The Hyd-Mech M-20 is a powerful bandsaw designed for efficient and accurate stock cutoff. This machine features a programmable length controller (PLC) for automatic operation, allowing you to program and store up to 99 jobs with varying lengths and quantities. The PLC also enables single-cut operation in manual mode. The M-20 incorporates a hydraulic system for blade control and a variable speed control for optimization. This comprehensive design minimizes production downtime and maximizes your cutting efficiency.
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OPERATIONS & MAINTENANCE M A N UA L I N B A N D S A W T E C H N O L O G Y M-16 / M-20 Dear Customer, As a businessman you understand the necessity of keeping the cost of each step of production to an absolute minimum without sacrificing quality. In the purchase of any new piece of equipment you are looking to increase your production and consequently reduce your cost, while maintaining or improving quality. With these points clearly in mind we have designed the HYD-MECH M-16 / M-20. Our goal is to change stock cutoff from a "necessary evil" to a money making and time saving part of your operation. Please use this manual to familiarize yourself and your employees on the proper operation and maintenance of the M-16 / M-20. We appreciate the confidence you have shown in our product and wish you every success in its use. Sincerely, Stan Jasinski, P. Eng., HYD-MECH ENGINEERING LTD. Founder HYD-MECH GROUP 1079 Parkinson Road P.O. BOX 1087 Woodstock, Ontario N4S 8P6 Published 1/99 Phone: (519) 539-6341 Fax: (519) 539-5126 e-mail: [email protected] THIS PAGE INTENTIONALLY LEFT BLANK SECTION 1 - INSTALLATION TABLE OF CONTENTS Safety Precaution .................................................................................................. 1.1 Lifting Instruction .................................................................................................. 1.2 Foundation, Levelling and Anchoring ....................................................................... 1.3 Wiring Connections .................................................................................................. 1.4 Cutting Fluid and Hydraulic Oil ................................................................................ 1.5 SECTION 2A - Control Console Start-Up .................................................................................................................... 2.1 Manual Operation .................................................................................................. 2.1 Operator control panel switches (Detailed explanations) ........................................... 2.2 Control System, Mitsubishi PLC 100 ....................................................................... 2.5 PLC Control description ................................................................................ 2.6 Function button description ................................................................................ 2.7 Single Cycle Operation ................................................................................ 2.8 Automatic operation ......................................................................................... 2.9 Working With A Queue ................................................................................ 2.10 Kerf correction .................................................................................................. 2.11 SECTION 2B - SAW CUTTING CONTROLS Blade Basics ........................................................................................................... 2.13 Variable Speed Control ......................................................................................... 2.13 Hydraulic Feed Control ......................................................................................... 2.14 Cutting Parameter Chart (usage instruction) .............................................................. 2.15 Step 1 Determine Effective Material Width .................................................... 2.16 Step 2 Set Feed Force Limit ...................................................................... 2.17 Step 3 Determine Optimum Blade Pitch, Teeth Per Inch .................................. 2.18 Step 4 Determine Optimum Blade Speed .................................................... 2.19 Step 5 Determine Feed Rate Setting ............................................................. 2.19 Additional Cutting Set-Up Examples ....................................................................... 2.20 SECTION 2C - MECHANICAL CONTROLS Coolant Flow ........................................................................................................... 2.23 SECTION 3 - MAINTENANCE AND TROUBLESHOOTING Lock-out and procedure ......................................................................................... 3.1 Blade Changing .................................................................................................. 3.2 Blade Brush ........................................................................................................... 3.3 Blade Guides ........................................................................................................... 3.3 Lubrication ........................................................................................................... 3.4 Hydraulic Maintenance ......................................................................................... 3.5 Cleanliness ........................................................................................................... 3.5 Trouble Shooting .................................................................................................. 3.6 Programmable Lenght Control ................................................................................ 3.9 Mitsubishi PLC 100 Parameters ................................................................................ 3.10 PLC 100 Trouble Shooting ......................................................................................... 3.11 PLC 100 Inputs and Outputs ................................................................................ 3.17 PLC 100 Calibration Procedure ................................................................................ 3.19 Service Record & Notes ......................................................................................... 3.21 Pg .i M1620 SECTION 4 - ELECTRICAL SYSTEM ................................................................................................... 4.1 General Information M-16A and M-20A Electrical Components (photos) ..................................................... 4.2 Electrical Components List ......................................................................................... 4.4 M-16 Power Components List ................................................................................ 4.6 M-20 Power Components List ................................................................................ 4.7 M-16/20 Electrical Schematic (M16/20 MIT-7-00-1d) ........................................... 4.8 M-16/20 Wiring Diagram (M16/20 MIT-7-00-2d) (pg.1 of 3) ......................... 4.9 Input & Output Devices (M16/20 MIT-7-00-2d) (pg.2 of 3 & pg. 3 of 3) ................ 4.10 SECTION 5 - HYDRAULIC SYSTEM M-16A Hydraulic Components List ................................................................................ M-20A Hydraulic Components List ................................................................................ Cylinder Piston and Gland Assemblies ...................................................................... M-16/20A Hydraulic Schematic M16-6-00-1d ........................................... M-16/20A Hydraulic Plumbing Diagram M16-6-00-2d ........................................... SECTION 6 - MECHANICAL ASSEMBLIES 5.1 5.2 5.3 5.4 5.5 Blade Brush Assembly .................................................................................................. 6.1 Guide Arm & Carbide Assemblies ................................................................................ 6.2 Blade Tension Assembly ......................................................................................... 6.4 Pivot Link Assembly .................................................................................................. 6.5 Hydraulic Tank Assembly ......................................................................................... 6.6 Hydraulic Pump Assembly ......................................................................................... 6.7 Front Vise and Conveyor Assembly ................................................................................ 6.8 Shuttle Vise Assembly ......................................................................................... 6.10 Shuttle Datum Jaw Assembly ................................................................................ 6.11 Length Control Assembly ......................................................................................... 6.12 Chip Auger Assembly .................................................................................................. 6.13 Coolant Group ........................................................................................................... 6.14 Doors and Covers .................................................................................................. 6.15 Drive Assembly ........................................................................................................... 6.16 M-16 Gearbox Assembly ......................................................................................... 6.19 M-20 Gearbox Assembly ......................................................................................... 6.20 SECTION 7 - SAW OPTIONAL EQUIPMENT Bundling Assembly .................................................................................................. 7.1 Bundling Assembly and parts list ................................................................................ 7.2 Vertical Roller Assembly ......................................................................................... 7.3 M16-M20 Direct Drive Assembly ....................................................................... 7.4 Mitsubishi PLC 500 Controller ....................................................................... 7.6 Digital Angle Display ................................................................................ 7.6 Variable Vise Pressure ......................................................................................... 7.6 Out of Stock Switch ......................................................................................... 7.6 SECTION 8 - SPECIFICATIONS M-16 Specification List .................................................................................................. Layout drawing M-16A ........................................................................................ M-20 Specification List ................................................................................................. Layout drawing M-20A ........................................................................................ SECTION 9 - WARRANTY 8.1 8.2 8.3 8.4 Warranty .................................................................................................................... 9.1 Mitsubishi Parameters List ........................................................................................ 