Pipe profiling machine

Operators manual
Official manual of the Pipe profiling machine Includes Type: SPC/TPC 330, 500, 600, 800, 1000, 1200, 1500, 2000, 3000 MPC350

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Operators Manual Pipe profiling machine

This manual belongs to the Pipe profiling machine. For any questions or comments you can contact: Manufacturer: Address: HGG Profiling Equipment b.v. Zuidrak 2 1771 SW, Wieringerwerf the Netherlands +31 (0) 227 50 40 30 16-03-2011 3.0

Country: Phone: Release date: Version:

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Preface
The objective of this manual is to provide information concerning the operation of the Pipe profiling machine (PPM). The term PPM includes the SPC/TPC and MPC machines. The term machine is applicable to the description of the product as indicated on the front page of this manual. This manual is part of a set of manuals for the PPM. The complete set of manuals consist of the following manuals: Operators manual This manual describes the operation procedures of the profiling machine. This manual also contains a number of important notes for safe use of the Pipe profiling machine. This manual describes the programming of all the profiles of the machine in relation to the position, marking point, where the profile will be cut. This manual contains the maintenance schedule which indicates all grease points of the machine including grease type and period for each grease point. This users manual describes how a new user can start working with the ProCAM application including de modules in the ProGRAM group (MDI, Nesting and Viewer) The ProCAM course manual covers the ProCAM application including the modules in the ProGRAM group (MDI, Nesting and Viewer). This manual describes the operation procedures and important safety notes of the plasma cutting machine. This manual describes the operation procedures, service procedures and important safety notes of the dust collector. Assembly drawings, electrical schemes and connection lists.

Programmers manual

Maintenance manual

ProCAM framework and ProGRAM user manual ProCAM course manual

Instruction manual plasma machine* Dust collector manual*

Drawings
* Option

For safe operation and to ensure the reliability of the Pipe profiling machine it is necessary that all the above manuals are available to all the people who work with the machine and to those who are related to the machine like supervisors, maintenance engineers, service engineers and work preparation. It is important that everybody who works with the profiling machine is aware of the safety notes as described in the chapter Safety in the operators manual. Use the machine only after you read and completely understood the contents of this manual. Operators and everybody related to the machine must keep safety in mind. For reliability and safe operation of the machine it is necessary that the maintenance is executed as described in the chapter maintenance. There are four levels of special notation used in this manual. WARNING! CAUTION! ATTENTION! NOTE! A warning statement will typically describe the potential hazard, its possible effect, and the measures that must be taken to reduce the hazard. Damage to the equipment or products could result if the specified action is not complied with. Provides extra information to notify the user for potential problems. Provides information or gives a tip for easier operation.

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Table of contents
Operators Manual Pipe profiling machine .......................................................................................... 2 Preface .................................................................................................................................................... 3 Table of contents ................................................................................................................................... 4 1. Introduction .................................................................................................................................... 4 1.1 1.2 1.3 2. INTENDENT USE OF THE MACHINE ............................................................................................................ 4 NON-INTENDED USE OF THE MACHINE ..................................................................................................... 5 QUALIFICATION OF PERSONNEL ............................................................................................................... 5

Safety ............................................................................................................................................... 6 2.1 2.2 2.3 QUALIFICATION OF PERSONNEL ............................................................................................................... 6 PERONAL SAFETY INSTRUCTIONS ............................................................................................................. 6 SAFETY LABELS ....................................................................................................................................... 7

3.

Description of the machine ........................................................................................................... 8 3.1 INTRODUCTION ........................................................................................................................................ 8 3.2 LAY-OUT .................................................................................................................................................. 9 3.2.1 Machine style .................................................................................................................................. 9

4.

