W&H 206 User manual



MODEL 206 MOLDER
OPERATOR’S MANUAL






Williams&Hussey
465ThirdAveSE
Bri,IA50423
800/258.1380641/843.3240
[email protected]
www.williamsnhussey.com
This manual is provided for your convenience in the use
and care of your machine. These instructions include
operation, precautions, preventative maintenance and
other pertinent data to assist you in assuring long life and
dependable service from your machine.
MolderModel:206.208/230.1v2.0
206.208/230.3v2.0

ForSerialnumbers20210492060001forward
April2021
WARNING: FOR YOUR SAFETY READ AND UNDERSTAND THIS MANUAL
PRIOR TO USING THE SAW. REVIEW ALL SAFETY RULES AND OPERATING
INSTRUCTIONS FREQUENTLY.
www.williamsnhussey.com
1 [phone] [phone] fax [phone]
Customer Service is available Monday
-Friday, 8:00 AM- 4:30 PM CST

SPECIFICATIONSACCESSORIES
MOTOR2HP  ELLIPTICALJIG EJ‐92
RPM6900
FEEDRATE   0‐19FPMCRANKEXTENSION54‐306
MAXPROFILEDEPTH ¾”
MAXPROFILEWIDTH 6¾”
PLANINGWIDTH  7”
MINSTOCKLENGTH 9”
MINSTOCKTHICKNESS ¼”
MAXSTOCKTHICKNESS 8”
WORKINGHEIGHT 35”
OVERALLHEIGHT  50”
OVERALLWIDTH  22”
OVERALLLENGTH28”
SHIPPINGWEIGHT 260#

SAFETY RULES

YourW&HMolderhasbeendesignedformaximumsafety,however,aswithallpowertools;thereisapossibilityofincidentor
injurytotheoperator.Therefore, itisimperavethatthismanualiscompletelyreadandunderstoodbeforeusing.
UseyourW&HMolderwithrespectandcauon.Followingstatedandinherentsafetyprecauonswillconsiderablylessenthe
possibilityofpersonalinjury.Ifnormalsafetymeasuresarenottakenorareoverlooked,thepossibilityofincidentrisestremen‐
dously.Thesesafetymeasuresaresimpletofollow,andtheinjuriesthatcouldhappenarenotworththefewminutessavedby
ignoringsafety.

TheW&HMolderwasdesignedforspecificapplicaons.Donotmodifyorusethemachineforanypurposeotherthanwhatthis
manualdescribesasitscapabilies.Substungamotorwithahorsepowerrangover2HPconstutesamodificaon.Anymodi‐
ficaonsorimproperusetotheMolder‐Planermayresultinpersonalinjury,andwillvoidthewarranty.Pleasecontactusifyou
areunsureaboutsafetyprotocolbeforeusingthemachine.





SAFETYCHECKLIST DON’TTAKEUNNECESSARYRISKS!

Failure to read and apply manual instrucons will cause poor performance, unnecessary repairs and injury.
Wearsafetyglasses,hearingproteconandrespiratoryprotecon.
Disconnectthepowerbeforeservicingorchangingknives.
Wearfootwearthatdoesnotslip.Thiswillhelpyoukeepproperfoongandbalance.Alwaysstandbesidethemachine,neverin
thewayofthein‐feedandout‐feedareas.
Keepknivessharpandclean.
Makesurethemachinehaspropergrounding.
Makesureallguardsaresecuredandinworkingorder.
Removealladjusngkeysandwrenchesbeforestarng.
Checkthestockforlooseknots,nails,andforeignmaer.
Keepthemachineinadry,clean,andwell‐litarea.
PREPARING TO USE THE MACHINE
1.Disconnectthepowersourcewhilegoingthroughtheseprocedures.

2.Checkknivestoensurethattheboltsareght.Ifmolding,setyourguidesforthestockpaththroughtheknifearea.If
plaining,youmayormaynotwishtosetyourguides.Manymes,theyarenotneededinplaining.

