Page 2 Operation and Maintenance Manual ® SmartSet Pro Component Saw Manual U.S. and other patents pending. MiTek 001048 Machinery Division Date created 1 October 2000 Revision 301 Fountain Lakes Industrial Drive Revision date 21 May 2007 St. Charles, MO 63301 Print date...
Page 3: Table Of Contents
Purpose and Scope of This Equipment Manual 1 Navigation 2 Formatting Cues 2 Additional Resources 3 Supplemental Documentation 3 Web Site 3 Contacting MiTek 3 General Information Chapter 2 Introduction to the Equipment 4 Purpose of the Equipment 4 Description of the Equipment 4 Components 4 001048 Rev.
Page 4 Personal Safety Procedures 5 Features and Options 7 General Specifications 8 Truss Terminology 9 Prior to Installation Chapter 3 MiTek’s Responsibilities 11 Customer’s Responsibilities 12 Space Requirements 13 Space for the Equipment 14 Space for Operation and Maintenance 14 Location Requirements 14...
Page 5 Table of Contents Startup 43 Manual Settings Checklist 44 Operation Chapter 6 Touch Screen Operation 45 General Operation 45 Shutdown 46 Emergency Stop (E-Stop) Operation 47 E-Stop Pushbuttons 47 Perimeter Safety Cable 48 Calibration 49 Screens 51 Screen Information 51 Main Menu 51 Fault Screens 52 Operation Screens 58...
Page 6 Table of Contents Lubricating the Carriage V-Wheels 91 Lubricating the Air Line Lubricator 91 Lubricating the Air Brake Cylinders 92 Lubricating the Vertical Acme Screws 92 Lubricating With Grease 93 Bearings 93 Motors and Gearboxes 94 Manually Releasing a Brake 94 Cleaning Motors 95 Lubricating Motors 95 Adding and Changing Oil in Gearboxes 97...
Page 7 Table of Contents Carriage 133 Preventive Maintenance for the Carriage 133 Replacing a Roll Pin in the Hold-Down Spur Gears Waste Conveyor and Incline Conveyor 134 Adjusting the Belt Tracking/Tension 134 Replacing a Conveyor Belt 135 Pneumatic System Maintenance 137 Maintaining the Lubricator on the Saw 139 Maintaining the Regulators 140 Limit Switches 141...
Page 8 Table of Contents Navigating the Troubleshooting Appendix 167 Troubleshooting Appendix A 167 Safety Notes for Troubleshooting 168 Operational Notes for Troubleshooting 169 Symptoms and Solutions 171 Mis-Cut Boards 171 Saw Not Operating Correctly 174 Computer-Related Problems 178 Centerlines and Angles 179 Infeed Conveyors 181 Hold-Downs 182 Lumber Stops 183...
Page 9 Document Evaluation Form in the appendices. Mail or fax the form to: MiTek, Machinery Division 301 Fountain Lakes Industrial Drive St. Charles, MO 63301 Attn: Engineering Manager Fax: 636-328-9218 Your support in helping MiTek provide unsurpassed machinery and support is appreciated. 001048 Rev. A Legal Notice viii...
Page 10: Notice Of Changeix
Notice of Change Use this page to record Service Bulletins and Notices that you receive to keep your manual updated. Operation and Maintenance Manual ® SmartSet Component Saw Manual Service Bulletin Dated Title or Notice # 001048 Rev. A Notice of Change...
Page 11: Safety (English)
Safety (English) For safety information in Spanish, refer to page xxiii. Be Careful. Be Safe. 001048 Rev. A Safety (English)
Page 12: Safety Indicators
SmartSet Pro Saw ® Safety Indicators The following safety alert symbols and signal words are used throughout this document to indicate safety hazards. Please pay careful attention when you see them. The level of severity differs for each symbol or signal word. The definitions below can also be found in ANSI z535.4-2002.
Page 13: Safety Rules
SmartSet Pro Saw ® Safety Rules Because it is impossible to anticipate every circumstance that might involve a hazard, the safety information provided in this equipment manual and on the machine is not all- inclusive. If this machine is operated or serviced using a procedure not specifically recommended by the manufacturer, the procedure shall be approved by a professional engineer to ensure it will not render the equipment unsafe.
Page 14 SmartSet Pro Saw ® Lockout/Tagout • Before performing maintenance on the pneumatic or hydraulic systems, bleed the lines to eliminate pressure. • Lockout/tagout all energized systems before performing maintenance on them. Refer to the Lockout/Tagout Guidelines section on page xiv. Keeping a Safe Environment •...
Page 15: Lockout/Tagout
SmartSet Pro Saw ® Lockout/Tagout Lockout/Tagout Guidelines All lockout/tagout guidelines must be met according to OSHA 29 CFR 1910.147. A specific procedure should be included in your company’s energy control program. This manual is not intended to replace your company’s de- energizing or lockout/tagout procedure required by OSHA, but merely to provide general guidance.
Page 16: Electrical Lockout/Tagout Procedures
SmartSet Pro Saw ® Electrical Lockout/Tagout Procedures When Working on a Machine Outside the Machine’s Main Electrical Enclosure If working on the electrical transmission line to the machine, follow the procedure on page xvii. Before performing maintenance on any machine with electrical power, lockout/tagout the machine properly.
Page 17 SmartSet Pro Saw ® Figure ii-1: Lockout/Tagout on the Main Electrical Enclosure Sample of a Lock and Tag Attached to a Machine’s Electrical Enclosure 001048 Rev. A Safety (English)
Page 18 SmartSet Pro Saw ® When Working on a Machine Inside the Machine’s Main Electrical Enclosure or in the Electrical Transmission Line to the Machine Before opening the main electrical enclosure, or attempting to repair or replace an electrical transmission line to the machine, lockout/tagout the machine properly. Follow your company’s approved lockout/tagout procedures which should include, but are not limited to the steps here.
Page 19: Pneumatic System Lockout/Tagout Procedure
SmartSet Pro Saw ® Pneumatic System Lockout/Tagout Procedure When Lockout/Tagout is Not Required If working on components other than the pneumatic system, but that requires you to be near the vicinity of movable pneumatic components, you must, at a minimum, physically restrain the pneumatic components from moving.
Page 20: Restricted Zone
SmartSet Pro Saw ® Restricted Zone DANGER Stay out of the restricted zone when equipment is in use. Serious injury or death may result if personnel are in the restricted zone. Optional Skatewheel Outfeed Conveyor Optional Incline Conveyor Optional Ready-Feed Conveyor 001048 Rev.
Page 21: Safety Test
SmartSet Pro Saw ® Safety Test WARNING CRUSH HAZARD. Perform the safety tests described before operating the equipment at the initial startup, after performing any maintenance, and in accordance with the maintenance schedule. The test procedure MUST be performed by qualified personnel at startup and after ANY maintenance, adjustment, or modification.
Page 22: Checking Saw Blades
SmartSet Pro Saw ® Checking Saw Blades DANGER ELECTROCUTION, HIGH PRESSURE, CRUSH, AND CUT HAZARDS! Disconnect power and remove compressed air using approved lockout/tagout procedures on the power and air supplies before climbing into the saw. Failure to properly lockout/tagout this saw and remove the air supply may cause a blade to move causing severe personal injury.
Page 23: Inspecting
SmartSet Pro Saw ® Inspecting 1. While still standing in the saw waste conveyor, visually check for cables that may interfere with the proper operation of the saw. Secure cables only as necessary. 2. Check that all guards are in place and secure. a) Check the stationary and movable hold-down guards.
Page 24: Seguridad (Español)
Seguridad (Español) Sea cuidadoso. Protéjase. 001048 Rev. A Seguridad (Español) xxiii...
Page 25: Indicadores De Seguridad
SmartSet Pro Saw ® Indicadores de seguridad Los siguientes símbolos de alerta de seguridad y palabras de advertencia se utilizan a lo largo de este documento para indicar riesgos de seguridad. Preste suma atención cuando los vea. Cada símbolo o palabra indica un nivel de gravedad diferente. Las definiciones incluidas a continuación también pueden consultarse en la norma ANSI z535.4-2002.
Page 26: Reglas De Seguridad
SmartSet Pro Saw ® Reglas de seguridad Debido a la imposibilidad de anticipar todas las circunstancias que podrían constituir un riesgo, la información de seguridad suministrada en este manual del equipo y sobre la máquina no es exhaustiva. Si se utiliza o realiza el mantenimiento de esta máquina utilizando un procedimiento no recomendado específicamente por el fabricante, el procedimiento deberá...
Page 27 SmartSet Pro Saw ® Instalación del equipo • Siga las instrucciones de instalación al pie de la letra. Procedimientos de Bloqueo/Etiquetado • Antes de realizar el mantenimiento de los sistemas neumáticos o hidráulicos, purgue las líneas para eliminar la presión. •...
Page 28 SmartSet Pro Saw ® estar en su lugar antes y durante el uso de la máquina. No desconecte ni evite nunca ningún dispositivo de seguridad ni interbloqueo eléctrico. • Inspeccione periódicamente la calidad del producto terminado. Seguridad eléctrica • No utilice líquidos en el interior de los gabinetes eléctricos. •...
Page 29: Bloqueo/Etiquetado
SmartSet Pro Saw ® Bloqueo/Etiquetado Pautas de bloqueo/etiquetado Deben cumplir con todas las pautas de bloqueo/etiquetado conforme a la norma OSHA 29 CFR 1910.147. El programa de control de energía de la compañía debe incluir un procedimiento específico. El objetivo de este manual no es reemplazar el procedimiento de desenergización o bloqueo/ etiquetado requerido por la OSHA, sino proporcionar pautas orientativas generales.
Page 30: Procedimientos De Bloqueo/Etiquetado Eléctricos
SmartSet Pro Saw ® Procedimientos de bloqueo/etiquetado eléctricos Cuando trabaja en una máquina fuera del gabinete eléctrico principal de la máquina Si trabaja en la línea de transmisión eléctrica a la máquina, siga el procedimiento de la página xxxi. Antes de realizar el mantenimiento de cualquier máquina con alimentación eléctrica, bloquee y etiquete la máquina de forma adecuada.
