H18A-120 & H22A-120

393071

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.

To ensure you are maximizing the power and versatility of your new HYD·MECH bandsaw, please take the time to
familiarize yourself and your employees with the correct operation and maintenance procedures as outlined in this
manual. Please keep this instruction manual for future reference in a known location and easily accessible to all users of
the device.

HYD·MECH offers a great variety of options, components, and features for its various models. Therefore, some of the
equipment described in this manual (various illustrations and drawings) may not be applicable to your particular machine.

The information and specifications provided in this manual were accurate at the time of printing. HYD·MECH reserves the
right to discontinue or change specifications or design at any time without notice and without incurring any obligation.

Thank you.

Hyd·Mech Group Limited

P.O. Box 1659, 1079 Parkinson Road
Woodstock, Ontario, N4S 0A9
Phone : (519) 539-6341
Service : 1-877-237-0914
Sales : 1-877-276-SAWS (7297)
Fax : (519) 539-5126
e-mail : [email protected]

PRINTED APRIL 2017

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 TABLE OF CONTENTS

SECTION 0 - SAFETY INSTRUCTIONS

SUMMARY .......................................................................................................................................0.1
BASIC RULES ..................................................................................................................................0.3
RESPONSIBILITIES OF THE OWNER............................................................................................0.3
RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL ...........................0.4
SAFETY HAZARD LABELS .............................................................................................................0.6

SECTION 1 - INSTALLATION
SAFETY PRECAUTIONS.................................................................................................................1.1
FOUNDATION, LEVELLING AND ANCHORING .............................................................................1.2
BARFEED INSTALLATION ..............................................................................................................1.2
MACHINE GUARD INSTALLATION .................................................................................................1.8
WIRING CONNECTIONS................................................................................................................1.10
EARTH GROUNDING PROCEDURE .............................................................................................1.10
HYDRAULIC OIL AND CUTTING FLUID ........................................................................................1.10

SECTION 2 - OPERATING INSTRUCTIONS

BLADE BASICS................................................................................................................................2.1
VARIABLE SPEED CONTROL.........................................................................................................2.1
THE CONTROL PANEL ...................................................................................................................2.1
START-UP ........................................................................................................................................2.1
PLC 100 CONTROL SYSTEM .........................................................................................................2.2
MANUAL MODE ...............................................................................................................................2.5
SINGLE CUT MODE OPERATION ..................................................................................................2.6
AUTOMATIC OPERATION ...............................................................................................................2.7
WORKING WITH A QUEUE .............................................................................................................2.8
WORKING WITH A REPEATING QUEUE .......................................................................................2.8
PARAMETERS .................................................................................................................................2.9
HYDRAULIC FEED CONTROL.......................................................................................................2.11
CUTTING PARAMETERS CHART ..................................................................................................2.12
ADDITIONAL CONTROLS ..............................................................................................................2.18
COOLANT FLOW ............................................................................................................................2.18
HEAD UP AND DOWN LIMIT SETTING .........................................................................................2.19
VARIABLE VISE PRESSURE (OPTION) .......................................................................................2.19
BUNDLING OPERATION (OPTION) ..............................................................................................2.20

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 SECTION 3 – MAINTENANCE
SAFETY DURING MAINTENANCE AND TROUBLESHOOTING ....................................................3.1
LOCK OUT PROCEDURE ...............................................................................................................3.1
BLADE CHANGE MODE PROCEDURE..........................................................................................3.2
BLADE REMOVAL............................................................................................................................3.3
BLADE INSTALLATION ....................................................................................................................3.3
BLADE BRUSH ADJUSTMENT .......................................................................................................3.4
BLADE TRACKING ADJUSTMENT .................................................................................................3.4
IDLER WHEEL TRACKING .............................................................................................................3.4
DRIVE WHEEL TRACKING .............................................................................................................3.5
GEARBOX LUBRICATION (H18ASV - A503 GEARBOX, H22ASV - A603 GEARBOX) .................3.5
OUTPUT SHAFT LUBRICATION .....................................................................................................3.5
CAM FOLLOWER ADJUSTMENT ...................................................................................................3.6
LUBRICATION..................................................................................................................................3.6
HYDRAULIC MAINTENANCE..........................................................................................................3.7
CLEANLINESS .................................................................................................................................3.7
TROUBLESHOOTING .....................................................................................................................3.8
PLC TROUBLESHOOTING ............................................................................................................3.10
M12 PIN ASSIGNMENTS FOR I/P & O/P DEVICES ......................................................................3.12
STANDARD PARAMETER VALUES ...............................................................................................3.14
ACTUAL PARAMETER VALUES ....................................................................................................3.16

SECTION 4 - ELECTRICAL
ELECTRICAL SCHEMATICS: SEE PDF ON ATTACHED CD .........................................................4.1

SECTION 5 - HYDRAULIC
HYDRAULIC SCHEMATICS & PLUMBING DIAGRAMS: SEE PDF ON ATTACHED CD ...............5.1

SECTION 6 - MECHANICAL ASSEMBLIES

MECHANICAL ASSEMBLY DRAWINGS & PARTS LIST: SEE PDF ON ATTACHED CD................6.1

SECTION 7 - OPTIONS
OPTIONAL ASSEMBLY DRAWINGS: SEE PDF ON ATTACHED CD .............................................7.1
BLADE DEVIATION MONITOR ........................................................................................................7.2

SECTION 8 - SPECIFICATIONS
H18A-120 SPECIFICATIONS...........................................................................................................8.1
H18A-120 MACHINE LAYOUT ........................................................................................................8.2
H22A-120 SPECIFICATIONS...........................................................................................................8.3
H22A-120 MACHINE LAYOUT ........................................................................................................8.4
H22A-120 with OV MACHINE LAYOUT ..........................................................................................8.5

SECTION 9 - WARRANTY
WARRANTY .....................................................................................................................................9.1

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 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 – What operators and maintenance people must have read and understood.
Signatures – Everyone involved with this machine must sign to confirm they have read and understood mandatory
information.
Basic Rules – only use this machine when
• It is in good working order.
• All safety equipment is in place and functional.
• Operations are in compliance with this manual.
• 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, check its function at the beginning of each shift, and report any shortcomings.
• Shut down machine and report any faults or malfunctions that could impair safety.
• Understand and obey safety hazard labels.
• Not to wear un-restrained long hair, loose clothing or jewellery.
• Wear all required personal protective equipment.
• Not to wear gloves within 24 inches of moving blade.
• Maintain a clean working area and machine.
• Always use Lock-out when performing maintenance or repairs.

0.1
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. If you feel any uncertainty, stop and find a safer approach to the action. If you’re still uncertain, ask for advice
from your supervisor.
The SAFETY FIRST approach is particularly necessary when you do something new, or different, and most people
instinctively recognize this, although impatience may still cause them to take unnecessary risks.
Danger also lurks in the routine task that we 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
situation. 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 much production you’ll lose if
you get hurt.
You owe it to yourself, your family, and your co-workers to PUT SAFETY FIRST.
Mandatory Information
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
Personnel involved in installation and maintenance of the machine must have read and understood all sections of the
manual
Persons who have difficulty reading, or for whom English is not their first language, must receive particularly thorough
instruction.
Signatures
Everyone involved in operation of this machine must sign below to confirm that:
I have read and understood all parts of Section 0 – Safety, and Section 2 – Operating Instructions.

Name Date Signature

Everyone involved in the installation, inspection, maintenance, and repair of this machine must sign below to confirm that:
I have read and understood all parts of this Operation and Maintenance Manual.

Name Date Signature

0.2
BASIC RULES

Intended Use
Our machines are designed and built in line with the state of the art, and specifically in accordance with
American National Standards Institute Standard B11.10 Safety Requirements for Metal Sawing Machines.
However, all machines may endanger the safety of their users and/or third parties, and be damaged,
or damage other property, if they are operated incorrectly, used beyond their specified capacity, or for
purposes other than those specified in this Manual.

Exclusion 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 Instructions Sections of the
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.

RESPONSIBILITIES OF THE OWNER

Organization of work

This Operation and Maintenance Manual must always be kept near the machine so that it is accessible to
all concerned.

The general, statutory and other legal regulations on accident prevention and environmental protection
must also be observed, in addition to the Manual material. The operators and maintenance personnel
must be instructed accordingly. This obligation also includes the handling of dangerous substances and
the provision and use of personal protective equipment.

Choice and qualification of personnel

Ensure that work on the machine is only carried out by reliable persons who have been appropriately
trained for such work.
Training
Everyone working on or with the machine must be duly trained with regard to the correct use of the
machine, the correct use of safety equipment, 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.

0.3
 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. Observe the minimum age limits required by law.

Condition of Machine and Workplace

Ensure that the machine and its safety equipment are kept in good working order.

Ensure that the work area is well lit, and protected from the elements, such as rain, snow, abrasive dust,
and extremes of temperature.

Ensure that the machine is installed with sufficient clearance around it for the safe loading and unloading
of work pieces.

RESPONSIBILITIES OF THE OPERATOR AND MAINTENANCE PERSONNEL

Safety equipment
All machines are delivered with safety equipment that must not be removed or bypassed during operation.
The correct functioning of safety equipment on the machine must be checked:
• At the start of every shift.
• After maintenance and repair work
• When starting for the first time, and after prolonged shutdowns

Emergency Stop Button (E-Stops)

Always be aware of the location of the Emergency Stop Button(s). Do not allow material or objects to
block your access to an Emergency Stop.
Damage
If any changes capable of impairing safety are observed in the machine or its operation, such as damage,
malfunctions, or irregularities, then appropriate steps must be taken immediately, the machine switched
off, locked-out, and the fault reported to the responsible person.
Safe 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 off and locked-out before starting to remedy any faults.
Safety hazard labels
Safety hazard labels and other instructional labels on the machine must be observed. They must be
clearly visible and legible at all times. If they become damaged they must be replaced.

0.4
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.
Gloves
Experience has shown that careless use of gloves around machinery is a major factor in serious hand
injuries.
Gloves should not be worn when operating or adjusting the machine, except:
Wear protective gloves when handling bandsaw blades at blade changes.
Gloves may be worn when handling work pieces, only if the machine is in Manual Mode and the
bandsaw blade is not running.
If the machine is running in Auto Mode, and only if the cut parts are greater than 24 inches
long, it may be possible to safely wear gloves for handling the cut parts, but the wearer of the
gloves must never put his hands near the blade for any reason. If the cut parts are less than 24
inches long, it is required to arrange their automatic flow into a parts bucket or other suitable
arrangement to avoid the necessity to pick them off the machine by hand.
Hearing protection
Ear protection must be worn whenever necessary.
The level and duration of noise emission requiring hearing protection depends 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 upon the necessary hearing protection
required.
In the absence of such measurements, it is advisable for anyone exposed to long periods of moderate to
loud noise to wear hearing protection. It is important to understand that hearing loss is gradual and easily
goes un-noticed until it is serious and irreversible.
Workplace
A clear working area without any obstructions is essential for safe operation of the machine. The floor
must be level and clean, without any build-up of chips, off-cuts, coolant, or hydraulic oil.
The workplace must be well lit, and protected from the elements, such as rain, snow, abrasive dust, and
extremes of temperature
Nothing may ever be placed on, or leaned against the machine, with the obvious exception of the work
piece on the table and conveyor of the machine.

0.5
 Master Disconnect
Lock-out the machine before undertaking any maintenance or repair work on it. ‘Lock-out’ refers switching
off the master electrical disconnect switch, and locking it out so that it cannot be switched on again
without authorization.
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.
• Rotary switch mounted on the side of the operator interface console.
• Lever switch mounted in separate box mounted on the machine.
• Supply disconnect switch supplied by user at installation and usually wall-mounted within sight of
the machine, depending upon local regulations.
In almost all jurisdictions, it is required that owners of industrial equipment establish and post
lock-out procedures. 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 capacitors, and this requires time to
dissipate. After locking out power, wait 3 minutes before beginning to work on machine electrical
circuits.
If compressed air is supplied to the machine to power a mist lubrication system or other devices,
it should be disconnected, and any stored air pressure released before working on the machine.
The weight of individual machine components represents stored potential energy that can be
released if they fall when disconnected. Secure these components with adequate hoisting gear
before disassembly.

SAFETY HAZARD LABELS

The safety hazard labels attached to your machine represent important safety information to help you avoid personal injury
or death.
All supervisors, operators, and maintenance personnel must locate and understand the safety information associated with
each hazard label prior to operating or servicing the machine.
The safety hazard labels shown below are located at various positions on the machine to indicate possible safety hazards.
The location and re-order part number of all the safety labels associated with this particular model of bandsaw are indicated
at the end of this section of the manual. It is important to replace any safety hazard label that becomes damaged or illegible.

HAZARDOUS 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 is still present in the machines electrical circuits.
The machine’s Electrical Disconnect Switch does disconnect voltage from the
machine’s circuits; however hazardous voltage is still present inside the main electrical cabinet, on the infeed (line) side of
the main fuses. Therefore keep hands and tools away from the infeed side of the control panel main fuses. If these fuses
need to be replaced, use a fuse puller.
Allow three minutes after locking-out power before opening any electrical enclosures. Your machine may be equipped with a
variable frequency drive that stores high voltage within its capacitors. Three minutes will allow sufficient time for this voltage
to safely discharge.
Never spray coolant directly at electrical components or cabinets.