3.Whenmolding,theheadscalesengmustbesettowithin3/16”oftheheightofyourstock.The“0”onyourscaleisset
tothetopofyourGS‐2guidesystemsub‐plate.Thismeansyouwouldsetthemachineheadreferencetothescaleat¾”
inordertotakeafullprofilepassona¾”pieceofstock.Youcouldsetthemachineheadinreferencetothescaleat
15/16”foramaximumheightfirstpass(3/4”+3/16”).Thissengwillprovidetheproperrollertension.Anyotherseng
higherfromthethicknessofthestockenteringthemachineisunacceptableanddangerous.Seethemoldingseconfor
moreinformaon.

4Thechipextractorloadsfirstundertheout‐feedendoftheheadwithalipunderthecasthead.Youthenfinishby
aachingthechipextractorwithitspin.Makesurethepinisinsertedallthewayinunlyoufeelit“catch”onthe
spring‐loadedcatch.

5.Checkrotaonalclearanceoftheknifewiththechipextractorinplace.Rotatetheknifebyhandatthe5”pulleycutout
ontheinnerbeltguardtoensuretheknifeareaisclear.

6.Donotstandorletothersstandintheout‐feedareaordirectlyinlinewiththein‐feedofthemachine.
7.Withtheheadsetintheproperposion,ghtentheheadlockingboltfirmly.Thisisessenalforsafetyandtoensurethe
machineheadwillstaywhereyouhavesetit.

8.Testapieceofstock,withthemachineoff,toseeifitwillmakecontactwiththein‐feedroller.

UNPACKING INSTRUCTIONS
Remove clear packaging.
Inspect the machine for any shipping damage.
Remove the side covers.
Cut the zip-tie around the motor.
Remove the motor shipping boards.
Remove the lag bolts holding the machine to the pallet.
Lift the machine off of the pallet.
Re-install the sides.
Before elevating the molder, loosen the motor lock.






Side panel Zip‐Tie Lag bolts

















Motor shipping boardsMotor lock

Wiring your 154/ 206 220Volt Molder

Wire#1isahotwire

Wire#2istheneutral

Wire#3isahotwireCauon:
Ifyouhave3phasedonotsplit
Green/yellowstripeisgroundthewildlegofffor1phase
Wiringforyour220Vmolder.
Wiring your 154/ 206 3phase molder
ConnectpowertotheBlack,Red,andorangecoloredwires.
Note:Orangeisforawildlegifyouhaveone.Failuretodosowilldamagethecontrolpanel.
Ifyoufacilitydoesnothaveawildlegconnectasperdiagram
Ifyourmachineisrotangtheincorrectwayswitchonlytheblackandredwires

greenisground
whiteisneutral


Wiring your 209 molder

wire#1isHot
wire#2isneutral
wire#3isnotused
Green/Yellowstripeisground

PleasenotethattheGrey#12‐4wirethatisusedonthesinglyphase
machinesarepreprintedwithleadnumbersonthembelowisthewiring
instruconsforwiringinyourplugordirectlyintoyourpowerbox.Please
callwithanyquesons.

Electrical controls:
Photoatrightshowsthestandardelectricalcontrolboxthathousesthe
contactortocontrolthecuerheadmotorandtheDCdriveboardtocon‐
trolthefeedwheels.Theimagebelowshowsthestart/staoncontrols
fromthefrontofthemachineandtheirpurpose.
E‐Stop—willshutdownbothcuerheadandfeedrollers.
Start/stopstaon‐willstartandstopthecuerhead
SpeedDial—willcontrolthespeedofthefeedrollers0isstop10isfastest

E‐Stop
Start/StopSpeedDial
MagnecStarter
assembly
Doublepolefuse
holderandLinefuses
DCDriveBoard
DriveMotor:thedrivemotorispluggedinto
theelectoralboxthroughthespecialplug
thatiswiredintothecontrolboxandthe
motor.Asshownbelow.
Addingplugtocord:simplyaddtheplugfromyourlocalhardware
storethatmatchesyourfacility.Wedonotshipwiththeplugindue
tothefactthattherearesomanydifferentversions.