Operating the machine ................................................................................................................ 10 4.1 MAIN DRIVE ........................................................................................................................................... 10 4.2 REMOTE CONTROL ................................................................................................................................. 11 4.3 USING THE REMOTE CONTROL................................................................................................................ 13 4.3.1 Control buttons.............................................................................................................................. 14 4.3.2 Display .......................................................................................................................................... 15 4.3.3 Navigation bar .............................................................................................................................. 16 4.4 INFORMATION WINDOW ......................................................................................................................... 18

To start and to stop the machine ................................................................................................ 20 Before starting the machine .......................................................................................................................... 20 5.2 USING THE MAIN DRIVE.......................................................................................................................... 21 5.3 USING THE PIPE SUPPORT ....................................................................................................................... 23 5.4 LOADING AND UNLOADING THE MACHINE ............................................................................................. 25 5.5 TO START CUTTING ................................................................................................................................ 26 5.6 TO CUT NEAR THE MAIN DRIVE............................................................................................................... 27 5.7 TO CUT BEHIND THE MAIN DRIVE (OPTION) ............................................................................................ 27 5.8 EMERGENCY STOP .................................................................................................................................. 28

Settings ......................................................................................................................................... 29 6.2 6.3 OPERATOR SETTINGS ............................................................................................................................. 29 TORCH SETTINGS ................................................................................................................................... 30

7 8

Maintenance .................................................................................................................................. 31 Service ........................................................................................................................................... 32

Appendix A: Terminology ................................................................................................................... 33

1. Introduction
1.1 Intendent use of the machine

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This machine is a Pipe profiling machine and should be used for profiling steel pipes with an oxygas cutting process (oxyfuel) (ox or plasma cutting process. For the explaination of these two processes, see appendix A Terminology. The machine should be used for industrial applications only. The machine is suitable for cutting the pipe range as described in the Technical specifications or the nameplate. nameplate A nameplate like Figure 1 is located on the side of the main drive unit. A nameplate like Figure 2 is located on the front side of each pipe trolley. You should always keep these nameplates clean and in legible condition.

Figure 1: Nameplate Pipe profiling machine

Figure 2: Nameplate Pipe trolley

1.2 Non-intended use of the machine

This machine should not be used for cutting or igniting flammable material. Non-intended intended use of the machine can Cause ause injury to personnel Damage amage the machine or other equipment Reduce the machine reliability and the machine performance

1.3 Qualification of personnel

Operator Operators are instructed persons who are adequately advised to avoid the dangers this machine may create. create Instruction should include instructions in operation under normal conditions and emergency situations. Operators are persons who start, stop, load, u unload, program and clean the machine. Mechanic Mechanics have technical knowledge or sufficient experience to enable them to avoid the dangers which electricity, pneumatics, hydraulics and mechanics may create. Mechanics are persons who maintain and clean the machine.

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2. Safety
2.1 Qualification of personnel
The machine is only operated by instructed operators and mechanics. Risks can especially be caused when the machine. is operated, maintained or cleaned by in-experienced or non instructed personnel. is operated, cleaned or maintained insufficiently. is used for purposes other than written in chapter 1 Introduction. Operators and mechanics must: read and understand the chapter 2 Safety of this manual. have sufficient knowledge to accomplish the activities concerning the machine. have knowledge of the presence and working of the emergency stop mechanism of the machine. have knowledge of the presence and working of all other safety facilities of the machine. have knowledge of their specific tasks and authorizations. omit all activities that are dangerous to the health. omit all activities that can cause damage to the machine and the products of the machine. Operators and mechanics have to make sure that: the area surrounding the machine is clean and free of persons, tools and other (flammable) objects or liquids. the machine is only operated when the machine is in good condition. the machine is only operated when the provided protective covers are correctly installed on the correct location.