Page 31 SmartSet Pro Saw ® Figura iii-1: Bloqueo/etiquetado en el gabinete eléctrico principall Ejemplo de un candado y etiqueta fijados al gabinete eléctrico de una máquina 001048 Rev. A Seguridad (Español)
Page 32 SmartSet Pro Saw ® Cuando trabaje en una máquina dentro del gabinete eléctrico principal de la máquina o en la línea de transmisión eléctrica a la máquina Antes de abrir el gabinete eléctrico principal o intentar reparar o reemplazar una línea de transmisión eléctrica a la máquina, bloquee y etiqueta la máquina en forma adecuada.
Page 33: Procedimiento De Bloqueo/Etiquetado Del Sistema Neumático
SmartSet Pro Saw ® Procedimiento de bloqueo/etiquetado del sistema neumático Cuando no se requiere bloqueo/etiquetado Si trabaja con componentes que no son del sistema neumático pero que requieren su presencia en la proximidad de componentes neumáticos móviles, debe, como mínimo, trabar físicamente estos componentes para que no se muevan.
Page 34: Solución De Problemas Con Una Máquina Energizada
SmartSet Pro Saw ® Solución de problemas con una máquina energizada Sólo un electricista calificado que utilice el equipo de protección personal y siga los procedimientos recomendados en la norma NFPA 70E debe intentar realizar tareas de reparación o mantenimiento en un área o componente energizados de la máquina o en su proximidad.
Page 35: Zonas Restringida
SmartSet Pro Saw ® Zonas restringida Manténgase alejado de la zona restringida cuando el equipo esté en uso. Pueden producirse lesiones graves o incluso la muerte si el personal está en la zona restringida. Banda Sinfín del Lado de Salida SIERRA Banda Sinfín Inclinada Banda Sinfín de...
Page 36: Prueba De Seguridad
SmartSet Pro Saw ® Prueba de seguridad RIESGO DE APLASTAMIENTO. Realice las pruebas de seguridad que se describen antes de utilizar el equipo por primera vez, después de cualquier tarea de mantenimiento y conforme con la frecuencia de mantenimiento establecida. El procedimiento de prueba DEBE ser realizado por personal calificado durante la puesta en marcha y después de CUALQUIER tarea de mantenimiento, ajuste o modificación.
Page 37: Verificación De Las Hojas De La Sierra
SmartSet Pro Saw ® Verificación de las hojas de la sierra DANGER ¡RIESGO DE ELECTROCUCIÓN, ALTA PRESIÓN, APLASTAMIENTO Y CORTE! Desconecte la alimentación y elimine el aire comprimido utilizando procedimientos de bloqueo/etiquetado aprobados en el suministro de alimentación y aire antes de subirse a la sierra. Si no se realiza el bloqueo/etiquetado adecuado de la sierra y no se elimina el suministro de aire, pueden producirse lesiones personales graves.
Page 38: Inspección
SmartSet Pro Saw ® Inspección 1. Mientras está de pie en la banda transportadora de desperdicios, inspeccione visualmente que no haya cables que interfieran con el funcionamiento adecuado de la sierra. Fije los cables cuando sea necesario únicamente. 2. Verifique que todos las protectores estén en su lugar y bien fijadose. a) Verifique los protectores sujetadores fijos y móviles.
Page 39: Introduction Chapter
This manual addresses the most recent versions of the equipment as of the creation or revision date on the title page. For earlier revisions, contact MiTek Machinery Division Customer Service and order the part number listed on the title page.
Page 40: Navigation
SmartSet Pro Saw ® Navigation The graphics in Table 1-1 are used throughout the manual to quickly communicate a specific type of information. Table 1-1: Navigational Tools Used Throughout the Manual Graphic Explanation Important safety note! Indicates that you must lockout/tagout the equipment using approved methods described in OSHA 29 CFR 1910.147 before continuing with the procedure.
Page 41: Additional Resources
PLC. The supplemental documentation is provided at the time of installation, or it may be found inside an electrical enclosure. Refer to these documents when you need more detailed information on these components than the MiTek manual provides.
Page 42: General Information Chapter
Description of the Equipment The SmartSet Pro saw is a self-contained wood cutting machine consisting of up to six (6) blades located in two sets of three (3) blades each. One set is considered the “stationary end.”...
Page 43: Safety Procedures
SmartSet Pro Saw ® Safety Procedures Saw Blades Inspect all saw blades twice each day, once in the morning before start-up, and again at noon. Never attempt to operate a saw blade that has chipped or bent teeth, or teeth that are not sharp.
Page 44 SmartSet Pro Saw ® Protecting Hearing Hearing protection is mandatory at all times that machine is in use. Never Leaving the Saw Unattended Never leave the saw unattended with the power supply on. Be certain all saw rotation has stopped and all electrical power has been shut off before leaving the machine. Angulation Never angulate or move any saw while the blade is in motion.
Page 45: Features And Options
SmartSet Pro Saw ® Features and Options Table 2-1 lists the main features of the SmartSet Pro. Table 2-1: Main Features Features Individual centerline powered adjustment for each of the five saw blades Powered angulation on all five blades Powered carriage travel...
Page 46: General Specifications
SmartSet Pro Saw ® General Specifications Table 2-3: General Specifications Blades Specs 7-1/2 HP–3450 rpm with 20"carbide tip Blade 1 blade (16'' blade optional) 7-1/2 HP–3450 rpm with 16"carbide tip Blade 2 blade (20'' blade optional) 7-1/2 HP–3450 rpm with 16" carbide tip Blade 3 blade (20'' blade optional) 7-1/2 HP–3450 rpm with 20"...
Page 47: Truss Terminology
SmartSet Pro Saw ® Truss Terminology Table 2-4: Truss Terminology Length Types Height Types Overall length Board height Centerline length Centerline height Top length Centerline height Bottom length Centerline height Figure 2-1: Terminology Diagram Overall Length Top Length Bottom Length Centerline Length Pivot Axis Length Overall Length...
Page 48 SmartSet Pro Saw ® Figure 2-2: Parts of a Truss 001048 Rev. A General Information...
Page 49: Prior To Installation Chapter
Chapter Chapter MiTek’s Responsibilities MiTek will provide the following items and information prior to the installation date: 1. A Prior to Installation package that: • Outlines this chapter and requests your signature of agreement. • Gives dates to expect shipment, delivery, and installation.
Page 50: Customer's Responsibilities
The equipment discussed in this manual must be used in dry conditions under a roofed area. The standard electrical requirements are shown in Table 3-3. Electrical Contact your MiTek representative immediately if custom Requirements power specifications need to be arranged. Pneumatic Requirements See page 16.
Page 51: Space Requirements
SmartSet Pro Saw ® Space Requirements Refer to your individual layout when planning your space allocation. MiTek can provide help with plant layout and space utilization upon request. Figure 3-1: Sample of a Layout for a Complete System Optional Skatewheel...
Page 52: Space For The Equipment
SmartSet Pro Saw ® Space for the Equipment It is the customer’s responsibility to provide adequate space for the installation, operation, and protection of the equipment. The physical dimensions of the equipment are shown in Table 3-2. Additional space is required for operation, maintenance, and optional equipment.
Page 53: Electrical Requirements
60 Hz Phases If the facility does not have 230 VAC electrical power, MiTek can supply a transformer to step up facility power from 208 VAC or step down power from 440 or 480 VAC. However, incoming power must be 3-phase power at 60 Hz, regardless of the voltage supplied to the saw or a transformer.
Page 54: Compressed Air Requirements
SmartSet Pro Saw ® Compressed Air Requirements The saw compressed air connection is a 1/4-in. NPT female port located on the filter- regulator-lubricator (FRL) assembly mounted to the left of the stationary electrical enclosure. Connections can be hard piped to the FRL port. However, for ease of Quick disconnect installation, it is recommended that a hose and a hose barb be used to make the final fittings are not...
Page 55: Shipping Information
Table 3-4: Shipping Information Contents of Shipment Approximate Weight SmartSet Pro saw Approx. 18,000 lb Customer-Supplied Parts The customer must supply the parts shown in Table 3-5. Some must be installed before installation occurs and some must be available for use at the time of installation.
Page 56: Delivery
The weight of each major component is given in Table 3-4. Even if a MiTek representative is present, it is the customer’s responsibility to provide equipment and labor for unloading, placement, and wiring of the equipment. Exercise extreme caution to avoid damage or misalignment during unloading.
Page 57: Lifting And Moving Methods
SmartSet Pro Saw ® Notify MiTek Machinery Division Customer Service of any unacceptable findings discovered during the receipt inspection. Although your findings may not appear to be a problem, they may cause premature failure of components, poor performance, or erratic performance.
Page 58 SmartSet Pro Saw ® Figure 4-1: Lifting Methods 001048 Installation...
Page 59: Leveling The Saw
SmartSet Pro Saw ® Figure 4-2: Lifting the Saw with a Forklift Truck Leveling the Saw To maintain accuracy of the saw it is essential that it be on a level plane. There are five leveling footpads on each side of the machine base frame for the purpose of leveling the saw.
Page 60: Installing The Easyfeed
SmartSet Pro Saw ® Installing the EasyFeed 1. Position the EasyFeed in place using bolt and locknut. 2. Rotate until the mounting screw is aligned. 3. Tighten the bolts and screws, then install the infeed chain and adjust tension 1– 2 in.
Page 61 SmartSet Pro Saw ® 2. Locate the hardware: • (2) 3/8-16x1-1/4 hex head cap screws • (2) 3/8-in. lock washers • (2) 3/8-in. nuts 3. Using a forklift, lift the incline conveyor and attach the leg supports. 4. Lower the incline conveyor, and reposition the forklift truck at the end of the incline farthest from the saw.
Page 62: Installing Guards
SmartSet Pro Saw ® Installing Guards Two guards are shipped loose for field installation—one guard for the front left-hand side, and one for the front right-hand side. Both guards are attached to the respective hold-down moveable structure in such a fashion that the guards move up and down together with the hold-down.
Page 63: Electrical
SmartSet Pro Saw ® Electrical WARNING ELECTROCUTION HAZARD! All electrical work must be performed by a licensed electrician and in conformance with applicable codes. Follow approved lockout/tagout procedures. Before making electrical connection from the in-house supply, check the following: • The voltage nameplate located on the primary (large) panel box. This is the voltage the saw has been wired for at the factory.
