Mitek Hornet II Guide

Safety, Operation & Maintenance Manual
Hornet II™ saw
Linear Cut Processing Systems
MiTek Component Automation
301 Fountain Lakes Industrial Drive
St. Charles, MO 63301
Phone: [phone]
Fax: [phone]
[e-mail]
PN 001079
Creation date: 1/1/2023
Created by: A. Moll
Applies to: Gen. 2

Safety, Operation, & Maintenance Manual
Linear Cut Processing Systems
Table of Contents
1 Safety .................................................................................................................. 1
1.1.1 Safety Indicator Signal Word ..............................................................1
1.1.2 General Safety & Equipment Rules .................................................... 2
1.2 Safety Rules................................................................................................. 2
1.2.1 Know Your Equipment.........................................................................2
1.2.2 Personal Safety.................................................................................... 3
1.2.3 Installing the Equipment ..................................................................... 3
1.2.4 Keeping a Safe Environment ...............................................................3
1.2.5 Operating and Maintaining the Equipment ........................................ 4
1.2.6 Electrical Safety Notes......................................................................... 5
1.2.7 General Warnings ...............................................................................6
1.2.8 E-Stop Locations.................................................................................. 6
1.3 Lockout/Tagout...........................................................................................7
1.3.1 Lockout/Tagout Guidelines .................................................................7
1.3.2 Electrical Lockout/Tagout Procedures................................................. 8
1.3.3 Troubleshooting with an Energized Machine....................................12
1.4 Emergency Stop Buttons/Mechanisms .................................................... 12
1.4.1 Overview and Locations ...................................................................12
1.4.2 Engaging and Disengaging an E-Stop................................................13
1.4.3 Safety Guards....................................................................................14
1.4.4 Audible Alerts....................................................................................14
1.5 Safety Tests ...............................................................................................14
1.5.1 Inspecting the Hornet II Saw ............................................................. 14
1.5.2 E-Stop Test ........................................................................................14
1.6 Restricted Zone......................................................................................... 16
1.6.1 Marking the Restricted Zone............................................................. 16
2 Safety Symbol Definitions.................................................................................17
2.1 Declaration of Safety Conformity .............................................................24
3
Introduction ....................................................................................................... 25
3.1 Introduction to the Manual ......................................................................25
3.2 Additional Resources ................................................................................25
4 Main Components and Optional Equipment....................................................26
4.1
Main Components ...................................................................................... 26

Safety, Operation, & Maintenance Manual
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4.2 Optional Features .....................................................................................27
4.3 Dust Extraction Methods..........................................................................27
4.4 Air Valve Assemblies.................................................................................27
5 Printer Components ..........................................................................................30
5.1 Print Areas ................................................................................................31
5.1.1
Reading the Printed Data .................................................................... 31
5.1.2 Modifying the Printed Data ..............................................................32
5.2 Controller..................................................................................................33
5.3 Ribbon Cables ........................................................................................... 34
5.4 Pen Stalls...................................................................................................35
6
CutBuilder Software ...........................................................................................36
6.1 Software Overview ...................................................................................36
6.2
Home Screen Panels ...................................................................................36
6.3 Home Screen Panes ....................................................................................37
6.4
Customizing the Home Screen Panels with Panes .........................................39
6.4.1 View Menu........................................................................................ 40
6.4.2 Arranging Panes................................................................................40
6.5
Software Control Buttons Overview ............................................................ 43
6.5.1 Standard Software Buttons ..............................................................43
6.5.2 Optional Software Buttons (for Optional Equipment) .....................44
7
Pre- Operation....................................................................................................46
7.1.1 Passwords ......................................................................................... 46
7.1.2
Pre-Operation Software Checks ..........................................................46
7.2
Pre-Operation Physical Checks ....................................................................47
8 Operation ..........................................................................................................47
8.1 Start Conditions.........................................................................................47
8.1.1
Homing the Saw Angle .......................................................................49
8.2 Physical Control Buttons........................................................................... 50
8.2.1 Auto Loading Live Deck (Optional) ...................................................50
8.2.2 HMI Enclosure...................................................................................51
8.3
Manual Mode ............................................................................................52
8.3.1 Relative Move Pusher (Distance) ......................................................52
8.3.2 Move Infeed Pusher (Position) .........................................................54
8.4
Cut-Set Mode/Job Manager ........................................................................55
8.4.1 Job Manager ..................................................................................... 55
8.4.2 Populating Cut Sets from a Specified Job ......................................... 59

