Hyd-Mech H-18 ASV User manual

Thank you,
On behalf of everyone at HYD·MECH Group Limited, I would like to thank and congratulate you on your decision to pur-
chase a HYD·MECH bandsaw.
Your new machine is now ready to play a key role in increasing the efciency 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 famil-
iarize yourself and your employees with the correct operation and maintenance procedures as outlined in this manual.
We sincerely appreciate the condence you have demonstrated in purchasing our product and look forward to building a
long and mutually benecial relationship.
Thank you
Hyd·Mech Group Limited
P.O. Box 1030, 1079 Parkinson Road
Woodstock, Ontario, N4S 8A4
Phone : [phone]
Service : 1-877-237-0914
Sales : 1-877-276-SAWS (7297)
Fax : [phone]
e-mail : [email protected]
H-18/22 ASV
393115
November 2004, REV G

TOC.1
TABLE OF CONTENTS
SECTION 1, INSTALLATION
SAFETY PRECAUTIONS............................................................................................................................................1.1
H-18/22 SV LIFTING INSTRUCTIONS .......................................................................................................................1.2
FOUNDATION, LEVELLING AND ANCHORING ........................................................................................................1.3
WIRING CONNECTIONS............................................................................................................................................1.3
HYDRAULIC OIL AND CUTTING FLUID ....................................................................................................................1.4
SECTION 2, OPERATION
BLADE BASICS ..........................................................................................................................................................2.1
VARIABLE SPEED CONTROL ................................................................................................................................... 2.1
THE CONTROL PANEL ..............................................................................................................................................2.1
MANUAL OPERATION................................................................................................................................................2.1
PLC 100 CONTROL SYSTEMS..................................................................................................................................2.4
OPERATION OVERVIEW ...........................................................................................................................................2.4
ACTIVATING THE PLC ...............................................................................................................................................2.5
FUNCTION KEY DESCRIPTIONS..............................................................................................................................2.5
SINGLE PART CYCLE OPERATION ..........................................................................................................................2.6
KERF CORRECTION..................................................................................................................................................2.6
AUTOMATIC OPERATION..........................................................................................................................................2.7
PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE.............................................................2.7
JOB IN PROGRESS....................................................................................................................................................2.7
WORKING WITH A QUEUE........................................................................................................................................2.8
HYDRAULIC FEED CONTROL...................................................................................................................................2.9
CUTTING PARAMETERS CHART..............................................................................................................................2.10
CUTTING SOLIDS ......................................................................................................................................................2.10
CUTTING STRUCTURALS.........................................................................................................................................2.10
ADDITIONAL CONTROLS ..........................................................................................................................................2.13
COOLANT FLOW........................................................................................................................................................2.13
HEAD UP AND DOWN LIMIT SETTING .....................................................................................................................2.14
VARIABLE VISE PRESSURE (OPTION) ...................................................................................................................2.14
BUNDLING OPERATION (OPTION) ..........................................................................................................................2.15
SECTION 3, MAINTENANCE & TROUBLESHOOTING
LOCK -OUT.................................................................................................................................................................3.1
LOCK OUT PROCEDURE ..........................................................................................................................................3.1
BLADE CHANGING PROCEDURE ............................................................................................................................3.1
BLADE BRUSH ADJUSTMENT ..................................................................................................................................3.2
BLADE TRACKING ADJUSTMENT ............................................................................................................................3.2
IDLER WHEEL TRACKING.........................................................................................................................................3.2
DRIVE WHEEL TRACKING ........................................................................................................................................3.2
CAM FOLLOWER ADJUSTMENT ..............................................................................................................................3.3
LUBRICATION.............................................................................................................................................................3.3
GEARBOX LUBRICATION (H-18ASV WITH A503 GEARBOX) .................................................................................3.4
OUTPUT SHAFT LUBRICATION ................................................................................................................................3.5
HYDRAULIC MAINTENANCE.....................................................................................................................................3.5
CLEANLINESS............................................................................................................................................................3.6
TROUBLE SHOOTING ...............................................................................................................................................3.6
PROGAMMABLE LOGIC CONTROL..........................................................................................................................3.8
PLC PARAMETERS ....................................................................................................................................................3.8
PLC TROUBLESHOTTING.........................................................................................................................................3.10
FUSES.........................................................................................................................................................................3.15
MITSUBISHI FX2N 48MR INPUTS AND OUTPUTS ..................................................................................................3.16
ENCODER & PROXIMITY SENSOR CONNECTIONS...............................................................................................3.17
CALIBRATION PROCEDURE.....................................................................................................................................3.18
HEAD HEIGHT CALIBRATION PROCEDURE ...........................................................................................................3.19