9.2 Pg .ii M1620 INSTALLATION SECTION 1 - INSTALLATION SECTION 1 SECTION 1 - INSTALLATION SECTION 1, INST ALL ATION INSTALL ALLA 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 fluid leaks. In the event of damage caused during shipping, contact your carrier to file a damage claim. SAFETY PRECA UTIONS PRECAUTIONS The M16/20 has been designed to give years of reliable service. It is essential that operators be alerted to the safe operation of this saw, and the practices to avoid that could lead to injury. The following safety rules are at the minimum necessary for the safe installation, operation, and maintenance of the saw. Take every precaution for the protection of operators and maintenance personnel. . * POWER HOOK-UPS AND REPAIRS SHOULD BE ATTEMPTED ONLY BY QUALIFIED TRADESMEN. * THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK INTO THE SAW. SECURE THE SAW TO THE FLOOR. * THE AREA AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID OBSTACLES OPERATORS COULD TRIP OVER. * THE M16/20 SHOULD ONLY BE OPERATED ACCORDING TO THE SPECIFICATIONS OF THE SAW. AVOID UNSAFE USAGE PRACTICES. * IF AT ANY TIME THE SAW DOES NOT APPEAR TO BE OPERATING PROPERLY IT SHOULD BE STOPPED IMMEDIATELY AND REPAIRED. * OPERATOR : THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ARE IN PLACE AND CLOSED. * OPERATOR : KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE AND VISES. * OPERATOR : LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING THE SAW. COVER LONG HAIR. * OPERATOR : STOCK SHOULD NOT BE LOADED ONTO THE SAW IF THE BLADE IS RUNNING. * OPERATOR : LONG AND HEAVY STOCK SHOULD ALWAYS BE PROPERLY SUPPORTED IN FRONT OF AND BEHIND THE SAW. * OPERATOR : NEVER ATTEMPT TO DISLODGE OR MOVE STOCK WHILE THE BLADE IS MOVING. TAKE THE TIME TO STOP THE SAW BLADE, REMOVE OBSTRUCTIONS, AND RESTART BLADE. * OPERATOR: MUST WEAR EYE PROTECTION. * OPERATOR: MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION, BLADE GUIDES, AND THRUST BEARINGS. * OPERATOR: HOLD WORK-PIECE FIRMLY AGAINST TABLE. * OPERATOR: DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED. * NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROM HYD-MECH. ANY APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL. Pg 1.1 M-16 AND M-20 LIFTING INSTR UCTION INSTRUCTION This mac hine is designed to be lifted in one led piece der to lift the mac hine it machine one,, fully assemb assembled piece.. In or order machine needs to be in following condition. - Sa w head in its bottom position a grees Saw att 90 de deg ees.. - Shuttle vise fully forward. - Coolant tank emptied. aps rra ated ffor or 7400 lbs and 7700 lbs ffor or M-20 (M-16P is 6400 lbs Fle xib le lifting str lbs,, M-20P is 6800 lexib xible stra lbs) should be connected to the lifting lugs a h corner of the mac hine as shown below att eac each machine below.. Chains should not be used as the y ma y cause dama ge to v arious par ts of the mac hine they may damag various parts machine hine.. Front View The 4 lifting lugs are circled. Pg 1.2 Rear View FOUND ATION FOUNDA TION,, LEVELLING AND ANCHORING Machine location should be carefully selected. A flat concrete floor 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 levelled in both directions, i.e. along and across its infeed conveyor especially when machine is to be inserted into a larger conveyor system. Four levelling 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 floor. In cases when the machine is to be anchored permanently, anchoring holes are provided. They are located next to the levelling screws. NOTE: In some cases levelling the saw infeed 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). 2 leveling bolts at the idler side of the machine are shown. Use Precision Level on Outfeed Table in both directions Level saw from front to rear and from side to side Pg 1.3 WIRING CONNECTIONS After the machine is levelled 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 qualified personnel should be allowed to do the work. The first two areas that need to be checked are: - There is 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, - 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 diconnected. 2) Push the lockout tab to the right and pull the door open. In the case of a 240V machine, the disconnect box will be smaller. To close the door properly, reverse the above steps. ON / OFF SWITCH SHOW IN "OFF" POSITION Pg 1.4 Disconnect Box SAFETY LOCK OUT HOLE OCKOUT L1 L2 L3 Main Power Connections GROUND CUTTING FL UID FLUID The M16/20 uses a pump and reservoir to circulate the necessary cutting fluid to the blade for maximum blade life. Your saw blade supplier will be able to provide information on the cutting fluid products that are available for your needs. No cutting fluid (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 w ash down gun on the fr ont of the sa w wash front saw HYDRA ULIC OIL HYDRAULIC As shipped, the saw oil tank is filled 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 Le vel Gaug e on the pow er pac k door Lev Gauge power pack door.. Oil F iller Ca p ffound ound inside pow er pac k door Filler Cap power pack door.. Pg 1.5 THIS PAGE INTENTIONALLY LEFT BLANK OPERATING INSTRUCTIONS SECTION 2 - OPERATING INSTRUCTIONS SECTION 2 SECTION 2 - OPERATING INSTRUCTIONS ST AR T-UP STAR ART SECTION 2A, THE CONTROL CONSOLE The M-16/M-20 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 can not overstress the importance of familiarizing yourself with the controls of the M-16 or M-20 prior to starting the machine. NOTE: 1) ALL SWITCHES MUST BE IN THE CENTER NEUTRAL POSITION TO START THE MACHINE! 2) WHEN STARTING THE MACHINE FOR THE FIRST TIME MAKE SURE THAT BLADE IS MOVING IN A COUNTERCLOCKWISE DIRECTION, AND THAT THE HYDRAULIC PRESSURE IS 900 PSI (6200kP). IF THERE IS NO IMMEDIATE PRESSURE, SHUT THE SAW DOWN AND CHANGE THE PHASE ORDER AS STATED ON Pg. 1.5. Operator Control Console. MANU AL OPERA TION MANUAL OPERATION Manual Operations can be performed when the PLC 100 controller is set to MAN (AUTO is active when a RED light is on above the AUTO/MAN button) button). All functions are self-explanatory except head swing movements. The pushbuttons are labeled FAST & SLOW, when depressed partially, the movement is SLOW, when fully depressed, the movement is FAST. Specific control button functions are described on the following pages. Pg. 2.1 OPERATOR PANEL SWITCHES TOP ROW FRONT VISE - This switch has three positions, CLOSE, OPEN, and HOLD. In CLOSE, the vise will close all the way, or until it encounters enough resistance to stop it. 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 indefinitely without creeping. HEAD CONTROL - This switch has three positions: UP, HOLD and DOWN. The switch is inactive unless the PLC is in manual mode. In the UP position, the head will rise until it trips the head up limit which is adjustable via the PLC. In the HOLD position the head will stay still. In the DOWN position the head will descend until it reaches the bottom of the stroke. The speed of descent is controlled by the Head Feed and Head Force Limit controls. BL ADE ST AR T - The blade can be started only when the hydraulics are BLADE STAR ART running in either manual or auto mode. NOTE: In automatic Mode the head will not descend until the blade has been started, which the PLC will prompt the operator to do so. HYDRAULIC START - To start the hydraulic system, the switches for the NEUTRAL" position. The head and both vises must be in the "NEUTRAL" "HYDRAULIC START" button must be depressed and held in momentarily until the PLC display becomes active. CY CLE ST AR T/P AUSE - This button starts the cutting cycles and will stay CYCLE STAR ART PA 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. Pg. 2.2 OPERATOR PANEL SWITCHES CENTER ROW COOL ANT - This switch has three positions, WASH, OFF, and ON. In the COOLANT WASH 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 ON 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, CLOSE, OPEN, and HOLD. In CLOSE, the vise will close all the way, or until it encounters enough resistance to stop it. 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 indefinitely without creeping. BL ADE ST OP B UTT ON - Stops the blade. If the blade is stopped during a BLADE STOP BUTT UTTON cycle, the cycle will continue but will not let the head descend until the blade is started. ST OP - This mushroom button stops the blade and hydraulic motors. Both STOP vises will hold their position but, pressure will begin to fall off. Long pieces of work should always be supported so they will not become loose over time and fall while the machine is shut down. BOTTOM ROW HEAD SWING 90 - This is a two position push button. By pressing the button in partially, the head will SLOWLY swing towards the 90 degree position until it reaches 90 degrees or the button is released. This allows for a fine 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. Pg. 2.3 OPERATOR PANEL SWITCHES BOTTOM ROW (continued) HEAD SWING 30 - This is a two position push button. By pressing the button in partially, the head will SLOWLY swing towards the 30 degree position until it reaches 30 degrees or the button is released. This allows for a fine 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. GUIDE ARM - This switch controls the position of the idler (left) guide arm. OPTIONAL CONTROLS CENTER ROW BLADE SPEED - This option is the REMOTE BLADE SPEED. This dial will increase or decrease the speed at any time while the blade is running. BOTTOM ROW WORK LAMP - This option switch has two positions, OFF and ON. LASER GUIDE - This option switch has two positions, OFF and ON. FAST APPROACH - (On Machines equipped with Electric Fast Approach) By depressing this button, the head will descend at an accelerated rate when the head is receiving a signal from either the head selector switch in manual mode or the PLC in automatic mode. Pg. 2.4 MITSUBISHI BASED PLC CONTROL SYSTEM NOTE: This instruction manual is applicable to the M16A, M20A, H18A to H32A machines equipped with a Mitsubishi PLC, c/w feed rate display, manufactured after and including the following serial numbers: Machine Model Serial # M-16A S0298036 M-20A T0198019 H-16A B0398162H H-20A C0398114H H-26A D0598036H H-32A OPERATION OVERVIEW The PLC is a programmable length controller which allows the operator to run the machine in both manual and automatic modes. In manual mode, all functions can be operated by using a combination of selector switches on the control console and the PLC function buttons. Also the operator has the ability to execute a single cut utilizing a preprogrammed "Single Part Cycle". In automatic mode, the PLC has the capacity to program and store 99 jobs. Designated job numbers can be programmed for quantity required (maximum of 999 pieces) and lengths from 0" to 220" (5588mm). 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 operations, use the large red mushroom "emergency stop" button located on the control panel to shut down the machine. Pg. 2.5 PLC CONTROL DESCRIPTION ACTIVATING THE PLC Position the head, fixed vise, and shuttle vise switches to the NEUTRAL (center) positions. If any of these switches are not in the NEUTRAL position, the hydraulics will not start. The PLC control will become active when the HYDRAULIC START button is depressed and "held in" momentarily. First, the PLC's current revision number will be shown on the display window. The AUTO/MAN indicator light will be off and all MANUAL controls are enabled. The "LTH" value (shuttle vise position) will always display zero at start up. The "LTH" value can be reset or cleared at any time in MANUAL mode by pressing the CLEAR function button. PLC CONTROL PANEL DISPLAY WINDOW BLADE SPEED IN SURFACE FEET (METERS) PER MINUTE SHUTTLE VISE POSITION PLC FUNCTION BUTTONS CURSOR BUTTONS SFM 000 LTH 0.000 KERF CLEAR/HOME AUTO MAN JOB FWD 7 7 7 QUEUE REV FAST METRIC INCH SLOW 8 9 8 9 8 0 9 NUMERIC KEY PAD Pg. 2.6 CLEAR CLEAR DATA KEY AT CURSOR POSITION INACTIVE KEYS ENTER DATA ENTRY KEY FUNCTION B UTT ON DESCRIPTION BUTT UTTON If a red indicator light above a function button is illuminated, it means that the function printed in red at the top of the button is enabled. No light indicates the the function printed in black at the bottom of the function button is enabled. The following are the function buttons for AUTO and MAN modes: KERF CLEAR/HOME AUTO MODE - This button is held for 5 seconds to recall or set the "KERF" value. MAN MODE - 1) This button is used to reset the "LTH" counter to zero. 2) If pressed and held in for a few seconds, the HEAD HOME cycle will be initiated. NOTE: Before using SINGLE CUT or AUTO, it is necessary to "HOME THE HEAD". This must be repeated any time the hydraulic system has been shut down so the machine knows where it's HOME position is. AUTO MAN AUTO / MAN MODE - This button will toggle between MAN and AUTO modes. Auto mode cannot be accessed JOB FWD AUTO MODE - This button will allow editing of a job to be executed. unless front vise is closed. - Also used to stop an automatic job in progress by switching to MANUAL mode. MAN MODE - This button will advance the shuttle vise toward the head (home position) and if pressed simultaneously with "REV", to recall parameters. (Front vise must be in the closed position to gain access to parameters) QUEUE REV AUTO MODE - This button will allow viewing of the current QUEUE or the editing of a new QUEUE to be executed. MAN MODE - This button will retract the shuttle vise away from the head and if pressed simultaneously with "FWD", to recall parameters. ( Front vise must be in the closed position to gain access to parameters) FAST SLOW AUTO MODE - This button is disabled. METRIC INCH AUTO / MAN MODE - This button toggles to allow length values to be displayed either in millimeters or inches MAN MODE - This button will toggle between FAST and SLOW speed for the shuttle vise. and the blade speed in either surface feet per minute or meters per minute. It becomes disabled once an AUTO cycle is initiated. Pg. 2.7 SINGLE P AR T CY CLE OPERA TION PAR ART CYCLE OPERATION In MAN mode, the PLC allows the operator to initiate a "Single Part Cycle " to cut one piece at a desired length. To accomplish this, follow the procedure below. Before initiating this procedure, the head should be "HOMED". See function button description for KERF . CLEAR/HOME 1) A trim cut should be made before initiating the "Single Part Cycle " operation. 