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H28SV & H32SV 393188 THANK YOU, On behalf of everyone at HYD·MECH Group Limited, we would like to thank and congratulate you on your decision to purchase a HYD·MECH bandsaw. Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to reduce cost while boosting quality and productivity.
SECTION 0 - SAFETY INSTRUCTIONS SUMMARY All persons operating this machine must have read and understood all of the following sections of this Manual: Section 0 SAFETY Section 2 OPERATING INSTRUCTIONS However, as a memory aid, the following is a summary of the Safety Section. Put Safety First Mandatory Information –...
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FOREWORD Put Safety First! This Safety Section contains important information to help you work safely with your machine and describes the dangers inherent to bandsaws. Some of these dangers are obvious, while others are less evident. It really is important to PUT SAFETY FIRST. Make it a habit to consider the hazards associated with any action BEFORE you do it.
Manual, and When all operations and procedures are in compliance with this Manual. Hyd-Mech Group cannot accept any liability for personal injury or property damage due to operator errors or non-compliance with the Safety and Operating Instructions contained in this Manual.
Define responsibilities Clearly define exactly who is responsible for operating, setting-up, servicing and repairing the machine. Define the responsibilities of the machine operator and authorize him to refuse any instructions by third parties if they run contrary to the machine’s safety. Persons being trained on the machine may only work on or with the machine under the constant supervision of an experienced operator.
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Clothing, jewellery, protective equipment Personnel operating or working on the machine must not wear un-restrained long hair, loose-fitting clothes and dangling jewellery. When operating or working on the machine, always wear suitable, officially tested personal protective equipment such as safety glasses and safety boots and any other equipment required by plant regulations.
On Hyd-Mech machines the Master Disconnect Switch will be of one of four types: • Rotary switch mounted in electrical control cabinet door and inter-locked with door.
MOVING BANDSAW BLADE WILL CUT Do NOT operate with guard removed. Do NOT place hands or fingers near moving bandsaw blade. For blade changing, always follow the proper Blade Changing Procedure, as given in Section 3 of this manual. PINCH POINT Machine parts may move without warning, either because the machine is operating automatically, or because another person initiates the motion.
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Item N0. 391938 Located on the cover of the main electrical panel.
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Item N0. 391340 Idler Guide Arm Drive Guide Arm Item N0. 391937...
MAINTAIN PROPER ADJUSTMENT OF BLADE TENSION, BLADE GUIDES, AND BEARINGS • HOLD WORKPIECE FIRMLY AGAINST TABLE. • DO NOT REMOVE JAMMED CUTOFF PIECES UNTIL BLADE HAS STOPPED. NO MODIFICATIONS TO THE MACHINE ARE PERMITTED WITHOUT PRIOR APPROVAL FROM HYD-MECH. ANY APPROVED MODIFICATIONS SHOULD ONLY BE UNDERTAKEN BY TRAINED PERSONNEL.
FOUNDATION, LEVELLING AND ANCHORING The machine location should be carefully selected. A flat concrete floor area should be chosen. It should have enough free space surrounding the machine to enable free access for safe operation and maintenance. Machine should be leveled in both directions i.e. along and across its in-feed conveyor especially when machine is to be inserted into a larger conveyor system.
H28SV & H32SV DISCONNECT SWITCH INSTALLATION Due to shipping, the machine disconnect box has been removed and is located on top of the hydraulic compartment. Mounting Bolts 1. Remove all four mounting bolts. 2. Push gray conduit back into hydraulic compartment.
WIRING CONNECTIONS After the machine is leveled and anchored the necessary power hook-up needs to be performed. In order to provide safe operation as well as to prevent potential damage to the machine, only qualified personnel should make the connections. BEFORE START-UP THE FOLLOWING TWO POINTS SHOULD BE CHECKED: 1.
EARTH GROUNDING PROCEDURE The customer is to provide and install a ground rod approximately .60 (15mm) diameter, copper clad steel, to be driven no less than 8’ (2.5m) into the ground, no more than 10’ (3m) away from control enclosure. The ground rod is to be connected to customer’s in plant ground system.
SECTION 2 - OPERATING INSTRUCTIONS This section has been prepared to give the operator the ability to set up the saw for most cutting situations. Before cutting any material, the operator should be familiar with all operations and controls as well as the basic cutting theory described below.
ENABLE This ENABLE push button must be pushed and held simultaneously with the “FRONT VISE OPEN or CLOSE” switch in order for the vise to move. If either the ENABLE button or the FRONT VISE switch are released, then the vise will stop moving.
