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Mitek Hornet II Saw Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL
001079 REV. A
Hornet II™ Saw
CAUTION:
MiTek recommends printing
this manual in high resolution
using color ink. Many of the
graphics may be unclear and
may create an unsafe condition
if this recommendation is not
followed.
®
Copyright © 2024 MiTek
. All rights reserved. Patented. See Legal Notice
for list of patents. Manual applies to United States equipment.

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  • Page 1 Many of the graphics may be unclear and may create an unsafe condition if this recommendation is not followed. ® Copyright © 2024 MiTek . All rights reserved. Patented. See Legal Notice for list of patents. Manual applies to United States equipment.
  • Page 2 001079 REV. A Hornet II™ Saw Part # and Rev. 001079 rev. A Print Date 13 September 2024 Effectivity All Frames Revision Date 01 September 2024 Revised By A. Moll Orig. Release Date 1 January 2023 Created By A. Moll...

  • Page 3: Legal Notice

    Legal Notice Patents Made and sold under one or more of the following patents: U.S. 4,986,052 U.S. 5,837,014 U.S. 6,219,975 U.S. 5,385,339 U.S. 5,854,747 U.S. 6,260,263 U.S. 5,493,834 U.S. 5,873,567 U.S. 6,317,980 U.S. 5,568,862 U.S. 5,884,448 U.S. 6,389,762 U.S. 5,630,697 U.S.

  • Page 4: Return Goods Policy

    Legal Notice Return Goods Policy Return goods cannot be accepted without prior authorization and are subject to a restocking charge. The Seller certifies the articles specified herein were produced in compliance with all provisions of the Fair Labor Standards Act of 1938, as amended, including Section 12.—Rev.

  • Page 5: Table Of Contents

    ABLE OF ONTENTS Legal Notice Return Goods Policy ..........iv Corrections and Improvements .
  • Page 6 HORNET II: TABLE OF CONTENTS Introduction to the Manual ..........43 Understanding the Manual .
  • Page 7 HORNET II: TABLE OF CONTENTS Optimization and Scrap Cutting ........81 Maintenance Introduction to Maintaining Your Machine .
  • Page 8 HORNET II: TABLE OF CONTENTS Safety Notes for Replacing Parts ........132 Drawing Set Glossary Original Instructions: 001079 rev.

  • Page 9: Safety (English)

    CHAPTER 1 Safety (English) Safety Indicator Signal Words The following signal words and colors are used throughout this document to indicate safety hazards. Pay careful attention when you see them. The level of severity differs for each signal word and color. Signal words are accompanied by graphics showing what personnel should or Refiérase a la should not do.

  • Page 10: General Safety & Equipment Rules

    HORNET II: SAFETY General Safety & Equipment 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 11 An E-stop may cause components to move without warning. • Only use procedures described in this manual. Any other procedures should be discussed with MiTek to verify it is done safely. For topics not covered in this manual or online, contact MiTek for advice.

  • Page 12: E-Stop Locations

    Never disconnect or bypass any safety device or electrical interlock. • Torque bolts and fasteners to the specifications given by MiTek. If no torque specification is given, use industry standards. • Only qualified maintenance personnel shall make adjustments or remove, repair, or install safety devices.

  • Page 13: General Warnings

    HORNET II: SAFETY General Warnings WARNING HIGH VOLTAGE ELECTRICITY! May cause serious personal injury or death. Ensure only qualified electricians perform electrical service work. WARNING Read the equipment manual, safety labels, and all safety information provided before operating or maintaining this equipment. WARNING CRUSH OR CUT HAZARD Guards must always be in place during operation to avoid serious...

  • Page 14: Lockout/Tagout

    HORNET II: SAFETY Lockout/Tagout Lockout/Tagout Guidelines Lockout/tagout all energized systems before performing maintenance on them. 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 15: Electrical Lockout/Tagout Procedures

    HORNET II: SAFETY Electrical Lockout/Tagout Procedures Working on a Machine Outside the Machine’s Main Electrical Enclosure If you are working on the electrical transmission line to the machine, follow the procedure on page Before performing maintenance on any machine with electrical power, lockout/ tagout the machine properly.
  • Page 16 HORNET II: SAFETY Figure 1-2: Example of a Lockout/Tagout Mechanism on an Electrical Enclosure 4. Restrain or de-energize all pneumatic components, hydraulic components, and other parts that could have live or stored power. 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.
  • Page 17 HORNET II: SAFETY 1. Engage an E-stop on the Figure 1-3: Sample of a Lockout/ machine. Tagout Mechanism on a Power Source Panel 2. Shut the power to the machine off at the machine’s power source which is usually an electrical service entry panel on the facility wall.

  • Page 18: Hydraulic Or Pneumatic System Lockout/Tagout Procedure

    HORNET II: SAFETY Hydraulic or Pneumatic System Lockout/Tagout Procedure Before working on or near hydraulic or pneumatic components, bleed the lines of pressure. When Lockout/Tagout Is Not Required If working on components other than the hydraulic or pneumatic system, but that requires you to be near the vicinity of movable hydraulic or pneumatic components, you must, at a minimum, physically restrain those components from moving.

  • Page 19: Troubleshooting With An Energized Machine

    HORNET II: SAFETY Troubleshooting with an Energized Machine Only a qualified electrician, using the personal protective equipment and following the procedures recommended in NFPA 70E should ever attempt service or repair of or near an energized area or component of the machine. Whenever maintenance is performed while the equipment is electrically energized, there is a potential electric arc flash hazard.