2) Make sure the fixed vise switch is in the closed position. 3) Make sure the head is set so that the blade is above the material and the head selector switch is in the HOLD position. 4) The cursor will be flashing at the CUT position. Key in the desired value from 0" to 220" and press ENTER If the value is incorrect, re-enter the value and press ENTER SFM 0 CUT 1 0.250 LTH 0.000 LENGTH 5) If the blade is not running, you will be prompted by the word "BLADE" flashing on the display window. Start the blade and adjust the blade speed as required. BL ADE SPEED BLADE SFM 0 CUT 1 0.250 L TH 0.000 BL LTH BLADE ADE FLASHING 6) You will then be prompted by the word "START" flashing on the display window to begin the cut. Press CYCLE START and the cycle will begin. SFM 100 LTH 0.000 CUT 1 0.250 ST AR T ART STAR FLASHING 7) When the start button is pressed, the shuttle vise will move to the forward home position before executing the length movement. The head will descend and make the cut. SFM 100 CUT LTH 5.000 FR 1.2 8) When the cut is completed, the blade will stop, the head will rise to the previous head height setting and the display window will reset for the next cut. SFM 0 LTH 0.000 CUT 0.000 9) To cut another piece, repeat steps 2 through 6. Pg. 2.8 NOTES: 1) To "PAUSE" the "SINGLE CUT CYCLE", depress the "CYCLE START" button. The "CYCLE START" button will begin to flash and the screen will indicate a paused condition. All movements will immediately cease. To continue the cycle, depress "CYCLE START" button again. 2) To cut multiple pieces, switch to AUTO MODE and follow the automatic procedures. NOTE: Whenever a new job or new material is being loaded for production, the head height should be properly set to clear the material, material positioned for a trim cut and the front vise closed (in "MANUAL MODE"). Before entering AUTO mode, the head should be "HOMED". See function button description for KERF . CLEAR/HOME AUT OMA TIC OPERA TION UTOMA OMATIC OPERATION When the AUTO/MAN button is pressed, the red indicator light above it will come on, and the blade will stop if it has been running. The screen will change to the JOB display window as shown below and be ready for editing or starting a new job. All manual functions will be disabled. JOB DISPLAY WINDOW Blade Speed Length Job Number JOB 0 RQ 0 LTH 0.000 CT 0 Required Quantity Cut Quantity PROCEDURE FOR EDITING OR ST AR TING A NEW JOB IN A UT O MODE STAR ARTING AUT UTO ENTER 1) In AUTO mode, key in a job number from 0 to 99 and press If the job number has previously been programmed, the QUANTITY REQUIRED (RQ), LENGTH (LTH) and QUANTITY CUT (CT) will be displayed. The values displayed can be edited and the job will be stored in memory with the new values. To navigate through the values, use the CURSOR keys. NEW JOB VALUES Length JOB 99 RQ 10 LTH 15.000 CT 5 Quantity Previously Cut 2) After the values are entered, press the CYCLE START button, the switch will illuminate, the display window will prompt you to "SET MTL. HEIGHT". Using the head selector switch, position the head above the work-piece. SET MTL. HEIGHT & PRESS "ENTER" 3) After setting blade height, you will be prompted to "START THE BLADE FOR TRIM CUT" ST AR T THE BL ADE STAR ART BLADE FOR TRIM CUT 4) After starting the blade, the head will descend for the trim cut and continue to complete the required job. SFM 100 J1 LTH 5.000 RQ 2 CT 0 Display while head in up position and material advanced. 5) At the completion of the job, the machine will shut down. SFM 100 FR 1.2 J1 RQ 2 CT 0 Display while head is descending during cut. Pg. 2.9 NOTE: The "CT" value is the accumulated total number of parts that have been cut from the JOB number since it was last reset. The machine will only cut the quantity which is the difference between REQUIRED QUANTITY and CUT QUANTITY. When REQUIRED QUANTITY equals CUT QUANTITY, the machine AUTO CYCLE will stop and you will be unable to restart the same job until the "CUT QUANTITY" value has been reset. NOTE: Before entering "AUTO MODE" and working with a "QUEUE", follow the same procedures as outlined on the previous page in "AUTOMATIC OPERATION" with regards to setting up for initial trim cut. WORKING WITH A QUEUE The purpose of a QUEUE is to allow the operator to run several jobs (max of 5) in series if they are of like material. In AUTO mode, press QUEUE and the display window will appear as shown. REV VIEW Q - QUEUE NEW Q - ENTER If you choose to VIEW the QUEUE, press QUEUE The display window will show the jobs in the current QUEUE. REV Two jobs at a time are shown. A 4 R 20 B10 R 200 First Job Second Job L12.250 L29.050 Length To Cut Quantity To Cut Use the CURSOR buttons to view all the jobs. To run the QUEUE as it is displayed, press the CYCLE START button on the control panel. No editing is possible in the VIEW mode. The screen will now prompt you to start the blade for a trim cut. ST AR T THE BL ADE STAR ART BLADE FOR TRIM CUT If you choose to Edit the QUEUE, press window will show an empty Queue. ENTER This will clear any jobs that are in the QUEUE and the display A 0 R 000 L00.000 B 0 R 000 L00.000 Pg. 2.10 CONTINUED To fill the QUEUE, follow these two steps. 1) Key in a job number and press ENTER. If that job number has previously been programmed, it's values will be displayed. The cursor will move to the next position in the QUEUE. Up to five jobs may be in the QUEUE at any time. The job values cannot be edited in this mode. 2) When the desired jobs have been entered, you may press the CYCLE START button on the control panel to execute the jobs in the QUEUE. (Follow the same procedures to initiate a cycle as in "AUTOMATIC OPERATION") At completion of the "QUEUE", the machine will shut down. KERF CORRECTION When making mitred cuts, the part length must be set longer than the desired length by an amount we will call the "KERF CORRECTION" This is due to the fact that the PLC does not account for a difference in the kerf value at various angles. The standard kerf and corrected values are as follows: STD KERF @ 90DEG 75 60 55 50 45 40 35 30 1" BLADE .059 .061 .068 .072 .077 .083 .092 .103 .118 1 1/4" BLADE .066 .068 .076 .081 .086 .093 .103 .115 .132 1 1/2" BLADE .074 .077 .085 .090 .097 .105 .115 .139 .148 2" BLADE .086 .089 .094 .105 .112 .122 .134 .150 .172 Pg. 2.11 SECTION 2B S CONTROLS 2B,, SAW CUTTING CONTROL 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. BL ADE B ASICS 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 definitely 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 five 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 sufficiently lap (polish) the new blade so that it does not snag the material being cut. Proper break-in will alleviate blade vibration, improve surface finish, 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, Pg 3.2 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 flow or periodic oiling of the blade is necessary to prevent the blade from being scored by the carbide guides. 3. The stock being cut must be securely clamped in the vises. 4. The proper feed force should be chosen. (see section 2B - Saw Cutting Parameters: Step 2) 5. The proper blade speed must be selected. (see section 2B - Saw Cutting parameters: Step 4) 6. The proper feed rate must be applied. (see section 2B - Saw Cutting Parameters: Step 5) VARIABLE SPEED CONTROL Blade speed can be adjusted infinitely between 75 to 400 SFM (23 to 122m/min) (Surface Feet/ Minute). Adjustment should be made only when the blade is running. Clockwise rotation of knob increases blade speed while counter clockwise rotation decreases blade speed. If the saw is equipped with an inverter (variable frequency drive) unit, then the blade speed is controlled with a dial on the control panel. Speed adjuster adjuster.. Speed adjuster for inverter equiped sa w. saw Pg 2.13 HYDRA ULIC FEED CONTROL HYDRAULIC The Hydraulic Feed Control is located adjacent to the drive wheel box. These controls allow independent control of Feed Force and Feed Rate. Feed Force Knob Used to set Feed Force Limit (counterclockwise rotation to increase and clockwise rotation to decrease). Fast Approach Lever Depress for fast head descent. Feed Rate Knob Used to set Feed Rate (counterclockwise rotation to increase and clockwise rotation to decrease). Hydraulic Feed Control Pg 2.14 CUTTING P ARAMETERS DOOR CHAR T PARAMETERS CHART A full size DOOR CHART is mounted on the drive door of the saw. The chart contains five steps for the operator to follow in order to achieve optimum performance of the saw. Saw Cutting Parameters Door Chart DOOR CHART EXAMPLE #1 We will use the door chart to set up the saw for cutting 8" (200mm) Diameter #1045 Carbon Steel. STEP 1 DETERMINE EFFECTIVE MATERIAL WIDTH - W ( inches ) or (mm) Effective material width, W (in.) for most common shapes of materials, is the widest solid part of the material to be in contact with blade during cutting. For simple shapes, as illustrated on the chart, this can be directly measured. For bundles of tubes and structurals, measuring the effective width is difficult. Effective width is 60% to 75% of the actual material width. Material Width Chart NOTES: 1) Both effective material width and guide arm width are used in setting the saw. 2) Guide arm width is the distance between the guide arms and is used in STEP 2. 3) Effective material width, as determined here in STEP 1, can be thought of as the average width of material seen by each tooth, and it is used in STEPS 3 and 4. In Example #1, for an 8" (200 mm) diameter solid, Effective Material Width is 8" (200mm). Pg 2.15 STEP 2 SET FEED FORCE LIMIT The Feed Force Limit is the maximum amount of force with which the head is allowed to push the blade into the work-piece. FEED FORCE LIMIT should be set with the head in the down mode, according to the label. CUTTING SOLIDS For cutting solids, the wider the section, the less FF should be set, to avoid blade overloading. See the graph below. EXAMPLE: When cutting a solid which is 1/2 of machine capacity using the graph, locate 50% on the horizontal line and travel upwards to the plotted line and then travel directly across to the vertical FF Setting line. The point that you have arrived at shows a setting of 40% for a piece 50% of capacity. CUTTING STRUCTURALS A reduced Feed Force Setting is used when cutting structurals: For structurals, a blade finer than Optimum can be used for more efficient cutting. If a finer than optimum blade is going to be used; Feed Force Setting should be reduced even further. For OPTIMUM BL ADE SELECTION BLADE SELECTION,, see STEP 3 BL ADE BLADE Pg 2.16 FF SETTING 1 OPTIMUM PIT CH PITCH FROM STEP 3 20% 2 PIT CH FINER PITCH THAN OPTIMUM 0% STEP 3 DETERMINE OPTIMUM BLADE PITCH - TEETH PER INCH (T.P.I.) Selecting a blade with proper tooth pitch is important in order to achieve optimal cutting rates and good blade life. For cutting narrow or thin wall structural materials a fine blade with many teeth per inch (T.P.I.) is recommended. For wide materials a blade with a coarse pitch should be used. See the sketch below for the blade pitch changes for differing effective material widths. Optimum Blade Pitch ( T.P.I. ) for Material Width ( Inches ) It is impractical to change the blade to the proper pitch every time a different width of material is cut and it is not necessary, but remember that the optimum blade will cut most efficiently. Too fine a blade must be fed slower on wide material because the small gullets between the teeth will get packed with chips before they get across and out of the cut. Too coarse a blade must be fed slower because it has fewer teeth cutting and there is a limit to the depth of a cut taken by each tooth. Allowance for the use of a non-optimum blade is made in STEP 5. In our Example #1 : Effective material width of 8" (200 mm) Optimum blade has 2/3 teeth per inch. Pg 2.17 STEP 4 DETERMINE OPTIMUM BLADE SPEED, V (ft/min) (m/min) The relationship between optimum blade speed and effective material width for various materials is represented on the graph shown. Optimum Blade Speed Curves The graph shows that as effective material width gets wider or as material gets harder, lower blade speeds are recommended. If material is narrow or soft, higher blades speeds should be selected. In Example #1 - 8" (200mm) diameter #1045 Medium Carbon Steel solid bar is to be cut. - On the graph above find the Medium Carbon Steel