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Содержание 393298

Страница 1: ...y of your new HYD MECH band saw please take the time to familiarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual We sincerely appreciate the confidence you have demonstrated in purchasing our product and look forward to building a long and mutually beneficial relationship Thank you HYD MECH GROUP LIMITED P O BOX 1659 Woodstock Ontario...

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Страница 3: ...K LIFT 1 2 FOUNDATION LEVELLING AND ANCHORING 1 3 EARTH GROUNDING PROCEDURE 1 3 POWER WIRING CONNECTIONS 1 4 HYDRAULIC OIL 1 4 CUTTING FLUID 1 4 SECTION 2 OPERATING INSTRUCTIONS OPERATOR CONTROL PANEL 2 1 START UP 2 1 CONTROL CONSOLE 2 2 OPERATION CONTROLS 2 2 HYDRAULIC FEED CONTROL 2 2 STARTING THE MACHINE 2 10 MANUAL MODE Machine Operation 2 12 SETTING HEAD UP AND HEAD DOWN LIMITS 2 13 PROGRAMMI...

Страница 4: ...ARBOX LUBRICATION 3 10 S20A PARAMETER DEFINITIONS 3 13 MEP31 AND MEP32 CONTROLLER TROUBLESHOOTING 3 14 MACHINE ALARMS AND TROUBLESHOOTING 3 16 SECTION 4 ELECTRICAL FOR ELECTRICAL SCHEMATICS SEE PDF ON ATTACHED CD 4 1 SECTION 5 HYDRAULIC HYDRAULIC SCHEMATICS AND PLUMBING DIAGRAMS SEE PDF ON ATTACHED CD 5 1 SECTION 6 MECHANICAL ASSEMBLIES MECHANICAL ASSEMBLY DRAWINGS AND PARTS LIST SEE PDF ON ATTACH...

Страница 5: ...l materials are within designed specifications and are non hazardous Owner is responsible to keep Manual accessible at the machine ensure only reliable fully trained personnel work with the machine clearly define responsibilities of all personnel working with the machine keep the machine in good working order Operator and Maintenance Personnel are responsible to keep all safety equipment in order ...

Страница 6: ...have done over and over Here familiarity boredom or tiredness may lull us into unthinking automatic repetition Be alert for this and when you feel it happening stop and take stock of your situa tion Review the safety hazards associated with what you are doing That should get your brain working again Certainly production is important but if you think you re too busy to put safety first think how mu...

Страница 7: ...derstood all parts of Section 0 Safety and Section 2 Operating Instructions Name Date Signature Everyone involved in the installation inspection maintenance and repair of this machine must sign below to confirm that I have read and understood all parts of this Operation and Maintenance Manual Name Date Signature ...

Страница 8: ... of Misuse Misuse includes for example Sawing hazardous materials such as magnesium or lead Sawing work pieces which exceed the maximum workload appearing in the Specifications Operating the machine without all original safety equipment and guards Liability The machine may only be operated When it is in good working order and When the operator has read and understood the Safety and Operating Instr...

Страница 9: ...nt the foreseeable dangers that may arise during operation of the machine and the safety precautions to be taken In addition the personnel must be instructed to check all safety devices at regular intervals 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 ...

Страница 10: ...afe operation The machine may only be operated when in good working order and when all protective equipment is in place and operational Keep a safe distance from all moving parts especially the blade and vises Stock should not be loaded onto the saw if the blade is running Long and heavy stock should always be properly supported in front of and behind the saw Faults The machine must be switched of...

Страница 11: ...ds upon the national regulations in the country in which the machine is being used The actual level of noise emission by band sawing machines depends upon work piece size shape and material blade type blade speed and feed rate The only practical course of action is to measure the actual noise emission levels for the type of work that is typically done With reference to national standards decide up...

Страница 12: ... that owners of industrial equipment establish and post lock out pro cedures Know and use the lock out procedures of your company or organization Residual Risks The machine is still not completely de energized if an electrical cabinet door type switch is locked out The line side of the disconnect switch itself remains energized Variable speed blade drives store dangerous voltage in their capacitor...