VARI‐FEEDOPERATIONALTIPS

ThemaincontrolstartbuonstartstheknifemotorandtheVariFeedmotor.Thespeedcontrolknobcontrolsthespeedofthe
feedrollers.

Thestockfeedrateisapproximatelyfrom0to19fpm(feetperminute),dependingonwheretheknobisset.Higherratesoffeed
areonlyrecommendedforlighterdepthsofcuts.Turntheknobclockwisetoincreasethefeedrate.

Whenthedialisinthe9o’clockposionthefeedspeedisapproximately4fpm.
Atthe12o’clockposion=approximately6fpm
Atthe3o’clockposion=approximately14fpm
Atthefulltotherightposion=approximately19fpm

Alwaysremembertosetyourstockratepriortoenteringthestockintothemachine.Thefeedratemaybechangedduringthecut.

Thevari‐feedoponallowsforhighfeedratesonreliefcutsonthebacksideofcasings.Thevari‐feedmul‐passcombinaonpro‐
videstheversalityofslowfeedratesondeephardwoodprofilesmakingpossibletwoorthreepassestofinish.

Ondeepandwideprofilesyoucannowraisetheknifeforaparalprofilecutandenterthestockveryslowly,whileengagingthe
buintotheknifegently,lengstockmoveundertheout‐feedrollerbeforeengagingahigherfeedrate.Thisreducestheinci‐
denceofalargechipout,achaermarkorsnipeonthefirstfewinchesofyourstock.Youhavethesameadvantagesexingthe
cut.

Asthegrainstructurechangesthroughoutthecutyoucanvarythestockfeedratetoreducethepossibilityofchipoutsandspoil‐
ageofyourpieceofstock.

Beforestarngthemachinefirstfamiliarizeyourselfwiththerestofthis“OwnersManual”.Itisveryimportanttosafelyoperate
themachineasoutlinedinthis“OwnersManual”.Operatethemachineonlywithinthedescribeddesignintent.

Besureyoucheckforrotaondireconbeforeyouusethemachine.Seetherotaonillustraoninthechangingknivessecon.

MOTORLOCK
Yournewlydesignedmachinebasehasamotorlock.Thisnewdeviseallowsyoutolockyourmotorinplacetokeepitfrombounc‐
ingonthebeltduringinterruptedcutsetc.Italsoallowsyoutomodifythebelttensionwhichcanaidyouinachievingthefinish
qualityyouarelookingfor.

Toreducetensionyoucancranktheheaddowntowithin1/4”oftheactualsengyouwilluseandlockyourmotor.Thenreset
yourheadtothe1/4”lowerrunningposionandyourtensionwillbereduced.Youcanvarythe1/4”factortoachievethetension
youdesire.

Always unlock the motorbeforeresengthemachineheadheight.

CHANGINGKNIVESDISCONNECTPOWERBEFORECHANGINGKNIVES!

PLANERKNIVES
CAUTION;whenplaningalwaysbackoffallfourpressurescrewstoaposion¼”higherthanthefullyseatedposion.Youwillcre‐
atetoomuchrollerpressureandfeederproblemsifyoudon’t.

Removethechipextractorbypullingoutthepinandliingtheinfeedendupfirstandpullingitbacktoclearthelipshold.Cleanoff
knivesandmachinearbor.Setoneknifeatameinplaceagainstthelipofthearbor.Placethe“bevel”oftheknifeasshowninthe
illustraonbelow.Tightentheeightboltssecurelyusinga7/32”allenwrench.Aerghtening,doublechecktoseethattheknives
aresnugagainstthelip.

MOLDINGKNIVES

Cleanoffknivesandmachinearbor.Setoneknifeatameinplacewiththebevel
edgeposionedasshownintheillustraonbelow.Pushtheknifefirmlydownagainst
thearborlipandsidewaysagainsttheboltsinthedireconofthetubesideofthe
machine.Holdsecurewhileghteningthebolts.