Curve which represents the optimum blade speeds for 1045 Carbon Steel. - On the horizontal axis (effective material width axis) find number 8 which represents effective material width of an 8" (200mm) diameter solid. - Find the point where a vertical line from 8" (200mm) intersects the Medium Carbon Steel Curve. - From this intersection point run horizontally left to the vertical axis (optimum blade speed axis) and find the point marked 200. For 8" (200mm) diameter, 1045 Carbon Steel solid bar 200 ft/min (60m/min) is the optimum blade speed. NOTE: 1. Higher than optimum blade speed will cause rapid blade dulling. Lower than optimum blade speeds reduce cutting rates proportionately and do not result in significantly longer blade life except where there is a vibration problem. If the blade vibrates appreciably at optimum speed as most often occurs with structurals and bundles, a lower blade speed may reduce vibration and prevent premature blade failure. Pg 2.18 2. Material Hardness - The graph above illustrates blade speed curves for materials of hardness 20 RC (225 Bhn) or lower. If the material is hardened then the multipliers need to be used. These multipliers are given in the NOTE at the bottom right of the graph. As the hardness increases the optimum blade speed decreases. The following table gives examples of the optimum blade speeds for different materials. NO NO.. 1 2 3 4 5 6 MA TERIAL S MATERIAL TERIALS OPTIMUM BL ADE SPEED BLADE ft/min m/min 5" (125mm) Dia Solid Carbon Steel 12" (300mm) I-Beam 4" x 4" (100 x 100mm) R ec T ube all Rec Tube ube,, 1/4" (6mm) W Wall 4"(100) 400 Stainless Steel 2" x 2" (50 x 50mm) R ec T ube 1/4" (6mm) W all Rec Tube Wall Bundle 5 x 5pcs 10" x 10" (500 x 500mm) 3" x 3" (75 x 75mm) Inconel STEP 5 225 290 350 140 70 90 110 45 325 60 100 20 Materials and Blade Speed DETERMINE FEED RATE SETTING, FR (in/min) (mm/min) Feed Rate Knob FEED RATE is the vertical speed at which the blade descends through the work-piece. The FEED RATE Knob controls FEED RATE of the blade descent in the range 0 to 15 in/min (380mm/min). The FEED RATE should be adjusted only in one direction (from O to required value). If you go too far, go back to O and come back up. To set FEED RATE for particular cutting situations use the Graph below, which represents the relationship between FEED RATE, blade speed and blade pitch. For Example #1, it is known from Step 3 that optimum blade pitch is 2/3, and from Step 4 that blade speed, is 200 ft/min (60mm/min). From the Graph on the left, the FEED RATE is determined in the following way: - On the horizontal axis (blade speed axis), find 200 ft/ min(60mm/min). - Find the point where a vertical line from 200 ft/min (60mm/min) would intersect the 2/3 blade pitch curve. - From this intersection point run horizontally left to the vertical (FEED RATE) axis, to arrive at 1.8 in/min (45mm/min) FEED RATE. Thus 1.8 in/min (45mm/min) is the FEED RATE for cutting 8" (200mm) diameter 1045 Carbon Steel when the optimum 2/3 pitch blade is used. Feed Rate Calculation Pg 2.19 Feed Rate, CONTINUED If the saw is fitted with a blade coarser than optimum (e.g.. 1.4/2.5 TPI) we can still use the graph, but we go to the 1.4/2.5 curve. As a result we find that the FEED RATE is decreased to 1.3 in/min (133mm/min) for this blade. If however, the machine is fitted with a finer than optimum blade (e.g.. 3/4 TPI) we use the graph for the optimum blade as before, and then use a multiplier given by the table below. NOTE: Use the following chart when cutting solids. For structurals, see "CUTTING STRUCTURALS" in STEP 2. Optimum versus Actual Blade Pitch ADDITION AL CUTTING SETUP EXAMPLES ADDITIONAL EXAMPLE # 2 Material STEP I STEP 2 STEP 3 STEP 4 STEP 5 Pg 2.20 Round Steel Tube SAE 4320 - Hardened to 35 RC ( 325 Bhn ) Dimensions - 6" O.D. x 4" I.D. (150mm O.D. x 100mm I.D.) Effective Material Width: 4 1/2" (.75 X 6) 114mm (19 x 6) Feed Force limit setting for 6" Diameter material Refer to Feed Force Limit Setting in Step 2 Optimum blade pitch (TPI): Actual blade pitch on the saw: 3/4 T. P. I. 4/6 T. P. I. Optimum blade speed for 4 1/2" effective225 ft/min (70m/min) material width Blade speed reduced by hardness factor:225 ft/min X .60 = 135ft/min (70m/min x .60 = 42m/min) Feed Rate for 3/4 TPI blade: Feed Rate for 4/6 TPI blade: (reduced by finer than optimum blade pitch factor) 1.8 in/min (45mm/min) 1.8 in/min X .70 = 1.3in/min (45mm/min x .70= 31.5mm/min) ADDITION AL CUTTING SETUP EXAMPLES ADDITIONAL EXAMPLES,, CONTINUED EXAMPLE # 3 Material Bundle Dimensions STEP I STEP 2 STEP 3 STEP 4 STEP 5 -Low carbon steel 2" x 2" Tube with 1/4" wall, 12 piece bundle (50mm x 50mm with 6mm wall) - 6" x 8" (150mm x 200mm) Effective Material Width: 5" ( .6 X 8" ) 120mm (.6 x 200) Feed Force limit setting for 8" Diameter material Refer to Feed Force Limit Setting in Step 2 Optimum blade pitch (TPI): 3/4 T. P. I. Optimum blade speed for 5 " effective material width 320 ft/min (100m/min) Feed Rate for 3/4 TPI blade: 4.0 in/min (100mm/min) Pg 2.21 SECTION 2C S CONTROLS 2C,, MECHANICAL CONTROL COOL ANT FL OW COOLANT FLO A generous flow of coolant should be applied in order to increase production and blade life. The machine is provided with two independently controlled coolant spouts. One is on the adjustable guide arm, this one should always flood the blade with coolant. Slight readjustment may be required when changing the blade speed. A properly adjusted flow of coolant should cover the blade which in turn will carry it into the cutting area. The flow adjusting tap is shown below. The second is mounted on the fence for the coolant hose which should be used in cases when cutting solid bars, bundles or wide structurals. The flow of coolant should be directed into the opening created by the blade. NOTE: When cutting materials that do not need coolant (cast iron) some coolant flow is required to provide blade lubrication to prevent blade scoring by carbides. Flow Adjusting Valves (2) Coolant adjusting taps Pg 2.23 THIS PAGE INTENTIONALLY LEFT BLANK MAINTENANCE AND TROUBLE SHOOTING SECTION 3 - MAINTENANCE AND TROUBLE SHOOTING SECTION 3 SECTION 3 - MAINTENANCE AND TROUBLE SHOOTING SECTION 3, MAINTEN ANCE AND TROUBLE SHOO TING MAINTENANCE SHOOTING LOCK -OUT Purpose: To prevent injury to workers caused by unexpected start-up of machines being worked on. OR Where the starting of a machine or device may endanger the safety of a worker a) Control switches or other control mechanisms shall be locked out; AND b) Other effective precautions necessary to prevent such starting shall be taken LOCK OUT PROCEDURE: Whenever work is to be performed on a machine, the following steps shall be taken: 1. Operator shuts down the machine 2. The person in charge should follow Lockout procedures as is required by his organization. The main power disconnect box is supplied with a suitable mechanism for this purpose as shown below. 3. An attempt to start, is made to check that correct main disconnect is turned off. 4. The person in charge adds a warning tag to his lock, showing nature of work, date, and workers involved. 5. Each operator working on the machine will place his own safety lock on the disconnect switch. He keeps his key with him while his lock is in place. Each operators lock should have a tag attached with his name and department. Safety lock & id tag to be placed in this area. Pg 3.1 BL ADE CHANGING BLADE We can not overstress the safety precautions which should be followed during this operation. Safety glasses, gloves as well as a long sleeve shirt should be worn. The hydraulics should be off at all times when the operator has his / her hands in contact with the blade. With safety in mind, the following procedure should be followed: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) With the blade stopped and the head in the 90 degree position, open the drive door. Release the carbide guide handles Remove the lower blade guard. Swing the head to approximately 45 degrees and open the idler door. Turn the Blade Tension Switch to "-" to release the tension on the blade until it becomes free. Remove the blade from both wheels. Push the blade down and out of the carbide guides and remove the blade. Install a new blade on the wheels and slide the blade up and into the carbide guides. Turn the Blade Tension Switch to "+" to put tension on the blade until it stops and close the door. Install the lower blade guard and turn the carbide guide handles clockwise until they rest against the stop or the coolant valve. Jog the blade from the control panel, but do not run until this procedure is complete. With the blade stopped, inspect the tracking position and the blade brush position. Refer to the following pages for correct positions. Swing the head to 90 degrees and close the drive door. Carbide guide handle, drive side. Carbide guide handle, idler side. Lower blade guard Blade brush assembly, behind drive door. Blade tension switch, behind idler door. Pg 3. 2 BL ADE BR USH ADJUSTMENT BLADE BRUSH The blade brush, located behind the drive wheel door, is properly set when the machine leaves the factory, but it wears out during operation and needs to be readjusted periodically. The plastic drive wheel that is driven by the drive wheel face should be held against the blade face with the minimum force that is necessary. As the blade brush wears it is necessary to periodically adjust it closer to the blade or if a new brush is installed, further away from the blade. As shown below, there are two springs on socket head screws holding the brush assembly gainst the blade. There is also an adjusting socket set screw with a hex nut on it. Loosen the hex nut with a 9/16" wrench and turn the set screw counter clockwise with a 3/16" allen key. This will move the brush closer to the blade. Adjust the set screw so that the brush cleans to the bottom of the blade gullets and tighten the hex nut. Adjusting setscrew and hex nut. BL ADE GUIDES ADJUSTMENT BLADE Each guide arm is provided with a set of blade guides. Both sets are identical. Each set consists of a top carbide, fixed carbide pad and adjustable carbide pad. Idler Blade guide Drive Blade guide Pg 3.3 LUBRICA TION UBRICATION The design of the M-16, M-20 was intended to minimize maintenance, although periodically certain moving parts need lubrication. We recommend that this periodic lubrication be done once a month using any general purpose grease at the points indicated with a circle. Pg 3. 4 Adjustable guide arms bar. Horizontal pivot pivot. Idler wheel tensioner. Bundling guides. Shuttle bearing housing. (not present on P models) 1 Point on each bearing housing Lubricated every two months. Vise shafts. 4 Points (under plugs) (2 points on P models) Lubricated every two months. HYDRA ULIC MAINTEN ANCE HYDRAULIC MAINTENANCE There are only FIVE items of routine maintenance associated with the hydraulic system. 1. OIL FILTER - Ten micron filtration of the hydraulic oil is provided by a spin on type filter mounted on the tank return line . The element should be changed after the first 50 Hours of operation and then every 500 working hours. Suitable replacement elements are: CANFLO RSE-30-10 GRESEN K-22001 PARKER 921999 ZINGA AE-10 2. OIL LEVEL - Oil level should be maintained in the upper half of the level gauge. Normally the rate of oil consumption will be very low and it should be unnecessary to add oil more often than at filter changes. Add oil only to the top line on level gauge. The M-16, M-20 is shipped from the factory with Texaco Rando HD 46 hydraulic oil. Generally any brand of recognized mineral hydraulic oil with the same properties should be compatible with Duro AW46, but to avoid any risk we suggest staying with Rando HD 46. If it is desired to change brands, it is necessary to drain the tank and 1/3 refill it with the new oil, operate through several full strokes of each cylinder, drain the tank again, and finally fill the tank with the new brand. Hydraulic tank capacity is approximately 11 US gallons (42 L). Recommended replacement oils for Texaco Rando HD 46: Chevron AW Hydraulic Oil 46 Esso NUTO H46 Mobil Mobil DEC 25 Shell Tellus 46 3. OIL TEMPERATURE - Oil temperature is indicated by a thermometer contained in the level gauge . Oil temperature during steady operation should stabilize at about 50 - 55 F° ( 10-12°C ) above room temperature. Thus in a 70 F° (20°C) shop one might expect an oil temperature of about 120 F° (50°C) Oil temperature should never exceed 160 F° (70°C) 4. OIL PRESSURE - Oil pressure is factory set to 900 PSI (6200 kPa) and should not require further attention except precautionary observation at start-up and every few days thereafter. 