Page 64: Making Pneumatic Connections
SmartSet Pro Saw ® Making Pneumatic Connections A 3/8 in. air line with quick disconnect fitting should now be connected to the fitting on the filter, regulator, and lubricator located at the stationary end of the saw. Set the regulator to 100 psi.
Page 65: Checking Motors Before Starting
Startup Chapter 5 This chapter describes the procedures required before Purpose of Purpose of operating your equipment. Chapter Chapter Checking Motors before Starting Visual Checks Before turning the electric power on and starting the various motors, make certain they are ready for use.
Page 66: Doing Pre-Start Checks
SmartSet Pro Saw ® the rear of the main base frame. With all air disconnected, hand rotate each saw blade. They should rotate freely without binding or drag. If they do not rotate freely, chances are the brake needs adjusting. Follow the procedure for air brake adjustment in the Adjustments and Settings section in the Maintenance chapter on page 105.
Page 67: Starting Up
SmartSet Pro Saw ® Starting Up Whenever the emergency limit switch or emergency pushbuttons are actuated, or the air supply is disconnected, the E-stop button on the operator console indicates this condition. Initial startup will consist of functional testing of all motion components of the saw except for the main horizontal scrap conveyor and the incline conveyor.
Page 68 SmartSet Pro Saw ® stationary DOWN and hold-downs carriage DOWN buttons will move the hold-downs down. Press the hold-downs stationary UP button to raise the stationary (left) hold-down. Press the hold-downs stationary DOWN button to lower the stationary hold-down. Repeat the operation for the carriage hold-down.
Page 69: Adjusting Scrap Conveyor Belt Tracking
SmartSet Pro Saw ® Test 5: Saw Blade Angulation Motors Press the MANUAL button on the Main Menu to go to the Manual screen. On the Manual screen, press the ANGLE 3- (angle up) button to angulate the blade 3 up. Return it to 90°...
Page 70 SmartSet Pro Saw ® First, start the conveyor belt running by touching the scrap systems waste START button on the Auxiliary screen. See the Auxiliary Screen section on page 71. Observe the optional incline scrap conveyor belt to be sure it is running uphill in the right direction. If it is not running in the right direction it will be necessary to re-phase the incline conveyor motor.
Page 71 SmartSet Pro Saw ® When the adjustment is made at the drive end, it will be necessary to loosen the bolts that hold the reducer gearbox to its mounting plate, thus allowing it to move with the roller as the adjustment takes place. After each adjustment these gearbox bolts must be tightened before conveyor startup.
Page 72: Settings And Adjustments
SmartSet Pro Saw ® Settings and Adjustments Example 1: Bottom Chord Refer to Figure 3-3: Saw Bottom Chord Data on page 39 and Figure 3-4: Saw Scissors Bottom Chord Data on page 40. Type Truss: Howe Pitch and Span: 3:12 pitch – 24 ft-8 in. span: 1/4 in. heel Blades used: 2, 3, and 5 Feed Speed:...
Page 73: Example 2: Top Chord
SmartSet Pro Saw ® Trial Run 1. Turn power on. 2. Angulate blade 5–14. 3. Be sure all other blades are at 90. 4. Place 2 x 4 on edge in feed conveyor at the root of the lumber pivot arm, and push it against the lumber stop.
Page 74: Example 3: Web
SmartSet Pro Saw ® Hold-downs: Position approx. 2 in. to the inside of feed chains and set both at the 2 x 4 setting on the scale. Center Lumber Support:Position approximately midway between feed chains; lock in place To move the blade 2 out-of-cut, angulate blade to 15 with horizontal plane and raise centerline above lumber width.
Page 75: Example 4: Floor Web
SmartSet Pro Saw ® Settings Blade 1: Angulate to 28. Blade 2: Angulate to 76. Blade 3: Angulate to 76. Blade 4: Angulate to 14. Blade 5: Move out-of-cut and do not use. Carriage: Set to 5 ft 8-5/8 in. Centerline: Set all four blades to centerline of material.
Page 76 SmartSet Pro Saw ® Carriage: Set to 5 ft 8-5/8 in. Centerline: Set all four blades to centerline of material. Lumber Stop: Set at 1/2 in. mark to the left of "0" on scale Feed Chains: Position 8–10 in. from the saw blades Heel Cut Skid Bar: Do not use.
Page 77 SmartSet Pro Saw ® Figure 5-1: Saw Bottom Chord Data 001048 Rev. A Startup...
Page 78 SmartSet Pro Saw ® Figure 5-2: Saw Scissors Bottom Chord Data 001048 Rev. A Startup...
Page 79 SmartSet Pro Saw ® Figure 5-3: Saw Top Chord Data 001048 Rev. A Startup...
Page 80 SmartSet Pro Saw ® Figure 5-4: Saw Web Data 001048 Rev. A Startup...
Page 81: Startup
SmartSet Pro Saw ® Startup Before starting up the saw, make certain that all safety rules and procedures have been followed to ensure that no unsafe conditions exist. Turn on the compressed air supply to the saw. Make sure the disconnect switch on the carriage-end electrical enclosure is in the ON position.
Page 82: Manual Settings Checklist
When this screen displays, touch anywhere on the screen to start operation. Manual Settings Checklist The SmartSet Pro is approximately 3/4 automated, but some settings must be entered manually before initializing a setup. See the checklist below for items that must be entered or verifieds manually.
Page 83: Touch Screen Operation
Touch Screen Operation General Operation The SmartSet Pro saw uses a touch screen as the main operator interface. All electrically operated functions can be controlled either manually or semiautomatically from the touch screen. Alarm or fault conditions are also reported by the touch screen.
Page 84: Shutdown
SmartSet Pro Saw ® Shutdown The saw can be shut down at anytime. While the power switch on the touch screen may be used to shut down the screen, it is recommended to use the main power disconnect to power down the saw. A lockout provision is included in the disconnect handles to lock out the saw prior to any maintenance work.
Page 85: Emergency Stop (E-Stop) Operation
Figure 6-1: Operator’s Control Station E-Stop Pushbuttons The SmartSet Pro saw has three E-stop pushbuttons—one located at the electrical enclosures on either end, and one at the operator’s control station as shown in Figure 5-4 on page 47. The E-stop pushbutton at the operator’s station also has a pilot light in it to inform the operator if any emergency stop has been activated.
Page 86: Perimeter Safety Cable
SmartSet Pro Saw ® Perimeter Safety Cable Additionally, there is a full-length perimeter safety cable (pull cable) switch. Refer to Figure 5-4 on page 47. Pull the perimeter safety cable away from the saw to cease power transmitting to the control circuit. The cable should be pulled until a click is felt and the E- stop is triggered.
Page 87: Calibration
It is important to follow the correct calibration procedure. Failure to follow this procedure can lead to inaccurate cuts. The SmartSet Pro saw uses second generation auto-calibration technology to maintain cutting accuracy. Each angle and centerline has a home proximity switch mounted in a fixed location (45°...
Page 88 SmartSet Pro Saw ® 5. If the cut is not square, use the Manual screen to adjust the blade angle. 6. Make adjustments and test cuts until the cut is square. 7. Enter 90° for the blade on the Calibration screen. 8.
Page 89: Screens
Figure 5-7. Figure 6-3: Main Menu Screen Status Indicators MiTek Information Control Page Buttons In this manual, screen items that cause an action are termed controls or buttons, items that show status or faults are called indicators, and items that show numerical data are called displays.
Page 90: Fault Screens
SmartSet Pro Saw ® Fault Screens Figure 6-4: Home Proximity Switch Fault Screen A home proximity fault can occur two ways: if the proximity switch sees the target outside of the home zone, or if the proximity switch does not see the target in the home zone. If a home proximity fault occurs, press RESET ALARM.
Page 91 SmartSet Pro Saw ® Figure 6-5: Count Proximity Switch Fault Screen A count fault occurs when an axis is commanded to move, and the controller does not receive any position feedback pulses from the count proximity switch. This can be caused by a faulty proximity switch or by a stalled axis.
Page 92 SmartSet Pro Saw ® Figure 6-6: Variable Frequency Drive Fault Screen A VFD (Variable Frequency Drive) fault is displayed whenever one of the VFDs has “tripped out”. While a variety of conditions can “trip out” a VFD, the most common will be an over-current condition.
Page 93 SmartSet Pro Saw ® Figure 6-7: Motor Overload Fault Screen An overload fault is displayed whenever one of the overloads has “tripped out”. While a variety of conditions can “trip out” an overload, most common will be an over-current condition. This is caused by mechanical binding, lack of lubrication, or, in extreme cases, when an axis stalls.
Page 94 SmartSet Pro Saw ® Figure 6-8: Emergency Stop (E-Stop) Fault Screen An emergency stop fault occurs whenever any E-stop on the machine is activated. Reset the indicated E-stop to resume operation. The MAIN MENU button will return you to the Main Menu. 001048 Operation...
Page 95 SmartSet Pro Saw ® Figure 6-9: Miscellaneous Fault Screen There are two miscellaneous faults: the DC Power Supply fault, and the Air Pressure Switch fault. The Power Supply fault indicates failure of the 24-VDC power supply. The Air Pressure Switch fault indicates that the incoming air supply pressure has dropped below 85 psi. The HELP button will display the Misc.
Page 96: Operation Screens
SmartSet Pro Saw ® Operation Screens Figure 6-10: Semi-Automatic Screen Page Buttons Blade Angle and Centerline Board Buttons Counter and Length Setup Initiate and Abort Blades Start and Stop Buttons The Semi-Auto screen has controls for each saw blade angulation and centerline setting, for the length and board counter settings, to initiate or abort the setup, to start and stop the saw blades, and to select other screens.
Page 97 SmartSet Pro Saw ® it is called on. The keypad will remain in this location until moved again or until the power is shut off, when it reverts back to the default location (upper right-hand corner). The DEL (delete) key causes the cursor to backspace and delete the last number entered. The ESC (escape) key closes the keypad without entering any data.
Page 98 SmartSet Pro Saw ® only a short distance to clear the board path. Refer to the Defaults Page screen section on page 68 for more information. This feature is available only on blades 1–4. When a blade is flagged as out-of-cut it cannot be started. Blades 1–4 angulation control and centerline control buttons are colored gray as an indicator.