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HYDRAULIC START To start the hydraulic system, the switches for the head and both vises must be in the “NEUTRAL” position. The “HYDRAULIC START” button must be depressed and held in momentarily until the PLC display becomes active. CYCLE START / PAUSE To start the Automatic cycle, simultaneously press the ENABLE and the CYCLE START push buttons.
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WORK LAMP This switch has two positions, OFF and ON. BLADE CHANGE MODE This lock is provided for the safety of the operator during the blade changing procedure. When the lock is in the “ON” (I) position, the door interlocks are disabled and the only func- tions that are active are the HEAD and BLADE TENSION controls.
PLC 100 CONTROL SYSTEMS NOTE: This instruction manual is applicable to the H-18/22 SV equipped with a MITSUBISHI PLC. OPERATION OVERVIEW DISPLAY WINDOW NAVIGATION KEYS ENTER KEY The PLC is a programmable logic controller which allows the operator to run the machine in both manual and automatic modes.
ACTIVATING THE PLC Position the head, fixed vise, and shuttle vise switches to the NEUTRAL (center) positions. If any of these switches are not in the NEUTRAL position, the hydraulics will not start. The PLC control will become active when the HYDRAULIC START button is depressed and “held in”...
SINGLE PART CYCLE OPERATION In MAN mode, the PLC allows the operator to initiate a “Single Part Cycle” to cut one piece at a desired length. To accomplish this, follow the procedure below. 1. A trim cut should be made before initiating the “Single Part Cycle” operation. 2.
AUTOMATIC OPERATION When the FRONT VISE Closed is activated and the AUTO/MAN button is pressed, the red indicator light above it will come on, and the blade will stop if it has been running. The screen will change to the JOB display window as shown below and be ready for editing or starting a new job.
WORKING WITH A QUEUE The purpose of a QUEUE is to allow the operator to run several jobs (max of 5) in series if they are of the same material and shape. In AUTO mode, press the key below the word “QUE” on the display and the display window will appear as shown. If you choose to VIEW the QUEUE, press the key below the words “VIEW QUE”...
SHUTTLE EMERGENCY STOP A second emergency stop push button is mounted to the shuttle above the shuttle vise cylinders. This mushroom button stops the blade and hydraulic motors. Both vises will hold their position but, pressure will begin to fall off. Long pieces of work should always be supported so they will not become loose over time and fall while the machine is shut down.
CUTTING PARAMETERS CHART A full size CUTTING PARAMETERS CHART is mounted on the front of the saw. The chart contains five steps for the operator to follow in order to achieve optimum performance of the saw. These steps are detailed on the following pages. Saw Cutting Parameters Chart CHART EXAMPLE #1 We will use the parameters chart to set up the saw for cutting 8”...
STEP 2: SET FEED FORCE LIMIT The Feed Force Limit is the maximum amount of force with which the head is allowed to push the blade into the work-piece. CUTTING SOLIDS For cutting solids, the wider the section, the less FF should be set, to avoid blade overloading. See the graph below. % OF FF SETTING (INDICATED...
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STEP 3: DETERMINE OPTIMUM BLADE PITCH - TEETH PER INCH (T.P.I.) Selecting a blade with proper tooth pitch is important in order to achieve optimal cutting rates and good blade life. For cutting narrow or thin wall structural materials a fine blade with many teeth per inch (T.P.I.) is recommended. For wide materials a blade with a coarse pitch should be used.
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STEP 4: DETERMINE OPTIMUM BLADE SPEED, V (ft/min) (m/min) The relationship between optimum blade speed and effective material width for various materials is represented on the graph shown. The graph shows that as effective material width gets wider or as material gets harder, lower blade speeds are recom- mended.
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The following table gives examples of the optimum blade speeds for different materials. MATERIALS OPTIMUM BLADE SPEED (ft/min) (m/min) 5” (125mm) Diameter Solid Carbon Steel 12” (300mm) I-Beam 4” x 4” (100mm x 100mm) Rect. Tube 1/4” (6mm) Wall 4” (100mm) 400 Stainless Steel 2”...
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FEED RATE, continued If the saw is fitted with a blade coarser than optimum (e.g.: 1.4/2.5 TPI) we can still use the graph, but we go to the 1.4/2.5 curve. As a result we find that the FEED RATE is decreased to 1.3 in/min (133mm/min) for this blade. If however, the machine is fitted with a finer than optimum blade (e.g.
ADDITIONAL CUTTING SETUP EXAMPLES, continued EXAMPLE # 3 Material: Bundle low carbon steel 2” x 2” Tube with 1/4” wall, 12 piece bundle (50mm x 50mm with 6mm wall) Dimensions: 6” x 8” (150mm x 200mm) Effective Material Width: 5” ( .6 X 8” ) 120mm (.6 x 200) Step 1 Feed Force limit setting for 8”...