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8.4.3 Selecting Stock Lengths..................................................................... 60
8.4.4 Optimizing Material ..........................................................................61
8.4.5 Cut Sets .............................................................................................62
8.5
Cutting Procedure ......................................................................................63
8.5.1 Loading Lumber and Lumber Considerations...................................63
8.5.2 Cutting Procedure Overview .............................................................64
8.6
System Settings ......................................................................................... 65
9 Maintenance .....................................................................................................67
9.1 Introduction to Maintaining Your Machine..............................................67
9.2 Overview Graphics....................................................................................68
9.3 Cleaning and Inspecting............................................................................68
9.3.1 Cleaning ............................................................................................68
9.3.2 Inspecting ......................................................................................... 68
9.4 Calibration ................................................................................................69
9.4.1 Calibration of the Pusher.................................................................. 69
9.4.2 Calibration of the Angle.................................................................... 71
9.5 Belts ..........................................................................................................73
9.5.1 Motor Belt Replacement ..................................................................73
9.5.2 Blade Belt Replacement .................................................................... 76
9.6 Bearings and Lubrication ..........................................................................77
9.6.1 Applying Bearing Lubricant............................................................... 77
9.6.2 Bottom Plate Printer Rails ................................................................81
9.6.3 Support and Tracking Rollers............................................................81
9.7 Saw Blade..................................................................................................82
9.8 Pneumatic System ....................................................................................84
9.8.1 Removing Pressure from the Pneumatic System .............................84
9.8.2 Filter/Main Regulator ....................................................................... 86
9.8.3 Maintaining the Filter / Regulator(s) ................................................86
9.9 Printers ..................................................................................................... 89
9.9.1 Removing the Controller ..................................................................89
9.9.2 Removing the Pen Stalls ...................................................................90
9.9.3
Cleaning the Printer(s) ........................................................................91
9.9.4 Ink Cartridges .................................................................................... 93
9.10 Electrical Systems .....................................................................................95
9.10.1 Electrical Enclosure...........................................................................95
9.10.2 Sensors.............................................................................................. 95

Safety, Operation, & Maintenance Manual
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10 Maintenance Checklists....................................................................................98
10.1 Safety Notes For Maintenance Checklists ................................................98
10.2 Daily and Weekly Checklist.......................................................................99
10.3 Monthly Checklist ................................................................................... 100
10.4 Annual Checklist .....................................................................................101

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1Safety
1.1.1 Safety Indicator Signal Word
The following signal words and colors are used throughout this document to
indicate safety hazards. Pay careful attention when you see them. The level of
severity differs for each signal word and color.
Signal words are accompanied by graphics showing what personnel should or
should not do. The graphics are called safety symbols and are defined in the
General Warnings section, but more specific text is provided every time a
graphic is used throughout the manual. Everyone near the machine must be
trained on how to read these safety indicators.
Failure to comply with the instructions accompanying each signal word may
result in property damage, personal injury, or even death. Personnel must
follow all safety procedures and practices to ensure the safest possible
operation of this equipment. However, at no time is this document a
substitute for common sense. Personnel must ensure that the work
environment is safe and free of distractions.
Indicates an imminently hazardous situation which, if not
avoided, is likely to result in death or serious injury.
Indicates a potentially hazardous situation, which, if
n not avoided, may result in death or serious injury.
Indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
Calls attention to information that is significant to
understanding the operation at hand or the potential for
property damage.
Applies to conditions that may affect the environment
but do not have an immediate, direct effect on
personnel or equipment
Environmental
Notice
Caution
Warning
Danger