Page 99 SmartSet Pro Saw ® Figure 6-14: Board Counter and Length Buttons Length Length Actual Length Setpoint The board COUNTER and LENGTH buttons allow entering data in a numeric form. Pressing either of these buttons will open the pop-up keypad. Refer to Figure 5-15 on page 58.
Page 100 SmartSet Pro Saw ® If a problem is detected during a setup, the setup can be stopped either by pressing the setup ABORT button or by pressing an E-stop button. The setup ABORT button will halt all blade and carriage movement. The setup can be restarted by pressing setup INITIATE again.
Page 101 SmartSet Pro Saw ® Figure 6-17: Manual Screen 5/6 In-Cut/ Out-of-Cut Blade Angle and System Centerline Indicator Movement Mode Length The Manual screen allows complete manual control of all axes. Each angle and centerline can be moved up or down, the carriage can be moved, and blades 5 and 6 can be moved into the cut or out of the cut at the touch of a button.
Page 102 SmartSet Pro Saw ® WARNING CRUSH AND CUT HAZARD. It is the operator’s responsibility to ensure that the feed chains, lumber hold-down, and all other objects are clear of the blade travel paths while moving any angle or centerline. Failure to exercise care may result in serious injury or death. The angle actual and centerline actual displays will indicate the current position of the blade.
Page 103 SmartSet Pro Saw ® Figure 6-21: System Monitor Indicator The system monitor indicator alerts the operator when any fault has occurred. During normal operation the system monitor will display the ALL SYSTEMS OK message in blue with a dark blue border as shown in Figure 5-26. When any fault occurs the system monitor will display FAULT EXISTS in red with a red border as shown in Figure 5-18 on page 60.
Page 104 SmartSet Pro Saw ® < LENGTH (low speed in) or LENGTH > (low speed out) buttons will cause the carriage to creep in or out at a minimal speed. This is useful for setting exact positions on the Manual screen. The length actual display shows the current carriage position in the feet-inches-16ths format.
Page 105 SmartSet Pro Saw ® Figure 6-25: Angle and Centerline Calibration Buttons Angle Calibration Centerline Calibration Angle Actual Display Centerline Actual Display Pressing the ANGLE (angle calibration) button or the C-LINE (centerline calibration) button will cause the pop-up keypad to open allowing the entry of calibration data. Refer to Figure 5-15 on page 58.
Page 106 SmartSet Pro Saw ® Figure 6-28: Enter Button The ENTER button must be pressed to send the calibration data to the controller. If calibration data is being entered for more than one axis, it is not necessary to press ENTER after each entry. Simply press ENTER after all calibration data is entered. All data will be sent to the controller at this time.
Page 107 SmartSet Pro Saw ® The blade can quickly be sent to this location by using the quick out-of-cut button. Refer to the Semi-Auto Screen section on page 58 for more details. A toggle switch called CUTTING LENGTH OF SAW exists on saws that have an extended frame.
Page 108 SmartSet Pro Saw ® When cutting a long cut (scarf cut) with blades 5 and 6, it is advisable to slow the speed of the feed chains down to obtain the best cut quality. The SET SPEED button is used to set the maximum feed speed when either blade 5 or blade 6 is in the cut.
Page 109 SmartSet Pro Saw ® Figure 6-36: Page Button Press MAIN MENU to return to the Main Menu. Figure 6-37: Total Boards Cut Display The total boards cut display indicates the total number of boards cut since the last reset period of the saw. Figure 6-38: Auxiliary Screen Infeed Blades...
Page 110 SmartSet Pro Saw ® Figure 6-39: Saw Blade Buttons Pressing any of the blades START buttons will release the blade brakes and start that saw blade. Saw blades will not start if they are flagged as out-of-cut. Refer to the section on blade angle and centerline controls for further details.
Page 111 SmartSet Pro Saw ® The system monitor indicator alerts the operator when any fault has occurred. During normal operation the system monitor will display the ALL SYSTEMS OK message in blue with a dark blue border as shown in Figure 5-47. When any fault occurs, the system monitor will display FAULT EXISTS in red with a red border.
Page 112 SmartSet Pro Saw ® The START FEED button will start the feed chains in the forward direction. The chains will run until stopped. The SET SPEED button will cause a pop-up keypad to open, as shown in Figure 5-15 on page 58.
Page 113: Introduction To Maintaining Your Equipment
Maintenance Chapter 7 This chapter provides step-by-step instructions as well as information to help you understand how your equipment Purpose of Purpose of works to enable you to make repairs and perform Chapter Chapter preventive maintenance. Introduction to Maintaining Your Equipment WARNING MOVING PARTS CAN CRUSH AND CUT.
Page 114: Additional Information About Maintenance
Additional Information about Maintenance It is critical to the future performance of the SmartSet Pro saw that only specified replacement parts are used if maintenance replacement is required. Further, no electrical...
Page 115: Performing Maintenance Safely
SmartSet Pro Saw ® Performing Maintenance Safely Before Operating This Equipment DANGER ELECTROCUTION, HIGH PRESSURE, CRUSH AND CUT HAZARDS! Read this section AND the safety section in the preliminary pages before operating or maintaining this equipment. Do not operate this machine until you have a thorough understanding of all controls, safety devices, E-stops, and operating procedures outlined in this manual.
Page 116: Making Adjustments To The Machine
SmartSet Pro Saw ® Making Adjustments to the Machine CAUTION Failure to follow the step-by-step procedure may result in incorrect adjustment of this machine and could cause blade collisions and incorrect cuts. Only trained personnel should make mechanical adjustments to this machine.
Page 117: General Maintenance
SmartSet Pro Saw ® General Maintenance At the end of each workday, the following maintenance is recommended. To blow off dust, use compressed air. To lubricate chains and sprockets, rack and pinions, spur gears,slides, and castings, and Acme screws, use a kerosene and oil mixture: 10 parts kerosene: 1 part 30-weight motor oil For the carriage V-track and the square drive shaft, use straight kerosene to avoid sawdust buildup.
Page 118: Calibration
SmartSet Pro Saw ® Calibration Review the section Changing Calibration Settings if you are unfamiliar with the calibration process. Checking Daily Calibration Check calibration of the saw every day to ensure the accuracy of the cuts. The daily procedure includes checking: •...
Page 119 SmartSet Pro Saw ® Figure 7-1: Daily Calibration Test Boards Calibration Test Board 1 45° 45° 1.12" Blade 1 45° CL=1.12 (1-12/16") Centerline Blade 2 45° CL=1.12 (1-12/16") Blade 3 45° CL=1.12 (1-12/16") Blade 4 45° CL=1.12 (1-12/16") Blade 5 out-of-cut Blade 6 out-of-cut...
Page 120 SmartSet Pro Saw ® 7. Check the length of both boards with a tape measure. Allow 1/16-in. tolerance. 8. Check the angles with a framing square. Allow 1/16-in. tolerance. 9. Check the centerlines with a framing square. Measure from the bottom, which is always the side with the notch in it.
Page 121 SmartSet Pro Saw ® Figure 7-3: Checking Length and Centerline on Test Boards Always measure the centerline from the bottom of the board. 10. If any of the measurements taken during this check do not match what was expected, refer to the applicable section of this manual for instructions of how to adjust the correct component at fault.
Page 122 SmartSet Pro Saw ® Figure 7-4: Resolving Calibration for a Failed Test 001048 Rev. A Maintenance...
Page 123: Changing Calibration Settings
SmartSet Pro Saw ® Changing Calibration Settings If the numbers displaying on the touch screen do not match the numbers measured on the cut board, change the calibration settings. Before recalibrating: • Check the quality of the test lumber. If it is bowed, twisted, or distorted in any way, If you attempt to it will make the test unusable.
Page 124 SmartSet Pro Saw ® 4. Lower the hold-down another 1/2 in. downward (as shown). 5. If necessary, adjust the pointer to 2x4. 6. Press the CALIBRATE button. 7. Press the corresponding button for the carriage hold-down. This will open a menu where you can change the height for the hold-down.
Page 125: Adjusting The Centerline Scale And Pointer
SmartSet Pro Saw ® Adjusting the Centerline Scale and Pointer If the measured centerline on the board is different than expected: • Set the calibration (refer to the Calibration section for procedure). • Adjust the pointer to the measured amount. •...
Page 126: Lubrication
SmartSet Pro Saw ® Lubrication Use a high-quality bearing grease to lubricate the following components. The Maintenance Checklists list cleaning and inspection actions that should be taken at the beginning of each shift, every two (2) hours, weekly, monthly, and quarterly. This section provides more detailed information for the actions on the checklists that require it.
Page 127: Inspecting
SmartSet Pro Saw ® Every 2 Hours ° 1. Set all blades to 30 2. Lockout/tagout the equipment. 3. Using a 4-ft long wand (with an L-shaped end for the blower), blow off all sawdust and wood chips that have accumulated during the day on the saw. The Maintenance Checklists list specific components that are affected.
Page 128: Lubricating The Saw Blade Motors
SmartSet Pro Saw ® level. If oil does not seep out of the hole, oil should be added. Using a small funnel inserted into the hole, add oil to bring the level up to the bottom of the hole. See Table 7-1. Once each year the oil should be drained and replaced.
Page 129: Lubricating The Feed Conveyor Extension Rack And Pinion Gear
SmartSet Pro Saw ® Lubricating the Feed Conveyor Extension Rack and Pinion Gear Once a month thoroughly clean the feed conveyor extension rack and pinion gear and lubricate with a light spray coat of kerosene/oil mixture. Lubricating the Square Drive Tube Once a month spray the square drive tube with a light coat of kerosene/oil mixture.
Page 130: Lubricating The Air Brake Cylinders
SmartSet Pro Saw ® Lubricating the Air Brake Cylinders Each week inject five or six drops of light machine oil such as WD40 into the air line of each pancake cylinder at the drain cock of the cylinder. Disconnect all air to the machine and then systematically disconnect the air line at each cylinder;...
Page 131: Lubricating With Grease
SmartSet Pro Saw ® Lubricating With Grease Proper amounts of motor oil and grease must be maintained at all times. The type of lubrication used, frequency of application, oxidation, and contamination of the lubricant affect service life and parts efficiency of gears and bearings. Improved performance will be obtained by following the guidelines in this manual.