2.2 Peronal safety instructions

An operator has to keep the following safety instructions in mind:

Do not use the machine without following the instructions in the manuals. Read and understand the Operators manual and all safety labels before operating or maintaining this machine. Read and understand the Instructions manual plasma machine, when plasma cutting is used. Read and understand the Installation and operation manual dust collector, when a dust collector is used. Keep these manuals to hand at all times and read it as many times as necessary for a complete understanding. Only instructed operators are permitted to operate this machine. Instruction should include instructions in operation under normal conditions and emergency situations. Before starting this machine, check that: All persons are clear of the machine. No maintenance work is being performed on the machine. All guards are in place. The machine is free of jams and other obstacles. Never leave the machine stopped in such a manner that another worker can start the machine while you are working on or within the machine. Never reach into the machine for any reason unless the machine is at a complete stop. Never change or defeat the function of electrical interlocks or other machine shutdown switches. Never modify the machinery in any way. Never exceed the maximum pipe load. To prevent wedging, keep your body away from the pipe trolley wheel units, pipe trolley rails, cutting trolley track and when the machine is in operation or maintenance. Flames from the torch will burn skin! Keep your body away from the torch. Always keep safety in mind.

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Never look directly into the flame, the the bright light could damage your eyesight. Always use safety glasses. The cutting device on the machine is also applied with a UV protection glass shield. Use this to protect your eyes. For safety reasons operators have to wear: Safety shoes. Flame proof overall or flame proof clothing. clothing Flame proof gloves. Ear protection. Safety glasses.

2.3 Safety labels The residual risks of the PPM are expressed by safety labels. The following safety labels are placed: Label Description Fire, naked flame and smoking prohibited. Warning! Danger! Warning! Rotating parts. Warning! Hot surface inside. Wear flame proof clothing. clothing Wear flame proof safety gloves. gloves Wear safety shoes. shoes Wear eye and ear protection. protection Read and understand operator's manual before operating this machine. Location Front side Main Drive Unit. Front side of Cutting trolley. Front side Pipe trolleys. Right and left side Cutting trolley. Front side Main Drive Unit. Front side Main Drive Unit. Front side Main Drive Unit. Front side Main Drive Unit. Front side Main Drive Unit.

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3. Description of the machine

3.1 Introduction
The Pipe profiling machines are used to cut pipe-to-pipe and pipe-to-plate connections with constant welding preparations over the entire pipe length. The SPC/TPC machine range and MPC can be used for several industries. The various shapes are cut by moving multiple computer controlled axis. The SPC/TPC machine range is able to cut the following profiles:

Saddle pieces. Holes. Chamfer. Mitre saddles. Mitre holes. Oblong holes.

The MPC can also cut these profiles. In addition the MPC can also cut various kind of profiles in SHS- and RHS- tubes.

Figure 3: Various profiles

The PPM machines consists of the following main components:

Base frame. Pipe support system (pipe trolley and/or roller ball gutter). Cutting trolley with integrated biaxial cutting head, gas pressure controls and control unit at te rearside. Main drive. Remote control with touch screen and keyboard.

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3.2 Lay-out 3.2.1 Machine style

The SPC stands for Stationary Pipe Cutting machine. This type of machine is anchored on a foundation frame which is positioned within the concrete flooring. The TPC stands for Transportable Pipe Cutting machine. This type of machine is anchored on a specially designed frame. Because this frame fits in a container it can be easily transported. Breaking down and rebuilding the machine it is not necessary. On its new location the container frame needs to be leveled again. The MPC stands for Multiple Profile Cutting machine. This type of machine is ancored on a foundation frame which is positioned within the concrete flooring. SPC330 Cutting trolley Dust collector (optional) Gas pressure controls Main drive Remote control Chuck

Roller ball gutter

Figure 4: Layout SPC 330 machine range

SPC500-1200 Dust collector (optional) Main drive Chuck Cutting trolley Gas pressure controls Remote control Pipe trolley

Figure 5: Layout SPC 500-1200 machine range

SPC1200-3000 Dust collector (optional) Cutting trolley Main drive Chuck Gas pressure controls Remote control

Figure 6: Layout SPC 1000-3000 machine range

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MPC 350
Cutting trolley Gas pressure controls Pipe trolley Remote control Dust collector (optional) Main drive Chuck

