
18. Know the tool you are using - its application, limitations, and
potential hazards.
19. Some dust created by power sanding, sawing, grinding, drilling
and other construction activities contains chemicals known to
cause cancer, birth defects or other reproductive harm. Some
examples of these chemicals are:
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Lead from lead based paints
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Crystalline silica from bricks and cement and other masonry products, and
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Arsenic and chromium from chemically treated lumber.
20. Your risk from these exposures varies, depending on how often
you do this type of work. To reduce your exposure to these
chemicals: work in a well ventilated area, and work with approved safety equipment, such as dust masks that are specifically designed to filter out microscopic particles.
General Electrical Cautions
This saw should be grounded in accordance with the National Electrical Code and local codes and ordinances. This work should be
done by a qualified electrician. The saw should be grounded to
protect the user from electrical shock.
Wire Sizes
Caution: for circuits which are far away from the electrical service
box, the wire size must be increased in order to deliver ample voltage to the motor. To minimize power losses and to prevent motor
overheating and burnout, the use of wire sizes for branch circuits or
electrical extension cords according to the following table is recommended:
Conductor
Length
12. Never brush away chips while the machine is in operation.
13. Keep work area clean. Cluttered areas invite accidents.
0-50 feet
50-100 feet
Over 100 feet
14. Remove adjusting keys and wrenches before turning the machine back on.
3
AWG (American Wire Gauge) Number
240 Volt lines
120 Volt lines
No. 14
No. 14
No. 14
No. 12
No. 12
No. 8
Safety Instructions
Misuse of this machine can cause serious injury.
For safety, this machine must be set up, used and properly serviced.
Read, understand and follow instructions in the Parts and Maintenance manual.
DISCONNECT POWER before adjusting or servicing the saw or
changing a blade.
USE RIGHT TOOL. Don’t use a tool a or attachment to do a job for
which it was not designed.
STAY CLEAR of all moving parts. Keep hands and fingers away
form the saw blade.
WEAR PROPER APPAREL. No loose clothing or jewelry to get
caught in moving parts. Rubber-soled footwear is recommended
for best footing.
WHEN MOVING SAW, with hinged frame (saw head), secure the
head in its down position.
WHEN CUTTING MAGNESIUM, take special precautions. Use a
sharp saw blade, make only dry cuts, prevent chip accumulation,
and keep fire-fighting equipment nearby.
THIS SAW SHOULD BE GROUNDED WHILE IN USE TO PROTECT THE OPERATOR FROM ELECTRICAL SHOCK.
CORD CONNECTED TOOLS. If the saw is equipped with an approved 3-conductor cord and a 3-prong grounding type plug, it
should only be connected to a properly equipped and grounded
receptacle. The green conductor in the cord is the grounding wire.
Never connect the green wire to a live terminal.
Use only a 3-wire extension cord having a 3-pronged receptacle, a
3-pronged plug and ample amperage rating. Replace or repair a
damaged or worn cord immediately.
PERMANENTLY CONNECTED TOOLS. The saw should be connected to a grounded, metal-enclosed wiring system or an equipment-grounding conductor should be run with the circuit conductors and connected to the saw’s grounding terminal or lead.
To reset the manual starter after a power interruption, return the
switch to OFF and press the RESET button before restarting.
KEEP GUARD IN PLACE and in working order.
REMOVE ADJUSTING KEYS AND WRENCHES. Form a habit.
Check to see that all keys and wrenches are removed from the tool
before turning the tool on.
KEEP WORK AREA CLEAN. Cluttered areas and benched invite
accidents.
AVOID DANGEROUS ENVIRONMENT. Do not use power tools in
damp or wet locations. Keep your work area well lighted.
KEEP CHILDREN AWAY. All visitors should be kept a safe distance from work area.
MAKE WORKSHOP KID-PROOF with padlocks, master switches,
or by removing starter keys form tools.
DON’T FORCE TOOL. It will do the job better and safer at the rate
for which it is designed
4
USE SAFETY GLASSES. Also use face or dust mask if operation
is dusty.
SECURE WORK. Use clamps or a vise to hold work. Provide
adequate support to prevent injury from falling work pieces.
MACHINE SET UP
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Always avoid using machine in damp or poorly lighted work
areas.
Always be sure machine is securely anchored to the floor
Always keep machine guards in place.
Always put start switch in “OFF” position before plugging in
machine.
MACHINE USE
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Never operate with machine guards missing.
Always wear safety glasses with side shields (See ANSI
Z87.1)
Never wear loose clothing or jewelry.
Never overreach - you may slip into the machine.
Never leave machine running while away from it.
Always shut off the machine when not in use.
MACHINE SERVICING
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Always unplug machine from electrical poser while servicing.
Always follow instructions in Parts and Maintenance manual
when changing accessory tools or parts.
Never modify the machine.
Read and follow these simple rules for best results and full benefits from your machine. Used properly, WELLSAW’s machinery
is among the best in design and safety. However, any machine
used improperly can be rendered inefficient and unsafe. It is absolutely mandatory that those who use our products be properly
trained in how to use them correctly. They should read and understand the Parts and Maintenance manual as well as all labels
affixed to the machine. Failure in following all of these warnings
can cause serious injury.
FULL YEAR LIMITED WARRANTY
This WELLSAW is warranted against defects in material or workmanship installed or performed at the factory. Within one year from date
of purchase, we will free of charge and at our option, either repair or replace any part of this WELLSAW which our examination discloses
to be defective because of workmanship or a defect in the material. This warranty does not apply if this WELLSAW has been used in a
manner not consistent with its’ design or which has been subject to accident, alteration, abuse or misuse or which fails due to lack of care
or is the result of inadequate power supply and specifically does not apply to normal wear parts. THERE ARE NO WARRANTIES WHICH
EXTEND BEYOND THE DESCRIPTION OF THE FACE HEREOF.
WELLSAW shall not be liable for consequential or incidental damages suffered or incurred with respect to defective materials or workmanship.
We do not authorize any person or representative to make any other warranty or to assume for us any liability in connection with the sale
of our products other than those contained herein. Any agreements outside of or contradictory to the foregoing shall be void and of no
effect.
All transportation costs on products or parts submitted to WELLSAW under this warranty must be paid by the user. No products or parts
are to be returned without first obtaining permission.
RECEIVING AND INSTALLATION
Un-crating
Carefully remove the protective crating and skid so the saw and its parts are not marred or otherwise damaged. In the event of damage
in transit, notify the carrier and file a Proof of Loss Claim immediately.
Shortages
Inspect the complete shipment carefully against the itemized packing list. Make sure that all items are present and in good condition. In
the event of any shortage, notify the distributor from whom you purchased the saw and the carrier who made the final delivery.
Utility Hook-Up
The use of a qualified electrician is always recommended when connecting the saw to the main power supply. Electrical codes differ from
area to area and it is the customer’s responsibility to ensure that their saw complies with applicable codes. Your WELLSAW is pre-wired
at the factory for a specified voltage. Always check the motor and electrical panel to ensure that they are both wired to correspond to
your electrical power supply.
PARTS ORDERING
When contacting your WELLSAW Supplier of the Company for parts or service, it is essential that you have
your MODEL NUMBER, SERIAL NUMBER and PURCHASE DATE available. Jot them down here for handy
reference.