  • Page 20: Safety Tests

    2. Make sure sharp objects are clear of all pneumatic and electrical system cables. 3. Check the Hornet II saw for debris or tools that would block the path of parts. Remove any that you may find. The following locations are especially important: •...

  • Page 21: Inspecting Labels/Guards

    HORNET II: SAFETY • Saw chamber 4. Check saw blade condition (See Replacing a Saw Blade on page 97). 5. Remove lockout/tagout and return electrical power and pneumatic pressure to the machine. See Daily Startup on page 6. Press the illuminated blue Reset button. The Reset button light should turn off to indicate the machine is ready for normal operation.

  • Page 22: Testing Movement While E-Stop Is Active

    HORNET II: SAFETY • The infeed pusher and auto loading mechanism stop • All illuminated E-stops are solid red • The bolt that stops the saw blade is engaged • If the saw blade and integrated components stop as expected, repeat the procedure to test all E-stops listed in step 3.

  • Page 23: Restricted Zone

    HORNET II: SAFETY 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. Always look for personnel in the restricted zone before operating equipment.

  • Page 24: Safety Symbol Definition

    HORNET II: SAFETY Safety Symbol Definition The safety symbols shown in this section are found throughout the manual to indicate hazards related to this machine. All personnel expected to operate or maintain this machine should be familiar with these safety symbols and their meanings.
  • Page 25 HORNET II: SAFETY Slip hazard. Use of appropriate footwear is required. Trip hazard. Pay attention when walking in this area. Kickback hazard. Keep hands clear of cutting parts. Original Instructions: 001079 rev. A...
  • Page 26 HORNET II: SAFETY Keep hands and body clear. Crush hazard from above. Hot surface. Surface temperature can exceed 158°F (70°C) during normal operation. Do not touch. Ventilate. Slots and openings in the cabinet are provided for ventilation to ensure reliable operating of the equipment. To protect the equipment from overheating, those openings must not be blocked or covered.
  • Page 27 HORNET II: SAFETY Keep hands away from moving parts. High pressure hose. Use appropriate PPE when working on equipment. Maintain safe pressure level at all times. High pressure hydraulic hose. Use safe operating procedures at all times. Equipment has automatic restarting capability. Lockout/tagout on the upstream disconnect before servicing.
  • Page 28 HORNET II: SAFETY The operation of this equipment requires the use of PPE. Do not operate without wearing the required protective clothing. Refer to manual. After installation, read the user’s guide carefully before operating. Follow all operating and other instructions carefully.
  • Page 29 HORNET II: SAFETY Circuits are live. Lockout/tagout on the upstream disconnect prior to servicing. Lockout in a de-energized state. Lift point. In order to decrease the likelihood of damage to the equipment, use only the lift points indicated in the manual. Open switch before adjusting equipment.
  • Page 30 HORNET II: SAFETY Use of lift equipment is mandatory. Consult material safety data sheet. Unplug equipment before servicing. No open flames in this area. No smoking in this area. Hazardous moving parts are located behind this access panel. Do not operate this equipment without all guards and covers in place. Do not place containers with liquids such as coffee, water, soda, etc.
  • Page 31 HORNET II: SAFETY No lift point. Do not lift this device with a hook/crane assembly. Equipment damage occurs. Refer to the installation instructions. Do not step or stand upon this equipment. Stepping or standing on this equipment may result in serious injury. Not a step.
  • Page 32 HORNET II: SAFETY Do not discard into the municipal waste stream. Indicates notes regarding lubrication. Original Instructions: 001079 rev. A...

  • Page 33: Declaration Of Safety Conformity

    HORNET II: SAFETY Declaration of Safety Conformity Conforms electrically to the following: • NFPA 79 • NEC Electrical Code • Electrical enclosures carry UL 508A and the CUL for Canada • Safety circuit conforms to Category 4 redundant monitoring Conforms mechanically to the following: •...

  • Page 34: Seguridad (Español)

    CHAPTER 2 Seguridad (Español) Indicadores de seguridad: Palabras de aviso Las siguientes palabras y colores de aviso se utilizan a lo largo de este documento para indicar riesgos de seguridad. Preste suma atención cuando los vea. El nivel de gravedad es diferente por cada palabra o color de aviso. Las palabras de aviso van acompañadas por gráficos que muestran al personal lo que deben y no deben hacer.

  • Page 35: Reglas De Seguridad Para El Equipo De General

    HORNET II: SEGURIDAD Reglas de seguridad para el equipo de general 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 36 Un paro de emergencia puede causar que los componentes se muevan sin previo aviso. • Use solamente los procedimientos descritos en este manual. Cualquier otro procedimiento debe analizarse con MiTek para verificar que sea seguro. Original Instructions: 001079 rev. A...

  • Page 37: Ubicación De Un Paro De Emergencia

    No desconecte ni evite nunca ningún dispositivo de seguridad ni interbloqueo eléctrico. • Apriete los pernos y tornillos al par de apriete especificado por MiTek. Si no se especifica el par de apriete, use los estándares de la industria.

  • Page 38: Advertencias Generales

    HORNET II: SEGURIDAD Advertencias generales WARNING ¡ELECTRICIDAD DE ALTO VOLTAJE! Puede causar lesiones personales graves o la muerte. Asegúrese de que solo electricistas calificados realicen trabajos de servicio eléctrico. WARNING Lea el manual del equipo, las etiquetas de seguridad y toda la información de seguridad suministrada antes de operar o hacerle mantenimiento a este equipo.