0.6
 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. Keep hands clear of all labelled pinch points, whenever the machine is running. Machine vises
can exert great force and cause severe injury. Keep hands clear of vises and work piece when vises are opened or closed.
Be aware that vise closing or opening may result in potentially dangerous work piece movement. Be aware also that the
opening motion of a vise may create potential pinch points.

MOVING PARTS CAN CRUSH AND CUT

Keep hands clear of chip auger. Lock-out power in accordance with your company’s lock-out procedures before attempting
to clear a jam in the chip auger.
Be aware that the chip auger may start unexpectedly, either because the machine is operating automatically, or because
another person initiates the motion.
If the chip auger is stalled because of a jam, it may start without warning when the jam is cleared, unless the machine power
is locked out.

0.7
 Item #: 391938

Chip Augar
Item #: 391335 Item #: 391340

0.8
Fixed Vise

Item #: 391397

Item #: 392801

Shuttle Vise

Item #: 392801

0.9
 SECTION 1 - INSTALLATION
Upon delivery of your new H18A_H22A 120 saw, it is imperative that a thorough inspection be undertaken to check for any
damage that could have been sustained during shipping. Special attention should be paid to the electrical and hydraulic
systems to check for damaged cords, hoses and fluid leaks. In the event of damage caused during shipping, contact your
carrier to file a damage claim.

SAFETY PRECAUTIONS

The machine has been designed to give years of reliable service. It is essential that operators be alerted to the safe oper-
ation of this saw and the practices to avoid that could lead to injury. The following safety rules are at the minimum neces-
sary for the safe installation, operation, and maintenance of the saw. Take every precaution for the protection of operators
and maintenance personnel.

• POWER HOOK-UPS AND REPAIRS SHOULD ONLY BE ATTEMPTED BY QUALIFIED TRADESMEN.

• THE SAW SHOULD BE LOCATED IN AN AREA WITH SUFFICIENT ROOM TO SAFELY LOAD STOCK INTO
THE SAW. SECURE THE SAW TO THE FLOOR.

• THE AREA AROUND THE SAW SHOULD BE MAINTAINED IN A CLEAN AND TIDY CONDITION TO AVOID
OBSTACLES OPERATORS COULD TRIP OVER.

• THE H18A_H22A 120 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 ARE IN PLACE AND
CLOSED.

• KEEP A SAFE DISTANCE FROM ALL MOVING PARTS - ESPECIALLY THE BLADE AND VISES.

• LOOSE CLOTHING AND GLOVES SHOULD NEVER BE WORN WHILE OPERATING THE SAW. COVER LONG
HAIR.

• 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.

• NEVER ATTEMPT TO DISLODGE OR MOVE STOCK WHILE THE BLADE IS MOVING. TAKE THE TIME TO
STOP THE SAW BLADE, REMOVE OBSTRUCTIONS, AND START THE BLADE.

• MUST WEAR EYE PROTECTION.

• 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.

1.1
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.

Six leveling screws are provided, one in each corner of

the machine base plus one in the hydraulic cabinet. Steel
plates are to be placed under each screw to prevent their
sinking into the concrete floor. In cases where the ma-
chine is to be anchored permanently, anchoring holes are
provided. They are located next to the leveling screws.

NOTE:
In some cases leveling the saw in-feed and auxiliary con-
veyor with a slight slope towards blade is recommended.
This will prevent coolant from running down the raw stock.
(This is especially true when cutting tubing or bundles).

BARFEED INSTALLATION

1. Prepare the machine base for mating with the barfeed. Place shims into position and place a bead of silicone on
the surfaces shown below.

Shim

Bead of
silicone

1.2
2. Move the barfeed into its proper position in relation to the machine. Make sure the lip of the conveyor seals prop-
erly with the bead of silicone.

3. Position the mounting holes of the front - end bracket of the barfeed. First fasten the two horizontal hex head
bolts (The two socket set screws are used to align the barfeed), and then tighten the two vertical hex bolts.

Horizontal hex bolts Socket set screws

Barfeed front end

bracket

Vertical hex bolts of

front end bracket

1.3
4. Fill all gaps between the barfeed and machine base with silicone.

Fill gaps on both

sides of the
barfeed.

5. Fasten the drip pan between the barfeed and machine base. Use a sheet of cork to make a gasket for the drip
pan.

Drip pan

Make a gasket to seal this surface (Do the

same for the other side of the conveyor)

6. The barfeed should be levelled in both directions i.e. along and across its in-feed conveyor. Six levelling screws
are provided, three down each length of the conveyor. Steel plates are to be placed under each screw to prevent
their sinking into the concrete floor. In cases where the machine is to be anchored permanently, anchoring holes
are provided. They are located next to the levelling screws.

NOTE: Levelling the barfeed with a slight slope towards the blade will prevent coolant from running down the raw
stock.

1.4
7. The barfeed support bracket should be fastened once it is levelled and anchored.

Bracket

8. The shipping supports must be removed once the barfeed is fastened to the machine.
The conveyor support is bolted and tack welded to the table; therefore, the welds must be ground off and the bolts
removed in order to disassemble the support.

Tack welded
2 spots

1.5
 Two brackets support the shuttle vise for shipping, one on each side of the conveyor. Make sure they are removed
before attempting to move the shuttle.
Shuttle support brackets

9. Remove the three cable covers that line the barfeed table. Unpack and unravel the cable track holding the wires
and hoses for the barfeed shuttle. Fasten the two brackets that will hold the cable track in place. The M12 port
can now be fastened to the barfeed table.
M12 port

Mounting brackets

10. Feed hydraulic hose #21L up through the shuttle frame and attach to the valve as shown below. Hose #21 and
#22 are to be connected at the bottom of the shuttle frame.
Hose 21 Hose 22

Hose 21L

1.6
11. The M12 connector of wire #23 is to be connected under
the gearbox.

12. The two wire connections of the servo motor can now be
connected.

13. Connect wire #17, #18, and #19 to the limit switches attached to the shuttle vise frame. Make sure the cover
plate is secure and in the proper position.

Cable #17

Cable #19

Cable #18

14. Layout the wires and cables onto the barfeed table and
then fasten the three covers into place.

1.7
MACHINE GUARD INSTALLATION

15. Position the three pieces of the safety guard around the barfeed. The idler side guard is connected to the ma-
chine column by a hex bolt. The drive side guard is connected to the control box by a hex bolt. The rear guard is
connected to the rear of the barfeed frame with two hex bolts.

A pulley is mounted on a bracket and attached

to each rear corner of the safety guard.

1.8
16. Fasten the trip wire control box to the safety guard and complete the wire connections (see schematics). The
box is attached to the mounting plate with four socket head cap screws. The plate is mounted to the safety guard
with two hex bolts.

17. Attach the eyebolt to the idler side column. Fasten the wire rope to the spring and then proceed to feed it through
the eyebolts and pulleys along the guardrail. Loop the other end of the wire rope around the eyebolt of the trip
wire control box. Tighten or loosen the idler side column eyebolt to adjust the tension on the wire rope. The
switch cannot be activated if there is not enough tension on the wire rope.

1.9
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. Signs of damage that may have occurred during shipping to the electrical
cables and the hydraulic hoses.
2. The hydraulic oil level is between the upper and lower lines on the level
gauge.

As supplied, the machine is set to run on three phase voltage as indicated on the
serial plate and voltage label.

Power connection to the machine is made to L1, L2, L3 and Ground terminals in the main electrical box found beside the
conveyor on the drive side. For machines equipped with a variable frequency drive unit, an earth ground is also recom-
mended.

During the initial hook-up it is very important to check that the phase order is correct. This is indicated by the hydraulic
pressure gauge registering a pressure rise and the blade running in a counter clockwise direction. If the hydraulics do not
register an immediate pressure rise, shut the hydraulics off and change the phase order.

ATTENTION: Running the hydraulics “backwards” can damage the hydraulic pump.

EARTH GROUNDING PROCEDURE

1. Customer to provide and install a ground rod approx. 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. Ground rod 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 rod does not exceed 3 ohms. Cus-
tomer is advised to consult local power company for further information on grounding.
4. Ground rod to be connected to ground terminal in control enclosure using insulated, 8 AWG stranded copper wire.

An additional point to check is ensuring continuity of ground within control enclosure. Start with main power entrance
ground terminal where internal ground conductors should originate and connect to, DIN terminal strip, control transformer
and the lid of control enclosure. Also PLC and Interface units should have their own ground conductors connected to one
of the main ground terminals.
Properly functioning ground system will;
• Provide safety for personnel.
• Ensure correct operation of electrical/electronic devices.
• Prevent damage to electrical/electronic apparatus.
• Help dissipate lightning strokes.
• Divert stray radio frequency (RF) energy from electronic/control equipment.

HYDRAULIC OIL AND CUTTING FLUID

The H18A_H22A 120 bandsaw is supplied with Texaco Rando HD46 hydraulic oil. If it is necessary to change the oil to a
different brand see the HYDRAULIC SECTION for equivalent grade oil.

No cutting fluid is supplied with the machine. There are two types of coolant available:

• Oil based; dilute 1:10 ratio (one part concentrated coolant to 10 parts water)
• Synthetic; dilute as recommended by the manufacturer.

1.10
 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. The saw is equipped with variable blade speed and hydraulic feed control, as well as an extensive door chart to
guide the operator to the correct setting of these controls.

BLADE BASICS

Technology is rapidly changing all aspects of production machining. Metal cutoff is no exception. The advances made
in the bandsaw blade industry have definitely brought down the cost per cut, despite the three fold higher price of high
technology blades. Variable pitch, bi-metal blades (like the 4/6 or 3/4 bi-metal blade supplied with the machine) last much
longer, cut faster, and more accurately than conventional carbon steel blades. In order to take advantage of the superiority
of bi-metal blades, it is critical to properly “break-in” a new blade. This is accomplished by taking two or three cuts through
solid four or five inch diameter mild steel at an extremely slow feed rate. (It is also advisable to utilize a slow blade speed.)

These two or three slow cuts sufficiently lap (polish) the teeth on the new blade so that it does not snag the material being
cut. Proper break-in will alleviate blade vibration; improve surface finish, accuracy, and blade life.

After “break-in”, the following six points must be closely monitored to ensure long blade life:

1. Proper blade tension should be maintained. (See Section 3, Maintenance and Troubleshooting)

2. Generous coolant application is essential with most materials. A high quality and well mixed coolant will extend
blade life, and also increase cutting rate and quality. On those materials where coolant is undesirable for cutting,
a slight coolant flow or periodic oiling of the blade is necessary to prevent the blade from being scored by the
carbide guides.

3. The stock being cut must be securely clamped in the vises.

4. The proper feed force should be chosen. (see Saw Cutting Parameters: Step 2)

5. The proper blade speed must be selected. (see Saw Cutting parameters: Step 4)

6. The proper feed rate must be applied. (see Saw Cutting Parameters: Step 5)

VARIABLE SPEED CONTROL

Blade speed can be adjusted infinitely between 50 to 350 SFM (Surface Feet/Minute) (15.9 to 109 m/min) for H18A and
40 to 300 SFM (Surface Feet/Minute) (12 to 91.5 m/min) for H22A.
Adjustment should be made only when the blade is running.

THE CONTROL PANEL

START-UP

The control console has been designed to simplify the operation of the saw, to give the operator the ability to stop
any function at any time, and to be able to control all the functions remotely. We cannot overstress the importance of
familiarizing yourself with the controls prior to starting the machine.

NOTE:
1. WHEN STARTING THE MACHINE FOR THE FIRST TIME MAKE SURE THAT BLADE IS MOVING IN A
COUNTERCLOCKWISE DIRECTION, AND THAT THE HYDRAULIC PRESSURE IS 1000 PSI (6890 kP) FOR
H18A AND 1100 PSI (7584 kP) FOR H22A. IF THERE IS NO IMMEDIATE PRESSURE, SHUT THE SAW DOWN
AND CHANGE THE PHASE ORDER.

2.1
PLC 100 CONTROL SYSTEM
OPERATION OVERVIEW

The PLC is a programmable logic controller that allows the operator to run the machine in both manual and automatic
modes.
All of the machine functions are also controlled from the PLC operator interface. There are four function buttons on
either side and eight function buttons below the display. The functions of the buttons below the screen are labeled on the
buttons themselves. The functions of the buttons to the left and right and the middle six buttons below the display are
indicated on the display in a coloured box immediately beside the button. The far left and right buttons below the display
are permanently labeled.

NOTE:
1. THE FUNCTION OF THE BUTTONS LABELED ON THE DISPLAY MAY CHANGE DEPENDING ON THE
SCREEN MODE BEING DISPLAYED.
2. ALL FUNCTIONS ARE NOT DISPLAYED ALL THE TIME. ADDITIONAL FUNCTIONS MAY BE ACCESSED BY
PRESSING THE FUNCTION BUTTON LABELED NEXT (IF DISPLAYED).

