Amada HFA-250 User manual

HFA250/400T/TW US-E01-200409
HORIZONTAL BANDSAW
HFA-250/250W/400/400W
(HFA-252T/252TW/407T/407TW)
OPERATOR'S MANUAL

ii
PREFACE Read this manual carefully to obtain a thor-
ough knowledge of machine operation and maintenance.
Be sure to follow the instructions to ensure proper proce-
dures and prevent injuries and accidents. Do not operate
the machine by guesswork. Keep the manual at hand
and refer to it whenever you are not sure of how to perform
any of the procedures.
Printed in Japan
Operator's Manual:
HFA-250/250W/400/400W Horizontal Bandsaw
© 2004 by AMADA CO., LTD.
No part of this publication may be photocopied or otherwise reproduced with-
out the prior written permission of AMADA CO., LTD.

iii
CONTENTS
Safety Rules & Cutting Precautions............................................................vii
Part I Description...........................................................................I-1
Identification of machine parts................................................... I-2
HFA-250 and HFA-250W machines....................................... I-2
HFA-400 and HFA-400W machines....................................... I-4
Specifications............................................................................. I-6
HFA-250 and HFA-250W machines....................................... I-6
HFA-400 and HFA-400W machines...................................... I-10
Sound level............................................................................ I-14
Automatic backgauge function.............................................. I-15
Optional accessories ................................................................ I-16
Part II Installation...........................................................................II-1
Location .....................................................................................II-2
Carrying .....................................................................................II-4
Cleaning.....................................................................................II-5
Leveling......................................................................................II-6
Removing shipping bracket .......................................................II-7
Supplying hydraulic oil...............................................................II-8
Supplying cutting fluid................................................................II-9
Supplying electric power...........................................................II-10
Connecting power cable........................................................II-11
Checking electrical connections............................................II-12
Installing fire control devices.....................................................II-13
Part III Controls..............................................................................III-1
Machine circuit breaker switch.................................................. III-2
Control panel............................................................................. III-3
Other controls .......................................................................... III-12
Description of displays............................................................. III-17
Contents of displays............................................................. III-19
Initial display ..................................................................... III-19
Station data setup display................................................. III-19
(Continued on next page.)

iv
All station delete confirmation display.............................. III-23
Runout setup display........................................................ III-23
Station delete confirmation display................................... III-24
Setup display.................................................................... III-24
Result display ................................................................... III-25
Daily report display........................................................... III-26
ALARM HISTORY display................................................ III-27
PASSWORD display......................................................... III-27
Part IV Operation ...........................................................................IV-1
Inspection before start of day’s work........................................IV-3
Turning on machine..................................................................IV-3
Selecting saw blade.................................................................. IV-3
Unfolding and folding saw blade............................................... IV-4
Unfolding saw blade..............................................................IV-4
Folding saw blade................................................................. IV-6
Installing saw blade ..................................................................IV-8
Adjusting position of wire brush............................................... IV-11
Adjusting position of movable saw blade guide.......................IV-12
Loading and positioning work.................................................. IV-13
Loading work........................................................................IV-13
Positioning work...................................................................IV-15
Positioning remnant for cutting further .............................IV-17
Semiautomatic positioning function ..................................... IV-18
Setting cutoff length..........................................................IV-18
Semiautomatic positioning................................................ IV-19
Adjusting cutting fluid flow rate................................................ IV-21
Running in new saw blade.......................................................IV-22
Stack cutting............................................................................IV-23
Stacking workpieces ............................................................IV-23
Using multi-vises (optional).................................................. IV-24
Runout detector (optional)....................................................... IV-27
Setting runout tolerances..................................................... IV-27
Handling cutting data............................................................... IV-29
Entering and storing cutting data ......................................... IV-29
Checking cutting data (calling station)................................. IV-33
Changing cutting data.......................................................... IV-33
Canceling cutting data.......................................................... IV-33
Conditions for execution of cutting data............................... IV-34