MODEL:
SERIAL NUMBER:
PURCHASE DATE:
5
MODEL 1316S-AUTOMATIC OVERVIEW
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Control Panel
Frame Height Adjustment
Blade Motor
Metering Valve
Coolant Manifold
Blade Guide
Emergency Stop
End of Cut Switch
Blade Tensioner
Air Vise Cylinder
Coolant Hose
Table Lock
Table Swivel
Coolant Tank & Pump
Pointer
Holddown Clamps
Stationary Vise
Shuttle Table
Emergency Stop
Electrical Disconnect
Regulator
Filter Regulator Lubricator
Hydraulics (inside)
Chip Pan
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MODEL 1316S-AUTOMATIC OVERVIEW
MANAGED FROM THE CONTROL PANEL
MANAGED BY THE OPERATOR
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Length of Cut
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Number of Cuts
With stock placed on the infeed conveyor and against
the blade, adjustments can be readily made to:
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Blade Motor Start, Stop and Band Speed
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Position of both Vise Jaws
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Saw Head Raise, Lower, or Stop
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Height of Saw Head when raised
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Clamp and Unclamp both Vise Jaws
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Position of Moveable Blade Guide
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Move Shuttle Carriage Forward or Return
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Swivel of Saw Head (if making miter cut)
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Automatic or Manual Sawing Mode
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Sawing Force Control and Feed Rate Control
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Feed Rate Control
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Rate of Coolant Flow to each Blade Guide
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Blade Tension (when changing blade)
7
TROUBLE SHOOTING
2. Keep the blade guides as close as possible to the
workpiece.
NOTES ON SAWING
It is widely recognized that a proficient operator is a key to
optimum bandsawing. He makes certain the machine is
properly maintained and adjusted for dependable operation. He carefully sets up each cutting job to prevent damage to the machine and obtain the best performance from
the equipment.
3. If teeth wear off unusually fast, use a slower band
speed.
PREMATURE DULLING OF BLADE
1. Feed rate too high or low. Check recommendation.
Experienced blade dealers can be very helpful in selecting
the grade and proper tooth blade for each sawing job. All
blades should be straight, have sharp teeth with uniform
set, and be “broken in” at a reduced feed rate to obtain
good cutting performance and blade life.
2.
3.
4.
5.
Every cutting situation has special characteristics requiring
some experimentation to determine which blade, speed
and feed rate will achieve the most satisfactory result.
Cutting charts indicate a good starting point, but must be
modified by direct experience if optimum performance is
desired.
6.
7.
8.
9.
10.
11.
Here are some helpful pointers for adjusting speed and
feed for cutting performance.
1. Make sure the saw is cutting a good chip from the
workpiece.
12.
2. Watch for blue chips or excessive “smoke” indicating
heat in the cut which could damage the blade or work
harden the material being cut.
Blade speed too slow or too fast.
Faulty material; heavy scale, hard spots, etc.
Verify material analysis
If coolant flow is not covering saw teeth, increase coolant flow rate.
If saw is vibrating in cut, reduce a blade speed or
increase feed rate.
Chipped or broken tooth may be lodged in cut.
“Chip welding” caused by improper feed and speed.
Incorrect coolant mixture.
Incorrect blade selection.
Improper break-in of new blade. New blades should
be run initially with reduced feed pressure for approximately 50 to 100 square inches.
Saw blade teeth may be hitting blade guides. Check
for proper blade size.
SAW BLADE VIBRATION
1.
2.
3.
4.
5.
6.
7.
8.
3. Watch for excessive vibration or chatter marks on the
cut-off piece indicating possible damage to the saw
teeth by “hammering”
4. Check the cut-off for flatness. A dull blade or excessive
feed will produce a “belly” in the cut.
5. Inspect the blade for worn, rounded or shiny cutting
edges. avoid force cutting which will allow chips to
“weld” to saw teeth and eventually cause the teeth to
be stripped off the blade.
6. When experimenting, start with a slow speed and feed
rate. Gradually increase blade speed and then feed
pressure by small amounts until adverse effects are
noted. You can then set the speed and feed at a reasonable level for continuous cutting. Remember that
blade speed and feed pressure must be balanced to
keep cutting a good chip.
Incorrect blade speed for material.
Blade tension insufficient.
Back-up bearing may be worn.
Incorrect choice of saw tooth pitch.
Incorrect coolant mixture.
Incorrect feed setting. Increase feed.
Work piece not firmly clamped to vice.
Worn or improperly adjusted saw guides. Check and
make necessary adjustments.
BLADE TEETH CHIPPING OR RIPPING OUT
1. Blade pitch too coarse. Use a fine pitch saw blade on
thin work sections.
2. Improper break-in of new blade. Do not start a new
blade in an old cut.
3. Work piece not held firmly enough. Clamp work securely.
4. Introduce cooling if it is not being used.
5. Faulty material; scale or hard spots.
6. Blade gullets may be loaded. Use higher viscosity
lubricant or coolant.
7. Blade speed and feed may need adjustment.
CUTTING TIPS
1. Select blade and speed for material being cut. Use the
coarsest tooth blade suitable for the workpiece while
proving for at least two teeth cutting at all times. Use
fastest suitable band speed and minimum feed source
adequate to produce good cutting action. Work with
work-hardening steels, maintain a steady feed; do not
let teeth rub without cutting.
8
PREMATURE BLADE BREAKAGE
INACCURATE CUT-OFF
1.
2.
3.
4.
5.
6.
1. Is conveyor or stock stand level with saw bed?
2. Insufficient blade tension.
3. Blade guides too far apart. Always set blade guides
as close to the piece as possible.
4. Blade may be dull. Check and replace if necessary.
5. Feed pressure too high. Reduce it.
6. Blade guides loose, worn or out of alignment.
7. Too many teeth-per-inch. Blade not cutting freely.
8. Chip brush not cleaning teeth properly.
9. Dirty coolant.
10. Check for loose fasteners.
Poor weld in the blade.
Feed rate set too high. Reduce it.
Excessive blade speed. Adjust it.
Blade guides set too tight or misaligned.
Blade tension set too high.
Blade running against flange on wheels.
Adjust wheel pitch.
BLADE SQUEAL
1. Feed rate too light for blade speed. Increase feed
rate and/or reduce blade speed.
BLADE SLIPS OFF BAND WHEELS
ROUGH CUT / POOR FINISH
1. Blade not tensioned correctly.
2. Wheel pitch not set properly.
3. Guides set too tight.
1. Excessive feed rate. See recommendations.
2. Blade too coarse. Use finer blade pitch.
3. Inadequate cutting fluid. Replace.
GULLETS OF BLADE TEETH LOADING
BLADE STALLS IN WORK
1. Blade pitch too fine. Review blade selection.
2. Incorrect blade speed. Consult cutting chart.
3. If not using coolant, apply it.
1.
2.
3.
4.
5.
CHIPS WELDING TO BLADE TEETH
1. Cutting rate too high.
2. Chip brush may be out of adjustment.
3. Check coolant and application.
Insufficient blade tension.
Excessive feed pressure.
Blade tooth spacing too coarse.
Motor worn or defective.
Guides too tight against blade.
BLADE DOES NOT TRACK PROPERLY
BLADE BECOMING SCORED
1. Set wheel pitch so that blade runs to wheel flange
but not against it.
1.
Saw guides may be worn. Check and replace if
necessary.
2. Too much pressure on saw guides. Adjust.
3. Guides may be out of alignment.
2. Is blade tension correct?
BLADE MAKING BELLY-SHAPED CUT
When the blade has completed a cut through the material, the saw frame drops onto a limit switch actuator
which shuts the motor off.
3. Is back of blade riding against backup bearing? If
not, adjust it.
AUTOMATIC STOP
1. Blade tension too light. Increase it.
2. Saw guides too far from work piece.
3. Blade pitch too fine. Use larger pitch and positive
rake tooth form.
4. Feed force too heavy. Decrease it.
When changing a blade or doing any other maintenance
or repair, be sure the automatic stop is engaged and
disconnect the main power supply.
It is necessary to raise the saw frame to clear the limit
switch actuator before the saw can be started.
