Views: 222 Author: Leah Publish Time: 2025-03-20 Origin: Site
Content Menu
● Tools and Materials Required
● Step 1: Remove Existing Tension Assembly
● Step 2: Install New Tension Sensor
● Step 3: Calibrate the Sensor
● Step 4: Troubleshooting Common Issues
● Step 5: Advanced Troubleshooting Techniques
● Additional Tips for Optimal Performance
● FAQ
>> 1. What is the required tension range for Hyd-Mech S20P blades?
>> 2. How do I reset the tension sensor after a blade change?
>> 3. Can I use third-party tension sensors?
>> 4. Why does the tension reading fluctuate during cuts?
>> 5. How to access the sensor's diagnostic logs?
Installing a blade tension sensor on your Hyd-Mech S20P bandsaw ensures precise blade tension control, critical for optimal cutting performance and blade longevity. This guide provides detailed instructions, safety protocols, and troubleshooting tips for a successful installation.
- Hyd-Mech S20P-compatible blade tension sensor kit
- Multimeter
- 6mm hex wrench set
- Torque wrench (20-50 Nm range)
- Hydraulic oil (ISO 32 or equivalent)
- Safety gloves and goggles
- Manufacturer-provided calibration software (if applicable)
Power Disconnection
- Turn off the main power disconnect switch.
- Lock out the electrical panel using a safety padlock.
- Verify zero hydraulic pressure using the gauge near the control box.
Workspace Preparation
- Clear coolant residue from the blade housing area.
- Stabilize the saw head at mid-height using the manual override.
1. Release Blade Tension:
- Rotate the tension knob counterclockwise until the indicator drops below 1,000 lbs.
- Secure the blade guard using the quick-release bolts.
2. Disconnect Wiring:
- Label and remove the two 24V DC wires from the legacy tension gauge.
- Detach the hydraulic line using a flare-nut wrench (¼-turn increments).
Tension knob adjustment Always depressurize hydraulic systems before disassembly.
1. Mount Sensor Bracket:
- Align the sensor bracket with pre-drilled holes on the saw frame.
- Torque M8 bolts to 35 Nm using a cross-pattern sequence.
2. Connect Hydraulic Lines:
- Attach the high-pressure hose to the sensor's port (hand-tighten + ½ turn).
- Prime the line by cycling the hydraulic pump 3-5 times.
3. Electrical Wiring:
- Route the sensor's 4-20mA output cable through the existing conduit.
- Terminate wires to terminals 17 (signal+) and 18 (signal-) on the PLC board.
1. Initialize the System:
- Power on the machine and navigate to Parameters > Blade Tension.
- Select Calibration Mode and input the sensor's serial number.
2. Set Baseline Values:
- Apply 2,200 lbs of tension using the manual override and confirm via the LCD.
- Adjust the potentiometer until the display matches the reference value.
3. Verify Dynamic Response:
- Perform test cuts on 2" mild steel at varying feed rates (2.75–4.0).
- Monitor tension fluctuations (±5% tolerance) using the real-time graph.
| Symptom | Solution |
|---|---|
| Err Code 07 | Check wiring continuity (resistance <1Ω) |
| Tension Drift | Re-prime hydraulic lines |
| No LCD Feedback | Verify 24V power supply to sensor |
For more complex issues, consider the following steps:
1. Hydraulic System Check:
- Inspect for leaks or blockages in the hydraulic lines.
- Ensure proper hydraulic oil levels and condition.
2. Sensor Calibration Verification:
- Re-run the calibration process to ensure accuracy.
- Compare baseline values with manufacturer specifications.
3. Electrical Noise Reduction:
- Use shielded cables for all sensor connections.
- Ground the sensor housing to the machine frame.
- Clean sensor ports monthly with isopropyl alcohol.
- Recalibrate every 500 operating hours or after blade changes.
- Regularly inspect the hydraulic system for signs of wear or damage.
1. Blade Selection:
- Choose blades with the correct tooth pitch and material for your cutting tasks.
- Regularly inspect blades for wear and replace as needed.
2. Coolant System Maintenance:
- Ensure proper coolant flow and pressure.
- Regularly clean the coolant system to prevent clogging.
3. Saw Head Alignment:
- Periodically check and adjust the saw head alignment to ensure square cuts.
- Use a precision square to verify alignment.
Proper installation of the Hyd-Mech S20P blade tension sensor enhances cutting accuracy and reduces blade wear. By following these steps and using manufacturer-specified tools, operators can maintain peak saw performance. Regular maintenance and troubleshooting are crucial for extending the lifespan of both the sensor and the bandsaw.
Maintain 2,200–2,650 lbs for standard bi-metal blades.
Navigate to Parameters > Reset Tension and cycle the hydraulic system.
Only Hyd-Mech-certified sensors guarantee compatibility with the PLC interface.
Worn thrust bearings or improper blade alignment are likely causes.
Connect a USB cable to the service port and export data via Hyd-Mech's proprietary software.
[1] https://www.youtube.com/watch?v=5bHdDtfJZDw
[2] https://fabtechsolutions.com/wp-content/uploads/2019/08/S20A_Service_Parts_Manual.pdf
[3] https://www.youtube.com/watch?v=OcwbyNDr11Q
[4] https://www.westwaymachinery.com/wp-content/uploads/2021/08/HYD-MECH-MODEL-S-23P-MANUAL.pdf
[5] https://www.manualslib.com/manual/2220473/Hyd-Mech-S-20-A.html
[6] https://www.westwaymachinery.com/wp-content/uploads/2021/08/HYD-MECH-MODEL-S-20P-MANUAL-min.pdf
[7] https://fabtechsolutions.com/wp-content/uploads/2019/08/DM1318P_Service_Parts_Manual.pdf
[8] https://fabtechsolutions.com/wp-content/uploads/2019/08/H-14A_Service_Parts_Manual.pdf
[9] https://www.manualslib.com/manual/2330861/Hyd-Mech-S20p.html