v
Head-end positioning function (optional).................................IV-35
Setting cutoff length..............................................................IV-36
Head-end positioning operation...........................................IV-37
Going from head-end positioning operation to
automatic operation..............................................................IV-39
Operation.................................................................................IV-40
Manual operation..................................................................IV-40
Starting cutting..................................................................IV-40
Ending cutting...................................................................IV-41
Interrupting or stopping cutting.........................................IV-41
Automatic operation .............................................................IV-41
Before starting automatic operation..................................IV-41
Starting cutting without trimming head end ......................IV-42
Starting cutting after trimming head end...........................IV-42
Ending automatic operation..............................................IV-43
Interrupting automatic operation.......................................IV-43
Stopping automatic operation after detection of
excessive runout...............................................................IV-43
Stopping automatic operation...........................................IV-44
Interrupt station function.......................................................IV-45
Inserting interrupt station in current station ......................IV-46
Inserting interrupt station between stations to
be executed......................................................................IV-48
Inserting interrupt station as first station of
automatic operation during head-end trimming................IV-50
Self-diagnostic function........................................................IV-52
Ending operation......................................................................IV-53
Part V Troubleshooting .................................................................V-1
Operating troubles .....................................................................V-2
Alarm code list ...........................................................................V-6
Part VI Maintenance.......................................................................VI-1
Checking before start of day’s work..........................................VI-2
Periodic maintenance ...............................................................VI-4
Every day ..............................................................................VI-4
Cleaning.............................................................................VI-4
Lubrication.........................................................................VI-4
(Continued on next page.)

vi
Every month..........................................................................VI-5
Cleaning ............................................................................VI-5
Lubrication......................................................................... VI-6
First three months (or 500 hours) .........................................VI-8
Changing speed reducer oil (for first time)........................ VI-8
Every six months...................................................................VI-8
Changing cutting fluid........................................................VI-8
Changing hydraulic oil....................................................... VI-9
Checking and changing backup rollers ............................ VI-10
Checking and changing guide rollers ............................... VI-10
Every year............................................................................ VI-11
Changing speed reducer oil
(for second and subsequent times).................................. VI-11
Appendix A Options................................................................................A-1
Multi-vises..................................................................................A-2
Vise pressure control valves......................................................A-2
Runout detector (factory option)........................................................A-2
Roller table.................................................................................A-3
Roller stand................................................................................A-3
Head-end positioning function (factory option)..........................A-3
Rotating beacon lights (factory option)......................................A-4
Wheel cover open limit switch (factory option)..........................A-4
Appendix B Safety Data Sheets.............................................................B-1
Shell Tellus Oil C32....................................................................B-2
Esso Lithtan EP2.......................................................................B-6
Amada Gear Oil EP320............................................................B-10

vii
Safety Rules
&
Cutting Precautions
SAFETY RULES
Observe these safety rules to prevent injuries and accidents. (The illustrations
may be partly different from the actual machine in detail.)
a) Use roller tables on both front
and rear sides of the machine
when cutting long work. It is
dangerous if the work falls off
the machine when the roller
tables are not used.
b) Never wear gloves and loose
clothing when operating the
machine. It is dangerous if
they are caught in the running
machine.

viii
c) Use a water-soluble cutting
fluid on this machine. Oil-
based cutting fluids may emit
smoke or catch fire, depending
on the condition of their use
(such as insufficient flow rate).
When using an oil-based cutting
fluid, strictly observe the precautions
described in “Cutting Method” on
page xv.
d) Be sure to prohibit any use of
fire in the shop, and install a
fire extinguisher or other fire
control device near the
machine when cutting
titanium, magnesium, or any
other material that produces
flammable chips. Never
leave the machine unattended
when cutting flammable
materials.
e) Never cut on this machine
carbon or any other material
that produces and disperses
explosive dust. Sparks from
motors and other machine
parts may ignite and explode
the air-borne dust.
The machine needs special
measures for cutting explosive
materials (for details, refer to page
xvi).

ix
f) Be sure to confirm that the
area around the machine is
cleared of people and
obstacles every time before
starting the machine or
operation.
g) Never start the saw blade
unless it has been confirmed
that the work is firmly clamped.
If the work cannot be securely
clamped with the vise, be sure
to clamp it using jigs. It is
dangerous if the work is
clamped loosely and forced
out of the vise during cutting.
h) When cutting a thin or short
piece from the work, take
preventive measures to keep
the cut piece from falling. It is
dangerous if the cut piece falls
or rolls.

x
i) Never operate the machine
with the wheel cover, the saw
blade cover, and other covers
removed or opened. It is
dangerous if your hands or
clothing are caught in the
running machine.
j) Never take your eyes off the
machine or lean on the
machine during operation.
Be ready for a situation that
demands immediate attention
to prevent an accident.
k) Never touch the running
saw blade or chip
conveyor. It is
dangerous if your hands
or clothing are caught in
the running saw blade or
chip conveyor.