  • Page 39: Bloqueo/Etiquetado

    HORNET II: SEGURIDAD 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 40: Procedimientos De Bloqueo/Etiquetado Eléctricos

    HORNET II: SEGURIDAD 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 page Antes de realizar el mantenimiento de cualquier máquina con alimentación eléctrica, bloquee y etiquete la máquina de forma adecuada.
  • Page 41 HORNET II: SEGURIDAD Figura 2-2: Mecanismo de bloqueo/etiquetado en un gabinete eléctrico principal 4. Trabe o desenergice todos los componentes neumáticos y otras piezas que tengan alimentación directa o almacenada. Original Instructions: 001079 rev. A...
  • Page 42 HORNET II: SEGURIDAD 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 etiquete la máquina en forma adecuada.

  • Page 43: Procedimiento De Bloqueo/Etiquetado Del Sistema Hidráulico O Neumático

    HORNET II: SEGURIDAD Procedimiento de bloqueo/etiquetado del sistema hidráulico o neumático Antes de realizar el mantenimiento de los sistemas neumáticos, purgue las líneas para eliminar la presión. 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 44: Solución De Problemas Con Una Máquina Energizada

    HORNET II: SEGURIDAD 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 45 HORNET II: SEGURIDAD Table 2-2: Cómo tratar el contacto con una sustancia peligrosa Si una Haga esto... sustancia entra Tinta de impresora Limpiador de en contacto impresora con... La piel/ropa Enjuague, quítese la Enjuague, quítese la ropa y lave la piel con ropa y lave la piel con jabón jabón...

  • Page 46: Pruebas De Seguridad

    HORNET II: SEGURIDAD Pruebas de seguridad Este procedimiento de prueba DEBE ser realizado por personal calificado durante la puesta en marcha y después de CUALQUIER tarea de mantenimiento, ajuste o modificación. La prueba permite comprobar si el sistema de seguridad y el sistema de control de la máquina funcionan juntos y detienen la máquina de manera adecuada.

  • Page 47: Inspección De Etiquetas/Protectores

    HORNET II: SEGURIDAD 7. El filtro/regulador principal y otros subreguladores deben coincidir con las presiones nominales detalladas en Sistema neumático en la página 114. 8. Jale de la manija de las puertas delantera y posterior de la cámara de la sierra (2 en total) para verificar que ambas puertas estén cerradas y bloqueadas.

  • Page 48: Prueba De Movimiento Mientras El Paro De Emergencia Está Activo

    HORNET II: SEGURIDAD • Todos los paros de emergencia iluminados están de color rojo fijo • El perno que detiene la cuchilla de la sierra está acoplado • Si la cuchilla de la sierra y los componentes integrados se detienen según lo esperado, repita el procedimiento para probar todos los paros de emergencia indicados en paso 3.

  • Page 49: Zona Restringida

    HORNET II: SEGURIDAD Zona Restringida DANGER Manténgase afuera 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. Asegúrese que no haya personal en la zona restringida antes de operar el equipo.

  • Page 50: Marcar La Zona Restringida

    HORNET II: SEGURIDAD Marcar la zona restringida La zona restringida deberá marcarse de tal manera que todas las personas que se encuentren cerca del equipo puedan ver claramente el área donde pueda haber peligro. Refiérase a la página XX. Información adicional Definiciones de los símbolos de seguridad página (Safety Symbols Definitions)

  • Page 51: Introduction

    In order for this manual to be useful, the appropriate sections must be easily accessible by operators and maintenance personnel. This manual addresses the most recent version of the equipment as of the date listed on the title page. For earlier revisions, contact MiTek as described on page Original Instructions: 001079 rev. A...

  • Page 52: Understanding The Manual

    HORNET II: INTRODUCTION Understanding the Manual Hyperlinks References to page numbers throughout the manual can be selected to immediately take you to the relevant section. The Drawing Set A list of drawings can be found in the back of this equipment manual or in a separate 11x17 binder.

  • Page 53: Operator Training Outline

    HORNET II: INTRODUCTION Operator Training Outline This training outline is intended to help MiTek Installation Technicians guide the training of machine operators during initial installation of a machine. Click on text in (parentheses) to jump to a specific section. Subject Training and Related Links •...

  • Page 54: Additional Resources

    HORNET II: INTRODUCTION Additional Resources Website Visit the MiTek website for up-to-date information on all MiTek equipment. You may also find the following information there: • The latest revisions of this manual • Service bulletins pertaining to your equipment • Support, safety, and training information •...

  • Page 55: General Information

    General Information Introduction to the Equipment Purpose of the Equipment The Hornet II saw is used for cutting and marking in both wall panel applications. The system can cut/mark common wall panel framing parts such as sills and headers. Description of the Equipment...

  • Page 56: Main Components

    HORNET II: GENERAL INFORMATION Main Components Graphical Overview Figure 4-1: Main Components of the Hornet II Saw Optional Components on page 49 for graphics of other components not shown here. Descriptions Table 4-1 lists some of the main components that are included with all versions of this equipment.

  • Page 57: Optional Components

    Figure 4-2: Auto Loading Live Deck (Infeed Component) Descriptions Table 4-2 lists some of the optional components that may be added at the point of sale. Contact MiTek for more information. Table 4-2: Optional Components Component Description 5’ Outfeed Table An optional length extension for the outfeed table.

