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OPERATIONS & MAINTENANCE M A N U A L B A N D S A W T E C H N O L O G Y...
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H-22A 2 0 0 1 , r e v b , 3 9 3 1 3 0 THANK YOU, On behalf of everyone at HYD . MECH, I would like to thank and congratulate you on your decision to purchase a HYD . MECH band saw.
HOLD WORKPIECE 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...
FOUNDATION, 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. Machine should be levelled in both directions ie. along and across its infeed conveyor specially when machine is to be inserted into a larger conveyor system.
WIRING CONNECTIONS After the machine is levelled and anchored the necessary power hook-up needs to be performed. In order to provide safe operation as well as to prevent potential damage to the machine, only qualified personnel should make the connections. BEFORE START-UP THE FOLLOWING TWO POINTS SHOULD BE CHECKED: -signs of damage that may have occurred during shipping to the electrical cables and the hydraulic hoses.
START-UP The H-22A 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 "H"...
OPERATOR PANEL CONTROLS 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.
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BLADE SPEED - This dial will increase or decrease the speed at any time while the blade is running. BLADE STOP BUTTON - Stops the blade. If the blade is stopped during a cycle, the cycle will continue but will not let the head descend until the blade is started. STOP - This mushroom button stops the blade and hydraulic motors.
MITSUBISHI BASED PLC CONTROL SYSTEM NOTE: This instruction manual is applicable to the M16A, M20A, H14A, H18A, H22A, H28A, H32A 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...
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"...
FUNCTION BUTTON DESCRIPTION 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.
SINGLE PART 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 KERF function button description for 1) A trim cut should be made before initiating the "Single Part Cycle "...
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 (and auxillary vise is used) closed (in "MANUAL MODE").
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"...
SECTION 2B, SAW CUTTING CONTROLS 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.
HYDRAULIC FEED CONTROL The Hydraulic Feed Control is located to the left of the control panel. 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).
CHART EXAMPLE #1 We will use the parameters 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.
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.
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.
SECTION 2C, MECHANICAL CONTROLS COOLANT FLOW A generous flow of coolant should be applied in order to increase production and blade life. Machine is provided with two independently controlled coolant spouts. -One from the adjustable guide arm. This one should always flood the blade with coolant.
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OPTIONAL BUNDLING CONTROLS Both the front vise bundling and the shuttle vise bundling can be operated independantly. Both of the bundling actions can be controlled independantly in relation to the close time of the vise jaws or turned off completely. To turn the bundling on, turn the ball valve handle for each of the cylinders (shown in the Shuttle vise...
SECTION 3, MAINTENANCE AND TROUBLE SHOOTING LOCK -OUT Purpose: To prevent injury to workers caused by unexpected start-up of machines being worked on. Where the starting of a machine or device may endanger the safety of a worker Control switches or other control mechanisms shall be locked out; Other effective precautions necessary to prevent such starting shall be taken LOCK OUT PROCEDURE Whenever work is to be performed on a machine, the person in charge should follow Lockout procedures as is...
The brush should be replaced as it becomes worn to approximately 70% of it's original 3" diameter. Replacements can be purchased through your Hyd-Mech Dealer. Blade brush and adjusting nut & screw. Pg 3.2...
BLADE GUIDES ADJUSTMENT 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. To adjust the carbides, loosen the set screws in the handle bases and remove the handles.
CAM FOLLOWER ADJUSTMENT There are two cam followers mounted on the head frame. The set of cam followers is shown in the photo. One of them is fixed and the other is adjustable. The cam followers are factory set and usually do not require adjustment. In a properly adjusted system of cam followers only one side should be in contact with the guide.
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.
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.
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PROBLEM PROBABLE CAUSE SOLUTION 9a. Motor overload has tripped. 9a. Depress each of the over- 9. Saw will not start. load buttons located in the electrical box. Depressing one button at a time and trying to start the saw will indicate which motor was overloaded.
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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.
PLC 100 PARAMETERS Parameter Definition HGT CLB "ENTER" This is to be used only if calibration is required. Call Hyd-Mech Service department for instruction. ACT HT - Actual Height Value. Value that must be entered after performing Head Height Calibration procedure (see Pg.
PLC 100 TROUBLESHOOTING PROBLEM #1, for automatic models with a shuttle. PLC is not measuring lengths. POSSIBLE 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...
PROBLEM # 2, for automatic models with a 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...
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.
PROBLEM # 3, for P models, disregard all references to a shuttle. AUTO cycle not being completed. In the AUTO mode, the PLC controls saw functions through output relays. For a certain function to be actuated, the PLC must first see specific input(s). Like the output relays, the input relays are located on the PLC unit.
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).
Input / Output Terminal Information : Inputs - X0 - Length Encoder, Channel A X10 - Shuttle Vise Close Switch X1 - Length Encoder, Channel B X11 - Shuttle Vise Open Switch X2 - Blade Speed X12 - Front Vise Close Switch X3 - Head Encoder, Channel A X13 - Front Vise Open Switch X4 - Head Encoder, Channel B...
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.
HEAD HEIGHT 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 00.000 3) With the cursor on the , press the ENTER key.
1)The PLC is equipped with a lithium battery to keep the program stored while the power 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.