TOC.2
SECTION 4, ELECTRICAL
GENERAL INFORMATION..........................................................................................................................................4.1
INITIAL HOOKUP........................................................................................................................................................4.1
H-18/22 SV ELECTRICAL SCHEMATIC, NO OPTIONS 208/240 VAC ......................................................................4.8
H-18/22 SV ELECTRICAL WIRING DIAGRAM, NO OPTIONS 208/240 VAC............................................................ 4.12
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, NO OPTIONS 208/240 VAC ........................4.18
H-18/22 SV ELECTRICAL SCHEMATIC, WITH OPTIONS, 208/240 VAC .................................................................4.20
H-18/22 SV ELECTRICAL WIRING DIAGRAM, WITH OPTIONS, 208/240 VAC .......................................................4.24
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH OPTIONS, 208/240 VAC ................... 4.30
H-18/22 SV ELECTRICAL SCHEMATIC, NO OPTIONS 480/575 VAC ......................................................................4.32
H-18/22 SV ELECTRICAL WIRING DIAGRAM, NO OPTIONS 480/575 VAC............................................................ 4.36
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH NO OPTIONS, 480/575 VAC............. 4.42
H-18/22 SV ELECTRICAL SCHEMATIC, WITH OPTIONS, 480/575 VAC .................................................................4.44
H-18/22 SV ELECTRICAL WIRING DIAGRAM, WITH OPTIONS, 480/575 VAC .......................................................4.48
H-18/22 SV ELECTRICAL WIRING DIAGRAM INPUTS & OUTPUTS, WITH OPTIONS, 480/575 VAC ................... 4.54
SECTION 5, HYDRAULIC SYSTEM
GLAND ASSEMBLIES ................................................................................................................................................5.2
PISTON ASSEMBLIES................................................................................................................................................5.2
H-18/22 SV HYDRAULIC SCHEMATIC ......................................................................................................................5.3
H-18/22 SV PLUMBING DIAGRAM ............................................................................................................................5.4
SECTION 6, MECHANICAL
H-18 SV BLADE BRUSH ASSEMBLY......................................................................................................................... 6.1
H-22 SV BLADE BRUSH ASSEMBLY......................................................................................................................... 6.2
H-18/22 SV GUIDE ARM ASSEMBLY.........................................................................................................................6.3
H-18/22 SV CARBIDE GUIDE ASSEMBLY................................................................................................................ 6.4
H-18/22 SV ANTI-VIBRATION ROLLER ASSEMBLY .................................................................................................6.5
H-18 SV IDLER WHEEL ASSEMBLY..........................................................................................................................6.6
H-22 SV IDLER WHEEL ASSEMBLY..........................................................................................................................6.7
H-18/22 SV HYDRAULIC PUMP ASSEMBLY.............................................................................................................6.8
H-18/22 SV HYDRAULIC TANK ASSEMBLY ..............................................................................................................6.9
H-18/22 SV FRONT VISE ASSEMBLY ....................................................................................................................... 6.10
H-18/22 SV SHUTTLE VISE DATUM LINE JAW ASSEMBLY ....................................................................................6.11
H-18/22 SV SHUTTLE VISE ASSEMBLY ................................................................................................................... 6.12
H-18/22 SV CHIP AUGER ASSEMBLY.......................................................................................................................6.13
H-18 SV DRIVE ASSEMBLY .......................................................................................................................................6.14
H-22 SV DRIVE ASSEMBLY .......................................................................................................................................6.16
SECTION 7, OPTIONAL EQUIPMENT
H-18/22 SV BUNDLING ASSEMBLY .......................................................................................................................... 7.1
H-18/22 SV OUTBOARD BUNDLING ASSEMBLY .....................................................................................................7.2
SECTION 8, SPECIFICATIONS
H-18 SV LAYOUT........................................................................................................................................................8.2
H-22 SV LAYOUT........................................................................................................................................................8.3
SECTION 9, WARRANTY
WARRANTY ................................................................................................................................................................9.1