HEAD UP and DOWN LIMIT SETTING The head up limit is used to restrict the distance the head travels for each stroke. It can be adjusted at any time by moving the switch trip plate to any position on the vertical bar. The trip plate & switches are found behind the head on the drive end near the gear box.
BUNDLING OPERATION (OPTION) The bundling vises can be operated in direct conjunction with the front and shuttle vises or at a slower clamping speed. Either bundling can be turned on or off at any time. The on / off valves are shown in the photos. The speed at which the bundling jaws open and close can be adjusted as required by turning the flow control valves (shown in the photos) for each bundling cylinder.
SECTION 3 – MAINTENANCE SAFETY DURING MAINTENANCE AND TROUBLESHOOTING “Lock-out”, or “Lock-out Tag-out” are terms that refer to procedures taken to prevent the unexpected start-up, or other release of energy, by a machine, whenever anyone is required to remove or bypass safety guards or devices, or whenever anyone is required to place part of his body in a hazard area.
RESTORING MACHINE TO USE After completion of all repairs or maintenance to the locked-out machine, it shall be restored to use as follows: The person(s) who performed the work shall verify that all areas around the machine are safe, before the machine is re-energized.
BLADE REMOVAL 1. With the blade change mode key switch in ‘OFF’, the blade stopped and the hydraulics ON, raise the saw head until the drive door will clear the electrical control panel. 2. Open the front vise about 12”. This will provide room between the two guide arms to easily grasp the blade with two hands, BUT DO NOT TOUCH THE BLADE UNTIL THE BLADE CHANGE MODE SWITCH IS TURNED TO THE ‘ON’...
BLADE TRACKING ADJUSTMENT Blade tracking is set so the teeth of the blade protrude .340” (8.6mm) +/- .01” (.25mm) for an H28SV, and .370” (9.4mm) +/- .01” (.25mm) for an H32SV from the face of the idler and drive wheels. Adjustments should always begin with the wheel that measures farthest out of specification.
“B”, turn tension switch to “+ RUN”, run the blade for a moment and recheck the tracking. H28SV GEARBOX LUBRICATION (A603 GEARBOX) The Bonfiglioli A603 gearbox used on the saw is supplied with 15 litres (3.96 US gallons) of Mobil SHC 634 synthetic oil.
H32SV DRIVE WHEEL TRACKING Release blade tension before adjusting. Loosen support hex nuts and set screws “A”. On bolts “B”, there is a jam nut between the gearbox and mounting plate; loosen this jam nut. Turning bolts “B” out by equal amounts ¼ turn at a time and tightening set screws “C”...
LUBRICATION The design of the saw is intended to minimize maintenance, although periodically certain moving parts do require lubrica- tion. We recommend that this periodic lubrication be done once a month using any general-purpose grease. In addition to the grease points shown, vise jaw guides, infeed rollers and bundling assemblies require greasing. Shuttle Shaft Bearing Housings Idler Wheel Slider Assembly Grease Nipple...
HYDRAULIC MAINTENANCE There are only FIVE items of routine maintenance associated with the hydraulic system: 1. OIL FILTER – Ten-micron filtration of the hydraulic oil is provided by a spin-on type filter mounted on the tank return line. The element should be changed after the first 50 Hours of operation and then every 500 working hours. Suitable replace- ment elements are: CANFLO RSE-30-10...
TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Blade worn. Replace blade. Low blade tension. Tension blade. Saw is cutting out of square vertically. Blade guides. Check for worn guides. Excessive feed rate. Reduce. Saw is cutting out of Stock not square in vises. Adjust accordingly.
PROBLEM PROBABLE CAUSE SOLUTION Reload with stock or reset the blade. Hold Saw starts but will not run On machines so equipped, the out-of- the hydraulic start button and release the after Start button has been stock or blade breakage limit switch blade tension or open vises far enough to released.
PROGRAMMABLE LOGIC CONTROL Note: The PLC is equipped with a lithium battery to keep the program stored while the power is shut down. The battery will need to be replaced every 3 to 5 years, depending on the usage. A visual warning will be displayed on the interface when the battery drains to a certain level.
PLC PARAMETERS SPEED CONST Blade speed adjustment number. If the actual blade speed is different than the displayed blade speed, a new speed factor will need to be calculated (providing the WHEEL TRGETS parameter is set correctly). Actual speed ÷ display + adjustment factor X existing speed factor = New Speed Factor WHEEL TRGETS Number of targets per revolution of the idler wheel.
