Hyd-Mech V-18 APC Manual

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Page 1 V-18 APC MAY 2014 393459 THANK YOU, On behalf of everyone at HYD . MECH, I would like to thank and congratulate you on your decision to purchase a HYD . MECH band saw. Your new machine is now ready to play a key role in increasing the efficiency of your operation, helping you to reduce cutting costs while boosting quality and productivity.
Page 3: Table Of Contents
SAFETY HAZARD LABELS ........................0.7 SAFETY PRECAUTIONS ........................... 1.1 SECTION 1 - INSTALLATION REMOVING HEAD RESTRAINTS ......................1.2 LEVELLING THE V-18 APC ........................1.2 INSTALLATION OF THE CONTROL PANEL ..................... 1.3 INSTALLATION OF THE INFEED BASE....................1.4 HYDRAULIC OIL ............................1.8 CUTTING FLUID ............................
Page 4 TROUBLE SHOOTING GUIDE ........................3.8 MITSUBISHI PLC 500 TROUBLESHOOTING ................... 3.10 SECTION 4 - ELECTRICAL V-18 APC ELECTRICAL ..........................4.1 FOR ELECTRICAL SCHEMATICS AND COMPONENTS PARTS LIST SEE PDF ON ATTACHED CD ... 4.8 SECTION 5 - HYDRAULIC HYDRAULIC SCHEMATICS & PLUMBING DIAGRAMS: SEE PDF ON ATTACHED CD ......5.1 SECTION 6 - MECHANICAL ASSEMBLIES MECHANICAL ASSEMBLY DRAWINGS &...
Page 5: Summary
SECTION 0 - SAFETY INSTRUCTIONS SUMMARY All persons operating this machine must have read and understood all of the following sections of this Manual: Section 0 SAFETY Section 2 OPERATING INSTRUCTIONS However, as a memory aid, the following is a summary of the Safety Section. Put Safety First Mandatory Information –...
Page 6 • Maintain a clean working area and machine. • Always use Lock-out when performing maintenance or repairs. FOREWORD Put Safety First! This Safety Section contains important information to help you work safely with your machine and describes the dangers inherent to bandsaws. Some of these dangers are obvious, while others are less evident. It really is important to PUT SAFETY FIRST.
Page 7: Basic Rules
Manual, and When all operations and procedures are in compliance with this Manual. Hyd-Mech Group cannot accept any liability for personal injury or property damage due to operator errors or non-compliance with the Safety and Operating Instructions contained in this Manual.
Page 8: Responsibilities Of The Operator And Maintenance Personnel
dangerous substances and the provision and use of personal protective equipment. Choice and qualification of personnel Ensure that work on the machine is only carried out by reliable persons who have been appropriately trained for such work. Training Everyone working on or with the machine must be properly trained with regard to the correct use of the machine, the correct use of safety equipment, the foreseeable dangers that may arise during operation of the machine, and the safety precautions to be taken.
Page 9 Damage If any changes capable of impairing safety are observed in the machine or its operation, such as damage, malfunctions, or irregularities, then appropriate steps must be taken immediately, the machine switched off, locked-out, and the fault reported to the responsible person. Safe operation The machine may only be operated when in good working order and when all protective equipment is in place and operational.
Page 10 On Hyd-Mech machines the Master Disconnect Switch will be of one of four types: • Rotary switch mounted in electrical control cabinet door and inter-locked with door.
Page 11: Safety Hazard Labels
SAFETY HAZARD LABELS The safety hazard labels attached to your machine represent important safety information to help you avoid personal injury or death. All supervisors, operators, and maintenance personnel must locate and understand the safety information associated with each hazard label prior to operating or servicing the machine. The safety hazard labels shown below are located at various positions on the machine to indicate possible safety hazards.
Page 12 PINCH POINT Machine parts may move without warning, either because the machine is operating automatically, or because another person initiates the motion. Keep hands clear of all labelled pinch points, whenever the machine is running. Machine vises can exert great force and cause severe injury. Keep hands clear of vises and work piece when vises are opened or closed.