9
CUTTING FORCE CONTROL FEATURE
For mildsteel use 50 lbs as a starting point. Turn the
thimble at the bottom of the valve. Note the force on
the scale.
SYSTEM OVERVIEW
The Wellsaw 1316S-Auto is equipped with a Cutting Force
Control System. Unlike a conventional scissor type saw the
Cutting Force Control carefully maintains a constant sawing
force on the blade all the way through the cut even with
changing cross sections like in beams or pipes. Even at
aggressive sawing rates there is no danger of overfeeding.
This allows the saw to perform at rates that would not be
possible otherwise without risk of damage to the blade. This
feature, in combination with the five horsepower motor gives
this machine the ability to cut heavier and tougher materials
than a conventional saw. And it runs confidently while
unattended even at high performance levels.
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Is simple to adjust
Produces straighter cuts
Shortens cut time
Provides longer blade life
Is self monitoring
BASIC PARTS OF THE SYSTEM ARE:
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A hydraulic cylinder is used to raise and lower
(feed) the saw frame/head.
A hydraulic pump is used to raise the head. This is
the same pump used to move the shuttle carriage.
An air-over-oil system provides supplemental feed
pressure to the system.
There is no counterbalance system needed for this
system.
3. Move the Feed Rate Control knob to the zero position.
To begin the saw cut:
1. Press the Blade Start button. Hold in until the motor
runs. Note the blade speed on the display. Adjust if
needed.
2. If you are starting an Auto cycle press Auto
3. Press the Head Lower / Cycle Start button.
4. Slowly open the Feed Rate Control knob.
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Feed Rate Valve on the control panel
Cutting Force Valve on the Drive End Blade
Guide
Downfeed Pressure Control Regulator on the
side of the machine.
Always be sure that the Cutting Force roller is resting
on top of the blade.
QUICK START INSTRUCTIONS
FEED RATE AND CUTTING FORCE
Locate the three controls
1. Air Pressure Regulator on the right side of the
machine. This is the second regulator after the primary
regulator
2. Cutting Force Valve on the Blade Guide
3. Feed Rate Control knob on Control Panel.
Before you begin the cut:
1. Adjust the Air Pressure Regulator to 10 psi. Pull the
knob down to adjust. Push up to lock.
2. Adjust the Cutting Force Valve to the desired force.
The saw head will lower and begin the cut.
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The Cutting Force Valve regulates the force of the
blade on the part being cut.
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The Feed Rate Control knob limits the rate that
the saw head falls. This can also be used to hold
the saw head at the start of the saw cut during the
set-up.
The Cutting Force Valve is the primary control and the
Feed rate control is secondary.
CUTTING FORCE VALVE SERVICE
INSTRUCTIONS
It may become necessary to open and clean the Cutting
Force Valve. Indications would be:
THREE CONTROLS IN THE SYSTEM
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Irregular feed rate control
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Unusual finish on the cut part
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Unexplained damage to saw blade
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Very slow cutting rate
Disassembling the valve for inspection and cleaning
1. Lower saw frame to bottom of stroke. Turn off the
Master Switch on the Control Panel. Turn off or
disconnect air power to the saw.
2. Loosen the saw blade.
3. On the Cutting Force Valve find the Push Rod
Assembly that fits between the Lever Arm (Part #
156266) and the valve body. Please refer to the
exploded view drawing.
4. While pushing down gently on the blade move the
bottom of the Push Rod Assembly off of the Lever
Arm. You can then lower the Push Rod Assembly. The
Spring (Part # 100136-011) will also fall out. Set these
items to the side.
5. Loosen the Cap (large hex nut, Part # 156256). Take
care that the Shell (Part # 156254) does not turn. Be
prepared to catch a small amount of oil with a shop
towel.
10
6. Loosen the Cap completely. The Shell with Adjusting
Nut (Part # 156259) will lower. Note the Plunger sitting
inside the Shell.
Cutting Force Control Valve
Test and Adjust
Problem: The Cutting Force is too heavy (the actual cutting
7. The Diaphragm may come down on top of the Shell or it force is higher than the value selected on the Thimble)
may remain up against the Valve Body.
Possible Cause:
8. Remove the Diaphragm and white plastic Needle.
1. The needle is held open on the valve seat by debris.
2. The length of the pushrod is too short.
Inspection and Cleaning
1. The Diaphragm should be flat and have no perforations
or wrinkles. If it has any defects it must be replaced.
Problem: The Cutting Force is too light or the saw head
stops during the cut: (the actual cutting force is lower than
2. Inspect the point of the Nylon needle. It must be smooth the value selected on the Thimble)
and free of debris. The point can be cleaned by twisting 1. Pushrod is too long.
it into a soft cloth. If it is has damage the valve will
Test: As a routine quick-check move the thimble on the
produce inconsistent force.
valve up to the lightest position (“30” on the Thimble or all
3. Remove the Plunger (Part # 156255). Inspect for
corrosion. Polish with a scrubbing pad to remove all
corrosion. Lubricate generously with a light grease.
4. Do not blow compressed air into the Valve Body.
Using an aerosol can spray light penetrating oil up into
the Valve Body. Allow it to drain. Again, do not blow
compressed air into the Valve Body.
Assembly
1. Remove the Thimble from the Shell.
2. Place all parts within arms reach.
3. Lubricate the steel Plunger with light grease and insert
into the Shell.
4. Lubricate the diaphragm liberally with hydraulic oil and
place on top of the Shell (and Plunger). Take care to
center the Diaphragm.
5. Stand the Needle in the center of the Diaphragm.
6. The Diaphragm is sandwiched between the Shell and
the Valve Body. Before the Shell is lifted up against the
Valve Body rotate the Shell so that the Force Scale is in
the desired position for the operator’s viewing. DO NOT
TURN THE SHELL ONCE IT IS LIFTED AGAINS THE
VALVE BODY otherwise the diaphragm may become
wrinkled and the Valve will not function properly.
7. Lift the Shell up against the valve body. Hold the Shell
steady to prevent turning and with your other hand
install the Cap nut. Lightly tighten by hand only.
8. Install the Thimble into the Shell. Turn up all the way
until it seats gently.
9. Install the Spring and Pushrod Assembly and position
on top of the Lever Arm.
10. Retighten the saw blade.
11. Adjust the Cutting Force Valve “30” or all the way up.
12. Power up the machine and make a test cut. They
system is self bleeding.
13. Please refer to the Test and Adjust notes for further
details.
the way up), open the Feed Control Valve (on the Control
Panel) to position 3 then press the Head Lower/Cycle Start
button. The saw head should descend at a slow rate (blade
motor is off). Insert a 40 thousandths (.040") feeler gauge
between the top edge of the blade and the Cutting Force
roller (on the little arm). This should stop the saw head. If
not then adjust the push rod to lengthen it accordingly. If
the head continues down after the adjustment or the weight
cannot be lowered then there may be debris in the needle &
seat.
Adjustment:
Tools needed:
• Bathroom scale
• Small block of wood
• Two ½" open end wrenches
• .040"feeler gauge (or approximate substitute)
1. Place the block on the scale.
2. Raise saw head enough to move the scale and block
into place under the blade. The scale should be close to
the stationary vise jaw.
3. Turn the thimble in the Cutting Force valve all the way
up. This represents the minimum cutting force.
4. Open the Feed Rate control (on front panel) to position
3.
5. (Blade motor is off) Press and hold the green HEAD
LOWER /CYCLE START button. The saw head should
descend slowly and the blade will come down on the
wooden block.
6. Tap on the back edge of the blade with a screwdriver to
free up any tension in the guides. Note the value of the
scale. It should be about 10 to 20 lbs.
7. If the weight is too high the rod length is too short and
needs adjustment. Unlock the two jam nuts and extend
the pushrod. If the value is still too high after adjustment
then the needle valve must be inspected for debris. See
the Instructions for service on the valve.
