Hyd-Mech H10A Safety And Operating Instructions Manual
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Hyd-Mech H10A Safety And Operating Instructions Manual

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H10A
393311
REV A
Thank you,
On behalf of everyone at HYD·MECH Group Limited, I would like to thank and congratulate you on your decision to pur-
chase a HYD·MECH bandsaw.
Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to reduce cost
while boosting quality and productivity.
To ensure you are maximizing the power and versatility of your new HYD·MECH bandsaw, please take the time to famil-
iarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual.
We sincerely appreciate the confidence you have demonstrated in purchasing our product and look forward to building a
long and mutually beneficial relationship.
Thank you
Hyd·Mech Group Limited
P.O. Box 030, 079 Parkinson Road
Woodstock, Ontario, N4S 8A4
Phone : (59) 539-634
Service : -877-237-094
Sales : -877-276-SAWS (7297)
Fax : (59) 539-526
info@hydmech.com
e-mail :


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  • Page 1 H10A 393311 REV A Thank you, On behalf of everyone at HYD·MECH Group Limited, I would like to thank and congratulate you on your decision to pur- chase a HYD·MECH bandsaw. Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to reduce cost while boosting quality and productivity.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 0 - SAFETY INSTRUCTIONS SUMMARY ............................0. FOREWORD ............................0.2 BASIC RULES ..........................0.4 RESPONSIBILITIES OF THE OWNER ....................0.5 RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL ......0.6 RESIDUAL RISKS ..........................0.8 SAFETY HAZARD LABELS ......................0.9 HAZARDOUS VOLTAGE INSIDE ....................0.9 MOVING BANDSAW BLADE WILL CUT ..................0.9 PINCH POINT ..........................0.0 MOVING PARTS CAN CRUSH AND CUT ..................0.0 LOCATION AND PART NUMBERS OF SAFETY HAZARD LABELS ON H0SV ......0.0...
  • Page 4 SECTION 3 - MAINTENANCE AND TROUBLESHOOTING SAFETY DURING MAINTENANCE AND TROUBLESHOOTING ............3. LOCK-OUT PROCEDURE .......................3. RESTORING MACHINE TO USE AFTER LOCK-OUT ..............3.2 BLADE CHANGING PROCEDURE ....................3.2 NEW BLADE BREAK-IN ........................3.3 BLADE TRACKING ..........................3.3 DRIVE WHEEL ADJUSTMENT ......................3.3 IDLER WHEEL ADJUSTMENT ......................3.4 BLADE GUIDE ADJUSTMENT ......................3.4 BLADE BRUSH ADJUSTMENT .......................3.5 LUBRICATION ..........................3.5...
  • Page 5 SECTION 0 - SAFETY INSTRUCTIONS SUMMARY All persons operating this machine must have read and understood all of the following sections of this Manual: Section 0 SAFETY Section 2 OPERATING INSTRUCTIONS However, as a memory aid, the following is a summary of the Safety Section. Put Safety First Mandatory Information –...

  • Page 6: Foreword

    FOREWORD Put Safety First! This Safety Section contains important information to help you work safely with your machine and describes the dangers inherent in our machines. Some of these dangers are obvious, while others are less evident. It really is important to PUT SAFETY FIRST. Make it a habit to consider the hazards associated with any action BEFORE you do it.
  • Page 7 Signatures Everyone involved in operation of this machine must sign below to confirm that: I have read and understood all parts of Section 0 – Safety, and Section 2 – Operating Instructions. Name Date Signature Everyone involved in the installation, inspection, maintenance, and repair of this machine must sign below to confirm that: I have read and understood all parts of this Operation and Maintenance Manual.

  • Page 8: Basic Rules

    Manual. Hyd-Mech Group cannot accept any liability for personal injury or property damage due to operator errors or non-compliance with the Safety and Operating Instructions contained in this Manual.

  • Page 9: Responsibilities Of The Owner

    RESPONSIBILITIES OF THE OWNER Organization of work This Operation and Maintenance Manual must always be kept near the machine so that it is accessible to all concerned. The general, statutory and other legal regulations on accident prevention and environmental protection must also be observed, in addition to the Manual material.

  • Page 10: Responsibilities Of The Operator And Maintenance Personnel

    RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL Safety equipment All machines are delivered with safety equipment that must not be removed or bypassed during operation. The correct functioning of safety equipment on the machine must be checked: • at the start of every shift. •...
  • Page 11 Gloves Experience has shown that careless use of gloves around machinery is a major factor in serious hand injuries. Gloves should not be worn when operating or adjusting the machine, except: Wear protective gloves when handling bandsaw blades at blade changes. Gloves may be worn when handling work pieces, only if the machine is in Manual Mode and the bandsaw blade is not running.