Страница 13: ...VOLTAGE INSIDE Contact with high voltage may cause death or serious injury Never perform maintenance on or near electrical components until the machine s electrical power source has been disconnected Lock out power in accordance with your company s lock out procedures before any such maintenance The Stop or Emergency Stop push button does not disconnect the machine s power supply Hazardous voltage...

Страница 14: ...cause severe injury Keep hands clear of vises and work piece when the vises and bundling are opened or closed Be aware that vise and bundling closing or opening may result in potentially dangerous work piece movement Be aware also that the head swing either left or right and the advancement or retraction of the head may create potential pinch points Warning Pinch Point Item N0 392801 Danger Hazard...

Страница 15: ...A AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID OBSTACLES OPERATORS COULD TRIP OVER THE BANSAW SHOULD ONLY BE OPERATED ACCORDING TO THE SPECIFICATIONS OF THE SAW AVOID UNSAFE USAGE PRACTICES IF AT ANY TIME THE SAW DOES NOT APPEAR TO BE OPERATING PROPERLY IT SHOULD BE STOPPED IMMEDIATELY AND REPAIRED OPERATOR THE SAW SHOULD NEVER BE OPERATED UNLESS ALL GUARDS AND DOORS ...

Страница 16: ...used for retaining during shipping and for use with concrete floor an chors The smaller diameter threaded holes at each corner are used for leveling the saw properly The machine should be lifted from the SIDE as shown below Locate one fork 10 and the other 38 from the front edge of the machine NOTE DO NOT position the forks to allow contact with the hydraulic cabinet DAMAGE WILL RESULT S20A MACHIN...

Страница 17: ...rovide 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 2 The ground rod is to be connected to customer s in plant ground system This connection shall be made directly at the ground rod If applicable 3 It is desirable that the overall resistance to ground measured at the ground ...

Страница 18: ...made to terminals L1 L2 L3 and ground terminals If the machine is equipped with an auto transformer then the power cable is to be connected to the fuses located in the junction box Power junction box without auto transformer installed in the bandsaw Power junction box with auto transformer installed in the bandsaw Power junction box HYDRAULIC OIL The S20A is supplied with Texaco Rando HD46 hydraul...

Страница 19: ...n 2650 lbs 1200kg The Machine Disconnect Switch is located on the side on the machine control box It is a Thermal magnetic circuit breaker with under voltage coil and door locking device The switch consists of three power failure protection sys tems In the event of a power failure this switch disconnects all the electrical devices causing the machine to immediately shut down and prevents it from a...

Страница 20: ... side of the control console and consist of the Feed Force Setting knob the Feed Rate knob and the Head Fast Approach lever These controls allow the operator to control both the Feed Force Limit and the Feed Rate See Cutting Parameters Chart information on the following pages Feed Force Control Fast Approach Feed Rate Control OPERATION CONTROLS The electrical push buttons on the HMI allow for full...

Страница 21: ...ad motion will cease The vises remain as they are but if closed they will lose gripping force For this reason all long stock should be supported so that it will not fall To reset the button simply rotate through 45º BCM BLADE CHANGE MODE See page 2 23 With the selector switch in the left position all functions are operative With the selector switch in the right position only HEAD UP and HEAD DOWN ...

Страница 22: ...city A lit LED will be visible whilst HEAD UP is depressed HEAD UP LIMIT HEAD DOWN LIMIT HEAD UP LIMIT Depressed when the desired HEAD UP LIMIT SETTING is to be set A lit LED will be visible when the HEAD UP LIMIT has been reached HEAD DOWN LIMIT Depressed when the desired HEAD DOWN LIMIT SETTING is to be set A lit LED will be visible when the HEAD DOWN LIMIT has been reached BLADE SPEED DIAL This...

Страница 23: ...fixed jaw or until it encounters enough resistance to stop it A lit LED will be visible when FIXED VISE CLOSE is selected FIXED VISE OPEN The push button operates the fixed front vise When depressed and held the fixed vise will open all the way or until the push button is released A lit LED will be visible when FIXED VISE OPEN is selected Push button is also used to enter set up mode machine param...