There is also a numeric keypad and a set of navigation keys to the right of the display. All of these as well as the
EMERGENCY STOP button detailed descriptions follow.
To power up the control panel, the EMERGENCY STOP button must be pulled out. The display screen will scroll through
several screens and finally display in MANUAL MODE. Once the control panel has power, the MACHINE START key
must be pressed to start the hydraulic system. Now all of the controls have been activated.
In MANUAL MODE, the operator has the ability to execute a single cut utilizing a pre-programmed SINGLE CUT MODE.
In AUTOMATIC MODE, the PLC has the capacity to program and store 999 jobs. Designated job numbers can be
programmed for the quantity required (maximum 99 pieces). Piece lengths range from 0” to 214” (5436 mm). Jobs can
be run individually or in a QUEUE, which allows a maximum of 5 jobs to run consecutively.

2.2
 NOTE: If an emergency situation arises during any operation, use the large red
mushroom EMERGENCY STOP button located on the control panel to shut down
the machine.

The PLC operator interface is used in all four operating modes:

1. Manual Mode – permits the operator to control all machine functions using the pushbuttons, as well as the
operator interface function keys.

2. Single Cut Mode – permits the operator to enter part length, and then advance and cut a single part automatically.

3. Automatic Job Mode – is used to automatically cut a ‘job’ (a preset quantity of identical parts).

4. Automatic Que Modes – there are two alternative Que Modes, selectable by changing a PLC parameter.

• Automatic Queue Mode – is the standard queue mode. It is used to automatically cut up to five different
jobs, consecutively, from a single workpiece or bundle. When all jobs in the queue are completed the saw
shuts down.

• Multi Queue Mode – is used to repeat the same queue a preset number of times. This mode is primarily
used to cut parts in sets. To illustrate, consider cutting four pieces each, of three different parts, A, B,
and C. In the Auto Queue approach, each job is programmed with required quantity of 4. In multi Queue
approach, each job only has a quantity of 1, but the queue required is set to 4.

Auto Queue: A, A, A, A, B, B, B, B, C, C, C, C
Multi Queue: A, B, C, A, B, C, A, B, C, A, B, C

The same number of parts are cut, but Multi Queue procedures the parts in sets, and the first complete set is available
much sooner if large quantities are being cut.

FUNCTION DESCRIPTIONS
HEAD CONTROLS
HEAD UP Pressing this key will raise the head but it will stop and hold its position if the key is
released.
HEAD DOWN Pressing this key will lower the head to its bottom limit and will stop and hold its position
when pressed again, or if the HEAD UP key is pressed.
FIXED VISE CONTROLS
FIXED VISE OPEN Pressing this key will open the fixed (front) vise and will stop and hold its position if the key
is released.
FIXED VISE CLOSE Pressing this key will close the fixed (front) vise. To stop and hold its position, press again
or press the FIXED VISE OPEN key. The fixed vise must be closed to start the blade.
SHUTTLE VISE CONTROLS
SHUTTLE VISE OPEN Pressing this key will open the shuttle (rear) vise and will stop and hold its position if the
key is released.
SHUTTLE VISE CLOSED Pressing this key will close the shuttle (rear) vise. To stop and hold its position, press
again or press the SHUTTLE VISE OPEN key.

2.3
SHUTTLE CONTROLS
SHUTTLE FORWARD Pressing this key will move the shuttle towards the front of the saw and will stop and hold
its position if the key is released.
SHUTTLE REVERSE Pressing this key will move the shuttle towards the back of the saw and will stop and hold
its position if the key is released.
SHUTTLE SLOW / FAST Pressing this key will toggle between FAST and SLOW shuttle speed. The button display
will indicate FAST or SLOW.

BLADE CONTROLS
BLADE START/STOP Pressing this key will start or stop the blade. The blade will not start if the head is fully
down or if the fixed vise is not closed.
RIGHT ARROW KEY Pressing this key will cause the blade speed to increase until the key is released or the
(NAVIGATION KEYS) speed is at the maximum (350 SFM). The blade must be running to use this key and the
blade speed is shown on the display screen.
LEFT ARROW KEY Pressing this key will cause the blade speed to decrease until the key is released or the
(NAVIGATION KEYS) speed is at the minimum (70 SFM). The blade must be running to use this key and the
blade speed is shown on the display screen.
COOLANT CONTROLS
COOLANT ON Pressing this key will start the coolant flow.
COOLANT OFF Pressing this key will stop the coolant flow.
COOLANT AUTO Pressing this key will cause the coolant to flow only when the blade is running OR when
the blade is running and the head is descending.
MODE CONTROLS
SERVICE MODE The SERVICE MODE allows the user to adjust the various PLC parameters. The user
will be prompted for a password. Contact Hyd-Mech Group Limited to access this mode.
MANUAL MODE Pressing this key will put the saw in MANUAL MODE.
AUTO MODE Pressing this key will put the saw in AUTO MODE. To enter AUTO MODE, the FIXED
VISE must also be activated.

MACHINE & CYCLE CONTROLS

MACHINE START Pressing this key will activate the control panel, display, and start the hydraulic system.
The EMERGENCY STOP button must be pulled out. This key must be activated to use
the machine functions.
MACHINE STOP Pressing this key will shut down all machine functions including the control display and
hydraulic system. The display will not have a back light on. All jobs will remain in memory
as will the QUEUE.
CYCLE START The user will be prompted by the display to press this key as it is used to initiate an AUTO
or SINGLE CUT MODE cycle. Pressing this button will also initiate the QUEUE if pressed
when in the QUEUE screen.
CYCLE PAUSE Pressing this key will pause the cycle in progress. To resume the cycle, press the CYCLE
START key.

2.4
 PLC Operator Interface and Labeled Buttons

MANUAL MODE

MANUAL MODE is the default mode. All functions are enabled when in MANUAL MODE. The screen will look as follows:

2.5
SINGLE CUT MODE OPERATION

In MANUAL mode, the PLC allows the operator to initiate a SINGLE CUT MODE to cut one piece at a desired length.
Closing the front vise automatically initiates Single Cut Mode. Follow the procedure below.

1. A trim cut should be made before initiating the SINGLE

CUT MODE operation
2. Make sure the front vise is in the closed position.
3. Make sure the head is set so that the blade is above the
material.
4. ENTER LENGTH will be flashing. Key in the desired
length up to 214” (5436 mm) using the numeric keypad
and press enter.
5. Cycle start will be flashing in the display window.
6. Press the cycle start pushbutton. The pushbutton lights
and the Material Height Prompt Screen appears.
7. Set the material height using the Head Up & Head Down
push buttons and then press enter. Position the blade
about 3/8” above material.
8. If the blade is not running, you will be prompted by
the words BLADE START. Start the blade and adjust the blade speed as required.
9. When the cut is completed, the head will rise to the set material height, the blade will stop and the display window
will reset for the next cut.
10. To cut another piece, repeat steps 2 through 6.

NOTES:
1. To pause the SINGLE CUT CYCLE, press the CYCLE
PAUSE button. The CYCLE START button will be
displayed and the screen will indicate a paused
condition. All movements will immediately cease, except
blade will continue to run. To continue the cycle, press
CYCLE START.
2. To cut multiple pieces, switch to AUTO MODE and follow
the automatic procedures.
3. Whenever a new job or new material is being loaded for
production, the head up limit should be properly set to
clear the material positioned for a trim cut and the front
vise should be closed (in MANUAL MODE).

2.6
AUTOMATIC OPERATION
To enter AUTO MODE, the FIXED VISE must be closed, putting the saw in SINGLE CUT MODE. When the
AUTO MODE key is pressed, the red indicator will come on. The screen will change to the JOB display window
as shown below and will be ready for editing or starting a new job. All manual functions will be disabled.

PROCEDURE FOR EDITING OR STARTING A NEW

JOB IN AUTO MODE

1. In AUTO mode, key in a job number from 0 to 99,

the number of pieces to be cut, the number of pieces
already cut, and the length, pressing enter after each
value. If the number of pieces cut equals or exceeds
the number required, the cycle will not start. If the job
number has previously been programmed, the number
of pieces, length, and number cut will be displayed. To
navigate through the values, use the cursor keys. The
values displayed may be edited by using the numeric
keypad and pressing enter. The job will then be stored
in memory with the new values.

The job is now ready to start to run or other jobs can be programmed at this time. To run a certain job, press the QUEUE
key and then CLEAR to clear the QUEUE. Move the cursor to
the 1st job and key in the desired JOB #.

2. After the values are entered, press the CYCLE START

button. The Material Height Prompt Screen appears.

3. Set the material height using the Head Up & Head Down
push buttons and then press enter. Position the blade
about 3/8” above material.

4. The display window will prompt you to start the blade

for a trim cut (if the “Trim Cut” parameter has been
selected).

When the AUTO CYCLE commences, the screen will change to

the “Auto Mode Status” screen and the following events will take
place:

1. A trim cut will be performed.

2. After the trim cut, the shuttle will advance the material to
the LENGTH value.
3. The saw will now cut the material to the LENGTH value
compensating for the thickness of the blade.
4. Steps 2 and 3 will be repeated for the given number of
pieces to be cut.
5. At the completion of the job, the machine will shut off.

NOTES:
1. The CYCLE PAUSE key is used to pause a job in
progress. To resume the job, press the CYCLE START
key and the AUTO CYCLE will resume.
2. If PIECES CUT equals or exceeds NUMBER OF
PIECES, AUTO CYCLE will not start.

2.7
WORKING WITH A QUEUE

The purpose of a QUEUE is to allow the operator to run several jobs (maximum of 5) in series if they are of the same
material and shape.
To run a QUEUE, it is necessary to program in all job values as is done with programming a single job. After the jobs
are programmed in, press QUEUE, press CLEAR to clear the QUEUE, and enter the desired JOB #’s in the desired
sequence.

To run the QUEUE press CYCLE START. The pushbutton lights and the Material Height Prompt Screen appears.

Set the material height using the Head Up & Head Down push buttons and then press enter. Position the blade about 3/8”
above material.
If the blade is not running you will be prompted by the words BLADE START. Press the BLADE START key. The JOB
PROGRESS screen will appear and display each individual JOB as it is being run.
At the completion of the last job in the QUEUE, the machine will shut off if “0” has been entered in the POWER DWN
TIMER parameter or continue running the specified time up to a maximum of 180 minutes. The machine will automatically
advance the stock between jobs for trim cuts as needed.

WORKING WITH A REPEATING QUEUE

The QUEUE mode can also be set to repeat the sequence of jobs up to 99 times. To do this the QUEUE parameter in
SERVICE mode must be set at REPEAT.
To run a repeating queue, two additional rows are added to the QUEUE display screen after JOB E: QUEUE CUT (the
number of times that the QUEUE has been completed) and QUEUE REQUIRED (the number of times that the QUEUE is
required to be repeated.
When entering job data for jobs to be used in a repeating QUEUE be aware that:

# of parts cut = # of JOBS x QUEUE REQUIRED

For example:
JOB A is set to cut 1 piece
JOB B is set to cut 2 pieces
QUEUE REQUIRED is set to 5

When the cycle is initiated, 1 JOB A piece will be cut followed by 2 JOB B pieces with this pattern repeating 5 times.
This will give you a total of 5 JOB A pieces and 10 JOB B pieces.

The QUEUE may be exited to the previous screen at any time by pressing the JOB key.

2.8
PARAMETERS

The parameters can be accessed by pressing the service mode button on the panel. These parameters can be changed
without a password.

2.9
 PARAMETER DEFINITION

Blade Speed Display adjustment number. If actual blade speed is different than
SPEED CONSTANT displayed blade speed, a new Speed Constant will need to be calculated.
Speed Constant = old Speed Constant x actual speed / displayed speed.
Feed rate display constant value. If the actual feed rate differs from displayed value,
HEIGHT CONSTANT enter new Height Constant = old Height Constant x actual feed rate / displayed feed
rate.
CANTED HEAD Select Yes if the saw is equipped with a canted head.
MACHINE MODEL Select saw model: H18, H22, H28
SHUTTLE DRIVE Select the type of shuttle drive: Servo of Cylinder.
SHUTTLE FULL STROKE Maximum usable shuttle travel.
Specifies linear distance of shuttle movement in inches per one pulse generated by motion
LENGTH RESOLUTION
controller.
LENGTH BACKLASH Backlash value of the shuttle drive system.
Shuttle acceleration/deceleration time. Time, in milliseconds that the shuttle will
ACCEL/DECEL TIME
accelerate from 0"/s to full speed or decelerate from full speed to 0"/s.
MAX SHUTTLE SPEED Maximum shuttle speed constant.
MINIMUM FAST DISTANCE Not used.
TARGET WINDOW Not used.
FRONT VISE OPEN DWELL Delay time for the opening of the Fixed Vise in seconds.
SHUTTLE VISE OPEN DWELL Delay time for the closing of the Shuttle Vise in seconds.
CLOSE TIME Delay time for the closing of the Fixed of Shuttle Vise in seconds.
FEED RATE Activates feed rate display.
ACTUAL POSITION DISPLAY If this value is set to YES, displays Shuttle Vise actual position.
HOLD SHUTTLE HOME Hold Shuttle Vise home and closed during cut.
Allows user to override signal from proximity switch in case it is broken. When set to NO
BROKEN PROX machine will not run with broken proximity sensor. Set to YES allows machine to run,
but with out blade speed display, blade breakage, or stall protection.
MIN BLD SPEED Minimum blade speed on which blade breakage will be activated.