  • Page 12: Residual Risks

    On Hyd-Mech machines the Master Disconnect Switch will be of one of three types: • Rotary switch mounted in electrical control cabinet door and inter-locked with door •...

  • Page 13: Safety Hazard Labels

    SAFETY HAZARD LABELS The safety hazard labels attached to your machine represent important safety information to help you avoid personal injury or death. All supervisors, operators, and maintenance personnel must locate and understand the safety information associated with each hazard label prior to operating or servicing the machine. The safety hazard labels shown below are located at various positions on the machine to indicate possible safety hazards.
  • Page 14 PINCH POINT Machine parts may move without warning, either because the machine is operating automatically, or because another person initiates the motion. Keep hands clear of all labeled pinch points, whenever the machine is running. Machine vises can exert great force and cause severe injury. Keep hands clear of vises and workpiece when vises are opened or closed.
  • Page 15 Danger Moving parts can cut and crush Item No 39335 Danger Hazardous voltage inside Item No 39938 0....
  • Page 17 SECTION 1 - INSTALLATION Upon delivery of your new H0A saw, it is imperative that a thorough inspection be undertaken to check for any damage that could have been sustained during shipping. Special attention should be paid to the electrical and hydraulic systems to check for damaged cords and hoses, or for fluid leaks.
  • Page 18 FOUNDATION, LEVELING 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 leveled in both directions (from side to side &...
  • Page 19 Leveling inside the power pack enclosure WIRING CONNECTIONS After the machine is leveled and anchored the necessary power hook-up needs to be performed. The first two areas that need to be checked are: • There is no sign of shipping damage to the electrical conduits, cords or hydraulic hoses. •...
  • Page 20 EARTH GROUNDING PROCEDURE . Customer to provide and install a ground rod approx. 0.60 (5mm) diameter, copper clad steel, to be driven no less than 8’ (2.5m) into the ground, no more than 10’ (3m) away from control enclosure. 2. Ground rod to be connected to customer’s in plant ground system. This connection shall be made directly at the ground rod.
  • Page 21 SECTION 2 – OPERATING INSTRUCTIONS PLC 100 CONTROL SYSTEM OPERATION OVERVIEW The PLC is a programmable logic controller that allows the operator to run the machine in both manual and automatic modes. The control panel is divided into four parts: MANUAL ONLY on the left; MANUAL & AUTO in the centre; MACHINE on the right;...

  • Page 22: Manual & Auto Mode Controls

    MANUAL MODE ONLY CONTROLS HEAD CONTROLS HEAD UP Pressing this key will raise the head but it will stop and hold its position if the key is re- leased. HEAD DOWN Pressing this key will lower the head to its bottom limit and will stop and hold its position when pressed again, or if the HEAD UP key is pressed.

  • Page 23: Machine & Cycle Controls

    SERVICE MODE The SERVICE MODE allows the user to adjust the various PLC parameters. The user will be prompted for a password. Contact Hyd-Mech Group Limited to access this mode. MANUAL MODE Pressing this key will enable all of the “MANUAL MODE ONLY CONTROLS.”...

  • Page 24: Manual Mode

    MANUAL MODE MANUAL MODE is the default mode. All functions are enabled when in MANUAL MODE. The screen will look as follows: MANUAL MODE BLADE SPEED 0 SFM FEED RATE 0” / M LENGTH 0” SHUTTLE OVERTRAVELLED DISPLAY NOT REFERENCED “SHUTTLE OVERTRAVELLED - DISPLAY NOT REFERENCED”...

  • Page 25: Automatic Operation

    7. Set the material height using the Head Up & Head Down push buttons and then press enter. Position the blade about 3/8” above material. just the 8. If the blade is not running, you will be prompted by the words BLADE START. Start the blade and ad blade speed as required.

  • Page 26: Procedure For Editing Or Starting A New Job In Auto Mode

    PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE . In AUTO mode, key in a job number from 0 to 99, the number of pieces to be cut, the number of pieces already cut, and the length, pressing enter after each value. If the number of pieces cut equals or exceeds the number re- quired, the cycle will not start.

  • Page 27: Working With A Queue

    When the AUTO CYCLE commences, the screen will change to the “Auto Mode Status” screen AUTOMATIC MODE JOB# X IN PROGRESS BLADE SPEED 0 SFM FEED RATE 0” / M PIECES REQUIRED PIECES CUT LENGTH 0” and the following events will take place: .

  • Page 28: Working With A Repeating Queue

    Set the material height using the Head Up & Head Down push buttons and then press enter. Position the blade about 3/8” above material. If the blade is not running you will be prompted by the words BLADE START. Press the BLADE START key. The JOB PROGRESS screen will appear and display each individual JOB as it is being run.