Страница 24: ... are required i Press hold COMMAND ENABLE then press MACHINE START The EMERGENCY STOP button must be pulled out On initial start up press hold COMMAND ENABLE see symbol below then press MACHINE START BLADE START 1 COMMAND ENABLE For initial start up after the disconnect switch has been set to 1 ON press hold COMMAND ENABLE then press MACHINE START Push button is also used in conjunction with other...

Страница 25: ...n numerical data input is required MACHINE STOP When depressed all machine functions and hydraulic pump will shut down To continue using the saw follow the prompts displayed on the LCD All jobs will remain in memory as will the QUEUE 5 COOLANT MAN 6 COOLANT OFF COOLANT MAN When depressed COOLANT will flow continuously A lit LED will be visible when the COOLANT MAN is selected Push button is also u...

Страница 26: ...ic mode the following actions are required i Press hold COMMAND ENABLE then press CYCLE START COOLANT AUTO 7 FLOOD MIST 8 CYCLE START SHUTTLE FWD SHUTTLE FWD When depressed and held in MANUAL MODE the shuttle will travel towards the saw blade and will stop and hold its position when the button is released If ZEROING sequence is not executed each time the machine is started then SHUTTLE FWD will no...

Страница 27: ...data input is required AUTO MODE Depress to enter AUTO MODE A lit LED will be visible when AUTO MODE is selected Fixed Vise Close must be depressed for AUTO MODE to cycle to start Push button is also used to enter a decimal point when numerical data input is required AUTO MODE CYCLE PAUSE CYCLE PAUSE When depressed the controller will pause the cycle in progress To continue the cycle follow the ac...

Страница 28: ...T Depress RESET ENTER Depress ENTER shuttle home sequence starts All other function buttons will be in active with the excep tion of Head Up Head Down Fixed Vise Open Fixed Vise Close Shuttle Vise Open Shuttle Vise Close Do not depress ENTER if you wish not to initiate the shuttle home sequence Depress PAGE UP Main Menu page appears on LCD AUTO MODE 0 MANUAL MODE To select mode operation Depress M...

Страница 29: ... Blade Deviation Option If available CM Maximum current absorption of the blade motor C Blade motor current during cut CUTS EXECUTED The number displayed relates to those CUTS effectively completed before the machine was last switched off These will remain in the memory until they are replaced by further cuts carried out using the same program or until set to zero or modified by a new program HS H...

Страница 30: ...the Feed Rate Use the potentiometer to set the desired blade speed Once the cut is complete the blade will shut OFF and the head will remain in the down position MANUAL MODE Machine Operation Manual mode allows for a manual operation of the saw In this mode all functions are activated by selection of the respective function buttons on the HMI Cut in Manual Mode SHUTTLE VISE OPEN FIXED VISE OPEN SE...

Страница 31: ...ired head down position by pressing the HEAD UP or HEAD DOWN buttons Press the HEAD DOWN LIMIT button HEAD DOWN LIMIT will be set and the head will move to the UP LIMIT PROGRAMMING JOBS Prior to using the AUTOMATIC MODE JOBS need to be entered in the PLC Follow the steps outlined below 1 Depress AUTO MODE Screen will change on the LCD 2 Depress RUN PROG 3 Depress 1 to select JOB The above screen w...

Страница 32: ...ear ALL or PARTIAL JOBS move the cursor to the required JOB No and depress hold COMMAND ENABLE and then depress hold CLEAR button for 5 seconds All JOBS below and including the JOB No highlighted with the cursor will have length and quantity values set to Zero PROGRAMMING THE QUEUE Another aspect required for the AUTO MODE to run is to populate the QUEUE with the JOB No required Follow the steps o...

Страница 33: ...twice to exit An alternative way to enter QUE POS between 1 to 100 is to do the following when the cursor is flashing beside the QUE POS 1 Using the numerical keys enter the new QUE POS required and depress ENTER I e 60 The cursor will flash beside JOB No value at QUE POS 60 Enter the JOB No as described on page 2 13 Depress RUN PROG button twice to exit BLADE KERF This applies to the width of mat...