8. If the rod is adjusted too long the saw head will not
come down at all.
9. Remove the scale.
11
REVIEW OF CONTROL PANEL BUTTONS & OPERATION
MASTER START
Push green Master Start button and hold until illuminated.
This enables all machine operations. All Emergency Stop
buttons must be reset (out) to activate this button. Pushing
the emergency stop or loss of communication to the operator screen will disable the master start.
EMERGENCY STOP
Push to stop machine operation at any time. Pull out and
twist at the same time to reset. There are three emergency
stops on the machine, one on the operator station, one on
the top of the cutting head, and one at the end of the Barfeed. All three must be reset or out to operate the machine.
AUTO
Pushing this button puts the machine in the Automatic
Mode. The adjacent red indicator light is on when the machine is in Auto Mode. Push again and the red light will turn
off indicating the machine is in Manual Mode. This button
is also used to cycle stop the machine after running in Auto
Mode. If this button is pushed when running in Auto Mode,
the red light will go out and the saw will finish the current
cut cycle and then shut down. If this button is pushed while
the Operator Screen is in the “QUICK JOB” or “MULTIPLE
JOB” location the machine will cut the multiple length parts
as programmed. All other screens will enable the single
length programmed.
3 seconds after pushing are slow speed and then shifts
to high speed. This button is also used to home or zero
the machine. When power is first applied to the machine
a prompt asks the operator to “Zero Barfeed.” This prompt
goes away after the barfeed is moved fully forward with this
button and held for 3 seconds after stopping. The barfeed
can be zeroed at any time by simply holding down this button for 3 seconds while the barfeed is fully forward.
BARFEED VISE OPEN / CLOSE
Pushing this button will toggle the vise closed and then
open upon the next depression. The red light is on when the
vise is clamped. The machine will start in Automatic Mode
in either open or closed state.
BLADE START
When pushed and held for longer than one second the
blade will start. This is the only time delayed button and is
designed this way to avoid any non-intentional blade starts.
The Blade must be running or On to go into AUTO Mode.
The red light indicates the blade is On or running.
BLADE STOP
The blade motor stops when depressed. The red light is on
when the blade is off.
SAW VISE OPEN / CLOSE
Pushing this button will zero the current count of cut parts.
The count can also be changed on the Operator Screen.
Pushing this button will toggle the vise closed then open
upon the next depression. The red light is on when the vise
is clamped. The vise must be clamped before running in
AUTO Mode. A fault will be displayed if an attempt is made
to run in AUTO without this vise clamped.
NO TRIM CUT
HEAD RAISE
This feature allows the operator to feed the part length first
in Automatic Mode instead of making a trim cut first. Before
running the machine in Auto Mode, push this button and the
light will turn on indicating the machine will push the material forward in Auto Mode before making the first cut. This
feature is very beneficial for saving time if the trim cut has
already been made. Care should be taken not to bump into
the blade when positioning the stock.
Momentarily pushing this button will cause the cutting head
to raise until it touches the upper Limit Switch. This button
can be used as an abort or stop cut in the auto and manual
mode. The blade will also stop if it is running. The red light
is on when the cutting head raise valve is on.
RESET COUNT
BARFEED RETURN
While pushing this button in manual mode the barfeed
moves away from the operator or towards the back of the
machine. The barfeed stops when the button is released.
The red light indicates the barfeed valve is activated. The
first 3 seconds after pushing, the barfeed moves slow and
then shifts to high speed. The slow movement time is used
for ease of positioning material under the blade for a precise cut location.
BARFEED FORWARD
HEAD STOP
Momentarily pushing this button will stop the cutting head.
The red light is on when the head is stopped.
HEAD LOWER /CYCLE START
This button will cause the cutting head to lower or feed
when pushed in manual mode. The head will continue to
lower after the button is released if the blade is on. The
head will stop upon release if the blade is off. This button
is also used to cycle start the machine in automatic mode.
If the “NO TRIM CUT” feature is turn on in automatic mode
the machine will feed a length of material first when this button is pushed.
Pushing this button in manual mode will cause the barfeed
to move forward towards the operator or front of the machine. The light indicates the valve is activated. The first
12
13
Be sure to reset when
replacing the blade.
1
Cut Time
Previous Cut Time
Cut to Cut Cycle Time
Cuts This Blade
Reset Blade Cuts1
Saw Blade Run Time
Blade Speed
Data
Quick Job
NAVIGATING THE MENU
Current Job
Sequence Position
Current Length
Current Quantity
Current Cuts Made
Blade Speed
Cutting Force
Feed Rate
Reset Sequence
Sequence 1 thru
Sequence 15
Job Set-Up
Job Number
Length
Quantity
Blade Speed
Feed Rate
Cutting Force
Length
Multiple Job Auto
Current Length
Current Quantity
Current Cut
Reset to Len 1
Len 1 thru Len 6 inches
Qty 1 thru Qty 6
Length 1 thru
Length 6 mm

Single Length
Length inches
Quantity
Cuts Complete
Length in mm
Blade Speed
Actual Blade Speed





There are six screens. The SINGLE LENGTH screen is “Home Page.” Active Arrows will have pilot light.
Use the
Left Arrow to move to the screens left of the Home Page.
Use the
Right Arrow to move to the screens right of the Home Page.
Use the ESC button to move back toward the Home Page one screen at a time.
Use the
Down Arrow to scroll down a list.
Use the
Up Arrow to scroll up a list.
Press MOD to change a value, then press ENTER. Modify a value when it shows on the top line of the screen.
Jump back to the Home Page from any list by pressing the ESC button
Kerf
Accuracy
Position
Pulse Difference
Mechanical Offset
PLC Date
Saw Vise Open Time
Bar Feed Vise Open
Time
Display Date
Anti-Lift
Coolant Stop During
Shuttle
Set-up

Home Page
Model 1316S-Automatic
Control Panel Navigation Menu
THE SIX CONTROL SCREENS
The following is a description of items that will assist in
operating and manipulating data for the CNC length control.
These basic tools will be used in all the pages or screens
described.
•
The next piece of data is the “ CUTS COMPLETE”.
This shows how many parts have been cut. This
number can be changed if desired or reset using the
“RESET COUNT” on the touch key.
1. Use the up and down arrows to move around on the
current page displayed. The red light will be on next to
the arrow if it is allowed to move in that direction.
•
Metric Length is also provided in millimeters. If this
“LENGTH” mm is changed it also changes the ENGLISH inch value of the single length. The conversion
works in both directions. So that both metric and ENGLISH are always available.
2. Use the left and right arrows to move from page to
page. The “ESC” key must be used to return from the
direction you came, not the arrow key.
3. When changing the value of any number on any page,
the desired number to must be on the top of the 2 line
display. Then the “MOD” button is pushed. Enter the
new value and then push the “Enter” button. The new
value will then be showing.
4. If a message or alarm shows on the display and you
want to clear to perform other tasks simply push the
“ESC” button. If there is an active message the red
alarm light will be on. To display the alarm again, push
the “SHIFT” and “ENTER” key.
5. In several pages there is a RESET for sequences or
quantity. To use this reset, enter a value of 1 in the data
field by using the mod and enter key. The value will
automatically change back to “0” after momentarily “1”.
The reset is then complete.
DATA PAGE
This page is informational, and contains the following data:
•
CUT TIME : Current time in seconds required to make
a cut.
•
PREVIOUS CUT TIME: Time in seconds it took to complete the previous cut.
•
CUT TO CUT CYCLE TIME: Length of time it takes in
seconds to automatically cut a complete part.
•
CUTS THIS BLADE: Number of cuts made on the machine since the last “reset” of the blade cuts was done.