1.1
Upon delivery of your new H-18/22 SV 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 uid leaks. In the event of damage caused during shipping, contact your
carrier to le 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
operation of this saw, and the practices to avoid that could lead to injury. The following safety rules are at the minimum
necessary 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 BE ATTEMPTED ONLY 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 H-18/22 SV 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 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.
SECTION 1, INSTALLATION

1.2
1.3
H-18/22 SV LIFTING INSTRUCTIONS

1.2
1.3
FOUNDATION, LEVELLING AND ANCHORING
Machine location should be carefully selected. A at con-
crete oor 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 on in the hydraulic cabinet. Steel plates
are to be placed under each screw to prevent their sinking
into the concrete oor. In cases where the machine 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 the blade is recommended.
This will prevent coolant from running down the raw stock. (This is especially true when cutting tubing or bundles).
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 qualied 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 recommended.
During the initial hook-up it is very important to check that the
phase order is correct. This is indicated by the hydraulic pres-
sure 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.

1.4
HYDRAULIC OIL AND CUTTING FLUID
The H-18/22 SV bandsaw is supplied with Arco Duro 46 hydraulic oil. If it is necessary to change the oil to a different
brand see the HYDRAULIC SECTION for equivalent grade oil.
No cutting uid 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.

2.1
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 a variable blade speed control 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 denitely 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 ve 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 sufciently 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 nish, 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 ow 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 innitely between 60 to 350 SFM (Surface Feet/Minute) (18 to 107m/min). Adjustment
should be made only when the blade is running. Clockwise rotation of the knob increases blade speed while counter
clockwise rotation decreases blade speed.
THE CONTROL PANEL
START-UP
The H-18/22 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 can
not overstress the importance of familiarizing yourself with the controls of the H-18/22 prior to starting the
machine.
NOTE:
1. ALL SWITCHES MUST BE IN THE CENTER NEUTRAL POSITION TO START THE MACHINE!
2. WHEN STARTING THE MACHINE FOR THE FIRST TIME MAKE SURE THAT BLADE IS MOVING IN A COUN-
TERCLOCKWISE DIRECTION, AND THAT THE HYDRAULIC PRESSURE IS 1000 PSI (6890kP). IF THERE IS
NO IMMEDIATE PRESSURE, SHUT THE SAW DOWN AND CHANGE THE PHASE ORDER.
MANUAL OPERATION
Manual Operations can be performed when the PLC 100 controller is set to MAN (AUTO is active when a RED light is on
above the AUTO/MAN button). All functions are self-explanatory. Specic control button functions are described on the
following pages.