Page 14: Safety Precautions
If not performing properly, the machine should be stopped immediately and set-up, or repaired by a qualified person. Stock must not be loaded while the blade is running and the V-18 APC should not be operated unless all guards, covers, and doors are in place and closed.
Page 15: Removing Head Restraints
LEVELLING THE V-18 APC It is important that the V-18 APC be leveled and provision is made to secure the saw with concrete anchors to the floor. Using a machinist’s level, level the saw from side to side and from front to back.
Page 16: Installation Of The Control Panel
INSTALLATION OF THE CONTROL PANEL The V18 comes equipped with an articulating control panel. This panel is normally removed and placed on the saw table for shipping purposes. The control panel MUST BE REINSTALLED PRIOR TO MACHINE START UP. Take lifting precautions when installing the panel as it weights 150 LB. To re-install the panel, follow these steps: Remove all of the packing material.
Page 17: Installation Of The Infeed Base
INSTALLATION OF THE INFEED BASE • Fasten the infeed drip tray (A18-1-12B) to the infeed base with the provided fasteners. A18-1-12B • Move the infeed base into position under the wear plate and line up the holes for the roll pins. Wear Plate Roll Pins Infeed...
Page 18 • Use the leveling foot bolts to raise the infeed base towards the wear plate. Tighten the four socket head cap screws (390715) to mate the two pieces together. Level the infeed base with the machine by elevating the rear adjusting bolt. Once level has been achieved make sure that all four levelling bolts are touching the floor.
Page 19 • Remove the cover from the junction box, which is located on the left side of the infeed base. Insert cable #04 by feeding it through the liquid tight connector. Connect the four wires by matching the numbers labeled on each. Replace the cover of the junction box, and fasten the cover back to the base.
Page 20 • Plumb the hoses as per photo below. Refer to Hydraulic Plumbing Diagram 102A 101A...
Page 21: Hydraulic Oil
HYDRAULIC OIL The V-18 APC bandsaw is supplied with Texaco Rando HD46 oil. If it is necessary to change the oil to a dif- ferent brand it is good practice to empty the hydraulic tank using a pump. Fill the hydraulic tank approximately 1/3 full with the new brand of oil and operate the saw through several cycles with maximum cylinder extension.
Page 22: Earth Grounding Procedure
EARTH GROUNDING PROCEDURE 1. Customer to provide and install a ground rod approx. 0.60 (15mm) diameter, copper clad steel, to be driven no less than 8’ (2.5m) into the ground, no more than 10’ (3m) away from control enclosure. 2. Ground rod to be connected to customer’s in plant ground system. This connection shall be made di- rectly at the ground rod (if applicable).
Page 24: Section 2 - Operating Instructions
SECTION 2 - OPERATING INSTRUCTIONS START-UP The V-18 APC 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.
Page 25: Operator Panel Switches
OPERATOR PANEL SWITCHES TOP ROW SAW VISE - (vise between the shuttle & outfeed vises) 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.
Page 26 Depressing this button and either one of the head swing buttons simultaneously will also allow the head to swing at any point along the travel of the head. Note: These instructions are specific to the V-18 APC bandsaw with serial numbers beginning with: Serial # K0797074 SAFETY LOCK: This lock is provided for safety of the operator during blade changing procedure.
Page 27: Control System, Mitsubishi Plc 500
CONTROL SYSTEM, MITSUBISHI PLC 500 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.
Page 28: Plc Control Description
PLC CONTROL DESCRIPTION ACTIVATING THE PLC The PLC control will become active when all selector switches are in the neutral position and the HYDRAULIC START button is depressed and “held in” momentarily. If the head is not in the 90 position, the display will prompt you to “SWING THE HEAD THROUGH 90 DEGREES”...
Page 29: Function Button Description
FUNCTION BUTTON DESCRIPTION On the dual function buttons, if a green indicator light is illuminated, it means that the function printed in green on the top of the button is enabled. A red light indicates the function printed in red at the bottom of that button is enabled. MANUAL MODE (Green light) •...