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FEED RATE Activates feed rate display. (Not active on S20A, S23A and H10 machines) ACTUAL POSITION If this value is set to “YES,” displays shuttle vise actual position. HOLD SHT HOME Hold shuttle VISE home and closed during cut. BRKN PROX Allows user to override signal from proximity sensor in case it is broken.
PLC TROUBLESHOOTING Problem 1 (for automatic models with a shuttle) PLC is not measuring lengths Possible causes: 1. Encoder a. Pinion gear is loose on the encoder shaft b. A bad encoder 2. Encoder Cable a. Bad connections at the encoder or the PLC b.
Problem 2 (for automatic models with a shuttle) Inaccurate Lengths in Auto Mode Possible Causes: 1. Encoder a. Pinion not engaging the rack all the way from front to back. b. Mechanical interference. c. Pinion loose on the encoder shaft. 2.
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If the display does not read as specified: - Check the encoder pinion gear to be sure it can run smoothly down the rack and that the gear and rack teeth engage over the entire travel of the shuttle. - Check that the pinion gear is tight on the encoder shaft. - Check the encoders cable connections, a loose connection could easily cause this concern.
GENERAL RULE: Lowering the parameter value = longer shuttle travel = longer parts Increasing the value = shorter shuttle travel = shorter parts Problem 3 (for P Models, disregard all references to a shuttle) Auto Cycle Not Being Completed In auto mode, the PLC controls the saw functions through output relays. For a certain function to be actuated, the PLC must first see specific input(s).
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As mentioned, beside each input and output terminal there is a bank of red LED’s. Each light corresponds to an input or output. An input LED will light when it’s specific input signal is being received at the PLC and output LED’s will light when the PLC commands specific outputs.
MITSUBISHI PLC INPUTS AND OUTPUTS Input and output terminal identification: The top row of identification labels corresponds to the top row of terminals and the bottom row of labels to the bottom row of terminals. Input and output LED numbers correspond to the input or output of the same number. I.E. input LED #0 cor- responds to input X0.
FX3U-48MR-ES INPUTS OUTPUTS Shuttle Encoder, Channel A COM1 Fused 120Vac Supply Shuttle Encoder, Channel B Hydraulic Pump Start Blade Speed or Proximity Switch NOT USED Feed rate encoder A / Angle Encoder A NOT USED Feed rate encoder B / Angle Encoder B Blade Pilot Light &...
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LENGTH CALIBRATION PROCEDURE Prior to initiating the calibration procedures the following steps are to be taken: 1. The saw must not be in METRIC units. 2. Clear all jobs in the Queue. 3. All “optional” PLC parameters below must be inactive (See page 3.11) a.
To adjust “ACTUAL LGTH” value The Length Calibration Procedure MUST be performed. This may be done with material in the machine (cut and measure material length) or with no material in the machine (let machine complete the calibration cycle, then enter new value). If part length error gets longer as the programmed length increases;...
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NOTE: To determine if the encoder channels are connected, observe the actual height value parameter for the sign during head up movement while in calibration mode. If the actual height value shows as a negative number, the channels must be reversed and the calibration procedure repeated.
BLADE DEVIATION MONITORING SYSTEM (E1022) General description of the blade deviation monitoring system. This system monitors lateral blade deviation during cutting. If blade deflection increases beyond the pre-set warning limit, then the monitoring device sends a warning signal by means of flashing beacon mounted on the top of machine head.
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Change BLADE MONITOR parameter to ON by moving the cursor using the navigation keys to ON/OFF and pressing ENTER Repeating the above steps will disable the blade monitor option. Warning and shutdown limits adjustments To adjust the warning and shutdown limits, enter MONITOR LIMIT SETTING screen by pressing F4 (red LED should be ON) and then press function key F5 (Figure 1).
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Cut out maximum limit – (out - cutting towards outfeed, range 0 ~100). This parameter will adjust shutdown limit if blade is cutting towards the part. Increasing this value decreases sensitivity, which will result in a larger deviation from nominal straight, before shutdown sequence is initialized.
Warning response time (range 2 – 99 seconds) WARNING RESPONSE TIME If the blade deviation exceeds the preset warning limit for longer than warning response time, then the beacon light mounted on the top of the head will start flashing. Maximum limit response time –...
SECTION 9 - WARRANTY WARRANTY Hyd-Mech Group Limited warrants parts/components on each new bandsaw to be free from failure resulting from defec- tive material and workmanship under proper use and service for a period of two years on following the date of shipment from the factory.
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