Page 132: Motors And Gearboxes
SmartSet Pro Saw ® Motors and Gearboxes Manually Releasing a Brake When at rest under normal conditions, the blade brakes are on. If the blade will spin by hand, the brakes are released. Motors using pneumatic brakes do not have a manual brake lever, but you can manually release them using the correct air valve.
Page 133: Cleaning Motors
SmartSet Pro Saw ® Cleaning Motors Remove motor guards every week to clean and lubricate the motors, gearbox assemblies, chains, and sprockets that are under the guards. DANGER CRUSH AND CUT HAZARD Guards must always be in place during operation to avoid serious injury and possibly death.
Page 134 SmartSet Pro Saw ® 4. Ensure that all personnel are clear and restore power to the saw. 5. Run the motor for 15 to 30 minutes to allow purging of any excess grease. 6. Return motor to normal service. It is the responsibility of saw owners and operators to choose cleaning and lubrication solutions that comply with all local, state, and federal regulations, especially, environmental regulations.
Page 135: Adding And Changing Oil In Gearboxes
SmartSet Pro Saw ® Adding and Changing Oil in Gearboxes When additional oil is needed, use an oil recommended in Table 7-3 or a comparable type. Table 7-3: Recommended Motor Oils Ambient Temperature -30° to 15°F 16° to 50°F 51° to 110°F 111°...
Page 136: Replacing Motors
Only MiTek personnel shall make adjustments to the hub on the motor shaft. If service is required, remove the entire motor and call MiTek Customer Service to arrange for service. Failure to follow this restriction may result in blades coming loose from the motor shaft, which can result in severe injury, including death.
Page 137 Lockout/tagout before removing any motor. Before removing a blade motor, remove the blade. Never separate the saw blade hub and motor. Only MiTek personnel are trained to re-assemble the hub with a motor. Before removing an angulation motor, lock the quad in place.
Page 138 SmartSet Pro Saw ® Figure 7-8: Lock the Quad in Place 8. Disconnect wiring from the motor. CAUTION PERSONAL INJURY HAZARD. The motor is heavy. Use appropriate personnel and proper lifting techniques. 9. Remove the bolts attaching the motor to the motor plate and remove the motor. 001048 Rev.
Page 139: Changing The Rotation Of A Motor
SmartSet Pro Saw ® Installing a New Motor 1. Place the motor on the mounting plate and re-install the mounting bolts. 2. Reconnect the wiring. Hold-down and lumber stop 3. Reconnect all components that were removed per Table 7-4. motors have high- and low-voltage 4.
Page 140: Chains
SmartSet Pro Saw ® Chains Lubricating Chains Lubricate the chains with a kerosene and oil mixture (10 parts kerosene: 1 part 30-weight motor oil). Spray the mixture lightly onto the chain. Avoid saturation. • Lubricate angle chains every 2 hours. •...
Page 141 SmartSet Pro Saw ® Adjusting the Tension for Chains With a Take-Up Bracket If the chain has too much or too little slack, adjust using these steps. Refer to Figure 7-9 to see the angulation chain. CAUTION Do not remove links to adjust the chain tension! 1.
Page 142: Replacing A Chain
SmartSet Pro Saw ® Replacing a Chain When replacing a chain, pay careful attention to how the chain is threaded before removing it. 1. Lock the quad in place with a 1/2-13 hex head cap screw. The screw should be tight enough to hold the quad in place without damaging or disloding the slide.
Page 143: Air Brakes For Saw Blades
SmartSet Pro Saw ® Air Brakes for Saw Blades Inspecting Air Brakes 1. As you run and stop each blade, watch to determine if all blades are stopping correctly. The blade should stop in under 6 seconds. If not, adjust the brakes using the Aligning Air Brakes procedure.
Page 144 SmartSet Pro Saw ® Figure 7-11: Aligning Air Brakes Air Cylinder Brake shoe Saw Hub 4. Loosen the jam nuts (labeled 1 and 3). 5. Turn in the adjustment bolts (labeled 2 and 4) until the pads touch the hub, then back off the bolt a full turn.
Page 145: Replacing Brake Pads
SmartSet Pro Saw ® Replacing Brake Pads The brake lining, or brake pads, should be replaced when the blade stopping time exceeds 6 seconds and adjusting the brakes doesn’t solve the problem. Even if the blade stopping time is within 6 seconds, replace the brake lining if the pad or hub has grooves worn in it. 1.
Page 146: Saw Blades
SmartSet Pro Saw ® Saw Blades Inspecting Saw Blades 1. Inspect the brakes using the procedure in the Air Brakes for Saw Blades section on page page 105. 2. Saw blades must be kept sharp and smooth. Check for the following items on a daily basis, and replace, repair, or re-tip the blades if any of the following characteristics are found.
Page 147 SmartSet Pro Saw ® Correct Direction of Blade Teeth ® YBER Correct tooth direction is achieved when the tooth at the top of the blade looking from the operator’s side of the machine is facing the operator. The location and recommended size of each saw blade is shown in Figure 7-12.
Page 148: Adjusting The Saw Blade Taper-Lock Bushing Screws
Figure 7-13: Taper-Lock Bushing Screws Checking the Tightness In order to ensure a safe operating environment, MiTek recommends that you check the tightness of all taper-lock bushings on a monthly basis and whenever a saw blade is changed. Use the recommended torque settings in Table 7-6.
Page 149: Adjusting The Angulation
SmartSet Pro Saw ® Tightening the Hub to the Motor 1. Set a torque wrench to the appropriate minimum and maximum settings as shown in the table above. Figure 7-14: Tighten Hub Screws 2. To hold the hub in position, fasten two (2) cap screws to the saw hub. They should be the same size as, but not the same ones used on, the saw blade.
Page 150: Blade Adjustments
An accurate blade draft prevents splintering of the lumber. Figure 7-15 illustrates proper blade draft. The angle should be very slight and is set by MiTek during manufacturing. Small adjustments may be necessary after certain maintenance is performed.
Page 151 SmartSet Pro Saw ® 5. Press the INITIATE SETUP button. 6. Press the START button to start the blades. 7. Using the infeed conveyor FORWARD jog button, cut the board. 8. Press STOP to stop the blades. 9. Using the infeed conveyor FORWARD jog button, move the board to the trailing side of the blade.
Page 152 SmartSet Pro Saw ® Adjusting the Blade Draft After checking the blade draft, if an Figure 7-18: Locations of Shims adjustment is required, follow these steps and refer to Figure 7-18. 1. To increase draft in the 90° position add shims to the back (labeled 2). 2.
Page 153: Checking And Adjusting The Blade Alignment
SmartSet Pro Saw ® Checking and Adjusting the Blade Alignment Blade alignment is how well the blades line up with each other. When blades are aligned properly and in home position, the next blade in line should touch the board but not cut more than 1/64 in.
Page 154 SmartSet Pro Saw ® Adjusting the Blade Alignment for Blades 1-4 Follow this procedure and refer to Figure 7-19 to adjust the alignment of blades 1 through Figure 7-19: Blade Alignment for Blades 1-4 1. Loosen all jam nuts and mounting bolts. CAUTION Be careful not to lose any shim material behind the mounting bolts.
Page 155 SmartSet Pro Saw ® Adjusting the Blade Alignment for Blades 5 and 6 Follow this procedure and refer to Figure 7-20 to adjust the alignment of blade 5 and blade 6. Figure 7-20: Adjusting Blade Alignment for Blade 6 Stationary (For Blade 6) Securing Jam Nut...
Page 156: Checking And Adjusting The Blade Pivot Point
SmartSet Pro Saw ® Checking and Adjusting the Blade Pivot Point The pivot point is the point on the lumber where the blade pivots. Figure 7-21: Blade Pivot Point Pivot Point 30° 60° 90° Checking Blade Pivot Point Make a 90° cut, a 60° cut, and a 30° cut. On the first two cuts, cut all the way through the Summary board.
Page 157 SmartSet Pro Saw ® b) Using the infeed conveyor FORWARD jog button, move the board so that the blade cuts halfway through the board. c) Press STOP to stop the blades. d) Using the REVERSE jog button, move the board out of the machine. 13.
Page 158 SmartSet Pro Saw ® Figure 7-23: Mounting Plate on the Slide ® YBER 4. Mark the mounting plate for height. 5. Mark the mounting plate for depth (mark 1 on Figure 7-24). Figure 7-24: Marking the Mounting Plate 001048 Rev. A Maintenance...
Page 159 SmartSet Pro Saw ® 6. Make a second line for the amount needed to move the head (mark 1 on Figure 7- 24). 7. Mark along the top of the motor mount as a reference point for alignment (mark 1 on Figure 7-24).
Page 160: Infeed Conveyors
SmartSet Pro Saw ® ® YBER Infeed Conveyors Adjusting the Infeed Conveyor Chain Tension The infeed conveyor chain should have Figure 7-25: Infeed Conveyor enough slack so that you can gently pull Chain Tension Assembly up on the chain and see approximately 1 chain link distance of slack.
Page 161: Maintaining The Lumber Guide
SmartSet Pro Saw ® Adjusting the Infeed Conveyor Alignment Always start with the stationary-end infeed conveyor and align the carriage-end infeed conveyors immediately afterward. 1. Move the stationary-end infeed conveyor a comfortable distance away from the saw blades. 2. Lockout/tagout. 3.
Page 162 ® YBER SmartSet Pro Saw ® Adjusting the Lumber Guide Height The blade edge should be set at 1/16 in. above the surface of the flight (dog) that supports the board. Figure 7-27: Adjusting the Lumber Guide and Knife 1/16 inch Mounting Bolt 1.
Page 163: Replacing The Infeed Conveyor Sprocket
SmartSet Pro Saw ® Replacing the Infeed Conveyor Sprocket The feed chain sprockets should be replaced every three (3) years or sooner, depending on use. Disassembly Figure 7-28: Stationary End, Outfeed Side 1. Relieve the chain tension at the take-up sprocket.
Page 164: Adjusting The Drive Sprocket Tension
SmartSet Pro Saw ® Adjusting the Drive Sprocket Tension The tension should be set where the drive chain can deflect about 1 chain link when pushed between the drive sprocket and the idler sprocket. 1. Loosen the idler bolt. 2. Loosen the two jam nuts on the adjuster. 3.