2.2
2.3
FRONT VISE - This switch has three positions, OPEN, HOLD and CLOSE. With the switch held in the
OPEN position the vise will open all the way or until the switch is released. With the switch in the HOLD
position, the vise will stay where it is and will not move freely although it will not resist a large force
indenitely without creeping. In CLOSE, the vise will close all the way, or until it encounters enough
resistance to stop it.
HEAD CONTROL - This switch has three positions: UP, HOLD and DOWN. The switch is inactive un-
less the PLC is in manual mode. In the UP position, the head will rise until it trips the head up limit which
is adjustable via the PLC. In the HOLD position the head will stay still. In the DOWN position the head
will descend until it reaches the bottom of the stroke. The speed of descent is controlled by the Head
Feed and Head Force Limit controls.
BLADE START - The blade can be started only when the hydraulics are running in either manual or auto
mode.
NOTE: In automatic Mode the head will not descend until the blade has been started, which the PLC will
prompt the operator to do so.
HYDRAULIC START - To start the hydraulic system, the switches for the head and both vises must be in
the “NEUTRAL” position. The “HYDRAULIC START” button must be depressed and held in momentarily
until the PLC display becomes active.
CYCLE START / PAUSE - This button starts the cutting cycles and will stay illuminated white until the
cycles are completed. The PLC control system will prompt you to start the blade if it is not running. The
machine will then begin the automatic cycle until completed when it will shut itself off. The current cycle
can be PAUSED by pressing this button at any time during a cycle and restarted by pressing it again.
COOLANT - This switch has three positions, AUTO, OFF, and ON. In the ON position, the coolant
system will operate when there is power to the machine; this allows using the wash gun to clean the
machine. In the OFF position, the coolant system is inactive. In the AUTO position the coolant system
will only run when the blade is on. The coolant system can be run when the blade is on and the head is
descending by selecting this option in the PLC parameters.

2.2
2.3
SHUTTLE VISE - This switch has three positions, OPEN, HOLD and CLOSE. With the switch held in
the OPEN position the vise will open all the way or until the switch is released. With the switch in the
HOLD position, the vise will stay where it is and will not move freely although it will not resist a large
force indenitely without creeping. In CLOSE, the vise will close all the way, or until it encounters
enough resistance to stop it.
BLADE STOP BUTTON - Stops the blade. If the blade is stopped during a cycle, the cycle will continue
but will not let the head descend until the blade is started.
STOP - This mushroom button stops the blade and hydraulic motors. Both vises will hold their posi-
tion but, pressure will begin to fall off. Long pieces of work should always be supported so they will not
become loose over time and fall while the machine is shut down. This is a latched button and must be
pulled out to start the machine.
WORK LAMP - This option switch has two positions, OFF and ON.
LASER GUIDE - This option switch has two positions, OFF and ON.

2.4
2.5
PLC 100 CONTROL SYSTEMS
NOTE: This instruction manual is applicable to the H-18/22 SV equipped with a MITSUBISHI PLC manufactured after and
including the following serial numbers:
Machine Model Serial #
H-18S B1001099, B1001103
OPERATION OVERVIEW
The PLC is a programmable logic controller which allows the operator to run the machine in both manual and automatic
modes.
In manual mode, all functions can be operated by using a combination of selector switches on the control console and
the PLC function buttons. Also the operator has the ability to execute a single cut utilizing a preprogrammed “Single Part
Cycle”.
In automatic mode, the PLC has the capacity to program and store 99 jobs. Designated job numbers can be programmed
for quantity required (maximum of 999 pieces) and lengths from 0.1” to 220” (5588mm).
Jobs can be run individually or in a QUEUE which allows a maximum of 5 jobs to run consecutively and the queue can be
repeated automatically as well up to 99 times.
All machine operators should be familiar with the entire operation instructions prior to operating the machine.
NOTE: If an emergency situation arises during any operation, use the large red mushroom “STOP” button located on the
control panel to shut down the machine. To operate the machine, the “STOP” button must be pulled out.
DISPLAY WINDOW
PLC FUNCTION KEYS
NUMERIC KEY PAD CURSOR KEYS
ENTER KEY