5. BLADE TENSION - Is preset at the factory and should under normal conditions not require attention. CLEANLINESS The M-16, M-20 heavy duty design should endure heavy operating conditions and provide the customer with flawless machine performance. To extend good performance some care is required especially as cleanliness is concerned. The following areas should be kept clean: - Control console free of dirt and grease. - Door charts free of dirt and grease. - Wheel boxes free of chips. - Blade guides free of chips. - Outfeed table free of chips. - A large chip build-up should be avoided in the base of the saw. NOTE: All parts must be cleaned before any repair service can be performed on them. Pg 3.5 TROUBLE SHOO TING SHOOTING Most problems which may occur have relatively simple solutions which appear in this section. If the solution is not found here, contact the Hyd-Mech Distributor from whom you purchased your bandsaw. They have trained field service personnel who will be able to rectify the problem. PROBLEM 1. Saw is cutting out of square vertically. PROBABLE CAUSE SOLUTION 1a. Blade worn. 1a. Change blade. 1b. Low blade tension 1b. Reset blade tension. 1c. Blade guides 1c. Check for worn guides. 1d. Excessive feed rate 2. Saw is cutting out of square horizontally. 1d. Check for proper cutting parameters 2. 2. Adjust accordingly. 3. Blade comes off wheels. 3a. Not enough blade tension. 3a. Tension blade. 3b. Improper tracking. 3b. Set tracking. 4a. Not enough blade tension. 4a. Tension blade. 4b. Excessive feed force. 4b. Reduce. 4c. Excessive feed rate. 4c. Reduce. 5a. Blade speed too fast. 5a. Reduce. 5b. Guide arms too far apart. 5b. Adjust accordingly. 5c. Not enough blade tension. 5c. Tension blade. 6a. Excessive blade tension. 6a. Reduce blade tension. 6b. Excessive feed rate. 6b. Reduce. 7a. Blade pitch too fine. 7a. Select coarser pitch. 7b. Blade brush not cleaning. 7b. Adjust or replace blade brush. 7c. Excessive feed rate. 7c. Reduce. 7d. Excessive feed force. 7d. Reduce. 4. Blade stalls in cut. 5. Blade vibrates excessively. 6. Excessive blade breakage. 7. Tooth strippage Pg 3. 6 Stock not square in vises. PROBLEM 8. No coolant flow. 9. Saw will not start. PROBABLE CAUSE SOLUTION 8a. No coolant. 8a. Add coolant. 8b. Coolant line blocked. 8b. Blow out coolant line. 8c. Coolant pump inoperable. 8c. Check, replace if necessary. 9a. Control circuit fuse has blown. 9a. Replace the fuse with a 5 Amp 250 Volt AG1 type fuse. Random blowouts may occur but a quickly repeated blowout points to an internal wiring fault. 9b. Turn all switches to the center (neutral) position 9b. Vise or head selector switch not in the center (neutral) position. 10. Saw starts but will not run after Start button has been released. 10. On machines so equipped, the out-of-stock or blade breakage limit switch has been tripped. 10. Reload with stock or remount blade. Hold the hydraulic start button and release the blade tension or open vises far enough to deactivate the limit switch. 11. Saw starts but no hydraulic functions. 11a. If blade wheels run clock wise, wrong phase order in power connection to saw. 11a. Stop immediately; reverse any two of the three phase connections. 11b. If pump is noisy cause may be low hydraulic oil level. 11b. Stop immediately, add hydraulic oil. (See page 3.5 hydraulic maintenance.) 11c. Pump-motor coupling has separated. 11c. Adjust accordingly. Pg 3.7 PROBLEM PROBABLE CAUSE SOLUTION 12. No individual function will respond to its manual control switch. 12a. Observe pilot light(s) on relevant valve. If pilot light related to inoperative function fails to light, problem is electrical. 12a. Check the wiring to the relevant valve In Manual Mode 13. Head will not descend. In Automatic Mode (not applicable to "P" models) 14. Auto cycle will not start. Pg 3. 8 12b. Disassembly of hydraulic 12b. If pilot light related to valves should be under inoperative function does taken only by qualified light, problem may still be service personnel or those the coil . If problem remains knowledgeable with it may result from dirt in the hydraulic components. valve spool. 13a. Feed Rate Valve is fully closed - pointer is set on "0" or close to "0" in/min. 13a. Turn Feed Rate Knob in a counter clockwise to open valve. 13b. Feed Force Limit is set too low. 13b. Increase Feed Force Limit. 13d. Remove obstructions. 13d. Check for physical interference preventing the head from falling. 14. No job or job queue programmed to run. 14. Enter job numbers(s) and job data as described in Section 2C. PROGRAMMABLE L OGIC CONTROL, MITSUBISHI 100 LOGIC NO TE: The PLC is equipped with a lithium battery to keep the program stored while the power is NOTE: shut down. The battery will need to be replaced every 3 to 5 years, depending on usage. A visual warning will be displayed on the interface when the battery drains to a certain level. Battaries can be purchased through your Hyd-Mech Distibutor. The programmable length control (PLC) uses signals from limit switches, control panel switches, an encoder (rotary shaft or linear) and information which is programmed into it, to supply accurate automatic length control and sawing functions. The inputs used include; - a head up limit switch, a head down limit switch; - the machine function switches & push-button - also a signal from the auto/manual push button (telling the PLC whether auto or manual operation has been chosen). An encoder is attached to the shuttle assembly and travels with the shuttle to provide length information to the PLC. A proximity switch and target, mounted to the gearbox drive pulley or behind idler wheel, provides blade speed input to the PLC. The programmed information includes logic put into the PLC be its manufacturer, as well as information programmed in, through the keypad, by the assembly plant. Information from the assembly plant is referred to as the parameters. The parameters are important for the PLC to provide accurate sawing lengths and blade speed display. Following is a description of each parameter and the procedure to access them. To view the PLC parameters: For semiautomatic "P" models, refer to the PLC key description of For automatic models; P on Pg.2.7. In manual mode, with front vise switch in 'CLOSE' position press FWD. and REV buttons simultaneously ( not more than 0.5 sec. apart). The PLC will prompt for a password which is obtainable from Hyd-Mech Saws. If the password is correct a screen of parameters will appear. The display will show two lines of parameters at a time. The first display is for the machine's self calibration of it's length control. If the length control calibration is necessary, follow the calibration procedure on page 3.20. To move through the parameters use the cursor keys to scroll up or down. To change a parameter, cursor to that parameter line, and, using the number keys, type in the new value and press enter. To leave the parameters press the Auto/Man key. The following page lists the available parameters and their definition. Pg 3.9 PL C 100 P ARAMETERS PLC PARAMETERS Parameter DEFINITION NO TE: P ar ameter s with * ar e not rrequir equir ed on P models NOTE: Par arameter ameters are equired models.. HGT CLB "ENTER" This is to be used only if calibration is required. Call Hyd-Mech Service department for instruction. - Actual Height Value. Value that must be entered after performing Head Height Calibration procedure (see Pg. 3.20). This value represents the head full stroke height. (This parameter is not present on machines which have a head up and down limit switch. S-20A, H-12A and some early M-16/20A) FST APR DIST - Specified distance the head will move up above the preset material height. When the AUTO cycle reaches the function of head down, the head will fast approach the distance minus the FAST APPROACH OFFSET parameter. (Next parameter; FST APR OFST) FST APR OFST - Specified distance above the preset material height that the fast approach fuction will shut off. (I.E. If set for .250, the fast approach will shut off and normal feed will begin at .250" above the preset material height). DOWN DWL - Sampling time when head reaches down limit. In AUTO, head will not move up after reaching down limit until this delay time has elapsed. (1 = .01 seconds, Range = 300 - 999) *LTH CLB "ENTER" This is to be used only if calibration is required. Call Hyd-Mech Service department for instruction. *ACT LTH - Actual Length Value - Value entered after performing length calibration procedure (See Pg. 3.20). PLC uses this value to calculate it's length encoder resolution and stroke parameter. Note: If Calibration Procedure is activated and not completed, or activated and a value not entered for ACT LTH, this value will reset to 00.000 and the PLC will not be able to count/display lengths. *STROKE - Total length, in inches, the shuttle will travel in a single stroke. (Calculated & Entered by the PLC; cannot be changed by operator) *ACC DIST - Distance, in inches, the shuttle will travel slowly before reaching fast speed while starting to move in either direction. (i.e. 1.000). *DEC DIST - Distance, in inches, the shuttle will travel slowly reaching home or target position. (i.e. 1.000) *SLW DIST - Minimum fast speed distance, if programmed length is smaller than this parameter override to slow speed. (Shuttle) *TRG WD - Allowable +/- tolerance from programmed length. FVO DEL - Delay time for the opening of the fixed VISE. A value of 100 is approximately equal to about one second. (i.e. 75=.750 seconds delay) *SVO DEL - Delay time for the opening of the shuttle VISE. (i.e. 75 =.750) *CLS TIME - Delay time for closing front or shuttle VISE. (i.e. 75 =.750) SPD FCTR - Blade speed adjustment number. If Actual Blade speed is different than displayed Blade Speed a new speed factor will need to be calculated. (Providing wheel Trgs is set correctly): Actual speed / Display = adjustment factor Adjustment factor X Existing speed factor = New speed factor WHEEL TRG - Number of targets per revolution of the idler wheel. S-20A, S-23A, H-12 = 1 M-16/20, H-16/20, H-26/32 = 6 ACT POS - If this value is set to 1 displays actual position. HLD SHM HM - Hold shuttle VISE home and closed during cut. BRKN PROX - Allows user to override signal from prox switch in case it is broken. (When set to value - 0; machine will not run with broken proximity sender. Set to value - 1; allows machine to Run). BLDE CHAM - If this parameter is set to '1' ; When the AUTO cycle reaches the function of head up, the shuttle will retract the material from the blade by 1/8" before the head will move up. When the head reaches the up position the next length of material is shuttled into position. Pg 3. 10 ACT HT PL C 100 TROUBLESHOO TING PLC TROUBLESHOOTING PROBLEM #1 or automa tic models with a shuttle #1,, ffor automatic shuttle.. PLC is not measuring lengths. USES; POSSIBLE CA CAUSES; i) Encoder - pinion gear loose on encoder shaft - bad encoder ii) Encoder Cable - bad connection at encoder or PLC - open or shorted wire ii) PLC unit - damaged hardware iii) Display unit - no power from PLC unit - damaged hardware iv) Actual Length (ACT LTH) - preform self calibration procedure and enter value. Parameter value is set to 00.000 DIA GNOSIS; DIAGNOSIS; I) With the machine in MANUAL mode; bring the shuttle forward to the home position and clear the length display to read '0.000'. Run the shuttle, in slow speed, to the rear then back to home, moving full shuttle strokes. - length should accumulate on the display as a positive number when the shuttle moves away from the blade and should count is negative going back and goes in a positive direction coming toward home, then the green channel wire and the white channel wire should be reversed. - if the display alters between 0.000 and 0.001 or 0.000 and -0.001, then one of the encoder channels is not being recorded correctly. ii) To determine the cause, first, check the encoder cable connections at both ends to be sure all four wires are connected properly. (See page 3.18 for connection / wiring information) Measure the voltage: a) At encoder connector; - between 0 V pin and 24 V pin. This voltage should be a minimum of 22 to 26 VDC. If the voltage is incorrect; check encoder cable continuity - if OK, possible PLC problem. If the voltage is correct, go to step b) b) At encoder connector; - between 0 V and channel A and 0V and channel B. This should be slightly less than supply voltage at each channel. If voltage is incorrect at this point, check for proper continuity of these wires and repair as necessary. NOTE: c) When checking the encoder cable for continuity, each wire should also be checked for shorting to ground and shorting to each other. If voltage to the encoder is correct; go to Step C). At the encoder connection of the PLC; - between 0 V and A&B channels. With the shuttle moving slow, voltage should be approximately 10 -13 VDC. Input LED's