Page 165 SmartSet Pro Saw ® 3. Slide the universal joint off the shaft, being careful not to lose the key. 4. Remove the long square drive shaft. 5. Remove the main drive sprocket in the following manner: a) Loosen the setscrews on the square shaft drive sprockets. b) Slide the sprocket and tube out of the square bore bearings.
Page 166: Inspecting And Replacing Infeed Roll Pins
SmartSet Pro Saw ® 10. Tension the motor to the main drive shaft sprocket chain, using the slotted holes at the machine end of the motor mounting bracket. 11. Tension the hold-down drive chain pushing the idler (top) sprocket up in the slotted hole and tighten the axle nut.
Page 167: Hold-Downs
SmartSet Pro Saw ® Hold-Downs Adjusting the Hold-Down Chain Tension The hold-down chains must be Refer to the Tension Requirements section on page 102 for the correct tension guidelines. the proper length If the tension is incorrect, see Figure 7-30 and perform these steps to adjust the tension: of 207-1/4 in.
Page 168: Replacing Hold-Down Shoes
SmartSet Pro Saw ® Adjusting the Hold-Down Alignment 1. Move the stationary-end infeed conveyor and hold-down a comfortable distance away from the saw blades. 2. Lockout/tagout. 3. Loosen the bearing bolts on the front (infeed) side only and push or pull to make it perfectly aligned above the infeed conveyor.
Page 169: Replacing Hold-Down Sprockets
SmartSet Pro Saw ® Replacing Hold-Down Sprockets The hold-down sprockets should be replaced every three (3) years or sooner, depending on use. Disassembly 1. Place the saw in the Maual Mode by pressing the MANUAL button on the touch screen’s Main Menu. 2.
Page 170 SmartSet Pro Saw ® Figure 7-31: Hold-Down Sprocket and Hold-Down Assembly Jam nut Assembly 1. Replace the front sprocket as follows: a) Place the new sprocket in place and line it up with the bolt hole. b) Place the cap screw back in place and attach with the lock washer and nut. c) Tighten the cap screw.
Page 171: Replacing A Roll Pin In The Hold-Down Spur Gears
SmartSet Pro Saw ® b) Position the rear sprocket for chain alignment with the rear strips and tighten the set screws. c) Adjust the chain tension with front adjusting bolts to where the chain is on a horizontal plane with the slack indicated on page 102. d) Tighten the jam nut on the tension bolt.
Page 172: Waste Conveyor And Incline Conveyor
SmartSet Pro Saw ® Waste Conveyor and Incline Conveyor Adjusting the Belt Tracking/Tension Correct belt tracking (alignment) and tension is achieved when the belt sag between the idler rollers is approximately 1-1/2 in. and the belt tracks in the center of the pan. If the belt is moving toward one side and climbing the side guides, adjust the roller on that side only.
Page 173: Replacing A Conveyor Belt
SmartSet Pro Saw ® 5. Start the conveyor by pushing the waste conveyor button. Run the conveyor for approximately 5 minutes, and observe tracking. It may take more than a single adjustment to align the belt correctly. 6. Activate an E-stop. 7.
Page 174 YBER SmartSet Pro Saw ® Figure 7-33: Connecting Wire on Belt Lacing Connecting wire 3. Bend the ends of the rod or wire to prevent it from coming out. 4. Adjust the belt tension evenly at the head roller adjusting bolts. See the Adjusting the Belt Tracking/Tension section for correct tensioning guidelines.
Page 175: Pneumatic System Maintenance
SmartSet Pro Saw ® Pneumatic System Maintenance Figure 7-34 shows both pneumatic assemblies. The pneumatic system located on the saw frame controls the saw blade brakes, carriage brakes, and moves blades 5 and 6 out-of-cut. The pneumatic system located on the PC enclosure operates the PC enclosure’s cooler. WARNING COMPRESSED AIR HAZARD.
Page 176 SmartSet Pro Saw ® Figure 7-34: Pneumatic System Components Saw Pneumatics Filter/ Regulator Lubricator Stationary General Regulator Purpose Filter Remover PC Enclosure Pneumatics 001048 Rev. A Maintenance...
Page 177: Maintaining The Lubricator On The Saw
SmartSet Pro Saw ® Maintaining the Lubricator on the Saw The saw’s pneumatic system uses a lubricator to keep gaskets and seals in good condition. Checking the Oil Reservoir Check the oil level daily by viewing the sight gauge located on the reservoir daily. Refill or top off the oil when the reservoir is less than 3/4 full.
Page 178: Maintaining The Regulators
SmartSet Pro Saw ® Additional Maintenance WARNING COMPRESSED AIR HAZARD. To avoid injury, bleed all pressure from the lines before removing the reservoir. Ensure that the reservoir is securely attached to the lubricator body before returning pressure to the lines. Proper preventive maintenance for the lubricator also includes replacing the O-rings, seals, and gaskets at regular intervals.
Page 179: Limit Switches
SmartSet Pro Saw ® Additional Maintenance WARNING COMPRESSED AIR HAZARD. To avoid injury, bleed all pressure from the lines before disassembling the regulator. If a regulator is not operating at its optimum capacity, we recommend cleaning the regulator and replacing the O-rings, gaskets, diaphragm, and valve assembly. Mufflers on the filter/regulator should be replaced periodically, when air pressure becomes inefficient.
Page 180: Proximity (Prox) Switches
SmartSet Pro Saw ® Proximity (Prox) Switches How a Prox Switch Works Proximity (prox) switches communicate certain information to the PLC regarding the location of components. They use an electromagnetic field to detect when an object is near. The prox switches on this equipment monitor a shaft or cam with holes drilled at specific points.
Page 181: Adjusting A Prox Switch
SmartSet Pro Saw ® Table 7-7: Prox Switch Locations (Continued) Prox Switch Component It Affect Description Count Tracks the centerline of blade 2 Blade 2 Centerline Home Verifies the centerline calibration of blade 2 Count Tracks the centerline of blade 3 Blade 3 Centerline Home Verifies the centerline calibration of blade 3...
Page 182: Testing A Prox Switch Cable
SmartSet Pro Saw ® Testing a Prox Switch Cable If a prox switch is not communicating with the PLC, it may be caused by faulty cabling. Using a voltmeter and referring to Figure 7-36, follow these steps: Figure 7-36: Prox Switch Cable at the Switch Pin 2 - Blue Wire Pin 3 - Black Wire -24 VDC...
Page 183 SmartSet Pro Saw ® c) Check the appropriate green LED light on the appropriate 24 VDC input card in the PLC rack. d) If the cable is working, the green LED light will be on. 001048 Rev. A Maintenance...
Page 184: Electrical Components
SmartSet Pro Saw ® Electrical Components This equipment relies on highly technical electrical components to operate correctly. Most of the electrical components are located in the stationary-end electrical enclosure and the carriage-end electrical enclosure. The stationary- The stationary-end electrical enclosure is the main electrical enclosure. Although the 3- end disconnect phase wiring enters into this enclosure to power the entire saw, most components in this switch shuts off...
Page 185: Checking For Voltage To And From Components
SmartSet Pro Saw ® Replacing Filters Replace the filters every year. Vacuuming Vacuum dust from the electrical enclosures every week. Checking for Voltage To and From Components One of the first steps to take when troubleshooting an electrical component problem in the saw is to determine which electrical component is not working properly and why.
Page 186: Plc And Input/Output Cards
SmartSet Pro Saw ® PLC and Input/Output Cards A PLC is a programmable logic controller. It houses input cards that supply information to the PLC and output cards that allow the PLC to supply information to the rest of the saw. It is the “brain”...
Page 187 SmartSet Pro Saw ® To replace an input or output card: 1. Remove the terminal strip: Figure 7-38: Push Lever Up to Release Terminal Strip Each input and output card has a terminal strip on it so you can replace the card without removing individual wires.
Page 188: Vfd
• If a VFD experiences a fault, one of the fault numbers listed in Table A-16 in the Troubleshooting appendix will appear. Setting VFD Parameters Recommended VFD settings are listed in your electrical drawings. Contact MiTek Machinery Division Customer Service before attempting to reset any setting. Replacing a VFD (Variable Frequency Drive) There are a minimum of 16 VFDs on the saw.
Page 189 Top Cover Remove Side Cover All VFDs should be ordered through MiTek because they must be programmed before use. To replace a VFD: 1. Remove the two (2) covers labeled in Figure 7-40. 2. Ensure all wires entering the VFD have wire labels. If not, refer to your electrical drawings and adhere wire labels before disconnecting anything.
Page 190: Circuit Breakers
SmartSet Pro Saw ® Circuit Breakers Circuit breakers are used for certain components as an electrical circuit protection device. Using the Handle Manually operate the circuit breaker using the handle and the PUSH-TO-TRIP button on the circuit breaker. The handle has three (3) positions: On, Trip, and Off. Manually Tripping the Circuit Breaker to Test Manually trip the circuit breaker by pushing the PUSH-TO-TRIP button.
Page 191 SmartSet Pro Saw ® Cleaning Contacts To clean the motor starter contacts: CAUTION Never use pneumatic air inside electrical cabinets. It will force dust and particles into electrical components causing them to fail. 1. Lockout/tagout at the wall before opening the enclosure. 2.
Page 192: Maintaining The Perimeter Safety Cable
SmartSet Pro Saw ® Maintaining the Perimeter Safety Cable A properly tensioned perimeter safety cable Figure 7-41: Safety Cable and Switch will trip the E-stop switch when someone pulls it approximately 8 in. from its rest position at the mid-section of the saw. Resetting the Switch Once the cable is pulled, reset the E-stop circuit by pressing the button labeled in...
Page 193: Maintenance Jumper
SmartSet Pro Saw ® Maintenance Jumper The maintenance jumper allows the operator to bypass certain features of the saw to make troubleshooting easier. Saw blades will not start while the maintenance jumper is pulled. The arrow in Figure 7-43 shows the location of the maintenance jumper. WARNING ELECTROCUTION HAZARD! The maintenance jumper provides an important safety barrier...
Page 194: Blade-Installed Jumpers
110 VAC outlets, but very little power is reserved to operate them. They exist to give MiTek personnel access to an outlet for laptops for troubleshooting purposes. Do not use the outlets for tools, high-powered vacuums, or any other electrical equipment that could draw more than 3 amps of current.