Страница 34: ...DOWN LIMIT If the limits have been previously set then it is not necessary to re enter the limits Select AUTO MODE The following screen shown on the next page will appear Other features are 4 STEP If set to YES the machine will stop at the end of each cut of any JOB in any of the above cutting cycles and wait for the a start command from the operator to continue 5 LOOP If set to YES the QUEUE will...

Страница 35: ...epress RUN PROG button 2 Depress 4 to select CUTTING MODE 3 Depress 1 to select SINGLE JOB 4 Depress RUN PROG button twice to exit and the correct page will be displayed 5 JOB 0 Zero will always apply to SINGLE JOB mode and cannot be programmed for any other cut modes 6 Depress ENTER button until cursor flashes beside the LENGTH value ...

Страница 36: ... CUTS EXECUTED will be reset to 0 Zero 11 Select coolant type FLOOD MIST and then select coolant flow COOLANT MAN or COOLANT AUTO 12 Depress and hold COMMAND ENABLE then depress BLADE START Adjust the potentiometer to set the desired blade speed 13 Depress and hold COMMAND ENABLE then depress CYCLE START 14 Use the hydraulic feed controls to adjust the feed force limit and feed rate The SINGLE JOB...

Страница 37: ...t QUEUE 100 to go into QUEUE screen 6 Program the QUEUE with the required JOB No See page 2 14 for detailed explanation on programming the QUEUE 7 Depress RUN PROG button twice 8 Depress CLEAR The LCD will update the screen with the new JOB No LENGTH QTY REQ and CUTS EXECUTED will be reset to 0 Zero Load material and close FIXED VISE Set the HEAD UP LIMIT and HEAD DOWN LIMIT If the limits have bee...

Страница 38: ...l continue 14 If the QUEUE is programmed with only one job then once the SINGLE CYCLE is complete a high pitched tone is continuously heard and the following is displayed If the QUEUE is programmed with multiple JOBS then once the SINGLE CYCLE is complete with first JOB in the QUEUE the FIXED VISE will open and the following screen will be displayed Nr 1 refers to the JOB number 1 one This will va...

Страница 39: ...ss RUN PROG button 2 Depress 4 to select CUTTING MODE 5 Depress 2 QUEUE and then Depress 1 to select QUEUE 100 to go into QUEUE screen 6 Program the QUEUE with the required JOB No See page 2 14 for detailed explanation on programming the QUEUE 7 Depress RUN PROG button twice 8 Depress CLEAR The LCD will update the screen with the new JOB No LENGTH QTY REQ and CUTS EXECUTED will be reset to 0 Zero ...

Страница 40: ...used by depressing CYCLE PAUSE To restart the cycle depress and hold COMMAND ENABLE then depress CYCLE START The cycle will continue 14 Once the CONTINUOUS CYCLE is complete a high pitched tone is continuously heard and the following is displayed 4 Depress FIXED VISE CLOSE and then follow the instructions on the LCD to continue cutting 5 This sequence will continue until the QTY REQ for the JOB is...

Страница 41: ...NGE MODE BCM When the BCM switch is turned to the RIGHT position the machine will enter BLADE CHANGE MODE 1 The Machine will shut down 2 The LCD will display 3 Depress RESET 4 All functions with the exception of HEAD UP HEAD DOWN will be INACTIVE 5 Open the BLADE GUARD DOOR HEAD position may require movement using HEAD UP or HEAD DOWN for this to occur 6 Release Blade Tension until blade can be re...

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Страница 43: ...he FEEDER power which supplies power to the machine and which is connected to the machine via the Power Junction Box see picture below must be turned OFF and locked in the OFF 0 position by means of a padlock The key for this padlock must be kept by the person performing the work on the machine If more than one person is performing work on the machine then a multiple lock hasp shall be used and ea...

Страница 44: ...uards and covers shall be properly installed Each lock out padlock shall be removed by the person who applied it After the lock out padlocks are removed and before the machine is started the supervisor and all other employees who use the machine shall be informed that the lock out has been removed After notification is made the machine may be re started Machine Power Disconnect located on the side...