Delay in monitoring of the blade speed proximity switch during acceleration of the blade
SPD PROX DELAY
from start to desired speed set by the manufacturer.

If "0" selected, then the machine will shut down after the job is completed. This will allow
POWER DOWN TIMER the machine to continue running for a specified time after the job (in Manual Mode) for
the cycle (in Auto Mode) has been completed. Range from "0" to "180" minutes.

If YES is selected, the machine will perform a facing cut of the material at the beginning
TRIM CUT
of an automatic cycle.
If set to YES, when the AUTO CYCLE reaches the function of head up, the shuttle will
BLADE CLEAR retract the material from the blade by 1/8” before the head will move up. When the head
reaches the up position, the next length of material is shuttled into position.
Selecting YES activates the out of stock option, which prevents the shuttle vise from
OUT OF STOCK closing if an insufficient length of material is available for the next length advance. Also
stops the automatic cycle after completing the last cut.
When BLD is selected, coolant flows when the blade is running. Then BLD + DWN is
COOLANT
selected, coolant flows when the blade is running and head is moving down.
The Queue allows the operator to run several jobs (max 10) in series. If REPEAT is
QUEUE
selected the above series will be executed the selected number of times.

2.10
HYDRAULIC FEED CONTROL

The Hydraulic Feed Control is located to the left of the control panel. These controls allow independent control of
Feed Force (FF) and Feed Rate (FR)

FEED FORCE KNOB

Used to set feed force limit (counterclockwise
rotation to increase and clockwise rotation to
decrease).
FF IS NOT APPLICABLE TO H40 MODEL
FAST APPROACH LEVER.
Depress for fast head
descent EXTRA FINE METERING VALVE
Used to set feed rate (counterclockwise
rotation to increase and clockwise rotation to
decrease).

FEED RATE KNOB (Fine Metering)

Used to set feed rate (counterclockwise
rotation to increase and clockwise rotation to
decrease).

The FINE METERING DDF VALVE is equipped with two Feed Control Knobs. Extra fine Micrometer style Knob and Fine
Metering Knob. The main difference between both Feed Controls is that the Extra Fine Metering valve does not work with
the Feed Force Limit Valve. It is recommended to use only one feed control at a time with the second control valve shut.
The choice of control is arbitrary and a matter of trial.
In some cases Extra fine Metering provides better results in others Fine Metering Control.
As a rule of thumb:
Extra Fine metering valve should be used
• if required feed is in a range of .12-.25”/min
• and/ or when cutting hard material
• or when work hardening may occur.
Fine metering valve should be used
• When cutting structural steel
• and/ or bundles
• High feed rates required

2.11
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” (200mm) Diameter #1045 Carbon Steel.

STEP 1: DETERMINE EFFECTIVE MATERIAL WIDTH - W (inches) or (mm)

Effective material width, W (in.) for most common shapes of materials, is the widest solid part of the material to be in
contact with blade during cutting. For simple shapes, as illustrated on the chart, this can be directly measured. For
bundles of tubes and structurals, measuring the effective width is difficult. Effective width is 60% to 75% of the actual
material width.

Material Width Chart

NOTES:

1. Effective material width, as determined here in STEP 1, can be thought of as the average width of material “seen”
by each tooth, and it is used in STEPS 3 and 4.
In Example #1, for an 8” (200 mm) diameter solid, Effective Material Width is 8” (200mm).

2.12
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
ON LABEL)

MAT’L WIDTH AS %
OF SAW CAPACITY

EXAMPLE: When cutting a solid which is 1/2 of machine capacity using the graph, locate 50% on the horizontal line and
travel upwards to the plotted line and then travel directly across to the vertical FF Setting line. The point that you have
arrived at shows a setting of 40% for a piece 50% of capacity.

CUTTING STRUCTURALS: A reduced Feed Force Setting is used when cutting structurals.

2.13
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. The sketch can be referenced for the blade pitch changes for
differing effective material widths.

Optimum Blade Pitch (T.P.I) for Material Width (Inches)

It is impractical to change the blade to the proper pitch every time a different width of material is cut and it is not
necessary, but remember that the optimum blade will cut most efficiently. Too fine a blade must be fed slower on wide
material because the small gullets between the teeth will get packed with chips before they get across and out of the cut.
Too coarse a blade must be fed slower because it has fewer teeth cutting and there is a limit to the depth of a cut taken by
each tooth. Allowance for the use of a non-optimum blade is made in STEP 5.

Example #1: Effective material width of 8” (200 mm):

Optimum blade has 2/3 teeth per inch.

2.14
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. If material is narrow or soft, higher blades speeds should be selected.

Example #1

1. 8” (200mm) diameter #1045 Medium Carbon Steel solid bar is to be cut.

2. On the graph above find the Medium Carbon Steel Curve which represents the optimum blade speeds for 1045
Carbon Steel.
3. On the horizontal axis (effective material width axis) find number 8 which represents effective material width of an
8” (200mm) diameter solid.
4. Find the point where a vertical line from 8” (200mm) intersects the Medium Carbon Steel Curve.
5. From this intersection point run horizontally left to the vertical axis (optimum blade speed axis) and find the point
marked “200”.
6. For 8” (200mm) diameter, 1045 Carbon Steel solid bar 200 ft/min (60m/min) is the optimum blade speed.

NOTE:
1. Higher than optimum blade speed will cause rapid blade dulling. Lower than optimum blade speeds reduce
cutting rates proportionately and do not result in significantly longer blade life except where there is a vibration
problem. If the blade vibrates appreciably at optimum speed as most often occurs with structurals and bundles, a
lower blade speed may reduce vibration and prevent premature blade failure.

2. Material Hardness - The graph above illustrates blade speed curves for materials of hardness 20 RC (225 Bhn) or
lower. If the material is hardened then the multipliers need to be used. These multipliers are given in the NOTE at
the bottom right of the graph. As the hardness increases the optimum blade speed decreases.

2.15
The following table gives examples of the optimum blade speeds for different materials.

# MATERIALS OPTIMUM BLADE SPEED

(ft/min) (m/min)
1 5” (125mm) Diameter Solid Carbon Steel 225 70
2 12” (300mm) I-Beam 290 90
3 4” x 4” (100mm x 100mm) Rect. Tube 1/4” (6mm) Wall 350 110
4 4” (100mm) 400 Stainless Steel 140 45
5 2” x 2” (50mm x 50mm) Rect. Tube 1/4” (6mm) Wall
Bundle 5” x 5” pcs. 10” x 10” (500mm x 500mm) 325 100
6 3” x 3” (75mm x 75mm) Inconel 60 20
Materials and Blade Speed

STEP 5: DETERMINE FEED RATE SETTING, FR (in/min) (mm/min).

FEED RATE is the vertical speed at which the blade descends through the work-piece.

The FEED RATE Knob controls FEED RATE of the blade descent. The FEED RATE should be adjusted only in one direc-
tion (from “O” to required value). If you go too far, go back to “O” and come back up. To set FEED RATE for particular
cutting situations use the graph below, which represents the relationship
between FEED RATE, blade speed and blade pitch.

Example #1: It is known from Step 3 that optimum blade

pitch is 2/3, and from Step 4 that blade speed is 200 ft/min
(60mm/min). From the Graph on the left, the FEED RATE is
determined in the following way:
1. On the horizontal axis (blade speed axis), find
200 ft/min (60mm/min).

2. Find the point where a vertical line from 200 ft/min

(60mm/min) would intersect the 2/3 blade pitch curve

3. From this intersection point run horizontally left to the

vertical (FEED RATE) axis, to arrive at 1.8 in/min
(45mm/min) FEED RATE. Thus 1.8 in/min (45mm/min)
is the FEED RATE for cutting 8” (200mm) diameter 1045
Carbon Steel when the optimum 2/3 pitch blade is used.
Feed Rate Calculation

2.16
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. 3/4 TPI) we use the graph for the optimum blade as before, and
then use a multiplier given by the table below.

Optimum Vs Actual Blade Pitch

ADDITIONAL CUTTING SETUP EXAMPLES

EXAMPLE # 2

Material:
Round Steel Tube SAE 4320 - Hardened to 35 RC (325 Bhn )
Dimensions - 6” O.D. x 4” I.D. (150mm O.D. x 100mm I.D.)

Step 1 Effective Material Width: 4 1/2” (.75 X 6) 114mm (19 x 6)

Step 2 Feed Force limit setting for 6” Diameter material (Refer to Feed Force Limit, Setting in Step 2)

Step 3 Optimum blade pitch (TPI): 3/4 T. P. I.

Actual blade pitch on the saw: 4/6 T. P. I.

Step 4 Optimum blade speed for 4 1/2” effective 225 ft/min (70m/min) material width
Blade speed reduced by hardness factor: 225 ft/min X .60 = 135ft/min (70m/min x .60 = 42m/min)

Step 5 Feed Rate for 3/4 TPI blade: 1.8 in/min (45mm/min)
Feed Rate for 4/6 TPI blade: 1.8 in/min X .70 = 1.3in/min
(reduced by finer than optimum blade pitch factor) (45mm/min x .70= 31.5mm/min)

2.17
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)

Step 1 Effective Material Width: 5” ( .6 X 8” ) 120mm (.6 x 200)

Step 2 Feed Force limit setting for 8” Diameter material. (Refer to Feed Force Limit, Setting in Step 2)

Step 3 Optimum blade pitch (TPI): 3/4 T. P. I.

Step 4 Optimum blade speed for 5“ effective material width: 320 ft/min (100m/min)

Step 5 Feed Rate for 3/4 TPI blade: 4.0 in/min (100mm/min)

ADDITIONAL CONTROLS

COOLANT FLOW

The main coolant control is found on the control panel.

WASH: Coolant flows any time the machine is under power, permitting wash down with
spray nozzle without running machine.
OFF: No coolant flow.
ON: The coolant flows only when the blade is running or when the blade is running and
the head is descending. This is selectable via the PLC parameters.

The bandsaw is equipped with two independently controlled coolant spouts that are capable
of supplying a generous flow of coolant to the blade.
The left guide arm supplies a flow of coolant that should flood the blade as it moves through
the carbide pads into the material to be cut. The adjustable spout on the left guide arm
should be set with the blade speed to provide the flood of coolant necessary.
The right guide arm provides a coolant flow through the flexible hose that can be pointed directly where necessary. This
flexible hose should be used when cutting solid bars, bundles, or wide structurals. Set the flow of coolant directly into the
opening in the material where the blade is cutting.

NOTE: When cutting materials that do not need constant coolant, such as Cast Iron, some coolant flow is required for
blade lubrication to prevent blade scoring by the carbide pads as the blade moves through them.

2.18
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.

Head Up Limit: In order to maximize production in the automatic cycle the Head Up Limit should be set to just clear the
height of the material.

Head Down Limit: This limit is factory set and under ordinary cutting requirements should not be changed. If changed, it
may cause the machine to malfunction in the automatic cycle.

HEAD UP
LIMIT SWITCH

HEAD DOWN
LIMIT SWITCH

NON CANTED HEAD 6 DEGREE CANTED HEAD

HEAD DOWN L/S MOUNTED ON
MOVEABLE GUIDE ARM

VARIABLE VISE PRESSURE (OPTION)

This option allows the operator to adjust the vise pressure. This can be valuable when cutting light structurals and tubes.
By reducing the vise pressure from the system (H18=1000, H22=1100psi) pressure, distortion of materials is prevented.
The controls are located at the drive end of the machine next to the hydraulic compartment.

Variable vise pressure

read-out gauge

Variable vise pressure controls

2.19
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.

FRONT BUNDLING
SPEED ADJUSTMENT

SHUTTLE BUNDLING
AND VISE SPEED
ADJUSTMENT

FRONT VISE SPEED

ADJUSTMENT (LOCATED
ON BACK OF IDLER
SIDE)

FRONT BUNDLING ON/OFF

VALVE LOCATED ON FRONT
OF MACHINE

2.20
2.21
 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.
In almost all jurisdictions, it is required that owners of industrial equipment establish and post lock-out procedures. Know
and use the lock-out procedures of your company or organization. In the absence, of such posted procedures, use the
following procedure.

LOCK OUT PROCEDURE

Whenever work is to be performed on a machine, which requires removal or bypassing of safety guards or devices, or the
placement of part of anyone’s body in a hazard area, the following steps shall be taken:

1. Operator shuts down the machine.

2. The supervisor in charge of the machine must be informed of the intention to Lock-out the machine.
3. The 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 each person
shall apply his or her own lock to the hasp.
4. The Machine Power Disconnect Switch 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 each person
shall apply his or her own lock to the hasp.
5. Prior to starting any work on the locked-out machine, the supervisor shall attempt to start the machine to
ensure that the lock-out device provides adequate protection. Operating controls must be reset to the “OFF”
position after this test.
6. Work on the locked-out machine may now proceed.