Page 30: One Cut Mode
AUTO MODE • Energizes CYCLE START button. MANUAL MODE No function ONE CUT MODE Used to enter length value MANUAL MODE • After entering an angle value, pressing F2 will cause the screen to read “TO INITIATE MOVE- MENT TO XX.X DEGREES PRESS CYCLE START”. Upon pressing “CYCLE START” the head will swing to the programmed angle.
Page 31 ONE CUT MODE In MAN mode, switching the front vise to closed position changes the PLC to “One Cut Mode “ to cut one piece at a de- sired length. To accomplish this, follow the procedure below. 1. In “MAN MODE” position the head for the required angle by using the 45L or 45R function keys.
Page 32: Automatic Operation
AUTOMATIC OPERATION To enter AUTO MODE, the front vise switch must be in the closed position. When the AUTO/MAN button is pressed, the red indicator above it will come on, the screen will change to the PICK LIST display as shown on the following page and be ready for editing or starting a new job.
Page 33 PICK LIST SCREEN Before switching to AUTO MODE, position both the material for a trim cut as well as the head retracted to the rear limit switch so that no damage is caused by the shuttle moving the material into the blade (see “ONE CUT MODE”). 1.
Page 34: Working With A Queue
When the AUTO cycle commences, the screen will change to the “AUTO MODE STATUS” screen and the following events will take place: 1. The saw will perform a trim cut prior to the material feeding forward. 2. The head will swing to “A1” to perform the first cut (trim cut). 3.
Page 35: Variable Speed Control
VARIABLE SPEED CONTROL Blade speed can be adjusted infinitely between 65 to 385 SFM (20 to 117m/min). Adjustment should be made only when the blade is running. Clockwise rotation of dial on the control panel increases blade speed while counter clockwise rotation decreases blade speed. HYDRAULIC FEED CONTROL The Hydraulic Feed Control is located to the top of the control panel.
Page 36: Cutting Parameters Chart
CUTTING PARAMETERS CHART A full size CUTTING PARAMETERS CHART is mounted on the front of the main electrical panel. The chart contains five steps for the operator to follow in order to achieve optimum performance of the saw. These steps are detailed on the following pages.
Page 37 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 to be adjusted during head descent) CUTTING SOLIDS For cutting solids, the wider the section, the less FF should be set, to avoid blade overloading.
Page 38 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 fine blade with many teeth per inch (T.P.I.) is recommended. For wide materials a blade with a coarse pitch should be used.
Page 39 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.
Page 40 The following table gives examples of the optimum blade speeds for different materials. MATERIALS OPTIMUM BLADE SPEED (ft/min) (m/min) 5” (125mm) Diameter Solid Carbon Steel 12” (300mm) I-Beam 4” x 4” (100mm x 100mm) Rect. Tube 1/4” (6mm) Wall 4” (100mm) 400 Stainless Steel 2”...
Page 41 FEED RATE, continued If the saw is fitted 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 find that the FEED RATE is decreased to 1.3 in/min (133mm/min) for this blade. If however, the machine is fitted with a finer than optimum blade (e.g.
Page 42: Coolant Flow
HYDRAULIC CHIP CONVEYOR An option available with the V-18 APC is the hydraulic chip conveyor drive which provides an easier means of cleaning out the chips that accumulate while cutting. A Chip Conveyor control switch for the hydraulically driven chip conveyor is located on the operator control panel.
Page 43: Head Swing Brake
HEAD SWING BRAKE The brake assembly can be accessed by removing the brake cover. The brake should be adjusted with the head swing either to the extreme left or right. (Make sure system pressure is set properly). Maintain the machine in swing mode (either left or right).
Page 44: Section 3 - Maintenance And Trouble Shooting
SECTION 3 - MAINTENANCE AND TROUBLE SHOOTING LOCK-OUT Purpose: To prevent injury to workers caused by unexpected start-up of machines being worked on, Where the starting of a machine or device may endanger the safety of a worker. a) Control switches or other control mechanisms shall be locked out, b) Other effective precautions necessary to prevent such starting shall be taken.