2.4
2.5
ACTIVATING THE PLC
Position the head, xed vise, and shuttle vise switches to the NEUTRAL (center) positions. If any of these switches are
not in the NEUTRAL position, the hydraulics will not start. The PLC control will become active when the HYDRAULIC
START button is depressed and “held in” momentarily. First, the HMI and PLC’s current revision number will be shown on
the display window and nally the MANUAL MODE display window will appear as shown below. The AUTO/MAN green
indicator light will be on and all MANUAL controls are enabled. The “LTH” value (shuttle vise position) will always display
zero at start up. The “LTH” value can be reset or cleared at any time in MANUAL mode by pressing the CLEAR function
button.
FUNCTION KEY DESCRIPTIONS
If a red indicator light above a function button is illuminated, it means that the function printed in red at the top of the but-
ton is enabled. No light indicates the function printed in black at the bottom of the function button is enabled.
The following are the function keys for AUTO and MAN modes:
AUTO / MAN MODE
- This key will toggle between MAN and AUTO modes. Auto mode cannot be accessed unless the front vise is
closed.
- Also used to stop an automatic job in progress by switching to MANUAL mode.
UNLABELLED
- The function of theses keys are displayed directly above them. The function will change as the PLC is
switched from one mode to another and as process of each mode is changed.
INCH/MM / CLEAR
- While depressed momentarily, it resets the displayed length value to zero. If held depressed for a few sec-
onds, the displayed length will toggle between millimeters and inches and the blade speed in either surface feet
per minute or meters per minute. It becomes disabled once any cycle is initiated.
MANUAL MODE FUNCTION KEY DESCRIPTIONS
While in manual mode, the display will show the current function of the unlabelled key. They are shown below.
FWD
REV
S/F
FWD: FORWARD - This key will advance the shuttle vise toward the head (home position). If pressed simultaneously
with the REV key, (the front vise must be closed and a password is required) the parameters will be
displayed.
REV: REVERSE - This key will retract the shuttle vise away from the head (home position). If pressed simultaneously with
the FWD key, (the front vise must be closed and a password is required) the parameters will be dis-
played.
S/F : SLOW / FAST - This key will toggle between slow and fast shuttle speed.

2.6
2.7
SINGLE PART CYCLE OPERATION
In MAN mode, the PLC allows the operator to initiate a “Single Part Cycle” to cut one piece at a desired length. To accom-
plish this, follow the procedure below.
1. A trim cut should be made before initiating the “Single Part Cycle” operation.
2. Make sure the front vise switch is in the closed position and set the head up limit switch. The AUTO/MAN indicator
light will ash alternately green and red.
3. Make sure the head is set so that the blade is above the material and the head selector switch is in the HOLD
position.
4. The cursor will be ashing at the LENGTH position. Key in the desired value from 0” to 220” and press enter. If the
value is incorrect, re-enter the value and press enter again.
5. If the blade is not running, you will be prompted by the word “BLADE” ashing on the display window. Start the
blade and adjust the blade speed as required.
6. When the blade is started, the word “BLADE” will change to the word “CYCLE” ashing on the display window.
Press CYCLE START and the cycle will begin.
7. When the cycle button is pressed, the shuttle vise will move forward to the home position before executing the
length movement. The head will descend and make the cut.
8. When the cut is completed, the head will rise to the head up limit switch, the blade will stop and the display win-
dow will reset for the next cut.
9. To cut another piece, repeat steps 2 through 6.
NOTES:
1. To “PAUSE” the “SINGLE CUT CYCLE”, press the “CYCLE START” button. The “CYCLE START” button will be-
gin to ash and the screen will indicate a paused condition. All movements will immediately cease. To continue the
cycle, press “CYCLE START” button again.
2. To cut multiple pieces, switch to AUTO MODE and follow the automatic procedures.
KERF CORRECTION
When making cuts, the PLC must account for an amount called the “KERF” which is the material removed by the blade.
This value must be entered into the PLC and must be checked and adjusted as required when the blade has been re-
placed. This is due to the fact that there is a variance in the kerf value from blade to blade. The original value entered is
for the blade installed at the time of manufacture. If the kerf value is to be adjusted its value can be accessed while in
Auto Mode. Press and hold the key below the word “KERF” on the display until the display appears as shown. Enter the
desired kerf value and press enter.
NOTE: Whenever a new job or new material is being loaded for production, the head up limit switch should be properly
set to clear the material, positioned for a trim cut and the front vise closed (in “MANUAL MODE”).
ENTER KEY
LENGTH
BLADE SPEED
FLASHING
RETURNS TO THE
QUEUE
RETURNS TO
AUTO MODE