•
RESET BLADE CUTS: Resets the “cuts this blade”
number to zero. To reset , enter a “1.” The value will
momentarily go to 1 and then back to zero.
•
SAW BLADE RUN TIME: Total time the saw blade has
run since it was new. This value cannot be changed or
reset.
6. There are two small lights at the top left corner of the
operator interface. The top red one should remain blinking continuously, indicating the communication with the SETUP PAGE
control computer is OK. The machine cannot run and
Contains machine parameters that are adjustable. Most of
will automatically shut down if the light stops blinking.
these are factory set and will not have to be changed.
The lower green button indicates the current membrane
• KERF: Width of material the blade takes when making
button is activating when pushed.
a cut. The machine must know this value in order to
make accurate cuts. The default for a 1 inch blade is
55 or 0.055”. A wide kerf blade may take more material
Description & Operation
out in a cut, so this value may have to be increased.
SCREEN/PAGE
EXAMPLE: If a 1.000 inch part was being cut and the
actual measurement was 0.997 inches, the kerf would
have to be changed from 055 to 058 to get a perfect
1.000 inch part. After this change, all lengths will be accurate for this type of blade.
SINGLE LENGTH PAGE
Default page that appears when machine is first started.
•
Single length indicates the length of part and continuous cuts at that length. The first line of data is LENGTH
=. This can be changed at any time.
•
If the LENGTH = is changed while running in automatic
mode, the next length the barfeed locates will be the
new value entered. The number is in inches and is programmable with accuracy of 1/1000th of an inch.
•
The second piece of data is the “QUANTITY”. This is
the number of preset parts that will be cut before the
machine stops. If a value of zero is in this field the machine will continue to run until out of stock.
•
14
ACCURACY: Factory default is 3 which provides
positioning accuracy of better than +/- 0.002”. It can be
adjusted between 2 and 20. The purpose of a higher
number is only for cycle time in applications of long
lengths or production applications where 1 or 2 seconds
per part or shuttle makes a difference. The shuttle cycle
time is slightly faster due to positioning time for a higher
accuracy value such as 10 or 15.
A value of 10 would give a shuttle accuracy of +/-
0.006” which in most sawing applications is still very
high accuracy. A value of 2 would have an accuracy of
+/- 0.001” but may take slightly longer to position than
a higher value. In most cases the shuttle has more than
enough time to move to position because the saw is
making a cut.
multiple lengths. Up to six lengths can be programmed. The
operator must be on this page when starting the machine in
automatic mode for the multiple lengths to run. After starting, the operator may go to any other page desired. The
first quantity of zero in a length will cause a cycle stop and
a message displaying “QUICK JOB COMPLETE”.
•
POSITION: Barfeed’s actual position in thousandths
of an inch. If the saw was programmed to cut a 1.000”
part, the position at the time the barfeed clamps would
be approx. 1.055” with a 055 kerf. (On a single shuttle
part, the barfeed always feeds the desired length plus
the kerf.)
•
PULSE DIF: Pulse difference is the actual barfeed stop
error. It will always be within the ACCURACY window.
Optimum is “0”. This is for reference only and can be
used to watch each part position. All CNC machines
have an error window, most do not display this, they
only indicate the position will hold within the ACCURACY window.
The machine can be stopped at any time in the middle
of the process and then will continue where it left off after
startup. To reset the program back to the first part at any
time, simply change the value of “RESET” TO “1”. RESET
will automatically change back to “0” after reset. The “CURRENT LENGTH” will now show the first length and quantity
programmed.
•
MECH OFFSET: Mechanical offset is a single value
that can be changed to compensate for a machine that
is not perfectly level or aligned. The unit is 1= 0.0001”
or one ten thousandth of an inch per inch of programed
part length. The position sensor on the bafeed has a
guaranteed accuracy which should keep this value zero
for most applications, although if there was any error it
could be compensated for with this value. An example
would be if the length was programmed to 60.000” and
the actual measured length was 59.994” or six thousandths short, a value of “1” could be entered. Since
the value of “1” in this parameter is adding 0.0001”
per inch (or one ten thousandths of an inch per inch of
part length) the amount extra the barfeed would feed is
60.000” x 0.0001” = 0.006”. This is the amount needed
to get the exact 60.000” measured part. A 30.000” part
would add 0.003” per the offset. If the original measured part was long this mechanical offset would be a
negative value.
•
PLC DATE: Software revision date. 11233 is 11(November) 23 (23 rd) of 3 (2003).
•
SAW VISE OPEN TIME: The unit is in tenths of seconds. (7 = .7 seconds) The larger the number, the more
time the saw vise has to open. This is primarily used
when a saw has hold down options and more time is
needed to make the hold down raise higher to clear the
material.
•
BARFEED VISE OPEN TIME: The same as Saw Vise
Open Time.
•
DISPLAY DATE: The date of the display software revision MM-DD-YY.
QUICK JOB PAGE
The purpose of the quick job page is to “easily” program
EXAMPLE: If 2 different lengths were desired to be cut “on
the fly” the operator would enter a length value in LEN 1
and LEN2, and the corresponding quantity in QTY 1 and
QTY 2.
Make sure QTY 3 has a “0” in it so the machine cycle stops
after the 2 lengths programmed. LEN 1 = 26.098” QTY
1=4, LEN 2 = 3.078” QTY 2 = 16, QTY 3 = 0. This will cut
4 parts at 26.098 inches and then 16 parts at 3.078 inches
and then cycle stop.
•
CURRENT LEN: This value shows the current length
the saw is cutting.
•
CURRENT QTY: Current quantity or total number of
parts the operator wants for this length.
•
CURRENT CUT: Number of cuts made for the current
length.
•
RESET TO LEN 1: Changing this value to a “1” will
reset the program and start from the top or length 1
quantity 1. The value automatically changes back to
zero after reset.
•
LEN 1 Through LEN 6: Program the lengths in order
starting from length one to as many different lengths as
desired. The value is in inches.
•
QTY 1 Through QTY 6: Number of parts desired for
the matching length position. If a quantity of zero is
encountered, the saw will cycle stop at that position.
•
LEN 1 Through LEN 6 mm: Metric length for each
programmed length. Each length can be programmed
in millimeters at these fields.
MULTIPLE JOB AUTO
The purpose of this page is to recall stored jobs and run
them individually or in a sequenced order. This page must
be showing on the operator display when the machine is
started in automatic mode for this multiple job to run. After
starting in automatic, the operator can go to any other page
if desired. To view and change these jobs or lengths the
operator must go to the next page which is “JOB SETUP”.
There are 99 different jobs to choose from and they can be
sequenced in any order as programmed in SEQ 1 through
15
15. After the data is entered in a job the operator simply
puts the first job number in SEQ 1 that is to be cut and so
on for SEQ 2,3,4 etc.. When running automatic, the machine will cycle stop with the first “0” (zero) it encounters in
the “SEQ”.
EXAMPLE: If the operator wanted to run 3 different jobs
or lengths “on the fly” a job number would be programmed
into SEQ 1 through SEQ 3 and SEQ 4 would be “0”. SEQ
1=87, SEQ 2=34, SEQ 3=18, SEQ 4=0, would run the
three lengths and quantities programmed in those jobs, and
then cycle stop.
•
FEED RATE: This is the setting on the operator control
pointer for cutting head feed and is for reference only.
•
CUTTING FORCE: This is a reference for the cutting
force setting on the guide.
•
LENGTH mm: This is the metric length of cut in millimeters. If this value is changed the inch value above automatically changes to the correct value and visa versa.
After reviewing the push button descriptions and the cutting
saw controls in the main saw operation manual, a manual
machine movement or part cut can be made.
