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H-14P April 2005, Rev A 393303 THANK YOU, On behalf of everyone at HYD . MECH, I would like to thank and congratulate you on your decision to purchase a HYD . MECH band saw. Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to reduce cutting costs while boosting quality and productivity.
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 –...
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.
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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.
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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.
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.
Condition of Machine and Workplace Ensure that the machine and its safety equipment is kept in good working order. Ensure that the work area is well lit, and protected from the elements, such as rain, snow, abrasive dust, and extremes of temperature. Ensure that the machine is installed with sufficient clearance around it for the safe loading and unloading of work pieces.
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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...
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• Lever switch mounted in separate box mounted on the machine • Supply disconnect switch supplied by user at installation and usually wall-mounted within sight of the machine, depending upon local regulations. In almost all jurisdictions, it is required that owners of industrial equipment establish and post lock-out pro- cedures.
sECTIon 1 – InsTallaTIon Upon delivery of you r new H-4P 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.
lIfTInG anD sHIPPInG This machine is designed to be lifted in one fully assembled piece. In order to lift the ma- chine it needs to be in the following condition: • Saw head in its bottom position. • Coolant tank emptied. The H-4P may be lifted from the front with a forklift which has a capacity of 5000 lbs and a fork length of 72”...
4. Ground rod to be connected to ground terminal in control enclosure using insulated 8-gauge stranded copper wire. 5. An additional point to check is ensuring continuity of ground within control enclosure. Start with main power entrance ground terminal where internal ground conductors should originate and connect to, DIN terminal strip, control transformer and the lid of control enclosure.
sECTIon 2 - oPERaTIon InsTRUCTIons This section has been prepared to give the operator the ability to set up the saw for most cutting situations. The saw is equipped with variable blade speed control and hydraulic feed control, as well as an extensive door chart to guide the operator to the correct setting of these controls.
THE ConTRol ConsolE sTaRT-UP The H-4/8/22 control console has been designed to simplify the operation of the saw, to give the operator the ability to stop any function at any time, and to be able to control all the functions remotely. We cannot overstress the importance of familiarizing yourself with the controls of the H-4/8/22 prior to starting the machine.
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HYDRaUlIC sTaRT - To start the hydraulic system, the switches for the head and both vises must be in the “NEUTRAL” position. The “HYDRAULIC START” but- ton must be depressed and held in momentarily until the PLC display becomes active. CYClE sTaRT / PaUsE - This button starts the cutting cycles and will stay illuminated white until the cycles are completed.
MITsUbIsHI PlC ConTRol sYsTEM NOTE: This instruction manual is applicable to the M6P, M20P, H4P to H32P machines equipped with a Mitsubishi PLC, c/w feed rate display, manufactured with serial numbers ending with or higher than _ _ _ _ 0899. oPERaTIon oVERVIEW The PLC is a programmable logic controller which allows the operator to run the machine in both manual and automatic modes.
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To exit the “PASSWORD” back to “MAN”, press AUTO METRIC To exit the INCH “PARAMAETERS” mode, press at any time. NOTE: Consult the Hyd-Mech Service department before entering the parameters. AUTO MODE No function. MAN MODE No function. METRIC...
ManUal MoDE oPERaTIon In MAN mode, the PLC allows the operator to make a single cut. To accomplish this, take the following steps. . Open the vise. 2. Raise the head to so that the blade is above the material to be cut. 3.
. To “PAUSE” the cut, press the “CYCLE START/PAUSE” button, press it again to “RESUME”. 2. The blade speed, feed force and feed rate can all be adjusted during a cut if necessary. 3. To reset the material height, change the PLC to “MAN” and back to “AUTO”. CoolanT floW The main coolant control is found on the control panel.
HYDRaUlIC fEED ConTRol The Hydraulic Feed Control is located to the left of the control panel. These controls allow control of Feed Force Limit 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.
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CHART EXAMPLE # We will use the parameters chart to set up the saw for cutting 8” (200mm) Diameter #045 Carbon Steel. STEP , DETERMINE EFFECTIVE MATERIAL WIDTH - W (inches) or (mm) Effective material width, W (in.) for most common shapes of materials, is the wid- est solid part of the material to be in contact with blade during cutting.
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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.
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The following table gives examples of the optimum blade speeds for different materials. MATERIALS OPTIMUM BLADE SPEED ft/min m/min 5” (25mm) Dia Solid Carbon Steel 2” (300mm) I-Beam 4” x 4”(00 x 00mm) Rec Tube, /4” (6mm) Wall 4”(00) 400 Stainless Steel 2”...
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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 ma- chine is fitted with a finer than optimum blade (e.g.
VaRIablE VIsE PREssURE (oPTIon) This option allows the operator to adjust the vise pressure. This can be valuable when cutting light structurals and tubes. By reducing the vise pressure from the system pressure, distortion of materials is prevented. The controls are located at the drive end of the machine.
sECTIon 3 - MaInTEnanCE & TRoUblEsHooTInG Switch off before beginning work. • The emergency switch, which is used to turn the hydraulics off, should not be the only means of shutting the power off before cleaning or performing maintenance to the machine. The main power disconnect should be switched off and locked.
blaDE TRaCKInG and aDJUsTMEnT Blade Tension Slider Assembly 8. The blade tracking will stay fairly constant, however it should be checked occasionally as shown in the photo. The blade teeth should protrude from .270” to .290” (6.9mm to 7.3mm) from the face of the blade wheels. If the track- ing requires adjustment, follow the steps below 9.
blaDE GUIDE aDJUsTMEnT This machine is equipped with hydraulic carbide blade guides. There is no adjustment for this as the guides are controlled by the blade tension pressure. blaDE bRUsH aDJUsTMEnT The H-4P leaves the factory with the blade brush adjusted for maximum life of the brush.