Page 45: Blade Change Procedure
The blade wheel doors can be opened without the hydraulics shutting down. Head return limit over 3. The V-18 APC blade is only exposed to the operator at the cutting area. A hinged ride button cover protects the operator from the blade between the Idler wheel assembly and the actual cutting area.
Page 46: Blade Installation
BLADE INSTALLATION NOTES ABOUT NEW BLADES: • It is helpful to have two people to install a new blade. • A new blade will come folded into a compact coil. Follow the blade manufacturer’s instructions for safely unfolding blade. • The blade must be installed with the teeth facing out towards the front of the saw where it passes around the wheels, and with the teeth in the cutting area pointing towards the drive wheel.
Page 47: Idler Wheel Adjustment
If the brush gets worn to approximately 70% of its original 3” diameter it should be replaced. A brush may be purchased from your HYD-MECH dealer. BLADE GUIDES Blade brush & adjusting screw (circled).
Page 48: Head Forward Limit Setting
LUBRICATION The V-18 APC was designed with a goal to minimize the maintenance required so as to reduce downtime. Moving parts of the V-18 APC will require periodic lubrication nonetheless, primarily application of a general purpose grease to the guide arms, vise ways, and the linear bearings. The following photos show the location of grease fittings that should be lubricated monthly.
Page 49 PLUG One of 4 linear bearing block grease nipples. There is one at each corner of the head carrier cover. Remove round plastic plugs to gain access to the two back grease nipples Bearing Block ( X4 ) Vise Ways ( X2 ) Anti tip roller ( X2 ) INFEED ASSEMBLY Linear bearing block...
Page 50: Hydraulic Maintenance
NOTE: The V-18 APC is shipped from the factory with Texaco Rando HD 46 oil. Generally any brand of recognized mineral hy- draulic oil with the same properties should be compatible with Texaco Rando HD 46 oil, but to avoid any risk we suggest staying with Texaco Rando HD 46.
Page 51: Trouble Shooting Guide
TROUBLE SHOOTING GUIDE Most problems which may occur have one of the relatively simple solutions which appear in this section. If the solution is not found here, contact the Hyd·Mech Distributor from whom you purchased your bandsaw. They have trained field ser- vice personnel who will be able to rectify the problem.
Page 52 Blade tension is determined by system 2 Blade comes off wheels. 2a. Blade tension is insufficient. pressure. Check. (Extended head, check if blade tension gauge reads 650 psi). 2b. Blade tracking out of adjustment. Have tracking set to blade specification. Blade tension is determined by system 3 Blade stalls while cutting.
Page 53: Mitsubishi Plc 500 Troubleshooting
To view the parameters: Start the machine and, in manual mode, enter the parameter screen by pressing the PARAMETER key which is displayed on screen. Type the password which can be obtained from HYD-MECH and press ENTER. The parameter screen will appear.
Page 54 MITSUBISHI PLC 500 PARAMETERS To navigate through the parameters use the green arrow keys to move the cursor. To change a parameter, move the screen cursor to the desired parameter using the green arrow keys on the interface keypad. With the cursor on the value to be changed, type in the new value with the numeric keys.
Page 55 HEAD FEED RATE CALIBRATION With the cursor on the line that reads - HD CLB “ENTER” OFF, press the ENTER key. The line should then read - HD CLB “ENTER” ON, and the cycle start button should be flashing. The head will move fully forward (down on M16/20A) and then will move fully backward (up on M16/20A). At this point the procedure is done and the line should read - HD CLB “ENTER”...
Page 56 The above procedure is performed to allow for the original parameter to be reinstalled, in a case where there is no angle display due to loss of this value by PLC memory (electrical & mechanical components ok), or to allow for the original parameter to be modified, in a case where the angle display is inaccurate, and proper calibration cannot be performed.
Page 57 DP RADIUS: On M16/20: The distance in inches from the inside face of the fixed jar on the front vise (usually referred to as the datum line) to the pivot point of the head. On V18APC: The distance in inches from the top of the cutting table (the datum line on V18) to the pivot point of the head.