The machine can be stopped for any reason during the
middle of the cutting without affecting what is currently being cut. To Start all over again at SEQ 1, simply RESET the
pointer by entering a “1” into the “RESET” field.
The top lines of data on this page always show what is currently being cut.
A manual cut can be made by simply:
•
CURRENT JOB: This is the current job that will be or
is running. This value will change as the machine is
changing lengths or jobs while running automatically.
4. Starting the blade and adjusting the speed for the material to be cut.
•
SEQ: This is the current sequence position.
•
CURR LENGTH: This is the current length to be cut as
programmed in the corresponding job.
6. Slowly open the cutting head approach valve so the
cutting head begins to lower and cut the material.
•
CURR QUANTITY: This is the current number of parts
to be cut for the length shown.
•
CURR CUTS MADE: This is the total parts cut of the
current length.
•
BLADE SPEED: This is the current blade speed programmed in the current job. It is for reference only.
•
CUTTING FORCE: This is the current cutting force programmed into the current job. It is for reference only.
•
FEED RATE: This is the current feed rate for the current job and length. It is for reference only.
•
RESET SEQUENCE: Any time this is set to “1”, the
pointer is reset to SEQ 1.
•
SEQ 1 through 15: Enter the job in the order desired to
run starting with SEQ 1.
1. Clamping the part in the saw vise
2. Adjusting the cutting force if necessary
3. Closing the cutting head approach valve by rotating it
clockwise to zero.
5. Pushing the head lower push button
After the cut is complete, the blade will stop and the cutting
head will raise.
Steps 2,4 and 6 can be omitted when the operator becomes
proficient and the material is the same as previously
JOB SETUP
The purpose of job setup is to program and view the data in
each job. Change the job number field and the corresponding data is displayed. The data can be changed if desired at
any time. This data can also be changed while the machine
is running in automatic mode if desired.
• JOB #: This is the current job that corresponds to the
data or parameters below. Values are 1 through 99.
•
LENGTH: Length in inches for the current job shown
•
QUANTITY: Quantity of parts to be cut when run in auto
mode.
•
BLADE SPEED: This blade speed is in foot per minute
and is for reference.
16
MANUAL OPERATION
After reviewing the push buttton descriptions and the cutting 5. Pushing the head lower push button.
saw controls in the main saw operation manual, a manual
6. Slowly opening the cutting head approach valve so the
machine movement or part cut can be made.
cutting head begins to lower and cut the material.
A manual cut can be made by simply:
After the cut is complete, the blade will stop and the cutting
1. Clamping the part in the saw vise.
head will raise.
2. Adjusting the cutting force if necessary.
Steps 2,4 & 6 can be omitted when the operator becomes
proficient and the material is the same as previously cut.
3. Closing the cutting head approach valve by rotationg it
clockwise to zero.
4. Starting the blade and adjusting the speed for the material to be cut.
AUTOMATIC OPERATION
6. Set the cutting force and cutting head feed rate control
Automatic operation is simple to set up and easy to start.
to the desired value.
The following is in addition to the manual operation of the
machine and describes all of the factors for successful
7. Set the cutting pressure low (30-40) and the feed rate
operation. The Quick Start Guide also contains the basic
low (2-4) if you do not know where to start.
procedures for automatic operation. Automatic mode can be
started in “Single Length”, “Quick Job” or “Multiple Job”. The 8. Next, to begin cutting automatically, Start the saw
blade, push the “AUTO” button (Red light should come
Automatic startup is the same for single and multiple length
on next to the auto button showing the machine is in
cutting.
auto mode) and then push the “HEAD LOWER/ CYCLE
1. The blade speed should be known before attempting to
START” button. The machine will begin to make the trim
cut any material. Consult the chart in this manual or the
cut and the barfeed will move to the cut length position
blade supplier for this number.
and clamp the material.
2. Set both vises approximately 1/8 inch away from the
9. The machine can be cycle stopped by pushing the auto
material while they are in the “open” position.
button again (which puts the machine in manual mode,
red light). Immediate stop can be made by pushing the
“HEAD RAISE” BUTTON. The machine will also stop
if it runs out of stock or the “QUANTITY” number has
been cut.
3. Set the cutting head height so the head stops approximately 1/4 inch above the material.
4. Move the material under the blade manually or by
clamping the barfeed vise and using the barfeed in
manual mode to move the material and then clamp the
saw vise. The barfeed vise can be open or closed when
starting in auto. The position of the barfeed can be anywhere between 0 and the cut length to start in auto.
5. For a single length, enter the cut length desired in
LENGTH =. Enter the “QUANTITY” if only a certain
number of parts are to be cut. I the machine is to cut
the current length until it runs out of stock, leave the
QUANTITY = 0.
17
ELECTRICAL MAINTENANCE NOTES
The electrical print provided with this machine shows the
proper connections for all wiring. The fault/diagnostics
provided on the operator screen will assist with most issues
before an electrical maintenance person is called. The following information will provide the basic checks to assure
proper and accurate machine operation.
There are only a few areas to verify to quickly get this machine up and running automatically. All functions should be
working in manual mode before running auto.
1. The position system is working
2. The PLC should be on and running properly.
3. Lastly is the operator interface
POSITIONING SYSTEM
The run light on the processor must be on and “solid”, (not
blinking). This indicates the PLC is in the “RUN” mode and
is functioning properly.
The positioning system can be quickly verified in manual
mode by looking at the current ”position” in the setup page
on the operator station. Move the barfeed manually back
and forth to verify the number is changing properly. If not,
•
Check that the rod and sensor are tight without movement.
•
Make sure the 5VDC power supply is Working inside
the electrical enclosure.
•
If the barfeed already manually moves back and forth,
the PLC is OK, therefore the only items left are the
sensor, rod or voltage converters. These items have
been tested and they rarely go bad. However, if one
is bad, simply replace it as the average shop cannot
repair them. The voltage converter (part
# 921939)
is a small black electronic device about 1” by 1/2" with
four wire leads and is low cost and easy to replace. The
sensor or rod can be replaced individually if desired.
(part #920930).
If communication to the operator station is lost, the master
start (green light) cannot be turned on. No machine movement can occur until th communication is restored.
OPERATOR INTERFACE
The operator interface is working if you can manually move
something or change data. The display requires 24 VDC
and the connection of a cable (part #920764) to the PLC to
operate. The PLC Must be in run mode as described above
for all functions to work. A red light is flashing on the operator interface if it is communicating with the PLC.
This operator interface must be ordered from Wellsaw to be
assured of proper operation with this system.
In conclusion, there are few other components to check. All
components are the highest quality automotive grade and
will rarely fail. Components are stocked at the factory for
overnight shipment if necessary.
MOTION / BLADE BREAK SENSOR
This machine is equipped with a detector that monitors the
idle wheel movement. The proximity switch is monitored for
motion any time the blade is running. If the motion detector
does not sense motion of the machine blade and movement is stopped a fault is displayed. The LED indicator on
the switch and PLC input should be flickering on and off
while the blade is running for proper operation. If the blade
breaks while cutting, the idle wheel stops and causes a motion fault. The same occurs if the blade stalls while cutting
the material.
OUT OF STOCK SHUTDOWN
The out of stock shut down switch is located on the barfeed
vise. If the vise or clamp closes too far due to lack of material, the switch will open up causing the machine to cycle
stop. A fault will be displayed on the operator station.
PLC
If the position sensor is working, check all other components attached to the I/O of the PLC. Inputs to the PLC
have lights with their associated inputs. Each of these can
be tested for proper working order by testing the 24 VDC
wire to the PLC input and/or the light. This is a simple check
for a limit switch, etc. All inputs should be verified to be
working if an unknown problem occurs.