  • Page 58: Technical Specifications

    HORNET II: GENERAL INFORMATION Technical Specifications Table 4-3: General Specifications Specification Data Saw blade 508 mm diameter (20”) Pusher accuracy +/- 1/16” Angle accuracy +/- 0.1 degree Printers (Edge and Bottom Plate) 4 print heads Table 4-4: Lumber and Cut Capacity Specification Data Edge of board...
  • Page 59 HORNET II: GENERAL INFORMATION Table 4-8: Dimensional Specifications Saw Unit 3.19’ L x 3.33’ W x 6.01’ System: Saw, 20’ infeed rail, 20’ Outfeed 59.78’ L x 3.25’ W x 6.48’ table System: Saw, 20’ Infeed Rail, 20’ Outfeed 59.78’ L x 10.58 W’ x 6.48’ table, Auto Loading Live Deck Table 4-9: Approximate Weight Specifications Specification...

  • Page 60: Requirements To Meet For Installation

    Your Responsibilities During Installation MiTek supervises the installation to ensure that the system is installed properly and operates correctly. MiTek will also provide operating and maintenance training at the time the equipment is installed. The customer is responsible for providing all labor and equipment needed to complete the installation.

  • Page 61: Startup Procedures

    WARNING Do NOT attempt to start the system for the first time without a MiTek representative present. Starting the system without a MiTek representative present may result in equipment damage, serious injury, and/or death. Marking Restricted Zone The restricted zone must be marked and maintained so everyone near the equipment can clearly see the area where danger may exist.

  • Page 62: Operation

    CHAPTER 6 PERATION Safety Operating Notes WARNING ELECTROCUTION, HIGH PRESSURE, CRUSH, CUT, AND CHEMICAL HAZARDS. Read this section AND the safety section in the preliminary pages before operating or maintaining this machine. 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 63: Safety-Related Operating Procedures

    HORNET II: OPERATION Safety-Related Operating Procedures Stopping Methods The Hornet II Saw stops movement using a controlled stop or an emergency stop (E-stop). A controlled stop may be slower than an emergency stop, but a controlled stop is the preferred stopping method unless there is a safety emergency. Using an E- stop to stop the machine regularly may cause excessive wear on components.
  • Page 64 HORNET II: OPERATION Figure 6-2: How to Operate an E-Stop Pushbutton To activate a pushbutton, push the button in. The machine no longer operates. To release a pushbutton, twist the push button (left), or pull the pushbutton to release (right). Restart After E-Stop Procedure 1.

  • Page 65: Electrical Disconnect Switches

    HORNET II: OPERATION Electrical Disconnect Switches There is one disconnect switch located on the Hornet II. It is located on the main electrical enclosure. Figure 6-3: Everything You Need to Know About Disconnect Switches Electrical Enclosure Disconnect Switch Turning the disconnect handle to the On position supplies electrical power to the entire machine.

  • Page 66: Interlocked Doors Or Guards

    HORNET II: OPERATION Interlocked Doors or Guards Overview The following doors and guards located on the saw chamber are interlocked with the safety system to prevent entry while components are moving: • Front saw chamber door • Rear saw chamber door •...

  • Page 67: Safety-Related Indicators On The Machine

    HORNET II: OPERATION Safety-Related Indicators on the Machine This section covers the visual indicators that communicate important information about the status of the machine. Control Interface Indicator Lights The lights located on the operator interface indicate the following: E-STOP: Red light turns on when an E-stop is activated. This light must be off before the machine can operate.

  • Page 68: Hardware Overview

    HORNET II: OPERATION Hardware Overview Operator Hardware Controls This section describes the hardware controls available to an operator in a complete system. Figure 6-6: Operator Interface Controls Table 6-1: Description of Operator Interface Controls Name Function E-stop Stops all movement of the entire Hornet II. Reset Restores the safety controller and re-enables main power to the system.

  • Page 69: Powering Up Or Down

    HORNET II: OPERATION Auto Loading Live Deck (If Equipped) The Auto Loading Live Deck operation is integrated within the machine software in when in Auto mode, but manual operation occurs at the control station shown Figure 6-7. Figure 6-7: Auto Loading Live Deck Controls Table 6-2: Description of Auto Loading Live Deck Controls Name Function...

  • Page 70: Software Overview

    This section covers the CutBuilder softer that is accessible through the Hornet II control interface. This software controls all of the main components that comprise the Hornet II saw. The Hornet II control interface is designed as a touch-first device, but it can also be used with a mouse and keyboard (not recommended).

  • Page 71: Job Manager

    Contact information for machine support. Remote Support Opens a browser window to a service that allows for remote support with a MiTek representative. Job Manager The job manager is used to generate jobs for processing. Jobs can be imported from a file or manually created.
  • Page 72 HORNET II: OPERATION Figure 6-9: Job Manager • Import Jobs Displays a file explorer for importing jobs. The following file types are supported: • Shopnet • Virtek (limited support) Jobs can be imported via a USB drive or over the network.

  • Page 73: Jobs And Bundles

    HORNET II: OPERATION • Location Jobs can be categorized using the following locations: • Active includes currently loaded jobs available for processing. • Trash includes jobs that have been discarded. Jobs can be placed in the trash by selecting and dragging them to the trash can icon.