Страница 45: ... protection from the sharp blade 1 Open the Wheels door by unscrewing the two knobs 2 Loosen the Blade Tensioner by turning counter clockwise 3 Open the blade guard at idler guide arm by undoing the mounting screws and removing it as illustrated below ...

Страница 46: ...amage may be caused 6 Place the new blade in the carbide guides and then slide the blade over the wheels The teeth should be pointing towards the drive side as they pass through the carbide guides 7 Make sure there is a small amount of play between the blade and guide carbides The blade band should be snug but able to move freely up and down 8 If the amount of play is not sufficient for the blade ...

Страница 47: ...NT First inspect the blade wheels for wear or damage and repair as required Blade tracking adjustment should always begin at the wheel where the tracking is farthest out of specification Using the instructions below adjust the worst wheel jog the blade and recheck both wheels Repeat this process until both wheels are within specification Idler Wheel Adjustment The Idler Wheel must be adjusted so t...

Страница 48: ...ance between the blade and wheels flange 5 If necessary repeat steps until proper gap is achieved BLADE GUIDE ADJUSTMENT At the bottom of the guide arms are the blade guide block assemblies with carbide pads These assemblies will need to be adjusted occasionally as the carbide pads become worn or if a blade with different thickness is used To adjust properly follow this simple procedure 1 Make sur...

Страница 49: ...e whole guide block has to be changed BLADE BRUSH ADJUSTMENT The machine leaves the factory with the blade brush adjusted for maximum life of the brush This setting places the ends of the blade brush wires so as to contact the blade at the bottom of the blade gullets The plastic drive wheel that is driven by the drive wheel face should be held against the wheel face with the minimum force that is ...

Страница 50: ... the brush in position Lock the hex nut to prevent the set screw from loosening ANGLE BRAKE ADJUSTMENT The clamping force on the swivel brake can be adjusted to ensure that the Head is held securely and does not move dur ing cutting The brake handle should be adjusted so that it does not bottom out or hit its movement limit yet holds the head securely ANGLE BRAKE ADJUSTMENT PROCEDURE STEP 1 Loosen...

Страница 51: ... with slider 5 Move the slider by hand back and forth to locate any friction or excessive play 6 Loosen the nuts using tubular nut driver while holding the set screws firm with Allen key 7 Tighten the set screws to take up any play or loosen them up in case of excessive friction 8 Retighten the nuts with tubular nut drive 90 AND 30 DEGREE STOP ADJUSTMENT There are two adjustable mechanical stops f...

Страница 52: ... The lubricant should be applied as frequently as required Main lubrication points are indicated on the following pictures Runner Block Movable Guide Arm Vise Bundling Runner Block Shuttle Jaw 3 Head Cylinder Rod End Swivel Pivot GEARBOX LUBRICATION The Bonfignoli W86 gearbox used on the S20A is supplied with 0 64 litres 0 17 US gallons of Shell Tivella S320 synthetic oil This oil has an ISO Visco...

Страница 53: ...L 46 2 HYDRAULIC OIL LEVEL Units equipped with side Glass Oil level should be maintained in the middle of the side glass window Units without side glass Filler cap is equipped with dip stick for checking oil level Oil level should be maintained so the oil leaves a wet trace approximately half way on the dip stick 3 HYDAULIC OIL CHANGE It is recommended to change oil after every 2000 hours of opera...

Страница 54: ...d especially where cleanliness is concerned The following areas should be kept clean Control console free of dirt and grease Door charts free of dirt and grease Wheel boxes free of chips Blade guides free of chips Out feed tables free of chips A large chip build up should be avoided in the base of the saw NOTE All parts must be cleaned before any repair service may be performed on them ...

Страница 55: ...e 0 FIXED VISE OPENING NEV FTI 1 0 BLADE MOTOR OFF NEV RHL FHL 2 1 0 Controls when the blade motor is to stop Values are a NEV Never 2 b RHL Blade to stop when head is at the BACK limit 1 c FHL Blade to stop when the head is at the FWD limit 0 17 MINIMUM BLADE TENSION lbs Allows minimum blade tension to be set MAXIMUM BLADE TENSION lbs Allows maximum blade tension to be set 20 LASER LAMP OFF TIME ...