Page 58 If the display alters between 0.000 and 0.001 or 0.000 and -0.001, then one of the encoder channels is not being recorded correctly. To determine the cause, first, check the encoder cable connections at both ends to be sure all four wires are connected properly.
Page 59 LINEAR INACCURACY Load machine with a piece of stock for test cutting Open parameters screen Initiate length calibration (as described previously in this section) and measure cut length as accurately as possible. Re-enter new ACT LTH (Actual Length) value Re-cut test lengths and check if accuracy is satisfactory. Perform test cuts of three different lengths (i.e.
Page 60: Section 4 - Electrical
SECTION 4 - ELECTRICAL V-18 APC ELECTRICAL The electrical schematics on CD show some components labeled as TB1 to TB6 and these components are physically mounted on din rails. The illustration below shows the location of the Din rails with the installed components and the des- ignated TB number.
Page 61 From page 1, it can be seen that TB1 has the High Speed Counter, PLC and terminals mounted to it. For example, if the electrical schematic shows a terminal, described as This indicates that the terminal is located on din rail TB1 and is terminal #2.
Page 62 This would indicate that the terminal is mounted on TB1 and is terminal #5. A close up view of TB2 is shown. Page 1 shows the position of TB2 in the control panel. For example, if the electrical schematic shows a terminal, described as This indicates that the terminal is located on din rail TB2 and is terminal #3.
Page 63 This would indicate that the terminal is mounted on TB2 and is terminal #6. A close up view of TB3 is shown. Page 1 shows the position of TB3 in the control panel. For example, if the electrical schematic shows a terminal, described as This indicates that the terminal is located on din rail TB3 and is terminal #7.
Page 64 TB4 is located in another control panel and will be included on page 7.
Page 65 TB5 contains fusible terminals and a power supply. These are identified on the schematic as FU3 to FU8 and PWS for the power supply.
Page 66 TB6 Contains ground terminals (partially visible) mounted either side of the contactors MS1M & MS2M and are indicated on the schematic as TB6 & TB6 The mounting location in the control panel is shown on page 1 TB4 is located in the HMI panel (Human Machine Interface). This houses the selector switches and push but- tons.
Page 67: For Electrical Schematics And Components Parts List See Pdf On Attached Cd
DT, CR4 is the control relay labeled CR4. DT, LS2 is the limit switch for Head Advance function. DT, MS 1M is the contactor labeled MS 1M. DT, SS4 is the selector switch for Head Control. Page and Row Numbers In each title block of the project (electrical documentation) there are 2 headers, which are: 1.
Page 68: Section 5 - Hydraulic
SECTION 5 - HYDRAULIC HYDRAULIC SCHEMATICS & PLUMBING DIAGRAMS: SEE PDF ON ATTACHED CD...
Page 70: Section 6 - Mechanical Assemblies
SECTION 6 - MECHANICAL ASSEMBLIES MECHANICAL ASSEMBLY DRAWINGS & PARTS LIST: SEE PDF ON ATTACHED CD...
Page 72: Section 7 - Options
SECTION 7 - OPTIONS OPTIONAL ASSEMBLY DRAWINGS: SEE PDF ON ATTACHED CD...
Page 74: Section 8 - Specifications
SECTION 8 - SPECIFICATIONS SECTION 8 - SPECIFICATIONS V-18 APC BANDSAW SPECIFICATIONS at 90º rectangular 18”x 20”(457mm x 508mm) - 18”x 31”(457mm x 787mm) ext. option at 90º rectangular 18”x 28”(457mm x 711mm) with ext. head and 6º options at 90º rectangular 18”x18”(457mm x 457mm) with 6º...
Page 75: V-18 Apc Layout
V-18 APC LAYOUT...
Page 76: Section 9 - Warranty
MOTOR, GEARBOX, PUMP, ELECTRIC COMPONENTS, VALVES, HOSES, FITTINGS, and any other items used in the manufacture of the V-18 APC, but not originally manufactured by Hyd·Mech are subject to the original manufacturer’s warranty. Hyd·Mech will provide such assistance and information as is necessary and available to facilitate the user’s claim to such other manufacturer.

Hyd-Mech V-18 APC Manual

Section 1 - Installation

Section 2 - Operating Instructions

Section 3 - Maintenance and Trouble Shooting

Section 4 - Electrical

Section 5 - Hydraulic

Section 6 - Mechanical Assemblies

Section 7 - Options

Section 8 - Specifications

Section 9 - Warranty

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