  • Page 74: Material Type And Part Type

    HORNET II: OPERATION Figure 6-12: Jobs and Bundles Sections The jobs section always has two items available - the Asterisk and Scrap Cutting • * (Asterisk) Selects every job available. • Scrap Cutting Selects items designated for scrap cutting. See Optimization and Scrap Cutting on page 81 for more information on utilizing scrap cutting.
  • Page 75 HORNET II: OPERATION Selecting different part types will also change what appears on the Cut Parts tab. Cut Sets and Cut Parts on page 68 for more information. Figure 6-13: Material Type and Part Type Sections Selecting Material Types Once the desired material types for the job are selected, they will be highlighted blue.

  • Page 76: Cut Sets And Cut Parts

    HORNET II: OPERATION Cut Sets and Cut Parts After loading a job, then selecting the desired material types and part types, the Optimize button in the cut sets section will blink (see Figure 6-15). Selecting the optimize button will optimize the job for the least amount of waste based on what materials and lengths were selected.

  • Page 77: E-Stop Indicator

    HORNET II: OPERATION • Drop The length of waste (does not include intended scrap cuts). • Material The intended material type for that cut set. Double-tap the picture icon to display a pop-up with an image of what will be marked on the part. See Operating the Printer on page 80 for more information regarding marking.

  • Page 78: Printer Configuration

    HORNET II: OPERATION Figure 6-19: E-stop Indicator Screen Printer Configuration Clicking the printer configuration button (see Figure 6-18) will display a window with a depiction of each printer side by side. Selecting the information (I) button will display the current ink levels and cartridge status. Load Sets The load set function is used to start the job for processing after selecting from the available items from jobs, bundles, material type, and part type.
  • Page 79 HORNET II: OPERATION Figure 6-20: Load Cut Sets • Cut Sequence Displays information regarding what the saw is currently processing. It will also display error messages if the saw is unable to start or continue processing material. • General Features a reset button that will be highlighted red when there is a fault.

  • Page 80: Menu Bar In Detail

    HORNET II: OPERATION • Message • Close Closes the load set dialog box. • Infeed Control Allows for manual control of the auto loading live deck (optional) (if equipped). Menu Bar in Detail Figure 6-21: Menu Bar E-stop Indicator on page 69 Printer Configuration on page 70 for more information regarding those menus.

  • Page 81: System Diagnostics

    HORNET II: OPERATION • Hornet Saw A compressive list of all alarms with diagnostic Alarms information. • Toolbar Tools for managing and organizing the alarm list. System Diagnostics The system diagnostics window display will change depending on which menu is selected.
  • Page 82 HORNET II: OPERATION • Saw table rotation Figure 6-24: Manual Control Window Motion Main The motion main menu displays general and individual access states using the color red to indicate a fault. It also has a function for resetting the saw and enabling drives.
  • Page 83 Calibrating on page 90 for additional information regarding calibration. • Material Allows for changing the plunge speed and material Definitions type definitions. • MiTek For troubleshooting purposes. Only to be accessed by Maintenance MiTek support. Original Instructions: 001079 rev. A...
  • Page 84 HORNET II: OPERATION Settings Figure 6-27: Settings Window • Materials Change the properties of the available material types, including thickness, width, and grade. • Print Marking Change what information is printed on the processed material. See Operating the Printer on page 80 additional information regarding the print marking menu.

  • Page 85: Operating Procedure

    • Restart Computer Restarts the computer. Operating Procedure This section instructs operators how to effectively use the Hornet II saw. Note that this manual only addresses the use of the Hornet II. It does not address methods of designing or building a truss.

  • Page 86: Specialized Operating Procedures

    Specialized Operating Procedures Loading Material The Hornet II saw is designed to cut boards stacked 2-high. Keep in mind the following guidelines when loading material. • The Hornet II saw can process dimensional lumber up to 4x and 12”...
  • Page 87 HORNET II: OPERATION • Ensure all material used has no staples or pooled water. Staples can damage the print heads. • When loading material directly onto the infeed rail, ensure they are not stacked flush against the infeed pusher, and are tight up against the fence line.

  • Page 88: Operating The Printer

    HORNET II: OPERATION Operating the Printer The printer(s) print identification on each board as it enters the saw unit. Each saw is equipped with an edge printer and may have an optional bottom plate printer. To turn the printer(s) off, or back on, go to Settings > Marking Device Settings and check or uncheck Marker Enabled in the CutBuilder software.

  • Page 89: Optimization And Scrap Cutting

    Allows for changing the font size for different fields. Changing the font size is not recommended unless directed to by MiTek support as it may cause issues with print clarity. • Check or uncheck the box next to desired field to enable or disable it for marking.
  • Page 90 HORNET II: OPERATION Optimization attempts to generate cut sets with the least amount of waste. Waste is defined on the cut sets as ‘drop’ and does not include designated scrap cuts. Because scrap cuts are not considered waste, the scrap cut settings effect optimization and waste percentage.

  • Page 91: Optimization Options

    HORNET II: OPERATION Optimization Options The optimization options menu can be viewed by selecting the Options button, as seen in Figure 6-37. Ensure “Less Waste Optimizing” is selected under Cutting for best results. Figure 6-36: Cut Set Optimization Options The scrap cutting menu (Figure 6-37) under Cutting can be used to configure scrap cuts based on material and length.
  • Page 92 HORNET II: OPERATION Figure 6-38: Pick List Example Under Sorting, a sorting profile that determines how the cut sets are sorted can be selected. The Cut Sorting Profiles menu can be used to create new sorting profiles. See Figure 6-39. Figure 6-39: Cut Sorting Profiles Menu Original Instructions: 001079 rev.