X0 and X1 should flicker or go dim with the shuttle moving. If these LED's show no change with the shuttle moving, the encoder is likely at fault. Check that the pinion gear is securely fastened to the encoder shaft and that it can rotate along the rack as the shuttle moves. If all mechanical components are functioning correctly then the encoder is defective. If all tests check positive, the problem is in the PLC unit. Pg 3.11 PROBLEM # 2 or automa tic models with a shuttle 2,, ffor automatic shuttle.. Inaccurate lengths in AUTO mode. POSSIBLE CAUSES; i) Encoder - pinion not engaging rack all the way from front to back; mechanical interference, pinion loose on encoder shaft ii) Encoder Cable - bad connection at encoder or at PLC - intermittent open in one or more signal wires iii) Improper programmed information - existing parameter(s) incorrect - incorrect blade kerf iv) PLC - faulty PLC unit (not repairable in the field) GENERAL R ULES RULES 1) Inconsistent Cause: 2) Consistent Cause: 3) Linear Cause: - Normally, three types of length inaccuracies may occur. - lengths cut are not consistent, error changes. It doesn't matter how long the part required is the error is never the same. - most likely a defective electrical, hydraulic or mechanical component. - lengths cut are consistent and the error is also consistent. The error always stays the same regardless of part length. - Kerf value - lengths cut are consistent but the error increases as the part length increases. The longer the part the greater the error. - when self-calibration is executed, incorrect "Act Lth" value entered DIA GNOSIS; DIAGNOSIS; i) Check and record existing parameters. Also check for proper blade kerf. By making a cut part way into a piece of material and measuring the width of the cut, the operator can check blade kerf. INCONSISTENT INACCURACY; ii) - with the machine in MANUAL mode, move the shuttle all the way forward and clear (zero) the length display. Move the shuttle in reverse, in slow speed, all the way to the end of it's travel. Return the shuttle forward to the home position, also in slow. The display should read 0.000" +/.005". Do this test several times to be sure the read-out is repeatable. DIA GNOSIS; DIAGNOSIS; iii) Following the same procedure, run the shuttle alternating between fast and slow speed going back and coming forward. Again the display should be able to read 0.000" +/-.005" when returning to the home position. If the display does not read as specified: - check the encoder pinion gear to be sure it can run smoothly down the rack and that the gear and rack teeth engage over the entire travel of the shuttle. - check that the pinion gear is tight on the encoder shaft. - check the encoder cable connections, a loose connection could easily cause this concern. - remove the encoder from the machine and check that the shaft can rotate freely. There should be no binding or rough spots felt when spinning the shaft. Plug the encoder cable into the encoder, clear the length display, and rotate the shaft exactly (or as close as possible) one revolution. The display should read approximately 3.142" (positive or negative). Repeat this 3 or 4 times, spinning the shaft several times between tries. Pg 3. 12 CONSISTENT INACCURACY: (make sure blade kerf value is correct) - change "Actual Pos." parameter to 1. This will make the PLC show actual shuttle travel in AUTO With no material in the machine: - program JOB 1 for 2 pieces of 5" length, JOB 2 for 2 pieces of 10" length, and JOB 3 for 2 pieces of a length as one shuttle will allow. - enter JOBS 1, 2 and 3 into QUEUE. - record measurement on the display each time the shuttle vise reaches the target length and closes. It should equal the required length plus the programmed kerf value. Check that this measurement is +/-.002" for each length. If the overshoot /undershoot is very inconsistent, it could be related to an incorrect shuttle cushion period. This may be caused by "Decel. Dist." parameter being set too low, defective fast or reverse output relays on the PLC, or the hydraulic cushion valve (located at the hydraulic manifold) may be faulty. LINEAR INACCURACY: (not valid for machines with linear encoder) v) - load machine with a piece of stock for test cutting - open parameters screen - initiate length calibration (see 3.20) - re-enter new ACT LTH (Actual Length) value - recut test lengths and check if accuracy is satisfactory. Pg 3.13 PROBLEM # 3 or P models egar d all rref ef er ences to a shuttle 3,, ffor models,, disr disre ard efer erences shuttle.. AUT Oc ycle not being completed. UTO cy In the A UT O mode C contr ols sa w functions thr ough output rrela ela ys. F or a cer tain function to AUT UTO mode,, the PL PLC controls saw through elay For certain ted ir st see specif ic input(s). Lik e the output rrela ela ys, the input rrela ela ys ar e loca be actua ted, the PL Cm ust ffir specific Like elay elay are located actuated, PLC must irst on the PL C unit. Dir ectly beside input and output terminals ar e rred ed LED lights h light up when the lights,, whic which PLC Directly are cor eceiv ed or output is being actua ted. Obser vation of these input/output corrresponding input is being rreceiv eceived actuated. Observ LEDs can help to dia gnose A UT Oc ycle pr ob lems C UNIT dr awing on pa ge 3.17) diagnose AUT UTO cy prob oblems lems.. (See PL PLC dra pag When a pr ob lem occur s in the A UT O mode hec ked to see if the y ar e coming on prob oblem occurs AUT UTO mode,, the lights should be c chec heck they are at the pr oper time or a proper att all. INPUT LED's - If a specif ic input light does not come on when e xpected; specific expected; -c hec k ffor or a ffaulty/misadjusted aulty/misadjusted limit s witc h, push b utton, encoder or b y ffaulty aulty chec heck switc witch, button, by wiring/ connections connections.. - wiring ffor or eac h limit s witc h should be connected fr om the VDC terminal connection to each switc witch from par ticular limit s witc h, and fr om the limit s witc h to the input connector of the PL C. particular switc witch, from switc witch PLC NO TE: NOTE: All inputs ar e denoted b y "X" are by All outputs ar e denoted b y "Y" are by Following is information on output diagnosis and the sequence of inputs and outputs during AUTO cycle. AUT O CY CLE SEQUENCE UTO CYCLE SEQUENCE: 1) 2) 3) 4) 5) 6) Pg 3. 14 After the mode push button is in the AUTO position and the job has been Programmed into the PLC, and the Cycle Start push button pressed: Hydraulics running, the head should move to it's up limit, if it is not already there. Shuttle vise should open and come forward to the home position. HUP input light must come on for cycle to continue. HUP input on - cycle should continue, if not check outputs per step 2. HUP input not on - check that head up limit switch is being actuated, check limit switch/ limit switch wiring. Front vise should be closed, the shuttle vise should stay open and move back to the programmed length; FVC output should be on SVO output will light momentarily, REV output and FST output should be on when the shuttle moves back fast. As the shuttle approaches target length the FST output should shut off and the shuttle should travel slow for the "Dec. Dist." parameter, cushion distance. (i.e. 1.00") When the shuttle reaches target length, the SVC output should light, and the shuttle vise should close on the material. FVO output light should come monetarily on and front vise should open. FWD output should light as will as FST for the shuttle to move forward in fast speed. FST will turn off when the shuttle home cushion period is reached and the shuttle should slow down into the home position. FVC output should light and the front vise should close. FWD light should go out, HDN output should come on and the head should start to descend for the cut. If blade is not running at this time, auto cycle will hold until min. SFM is reached. Depending on "Hld Shtl Hm" parameter in the PLC, the shuttle may stay home and closed during the cut or may move back to pick up the next length. HUP input should go out as the head descends, and HUP L/S deactivates. 7) After the cut is completed HDN input should light, HDN output should go out, the HUP output should light and the head should move up. When the head reaches it's up limit, HUP input should come on, RHD output off and the cycle repeats with the next length being clamped on by the shuttle, front vise opening and the length being brought forward to home position. As mentioned, beside each input and output terminal there is a bank of red LEDs. Each light corresponds to its input or output. An input LED will light when it's specific input signal is being received at the PLC and output LED's will light when the PLC commands specific outputs. If an output LED is on but the output does not happen, check for voltage at the specific output wire. If voltage is not present then either the output relay is faulty/stuck or the output (3 amp) fuse has blown. (See fuse information below) If a fuse is blown, a shorted directional valve coil (good coil should measure 30 to 40 ohms), shorted noise suppresser at the coil, or shorted wiring could be the cause. If the fuse is good and no output voltage condition still exists, with the output light on, then the relay is defective. If this is the case the PLC will have to be returned to the manufacturer for repair. (Contact HYD-MECH SAWS). FUSES: The PLC has five glass fuses in line with it. Fuse 'F1' is a 2 amp instant blow fuse which feeds power to the input side of the PLC through input terminal 'L'. Fuses 'F2' to 'F5' are 3 amp time delay fuses which each supply power to a specific bank of output relays through that bank of relay's 'COM' terminal: F2 is wired to terminal 'COM 1' supplying Outputs F3 to terminal 'COM 2' supplying Outputs F4 to terminal 'COM 3' supplying Outputs F5 to terminal 'COM 4' supplying Outputs - Y0, Y1, Y2, Y3 - Y4, Y5, Y6, Y7 - Y10, Y11, Y12, Y14 - Y14, Y15, Y16, Y17 PROBLEM # 4 No Display. POSSIBLE CAUSES; i) No power to the PLC. ii) PLC unit failure. iii) Faulty connection of cable between PLC & Interface DIAGNOSIS; i) Check POWER LED (see page 3.17 - Status lights) - to be on when the PLC is switched on. If the light is on, PLC may have failed. Check for proper connection of cable at PLC & at interface. If connection is secure replace. If light is not on - check the (2 amp) PLC fuse. If the fuse is OK, check power to it. Pg 3.15 PROBLEM # 5 No Blade Speed Display. POSSIBLE CAUSES; i) Fault at proximity sender ii) Fault at the PLC - bad sender, misadjusted sender (gap should be approx. 0.015") - contamination on the end of the sender - bad connection of sender wiring - faulty PLC input DIAGNOSIS; i) Pg 3. 16 Check for LED light on the sender - light on indicates prox. sender power connections are correct and sender is activated. Problem could be with the sender, signal wire to the PLC or with the PLC. With blade running, proximity LED should pulse. Likewise, the PLC input LED (X2) should be pulsing. If both LED's are pulsing with the blade running, the PLC is the problem. If the sender LED is pulsing but the input (X2) LED is not; there is a problem between the sender and the PLC input (X2) terminal. - If the LED on the sender is not on, the problem is with the sender wiring or the sender is at fault MITSUBISHI 100 INPUTS & OUTPUTS A L S/S N OV G X0 X2 X4 X6 X10 X12 X14 X16 SG 24V X1 X3 X5 X7 X11 X13 X15 X17 MITSUBISHI B IN 0 1 2 3 4 5 C 6 7 Power 10 11 12 13 14 15 16 17 Run Batt V E FX2N-32MR Y0 Y2 COM1 Y1 Y3 Y4 Y6 COM2 Y5 Y7 Prog E OUT 0 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 Y14 Y16 Y10 Y12 COM3 Y11 Y13 COM4 Y15 Y17 F A - input terminals E - output indicating LED 's D B - input indicating LED's F - output terminal identification C - input terminal identification G - PLC status indicator lights D - output terminals Input and output terminal identification : - the top row of identification labels corresponds to the top row of terminals and the bottom row of labels to the bottom row of terminals. Input and Output LED numbers correspond to the Input or Output of the same number. ie. Input LED #0 corresponds to Input X0 . Output LED #0 corresponds to Output Y0 PLC Status indicators : Power - on when power exists to the PLC Run - on when the PLC is running Batt V - on when PLC memory backup battery has low voltage condition Prog E - on when PLC has a program error. Pg 3.17 Input / Output T erminal Inf orma tion : Terminal Informa ormation Inputs - X0 - Pop Down (H saw only) X1 - Open X2 - Blade Speed X3 - Head Encoder, Channel A X4 - Head Encoder, Channel B X5 - Head Down Limit X6 - Coolant Switch X7 - Coolant Switch X10 - Aux. Vise Close Switch X11 - Aux. Vise Open Switch X12 - Front Vise Close Switch X13 - Front Vise Open Switch X14 - Head Raise X15 - Head Lower X16 - Blade Run X17 - Cycle Start Outputs - Y0 - Machine Latch Y10 - Front Vise Close Y1 - Swing Encoder (M saw only) Y11 - Front Vise Open Y2 - Open Y12 - Open Y3 - Pop Down Roller (H saw only) Y13 - Blade Run Relay & Blade Brush Y4 - Aux. Vise Close Y14 - Open Y5 - Aux. Vise Open Y15 - Open Y6 - Coolant Pump Relay Y16 - Head Raise Y7 - Cycle Pilot Light Y17 - Head Lower ENCODER CONNECTIONS (Connection at encoder viewed from back at soldered connections) BK G W Pg 3. 