  • Page 29: Hydraulic Feed Control

    HYDRAULIC FEED CONTROL The hydraulic feed control is mounted on the front of the machine. The FEED RATE VALVE (FRV) sets the maximum feed rate when the blade encounters little or no resistance, as when cutting thin cross-sections, or falling freely without any work piece. The FEED FORCE VALVE (FFV) sets the degree of slow down as the blade encounters resistance from the work piece.
  • Page 30 CUTTING PARAMETERS CHART A full size CUTTING PARAMETERS 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. Examples of the correct use of this chart are on the following pages.
  • Page 31 STEP 2 - SET FEED FORCE LIMIT The Feed Force Value was originally developed as a means to limit maximum feed force, to prevent crooked cuts, espe- cially in wide materials. While it is possible to set the Feed Force Limit low enough that a dull blade would just stall and rub against the work piece, this may result in sluggish feeding.
  • Page 32 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. The graph shows that as effective material width gets wider or as material gets harder, lower blade speeds are recom- mended.
  • Page 33 Optimum Optimum Blade Blade Materials Speed Speed ft/min m/min 5” (25mm) diameter solid medium carbon steel 0” (250mm) I-Beam 4” x 4” (00mm x 00mm) Rect tube /4” (6mm) wall 4” 900mm) 400 stainless steel 2” x 2” (50mm x 50mm) Rect tube /4” (6mm) wall bundle 5 x 5 pcs 0”...
  • Page 34 Feed Rate for Blade Pitches Other than Optimum Pitch 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.
  • Page 35 ADDITIONAL CUTTING SETUP EXAMPLES EXAMPLE #2 Material - Round Steel Tube SAE 4320 hardened to 35 RC (325 Bhn) Dimensions - 6” O.D. x 4” I.D. (50 mm O.D. x 00mm I.D.) . Effective Material Width 4 ½ “ (.75 x 6) or 4mm (9 x 6). 2.
  • Page 36 Variable Vise Pressure Knob This knob is used to adjust the force applied to the work piece by the vises and bundling clamps. Lower force can avoid deforming the work piece when cutting light structurals and tubes. Clockwise knob rotation increases clamping force. The adjustment range is as follows.
  • Page 37 Coolant Controls The main coolant control is found on the control panel. If the optional Mist Coolant Option is supplied the Flood/Mist push button determines which system is active. Flood Coolant – the pump output is directed to four outlets: •...
  • Page 39 SECTION 3 - MAINTENANCE AND TROUBLESHOOTING SAFETY DURING MAINTENANCE AND TROUBLESHOOTING “Lock-Out”, or “Lock-out Tag-out” are terms that refer to procedures taken to prevent the unexpected start-up, or other release of energy, by a machine, whenever anyone is required to remove or bypass safety guards or devices, or whenever anyone is required to place part of his body in a hazard area.
  • Page 40 RESTORING MACHINE TO USE AFTER LOCK-OUT After completion of all repairs or maintenance to the locked-out machine, it shall be restored to use as follows: . The person(s) who performed the work shall verify that all areas around the machine are safe, before the machine is re-energized.

  • Page 41: Blade Tracking

    Repeat this process until both wheels are within specification: .200” - .220” (5mm to 5.6mm) of tooth overhang from the front of the wheel. Adjustment should not be required unless the wheel is being replaced. Hyd-Mech service should be contacted before making any adjustments to the wheel position. DRIVE WHEEL ADJUSTMENT On the wall behind the drive wheel are two adjusting bolt assemblies and two hex bolts.
  • Page 42 IDLER WHEEL ADJUSTMENT The tracking is adjusted by regulating the “push” set screws and the “pull” hex bolts. Before making any adjustments, bolts “A & B” should be loosened but remain snug. This will allow easy movement for the slide assembly. Loosening bolts “A” and turning in set screws “C”...
  • Page 43 If the brush gets worn to approximately 70% of its original 3” diameter it should be replaced. A brush may be purchased from you HYD-MECH dealer. LUBRICATION The H0A was designed to minimize the maintenance requirements. We recommend that this periodic lubrication be done once a month using any general purpose grease.
  • Page 44 Shuttle Linear Bearings (x4) Movable Guide Arm Linear Bearings (x2)
  • Page 45 Blade Tension Assembly Front Vise Ways Ball Screw The shuttle ball screw nut requires re-lubrication at 6 month intervals with lithium based grease. To re-lubricate the ball screw grease fitting: . As with linear bearings, grease should be pumped slowly until fresh grease exits from the unit. 2.