Outputs can also be verified by looking at the lighted output
on the PLC and by testing the voltage to the output. Blue
wire is 24 VDC and red is 120 VAC.
This PLC must be ordered from Wellsaw for proper operational software.
18
GENERAL OPERATING INFORMATION
REPLACING BLADE ON SAW
SUPPLEMENTAL FEED PRESSURE SYSTEM
Saws with Double Spring Tensioner
This system provides additional sawing downforce to ensure a positive chip load when the saw head angle is high
such as when cutting a large diameter solid stock. It is also
helpful when sawing very tough materials. The system consists of an air-over-oil volume chamber and an air pressure
regulator. Oil under pressure is applied to the top of the saw
head lifting cylinder. The pressure is adjusted at the second
regulator mounted on the side of the saw. For basic operation, the pressure should be set to 5 to 10 PSI. For large
or tough solid stock the pressure can be increased to a
maximum of 20 PSI.
Gloves must be worn for this operation.
1. Raise saw head far enough for the blade to clear the
top of the vise jaws.
2. Open both Wheel doors and open blade guards
3. Push blade brush idler arm away from the belt to release the tension and remove the belt.
4. On both blade guides turn the black knurled knob counter-clockwise until it stops. This opens the carbides.
5. Turn the Blade Tensioner T handle counter-clockwise
until the blade comes free from the bandwheels and
remove the band.
6. Install the new band around the bandwheels and into
the blade guides. Be sure that the teeth are pointing
away from the flange of the wheel. The teeth should
hang over the edge of the wheel. Also be sure that the
teeth are pointing in the direction that the blade will
travel.
7. Check to be sure that the blade is fully up into both
blade guides.
8. Turn the T Handle of the tensioner until the blade becomes snug on the wheels. Pull the blade up against
the wheel flange.
9. Continue to tighten the T Handle until the Pointer
reaches the block. See picture.
An oil level sight gauge is provided. Check the oil level with
the saw head is all the way down. The maximum level is
at the top ferrule. The minimum is half way down the sight
gauge.
To add oil, remove machine air pressure and remove the
pipe plug at the top of the sight gauge. Open the air line at
the exit port of the regulator. Fill to just below the top of the
sight gauge.
WHEEL PITCH ADJUSTMENT
If the saw blade runs too low, runs off the wheels, or runs
too high and rubs the wheel flange, a wheel adjustment
must be made. Loosen the blade before making the following adjustments:
IDLER WHEEL
•
10. Turn knobs on blade guides fully clock-wise. This
closes the carbides.
Adjust the idler wheel block. Loosen the 2 cap screws
in the block opposite the take up screw end, one-half
(½) turn. Tighten the opposite 2 cap screws one-half
(½) turn. Repeat if necessary.
11. Install blade brush belt and close the guards and wheel
doors.
12. After five minutes of operation stop the saw and open
the wheel doors. Inspect to be sure that the back edge
of the blade is properly tracking up to the flange of the
wheel. If the band is not tracking properly damage to
the wheels will result.
Blade running too low or off the wheel.
•
Blade running too high and against the idler wheel
flange.
The blade can become distorted, its top edge rolled
over and wheel flange will wear excessively. To correct this, loosen the two cap screws closest to the take
up screw one-half (½) turn. Tighten the opposite cap
screws one-half (½) turn. Repeat if necessary.
DRIVE WHEEL
Blade Tension Mechanism
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
101184
100030-007
100410-001
107321
155259
101198
155262
155263
100013-009
100053-005
100008-006
T-Handle
Flat Washer, 1/2
Thrust Bearing
Take Up Screw
Tensioner Slide Assembly
Spring
Tensioner Support
Tensioner Slide Stop
Cap Screw, BH, 10-32 x 1/2
Roll Pin, 3/16 x 1
Cap Screw, SH, 3/8-16 x 1
•
Blade running too low or off the drive wheels.
Loosen the two cap screws opposite the outside end of
the wheel plate one-half (½) turn. Tighten the two set
screws on the same end one-half (½) turn. Repeat if
necessary.
•
Blade running too high, and against the drive wheel
flange.
Loosen the cap screws closest to the outside end of
19
blade. If the shim slides between the blade and the rule
at either the top or bottom, the blade guides must be
adjusted.
the wheel plate and loosen the two set screws at the
same time by the same amount. Repeat if necessary. Make certain all screws are tight after adjustments have been made.
SAFETY
BLADE GUIDE ADJUSTMENT
Ensure that all bolts are properly tightened and that all
guards are in place before using the saw.
To properly align the saw blade for a straight and accurate cut, do the following:
OPERATION OF SWIVEL FEATURE FOR
MITER CUTTING
Square the stationary vise jaw. Make sure it is square
to the front of the vise slot. Check by placing a combination square against the front of the vise slot in the
saw bed. Slide the square toward the stationary vise.
Make any necessary adjustment to the vise jaw to bring
it into square. Set the combination square so that one
leg is along the face of the stationary vise and check to
see that the blade is square to the vise jaw. If it is not
square, follow the instructions for horizontal adjustment.
The angle of the cut is adjustable from 0° (90°) to 60°.
The angle is indicated by a pointer at the back of the
chip pan and a large scale on the edge of the cutoff turntable. The saw head is locked into position by means of
a control rod and locking block. There is a 0 stop on the
back of the saw bed. DO NOT ADJUST THIS STOP.
To adjust the angle of the cut, loosen the angle lock handle, pull the saw head, while lining up the pointer to the
desired angle shown on the scale. Then gently tighten
the handle. The lock requires very little pressure to hold
the head in place. DO NOT OVER TIGHTEN.
VERTICAL ADJUSTMENT
The back of the saw blade should just touch the carbide
back up guide when the saw is running but not cutting. To adjust, loosen the 2 cap screws [A] and move
the block up or down as required. (Before making this
adjustment, be sure the back of the blade is properly
contacting the flange on both the Drive and Idle wheels).
HORIZONTAL ADJUSTMENT
Loosen the 2 cap screws [B] securing the horizontal
adjusting block (items 11 & 12 on the parts drawing).
Turn the top adjusting bolt (item 5 on the parts drawing)
to move the blade either in, toward the saw bed, or out,
away from the saw bed.
Normally, the blade comes off the Drive Wheel with a
minimum amount of adjustment needed in the Horizontal
Adjusting Block. The Idle End adjusting block is more
likely to require adjustment.
BLADE TILT
To ensure the blade is perpendicular to the bed of the
saw, loosen the 2 cap screws [C] holding the Guide Support (28 & 29 on the parts drawing)and turn the bottom
adjusting bolt (13 on the parts drawing). Set the combination square on the saw bed with the end of the rule
butted against the blade above the set of the teeth. Use
a 1-1/2 thousandths (.0015") shim and slide it along the
top and bottom edge of the rule where it meets the saw
20
Stock Dimensions
Tooth Pitch
Material (Annealed)
Carbon Steels
1008-1013
1015-1018
1048-1065
1065-1095
Free Machining Steels
1108-1111
1112-1113
1115-1132
1137-1151
1212-1213
Manganese Steels
1320-1330
1335-1345
Nickel Chrome Steels
3115-3130
3135-3150
3310-3315
Molybdenum Steels
4017-4024
4032-4042
4047-4068
Chrome Moly Steels
4130-4140
4142-4150
Nickel Chrome Moly Steels
4317-4320
4337-4340
8615-8627
8630-8645
8647-8660
8715-8750
9310-9317
9437-9445
9747-9763
9840-9850
Nickel Moly Steels
4608-4621
4640
4812-4820
Chrome Steels
5045-5046
5120-5135
5140-5160
50100-52100
Chrome Vanadium Steels
6117-6210
6145-6152
Die Steels
A-2
D-2, D-3
D-7
O-1, O-2
O-6
0 - 1"
10/14, 8/12
1" - 3"
8/12, 6/10, 5/8
3" - 6"