18 F A E R B D C LUCAS ENCODER CALIBRA TION PROCEDURE FOR MITSUBISHI CALIBRATION PL C 100LE NO T APPLICABLE T O "P" MODEL S WITH 50E SOFTWARE PLC NOT TO MODELS In manual mode position a piece of material which is longer than the shuttle full stroke length (i.e.. M-16A=32.500") and close the front VISE. Simultaneously depress "FWD" & "REV" buttons on the PLC to access parameters. A password is required at this point which can be obtained from Hyd-Mech Service Department. SCREEN WILL DISPLAY: LTH.CLB TH.CLB.. "ENTER" ACT .L TH. CT.L .LTH. 0 00.000 With the cursor @ shown position (as illustrated above) press enter. The cycle start button will then start to flash & "0" will change to "1" indication self-calibration mode. Start the blade and the trim cut will be made. After the trim cut is made the head will rise, the shuttle will retract fully in slow, clamp the material and come fully forward in slow to the home position and make a cut. After the cut is complete "1" will change back to "0". Measure the cut part length. Cursor down to ACT.LTH. and enter length of cut part plus the actual kerf value. Then exit the parameters by toggling the AUTO/MAN button or put the front VISE in the hold position (the cycle start button will stop flashing). The ENC.RES. & full stroke values will now automatically be calculated and programmed by the PLC. *NOTE: When first entering the parameters screen if not running the self calibration do not use the enter key but use the cursor keys to scroll through the parameters. To check length control consistency: 1) Perform test cuts of three different lengths (i.e. 6", 12", 20") and measure as accurately as possible. 2) If the measurements indicate a linear problem (measured length error increases as the programmed length increases), the ACTUAL LENGTH value will have to be adjusted. 3) The Length Calibration Procedure MUST be performed to allow a change to the ACTUAL LENGTH parameter. This may be done with material in the machine (cut and measure material length) or with no material in the machine (let machine complete the calibration cycle, then enter new value). To adjust ACTUAL LENGTH parameter: - If part length error gets longer as the programmed length increases; ACTUAL LENGTH value should be increased. - If part length error gets shorter as the programmed length increases; ACTUAL LENGTH value should be decreased. - Make small adjustments at a time (i.e. .020" - .030") and recheck with test cuts. EXAMPLE: If part length error gets longer as programmed length increases: Existing ACT.LTH.=33.070" Change ACT.LTH. to 33.070 - .020 = 33.050" Pg 3.19 HEAD HEIGHT CALIBRA TION CALIBRATION 1) Enter the PLC parameter screen as per Length Calibration Procedure on Pg. 3.19. 2) Using the arrow cursor keys scroll down until the screen displays : HT CLB "ENTER" ACT HT 0 00.000 3) With the cursor on the 0 , press the ENTER key. The cycle start button will begin to flash, the head will move to it's down limit and then will move up to it's full upper limit. 4) Measure the distance from the vise horizontal wear strip to the blade teeth tips, and enter this value in the ACT HT parameter. Measurement must be made along the front vise datum jaw. Pg 3. 20 SER VICE RECORD & NO TES SERVICE NOTES DATE SERVICED BY COMMENTS Pg 3.21 THIS PAGE INTENTIONALLY LEFT BLANK ELECTRICAL SYSTEM SECTION 4 - ELECTRICAL SYSTEM SECTION 4 SECTION 4 - ELECTRICAL SYSTEM SECTION 4, ELECTRICAL SY STEM SYSTEM GENERAL INFORMA TION INFORMATION 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. In order to use the machine on a different supply voltage the following changes must be made: 1. Change the blade motor (or if equipped with a dual voltage motor, rewire it) 2. Change the hydraulic pump motor (or if equipped with dual voltage motor, rewire it) 3. Change the control transformer. 4. Change the blade and pump motor overloads, located adjacent to the contactor, to suit the full load current of the new or rewired motor. All other components are supplied from the control transformer and operate on 115V, single phase. They do not need altering. The machine is supplied for use on a 60HZ or 50Hz supply. WHEN CHANGING THE SUPPLY VOLTAGE, CAREFULLY OBSERVE THE ABOVE STEPS. THESE STEPS ARE ESSENTIAL TO AVOID SEVERE DAMAGE TO THE MOTORS AND CONTROLS. At initial hook-up it is important to check that the phase order is correct. This is indicated by the blade drive wheel revolving in a counter clockwise direction and the hydraulic pressure gauge registering a pressure rise. On the following pages are the electrical schematics and physical wiring diagrams along with a list and photos of electrical components. NO TE: 1)The PLC is equipped with a lithium battery to keep the program stored while the power NOTE: is shut down. The battery will need to be replaced every 3 to 5 years, depending on usage. A visual warning will be displayed on the interface when the battery drains to a certain level. Battaries can be purchased through your Hyd-Mech Distibutor. 2) If the machine is equiped with an inverter, do not turn disconnect on for 3 three minutes after disconnect has been shut off. Cycling power sooner than 3 minutes will result in damage to the Variable Frequency Drive. 3) All of the machines equipped with a Mitsubushi PLC have a snap on Ferrite core on the interface cable. This is placed near the interface in order to reduce "noise" Pg 4.1 M1620 ELECTRICAL COMPONENTS Head encoder (located behind a cover). Pg 4. 2 M1620 Coolant pump. Out of Stock Limit Switch. Hirschman connectors, directional control valve solenoids and electric motor. ELECTRICAL COMPONENTS ued COMPONENTS,, Contin Continued Shuttle Encoder (located on the drive side of shuttle under a cover) (not on P models). Proximity sensor (located behind idler wheel cover). Optional Digital Angle Display Encoder. 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The hydraulic tank is filled with Texaco Rando HD46 hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial start-up. M-16 HYDRA ULIC COMPONENTS LIST HYDRAULIC ,7(0 47< 3$57180%(5 0&% 0&$ 6& 0&$ 0&$ 0&$ 0&$ 0&% 6& '') 0%3$ '3&+ 3* '&93$%7 '&93$%& '&93$%7 '&93$%7 '&93$%& '&93$%& 393$& &+%& +<3 66 6) +<0 1%. 359 (%$ &+%& -%% 359 (% Hydraulic Manifold, Pump/Motor Assembly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g 5.1 M-20 HYDRA ULIC COMPONENTS LIST HYDRAULIC Hydraulic Manifold, Pump/Motor Assembly. ,7(0 Pg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g 5.3 Pg 5.4 Pg 5.5 THIS PAGE INTENTIONALLY LEFT BLANK MECHANICAL ASSEMBLIES SECTION 6 - MECHANICAL ASSEMBLIES SECTION 6 SECTION 6 - MECHANICAL ASSEMBLIES SECTION 6, MECHANICAL ASSEMBLES BL ADE BR USH ASSEMBL Y BLADE BRUSH ASSEMBLY ,7(0 47< 0 3$57180%(5 '(6&5,37,21 0* +<'5$8/,&02725 25,1*$'$372506757)137 GHJ(/%2:01370-,& 6[& 62&.(76(76&5(:&8332,17 )[ )/$762&.(7+($'&$36&5(: 0 &+,3$8*(5 Pg 6.1 GUIDE ARM & CARBIDE GUIDE ASSEMBLIES For M-16 only only.. Pg 6. 2 GUIDE ARM & CARBIDE GUIDE ASSEMBLIES TS LISTS ARTS ASSEMBLIES,, PAR ,7(0 47< 03$57180%(5 0$ $; 0 0 0 0 0 &5% &5% &5%7/ ); 6 -187% 6;' & '(6&5,37,21 *8,'($50%$5 62&.(7+($'&$36&5(: '5,9(*8,'($50 *8,'($50,16(57 *8,'($50+$1'/( 7+5($'('52' 7+5($'('52'&29(5 %$//.12%1& &$5%,'(3$')5217 &$5%,'(3$'5($5 723&$5%,'( )/$762&.(7+($'&$36&5(: &$5%,'(/2&.,1*+$1'/( +(;-$0187%/$&. 62&.(76(76&5(:'2*32,17 ',6&635,1* 0 -187 6;) &22/ &22/$ ); ,'/(5*8,'($50 +(;-$0187 62&.(76(76&5(:)/$732,17 25,1* &22/$1712==/(%$&.3/$7( &22/$1712==/(+ )/$762&.(7+($'&$36&5(: ,7(0 47< 03$57180%(5 0$ $; 0 0 0 0 0 &5% &5% &5%7/ ); 0 6;& &5%/ &5%/ &5%/ ( %$//.12% 0 -187 6;) &22/ &22/$ ); '(6&5,37,21 *8,'($50%$5 62&.(7+($'&$36&5(: '5,9(*8,'($50 *8,'($50,16(57 *8,'($50+$1'/( 7+5($'('52' 7+5($'('52'&29(5 %$//.12%1& &$5%,'(3$')5217 &$5%,'(3$'5($5 723&$5%,'( )/$762&.(7+($'&$36&5(: &$5%,'(/2$'(5%2/7 62&.(76(76&5(:&8332,17 +$1'/( %/$&.3/$67,&78%( &$5%,'(/2$'(5+8% ',6&635,1* %$//.12%1& ,'/(5*8,'($50 +(;-$0187 62&.(76(76&5(:)/$732,17 25,1* &22/$1712==/(%$&.3/$7( &22/$1712==/(+ )/$762&.(7+($'&$36&5(: Pg 6.3 Y ADE TENSION ASSEMBL BL ASSEMBLY BLADE Pg 6. 4 ,7(0 47< 03$57180%(5 0 0 0 %; /2& 6;) 0 0 0$ 0 0 0 0 9 6$ %; /2& 6% 56 +23$ :3 '(6&5,37,21 ,'/(5:+((/6+$)7 1)+(;+($'&$36&5(: +(;+($'&$36&5(: /2&.:$6+(5 62&.(76(76&5(:)/$732,17 %/$'(7(16,21$50 %/$'(7(16,216+$)7$66(0%/< 35(66,1*5($6(),77,1* %86+,1* %86+,1* &$3 $'-867,1*%2/7 ,'/(5:+((/ +(;+($'&$36&5(: /2&.:$6+(5 ,'/(5:+((/%($5,1*63$&(5 %$//%($5,1* ,17(51$/5(7$,1,1*5,1* '5,9( ,'/(5:+((/5(7$,1(5 PIV OT LINK ASSEMBL Y PIVO ASSEMBLY ,7(0 47< 03$57180%(5 0% 0 0 0 0% $[ *0 75' 0$ 6[& $[ [ '(6&5,37,21 3,927/,1.:(/'0(17 +'33/$67,&',6& ',6& 3,9276+$)7 3,927%$&.&29(5 62&.(7+($'&$36&5(: '85$/21%86+,1* 7+5867:$6+(5 +25,=217$/6+$)7 62&.(76(76&5(:&8332,17 62&.(7+($'&$36&5(: 52//3,1 Pg 6.5 Y ANK ASSEMBL ULIC T HYDRA ASSEMBLY TANK HYDRAULIC (This assembly is shown without the door which is welded on the level gauge side.) Pg 6. 6 ,7(0 47< 0 3$57180%(5 '(6&5,37,21 0 32:(53$&.:(/'0(17 6$ 2,/7$1./,' %[ +(;+($'&$36&5(: 6(66 ),//(5&$3 %5($7+(5PLFURQ 7[ 75866+($'0$&+,1(6&5(: 7)63 68&7,21675$,1(5 +3 3,3(3/8* GUDLQ 61$% /(9(/ 7(03(5$785(*$8*( 03( GHJ(/%2:0137)137 6$) ),/7(5+($' 6) PLFURQ5(7851),/7(5 % ),77,1*)137+26(%$5% 03)( GHJ(/%2:)137)137 ),77,1*0137+26(%$5% GHJ(/%2:01370-,& Y ULIC PUMP ASSEMBL HYDRA ASSEMBLY HYDRAULIC ,7(0 47< 0 3$57180%(5 7& /[ 1 /[ /2& %[ 394$56(&0 /2& %[ '(6&5,37,21 +353063(&,)<92/7$*( -$:7<3(&283/,1*)/$1*( -$:7<3(,16(57 -$:7<3(&283/,1*)/$1*( +3%(//+286,1* /2&.:$6+(5 +(;+($'&$36&5(: +<'5$8/,&3803 /2&.:$6+(5 +(;+($'&$36&5(: GHJ(/%2:1)0-,& 25,1*),77,1*1)0-,& ),77,1*GHJ6:,9(/)0-,& ),77,1*1))137 ),77,1*0137+26(%$5% Pg 6.7 FRONT VISE & CONVEY OR ASSEMBL Y CONVEYOR ASSEMBLY Pg 6. 8 FRONT VISE & CONVEY OR, PPAR AR TS LIST ARTS CONVEYOR, ,7(0 47< 0 3$57180%(5 '(6&5,37,21 0% 9,6(&219(<25:(/'0(17 0 )52176+$)7&$55,(5 %[ +(;+($'&$36&5(: /2& /2&.:$6+(5 6[& 62&.(76(76&5(:&8332,17 0$ 6+$)7 0$ 5($56+$)7&$55,(5 $[ 62&.(7+($'&$36&5(: [32 38//287'2:(/3,1 0 52//(578%( 56 %$//%($5,1* 0 %86+,1* 0$ 52//(56+$)7 0 9,6(-$:6+$)7 + 6+$)7:,3(5 [[ :($55,1* 675,3 0& 9,6(&</,1'(5 )[ )/$762&.(7+($'&$36&5(: 0$ &</,1'(5%5$&.(7 0% 029$%/(9,6(-$: )[ )/$762&.(7+($'&$36&5(: $[ 1)62&.(7+($'&$36&5(: 0 :($5675,3 )[ )/$762&.(7+($'&$36&5(: 0% '$780-$: $[ 62&.(7+($'&$36&5(: )[ )/$762&.(7+($'&$36&5(: 0' ,1)(('7$%/( 0 287)(('7$%/( )[ )/$762&.(7+($'&$36&5(: 0$ )5217&219(<25&29(5 $[ 62&.(7+($'&$36&5(: Pg 6.9 SHUTTLE VISE ASSEMBL Y ASSEMBLY Pg 6. 10 ,7(0 47< 0 3$57180%(5 '(6&5,37,21 0$ 6+877/(9,6()5$0( 0 9,6(-$:6+$)7 + 6+$)7:,3(5 [[ :($55,1* 675,3 0& 9,6(&</,1'(5 0$ &</,1'(5%5$&.(7 )[ )/$762&.(7+($'&$36&5(: 6+3$ (;7(51$/5(7$,1,1*5,1* 6[) 62&.(76(76&5(:)/$732,17 0% 029$%/(9,6(-$: $[ 62&.(7+($'&$36&5(: )[ )/$762&.(7+($'&$36&5(: 0 :($5675,3 )[ )/$762&.(7+($'&$36&5(: SHUTTLE D ATUM J AW ASSEMBL Y DA JAW ASSEMBLY ,7(0 47< 0 3$57180%(5 '(6&5,37,21 0 '$780/,1(-$::(/'0(17 0 (&&(175,&6+$)7 &0 52'(1' +;187 +(;187 0 '$78002817,1*3,1 6+3$ (;7(51$/5(7$,1,1*5,1* 0 <2/.:(/'0(17 6[ 62&.(76(76&5(:&8332,17 0 3,1 +;187 +(;187 6[ 62&.(76(76&5(:&8332,17 0 :($5675,3 )[ )/$762&.(7+($'&$36&5(: 0 &</,1'(53,1 0$ /,1.$ &-6 ),%(5*/,'(%86+,1* 0 /,1.3,1 0$ /,1.% Pg 6.11 LENGTH CONTROL ASSEMBL Y ASSEMBLY ,7(0 Pg 6. 12 47< 0 3$57180%(5 '(6&5,37,21 0$ /(1*7+&21752/5$&. $[ 62&.(7+($'&$36&5(: +* 6385*($5 0 (1&2'(5+,1* /8&$6(1&2'(5 ),/[ 3+,//,67(5+($'0$&+,1(6&5(: ./. .((36+(;187 $[ 62&.(7+($'&$36&5(: 0$ (1&2'(5&29(5 CHIP A UGER ASSEMBL Y AUGER ASSEMBLY CHIP AUGER INSTALLED ,7(0 47< 0 3$57180%(5 '(6&5,37,21 0* +<'5$8/,&02725 25,1*$'$372506757)137 GHJ(/%2:01370-,& 6[& 62&.(76(76&5(:&8332,17 )[ )/$762&.(7+($'&$36&5(: 0 &+,3$8*(5 Pg 6.13 COOL ANT GROUP COOLANT TO IDLER GUIDE ARM 3103-B NEEDLE VALVE 2101-4-4 ELBOW 1/4" MNPT 3/8" HOSE BARB (attached to idler guide arm) RVH-6 3/8" HOSE x 20' 590-06-12 3/8" BARB - 3/4-8 MALE 222.CB WASH HOSE GUN TO OUTFEED FENCE 598 SNAPLOC ASSY HOSE ASSEMBLY 2101-4-4 ELBOW 45 DEG 1/4" MNPT -1/4" FMNPT 125-6B 3/8" HOSE BARB RVH-6 3/8" HOSE x 5" 19CV0037VK CHECK VALVE RVH-6 3/8" HOSE x 19'7" 080-035 SPRING CLAMP (8) 101-C 3/8" FNPT T (attached to fence) 125-6B 3/8" HOSE BARB - 1/4" MNPT RVH-6 3/8" HOSE x 5" 19CV0037VK CHECK VALVE RVH-6 3/8" HOSE x 5'1" N6MEB4 90ELBOW (2) 3/8" BARB - 1/4"MNPT BPCROSS-04 1/4" FNPT BMI CROSS N6MCB4 3/8" HOSE BARB - 1/4" MNPT (2) RVH-6 3/8" HOSE x 7' 726-6B 1/4" FNPT - 3/8" HOSE BARB 2E-NT COOLANT PUMP Pg 6. 