  • Page 46: Gearbox Lubrication

    GEARBOX LUBRICATION The Bonfiglioli W86 gearbox used on the H10A is supplied with 0.64 litres (0.17 US gallons) of Shell Tivella S 320 synthetic oil. This oil has an ISO Viscosity Grade of 320 that is optimum for ambient temperatures from 20 - 40 Deg C [70 –...
  • Page 47 TROBLESHOOTING THE H10A Shaded actions to be performed only by qualified service personnel. ELECTRICAL PROBLEMS PROBLEM PROBABLE CAUSE SOLUTION  Saw will not start at all . Emergency Stop switch not Pull out E-stop knob reset .3 Safety interlock switches not...
  • Page 48 5 Shuttle will not move in Manual 5. Both vises closed on material. Open appropriate vise. Mode 5.2 Servomotor driver overload. Press E-stop and then turn off (Driver displays error code 50) Main Disconnect Switch to reset driver. Turn on Main Disconnect, pull out E-stop, and retry.
  • Page 49 Chart. 3.2 Excessive feed force. 3.2 See 6. 3.3 Wrong blade for workpiece 3.3 Seek advice ofblade supplier or material. Hyd-Mech dealer. 3.4 Ineffective cutting fluid. 3.4 Check fluid cleanliness and concentration. Seek advice of fluid supplier or Hyd-Mech dealer.
  • Page 50 Press the Fwd and Rev Keys simultaneously (no more than 0.5 sec apart). • The Display will prompt for a password that is available from the Hyd-Mech Service Department. • When the correct password is entered, the Display will show the first two lines of the Parameter Table •...
  • Page 51 PLC PARAMETERS (2100 V2.7 SOFTWARE) PARAMETER STD VALUE DEFINITION (RANGE) Blade Speed Display adjustment factor If actual blade speed is different from displayed value, SPEED CONST 42000 enter new Speed Const = old Speed Const x actual speed / displayed speed Height calibration factor Enter manually by overwriting, or correct automatically by Height Calibra-...
  • Page 52 Trim Cut function YES – the machine will perform an initial trim cut before shuttling stock forward at the beginning of TRIM CUT an Auto Job or Que (YES, NO) NO - the machine will make the first cut after shuttling stock forward at the beginning of an Auto Job or Que YES –...
  • Page 53 SECTION 4 - ELECTRICAL FOR ELECTRICAL SCHEMATICS AND COMPONENTS PARTS LISTS SEE PDF ON ATTACHED CD...
  • Page 55 SECTION 5 HYDRAULIC SYSTEM The H0A hydraulic system does not require any special work on a new machine before its start up. The hydraulic tank is filled with TEXACO RANDO HD 46 hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial start up.
  • Page 56 Pump Pressure Adjustment Filter Indicator Filler Breather Cleanout Cover System Pressure Gauge Filler cap and filter element location Oil Level Gauge Drain Plug Oil level should be maintained at the top portion of the level gauge glass window. Oil level gauge and drain plug...
  • Page 57 HYDRAULIC MAINTENANCE (REXROTH) 1. OIL FILTER- The oil filter should be changed every 500 hours or at least once a year. See section 5 for replace- ment filter element information. For units equipped with filter visual indicator replace filter element when indicator pointer is on red zone.
  • Page 59 SECTION 6 - MECHANICAL ASSEMBLIES FOR MECHANICAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD...
  • Page 61 SECTION - 7 OPTIONS FOR OPTIONAL ASSEMBLIES SEE PDF ON ATTACHED CD...
  • Page 63 SECTION 8 SPECIFICATIONS H-10A BANDSAW SPECIFICATIONS Capacity rectangular 0” x 0” (254mm x 254mm) Length 12’-6” (3810mm) Blade Width  /4” (34mm) thickness .042” (.mm) Blade Tension Blade Speed 50 - 350 sf/min (5.5 - 07 m/min) Blade Guides carbide inserts Blade Wheel Dia.
  • Page 64 H10A LAYOUT...
  • Page 65 SECTION 9 - WARRANTY Warranty Hyd-Mech Group Limited warrants parts/components on each new H0A bandsaw to be free from failure resulting from defective material and workmanship under proper use and service for a period of two years on following the date of shipment from the factory.
  • Page 66 MITSUBISHI PLC PARAMETERS SPEED CONSTANT HGT CONSTANT SHUTTLE FULL STROKE LGT CONSTANT ACCEL/DECEL MAX SHUTTLE SPEED FVO DWELL SVO DWELL CLS TIME ACTUAL POS DISPLAY BLADE TENS SENS BYPASS BROKEN PROXY MIN BLADE SPEED SPD PROXY DELAY POWER DWN TIMER TRIM CUT BLADE CLEAR COOLANT...

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