5/8, 4/6, 3/4, 3 Sabre
6"+
3/4, 2/3, 2 Sabre,
1 Tooth, 3/4" T.S.
Blade
Cutting
Speed
Rate
(SFPM)
(SIPM)
Blade
Speed
(SFPM)
Cutting
Rate
(SIPM)
Blade
Speed
(SFPM)
Cutting
Rate
(SIPM)
Blade
Speed
(SFPM)
Cutting
Rate
(SIPM)
250
250
200
200
8 - 10
8 - 10
5-7
4-6
275
275
200
200
9 - 12
9 - 12
5-7
5-7
280
250
175
150
12 - 15
12 - 15
8 - 10
6-8
250
230
150
120
9 - 12
9 - 12
6-8
6-8
300
300
300
275
300
9 - 11
8 - 11
7 - 11
6-8
8 - 10
330
330
330
250
320
12 - 14
11 - 13
10 - 13
8 - 10
11 - 13
275
275
275
250
300
13 - 15
12 - 15
13 - 16
8 - 11
13 - 15
220
220
220
200
255
11 - 14
12 - 15
11 - 14
7 - 10
11 - 14
250
250
5-7
5-7
250
225
5-8
5-7
200
200
8 - 11
7-9
175
175
7 - 10
5-8
260
220
200
4-6
4-6
3-4
260
200
180
5-7
4-7
4-5
230
180
180
5-7
6-8
5-7
225
150
160
5-7
5-8
4-6
300
300
250
3-5
3-5
3-5
270
270
220
4-7
4-7
4-6
250
250
200
6-8
6-8
5-7
220
230
180
5-8
5-8
3-5
280
230
4-6
3-5
250
200
5-8
4-6
250
200
8 - 10
5-7
220
170
6-8
4-6
250
230
250
250
220
250
200
250
250
240
3-5
3-4
4-5
3-5
2-4
3-5
1-3
4-5
2-4
4-5
225
200
230
230
200
220
160
230
230
220
4-6
4-5
6-7
4-6
3-5
4-6
2-3
4-5
3-5
4-6
200
200
230
230
200
220
160
230
200
200
5-7
4-6
6-8
5-7
4-6
5-7
2-4
5-6
4-6
5-7
170
170
200
180
150
180
150
180
180
180
4-6
4-5
6-7
4-6
3-5
4-6
2-3
4-5
3-5
4-6
250
220
200
3-5
3-5
3-5
220
200
180
5-6
4-6
3-5
220
200
180
6-7
5-7
4-6
200
170
160
5-6
4-6
4-5
280
280
250
180
4-6
4-6
3-5
2-4
250
250
230
160
5-7
6-7
4-6
3-5
250
240
230
150
8 - 10
7-8
5-7
4-6
200
180
200
100
7-8
5-8
4-6
3-5
225
225
4-5
3-4
225
200
5-7
4-5
200
200
6-8
5-6
170
150
5-7
4-5
210
110
90
240
230
2-3
1-2
1
3-4
3-4
200
100
80
210
200
3-4
1-2
1
4-5
4-6
190
90
70
190
180
3-4
1-2
1
5-6
5-7
180
80
70
170
150
2-3
1-2
1
4-5
4-6
21
Stock Dimensions
Tooth Pitch
Material (Annealed)
Silicon Steels
9255-9260
9261-9262
High Speed Tool Steels
T-1, T-2
T-4, T-5
T-6, T-8
T-15
M-1
M-2, M3
M-4, M-10
Hot Work Steels
H-12, H-13, H-21
H-22, H-24, H-25
Shock Resisting Tool Steels
S-1
S-2, S-5
Special Purpose Tool Steels
L-6
L-7
Stainless Steels
201, 202, 302, 304
303, 303F
308, 309, 310, 330
314, 316, 317
321, 347
410, 420, 420F
416, 430F
430, 446
440 A,B,C
440F, 443
17-4PH, 17-7PH
A-7
Beryllium Copper #25
BHN 100-120
BHN 220-250
BHN 310-340
Nickel Base Alloys
Monel
R Monel
K Monel
KR Monel
Inconel
Inconel X
Hastelloy A
Hastelloy B
Hastelloy C
Rene 41
Udimit
Waspalloy
Titanium
Titanium Alloys
TI-4AL-4MO
TI-140A2CR-2MO
0 - 1"
10/14, 8/12
1" - 3"
8/12, 6/10, 5/8
3" - 6"
5/8, 4/6, 3/4, 3 Sabre
6"+
3/4, 2/3, 2 Sabre,
1 Tooth, 3/4" T.S.
Blade
Cutting
Speed
Rate
(SFPM)
(SIPM)
Blade
Speed
(SFPM)
Cutting
Rate
(SIPM)
Blade
Speed
(SFPM)
Cutting
Rate
(SIPM)
Blade
Speed
(SFPM)
Cutting
Rate
(SIPM)
200
200
2-4
1-3
180
160
3-5
2-3
180
160
3-5
2-4
150
150
3-5
2-3
130
110
110
80
150
120
100
1-2
1-2
1-2
1
1-3
1-2
1-2
110
100
100
80
140
110
90
2-3
1-2
1-2
1
2-4
2-3
1-2
100
90
80
70
130
100
80
2-4
2-3
1-2
1
3-5
3-4
1-3
90
80
70
50
110
80
60
2-3
1-2
1-2
1
2-4
2-3
1-2
150
150
2-4
1-3
125
125
3-5
1-3
125
125
2-4
1-3
125
125
2-4
1-3
220
170
2-4
1-3
180
150
3-5
3-5
165
120
3-5
2-4
150
100
2-4
1-3
200
200
2-4
2-4
180
180
3-5
3-5
170
150
3-5
3-5
150
100
2-4
2-4
120
140
90
90
130
150
200
100
120
150
100
100
2-4
2-4
1
1
1-3
1-3
3-5
1-3
1-3
1-3
2-3
1-2
100
120
70
80
110
130
180
90
10
130
90
100
2-4
2-4
1
1
1-3
1-3
4-6
2-4
1-3
1-3
2-4
1-2
100
100
60
70
100
120
170
80
90
120
80
100
2-4
3-5
2
2
2-4
2-4
5-7
2-4
2-4
2-4
3-4
2-3
100
100
60
60
80
100
150
80
70
100
80
100
1-3
2-4
1
1
1-3
1-3
4-6
1-3
1-3
1-3
2-3
2-3
350
250
200
4-6
2-4
1-2
300
225
160
5-7
3-5
1-2
275
200
140
6-8
3-4
2-3
225
175
100
5-7
3-5
1-2
100
140
100
100
110
90
120
110
100
90
100
90
100
1-2
2-3
1
1-3
1-2
1
1-2
0-1
0-1
1
1
1
1-2
100
140
80
90
100
80
100
100
90
90
90
90
100
1-2
2-4
1
1-3
1-3
1
1-2
1-2
0-1
1
1-2
1-2
2-3
80
125
60
80
80
70
85
90
70
90
90
90
100
1-2
2-4
1
1-3
1-3
1
2-3
1-2
0-1
1 -2
1-2
1-2
2-3
60
75
60
60
80
60
75
75
60
90
90
90
100
1
2-3
1
1-2
1-2
1
1-2
0-1
0-1
1-2
1-2
1-2
2-3
100
100
0-1
0-1
90
90
0-1
0-1
80
80
0-1
0-1
70
60
0-1
0-1
22
The Original........Since 1926
2829 N. Burdick St.
Kalamazoo, MI 49004
Phone: 269-345-1132
Fax: 269-345-0095
website: www.wellsaw.com
email: [email protected]
23
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