14 DOORS and CO VERS COVERS Driv e Door Drive M16-32-00C (M20-32-00B) Log o La bel Logo Label S20-9-20 Blade Co ver Cov M16-3-12 Idler Side Co ver Cov M16-3-07B (M20-3-07B) Par ameter s arameter ameters La bel Label S20-9-25 Blade Guar d Guard M16-3-09B (M20-3-09D) Thumb Scr ew Scre 1/4-20x.75 Idler Door m16-33-00A (M20-33-00) The head m ust be must raised or s wung swung to open. Co ver Cov M16-5-10 Encoder Co ver Cov M16-56-00A Pg 6.15 DRIVE ASSEMBL Y, ASSEMBLY PARTS LISTS ON FOLLOWING 2 PAGES. Pg 6. 16 M16 DRIVE ASSEMBL Y, PAR TS LISTS ASSEMBLY ARTS LISTS.. ,7(0 47< 03$57180%(5 7& %; +0& %; 0/2& %; /2& 5% )% ; 5)$'0& %; )/7 /2& 6$ %; /2& )/7 0 0 9 %; 0/2& 0 0 %; /2& )/7 :3 '(6&5,37,21 +30272553063(&,)<92/7$*( +(;+($'&$36&5(: 5(12/'*($5%2; 0(75,&+(;+($'&$36&5(: /2&.:$6+(5 +(;+($'&$36&5(: /2&.:$6+(5 0(&+$1,&$/38//(< 635,1*38//(< '5,9(%(/7 63(('$'-867(5 287(5%2;6+(// +(;+($'&$36&5(: )/$7:$6+(5 /2&.:$6+(5 287(5%2;7$&+&29(5 +(;+($'&$36&5(: /2&.:$6+(5 )/$7:$6+(5 ,11(5%2;:(/'0(17 027256($7:(/'0(17 '5,9(:+((/ 0(75,&+(;+($'&$36&5(: /2&.:$6+(5 ,11(5'5,9(:+((/63$&(5 287(5'5,9(:+((/63$&(5 +(;+($'&$36&5(: /2&.:$6+(5 )/$7:$6+(5 '5,9(:+((/5(7$,1(5 Pg 6.17 M20 DRIVE ASSEMBL Y, PAR TS LISTS ARTS LISTS.. ASSEMBLY ,7(0 Pg 6. 18 47< 03$57180%(5 7& %; +0$ %; 0/2& %; /2& 5% )% [ 5)$'0% %; )/7 /2& 0 %; /2& )/7 0 0$ 6$ %; 0/2& %; /2& )/7 0$ $; 6; 0 0 0 '(6&5,37,21 +30272553063(&,)<92/7$*( +(;+($'&$36&5(: 5(12/'*($5%2; 0(75,&+(;+($'&$36&5(: /2&.:$6+(5 +(;+($'&$36&5(: /2&.:$6+(5 0(&+$1,&$/38//(< 635,1*38//(< '5,9(%(/7 63(('$'-867(5 96287(5:5$33(5 +(;+($'&$36&5(: )/$7:$6+(5 /2&.:$6+(5 7$&+20(7(5&29(5 +(;+($'&$36&5(: /2&.:$6+(5 )/$7:$6+(5 ,11(5%2;:(/'0(17 027256($7:(/'0(17 '5,9(:+((/ 0(75,&+(;+($'&$36&5(: /2&.:$6+(5 +(;+($'&$36&5(: /2&.:$6+(5 )/$7:$6+(5 '5,9(:+((/&$3 62&.(7+($'&$36&5(: 62&.(76(76&5(:1) 96$'-867(563$&(5 96'5,9(38//(<63$&(5,11(5 96'5,9(38//(<63$&(5287(5 Pg 6.19 Pg 6.20 OPTIONAL ASSEMBLIES SECTION 7 - OPTIONAL ASSEMBLIES SECTION 7 SECTION 7 - OPTIONAL ASSEMBLIES BUNDLING ASSEMBL Y ASSEMBLY SECTION 7, OPTIONS For customers who cut bundles, a bundling vise is available. For "P" model machines, only one bundling assembly is required for the single vise, an "A" model is shown below. When cutting a number of pieces at once, the vertical clamp holds the bundle down firmly to prevent cutting errors due to material slippage or vibration. This also helps to extend blade life. Bundling Cylinder (2) Bundling Vise Jaw (2) This option is shown with the standard vises closed and the BUNDLING VISES OPEN. (Parts drawing & numbers on next page) Pg 7.1 M1620 BUNDLING ASSEMBL Y ASSEMBLY SHUTTLE VISE ONLY. MOUNTED INSIDE TOP OF SHUTTLE FRAME. FRONT VISE ONLY SHUTTLE VISE ONLY. Pg 7. 2 M1620 ,7(0 47< 0 0$ 3$57180%(5 %81'/,1*6+$)7 )52179,6( '(6&5,37,21 $[ 62&.(7+($'&$36&5(: 0$ %81'/,1*6+$)7 6+877/(9,6( 0 02817,1*3/$7( )[ )/$762&.(7+($'&$36&5(: $[ 62&.(7+($'&$36&5(: 0$ %81'/,1*723+2/'(5 %[ +(;+($'&$36&5(: /2& /2&.:$6+(5 0$ %81'/,1*$50:(/'0(17 0$ :($5675,3 6[&2 62&.(76(76&5(:&21(32,17 675$,*+7*5($6(),77,1* [[ :($55,1* 675,3 + 6+$)7:,3(5 0& %81'/,1*&</,1'(5 6+3$ (;7(51$/5(7$,1,1*5,1* 0 %81'/,1*$506/,'(5 )/7 )/$7:$6+(5 /2& /2&.:$6+(5 $[ 62&.(7+($'&$36&5(: 66 %$//9$/9( $[ 62&.(7+($'&$36&5(: 3%'%2%1( 35(6685(5('8&,1*9$/9( %[ +(;+($'&$36&5(: GHJ(/%2:1)0-,& VER TICAL ROLLER ASSEMBL Y VERTICAL ASSEMBLY ,7(0 47< 0 3$57180%(5 '(6&5,37,21 0 02817,1*%5$&.(7:(/'0(17 0 6+$)7:(/'0(17 [ 52//3,1 0 9(57,&$/78%( 6+3$ (;7(51$/5(7$,1,1*5,1* 0 02817,1*%5$&.(7 /2& /2&.:$6+(5 %[ +(;+($'&$36&5(: )[ )/$762&.(7+($'&$36&5(: Pg 7.3 M1620 M-16A DIRECT DRIVE ASSEMBL Y ASSEMBLY Pg 7. 4 M1620 ,7(0 47< 03$57180%(5 7& VKDIWFXWWR /[ /[ +% %[ /2& +0$ LQSXWVKDIWFXWWR 0 %[ %[ 0 9 0 :3 0/2& %[ '(6&5,37,21 +353063(&,)<92/7$*( /29(-2<&283/,1*)/$1*( /29(-2<63,'(5 /29(-2<&283/,1*)/$1*( ',5(&7'5,9($'$3725 +(;+($'&$36&5(: /2&.:$6+(5 5(12/'6*($5%2;7/ *($5%2;$'-867,1*%2/7 0(75,&+(;+($'&$36&5(: 0(75,&+(;+($'&$36&5(: '5,9(:+((/63$&(5 '5,9(:+((/ '5,9(:+((/63$&(5 '5,9(:+((/5(7$,1(5 0(75,&/2&.:$6+(5 0(75,&+(;+($'&$36&5(: M-20A DIRECT DRIVE ASSEMBL Y ASSEMBLY ,7(0 47< 03$57180%(5 7& VKDIWFXWWR -[ -( -[ + +0$ VKDIWFXWWR /2& %; $0[ 6$ 0$ $[ 6[) 0/2& %[ 0$ %0[ %0[ '(6&5,37,21 +353063(&,)<92/7$*( &283/,1*)/$1*( PRWRU &283/,1*6/((9( &283/,1*)/$1*( JHDUER[ *($5%2;$'$3725 *($5%2;7/ /2&.:$6+(5 +(;+($'&$36&5(: 0(75,&62&.(7+($'&$36&5(: '5,9(:+((/ '5,9(:+((/&$3 62&.(7+($'&$36&5(: 62&.(76(76&5(:1))/$732,17 0(75,&/2&.:$6+(5 0(75,&+(;+($'&$36&5(: *($5%2;$'-867,1*%2/7 0(75,&+(;+($'&$36&5(: 0(75,&+(;+($'&$36&5(: Pg 7.5 M1620 MITSUBISHI PL C 500 CONTROLER PLC This option allows for automatic operation of the head angle, not available for "P" model machines. The PLC 500 operator interface. DIGIT AL ANGLE DISPL AY DIGITAL DISPLA This option displays the head angle via a digital encoder and display. Available with the PLC 100 only. VARIABLE VISE PRESSURE This option is useful when the material being cut is soft or is a structrual and may be distorted by the full vise pressure. 90.00 The head angle display. OUT OF ST OCK SWIT CH STOCK SWITCH For customers who plan to cut in the automatic cycle with limited supervision, an Out of Stock Limit Switch is available. It will stop the machine as soon as there is not enough material for the next cut in a cycle. Adjustable Switch Activator XCK-L115 Limit Switch Pg 7. 6 M1620 SPECIFICATIONS SECTION 8 - SPECIFICATIONS SECTION 8 SECTION 8 - SPECIFICATIONS SECTION 8, SPECIFICA TIONS SPECIFICATIONS M-16 SPECIFICA TION LIST SPECIFICATION DIMENSIONS IMPERIAL Capacity round rectangular at 45 deg at 30 deg 16" dia 16" x 25" 16" round, 14x16" rec. 11" round, 9x16" rec. METRIC 400mm dia 400 x 625mm 400mm round, 350x400mm rec. 275mm round, 225x400mm rec. Length Control programmable up to 99 jobs, with 5 in queue. Blade: length width thickness 18' 6" 1 1/4" .042" Blade: Speed 75-400 SFM (60-325 with VFD) 5640mm 32mm 1mm 20-122 m/min (18-99 with VFD) Blade: Tension (hydraulic) 30,000 psi 207000 kPa Blade: Guides carbides (water soluable coolant lubricated) Blade: Wheel Diameter 19" diameter 480 mm Motors: blade drive hydraulic 5HP 3HP 3.7kW 2.2kW Pumps: hydraulic pump (pressure compensated) coolant pump 6 1/2 gpm 24.5 L/min 3 1/2 gpm (150W) 13.2 L/min (150W) Hydraulic Tank 11 US gallons 42 L Hydraulic System Pressure 950 psi 6544kPa Vise Control hydraulic Shuttle Stroke (single stroke multi shuttle capability) 0-33" 0-838mm Table Height 32" 812mm Machine Weight 7400 lbs. 3356 kg Maximum Workload 8000 lbs. 3650 kg Overall Dimensions 130" W x 90" L x 66" H Noise Level 75-95 db 3300 W x 2286 L x 1676mm H 75-95 db Pg 8.1 Pg 8. 2 SPECIFICA TION M-20 SPECIFICATION DIMENSIONS IMPERIAL Capacity round rectangular at 45 deg at 30 deg 20" dia 20" x 30" 20" round, 18x20" rec. 12" round, 12x20" rec. METRIC 500mm dia 500 x 750mm 400mm round, 350x400mm rec. 300mm round, 300x400mm rec. Length Control programmable up to 99 jobs, with 5 in queue Blade: length width thickness 20' 6" 1 1/2" .050" Blade: Speed 75-400 SFM (60-350 with VFD) 6250mm 38mm 1.25mm 20-122 m/min (18-107 with VFD) Blade: Tension (hydraulic) 30,000 psi 207000 kPa Blade: Guides carbides (coolant lubricated) Blade: Wheel Diameter 22" diameter 560 mm Motors: blade drive hydraulic 10HP 3HP 7.5kW 2.2kW Pumps: hydraulic pump (pressure compensated) coolant pump 6 1/2 gpm 24.5 L/min 3 1/2 gpm (150W) 13.2 L/min (150W) Hydraulic Tank 11 US gallons 42 L Hydraulic System Pressure 950 psi 6544kPa Vise Control hydraulic Shuttle Stroke (single stroke multi shuttle capability) 0-33" 0-838mm Table Height 32" 812mm Machine Weight 7700 lbs. 3500 kg Maximum Workload 8000 lbs. 3650 kg Overall Dimensions 140" W x 90" L x 66" H Noise Level 75-95 db 35560 W x 2286 L x 1676mm H 75-95 db Pg 8.3 Pg 8. 4 Pg 8.5 Pg 8. 6 WARRANTY SECTION 9 - WARRANTY SECTION 9 SECTION 9 - WARRANTY SECTION 9, WARRANTY Hyd-Mech Group warrants each new M-16/20 bandsaw to be free from failure resulting from defective material and workmanship under proper use and service for a period of one year following the date of shipment to the user. Hyd-Mech's sole obligation under this warranty is limited to the repair or replacement without charge, at Hyd-Mech's factory, warehouse, or approved repair shop,of any part or parts which Hyd-Mech's inspection shall disclose to be defective. Return freight must be prepaid by the user. This warranty, in its entirety, does not cover maintenance items, including but not limited to lubricating grease and oils, filters, V-belts, saw blades, etc., nor any items therein which show signs of neglect, overloading, abuse, accident, inadequate maintenance, or unauthorized altering. MOTOR, GEARBOX, PUMP, ELECTRIC COMPONENTS, VALVES, HOSES, FITTINGS, and any other items used in the manufacture of the M-16/20 , but not originally manufactured by Hyd-Mech are subject to the original manufacturer's warranty. Hyd-Mech will provide such assistance and information as is necessary and available to facilitate the user's claim to such other manufacturer. Liability or obligation on the part of Hyd-Mech for damages, whether general, special or for negligence and expressly including any incidental and consequential damages is hereby disclaimed. Hyd-Mech's obligation to repair or replace shall be the limit of its liability under this warranty and the sole and exclusive right and remedy of the user. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, WRITTEN OR ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. This warranty may not be changed, altered, or modified in any way except in writing by Hyd-Mech Group. HYD-MECH GROUP 1079 Parkinson Road P.O. BOX 1087 Woodstock, Ontario N4S 8P6 Phone: (519) 539-6341 Fax: (519) 539-5126 e-mail: [email protected] Pg 9.1 MITSUBISHI PL CP ARAMETERS PLC PARAMETERS (refer to "Calibration Procedures" in Sec 3, for proper usage of paramters) PLC 100 ACT HT HGT CLB "ENTER" FST APR DIST FST APR OFST (OPTION) (OPTION) DO WN D WL DOWN DWL LTH CLB "ENTER" ACT L TH LTH STROKE ACC DIST DEC DIST SL W DIST SLW TR G WD TRG WL FVO DWL FV OD SV OD WL SVO DWL CL S TIME CLS SPD FCTR WHEEL TR GS TRGS ACT POS HLD SHT HM BRKN PRO X PROX BLD CHAM PLC 500 LTH CLB "ENTER" ACT LTH: STROKE: LNG TRG WD: ACC DIST: DEC DIST: SLW DIST: OFF . . . . . . FVO DWELL: SVO DWELL: CLS TIME: HD CLB "ENTER" ACT HD MVT: Pg 9. 2 DATE:___/____/____ OFF . ANG CLB "ENTER" TTL MEAS ANG: ANG TRG WD: ANG DEC: BP RADIUS: DP RADIUS: SPD FCTR: WHEEL TRG: ACT POS: HLD SHT HM: BRKN PROX: BLD CHAM SER#______________ OFF . . . . . . 1 OFF / ON OFF / ON OFF / ON VOL TAGE:_______ OLT OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL OPERATIONS & MAINTENANCE MANUAL Through its twinned distribution channel of authorized dealers and factory representatives, HYD•MECH services a worldwide network of customers from its two state-of-the-art manufacturing facilities in Houston,Texas, USA and Woodstock, Ontario, Canada. Check out the full range of Rock Solid Sawing Solutions at www.hydmech.com HYD•MECH GROUP LIMITED P.O. Box 1030, 1079 Parkinson Road Woodstock, Ontario Canada N4S 8A4 phone: (519) 539-6341 fax: (519) 539-5126 sales: 1-877-276-SAWS(7297) parts: 1-877-237-0914 HYD•MECH CORPORATION 6901 Avenue V., Houston,Texas USA 77011 website: www.hydmech.com e-mail: [email protected] ">
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Programmable Length Control
Automatic & Manual Modes
Hydraulic System
Variable Blade Speed
Coolant System
Queue Operation
Position the head, fixed vise, and shuttle vise switches to the neutral positions. Then, press and hold the HYDRAULIC START button momentarily until the PLC display becomes active.
You can program and store up to 99 jobs on the M-20.
Yes, you can stop an automatic job by switching to manual mode using the AUTO/MAN button on the PLC.
In manual mode, use the PLC to initiate a 'Single Part Cycle'. You will need to home the head first and then enter the desired cut length.
What type of blade coolant is recommended for the device?
Two types of coolant are available: oil-based (dilute 1:10) and synthetic (dilute as recommended by the manufacturer). It is recommended to consult your saw blade supplier for information on cutting fluid products suitable for your needs.
What type of blade coolant is recommended for the saw?
The manual specifies two types of coolant: oil-based (dilute 1:10) and synthetic (dilute as recommended by the manufacturer). Consult your saw blade supplier for specific cutting fluid product recommendations.
What type of hydraulic fluid is used for the machine?
The machine is shipped from the factory with Texaco Rando HD 46 hydraulic oil. If a change of brand is desired, any recognized mineral hydraulic oil with similar properties (such as Duro AW46) can be used. Recommended replacement oils include Chevron AW Hydraulic Oil 46, Esso NUTO H46, Mobil Mobil DEC 25, and Shell Tellus 46.
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