Страница 56: ...al component 2 Consistent lengths cut are consistent and the error is also consistent The error always stays the same regard less of part length Cause kerf value 3 Linear lengths cut are consistent but the error increases as the part length increases The longer the part the greater the error Cause incorrect LENGTH and OFFSET values entered in paremeter 26 DIAGNOSIS Check and record existing parame...

Страница 57: ... should be approx 0 015 Contamination on the end of the sensor Check BLADE SPEED PROXIMITY is set to YES in the parameters 2 Fault at the MEP32 CONTROLLER Bad connection of sensor wiring Faulty MEP32 CONTROLLER DIAGNOSIS Check for LED light on the sensor light ON indicates proximity sensor power connections are correct and sensor is ac tivated Problem could be with sensor signal wire to the MEP CO...

Страница 58: ...N Close FIXED VISE COMMAND DISABLED HEAD NOT AT UP LIMIT PRESS RESET Displayed if the head is not positioned at the Head Up Limit position when the cycle is STARTED Move the head to the HEAD UP LIMIT position before resuming the cycle COMMAND DISABLED AXIS X NOT ZEROED PRESS RESET Displayed when a shuttle movement FWD or REV is activated or a job cycle is started automatically without having initi...

Страница 59: ...ls 4 The STRAIN GAUGE input on the IUV card 5 Blade condition 6 Wiring connections EMERGENCY HEAD JAMMED PRESS RESET Displayed when the head cannot move upwards or downwards due to a mechanical or hydraulic obstruction 1 Check remove any mechanical obstacles 2 Check hydraulic powerpack hoses solenoid valves 3 Turn OFF main power wait 30 seconds and restart EMERGENCY BLADE TENSION OUT OF RANGE PRES...

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Страница 61: ...4 1 ELECTRICAL SCHEMATICS SEE PDF ON ATTACHED CD SECTION 4 ELECTRICAL ...

Страница 62: ......

Страница 63: ...5 1 SECTION 5 HYDRAULIC HYDRAULIC SCHEMATICS PLUMBING DIAGRAMS SEE PDF ON ATTACHED CD ...

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Страница 65: ...6 1 MECHANICAL ASSEMBLY DRAWINGS PARTS LIST SEE PDF ON ATTACHED CD SECTION 6 MECHANICAL ASSEMBLIES ...

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Страница 67: ...7 1 OPTIONAL ASSEMBLY DRAWINGS SEE PDF ON ATTACHED CD SECTION 7 OPTIONS ...

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Страница 69: ...Set carbide inserts Blade Wheel Diameter 17 3 4 Drive Blade drive 5 hp Hydraulic drive 1 hp Hydraulic System 440 psi Hydraulic Tank Capacity 4 75 U S Gallons Coolant Tank 6 U S Gallons Shuttle Stroke 0 29 single stroke Multi indexing standard Vise Control Hydraulic Table Height 31 Machine Work Load 5000 lbs Machine Weight 3600 lbs Dimensions 89 5 Wide x 86 75 Long x 55 High Options Full capacity b...

Страница 70: ...N NUMBER REV DATE BY REVISIONS STANDARD TOLERANCES UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES LINEAR ANGULAR X 015 IN XXX 005 IN XX 010 IN X X 0 5 DEG 125 MICROINCHES THIRD ANGLE PROJECTION TITLE DRWN BY A CHKED BY MAT L DATE SCALE SHEET REV DRAWING NUMBER WOODSTOCK ONTARIO CANADA N4S 8A4 HYD MECH GROUP LIMITED HYD MECH The Rock Solid Solution S20MA 0 00 2008 G P 2 27 09 1 32 1 B C D E F ...

Страница 71: ...ufacture of the S20A but not originally manufactured by Hyd Mech are subject to the original manufacturer s warranty Hyd Mech will provide such assistance and information as is necessary and available to facilitate the user s claim to such other manufacturer Liability or obligation on the part of Hyd Mech for damages whether general special or for negligence and expressly including any incidental ...

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