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1.1.2 General Safety & Equipment Rules
Because it is impossible to anticipate every circumstance that might involve
a hazard, the safety information provided in this equipment manual and on
the machine is not all-inclusive. If this machine is operated or serviced using
a procedure not specifically recommended by the manufacturer, the
procedure shall be approved by a professional engineer to ensure it will not
render the equipment unsafe. Use extreme caution and common sense at all
times.
1.2 Safety Rules
1.2.1 Know Your Equipment
•Read this manual completely before using or maintaining the
equipment. Do not operate this machine unless you have a
thorough knowledge of the controls, safety devices, emergency
stops, and operating procedures outlined in this manual.
•Read and follow all safety notes. Failure to comply with these
instructions may result in economic loss, property damage, and/or
personal injury including death.
•Refer to the lockout/tagout guidelines on the following pages
to safely perform maintenance and troubleshooting of this
equipment.
•Observe and obey all safety labels. Replace worn labels immediately.
•Use this equipment solely for the purpose described in this manual.
•Only qualified personnel should attempt to operate or perform
maintenance on this equipment. “Qualified personnel” is defined
as:
...a person or persons who, by possession of a recognized degree or
certificate of professional training, or who, by extensive knowledge,
training, or experience, has successfully demonstrated the ability to
solve problems relating to the subject matter and work—ANSI B30.2-
1983
...one who has skills and knowledge related to the construction and
operation of the electrical equipment and installations and has
received safety training on the hazards involved—NEC 2002
Handbook

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1.2.2 Personal Safety
•Always wear safety glasses and hearing protection in an
industrial environment.
•Utilize a filtering face piece (dust mask) when working
near sawdust.
•Wear proper clothing and appropriate personal protective
equipment (e.g., safety glasses and hearing protection.) Do not
wear loose clothing or jewelry. Confine long hair by tying it back.
•Use caution when lifting heavy parts or material.
1.2.3 Installing the Equipment
•Follow installation instructions completely.
•Use proper lifting equipment rated for the proper weight.
•This equipment is not for use in a residential area.
1.2.4 Keeping a Safe Environment
•Pay attention to your surroundings.
•Keep children away. All visitors should be kept a safe distance
from the work area. Hazards may not be apparent to individuals
unfamiliar with the machine.
•Keep work areas well lit.
•Keep the work area clean and free of any trip or slip hazards.
•Do not use the equipment in damp or wet locations or expose it to
rain or snow.
•Minimize dust clouds and protect your equipment by cleaning
dust in this manner:
oShut down electrical power and sources of ignition
oVacuum dust prior to blowing with air
oPowered cleaning equipment such as vacuums must
be consistent with local governmental codes for use
in dusty conditions.

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1.2.5 Operating and Maintaining the Equipment
•Ensure that all people, tools, and foreign objects are clear of the
restricted zones before operating this equipment.
•Perform safety tests to ensure all E-stops are working properly
before operating the equipment at the initial startup, after
performing any maintenance, and in accordance with the
maintenance schedule.
•Always push an E-stop button before approaching a machine
for any reason. An E-stop may cause components to move
without warning.
•Only use procedures described in this manual. Any other procedures
should be discussed with MiTek to verify it is done safely. For topics
not covered in this manual or online, contact MiTek for advice.
•In case of machine malfunction, stop the machine immediately using
an E-stop, lockout/tagout, and report the malfunction to a
supervisor.
•Never leave the machine running unattended. Turn the power off!
Do not leave the machine until all parts have come to a complete
stop and all electrical power has been shut off.
•Check for worn or damaged parts regularly. Repair or
replace them immediately.
•Only use exact replacement parts specified. Using unapproved
parts may void the warranty and can be a safety risk.
•Keep the hydraulic, pneumatic, and electrical systems in good
working order at all times. Repair leaks and loose connections
immediately. Never exceed the recommended pressure or
electrical power.
•Check that all guards and safety devices are in place and in working
order before each shift starts. All protective guards and safety
devices must be in place before and during use of the machine.
Never disconnect or bypass any safety device or electrical interlock.
•Torque bolts and fasteners to the specifications given by MiTek. If no
torque specification is given, use industry standards.
•Only qualified maintenance personnel shall make adjustments or
remove, repair, or install safety devices. Only qualified electricians
should perform electrical work.
•Periodically inspect the quality of the finished product.
•Document all preventive and repair maintenance over the life of
the machine to improve machine efficiency and reduce the risk of
accidents.