xi
l) Never try to adjust the
wire brush on the saw
blade or remove chips
when the saw blade is
running. It is dangerous
if your hands or clothing
are caught in the running
saw blade.
m) Stop the saw blade whenever
cleaning the machine. It is
dangerous if your hands or
clothing are caught in the
running saw blade.
n) Never step or stand on the
roller table. It is dangerous if
your foot slips on the rollers
and you fall.

xii
o) Turn off the shop circuit
breaker switch before
servicing the machine. Then
post a sign to inform people
that the machine is under
maintenance.
SERVICING
p) Never modify the machine's parts or electric circuits or change them with
unauthorized parts or circuits. Doing so will cause machine problems and
damage and disrupt the safety of the machine and the operator.

xiii
DANGER and WARNING plates
Keep the DANGER and WARNING plates well noticeable and never remove
them.
DANGER
Do not open cover
while
machine is running.
DANGER
Keep away
from machine
when running.
DANGER
Do not touch
the blade
when running.
DANGER
Do not step
on the roller.
DANGER
High voltage.
Turn off
before servicing.
DANGER
Keep hands away
from chip conveyor.
WARNING
Do not operate
machine unattended.
Oil-based cutting fluid may
catch fire.
Titanium, magnesium, etc,
are flammable.
Do not cut carbon.
Hazard seriousness level
DANGER Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury.

xiv
CUTTING PRECAUTIONS
The selection of an appropriate saw blade and cutting method is
important in cutting the work safely and efficiently. Select an
appropriate saw blade and cutting method by fully considering the work
to be cut and the requirements of your job (such as cutting accuracy,
cutting speed, economy, and safety control).
Selecting saw blade
The tooth form, pitch, and grade of an appropriate saw blade change
with the material, shape, size, and fixing method of the work to be cut.
An appropriate saw blade also varies with the requirements of your job
(such as cutting accuracy, cutting speed, and economy) even when the
same work is to be cut. Consult AMADA about the selection of saw
blades for specific jobs.
The pitch of an appropriate saw blade for cutting round or rectangular
bars is shown in the table below.
Saw blade pitches for cutting round or rectangular bars (teeth per inch)
Variable pitch 3-4 2-3
Regular pitch 6 4 3 2
Maximum cutoff
width mm {in.} 50 or less {2 or less} 50 to 100 {2 to 3.9} 100 to 150 {3.9 to 5.9} 150 to 200 {5.9 to 7.9} 200 to 250 {7.9 to 9.8} 250 to 300
{9.8
to
11.8}
300 or more
{11.8or more}

xv
Cutting method
According to its material, the work may be cut wet (or with a cutting fluid),
or dry (or without a cutting fluid). The materials to be cut wet or dry are
listed in the table below.
Wet cutting Use a water-soluble cutting fluid on this machine.
Select an appropriate cutting fluid by referring to Appendixes 1 to 3.
The main composition and characteristics of cutting fluids vary from
manufacturer to manufacturer. Some cutting fluids may adversely
affect the human body. For the main composition, characteristics,
effect on the human body, and other details, consult the manufacturers
of specific cutting fluids. Do not use cutting fluids of unknown
composition.
Oil-based cutting fluids may emit smoke or catch fire, depending on the
condition of their use. When using an oil-based cutting fluid on the
machine, strictly observe the following precautions:
•When the cutting operation is continued with an insufficient
discharge of the cutting fluid, the cutting fluid may emit smoke or
catch fire. Take care so that the cutting fluid is discharged in a
sufficient amount during the cutting operation.
•Some cutting fluids may degrade the cutting fluid hose. Periodically
inspect the cutting fluid hose for any leakage of the cutting fluid. As
soon as the cutting fluid hose is found to be leaking, change it.
•When covered with the cutting fluid, dust is very flammable. Be
sure to clean the machine every day.
•When the oil-based cutting fluid is used for cutting a flammable
material like titanium or magnesium, the risk of fire is much higher
than when a water-soluble cutting fluid is used. Strictly observe the
precautions described in "Cutting Flammable Materials" on page xvii.
•Install a fire extinguisher or other fire control device near the machine
to provide against a fire.
•Never leave the machine unattended during the cutting operation.
Never use oils other than cutting fluids (kerosene, for example) because
they have the high possibility of causing a fire.