KNIFESHARPENING
Forfastandprofessionalresultswithminimumedgeloss,returnyourknivestothefactoryforre‐sharpening.Haveyourknivesre‐
sharpenedwhenyoufirstnocesomedullness.Thisgivesopmalperformanceandmaximumlifespanoutoftheknives.

Moldingknivesshouldbesurfacegroundonthefaceinpairsortheprofilesshouldbereground.Somemesitisbeertoregrind
theprofile.Ifyousendthemtousforregrinding,wewillusethebestmethodthatwillprolongtheuseofyourknives.
Planingknivesmaybegroundonthesurfaceoronthebevel.

Bothmoldingandplaningkniveshaveanedgeangleof57degreesmeasuredoffthebackoftheknife.
Theuseofdullkniveswillputastrainonthefeedmechanismandwillresultinyourneedofarepair.Anyproblemscreateddueto
theuseofdullknivesarenotcoveredunderthewarranty.
HOWTOMOLD
Youwillnormallyusetheguidesub‐plate.Whenusingtheoponaljigyouwilltakeitoff.Alwaysuseyoursub‐plateonanyjob
wheretheknifeisdesignedtocutbelowtheboomofthestock.Thistypeofknifewillhitthebaseofthemachineifasub‐plateis
notused.Anexampleofthissituaonwouldbethemoldingofhalforquarterrounds.
KNIFE
ARBOR
KNIFE BEVEL
INFEED SIDE OUT-FEED SIDE
VIEW FROM PULLEY SIDE OF MACHINE
ROTATION

The“0”onyourheadsengscalereferencesthetopofthe½”sub‐platesuppliedwithyourmachine.Forexample,ifyouwere
millinga¾”pieceofstockyouwouldsetthemachineheadatthe¾”seng.Adjusngyourmachineheadtothisscalesengwill
giveyouafullpasscutandacompletelyfinishedprofile.Thisisamul‐passmachineandwithmul‐passyoucanadd3/16”,inthis
example,tothe3/4”dimensionforafirstpasssengof15/16”.Inthisexampleyoumaysetthemachineheadtoanyscaleseng
between3/4”and15/16”forafirstpass.Thesesengsallowyoutoachieveproperrollertensionforholdingthestockandprovid‐
ingasafeoperaon.
Besureto check for sufficient feed roller contactbeforeproceedingtousethissetupandbesuretorotateyourmoldingknivesto
check for knife rotaon clearance with the chip extractor installedandthepoweroffbeforestarngthemachine.Turntheknife
arborbyturningthemotorpulleyattheinnerguardopening.

Othermoldingps
Stockheightshouldbewithin3/16”offinishedmoldingsize.Ifmakingonepassonlyitshouldbewithin1/32”.

Stockwidthshouldbeuniformandtofinishedmoldingsize.Sawrippingtowidthwillnotmakethestockuniformenoughfor
smoothflowthroughtheguides,andthus,willnotresultinasasfactorymolding.Werecommendthatallstockbeplanedinboth
widthandheighttofinishedmoldingsizebeforesenguptodotheprofile.

Whenghteningtheknives,pushthemfirmlyagainstthelipandsidewaysagainsttheboltsinthedireconofthetubesideofthe
machineforanexactprofilematchup.Holdsecurewhileghteningbolts.

Settheheadheighttowithin3/16”ofyourstockheight.Thiswillgiveyouproperrollertensiononyourmoldingstock.Thisisthe
correctwaytomold.Itisacceptabletoleave3/16”ofthecutformulplepasses.Butforsafetyreasonsleavenomorethan3/16”.

Onsomeextremelydeeporwidecuts,somepriorstockremovalwillberequiredbeforemolding.Youmayremovethisstockusing
oneoftherabbet/dadoknivesfoundinourcatalog.Youmayalsouseadadobladeonatablesaw.

Failuretosetyourheadheightwithin3/16”ofthestockheightwillcreateanextremesafetyhazardinthatpossiblynotenough
rollerpressurewillbeapplied,orthatnorollerpressureatallwillbeapplied.