Figure 7: Layout MPC350

4. Operating the machine

4.1 Main drive
All machines are controllable by using the remote control at the cutting trolley. Depending on the type of machine it is also possible to control the cutting trolley from controls located at the main drive. By cutting large pipe diameters, the remote control can be out of reach for the operater. Because of this the main drives for SPC1500-SPC3000 are applied with a motion controller for the cutting trolley and a reset button which has the same function as the clear error button on the touch screen in case of an error. Explanation of the buttons and switches on the main drive: Motion controller (SPC15003000) The cutting head can be moved in four directions by using the motion controller. (up and down (H-axis) and move along the rear frame (Y-axis)). Move chuck up (SPC1500 3000) Pressing this button will raise the chuck. Move chuck down (SPC15003000) Pressing this button will lower the chuck Close chuck (SPC15003000) Pressing this button will close the chuck and clamp the pipe with an adjusted clamp force. Open chuck (SPC15003000) Pressing this button will open the chuck Emergency switch In case of an emergency situation this switch must be operated. Reset / Clear error (SPC15003000) The reset button is to solve errors. It has the same function as the clear error button on the touch screen in case of an error. Power key switch The key switch can be used to shut on/off the machine. Main power This switch controls the main power of the machine (380V). NOTE! When the Main power switch is set to 0 the climate control in the control unit at the cutting trolley is also turned off. HGG advises to keep the main power set to 1 and to shut the machine down by using the key switch. By using the Reset and/or Emergency switch no dangerous situations will appear because all machine axis keeps their actual position. The SPC150-3000 machine resets the H-axis.

NOTE!

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Main drive (SPC330 SPC1200 and MPC350) Main power Control light Power key switch

Figure 8: Control panel at Main drive SPC250 SPC1200 and MPC350

Main drive (SPC1500 SPC3000)

Motion controller Figure 9: Control panel at Main drive SPC1500SPC3000 Close chuck

Move chuck up

4.2 Remote control

Move chuck down

Open chuck

The machine is controlled by the control unit at the rearside of the cutting trolley. The control unit consists of a industrial computer which runs the machine software and several other electronics built-in climate control unit to Emergency switch for controlling the machine. The control unit has a Reset / Clear error protect the unit against low temperatures and moisture. The remote control is the interface between the operator and machine. The entire machine is Power controllable key switch by this interface. Control light

Main power

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Touch screen Emergency switch USB-connection

Key-board

Figure 10: Remote control (The 5 buttons below, the 7 buttons on the right of the screen and the turning switch right below are preparations for future options)

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4.3 Using the remote control

The remote control is used to operate the machine. The remote control consists of an emergency stop, control buttons, keyboard and a touch screen. Important parameters of the cutting process are shown on the display. The operator will be guided through the different steps for starting the cutting process by blinking buttons. These blinking buttons are indicating the next steps of the cutting process. Menu bar

Information window

Navigation bar

Control buttons

Figure 11: Screen shot of the remote control

Display

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4.3.1

Control buttons

Figure 12: Control buttons 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. Top: move cutting head to highest position. Pipe offset: pre-defined distance from pipe. X-: rotate pipe clockwise. Gas off: switch off all gas valves Ini: change from ini mode to hold mode Stop/hold mode: interrupt the cutting process Force +: increase chuck force (option) Next: select next cut I plasma +: increase plasma current (option) Clear: clear error messages Home B: home B-axis of the cutting trolley Pipe: move cutting head to pipe Y-: Move cutting head to the left Dis. Lim: overrule the endswitch of the chuck Y+: move cutting head to the right Move cut: move the cut position in hold mode Preheat: switch the preheat on or off Heat: switch burner gas and oxygen on Skip: skip the geometrical control step before cutting (MPC) Force -: decrease chuck force (option) Prev: select previous cut I plasma -: decrease plasma current (option) Disp: change display Home Z and I: home Z and I axis of the cutting head Up: Move cutting head upwards Chk up: move chuck upwards X+: rotate pipe counter-clock-wise Chk in: close chuck +: increase cutting speed Back: move back in cut Test: switches the cutting oxygen valve on Hi preheat: combine preheat and burner X=0: reset x-position value Home chk: Home rotation of the chuck (X-axis) Down: move cutting head downwards Chk down: move chuck down Chk lock: chuck safety lock Chk out: open chuck -: decrease cutting speed Shift: to select second function buttons Go: start of acknowledge Auto: automatic cutting (option) Y=0: reset y-position value Home Y and H: home Y and H axis of the cutting trolley.