ELECTRICAL COMPONENTS, PHOTOS Mitsubishi PLC. Fuses & overloads. Control fuses. Transformer. Electrical control box layout. Hirschman connectors and directional control valve solenoids. 3 HP electric motor. Hydraulic control components. Pg 4.2...
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SECTION 5, HYDRAULIC SYSTEM The H-22 hydraulic system does not require any special work on a new machine before its start-up. The hydraulic tank is filled with Duro AW46 hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial start-up.
H-22 GUIDE ARM ASSEMBLY ITEM H-22 PART NUMBER DESCRIPTION H22-47-02 GUIDE AM BAR A1-.5x1 SOCKET HEAD CAP SCREW H22-47-00 IDLER GUIDE ARM H22-46-00 DRIVE GUIDE ARM H18-47-04 GUIDE ARM SPRING CARRIER 30 K2000-037 DISK SPRING H18-47-03 GUIDE ARM PISTON CRBL-01A CARBIDE SUPPORT CRBL-02 CARBIDE LOADER BOLT...
ANTIVIBRATION ROLLER ASSEMBLY ITEM H18-22 PART NUMBER DESCRIPTION AVR-471-01A BLOCK, IDLER SIDE AVR-461A-01 BLOCK, DRIVE SIDE A1-.375x2 SOCKET HEAD CAP SCREW 6200 2RS BALL BEARING AVR-461-03 BACK ROLLER RACE AVR-461-02A FRONT ROLLER RACE B3-10x30S METRIC SOCKET HEAD SHOULDER SCREW O-RING (.625x1/16) AVR-471-02A BUSHING 6000 2RS...
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H-22 IDLER WHEEL ASSEMBLY ITEM H-22 PART NUMBER DESCRIPTION H22-43-01A BACK PLATE H22-431-00 SLIDER WELDMENT S1-.5X1C SOCKET SET SCREW, CUP POINT H22-6-01 TENSION CYLINDER MOUNTING PIN H22-C5-00 TENSION CYLINDER MOUNTING PIN H22-43-02 TENSION TRACK A1-.875X3.25 SOCKET HEAD CAP SCREW A1-.875X2.5 SOCKET HEAD CAP SCREW S1-.875X1.5 SOCKET SET SCREW, FLAT POINT...
HYDRAULIC TANK ASSEMBLY ITEM H-18 PART NUMBER DESCRIPTION H16-611-00 POWER PACK WELDMENT H16-61-01 OIL TANK LID S1-.19x.5 SOCKET HEAD CAP SCREW SES-3-40-S-80 FILLER CAP & BREATHER, 50micron T1-.19x.5 TRUSS HEAD MACHINE SCREW 2103-4-4 90 deg ELBOW, MNPT/MJIC TFS-100-0-P SUCTION STRAINER MP-100-FE 90 deg ELBOW, FNPT/FNPT 30182B-12-8...
FRONT VISE DATUM LINE JAW ASSEMBLY ITEM H-18 PART NUMBER DESCRIPTION H18-512-00 DATUM LINE JAW H18-5-02 WEAR STRIP F1-.312x.5 FLAT SOCKET HEAD CAP SCREW H14-5-10 SMALL JAW MOUNTING PIN H14-5-12 SMALL DATUM JAW LINK H14-5-11 LARGE DATUM JAW LINK H14-5-15 LARGE JAW MOUNTING PIN SH-0125-PA 1 1/8 EXTERNAL RETAINING RING...
SHUTTLE VISE DATUM LINE JAW ASSEMBLY ITEM H-18 PART NUMBER DESCRIPTION H18-522-00A DATUM LINE JAW H18-5-02 WEAR STRIP F1-.312x.75 FLAT SOCKET HEAD CAP SCREW H14-5A-10 SMALL JAW MOUNTING PIN H14-5A-12 SMALL DATUM JAW LINK H14-5A-11 LARGE DATUM JAW LINK H14-5-15 LARGE JAW MOUNTING PIN SH-0125-PA 1 1/8 EXTERNAL RETAINING RING...
CHIP AUGER ASSEMBLY ITEM H-18 PART NUMBER DESCRIPTION MG.12.09.10 HYDRAULIC MOTOR 2503-6-4 O RING ADAPTOR, M STRT/FNPT 2103-4-4 90 deg ELBOW, MNPT/MJIC S1-.312x.25C SOCKET SET SCREW, CUP POINT F1-.375x1 FLAT SOCKET HEAD CAP SCREW H18-12-00 AUGER WELDMENT Pg 6.11...
H-22 DRIVE ASSEMBLY ITEM H-22 PART NUMBER DESCRIPTION PM70 GEAR BOX, 45.15:1 256TC 10HP, 1200RPM, SPECIFY VOLTAGE H22-41-02 UPPER MOUNTING PLATE H22-41-01 LOWER MOUNTING PLATE B1-.875x2 HEX HEAD CAP SCREW H20-44-01 DRIVE WHEEL H22-44-02 RETAINING CAP A1-.625x1.75 SOCKET HEAD CAP SCREW S1-.875x1.5 SOCKET SET SCREW, CUP POINT 24mmLOC...
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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.
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