Blade Tension Slider Assembly Shuttle Shaft Bearing Housings (4) (found below the shuttle) (Not on P Machines) Linear Bearings Found at GEaRboX lUbRICaTIon (H14 WITH a412 GEaRboX) the Drive Side of Main Post The Bonfiglioli A412 gearbox used on the H14 is supplied with 5.0 litres (1.32 US gallon) of Mobil SHC 630 synthetic oil.
• Varnish or sludge formation. • Burnt smell from the oil. However, if the machine is exposed to extreme temperature variation and high humidity, then the oil should be changed every 2000 operating hours or at least once a year. To change the oil, it is necessary to drain the tank and fill it to 1/3 full level with the new oil, operate through several fully automatic cycles with the index set to full stroke and the head to full rise.
TRoUblEsHooTInG PRoblEM PRobablE CaUsE solUTIon Blade worn Change blade Low blade tension Reset blade tension Saw is cutting out of square vertically Blade guides Check for worn guides Excessive feed rate Check for proper cutting parameters Saw is cutting out Stock not square in vises Adjust accordingly of square horizon-...
Observe pilot light(s) on relevant Check the wiring to the relevant valve valve. If pilot light related to inopera- tive function fails to light, problem is electrical 2a. 2a. No individual func- If pilot light related to inoperative Disassembly of hydraulic valves should tion function does light, problem may still be under taken only by qualified service...
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PlC PaRaMETERs Parameter 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. This value represents the head full stroke height. (This parameter is not present on machines which have a head up and down limit switch.
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HEaD HEIGHT CalIbRaTIon . Enter the PLC parameter screen as per Length Calibration Procedure above. 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.
sECTIon 4 - ElECTRICal sYsTEM GEnERal InfoRMaTIon This machine has been built to the customers requirements, however, if any voltage changes are required, consult Hyd·Mech service department before implementing any changes. InITIal HooKUP At initial hook-up it is important to check that the phase order is correct. This is indicated by the blade drive wheel revolv- ing in a counter clockwise direction and the hydraulic pressure gauge registering a pressure rise.
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Mitsubishi PLC Electrical Disconnect and Fuses Mitsubishi Inverter Transformer and Motor Starters...
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LIST OF H4P ELECTRICAL COMPONENTS Item Code as on Component Description Part Number H14P Schematic Manufacturer PB-Emergency Stop Red mushroom head, latching push button. ZB2 BT4 Telemecanique Push Button Mounting base with N/C contact block. ZB2 BZ02 Telemecanique 2PB-Hydraulic Start Green, illuminated, flush head push button.
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lIsT of H14PsV ElECTRICal CoMPonEnTs Item as on Component H14P Description Part number Manufacturer schematic FX2N-32MR Mitsubishi PLC. FX2N-32MR Mitsubishi Mitsubishi Interface MTA00 Mitsubishi Interface communication cable 37052 Hydrualic Hirschmann connector H/92783 Hirschmann Valve Connector Fuse holder USM Gould 5A Time-delay fuse ATDR5 Fuse holder for “power”...
sECTIon 5 - HYDRaUlIC sYsTEM The H-4P hydraulic system does not require any special work on a new machine before its start up. The hydraulic tank is filled with a #46 weight hydraulic oil and all machine functions have been tested at the factory to ensure proper operation upon initial startup.
HYDRaUlIC TanK assEMblY ITEM QUanTITY PaRT nUMbER DEsCRIPTIon H4-6-00A WELDMENT, POWER PACK DOOR M-S22A-6-0 LID, OIL TANK, MACHINED 390075 BOLT, HEX HEAD CAP, 0.32 - 8 x 0.75 394765 WASHER, LOCK, 0.32 363085 TANK COMPONENT, FILLER & BREATHER 393850 SCREW, MACHINE, 0-24 x 0.5 PHILLIPS TRUSS HEAD 36300 TANK COMPONENT, OIL SIGHT LEVEL GAUGE 3630...
VaRIablE VIsE PREssURE This option allows the operator to adjust the vise pressure. This can be valuable when cutting light structurals and tubes. By reducing the vise pressure, distortion of materials is prevented. Note: P machines only have one vise.
MOTOR, GEARBOX, PUMP, ELECTRIC COMPONENTS, VALVES, HOSES, FITTINGS, and any other items used in the manufacture of the H-14P, but not originally manufactured by Hyd·Mech are subject to the original manufacturer’s war- ranty. Hyd·Mech will provide such assistance and information as is necessary and available to facilitate the user’s claim to such other manufacturer.
PlC PaRaMETERs Speed Constant Wheel Targets Height CLB (Press Enter) Height Constant Lth CLB Actual Height (Press Enter) Length Constant Actual Length Accel Dist Decel Distance Min Fast Dist Target Window SVO Dwell FVO Dwell Close Time Feed Rate Hold SHT Home Actual Position Yes / No Yes / No...
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