2.6
2.7
AUTOMATIC OPERATION
When the AUTO/MAN button is pressed, the red indicator light above it will come on, and the blade will stop if it has been
running. The screen will change to the JOB display window as shown below and be ready for editing or starting a new job.
All manual functions will be disabled.
JOB DISPLAY WINDOW
PROCEDURE FOR EDITING OR STARTING A NEW JOB IN AUTO MODE
1. In AUTO mode, key in a job number from 0 to 99 and press enter. The REQUIRED QUANTITY (RQ), LENGTH
(LTH) and QUANTITY (CT) will be displayed. The values displayed can be edited by pressing ENTER after each
new value, and the job will be stored in memory with the new values. To navigate through the values, use the
CURSOR keys.
2. After the values are entered, press the CYCLE START button, the switch will illuminate, the display window will
prompt you to start the blade for a trim cut (if the “Trim Cut” parameter has been selected).
CAUTION:
If the head is in its down position, it will rise to the head up limit so that no damage to the blade will occur.
3. After starting the blade, the head will descend for the cut and the machine will complete the required job.
JOB IN PROGRESS
4. At the completion of the job, the machine will shut down if “0” has been entered in the “POWER DWN TIMER”
parameter or continue running for the specied time up to a maximum of 180 minutes.
NOTES:
1. The “CT” value is the accumulated total number of parts that have been cut from the JOB number since it was last
reset. The machine will only cut the quantity which is the difference between REQUIRED QUANTITY and CUT
QUANTITY. When REQUIRED QUANTITY equals CUT QUANTITY, the machine AUTO CYCLE will stop and you
will be unable to restart the same job until the “CUT QUANTITY” value has been reset.
2. The AUTO cycle may be exited and stopped at any time by pressing the key.
NOTE: Before entering “AUTO MODE” and working with a “QUEUE”, follow the same procedures outlined on the previous
page for “AUTOMATIC OPERATION” with regards to setting up for an initial trim cut.
JOB NUMBER
LENGTH
REQUIRED QTY
CUT QTY

2.8
2.9
WORKING WITH A QUEUE
The purpose of a QUEUE is to allow the operator to run several jobs (max of 5) in series if they are of the same material
and shape.
In AUTO mode, press the key below the word “QUE” on the display and the display window will appear as shown.
If you choose to VIEW the QUEUE, press the key below the words “VIEW QUE” on the display. The display window will
show the jobs in the current QUEUE. Four jobs at a time are shown.
Use the CURSOR buttons to view all the jobs. To run the QUEUE as it is displayed (jobs may be edited in this mode),
press the CYCLE START button on the control panel. The screen will now prompt you to start the blade for a trim cut.
If you choose to edit the QUEUE, press the key below the words “CLEAR QUE” on the display. This will clear any jobs
that are in the QUEUE and the display window will show an empty Queue. Jobs may be entered and edited in this mode.
To ll the QUEUE, follow these two steps.
1. Key in a job number and press ENTER. If that job number has previously been programmed, it’s values will be
displayed. The cursor will move to the next position in the QUEUE. Up to ve jobs may be in the QUEUE at any
time. The job values can be edited in this mode.
2. When the desired jobs have been entered, you may press the CYCLE START button on the control panel to ex-
ecute the jobs in the QUEUE. (Follow the same procedures to initiate a cycle as in “AUTOMATIC OPERATION”)
The QUEUE may be exited to the previous screen at any time by pressing the key under JOB. At completion of the
“QUEUE”, the machine will shut down if “0” has been entered in the “POWER DWN TIMER” parameter or continue run-
ning for the specied time up to a maximum of 180 minutes.
VIEW QUE CLEAR QUE
FIRST JOB
PROGRAMMED JOB
NUMBER
QUANITY TO CUT
LENGTH TO CUT