MACHINE DISCONNECT SWITCH USED FOR SAFETY

LOCKOUT PURPOSES

Machine Power Disconnect located on the door of the

main electrical panel.

1. Ensure switch is in the OFF position.

2. Install padlock and lock it.

3.1
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. No-one shall be permitted in un-safe areas around the machine. All guards 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.

BLADE CHANGE MODE PROCEDURE

Wear safety glasses, gloves, and a long sleeve shirt for protection when handling band saw blades during blade change.
NOTE THAT GLOVES SHOULD NEVER BE WORN NEAR A RUNNING BANDSAW BLADE. When handling new blades,
or ones that will be re-used, it is important to keep the teeth out of contact with concrete floors.

This machine is equipped with a hydraulic blade tension selector switch and a ‘Blade Change Mode’ key switch, located
on the operator control panel. The description of the switch functions will either be in English or portrayed as a pictogram.
(See pictures below)

The blade change mode keyswitch has two positions:

OFF or O – All normal operations of the band saw are operative.

ON or I – Hydraulic motor can be started.

Blade tension is operative.

3.2
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’ POSITION.
3. Turn the blade change key switch to the ‘ON’ position. The hydraulics will continue to run, but only the blade
tension switch is functional. The blade wheel doors can be opened without the hydraulics shutting down.
4. Remove the blade guard.
5. Open both blade wheel doors.
6. Release the blade tension by turning the switch briefly to ‘ – ‘. The blade tension switch also opens and closes
the hydraulic blade guides. By jogging the switch between ‘HOLD’ and ‘ – ‘, it is possible to regulate the degree of
tension on the blade.
7. Pull the top strand of the blade down out of its slot above the cutting area and forward out of the slots on the
inside walls of the blade wheel housings.
8. Pull the lower strand of the blade down out of the blade guides.
9. Store and dispose of the used blade.

BLADE INSTALLATION

NOTES ABOUT NEW BLADES

• A new blade will come folded into a compact coil. Follow the blade manufacturer’s instructions for safely unfolding
the blade.
• The blade must be installed with the teeth facing towards the front of the saw where it passes around the wheels,
and with the teeth in the cutting area pointing towards the drive wheel. This may require that the blade be turned
inside out before installation.

1. With the blade change mode key switch remaining in the ‘ON’ position, turn the blade tension switch to the ‘ – ‘
position for several seconds until the idler wheel has fully retracted and the blade guides have fully opened.
2. Insert the lower strand of the new blade into the blade guides and briefly turn the blade tension switch to the
‘ +/RUN ‘ position. This will close the hydraulic guides and assist in holding the blade in the guides.
3. Lift the upper strand of the blade up into its slot above the cutting area, and place it around the blade wheels.
4. Turn the blade tension switch briefly to ‘ +/RUN’ and then leave it in ‘HOLD’ to retain the blade lightly on the
wheels.
5. Adjust the blade position on the wheels so that the blade is not crooked on them and the teeth overhang the front
edge of the wheels.
6. Turn the blade tension switch to ‘+/RUN’.
7. Close both blade wheel doors.
8. Turn the blade change mode key switch to the ‘OFF’ position. The hydraulics will shut down.
9. Switch the hydraulics on, then start the blade and run for 20 seconds.
10. Stop the blade.
11. Turn the blade change key switch to the ‘ON’ position.
12. Open the blade wheel doors and inspect the blade tracking, plus the position of the blade brush. Refer to the
manual for tracking adjustments.
13. Close the blade wheel doors and turn the blade change mode key to the ‘OFF’ position.
14. Blade change procedure is now complete.

3.3
BLADE BRUSH ADJUSTMENT

The blade brush is properly set when machine leaves the factory, but it wears out during operation and needs to be
readjusted periodically. The blade brush assembly is found behind the drive side door and is shown below. To adjust the
assembly, loosen the hex nut, turn the setscrew counterclockwise until the wires on the brush touch the bottom of the
blade gullets and tighten the hex nut.
The brush should be replaced as it becomes worn to approximately 70% of it’s original 3” diameter. Replacements can be
purchased through your Hyd·Mech Dealer.

H18 SV H22 SV
BLADE BRUSH BLADE BRUSH

BLADE TRACKING ADJUSTMENT

For an H-18, blade tracking is set so the teeth of the blade protrude .260±.01” (6.6±.25mm) from the face of the wheels.
For an H-22, blade tracking is set so the teeth of the blade protrude .310±.01” (6.6±.25mm) from the face of the wheels.

IDLER WHEEL TRACKING

Release blade tension before adjusting. Adjust tracking by regulating “push” set screws and “pull” bolts. Loosening bolts
“A” and turning in set screws “C” by equal amounts will move the blade OFF the wheel. Loosening bolts “B” and turning in
set screws “D” by equal amounts will move the blade ON to the wheel. After each “C” or “D” set screw adjustment, tighten
bolts “A” or “B”, turn tension switch to “+RUN”, run the blade for a moment and recheck the tracking.

Note: Check the proximity sensor distance from the wheel target or spokes before starting the blade drive. Failure to do so
may result in damage to the sensor.

C A C D B D

A C D B

H18 SV H22 SV
Idler wheel tracking bolts & set screws

3.4
DRIVE WHEEL TRACKING

Release blade tension before adjusting. Loosening bolts “A” and turning in set screws “C” by equal amounts will move the
blade OFF the wheel. Loosening bolts “B” and turning in set screws “D” by equal amounts will move the blade ON to the
wheel. After each “C” or “D” set screw adjustment, tighten bolts “A” or “B”, turn tension switch to “+ RUN”, run the blade for
a moment and recheck the tracking.
B
A
D C
D C

H18SV F H22SV B A

C
A

D C

E B A
D
B
GEARBOX LUBRICATION (H-18ASV WITH A503 GEARBOX, H-22ASV WITH A603 GEARBOX)

The Bonfiglioli A503 gearbox used on the H18 is supplied with 8.4 litres (2.22 US gallons) of Mobil SHC 634 synthetic oil.
This oil has an ISO Viscosity Grade of 220 that is optimum for ambient temperatures from 20 – 40 Deg C [70 – 104 Deg
F]. If the machine will be operated for prolonged periods at ambient temperatures below 20 Deg C [70 Deg F] an oil of ISO
Viscosity Grade 150 should be substituted.

Because of the tilted orientation of the gearbox on the H18 and H22 saws, the correct oil level is about 1 inch below the
level plug, F, shown in the illustration.
Note: The H-22ASV with the A603 gearbox requires 15
The suggested oil change interval is given below: litres (3.96 US gallons) of Mobil SHC 634 synthetic oil.

Oil Temperature Mineral Oil Interval Synthetic Oil Interval

Deg C [deg F] [hours] [hours]
<65 [< 150 F ] 8000 25000
65 – 80 [150 F – 175 F] 4000 15000
80 – 95 [175 F – 200 F] 2000 12500

Oil can be changed by draining through plug, E, and filling at plug F. If the type
of oil is being changed, it is advisable to flush the old oil by filling the box with
the normal quantity of the new oil, running it briefly at moderate speed, and then
draining the box again, before re-filling it with a fresh quantity of the new oil.

OUTPUT SHAFT LUBRICATION

G
Always follow Lock-out Procedures before performing this lubrication.
Band tension load is carried by a grease lubricated spherical bearing. A grease
fitting is accessible through the spokes of the blade wheel, as shown at point G in
the accompanying illustration. Lubricate once per year with 30 ml [1 fluid once] of
NLGI Class 2 Lithium base mineral oil grease. This quantity represents about 20
to 30 strokes of a typical hand grease gun.
Vise jaw guides, infeed rollers and bundling assemblies also require periodic
greasing.

3.5
CAM FOLLOWER ADJUSTMENT

There are two cam followers mounted on the head frame. The set of cam followers are shown below. One of them is fixed
and the other is adjustable. The cam followers are factory set and usually do not require adjustment. In a properly
adjusted system of cam followers only one side should be in contact with the guide. The gap between the other and the
guide bar should be 0.003” – 0.005”. If it exceeds 0.005” you should contact your dealer to arrange for adjustment.

LUBRICATION

The design of the machine was intended to minimize maintenance, although periodically certain moving parts need
lubrication. 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, in-feed rollers and bundling assemblies require greasing.

2 SHUTTLE VISE GREASE NIPPLES 2 SHUTTLE

SHAFT BEARING HOUSINGS

4 GUIDE ARM GREASE

POINTS

IDLER WHEEL TENSIONER

(ONE AT BOTH ENDS) CAM FOLLOWER GREASE
NIPPLES

3.6
HYDRAULIC MAINTENANCE

1. OIL FILTER- Ten micron filtration of the 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. See section 5 for
replacement filter element information.

2. HYDRAULIC OIL- Machine hydraulic reservoir is filled with mineral oil Texaco Rando HD46. In case of changing the
brand, hydraulic system should be drained and thoroughly flushed. Following is a list of recommended replacement oils:
• TEXACO RANDO HD 46
• CHEVRON ECO Hydraulic oil AW ISO 46
• MOBIL DTE 25
• ESSO NUTO H46
• SHELL TELLUS OIL 46

3. HYDRAULIC OIL LEVEL - Oil level should be maintained in the upper half of the level gauge. Normally the rate of oil
consumption will be very low and it should be unnecessary to add oil more often than at filter changes if at all.

4. HYDAULIC OIL CHANGE - Oil visual inspection should be conducted with every filter change for following signs of
degradation:
• Milky or hazy oil color
• Burnt smell
• Varnish or sludge formation
• Increased viscosity
If one of the above is observed then oil should be changed. It is recommended to change oil after every 6000
hours of operation or every 2 years.

5. OIL TEMPERATURE - Oil temperature is indicated by a thermometer contained in the level gauge. Oil temperature
during steady operation should stabilize at about 50-55F (28-31 deg C) above room temperature. Thus in a
70F (21 deg C) shop one might expect an oil temperature of about 120F (49 deg C). Oil temperature should never exceed
155F (68 deg C).

6. HYDRAULIC PRESSURE - Hydraulic pressure is factory set and should not require any further attention. For correct
pressure see hydraulic schematic.

7. BLADE TENSION – Blade tension pressure is factory set and should not require
any further attention. For correct pressure see hydraulic schematic.

8. CARBIDE PRESSURE - Carbide lock pressure is factory preset:

• H-18SV 300 – 400 PSI
• H-22SV 150 – 200 PSI
The pressure gauge is not provided. There is a separate port to hook up a gauge if
setting needs to be verified or corrected.

CLEANLINESS Gauge Port

The heavy duty design should endure heavy operating conditions and provide the customer with flawless machine
performance. To extend good performance some care is required especially as 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 table 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 can be performed on them.

3.7
TROUBLESHOOTING

Most problems which may occur have relatively simply solutions which appear in this section. If the solution is not found
here, contact the Hyd·Mech Distributor from whom you purchased your bandsaw. They have trained field service
personnel who will be able to rectify the problem.

PROBLEM PROBABLE CAUSE SOLUTION

1a. Blade worn. 1a. Replace blade.

Saw is cutting out of 1b. Low blade tension. 1b. Tension blade.
1
square vertically. 1c. Blade guides. 1c. Check for worn guides.
1d. Excessive feed rate. 1d. Reduce.

Saw is cutting out of

2 2 Stock not square in vises. 2 Adjust accordingly.
square horizontally.

3a. Not enough blade tension. 3a. Reset blade tension.

3 Blade comes off wheels.
3b. Improper tracking. 3b. Set tracking.

4a. Not enough blade tension. 4a. Tension blade.

4 Blade stalls in cut. 4b. Excessive feed force. 4b. Reduce.
4c. Excessive feed rate. 4c. Reduce.

5a. Blade speed too fast. 5a. Reduce.

5 Blade vibrates excessively. 5b. Guide arms too far apart. 5b. Adjust accordingly.
5c. Not enough blade tension. 5c. Tension blade.

6a. Excessive blade tension. 6a. Reduce blade tension.

6 Excessive blade breakage.
6b. Excessive feed rate. 6b. Reduce.

7a. Blade pitch too fine. 7a. Select coarser pitch.

7b. Blade brush not cleaning. 7b. Adjust or replace blade brush.
7 Tooth strippage.
7c. Excessive feed rate. 7c. Reduce.
7d. Excessive feed force. 7d. Reduce.

8a. No coolant. 8a. Add coolant.

8 No coolant flow. 8b. Coolant line blocked. 8b. Blow out coolant line.
8c. Coolant pump inoperable. 8c. Check, replace if faulty.
1.Ensure all Emergency Stop push
buttons are released.
9a. Safety relay is not energized 9a.
2.Ensure Door interlock switches are
not activated.(Close Drive & Idler doors)
Depress each of the over-load buttons
located in the electrical box. Depressing
9b. Motor overload has tripped. 9b. one button at a time and trying to start the
9 Saw will not start. saw will indicate which motor was
overloaded.
Replace the fuse in the control panel.
Random blowouts may occur but a quickly
9c. Control circuit fuse has blown. 9c.
repeated blowout points to an internal
wiring fault.
Vise or head selector switch not in the Turn all switches to the center (neutral)
9d. 9d.
center (neutral) position. position.