Page 195: Recommended Preventive Maintenance
SmartSet Pro Saw ® Recommended Preventive Maintenance Daily Schedule Every 2 hours (break time), do as follows: 1. Angulate all blades to 30° and blow down the saw motors, chains, and axis with air. 2. Visually check every length, angle, and centerline indicator. 3.
Page 196 SmartSet Pro Saw ® 3. Check the air brakes for each saw blade motor. Run and stop each blade, and watch to see if all blades are stopping correctly. Adjust brake calipers if necessary as directed in the Air Brakes for Saw Blades section of this chapter. 4.
Page 197: Weekly Test Cut
SmartSet Pro Saw ® check the belt tracking (alignment) every 2 hours until he is confident that the conveyor is remaining aligned. 17. Check conveyor belt tracking. Realign as necessary using the adjustment procedure described above. If the conveyor is adjusted, the maintenance man must return to the conveyor to check the belt tracking (alignment) every 2 hours until he is confident that the conveyor is remaining aligned.
Page 198: Open The Electrical Cabinets And Inspect Them For Dust
SmartSet Pro Saw ® each direction and clean with a wet rag or steel wool. Remove all grease or debris from the slides and lubricate with straight kerosene. 4. Inject grease into all bearings on the saw including, but not limited to, all rack and pinion shafts, centerline screws, and square drive shaft bearings.
Page 199: Replacing Parts
SmartSet Pro Saw ® Replacing Parts Replacing the Hold-Down Shoes Use the following steps as a guide for replacing hold-down shoes. Disassembly 1. Run each hold-down until a chain connecting link is on or near the front sprocket. 2. Lock out all energy sources. 3.
Page 200: Replacing The Feed-Chain Sprockets
SmartSet Pro Saw ® Assembly 1. Install the new belt with the lacing connection near the head roller. 2. Bring the belt together so the lacing is intermeshed, and slide the rod or wire through the lacing. Bend the ends of the rod or wire to prevent it from coming out. 3.
Page 201 SmartSet Pro Saw ® Disassembly 1. Run both hold-down drive chains until a chain connecting link is on the lower side, out of the tube. 2. Lock out all energy sources. 3. Relieve the chain tension on the take-up sprockets at the front of the saw until the chain droops in the center.
Page 202: Replacing The Infeed Drive Sprockets
SmartSet Pro Saw ® d) Bring the universal joint up to the protruding shaft and position the key in the keyway. e) Slip the universal joint over the shaft making sure the key stays in its position between the two keyways. 3.
Page 203 SmartSet Pro Saw ® 8. Remove the main gearbox drive sprocket by loosening the set screws and pulling the sprocket from the motor shaft. Be careful not to lose key from the keyway. Assembly 1. Install the new sprocket on the main gearbox shaft with the hub of the sprocket toward the motor.
Page 204: Adjusting The Heel Cut Skid Bar
SmartSet Pro Saw ® Figure 7-44: Drive Sprocket Cluster Adjusting the Heel Cut Skid Bar The height of the heel skid bar is adjustable to ensure that its height is always the same as the top of the feed chains where the lumber rests. To adjust the heel skid bar, do as follows: 1.
Page 205: Navigating The Troubleshooting Appendix
Troubleshooting Appendix A Navigating the Troubleshooting Appendix This appendix is divided into tables according to the symptoms the machine is having. Most solutions have a more detailed explanation in the Maintenance chapter. If you have Refer to... an electronic file of this manual, click on any reference to another page or section, and it Maintenance will take you there.
Page 206: Safety Notes For Troubleshooting
SmartSet Pro Saw ® Safety Notes for Troubleshooting WARNING ELECTROCUTION, HIGH PRESSURE, CRUSH, CUT, AND CHEMICAL HAZARDS! Read all notes in this section AND the safety section in the preliminary pages before operating or maintaining this equipment. Most solutions are described in more detail in the Maintenance chapter and may have more safety notes included there.
Page 207: Operational Notes For Troubleshooting
SmartSet Pro Saw ® Operational Notes for Troubleshooting • Do not use compressed air Figure A-1: Never Use Compressed inside the electrical Air Inside an Electrical Enclosure enclosures! It may force contaminants into the electrical connections. • Clean and lubricate the equipment as a first step in most troubleshooting processes.
Page 208 SmartSet Pro Saw ® Figure A-2: Start Here to Determine Solutions Are affected saw components clean and lubricated and Are there any free of debris? Are there any alarms showing on mechanical the alarm status bindings or bar? damaged parts? Was the daily calibration done correctly?
Page 209: Symptoms And Solutions
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Symptoms and Solutions Table A-1: General Problem Possible Cause Possible Solution No power Machine or in-house main switch Nothing operates– Power ON light not Fuse or breaker Main incoming fuse or breaker illuminated Circuits open 10 amp fuse in Box 2...
Page 210 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-2: Mis-Cut Boards (Continued) Problem Possible Cause Possible Solution Calibration is wrong Check angle calibration. Angulation chain too tight or loose Check the angulation chain for proper tension. Lumber guide knife dull or at Check the lumber guide knife height setting.
Page 211 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-2: Mis-Cut Boards (Continued) Problem Possible Cause Possible Solution Use the center lumber support for long boards or a Lumber is not fully supported heel cut skid bar for long scarfs. Use heel cut skid bar.
Page 212: Saw Not Operating Correctly
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Saw Not Operating Correctly Setup problems specifically related to a centerline, angle, infeed, hold- down are covered in other tables in this appendix. Table A-3: Saw Not Operating Correctly Problem Possible Cause Possible Solution...
Page 213 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-3: Saw Not Operating Correctly (Continued) Problem Possible Cause Possible Solution One blade runs in the Wrong connection Swap any two phases of supply to the motor. wrong direction Loose connection on PLC rack 0 or Tighten both ends of the remote rack...
Page 214 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-3: Saw Not Operating Correctly (Continued) Problem Possible Cause Possible Solution Encoder spur gear not properly Ensure that encoder drive spur gear is tight in rack. meshed with rack Check set screws that joins encoder to shaft.
Page 215 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-3: Saw Not Operating Correctly (Continued) Problem Possible Cause Possible Solution Check centerline movement by using Manual Mode to move the centerline. Centerline unable to move to 3" Check for obstructions.
Page 216: Computer-Related Problems
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Computer-Related Problems Table A-4: Computer Related Problems Problem Possible Cause Possible Solution Check all cable connections at components Loose connections and terminal blocks. Touch screen is blank or black Turn power on to the monitor and the Power to touch screen or computer is off computer in the PC enclosure.
Page 217: Centerlines And Angles
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Centerlines and Angles Table A-5: Centerlines and Angles Problem Possible Cause Possible Solution Replace spider Spider is bad or coupler is loose Centerline will not hold Tighten coupler calibration Brakes on motor are worn Replace brake or motor.
Page 218 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-5: Centerlines and Angles (Continued) Problem Possible Cause Possible Solution Check that the PLC is in Run Mode. Refer to the electrical schematics. While jogging the centerline in the direction that the centerline Centerline will only PLC output is not operating will not move, check to see that the output card’s...
Page 219: Infeed Conveyors
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Infeed Conveyors Table A-6: Infeed Conveyors Problem: Possible Cause: What To Do: Determine which light does not come on. Possible The PLC did not receive a run causes are: signal back from each of the blades Loose or broken wire to the input card.
Page 220: Hold-Downs
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Hold-Downs Table A-7: Hold-Downs Problem: Possible Cause: What To Do: Check insert. Spider coupling is not assembled properly Hold-down does not Check set screws. move at all Clean, lubricate and inspect the moving Axis cannot move freely components.
Page 221: Lumber Stops
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Lumber Stops Table A-8: Lumber Stop Problem: Possible Cause: What To Do: Check insert. Spider coupling is not assembled properly Check set screws. Lumber stop does not Clean, lubricate and inspect the moving move components.
Page 222: Carriage
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Carriage Table A-9: Carriage Problem: Possible Cause: What To Do: Press INITIATE SETUP. If an “All axes in position” message displays, then the carriage should be in Axis is already in position the correct position for the setup.
Page 223 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-9: Carriage (Continued) Problem: Possible Cause: What To Do: Square drive shaft worn Repair damage or replace the tube. Carriage is abnormally Clean, lubricate and inspect the moving noisy or vibrates when V-wheels or angle are damaged or components.
Page 224: Alarm Conditions
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Alarm Conditions Alarms are specific conditions recognized by the saw that notify the operator something is or could be wrong. An alarm causes an icon on the alarms status bar located at the top of the Main Menu to illuminate. Table A-10: Alarm Conditions Problem Possible Cause...
Page 225 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-10: Alarm Conditions (Continued) Problem Possible Cause Possible Solution Check if PLC input turns ON and turns OFF. If input is coming on, the proximity switch & cable are okay. If not, replace input card.
Page 226 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-10: Alarm Conditions (Continued) Problem Possible Cause Possible Solution Axis is not calibrated properly Recalibrate. Check if PLC input turns ON and turns OFF. If input is coming on, the proximity switch &...
Page 227 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-10: Alarm Conditions (Continued) Problem Possible Cause Possible Solution Check wire connections to brake relay. Clean sawdust and other debris from brake relay. Brake relay did not energize Check that the brake relay is functioning properly.
Page 228: Motors
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Motors Refer to the Alarms troubleshooting chart before proceeding with this chart. Table A-11: Motors Problem: Possible Cause: What To Do: Bad motor Replace motor. Motor connections are loose Check motor connections.
Page 229: Vfd Faults
® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? VFD Faults The VFDs have many protective functions that occur when there is an error. The name of the alarm will be displayed on the LED when an error occurs and the motor will coast to a stop. Table A-12 lists alarm displays and protective operations.
Page 230 ® SmartSet Pro Saw Should you lockout/tagout to safely perform this action? Table A-12: VFD Protective Operations (Continued) Name of Alarm Display Description of Operation The temperature of the heat sink of the drive is high, possibly due to Heat sink overheat a broken cooling fan or other reasons.