  • Page 93: Maintenance

    OSHA CFR 1910.147 before continuing with the procedure. Overview Graphics Graphical Overview on page 48 for an overview on the main and optional components of the Hornet II saw. Original Instructions: 001079 rev. A...
  • Page 94 Maintenance Terminology The orientation and enclosure terminology in Figure 7-1 will be utilized throughout the maintenance section when referring to the different sides and enclosures of the Hornet II saw. Figure 7-1: Orientation and Enclosure Terminology Original Instructions: 001079 rev. A...
  • Page 95 HORNET II: MAINTENANCE Major Components The following graphics call out major components that will be referenced throughout the maintenance chapter. Figure 7-2: Major Components Visible from Infeed Side of Saw Figure 7-3: Major Components Visible from the Outfeed Side of Saw Original Instructions: 001079 rev.
  • Page 96 HORNET II: MAINTENANCE Figure 7-4: Major Components Visible from the Main Area of Saw Original Instructions: 001079 rev. A...

  • Page 97: Cleaning And Inspecting

    HORNET II: MAINTENANCE Cleaning and Inspecting Cleaning Saw Dust and Debris It is important to blow off and vacuum the equipment daily. Saw dust acts as an insulator and will prevent electrical components from working properly, and debris causes mechanical jams. CAUTION CRUSH AND CUT HAZARD Always replace guards after completing maintenance and before...

  • Page 98: Cleaning Surfaces

    HORNET II: MAINTENANCE Cleaning Surfaces If it should become necessary to clean the surfaces of this machine, disconnect it from its power source first. Do not use liquid cleaners, aerosols, abrasive pads, scouring powders or solvents, such as benzene or alcohol. Use a soft cloth lightly moistened with a mild detergent solution.
  • Page 99 HORNET II: MAINTENANCE Figure 7-5: MotionConfig Menu and the Calibration Sequence Area An automatic calibration will calibrate all of the major systems of the saw. To perform an automatic calibration, use the following procedure: 1. Open the Motion Main menu. See Figure 7-5.
  • Page 100 HORNET II: MAINTENANCE The Calibration Sequence area on the Calibration Routine screen will indicate which part of calibration the machine is currently performing. • No calibration taking place • Jogging rotate to endstop Currently calibrating the saw rotation table. • Jogging pusher forward Currently calibrating the pusher position in to printer photoeye relation to the printer photoeye sensor.

  • Page 101: Lubricating

    HORNET II: MAINTENANCE Figure 7-7: Enable Drives and Rotate Position 6. Enable the drives by pressing the Enable Drives button (see Figure 7-7) and re-start the calibration using the Start Auto Calibration button. 7. “No calibration taking place” will display in the Calibration Sequence area and the Start Auto Calibration button will no longer be green when calibration is complete.

  • Page 102: Motors And Gearboxes

    HORNET II: MAINTENANCE Motors and Gearboxes Motor Locations Figure 7-8: Front and Rear View of Saw Original Instructions: 001079 rev. A...
  • Page 103 HORNET II: MAINTENANCE Motor Maintenance Table 7-1: Overview of Motor Maintenance Motor Gearbox (if Requires Grease Requires Oil present) Infeed Pusher Saw Blade Auto Loading Live Deck (if equipped) Saw Table Rotation Checking and Changing Gearbox Oil Check the oil in the gearboxes once every 12 months (one shift) or every 6 months (two shifts).

  • Page 104: Saw Blade

    HORNET II: MAINTENANCE Drain and refill the oil every 20,000 hours or 4 years. Each gear motor includes a level plug and drain plug. Note that the exact location of each plug will vary between motors. The approximate amount of oil is listed in Table 7-3.
  • Page 105 HORNET II: MAINTENANCE Spec Description Dimension Kerf (blade thickness) 4.57 mm (.180”) Z= qty of teeth Ø = diameter of center hole 31.75 mm SK = keyways Hook 10º Face angle 0º Top angle 15º Angle left-to-right 10º (or right-to-left) of ATB* RPM max 3500 rpm Model # of saw blade...
  • Page 106 HORNET II: MAINTENANCE Front of Saw Chamber Direction of Teeth 4 Saw Blade Bolts (shown in green) Torque to 31ft-lb 10. Remove the saw blade and follow the below instructions to determine whether it should be discarded or kept for resharpening: CAUTION CUT HAZARD.
  • Page 107 HORNET II: MAINTENANCE 12. Place the new or sharpened saw blade so the holes align with the holes in the hub and the teeth hook points upward. See Figure 7-9 for the correct orientation. WARNING Use ONLY the bolts included in the saw blade kit. Use NEW bolts every time the blade is replaced.

  • Page 108: Printer

    Calibrating on page Printer Ordering Supplies To order supplies for the Hornet II printer, contact REA JET directly. MiTek does not sell the ink. Once an account is set up, future orders can be placed by providing a PO either of the ways listed here.

  • Page 109: Placing Your First Supplies Order Through Rea Jet

    Consumable supplies (ink) must be purchased from either REA JET or a local distributor prior to the saw’s installation, and it MUST be present at the installation of the saw. MiTek does not sell the ink. The most efficient way to place your first order is as follows.
  • Page 110 HORNET II: MAINTENANCE Figure 7-11: Bottom Plate and Edge Printers The printer enclosures contain pen stalls that the ink cartridges are inserted into. The ink cartridges directly mark a print target according to the signals received from the control unit(s). Each printer has 4 pen stalls and 4 ink cartridges. The part of the ink cartridge that is exposed and marks the material is commonly referred to as a print head.