3.8
 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
10 after Start button has been 10 stock or blade breakage limit switch 10
blade tension or open vises far enough to
released. has been tripped.
deactivate the limit switch.

If blade wheels run clockwise, wrong

Stop immediately; reverse any two of the
11a. phase order in power connection to 11a.
three phase connections.
saw.
Saw starts but no hydraulic
11 If pump is noisy cause may be low Stop immediately, add hydraulic oil. (See
functions. 11b. 11b.
hydraulic oil level. "Hydraulic Maintenance")
11c. Pump-motor coupling has separated. 11c. Adjust accordingly.

IN MANUAL MODE

Observe pilot light(s) on relevant valve.

This requires the attention of a qualified
12a. If pilot light fails to go on, problem is 12a.
service person.
electrical.
No individual function will
12 respond to its manual If pilot light related to inoperative Disassembly of hydraulic valves should be
control switch. function does light, problem may still under taken only by qualified service
12b. 12b.
be the coil . If problem remains it may personnel or those knowledgeable with
result from dirt in the valve spool. hydraulic components.

Feed Rate Valve is fully closed -

Turn Feed Rate Knob in a counter
13a. pointer is set on "0" or close to "0" 13a.
clockwise to open valve.
in/min.
13 Head will not descend.
13b. Feed Force Limit is set too low. 13b. Increase Feed Force Limit.
Check for physical interference
13c. 13c. Remove obstructions.
preventing the head from falling.
IN AUTOMATIC MODE

Enter job numbers(s) and job data as

14a. No job queue programmed to run. 14a.
14 Auto cycle will not start. described in Section 2.
14b. Pieces required equals pieces cut. 14b. Clear pieces cut.

3.9
PLC TROUBLESHOOTING

Problem #1

PLC is not measuring lengths.

Possible causes:

1a. Pinion gear is loose on the DRIVE shaft.

1b. A bad Servo Drive.

2a. Damaged PLC hardware.

3a. No power from the PLC unit.

Problem #2

Inaccurate Lengths in Auto Mode

Possible Causes:
1. Improper programmed information
a. Existing parameter(s) incorrect.
b. Incorrect blade kerf.

2. PLC
a. Faulty PLC unit (not repairable in the field)
b. Material slippage.
c. Decrease shuttle speed.

GENERAL RULES

Normally, three types of length inaccuracies may occur.

1. Inconsistent
a. Lengths cut are not consistent, error changes. It doesn’t matter how long the part required is the error is never
the same.
b. Cause: Most likely a defective electrical, hydraulic or mechanical component.
c. Material slippage.

2. Consistent
a. Lengths cut are consistent and the error is also consistent. The error always stays the same regardless of part
length.
b. Cause: Kerf Value.

3. Linear
a. Lengths cut are consistent but the error increases as the part length increases. The longer the part the greater
the error.
b. Incorrect PLC and/or SERVO parameters.

Diagnosis:
• Check and record the existing parameters. Also check for proper blade kerf. By making a cut part way into a piece
of material and measuring the width of the cut, the operator can check the blade kerf.

GENERAL RULE:
Lowering the parameter value = longer shuttle travel = longer parts
Increasing the value = shorter shuttle travel = shorter parts

3.10
Problem #3

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). Like the output relays, the input relays are located on the PLC unit. Directly beside the
input and output terminals are red LED’s (Light Emitting Diode), which will light up when the corresponding input is being
received or output being actuated. Observation of these input/output LED’s can help diagnose auto cycle problems. Refer
to the PLC inputs and outputs in this section. When a problem occurs in the auto mode, the lights should be checked to
see if they are coming on at the proper time or if they are coming on at all.

Input LED’s
If a specific input light does not come on when expected
• Check for a faulty/misadjusted limit switch, push button, encoder or faulty wiring or connections.
• Wiring for each limit switch should be connected from the VDC terminal connection to the particular limit switch,
and from the limit switch to the input connector of the PLC.
Note:
All inputs are denoted by an “X”
All outputs are denoted by a “Y”

The following is information on output diagnosis and the sequence of inputs and outputs during the auto cycle.

Auto Cycle Sequence:

After the mode push button is in the auto position, the job has been programmed into the PLC, and the cycle start push
button pressed:
1. Hydraulics running, the head should move to its up limit if it is not already there. The shuttle vise should open and
come forward to the home position. HUP input light must come on for the cycle to continue.
a. HUP input on – cycle should continue, if not check outputs per step 2.
b. HUP input not on – Check that the head up limit switch is being activated. Check the limit switch/limit switch
wiring.
2. Front vise should be closed; the shuttle vise should stay open and move back to the programmed length.
a. FVC output should be on and SVO output will light momentarily, REV output and FST output should be on when
the shuttle moves back fast.
3. As the shuttle approaches the target length the FST output should shut off and the shuttle should travel slowly for the
DEC DIST parameter (cushion distance). When the shuttle reaches the target length the SVC output should light and the
shuttle vise should close on the material.
4. FVO output light should momentarily turn on and the front vise should open.
5. FWD output should light as will the FST for the shuttle to move forward in fast speed. FST will turn off when the
shuttle home cushion period is reached and the shuttle should slow down into the home position.
6. FVC output should light and the front vise should close. FWD light should go out, HDN output should come on and
the head should start to descend for the cut. If the blade is not running at this time, the cycle will hold until minimum SFM
is reached. Depending on “HLD SHTL HM” parameter in the PLC, the shuttle may stay home and closed during the cut or
may move back to pick up the next length. HUP input should go out as the head descends and HUP L/S deactivates.
7. After the cut is completed HDN input should light, HDN output should go out, the HUP output should light and the
head should move up. When the head reaches it’s up limit, HUP input should come on, HUP output should turn off, and
the cycle repeats with the next length being clamped by the shuttle, the front vise opening and the material being brought
forward to the home position.

3.11
Problem #4

No Display

Possible Causes:
1. No power to the HMI.
2. PLC unit failure.
3. Faulty connection of cable between PLC and Interface.
4. Faulty HMI unit.

Diagnosis:
a. Check the power LED. This light should be on when the PLC is switched on.
b. If the light is on, the PLC may have failed. Check for proper connection of the cable at the PLC and at the inter
face. Also check the PLC fuse.
c. If the fuse is OK, ensure that power is being supplied to the fuse.

Problem #5

No blade speed display

Possible Causes:
1. Faulty proximity sensor
2. Misadjusted sensor (the gap should be approx .030” - .040”)
3. Contamination on the end of the sensor.
4. Faulty PLC unit.
5. Bad connection of sensor wiring

Diagnosis:
• Check for the LED light on the sensor. The light indicates that the sensor has power and is activated. The problem
could be with the sensor, signal wire to the PLC or with the PLC itself. With the blade running, the light on the back of the
sensor should “pulse”. Likewise, the PLC input LED X2, should also be “Pulsing”. If both LED’s are pulsing with the blade
running, the PLC is the problem. If the sensor is pulsing but the input LED on the PLC is not, there is a problem between
the sensor and the PLC unit.
• If the LED on the sensor is not on, the problem is with the sensor wiring or the sensor is at fault.

M12 PIN ASSIGNMENTS FOR I/P & O/P DEVICES

3.12
 PCB BOARD: FUSE LOCATION
# FUSE DESCRIPTION
1 3FU1, 3FU2 5 Amp Time Delay
2 4FU 2 Amp Time Delay
3 5FU1, 5FU2 2 Amp Fast Acting
4 6FU 5 Amp Time Delay

4FU 6FU 5FU1 5FU2 3FU1 3FU2

COMMUNICATION PLC OUTPUT

CABLE CABLE
PLC

PLC INPUT INPUT CONNECTIONS OUTPUT CONNECTIONS

CABLE

3.13
 STANDARD PARAMETER VALUES
Current
PARAMETER DEFINITION
Value
Blade Speed Display adjustment number. If actual blade speed is different than
SPEED CONSTANT displayed blade speed, a new Speed Constant will need to be calculated. 70000
Speed Constant = old Speed Constant x actual speed / displayed speed.
Feed rate display constant value. If the actual feed rate differs from displayed value,
HEIGHT CONSTANT enter new Height Constant = old Height Constant x actual feed rate / displayed feed 0.0421
rate.
CANTED HEAD Select Yes if the saw is equipped with a canted head. NO
MACHINE MODEL Select saw model: H18, H22, H28 H18/22
SHUTTLE DRIVE Select the type of shuttle drive: Servo of Cylinder. SERVO
SHUTTLE FULL STROKE Maximum usable shuttle travel. 119
Specifies linear distance of shuttle movement in inches per one pulse generated by motion
LENGTH RESOLUTION 0.001
controller.
LENGTH BACKLASH Backlash value of the shuttle drive system. 0.007
Shuttle acceleration/deceleration time. Time, in milliseconds that the shuttle will
ACCEL/DECEL TIME 2500
accelerate from 0"/s to full speed or decelerate from full speed to 0"/s.
MAX SHUTTLE SPEED Maximum shuttle speed constant. 7000
MINIMUM FAST DISTANCE Not used. 0.75
TARGET WINDOW Not used. 0.002
FRONT VISE OPEN DWELL Delay time for the opening of the Fixed Vise in seconds. 1
SHUTTLE VISE OPEN DWELL Delay time for the closing of the Shuttle Vise in seconds. 1
CLOSE TIME Delay time for the closing of the Fixed of Shuttle Vise in seconds. 1.2
FEED RATE Activates feed rate display. YES
ACTUAL POSITION DISPLAY If this value is set to YES, displays Shuttle Vise actual position. NO
HOLD SHUTTLE HOME Hold Shuttle Vise home and closed during cut. NO
Allows user to override signal from proximity switch in case it is broken. When set to NO
BROKEN PROX machine will not run with broken proximity sensor. Set to YES allows machine to run, NO
but with out blade speed display, blade breakage, or stall protection.
MIN BLD SPEED Minimum blade speed on which blade breakage will be activated. 30

Delay in monitoring of the blade speed proximity switch during acceleration of the blade
SPD PROX DELAY 5
from start to desired speed set by the manufacturer.

If "0" selected, then the machine will shut down after the job is completed. This will allow
POWER DOWN TIMER the machine to continue running for a specified time after the job (in Manual Mode) for 15
the cycle (in Auto Mode) has been completed. Range from "0" to "180" minutes.

If YES is selected, the machine will perform a facing cut of the material at the beginning
TRIM CUT YES
of an automatic cycle.
If set to YES, when the AUTO CYCLE reaches the function of head up, the shuttle will
BLADE CLEAR retract the material from the blade by 1/8” before the head will move up. When the head NO
reaches the up position, the next length of material is shuttled into position.
Selecting YES activates the out of stock option, which prevents the shuttle vise from
OUT OF STOCK closing if an insufficient length of material is available for the next length advance. Also YES
stops the automatic cycle after completing the last cut.
When BLD is selected, coolant flows when the blade is running. Then BLD + DWN is
COOLANT BLD
selected, coolant flows when the blade is running and head is moving down.
The Queue allows the operator to run several jobs (max 10) in series. If REPEAT is
QUEUE SINGLE
selected the above series will be executed the selected number of times.

3.14
 STANDARD SERVO PARAMETERS
MACHINE MODEL Units H22A-120
Servo 240VAC
480VAC MR-J2S-350A4
PAR. # PAR. DESCRIPTION
0 Control mode - 0000
3 Electronic gear numerator - 47280*
4 Electronic gear denominator - 100
5 In position range Pulse 1
7 Position command acceleration/deceleration ms 50
11 Acceleration time constant ms 0
12 Deceleration time constant ms 1750
13 S-pattern acceleration/deceleration time constant - 1000
17 Analog monitor output - 0002
19 Parameter block - 000E
Switch MAIN power OFF, wait 10 sec then switch ON
21 Function selection (command pulse) - 0010
22 Function selection (Slow, Stop, On, End of Stroke) - 0001
27 Encoder output pulses pulses/rev 100
28 Torque Limit % 75
31 Analog monitor 1 offset (MO1) mV 60
54 Function selection (output pulse rotation dirct.) - 1001
Switch MAIN power OFF, wait 10 sec then switch ON

Instructions on Changing Parameters on Servo Drive

1) Press the [MODE] button

2) Press the [SET] button twice
3) Use [UP] or [DOWN] button to change the parameter
4) Press the [SET] button to enter.
Note. For detailed information see Display and Operation procedure

* = Increasing the value in PARAMETER 3 will result in a longer cut

3.15
 ACTUAL PARAMETER VALUES

Current
PARAMETER DEFINITION
Value
Blade Speed Display adjustment number. If actual blade speed is different than
SPEED CONSTANT displayed blade speed, a new Speed Constant will need to be calculated.
Speed Constant = old Speed Constant x actual speed / displayed speed.
Feed rate display constant value. If the actual feed rate differs from displayed value,
HEIGHT CONSTANT enter new Height Constant = old Height Constant x actual feed rate / displayed feed
rate.
CANTED HEAD Select Yes if the saw is equipped with a canted head.
MACHINE MODEL Select saw model: H18, H22, H28
SHUTTLE DRIVE Select the type of shuttle drive: Servo of Cylinder.
SHUTTLE FULL STROKE Maximum usable shuttle travel.
Specifies linear distance of shuttle movement in inches per one pulse generated by motion
LENGTH RESOLUTION
controller.
LENGTH BACKLASH Backlash value of the shuttle drive system.
Shuttle acceleration/deceleration time. Time, in milliseconds that the shuttle will
ACCEL/DECEL TIME
accelerate from 0"/s to full speed or decelerate from full speed to 0"/s.
MAX SHUTTLE SPEED Maximum shuttle speed constant.
MINIMUM FAST DISTANCE Not used.
TARGET WINDOW Not used.
FRONT VISE OPEN DWELL Delay time for the opening of the Fixed Vise in seconds.
SHUTTLE VISE OPEN DWELL Delay time for the closing of the Shuttle Vise in seconds.
CLOSE TIME Delay time for the closing of the Fixed of Shuttle Vise in seconds.
FEED RATE Activates feed rate display.
ACTUAL POSITION DISPLAY If this value is set to YES, displays Shuttle Vise actual position.
HOLD SHUTTLE HOME Hold Shuttle Vise home and closed during cut.
Allows user to override signal from proximity switch in case it is broken. When set to NO
BROKEN PROX machine will not run with broken proximity sensor. Set to YES allows machine to run,
but with out blade speed display, blade breakage, or stall protection.
MIN BLD SPEED Minimum blade speed on which blade breakage will be activated.