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1.2.6 Electrical Safety Notes
•Do not use any liquids in the interior of electrical cabinets.
•When using solvents on and around the machine, remove power
to the machine to eliminate the chance of sparking, resulting in
explosion or fire. Wear a respirator approved for use with
solvents.

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1.2.7 General Warnings
1.2.8 E-Stop Locations
Refer to Emergency Stop Buttons/Mechanisms for location of E-stops.

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1.3 Lockout/Tagout
1.3.1 Lockout/Tagout Guidelines
Lockout/tagout all energized systems before performing maintenance on them.
All lockout/tagout guidelines must be met according to OSHA 29 CFR
1910.147. A specific procedure should be included in your company’s energy
control program. This manual is not intended to replace your company’s de-
energizing or lockout/tagout procedure required by OSHA, but merely to
provide general guidance.
The term “lockout,” as used in this manual, means placing a lockout device,
such as a keyed padlock, on any and all energy sources to ensure that the
energy isolating device and the equipment being controlled cannot be re-
energized or operated until the lockout device is removed.
•Energy sources include electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, or other energy.
•In the case of electrical energy sources, the main power and control
power to the machinery must be turned off and physically locked in
the Off position.
•Before performing maintenance on the pneumatic or hydraulic
systems, bleed the lines prior to lockout/tagout to eliminate
pressure.
If more than one person is working in a restricted zone, use a group lockout
device that will allow each person to use a lock that can be removed only by
the person performing the maintenance.
“Tagout” means that a prominent warning is securely fastened to an energy-
isolating device to indicate that the equipment shall not be operated.

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1.3.2 Electrical Lockout/Tagout Procedures
1.3.2.1 Working on a Machine Outside the Machine’s Main Electrical Enclosure
Before performing maintenance on any machine with electrical power,
lockout/ tagout the machine properly. When working on a machine outside
of the machine’s main electrical enclosure, not including work on the
electrical transmission line to the machine, follow your company’s approved
lockout/ tagout procedures which should include, but are not limited to the
steps here.
1. Engage an E-stop on the machine.
2. Turn the disconnect switch handle to the Off position. See Figure 1-1.
Figure 1-1: Disconnect Switch in Off Position
3. Attach a lock and tag that meet OSHA requirements for
lockout/tagout. See Figure 1-2.
4. Restrain or de-energize all pneumatic components, hydraulic
components, and other parts that could have live or stored power.

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Figure 1-2: Sample of a Lockout/Tagout Mechanism on an Electrical Enclosure

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1.3.2.2 Working on a Machine Inside the Machine’s Main Electrical Enclosure or in
the Electrical Transmission Line to the Machine
Before opening the main electrical enclosure, or attempting to repair or
replace an electrical transmission line to the machine, lockout/tagout the
machine properly. Follow your company’s approved lockout/tagout
procedures which should include, but are not limited to the steps here.
1. Engage an E-stop on the machine.
2. Shut the power to the machine off at the machine’s power source which is
usually an electrical service entry panel on the facility wall. One example of a
locked-out power source panel is shown in Figure 1- 3.
3. Attach a lock and tag that meets OSHA requirements for lockout/tagout.
4. Open the door to the enclosure in which you need access, and using a
multimeter, verify that the power is off.
Figure 1-3: Sample of a Lockout/ Tagout Mechanism on a Power Source Panel