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Shift functions Some control buttons have dual functions. Press Shift + button to activate these functions.

Figure 13: Control buttons 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. CT B+: move cutting trolley towards operater I+: positive rotation (I-axis) of cutting head CT B-: move cutting trolley away from operater Home I: Initialization of the I-axis of the cutting head. This can be used for calibrating the cutting head Auto +: Increase preheat time before piercing at automatic cutting (option) Z-: negative tilting of Z-axis cutting head Z+: positive tilting of Z-axis cutting head Free: release I and Z axis Auto -: Decrease preheat time before piercing at automatic cutting (option) Home Z: Home Z axis of cutting head I-: negative rotation (I-axis) of cutting head.

4.3.2

Display
Pressing the Display button will change the set of parameters displayed on the remote control. There are two sets of parameters available: The standard parameters are normally displayed and contain all the data useful for operating. The extended parameters are displayed when the Shift button is activated and contain the standard parameters and additional maintenance data.

On the status row of the display, the actual status of the machine can be read.

Status Ready Program Init Hold Heating Cutting Marking Move to

Description Machine is finished cutting Machine ready for programming Machine is initializing Machine is in hold mode. The cutting process can now be started. Machine is busy heating Machine is busy cutting Machine is busy marking Machine is moving to new position

On the Error message window of the display, the error messages of the machine can be read. On the Profile type window of the display, the active profile type can be read. On the V row of the display, the cutting speed in mm / minute can be read. On the X row of the display, the rotation of the pipe according to the zero-point can be read. The rotation distance is reset when the X=0 button on the remote control is pressed. On the Y row of the display, the position of the covered distance of the cutting trolley can be read. The covered distance is reset when the Y=0 button on the remote control is pressed.

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4.3.3

Navigation bar
With this button the operator can start a cutting process from a cutting file which has been made at the machine itself. First step is to make a cutting profile by the use of ProCAM (button Design at navigator bar). After that the generated GPD file can be loaded by this button. With this button you open a GPD-file. A GPD-file is a file which contains all the cutting data. GPD files can be generated with ProCAM. 1. 2. 3. 4. On the Navigation bar, click GPD. A window appears where cutting data can be entered. On the Project row, click List, then select a project name on the Change Project Name window. On the File name row, click List, then select a GPD name on the Change Project Name window. In the Leadin box, Leadout box and Cutting speed box, enter a leadin, leadout and cutting speed. Select Auto to automatically determine the cutting speed.

Locall GPD

GPD

Figure 14: Cutting data window NOTE! For the terminology Leadin and Leadout, see appendix A

TAF A TAF-file is a file containing the nested positions for a stock length. For more information see the ProCAM course manual. 1. 2. 3. 4. On the Navigation bar, click TAF. A window appears where cutting data can be entered. On the Project row, click List, then select a project name on the Change Project Name window. On the File name row, click List, then select a TAF name on the Change Project Name window. In the Leadin box, Leadout box and Cutting speed box, enter a leadin, leadout and cutting speed. Select Auto to automatically determine the cutting speed.

Select During cutting it is possible to repeat, restart or skip profiles. The Select button can be used to select and cut a particular profile in order to change the sequence of the profiles to be cut. The machine will move the cutting head to the start of the selected profile

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Figure 157: Select cut window Settings To acces the most commonly used machine settings. (See chapter 6 for more information about settings.) On the Navigation bar, click Settings. Design With the Design button you start ProCAM. With ProCAM you can create, modify, nest and view data files. On the Navigation bar, click Design. NOTE! Stop With this button the operator stops the cutting proces On the Navigation bar, click Stop. ATTENTION! Job The default job is used to set a default project. When the GPD button is used to open a project, the project name on the Enter Cutting data window is set to this job. On the Navigation bar, click Job, then enter a project name in the textbox. When pressing the stop button (at the navigator bar). The machine will lose its initializing point. Consult the ProCAM course manual and ProCAM framework and ProGRAM user manual for more information about ProCAM.