Delay in monitoring of the blade speed proximity switch during acceleration of the blade
SPD PROX DELAY
from start to desired speed set by the manufacturer.

If "0" selected, then the machine will shut down after the job is completed. This will allow
POWER DOWN TIMER the machine to continue running for a specified time after the job (in Manual Mode) for
the cycle (in Auto Mode) has been completed. Range from "0" to "180" minutes.

If YES is selected, the machine will perform a facing cut of the material at the beginning
TRIM CUT
of an automatic cycle.
If set to YES, when the AUTO CYCLE reaches the function of head up, the shuttle will
BLADE CLEAR retract the material from the blade by 1/8” before the head will move up. When the head
reaches the up position, the next length of material is shuttled into position.
Selecting YES activates the out of stock option, which prevents the shuttle vise from
OUT OF STOCK closing if an insufficient length of material is available for the next length advance. Also
stops the automatic cycle after completing the last cut.
When BLD is selected, coolant flows when the blade is running. Then BLD + DWN is
COOLANT
selected, coolant flows when the blade is running and head is moving down.
The Queue allows the operator to run several jobs (max 10) in series. If REPEAT is
QUEUE
selected the above series will be executed the selected number of times.

3.16
 ACTUAL SERVO PARAMETERS
MACHINE MODEL Units H22A-120
Servo 240VAC
480VAC MR-J2S-350A4
PAR. # PAR. DESCRIPTION
0 Control mode -
3 Electronic gear numerator - *
4 Electronic gear denominator -
5 In position range Pulse
7 Position command acceleration/deceleration ms
11 Acceleration time constant ms
12 Deceleration time constant ms
13 S-pattern acceleration/deceleration time constant -
17 Analog monitor output -
19 Parameter block -
Switch MAIN power OFF, wait 10 sec then switch ON
21 Function selection (command pulse) -
22 Function selection (Slow, Stop, On, End of Stroke) -
27 Encoder output pulses pulses/rev
28 Torque Limit %
31 Analog monitor 1 offset (MO1) mV
54 Function selection (output pulse rotation dirct.) -
Switch MAIN power OFF, wait 10 sec then switch ON

Instructions on Changing Parameters on Servo Drive

1) Press the [MODE] button

2) Press the [SET] button twice
3) Use [UP] or [DOWN] button to change the parameter
4) Press the [SET] button to enter.
Note. For detailed information see Display and Operation procedure

* = Increasing the value in PARAMETER 3 will result in a longer cut

3.17
 Instructions to Synchronize Powered Conveyor with Shuttle

To synchronize the Powered Conveyor with the Shuttle, the slow speed is to be
synchronized in MANUAL MODE and the fast speed in AUTOMATIC MODE.

1. MANUAL MODE procedure with Shuttle in slow speed

2. AUTOMATIC MODE procedure with Shuttle in fast speed.

In both cases, changes in conveyor speed must be carried out whilst the Shuttle is in
motion.

1. MANUAL MODE procedure with Shuttle in slow speed.

a) Select MANUAL MODE on HMI.

b) Front Vise must be OPEN.

c) Head must be in the UP position.

d) Shuttle Vise to be CLOSED.

e) The Shuttle must be at the back, next to the Powered Conveyor.

f) Select SLOW speed for Shuttle on HMI.

g) Lay a piece of flat bar on the Powered Conveyor with the end piece
approximately 1-2 inches from the Shuttle Vise Jaw.(See diagram)

h) In Manual Mode and in slow speed, move the Shuttle FORWARD.

i) Observe the distance between the end of the flat bar with the Shuttle Vise Jaw. If
the distance between the two increases then the Powered Conveyor speed
needs to be increased. If the distance between end of flat bar and Shuttle Vise
Jaw decreases, the powered conveyor speed needs to be decreased.

j) Move Shuttle and flat bar to the back of the machine. In the electrical panel, the
conveyor VFD must have parameter 79 set to 0. Then select parameter 902 (C2)
and press the SET button to read the parameter. Rotate the dial to select the
new value to input. At the HMI end, depress Shuttle Forward key. As the Shuttle
is moving forward, press the SET key on the Powered Conveyor VFD. (2 people
required for set up)This will set the new slow speed for the Powered Conveyor.
(Details on programming the VFD’S are attached)

k) Repeat above steps if required.

3.18
1. AUTOMATIC MODE procedure with Shuttle in fast speed.

a) Front Vise must be CLOSED

b) Select AUTO MODE on HMI.

c) Input a JOB with a length of 600 inches.

d) Start the AUTO cycle.

e) As the Shuttle starts to move back towards the Powered Conveyor, Close the
FEED RATE (Located left of HMI) The Shuttle will stop when it has reached the
back position.

f) Lay a piece of flat bar on the powered conveyor with the end piece approximately
1-2 inches from the Shuttle Vise Jaw.(See diagram)

g) Open the FEED RATE, trim cut will take place and the Shuttle will move forward.

h) Observe the distance between the end of the flat bar with the Shuttle Vise Jaw. If
the distance between the two increases then the Powered Conveyor speed
needs to be increased. If the distance between end of flat bar and Shuttle Vise
Jaw decreases, the powered conveyor speed needs to be decreased.

i) Move Shuttle and flat bar to the back of the machine. In the electrical panel, the
conveyor VFD must have parameter 79 set to 0. Then select parameter 903 (C4)
and press the SET button to read parameter. Rotate the dial to select the new
value to input.

j) In Auto mode select the last JOB with the length at 600 inches.

k) Start the AUTO cycle.

l) As the Shuttle starts to move back towards the Powered Conveyor, Close the
FEED RATE (Located left of HMI) The Shuttle will stop when it has reached the
back position.

m) Reposition the flat bar on the powered conveyor with the end piece
approximately 1-2 inches from the Shuttle Vise Jaw.

n) Open the FEED RATE, trim cut will take place and the Shuttle will move forward.

l) AFTER the Shuttle has ACCELERATED forward and continues its motion,
depress the SET key on the VFD to enter the new value. This will set the new
fast speed for the Powered Conveyor. (Details on programming the VFD’S are
attached)

o) Repeat the above steps if required.

3.19
3.20
 SECTION 4 - ELECTRICAL

ELECTRICAL SCHEMATICS: SEE PDF ON ATTACHED CD

4.1
 SECTION 5 - HYDRAULIC

HYDRAULIC SCHEMATICS & PLUMBING DIAGRAMS: SEE PDF

ON ATTACHED CD

5.1
 SECTION 6 - MECHANICAL ASSEMBLIES

MECHANICAL ASSEMBLY DRAWINGS & PARTS LIST: SEE PDF

ON ATTACHED CD

6.1
 SECTION 7 - OPTIONS

OPTIONAL ASSEMBLY DRAWINGS: SEE PDF ON ATTACHED CD

7.1
BLADE DEVIATION MONITOR

GENERAL DESCRIPTION OF THE BLADE DEVIATION MONITORING SYSTEM.

This system monitors lateral blade deviation during cutting. If the blade deflection increases
beyond the pre-set warning limit, then the monitoring device sends a warning signal by means of
a flashing beacon mounted on top of the machine head. If no steps are taken to correct this
condition, the machine will continue to cut until the pre-set shut-down limit is reached. At this
point the machine will behave in one of two ways selectable by a parameter setting:
1. Stop cutting, raise the head, and shut down
or
2. Finish the cut with the present degree of deviation and then shut down.
Operation of the system
The proximity transducer is enclosed in a housing mounted on the idler side guide arm. The
sensor converts the blade lateral deflection to an analog signal, which is sent to the PLC. After a
series of calculations the lateral deflection is displayed on the operator interface in the form of a
bar graph.
The bar graph appears in both the Manual Mode and Automatic Mode Screens. It is only active
when the blade is running and head is descending. The length of the bar graph is proportional to
the blade deflection. The bar graph extends from the screen centre towards the right if the blade
is deviating towards the front of the saw (cutting into the part), and extends from the screen
centre towards the left if the blade is deviating towards the rear of the saw (cutting into the
stock).
If a warning limit is reached and maintained longer than the preset response time, then the
beacon light mounted on top of the head will start flashing.
If a shutdown limit is reached and maintained longer than the preset response time, then the
machine will behave in one of two ways: stop cutting, raise the head, and shut down; or finish
the cut with present degree of deviation and then shut down.

Setup procedure
To enable the blade monitor system, follow the steps outlined below:
1. Enter the MONITOR LIMIT SETTING screen by pressing function key F2 labeled
LmtSet. The MONITOR LIMIT SETTING screen will be displayed (Fig. 2).
2. Enter the Parameter screen by pressing function key F6 labeled PARMTRS. The
PARAMETER SETTING screen will be displayed (Fig. 4).
3. Change the BLADE DEVIATION MONITOR parameter to ON by moving the cursor
using the navigation keys to ON/OFF and pressing ENTER. The value of Blade Monitor
parameter will change to ON.
4. Exit the Parameter screen by twice pressing the function key F8 labeled RETURN.

Repeating the above steps will disable the blade monitor option.

7.2
 Warning and shutdown limits adjustments
To adjust the warning and shutdown limits, enter the MONITOR LIMIT SETTING screen by
pressing function key F2 labeled Blade Devi. LmtSet .

F2

Navigation
Keys

Enter Key

Figure 1 Operator interface panel.

The MONITOR LIMIT SETTING screen will be displayed (Figure 2).
There are two scales, the upper one showing the preset right and left warning limits, and the
lower scale showing the preset right and left shutdown limits. All four limits (right and left
warning, and right and left shutdown) are set independently. To adjust the limits, move the
cursor to the desired limit and then use the function keys F1 through F4 to change its value.

Cut out warning limit Cut in warning limit

Cut out maximum limit Cut in maximum limit

Figure 2 Monitor Limit setting screen.

2
7.3
Cut out warning limit – (out - cutting towards outfeed, range 0 ~100) This parameter will
adjust the warning limit if the blade is cutting towards the part. Increasing this value decreases
sensitivity, which will result in a warning further away from nominal straight.
Cut in warning limit – (in - cutting towards infeed, range -100 ~ 0) This parameter will adjust
the warning limit if the blade is cutting towards the stock. Decreasing this value decreases
sensitivity, which will result in a warning further from away nominal straight.
Cut out maximum limit – (out - cutting towards outfeed, range 0 ~100). This parameter will
adjust the 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 the shutdown
sequence is initialized.
Cut in maximum limit – (in - cutting towards infeed, range -100 ~ 0) This parameter will adjust
the shutdown limit if the blade is cutting towards the stock. Decreasing this value decreases
sensitivity, which will result in a larger deviation from nominal straight, before the shutdown
sequence is initialized.

MIN This function key will move the selected slider to the far left.

When this function key is depressed once, the value of selected slider will
DEC decrement by 2.5%.

When this function key is depressed once, the value of selected slider will
INC increment by 2.5%.

MAX This function key will move the selected slider to the far right.

PARMTS This function key will access parameters screen.

RETURN This function key will return to previous screen.

Figure 3. Monitor limit setting function key description chart

To return from the MONITOR LIMIT SETTING screen to the AUTO or MANUAL screens, press
RETURN (F7 function key, Figure 1).
To access the PARAMETERS screen (Figure 4), press PARMTR (F6 function key).

7.4
3
Figure 4. Parameter settings screen.