Donotcutawiderstockareathantheknifewasdesignedtocut.Thiswillcauseexcessiveheatintheknife,burnyourstockand
putsaharmfulloadonthefeedsystem.

Therollpressurescrewsaresetatmaximummoldingpressurefromthefactory.Theyarescrewedintotheheadasfaraspossible
andthechecknutisghtened.

Whenyouusethemachineforplaningyouwillneedtoreducetherollerpressure.Loosenthepressurescrewlocknutandscrew
outeachpressuretoaseng¼”higherthanthefullyseatedposionandreghtenthelocknut.

Tochangethemoldingknives,removethechipextractor.Setoneknifeatameinplacewiththebeveledgetowardthein‐feed
endofthemachine.Firmlypushtheknifedownagainstthearborlipandsidewaysagainsttheboltsinthedireconofthetube
sideofthemachine.Holdsecurewhileghteningboltswitha7/32”allenwrenchordrive.

GUIDES

Guiding your stock
YourmachinecomeswiththeGS‐2guidesystem,whichincludesaflexguideandasolidguidetoguide,yourstock.To set these
guides,firstaachyourknivestotheknifearborintheposionyouhavechosen,oenaplacewhereyoucangetthemostoutof
yourrollersurfaces.Panelkniveswouldgotothefarright.Smallerknivestothepostsidehalfofthemounngareaandlarger
knivestothecentralposions.

Rolloneknifedownpoinngtothemachinebedandplaceasamplepieceofstockyouaregoingtomoldonthebed.Align the
stocktotheknifeprofileandcarefullylowerthemachineheadunltherollerputspressureonyourstocktoholditsecurely.

Aach your flex guidetothesideoftheprofilethatwillcuttheleastdeepintoyourstock.Thiswillgivethelongestpossiblelifeto
yourflexguide.Thebeveledporonoftheguideshouldbefacingthestock.Putabouta1/32”amount
ofpressureontheflexpartoftheguide.Thiswillkeepyoustockfromwanderingwithintheglide
path.Pullthehandlesupandawayfromthestockpath.

Aach your solid guide ontheothersideofthestock.Pushitupfirmlyagainstthestockandghten
thehandlesanglingthemawayfromthestockpath.
Remove your set up piece of stock byraisingthemachinehead,andpullingthestockoutfromthe
bed.

Your knives will usually cut into one or both guides.Thisisnormaland
expected.Theguidesareeffecveandlastalongmeaerbeingcut
intomanymes.

Asyoubecomemorefamiliarwiththemachineanditsuse,youwill
wanttomakewoodenguides to suit specific jobs.Alwaysmakeacom‐
pletesample(topandboom)ofcrownsandkeepsampletosetupon.

Makeyourboomcutfirstwhenmillingbed and crown moldings.You
maywanttoaddakeycutasaguidingmechanismforyourtopprofile.

When planing the edge of stock,ahigh,square,relievedguideisneededinordertohavetheedgereasonablysquareandtopro‐
videstability.Thecenterreliefsaretoreducefricon.

SomeprofilesaretoodeeptomakeontheW&H.Insomecasesyoucanrotatetheprofileintoaflaerposiontoeffecvelyre‐
ducethedepthofcut.A“V block”guidewouldbemadetoguideyourstock.Theprofilekniveswouldhavetobecustommadeto
useinthisVblockposion.

Whenmakingtongueandgroovestock,aseriousanddetailedapproachisneededinordertoachieveauniformfit.Carefullypre‐
inspectyourstockforcuppingandwarping.Youneedtoplaneallyourstocktooneuniformsize.

Theguidethicknessshouldbe3/8”thinnerthanyourstockoryourrollerwillscuffontheguideswhenthestockhaslethema‐
chineandtherollersareintheirrestposions.Whenrunningthinstock,youwillneedtofastenasub‐platebetweentheguidesto
maintainathickenoughguidetocontrolyourstock.