Page 231: Maintenance Checklists
Maintenance Checklists Appendix C Checklists for Preventive Maintenance Use the checklists in this appendix to schedule preventive maintenance. The checklists will guide you through all preventive maintenance tasks required to keep this equipment in top working condition. These pages are supplied with the intent that you will photocopy them and document the date that maintenance is done, leaving the original in the manual for future use.
Page 232: Daily Checklist
SmartSet Pro ® Daily Checklist Month and Year: _______________________ Week: __________________________ Action Shift 1 Lubricate the drive wheel chain Shift 2 (every 8 working hours) Shift 3 Shift 1 Lubricate the motor drive chain Shift 2 (every 8 working hours)
Page 233: Monthly Checklist
SmartSet Pro ® Monthly Checklist Year: _____________ MONTH APRIL JUNE (first half of year) Replace saw blades 1 month Grease the take-up bearing 3 months Inspect and dust brake motor 3 months Check regulator filter (6 months) 6 months Grease the guide wheels...
Page 234: Checklist By Working Hours
SmartSet Pro ® Checklist by Working Hours Year: _____________ Working Preventive Maintenance Action Sign and Date When Action is Performed Hours Grease the take-up bearing Inspect and dust brake motor Check filter (6 months) Grease the guide wheels Check oil level in brake motor...
Page 235: Periodic Checklist
SmartSet Pro ® Periodic Checklist Year: _____________ Preventive Maintenance Action Sign and Date When Action is Performed Grease the take-up bearing 3 months Inspect and dust brake motor 3 months Check filter (6 months) 6 months Grease the guide wheels...
Page 236: Parts List
Parts List Appendix C Navigating the Parts List Appendix Finding the Part Number The parts list provided here shows spare parts that should be kept in stock at all times. Use one of the methods shown in Table C-1 to locate your part number. For a complete list of replacement parts, or if you’re unsure of which spare part you need and would like to see a picture, use the electronic Parts Guide for this machine.
Page 237: Ordering The Parts With Your Part Number
SmartSet Pro Saw ® Ordering the Parts With Your Part Number There are three easy ways to order your part after you determine the part number. Each column in Table C-2 describes one of the methods. Table C-2: How to Order Your Part Using the Part Number Using Our eStore™...
Page 238: Safety Notes For Replacing Parts
SmartSet Pro Saw ® Safety Notes for Replacing Parts CAUTION Only use the exact replacement parts that are specified by MiTek. Substitutions may harm your equipment. WARNING CRUSH, CUT, HIGH PRESSURE, ELECTROCUTION, AND PERSONAL INJURY HAZARDS. Perform the safety tests described on page xx in the Safety (English) chapter or on page xxxv in the Seguridad (Español)
Page 239: Part Numbers
SmartSet Pro Saw ® Part Numbers Table C-3: SmartSet Pro Replacement Parts MiTek Part # Part Description Keep in Stock 370100 Hold-down springs 419118 Bearing 423534 Cylinder rebuild seal kits 434295 Saw brake air valve 480256 Centerline motor 480336 Angle motor...
Page 240: Technical Information
Technical Information Appendix D This appendix provides general information that will help you better understand how this equipment works. Understanding Overloads Purpose and Scope The information below has been collected to help you understand the role of an overload, how an overload works, and how to calculate the overload setting to protect the motor. The Importance of Protecting Your Motor The following statement describes the importance of protecting electric motors and is a good illustration of why we need overloads.
Page 241 SmartSet Pro Saw ® What is an Overload? So, what is an overload? The term literally means that too much load (what the motor is driving) has been placed on the motor. A motor is designed to run at a certain speed, called its synchronous speed.
Page 242 SmartSet Pro Saw ® Figure D-1: Motor Inrush Curve Inrush Normal Current Operating Current 1000 Current A 300 % Overload .01 0.1 10 100 1000 Time (s) An overload condition will occur when the rotor has difficulty turning and draws more current than it normally would need to keep it turning.
Page 243 SmartSet Pro Saw ® • A design that meets the special protective needs of motor control circuits • Allow harmless temporary overloads, such as motor starting, without disrupting the circuit • Will trip and open a circuit if current is high enough to cause motor damage over a period of time •...
Page 244 Class 30 has a longer time delay to be used on high inertia loads that require a long acceleration or have shock loading that causes repetitive motor inrush. The overload class that MiTek normally specifies for equipment is a Class 10. Since it is possible to burn out a motor in less than 20 seconds, we have chosen to protect the motor with the highest degree of protection.
Page 245 SmartSet Pro Saw ® Codes And Standards NFPA 79—Electrical Standard for Industrial Machinery, 2002 7.3.1.1 Motors. Motor overload protection shall be provided to each motor in accordance with Article 430, Part III, of NFPA 70, National Electrical Code. NEC 2002—National Electrical Code 430.32 (A) (1) Separate Overload Device.
Page 246 SmartSet Pro Saw ® Glossary of Overload Terms Full Load Amps (FLA) This is the current flow required by a motor during normal operation under normal loading to produce its designated horsepower. Motors having nothing attached to their shaft will draw less than the FLA current.
Page 247 SmartSet Pro Saw ® Motor Load A motor provides the conversion of electrical energy to mechanical energy that enables a machine to do work. The energy that a machine requires from a motor is known as the motor load. The motor load “seen” by a motor is dependant upon how the load is connected to the motor, the dimensions of the load, and the weight of the load.
Page 248 SmartSet Pro Saw ® NEMA Design Ratings NEMA ratings refer to the torque ratings. The following ratings apply to motors: NEMA B The NEMA B motor’s percentage of slip ranges from 2 to 4%. It has medium values for starting or locked rotor torque, and a high value of breakdown torque. NEMA A The NEMA A motor is similar in many ways to the NEMA B motor.
Page 249 SmartSet Pro Saw ® Class 20, and Class 30. Class 10, for example, has to trip the motor off-line in 10 seconds or less at 600% of the full load amps. This is usually sufficient time for the motor to reach full speed.
Page 250: Drawing Set
Powered Hold-Down Assembly – LH 77810 Carriage Conveyor Guard 77908 Proxy Switch Cover Weldment 77992 Outfeed Operator Guard 77993 Smartset Pro Final Assembly 78500 Smartset Pro Mechanical Assembly 78505 Vertical Adjustment Cam Cover 78508 Safety Devices & Guards Assembly 78555...
Page 251 SmartSet Pro Saw ® Table E-1: Attached Drawings (Continued) Description Drawing Number Electrical Assembly 78595 Infeed Guard Carriage 78667 Pneumatic Assembly – 5 Blade 79745 Blade Guard Stationary 79801 Emergency Stop Guard 79810 Electrical 90129 Electrical, 460V 90175 Swingarm, Enclosure 519663 Pivot Rear Guard Sub-Assembly 7008127...
Page 252: Document Evaluation
Document Evaluation Appendix F A form is included in this appendix so you can provide MiTek with feedback on the usefulness of this manual. We make an ongoing effort to improve the value of our documentation, and your views are important to us.
Page 253 Document Evaluation Form We appreciate your comments on how we can make this document more useful. Document Identification: ® Pro Saw Operation and Maintenance Manual 001048 SmartSet General Ratings: Poor Fair Good Excellent Content     Organization  ...
Page 254 Address: Phone: Email: Please mail this form to: Or fax this form to: 314-298-3439 MiTek Attn: Engineering Manager Machinery Operations 4203 Shoreline Drive Earth City, MO 63045 Attn: Engineering Manager If you do not receive a reply within 45 days, please call our Customer Service Department and ask for the Documentation Specialist or Engineering Manager: 800-523-3380.
Page 255: Glossary
Glossary actuate to activate, put into action aisle pad a type of jigging used when a connector plate needs to be embedded where the table surface gives way to a walk- through aisle amperage the strength of an electric current, expressed in amperes anchor plate a steel plate that holds the tables in place;...
Page 256 Glossary inner side refers to the end of the gantry head housing; the side closest to the tables; both ends have an inner side—one can see the inner side of both ends when standing on or between the tables jigging any of several devices used to hold the truss in place on the tables joystick...
Page 257 Glossary pendant control where the operator stands to use the pendant that controls station movement of the gantry head pilot valve a pneumatic valve that operates the setup valve to control the release or cessation of air in each setup; it is located on the bottom-chord end of one table in each setup plate see connector plate...
Page 258 Glossary Roller the large roller inside the gantry head that innately embeds the plates into the truss setup valve a component of the pneumatic system that control the flow of air to the rest of the setup side-eject a pneumatic system that raises the truss off the tables and allows the truss to be manually pushed or pulled off the side of the table and onto the stand-alone conveyors slider pad...
Page 259: Index
Index releasing 94 replacing 107 test xxi air pressure buttons adjusting regulator 140 angle and centerline calibration 67 minimum 140 blades 5/6 in-cut/out-of-cut 64 saw blade brakes 105 blades start and stop 62 air pressure, minimum 16 carriage 65 alarm feed chain 73 conditions 186 hold-down 72...
Page 260 Index tension 122 troubleshooting 175 lubrication 79 daily checklist 194 master link 104 danger logos xi replacing 104 DC power supply fault 57 tension defaults page screen 68 adjusting 103 document evaluation form 215 checking 102 drawings checklist description 212 by working hours 196 drawing numbers 212 daily checklist 194...
Page 261 Index feed chain buttons 73 incline conveyor 134 installing 22 feed chain motor test 29 positioning 22 filter 16 infeed regulator 141 roll pins 128 filter-regulator-lubricator (FRL) assembly spur gear 128 infeed conveyor floating keypad 58 adjusting floor web settings 37 alignment 123 forklift truck chain tension 122...
Page 262 1 understanding formatting 2 cards 148 page change ix input/output cards 148 purpose 1 pneumatic connection 26 manual screen 63 pneumatic system master link 104 components 138 misc. fault help screen 57 filter 16 mitek 001048 Rev. A Index...
Page 263 70 manual screen 63 responsibilities misc. fault help screen 57 of customer 12 miscellaneous fault screen 57 of mitek 11 motor overload fault screen 55 restricted zones xix, xxxiv operation screens 58 roll pin overload help screen 55...
Page 264 Index shipping information 17, 22 electronically operated functions 45 main operator interface 45 SmartSet Pro saw shutting down 46 centerline motors test 30 troubleshooting 178 conveyor bed 19 feed chain motor test 29 training provided 17 floor space requirements 19...

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