To set any of the numerical parameters, use the NAVIGATION keys (Figure 1) to place the
cursor over the number. Key in the desired value, and then press ENTER.
To change the ON/OFF parameters, place the cursor over the parameter, and press ENTER to
toggle between ON and OFF.
Warning response time (range 2 – 99 seconds)
WARNING RESPONSE TIME If the blade deviation exceeds the preset warning limit for longer than the
warning response time, then the beacon light mounted on top of the head
will start flashing.
Maximum limit response time – (range 2 – 99 seconds)
MAX LIMIT RESPONSE TIME If the blade deviation exceeds the preset shutdown limit for longer than the
shutdown response time, then the machine will execute the shutdown
sequence.
MACHINE RESPONSE IF MAX LIMIT If the shutdown sequence has been executed then, the machine will behave
REACHED in one of two ways:
NO/YES
BLD ST0P, HEAD UP AND MACHINE OFF
Stop cutting, raise the head, and shut down
NO/YES
FINISH CUT, MACHINE OFF
Finish the cut with present degree of deviation and then shut down
(range –2000 – +2000)

The number displayed here represents the position of the blade within the
SENSOR SETTING measuring range of the proximity transducer. At 0, the blade is exactly
centred within the sensing range. The display assists adjustment with the
prompts ‘SETTING, or ‘SET’. The prompt ‘SET’ appears when the
adjustment is within the acceptable range of – 100 +100.
[See sensor adjustment procedure section]
(range 0.1 sec – 10 sec)
DISPLAY REFRESH TIME
The refresh time is time between bar graph updates.
ON/OFF
BLADE DEVIATION MONITOR This parameter will activate or deactivate response of the blade deviation
monitoring system.

Figure 5. Parameter description chart

7.5
4
To return from the PARAMETER screen to the AUTO or MANUAL screens, press the
RETURN (F8 function key, then F7 Figure 1).
To access the HISTOGRAM screen (Figure 6), press HSTGRM (F2 function key).
To return from the HISTOGRAM screen to the AUTO or MANUAL screens, press Ret (F2
function key) and then press the RETURN (F8 then F7 function keys).

Figure 6. Histogram screen

The histogram records the last 30 minutes of the machine run time. This gives a graphical
representation of blade deviation over time. To reset the data buffer power down the machine.
To set the clock:
1. Press Service Mode key
2. Type password (79479)
3. Press Enter key
4. Enter new time
5. Press Enter key
6. To Exit press Ret (F2) function key
Relationship between Blade Deflection Display and Actual Cut Deviation
The digital display indicates the blade lateral deflection at the point where it passes the blade
deflection sensor, which is 1” past the idler side guide arm. The maximum deviation of the cut
surface will actually occur at or near the center of the cut, and will be several times larger than
that measured at the sensor. The display range of 0 +/-100 is proportional to the amount of
blade deviation. This depends on the type of material, shape of the work-piece and amount of
blade tension.
The actual amount is difficult to predict, experience with different work-pieces will
provide the best guide.

7.6
5
 Cut out warning limit Current deflection Cut in warning limit

Cut out maximum limit Cut in maximum limit

Figure 8 Auto Mode screen.

SENSOR ADJUSTMENT PROCEDURE

It is desirable for the un-deflected position of the blade to lie in the center of the sensing range
of the proximity transducer. This relation may be changed when new carbide guides are
installed, or guide arm alignment is adjusted. To reset the relation, proceed as follows:
1. To prevent accidental blade start during adjustment:
a. Use the disconnect switch to isolate the machine.
b. Open the electrical cabinet and turn OFF the manual motor starter labeled 2 O/L
and lock it in the off position by means of a padlock (Fig 9).

Figure 9.
c. Close the electrical cabinet and turn the disconnect switch to ON.

7.7 6
 d. Confirm that correct manual motor starter has been turned off by starting
hydraulics
e. Wait 1 minute and then attempt to start the blade motor. If the blade motor does
not start proceed to step 2.
2. Position the guide arm at mid point of the range between fully open and fully closed.
3. Raise the head to place monitor body at comfortable working height.
4. Press the F6 function key to enter the blade monitor limit setting screen.
5. To enter blade monitor parameters screen, press function key F5 labeled PARMTR.
6. Loosen the two hex socket cap screws.
7. By moving the block in perpendicular direction to the blade (Fig 10) observe the bottom
line of the BLADE MONITOR PARAMETERS screen labeled SENSOR SETTING. Adjust
the block until the prompt reads ‘SENSOR SET’. The adjustment is quite sensitive and
requires careful movement of the block in small increments. The display range limit is
from –2000 to +2000. The target setting is 0, but anywhere from –100 to +100 is
acceptable and will result in the display prompt ‘SENSOR SET’.
8. When adjustment is complete, lock the two hex socket cap screws.
9. Restore blade motor circuit:
a. Turn off the hydraulics.
b. Use the disconnect switch to isolate the machine
c. Open the electrical cabinet and remove padlock.
d. Turn ON the manual motor starter 2O/L.
10. Close electrical cabinet and turn on the disconnect switch.

Loosen these two hex

socket cap screws and
move the block in
perpendicular
direction to the blade.

Figure 10.

7.8 7
FLOOD MIST SELECTION

1. Selecting FLOOD or MIST coolant

2. In Auto Mode press NEXT (coolant) button to move to AUTO MODE ‐ 2

3. Use FLOOD/MIST button to select different type of coolant.

4. Use RETURN button to return to previous screen

7.9
 SECTION 8 - SPECIFICATIONS
H18A-120 SPECIFICATIONS

H18A-120 BANDSAW SPECIFICATIONS

Round 18" (457mm)

Capacity
Rectangular 18"x 18"(457mm x 457mm)

Length 19'-2" (5842mm)

Blade Width 1 1/2", (41mm) , or optional 1 1/4" ( 32mm)
Thickness .050" (1.3mm) or optional (.042", 1.1mm)

Blade Tension Hydraulic

Blade Speed VFD 50 - 350 sf/min (15.5 - 109 m/min)

Blade Guides Carbide inserts (water soluble coolant lubricated)

Blade Wheel Dia. 22" (559mm)

Blade drive 10 HP (7.5 KW)

Motors
Hydraulic pump drive 3 HP (2.2 KW)

Hydraulic 6 1/2 U.S. Gal. / min (25 Liters/min)

Pumps
Coolant 3 1/2 U.S. Gal. / min (13.5 Liters/min)

Hydraulic Tank 9.5 U.S. Gallons (36 Liters)

Coolant Tank 30 U.S. Gallons (114 Liters)

System Pressure 1000 PSI (6890 kPa)

Vise Control Hydraulic

Shuttle Stroke 0-120" (0 - 3048mm) single stroke, multi-indexing capability

Table Height 35" (889mm)

Control Panel Waist Height

Machine Weight 16000 lbs (7257 Kg)

Maximum Workload 10000 lbs (4535 Kg)

Overall Dimensions 127" (3225mm) Wide, 191" (4851mm) Long, 92.5" (2350mm) High

8.1
H18A-120 MACHINE LAYOUT

8.2
 H22A-120 SPECIFICATIONS

H22A-120 BANDSAW SPECIFICATIONS

Round 22" (559mm)

Capacity Rectangular 22" (559mm) wide x 22" (559mm) high
6 Cant 20" (508mm) x 22" (559mm) (H x W)

Length 22'-6" (6858mm)

Blade Width 2" (51mm)
Thickness .063" (1.6mm)

Blade Tension Hydraulic

Blade Speed VFD 40 - 300 sf/min (12 - 91.5 m/min)

Blade Guides Carbide inserts (water soluble coolant lubricated)

Blade Wheel Dia. 27" (685mm)

Blade drive 10 HP (7.5 KW)

Motors
Hydraulic pump drive 2 HP (2.2 KW)

Hydraulic 6 1/2 U.S. Gal. / min (25 Liters/min) pressure compensated

Pumps
Coolant 3 1/2 U.S. Gal. / min (13.5 Liters/min)

Hydraulic Tank 9.5 U.S. Gallons (36 Liters)

Coolant Tank 30 U.S. Gallons (114 Liters)

System Pressure 1100 PSI (7584 kPa)

Vise Control Hydraulic

Shuttle Stroke 0-120" (0 - 3048mm) single stroke, multi-indexing capability

Table Height 35" (889mm) with 6º cant head

Control Panel Waist Height

Machine Weight 20,000 lbs (9072 Kg)

Maximum Workload 15,000 lbs (68048 Kg)

Overall Dimensions 146" (3708mm) Wide, 192" (4877mm) Long, 100" (2540mm) High

8.3
 A B C D E F G H I J K L M
8 8

104

13 73
3/4-10 BOLT

7 7
Ø .75

13

42
160
H22A-120 MACHINE LAYOUT

6 6

192
29
11

167

5 5
103

87.5

70
0.25

39
34
26
4 4

8.4
110 3

FOUNDATION PLAN

3 3

100
92.50
2 2

35

1 1
146 STANDARD TOLERANCES UNLESS HYD - MECH GROUP LIMITED
REVISIONS HYD - MECH
OTHERWISE SPECIFIED WOODSTOCK. ONTARIO. CANADA N4S 8A4
The Rock Solid Solution

REV ECN NUMBER DATE BY TITLE

DIMENSIONS ARE IN INCHES
THE DATA/DESIGN CONTAINED HEREIN IS PROPRIETARY
- ECN00221 JUNE 2015 MS H22SV Canted Head with 10' Barfeed
LINEAR ANGULAR
AND CONFIDENTIAL.REPRODUCTION,PUBLICATION OR DRWN BY CHKED BY - SCALE SHEET REV
WR
DISTRIBUTION OF ANY PART REQUIRES WRITTEN CONSENT .X +/- .015 IN X.X =/- 0.5 DEG DATE: JULY 13 2004 DATE: - 1:40 - -
OF HYD-MECH GROUP.THIS DATA IS THE PROPERTY OF
.XX +/- .010 IN
HYD MECH GROUP AND ITS POSSESION CONFERS NO THIRD ANGLE PROJECTION MAT'L:
.XXX +/- .005 IN -
LICENSE TO USE OR RIGHT OR LICENSE TO DISCLOSE IT

TO OTHERS FOR ANY PURPOSE WHATSOEVER. = 125 MICROINCHES DRAWING NUMBER:

ALL RIGHTS RESERVED.
H22SV-0-04
0 0
A B C D E F G H I J K L M
 A B C D E F G H I J K L M
8 8

7 7

160.00
6 6

192.00

201.0
H22A-120 with OV - MACHINE LAYOUT

5 5

87.50

4 4

8.5
BLADE PLANE
28.0

3 3

100
92.50
2 2

35.00

1 1

STANDARD TOLERANCES UNLESS HYD - MECH GROUP LIMITED

H22SV 146.00 REVISIONS HYD - MECH
OTHERWISE SPECIFIED WOODSTOCK. ONTARIO. CANADA N4S 8A4
The Rock Solid Solution

REV ECN NUMBER BY TITLE

DATE DIMENSIONS ARE IN INCHES
THE DATA/DESIGN CONTAINED HEREIN IS PROPRIETARY
H22SV with 10' Barfeed OV option
LINEAR ANGULAR
AND CONFIDENTIAL.REPRODUCTION,PUBLICATION OR DRWN BY CHKED BY - SCALE SHEET REV
WR
DISTRIBUTION OF ANY PART REQUIRES WRITTEN CONSENT .X +/- .015 IN X.X =/- 0.5 DEG
OF HYD-MECH GROUP.THIS DATA IS THE PROPERTY OF
DATE: JULY 13 2004 DATE: - 1 : 16 - -
.XX +/- .010 IN
HYD MECH GROUP AND ITS POSSESION CONFERS NO THIRD ANGLE PROJECTION MAT'L:
.XXX +/- .005 IN -
LICENSE TO USE OR RIGHT OR LICENSE TO DISCLOSE IT

TO OTHERS FOR ANY PURPOSE WHATSOEVER. = 125 MICROINCHES DRAWING NUMBER:

ALL RIGHTS RESERVED.
H22SV-0-05
0 0
A B C D E F G H I J K L M
 SECTION 9 - WARRANTY

WARRANTY

Hyd·Mech Group Limited warrants parts/components on each new H18A_H22A 120 bandsaw to be free from failure
resulting from defective material and workmanship under proper use and service for a period of two years following the
date of shipment to the user. Hyd·Mech’s sole obligation under this warranty is limited to the repair or replacement without
charge, at Hyd·Mech’s factory, warehouse, or approved repair shop any part or parts which Hyd·Mech’s inspection shall
disclose to be defective. Return freight must be prepaid by the user.

This warranty, in its entirety, does not cover maintenance items, including but not limited to lubricating grease and oils,
filters, V-belts, saw blades, etc., nor any items therein which show signs of neglect, overloading, abuse, accident,
inadequate maintenance, or unauthorized altering.

MOTOR, GEARBOX, PUMP, ELECTRIC COMPONENTS, VALVES, HOSES, FITTINGS, and any other items used in the
manufacture of the H18A_H22A 120, 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 and consequential damages is hereby disclaimed. Hyd·Mech’s obligation to repair or replace shall
be the limit of its liability under this warranty and the sole and exclusive right and remedy of the user.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, WRITTEN OR
ORAL, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE.

This warranty may not be changed, altered, or modified in any way except in writing by Hyd-Mech Group Limited

HYD·MECH GROUP LIMITED

1079 Parkinson Road
P.O. BOX 1659
Woodstock, Ontario
N4S 0A9
Phone: (519) 539-6341
Fax: (519) 539-5126
Toll Free (877) 276-SAWS (7297)
E-mail, [email protected]

9.1