2.8
2.9
HYDRAULIC FEED CONTROL
The Hydraulic Feed Control is located to the left of the control panel. These controls allow independent control of Feed
Force and Feed Rate.
FAST APPROACH LEVER
DEPRESS FOR FAST HEAD DE-
SCENT
FEED FORCE KNOB
USED TO SET FEED FORCE LIMIT
(COUNTERCLOCKWISE ROTATION
TO INCREASE AND CLOCKWISE
ROTATION TO DECREASE).
FEED RATE KNOB
USED TO SET FEED RATE (COUN-
TERCLOCKWISE ROTATION TO
INCREASE AND CLOCKWISE
ROTATION TO DECREASE).

2.10
2.11
CUTTING PARAMETERS CHART
A full size CUTTING PARAMETERS CHART is mounted on the front of the saw. The
chart contains ve steps for the operator to follow in order to achieve optimum perfor-
mance of the saw. These steps are detailed on the following pages.
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 difcult. Effective width is 60% to 75% of
the actual material width.
NOTES:
1. Both effective material width and guide arm width are used in setting the saw.
2. Guide arm width is the distance between the guide arms and is used in STEP
2.
3. 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 Mate-
rial Width is 8” (200mm).
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. FEED FORCE LIMIT should be set with the head in the down mode, according to the label.
CUTTING SOLIDS
For cutting solids, the wider the section, the less FF should be
set, to avoid blade overloading. See the graph.
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:
For structurals, a blade ner than optimum can be used for more efcient cutting.
If a ner than optimum blade is going to be used, Feed Force Setting should be reduced even further.
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 ne blade with
% OF FF
SETTING
MAT’L WIDTH AS %
OF CAPACITY
BLADE FF SETTING
1 OPTIMUM PITCH
FROM STEP 3
20%
2 PITCH FINER THAN
OPTIMUM
0%

2.10
2.11
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.
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 efciently. Too ne 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.
In our Example #1: Effective material width of 8” (200 mm) & Optimum blade
has 2/3 teeth per inch.
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.
In Example #1
1. 8” (200mm) diameter #1045 Medium
Carbon Steel solid bar is to be cut.
2. On the graph above nd the Me-
dium Carbon Steel Curve which
represents the optimum blade
speeds for 1045 Carbon Steel.
3. On the horizontal axis (effective
material width axis) nd 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
nd 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 signicantly 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.
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 in the range 0 to 15 in/min (380mm/min). The FEED
RATE should be adjusted only in one direction (from “O” to required value). If you go too far, go back to “O” and come

2.12
2.13
back up. To set FEED RATE for particular cutting situations use the Graph below, which represents the relationship be-
tween FEED RATE, blade speed and blade pitch.
NO. MATERIALS OPTIMUM BLADE SPEED
ft/min m/min
1 5” (125mm) Dia Solid Carbon Steel 225 70
2 12” (300mm) I-Beam 290 90
3 4” x 4”(100 x 100mm) Rec Tube, 1/4” (6mm) Wall 350 110
4 4”(100) 400 Stainless Steel 140 45
5 2” x 2” (50 x 50mm) Rec Tube 1/4” (6mm) Wall
Bundle 5 x 5 pcs 10” x 10” (500 x 500mm) 325 100
6 3” x 3” (75 x 75mm) Inconel 60 20
For 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:
• On the horizontal axis (blade speed axis), nd 200 ft/min (60mm/min).
• Find the point where a vertical line from 200 ft/min (60mm/min) would intersect the 2/3 blade pitch curve.
• 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, continued
If the saw is tted 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 nd that the FEED RATE is decreased to 1.3 in/min
(133mm/min) for this blade. If however, the machine is tted with a ner 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.
NOTE:
Use the following chart when cutting solids. For structurals, see “CUTTING STRUCTURALS” in STEP 2.
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 (70m/min x .60 =
42m/min)
Blade speed reduced by hardness factor: 225