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1.3.2.3 Hydraulic or Pneumatic System Lockout/Tagout Procedure
Before working on or near hydraulic or pneumatic components, bleed the lines of
pressure. See the Pneumatic System section for further instruction.
When Lockout/Tagout Is Not Required
If working on components other than the hydraulic or pneumatic system, but that
requires you to be near the vicinity of movable hydraulic or pneumatic components, you
must, at a minimum, physically restrain those components from moving. If this is not
possible, lockout/tagout the entire hydraulic or pneumatic system.
When Lockout/Tagout Is Required
Before attempting repair or performing maintenance on a hydraulic or pneumatic line
or component, lockout/tagout the machine properly. Follow your company’s approved
lockout/tagout procedures.
Sample of a Lockout/Tagout on a Pneumatic System

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1.3.3 Troubleshooting with an Energized Machine
Only a qualified electrician, using the personal protective equipment and
following the procedures recommended in NFPA 70E should ever attempt
service or repair of or near an energized area or component of the machine.
Whenever maintenance is performed while the equipment is electrically
energized, there is a potential electric arc flash hazard. Refer to NFPA 70E for
the personal protective equipment required when working with electrically
energized components. Pneumatic and hydraulic components may move
unexpectedly if not de-energized. Physically restrain any components
capable of movement when working on or near those components.
1.4 Emergency Stop Buttons/Mechanisms
1.4.1 Overview and Locations
Ensure all operators and other personnel around the equipment know the location of
ALL safety stop (“Emergency Stop”/E-stop) buttons/mechanisms and the purpose and
proper procedures for using them.
An E-stop stops any movement and function of the machine (including toggling a locking
bolt to stop saw blade motion) but does not completely cut power. The machine will
need to be reset to resume functionality.
Note that raising the saw hood will also stop all motion, but the saw does not need to be
reset to resume operation and it will not engage the locking bolt in the saw unit.
A diagram of all E-stop locations (shown with optional equipment):

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1.4.2 Engaging and Disengaging an E-Stop
1. To activate an E-Stop, push on it. An E-stop will illuminate red in color when
engaged.
2. To deactivate an E-stop, pull on the button so it is in the up position and is no
longer illuminated.
3. To resume operation, press the Reset button in the CutBuilder software. The
reset button can be found on the Infeed Pusher panel.

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1.4.3 Safety Guards
•NEVER operate equipment if any of the safety guards are not properly installed.
•NEVER bypass, modify, or otherwise disable any of the safety guards.
1.4.4 Audible Alerts
•Whenever audible alerting features are in use, be sure to obey all warnings,
cautions, or other instructions heard from the audible system.
1.5 Safety Tests
This test procedure MUST be performed by qualified personnel at startup
and after ANY maintenance, adjustment, or modification. Testing ensures
that the safety system and machine control system work together to stop
the machine properly.
1.5.1 Inspecting the Hornet II Saw
1. Lockout/tagout the machine.
2. Check the Hornet II Saw for debris or tools that would block the path of parts.
Remove any that you may find. The following locations are especially important:
oInfeed pusher and squeezer
oOutfeed table
oSaw chamber
3. Check the physical condition of the Hornet II Saw.
4. Remove lockout/tagout and return electrical power and pneumatic pressure to
the machine.
5. Verify the machine has power by checking if E-stops are illuminated green.
6. Verify all doors are closed and locked.
1.5.2 E-Stop Test
1. Verify there is no material on the infeed end of the saw or inside
the saw chamber.
2. Initiate a cut cycle using the Cut Set/Load Set mode. The infeed
pusher will begin to move as will the saw blade.
3. Activate an E-stop. Verify that the following happens when the
pushbutton is depressed:
oThe infeed pusher and auto loading mechanism stop
oAll illuminated E-stops should turn solid red
oThe bolt that stops the saw blade should engage
4. If the E-stop does not engage properly, immediately lockout/tagout and service the
machine.

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5. Pull the E-stop to release it. The solid red light should no longer be
illuminated on any E-stops.
6. To resume operation, press the Reset button on the Infeed Pusher panel in the
CutBuilder software.