xvi
Dry cutting The machine needs special measures for performing dry cutting.
Consult AMADA. If dry cutting is performed without taking special
measures, chips may accumulate in machine parts and may cause the
operation or insulation failure of the machine.
The machine also needs special measures for cutting carbon and other
materials that produce and disperse explosive dust. Consult AMADA.
If such an explosive material is cut on the machine without special
measures, sparks from motors and other machine parts may ignite and
explode the air-borne dust.
Even if the machine is equipped with special measures for cutting
explosive materials, carbon and other air-borne dust may still explode.
Be sure to prohibit any use of fire in the shop and install a fire
extinguisher or other fire control device near the machine. Never leave
the machine unattended during cutting operation.
Materials to be cut wet or dry
JIS DIN NF BS AISI
Wet
Cutting
SUM11–43
SS
S20C–S55C
SUP3–13
SCr415–445
SCM415–822
SNC415–815
SNCM220–815
SUS201–631
SK1–7
SKS2–5,7–
SKD1,11,12
SKT
SKH2–59
SF
Aluminum
Aluminum alloy
Copper
Copper alloy
Magnesium
Titanium
Nickel base alloy
Monel
Inconel
9S20–9SMn36
St33–St52-3
CK22–CK55 (C22–C55)
55Cr3–50CrV4
34Cr4–41Cr4
34CrMo4–42CrMo4
X10CrNiS189–X20Cr13
C105W1–C70W2
105WCr6
X210Cr12
X155CrVMo12 1
X100CrVMo5 1
55NiCrMoV6
S18-1-2-5–S2-10-1-8
St37-3–St52-3
Aluminum
Aluminum alloy
Copper
Copper alloy
Magnesium
Titanium
Nickel base alloy
Monel
Inconel
S250Pb–45MF6.3
1C22–1C55
55C3–50CV4
20MC5–45C4
18CD4–42CD4
30NC11
20NCD2
Z10CNF18.09–Z20C13
Y2140–Y170
105WC13
Z200C12
Z160 CDV12
Z100 CDV5
55NCDV7
Z80WCV18-04-01–
Z110DKCWV09-08-04-02-01
F37–F52
Aluminum
Aluminum alloy
Copper
Copper alloy
Magnesium
Titanium
Nickel base alloy
Monel
Inconel
220M07–226M44
40A–50F
070M20–070M55
250A53–735A50
530A30–530A40
708M20–708A47
655M13
805A20
303S21–420S29
BW1C–BW1A
BD3
BD2 (BA2)
BH19
BT1–BM42
Aluminum
Aluminum alloy
Copper
Copper alloy
Magnesium
Titanium
Nickel base alloy
Monel
Inconel
1110–1144
30–70
1020–1055
1075–6150
5120–5147
4130–4145
8615–4340
303–420
W1-13–W1-7
D3
D2 (A2)
H19
T1–M42
Class A–D
Aluminum
Aluminum alloy
Copper
Copper alloy
Magnesium
Titanium
Nickel base alloy
Monel
Inconel
Dry
Cutting
FC10–35
FCMB
FCMP
SKD1
Carbon
GG10–GG35
GTS-35-10
X210Cr12
Carbon
Ft10D–Ft35
Z200C12
Carbon
150–350
B150/4–B690/2
BD3
Carbon
A48-20B–A48-50B
45006–90001
D3
Carbon

xvii
Cutting flammable materials
Chips of titanium or magnesium violently burn when they catch fire.
Once these chips burn, the resultant fire may explosively propagate
through surrounding chips. When an oil-based cutting fluid is used on
the machine, it may also be ignited and spread the fire.
When cutting such flammable materials, be sure to clean the machine of
accumulated chips at the start and end of every operation. During
automatic operation, stop the machine as required to remove the chips.
Take care so that the cutting fluid is discharged in a sufficient amount
during the cutting operation.
When cutting a flammable material, be sure to prohibit any use of fire in
the shop, install a fire extinguisher or other fire control device near the
machine. Never leave the machine unattended during the cutting
operation.
When carrying or disposing of chips, take due care so that they do not
catch fire. Be sure to prohibit any use of fire where the chips are
stored.
Cutting unknown materials
Before cutting an unknown material, consult the supplier of the material,
burn a small amount of chips from the material in a safe place, or follow
any other procedure to check to see if the material is flammable or not.