  • Page 111: Maintaining The Printer

    HORNET II: MAINTENANCE Maintaining the Printer General Maintenance Reminders • Always wear safety glasses and rubber gloves when handling ink. • If ink makes contact with a person’s skin, hair, eyes, or clothes, refer to Treatment for Hazardous Substances on page •...
  • Page 112 HORNET II: MAINTENANCE 1. Ensure the printer is completely powered off before cleaning the print heads. 2. Using distilled or deionized water, dampen a non-abrasive, lint-free cloth. Ensure it is not a dry cloth may cause scratches. You may wish to fold the cloth in quarters to prevent ink penetrating through.
  • Page 113 HORNET II: MAINTENANCE Figure 7-15: Pen Stall Lever 3. Gently pull up (at a 45 degree angle) on the top of the ink cartridge to remove it if necessary. 4. To place an ink cartridge into the pen stall, gently insert it at the same angle as removal (where the far end drops into the carriage first) and push down.

  • Page 114: Bearings (Lubrication)

    A thin film of grease should be visible on the guide rails at all times Because the linear bearings require frequent lubrication and can be damaged by overgreasing, MiTek recommends the following grease and grease gun be used. Grease Recommended Mobilux™ EP 2...

  • Page 115: Motor Arbor And Pivot Bearings

    HORNET II: MAINTENANCE Table 7-6: Grease Volume Per Bearing Size Linear Bearing Size Amount Bottom Plate Printer (size 20) 0.5 cm Manual grease Location and Number No.2 lithium- based grease Table 7-7: Assemblies Lubricated by Linear Guide Bearings Lubricated Assembly Qty.

  • Page 116: Auto Loading Live Deck (If Equipped)

    HORNET II: MAINTENANCE Figure 7-17: Motor Arbor and Pivot Bearings Location Auto Loading Live Deck (if equipped) The auto loading live deck bearings should be lubricated every month (one shift). Manual grease Use a grease gun to apply grease to the fittings shown in Figure 7-18.

  • Page 117: Auto Loading Live Deck Drive Shaft (If Equipped)

    HORNET II: MAINTENANCE Auto Loading Live Deck Drive Shaft (if equipped) Lubricate the auto loading live deck drive shaft bearings with #2 Lithium-based grease once a year. There is 1 grease fitting on each end of the drive shaft. See Manual grease Figure 7-18 for the drive shaft bearing location.

  • Page 118: Wheels

    HORNET II: MAINTENANCE Figure 7-20: Squeezer Arm Bearings Location Wheels Lubricating Wheels Support and Tracking Rollers There are 4 support and tracking rollers that support the rotating saw table. The rollers should be lubricated every month (one shift). Use a grease gun to apply of grease to the fittings shown in Figure 7-21.

  • Page 119: Belts

    HORNET II: MAINTENANCE Belts Blade Belt Replacement 1. Lockout/tagout. 2. Remove the guard between the motor and saw blade by removing the bolts indicated in Figure 7-22. Note that the guard has sensors that need to be removed before the guard can be removed. See Figure 7-34 on page 122.

  • Page 120: Wear Items

    HORNET II: MAINTENANCE Figure 7-23: Blade Belt Replacement 7. Pry the tensioner in Figure 7-23 to adjust the belt tension. The play for the blade belt should be approximately 1/4”. 8. Re-install the guard and sensors. Wear Items Brushes Brushes exist at some openings and rails to keep scrap and other debris from accidentally entering the saw chamber or causing an obstruction.
  • Page 121 HORNET II: MAINTENANCE Figure 7-24: Brush Location Examples (Saw Chamber) Replacing Brushes 1. Remove bolts securing existing brush. Retain for re-installation. 2. Remove and discard existing brush. 3. Use bolts removed in step 1 to install the new brush. Original Instructions: 001079 rev. A...

  • Page 122: Pneumatic System

    HORNET II: MAINTENANCE Pneumatic System CAUTION HIGH PRESSURE HAZARD. Bleed all pressure from pneumatic lines before performing maintenance on pneumatic components. Pressurized components may move suddenly or vent air to atmosphere, causing injury. The pneumatic system controls all of the components listed in Figure 7-8.

  • Page 123: Maintaining The Filter / Regulator

    Figure 1-5 on page 10 for an example. Maintaining the Filter / Regulator Purchasing a Filter / Regulator The filter/regulator can be purchased directly from MiTek. Refer to the Ordering Parts on page 194 for instructions on ordering parts. Adjusting the Pressure on the Filter / Regulator The pressure adjustment knob on the filter / regulator controls the operating pressure for the entire pneumatic system.
  • Page 124 Replacing Filter Element on the Filter / Regulator The regulator uses a filter that must be replaced every 6 months. This filter can be purchased through MiTek. Refer to the Ordering Parts on page 132 instructions on ordering parts. Use the following procedure to replace a filter element.