Figure 16: Current Job window Operator Before a operator starts a cutting project he can enter his name. This can provide the workpreperation usefull cutting status information when the company also uses ProMIS. Turn off The function of this button is to shut down the computer. See chapter 5 Start and stop the machine for more information about shutting down the machine completely. On the Navigation bar, click Turn Off.

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4.4 Information window

Cut position Cut position describes the actual position and output of various axes and sensors of the machine.

Figure 8: Cut position box

Position X-axis Y-axis I-axis Z-axis H-axis CH

Tool

Output [deg] [mm] [deg] [deg] [mm] [mm]

Description Displacement rotator Displacement cutting trolley (longitudinal) Rotation of the cutting head Tilting of the cutting head Elevation of the cutting trolley Chuck height (option)

Describes the setting of the cutting head tool and its kerf width.

Figure 98: Tool box

Tool Oxy fuel Marking tool Pierce tool Plasma

Time/date

Description Tool for making cuts Tool for marking Tool for piercing trough the material Tool for plasma cutting

The Time/date box provides the current time and date.

Figure 10: Time/date box Machine Status Machine status describes the current status of the machine.

Figure 20: Machine status box

Status Status

Program Ready

Description Machine is finished cutting

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Diameter Prog Diameter Drift sensor Datafile status

Program Init Hold Heating Cutting Marking Move to [mm] [mm] ON OFF

Machine ready for programming Machine is initializing Machine is in hold mode. Machine is busy heating Machine is busy cutting Machine is busy marking Machine is moving to new position Actual diameter (option) Programmed diameter (option) Drift sensor on (option) Drift sensor off (option)

Datafile status provides information on which data file is used for the cutting process.

Figure 21: Datafile status box

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5 To start and to stop the machine

Before starting the machine To start the machine Open the gas, oxygen and compressed air valves at the source. Start the dust collector according to Dust collector manual (option). Start the plasma unit according to Instruction manual plasma unit (option). On the Main drive, put the Main switch in the ON or 1 position (only first time after a runtime break). On the Main drive, put the Power key-switch in the ON or 1 position. Use the work station on the Remote control to log on. Logon as operator (default password: operator). Make sure the machine and the area surrounding the machine is clean and free of tools and other obstacles. Make sure you wear the correct personal protection equipment (PPE) as described in chapter 2.2 Personal safety instructions. Make sure all gasses for the cutting process are available and connected to the machine in the right order.

Figure 22: Windows Log On The HGG logon is for mechanics from HGG only. It takes a while before the machine user interface appears.

To home the machine Before the operator starts the cutting process the machine axis needs to be homed. The generated information will be stored and during the cutting process. SPC/TPC250 On the Remote control: o Press Home chuck diameter + Home CT + Home height chuck o Press Shift + Ini to home the cutting head. o Press Shift again to deselect the shift function, then press Home to home the cutting trolley. The machine is now in home position. SPC/TPC500 - 3000 On the Remote control: o Press Shift + Home to home the chuck, then press Ini to home the cutting head. o Press Shift again to deselect the shift function, then press Home to home the cutting trolley. The machine is now in home position. ATTENTION! The axis of the machine are not homed as long as the yellow lights keep blinking at the home buttons. When the axis are homed the lights stay yellow. During the cutting process too.

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To stop the machine Abort all cutting jobs. Shut down the plasma unit according to manual plasma unit (option). Shut down dust collector according to manual dust collector (option). On the Navigation bar, click Turn off to shut down the HGG cutting program. Press start and shut down to close Windows. Wait until the message its now safe to turn off your computer appears. On the Control unit, put the Power key-switch in the OFF or 0 position to shutdown the machine. Close the gas, oxygen and compressed air valves at the source.