xviii
Appendix 1: Classification of cutting fluids
Water-soluble cutting fluids
Color when diluted Main composition
Soluble Milky white or clear Mineral oil
Semi-synthetic Clear Mineral oil
Synthetic Clear Polymer
NOTE
ODilute each product to the specified ratio.
Oil-based cutting fluids
Main composition
Straight mineral oil Mineral oil
Fatty oil Animal or vegetable oil
Mixed oil Mixture of straight mineral oil and fatty oil
Chlorinated oil Straight mineral oil or mixed oil with addition of chlorine compound
Sulfurized oil
Active: Heavy cutting
Inert: Light cutting Straight mineral oil or mixed oil with addition of sulfur compound
Sulfochlorinated oil
Active: Heavy cutting
Inert: Light cutting
Straight mineral oil or mixed oil with addition of chlorine and sulfur
compounds
Appendix 2: Characteristics of cutting fluids
Water-soluble cutting fluids
Advantage Disadvantage
•Have high cooling effect
•Not flammable
•Economical
•Do not require cleaning of cut products
(especially when soluble)
•Remove paint
•Lose rust protection effect when deteriorated
•Foam
•Putrefy
•Decline in performance, depending on quality of
water used for dilution
Oil-based cutting fluids
Advantage Disadvantage
•Have high lubricating effect (suited for heavy
cutting)
•Have high cooling effect at elevated
temperatures
•Prevent chip weldment (suited for heavy cutting)
•Provide high corrosion protection for nonferrous
materials (inert type)
•Smoke
•Flammable
•Corrosive to nonferrous materials (active type)

xix
Appendix 3: Cutting fluids suited for specific materials
This table shows the general machinability of materials with different cutting fluids. Some
materials may be cut better with an oil-based cutting fluid than a water-soluble cutting fluid.
When using an oil-based cutting fluid, strictly observe the precautions described in "Cutting
Method" on page xv.
JIS
SUM11–43
FC10–35
S20C–S30C
FCMB
SS
S40C–S55C
SCM415–822
SNCM220–815
SKS2, 4, 5
SF
SCr415–445
SUP3–13
SNC415–815
SK1–7
SKS3, 7–
SUS201–631
SKD1, 11, 12
SKH2–59
SKT
Aluminum
Aluminum alloy
Magnesium
Copper
Copper alloy
Titanium
Nickel base alloy
Monel
Inconel
DIN
9S20–9SMn36
GG10–GG35
CK22–CK35
(C22–C35)
GTS-35-10
St33–St52-3
CK45–CK55
(C45–C55)
34CrMo4–42CrMo4
St37-3–St52-3
34Cr4–41Cr4
55Cr3–50CrV4
C105W1–C70W2
X10CrNiS189–X20Cr13
105WCr6
X210Cr12
X155CrVMo12 1
X100CrVMo5 1
S18-1-2-5–S2-10-1-8
55NiCrMoV6
Aluminum
Aluminum alloy
Magnesium
Copper
Copper alloy
Titanium
Nickel base alloy
Monel
Inconel
NF
S250Pb–45MF6.3
Ft10D–Ft35
1C22–1C25
1C45–1C55
18CD4–42CD4
20NCD2
F37–F52
20MC5–45C4
55C3–50CV4
30NC11
Y2140–Y170
Z10CNF18.09–Z20C13
105WC13
Z200C12
Z160CDV12
Z100CDV5
Z80WCV18-04-01–
Z110DKCWV09-08-04-02-01
55NCDV7
Aluminum
Aluminum alloy
Magnesium
Copper
Copper alloy
Titanium
Nickel base alloy
Monel
Inconel
BS
220M07–226M44
150–350
070M20–080A30
40A–50F
060A40–070M55
708M20–708A47
805A20
530A30–530A40
250A53–735A50
655M13
BW1C–BW1A
303S21–420S29
BD3
BD2 (BA2)
BT1–BM42
BH19
Aluminum
Aluminum alloy
Magnesium
Copper
Copper alloy
Titanium
Nickel base alloy
Monel
Inconel
AISI
1110–1144
A48-20B–A48-50B
1020–1030
30–70
1040–1055
4130–4145
8615–4340
Class A–D
5120–5147
1075–6150
W1-13–W1-7
303–420
D3
D2 (A2)
T1–M42
H19
Aluminum
Aluminum alloy
Magnesium
Copper
Copper alloy
Titanium
Nickel base alloy
Monel
Inconel
Soluble VO O OV
Semi-
synthetic VO O OV
Synthetic OO V OV
Oil-based VVVO
O: Best V: Good : Not good

xx