  • Page 125: Adjusting The Main Pressure Sensor

    HORNET II: MAINTENANCE 3. Unscrew the black plastic baffle holding the filter element and remove it from the regulator. Figure 7-27: Filter Element with Bowl Removed 4. Replace the filter element. Screw the black plastic baffle back into place. 5. Place the bowl back onto the regulator body by pushing up and turning. Make sure bowl is secure and the blue tab is in the locked position before returning pressure to the lines.
  • Page 126 HORNET II: MAINTENANCE Figure 7-28: Pressure Sensor Adjustment on Main Filter/Regulator Assembly 4. Replace the filter element. Screw the white plastic baffle back into place. 5. Place the bowl back onto the regulator body by pushing up and turning counterclockwise. Make sure it is secure before returning pressure to the lines.
  • Page 127 HORNET II: MAINTENANCE Figure 7-29: Additional Regulators 1. To adjust the regulator pressure, pull down on the black knob of the desired regulator and turn it either CLOCKWISE or COUNTERCLOCKWISE: • Turn the knob in a clockwise direction to decrease pressure •...

  • Page 128: Electrical System

    HORNET II: MAINTENANCE Electrical System A complete list of sensors is found in Figure 7-9. They are arranged in approximate order from the infeed to the oufeed side of the machine (facing the machine). Photos are shown on subsequent pages. Sensor Overview Table 7-9: Sensors List Sensor Name...
  • Page 129 HORNET II: MAINTENANCE Figure 7-32: Rear of Saw Sensors Figure 7-33: Fenceline/Infeed Sensor The infeed sensor features a blow-off to prevent sediment forming that generates false positives. Original Instructions: 001079 rev. A...

  • Page 130: Electrical Enclosures

    HORNET II: MAINTENANCE Figure 7-34: Saw Arm Sensors Electrical Enclosures VFD (Variable Frequency Drive) NOTICE Do not modify any parameters on any VFDs unless instructed by Automation Support! A VFD is an important part of several electrical circuits in the Hornet II. Verifying the voltage in and out of the VFD is always a good first step in the electrical troubleshooting process.
  • Page 131 HORNET II: MAINTENANCE Figure 7-35: Main Electrical Enclosure Figure 7-36: Operator Panel Electrical Enclosure Original Instructions: 001079 rev. A...
  • Page 132 HORNET II: MAINTENANCE Figure 7-37: Printer Controller Electrical Enclosure Original Instructions: 001079 rev. A...

  • Page 133: Troubleshooting

    Troubleshooting Getting Started with Troubleshooting If you have reviewed the information in the Maintenance chapter and this chapter but have not solved your problem, please call MiTek Machinery Division Customer Service for assistance. Safety Notes for Troubleshooting Read the safety section starting on page...

  • Page 134: Tools Required

    When the toolbox shown in the margin appears, you should gather the tools listed below it before beginning the procedure next to which it appears. Before beginning the troubleshooting process or calling MiTek Machinery Division Customer Service, gather the following tools: •...

  • Page 135: First Steps

    HORNET II: TROUBLESHOOTING First Steps Mechanical Troubleshooting Always clean and lubricate the equipment as a first step in most troubleshooting processes. Most mechanical malfunctions are caused by inadequate preventative maintenance. Electrical Troubleshooting 1. Lockout/tagout at the disconnect switch located on the equipment. NOTICE Never use compressed air inside an electrical enclosure.

  • Page 136: Maintenance Checklist

    CHAPTER 9 Maintenance Checklist Using the Maintenance Checklists Copy these checklists and place the copies with the Hornet II. Leave the original checklists in this manual for future use. Checklist Daily Checklist on page 129 Weekly Checklist on page 130 Monthly Checklist on page 131 Safety Notes for the Maintenance Checklists WARNING...

  • Page 137: Daily Checklist

    Hornet II: Maintenance Checklist Should you lockout/tagout to perform this action safely? Daily Checklist WARNING Lockout/tagout before performing maintenance. Month and year __________ If power is required, make sure all personnel are clear of the restricted zone. Week of __________ Action Shift Page...

  • Page 138: Weekly Checklist

    Hornet II: Maintenance Checklist Should you lockout/tagout to perform this action safely? Weekly Checklist WARNING Lockout/tagout before performing maintenance. Year __________ If power is required, make sure all personnel are clear of the restricted zone. Action Page Initials / Date Inspect linear bearing rails for lubricant (bottom plate printer) Replace saw blade...

  • Page 139: Monthly Checklist

    Hornet II: Maintenance Checklist Should you lockout/tagout to perform this action safely? Monthly Checklist WARNING Lockout/tagout before performing maintenance. Year __________ If power is required, make sure all personnel are clear of the restricted zone. Action Months Months Page Initials / Date (one shift) (two shifts) Check Auto Loading Live...

  • Page 140: Parts List

    APPENDIX 10 Parts List Ordering Parts Use the MiTek web site to locate parts and part numbers, then order them using one of these methods: By E-Mail By Phone Send an e-mail to mitekparts@mii.com with all Call relevant information, 1-800-523-3380.
  • Page 141 Drawings are inserted in the back of the manual or included in a separate binder, depending on the machine. Description Drawing Number Mechanical - RTL* Drawings are 501 and LTR** Drawings are 502 Hornet II Saw Assembly 76720-501/502 Sweeper Table 76687-501/502 Sweeper Assembly...
  • Page 142 Glossary affected employee an employee whose job requires him or her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him or her to work in an area in which such servicing or maintenance is being performed amperage the strength of an electric current, expressed in amperes...
  • Page 143 HORNET II: GLOSSARY lockout device a device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment, including blank flanges and bolted slip blinds; should be standardized within the facility in at least one of the following criteria: color;...
  • Page 144 HORNET II: GLOSSARY stand-alone conveyor the conveyor system that carries the truss from the tables to the Finish Roller and out to the stacker tagout device a prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until...

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