5.2 Using the main drive

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To adjust the clamping force of the chuck Before adjusting the clamping force the machine want to know if you are clamping the pipe from the outside or from the inner side of the pipe. At the navigator bar click settings check inside or outside depending on the clamping situation at the chuck. (see chapter 6 Settings) The clamp force of the SPC/TPC500-1200 machine range can be adjusted hydraulically by using the valve knob at the side of the main drive unit. The clamping force can be read from the pressure gauge.

Figure 23: Clamping force knob and pressure gauge The clamp force of the SPC 250 and SPC/TPC 1500-3000 machine range can be adjusted electrically by using the Force+ and Force- buttons on the remote control. To turn the jaws of the chuck (SPC330) The jaws of the chuck can be turned 180 in order to reach the machine's diameter range. Select the outer/ inner clamping direction in the setting. (see chapter 6) 1. 2. 3. 4. 5. 6. NOTE! Use a adjustable pin wrench and a wrench to demount the M6 bolt from the jaw, then remove the spike from the jaw. The spike contains spring collars. These spring collars must stay in this exact position. Use a socket wrench to demount bolt A. To demount the bolt B, place the socket wrench trough the opening on top of the jaw, then demount bolt B. The jaw can now be pulled from the chuck. Turn the jaw 180 , place it on the chuck and tighten it with bolt A and B. Replace the spike with spring collars. Use a adjustable pin wrench and wrench to tighten it. Repeat these steps for all the jaws.

For all other chucks the operator can just unscrew the bolts of the jaws. Turn the jaws and rebolt them. Dont forget to select the outer/ inner clamping direction in the setting. (see chapter 6)

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Spring collars M6 bolt Spike Location bolt B Location bolt A

Figure 11: Jaw SPC 330

Figure 25: Section view jaw SPC 330

5.3 Using the pipe support

Pipe trolley The pipe trolleys are supporting the pipe during cutting. This system places the centerline of the pipe in line with the machine centerline . The distance between the wheel units have to be set accordingly to the diameter of the pipe. The pipe trolleys can be manually transported over its rail. Depending on the type of machine the maximum load of the pipe trolley varies. The wheel distance can be set by use of the handle. CAUTION! Flames from the torch can cause damage to the equipment! To prevent damage to the wheel units, make sure to position the pipe trolleys in such a manner that programmed cuts do not run over the wheel units!

Adjusting the wheel distance The distance between each wheel unit is important in order to handle the complete diameter range. The correct distance between the wheel units is when the angle between the wheels is at o least 50 . WARNING! The wheel distance must have an angle of at least 50o! The material could roll of the rotator wheels and damage people or equipment if this warning is not complied with! 1. 2. 3. 4. Make sure the release valve (red knob) is closed by turning it clockwise. Pump the handle up and down to raise the wheel units until the wheel distance is correct. Pull the safety lever to close the hydraulic circuit. To lower the wheel units, push the safety lever, then turn the release valve slowly counterclockwise until the wheel units come down. Wheel units Safety lever Center of pipe Minimal 50 Center of wheel Figure 26: Advised wheel distance Figure 12: Layout pipe trolley Release valve Handle

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Pipe trolley at the MPC: For the MPC machines the pipe trolley can handle a various kind of profiles by the use of HGG Rotators. For example SHS-/RHS-beams. The pipe trolley is applied with an extra set of guiding rollers at which the rotator rolls. Lower the pipe trolley by opening the safety valve and the release valve. The angle between these roller positions needs to be at least 50 just like when a pipe trolley handles a pipe. The HGG rotator is mentioned further in this manual.

Figure 138: Layout pipe trolley HGG rotator for the MPC For handling non round tubes and profiles at the pipe trolley HGG has developed the HGG rotator. This piece of equipment rolls on the outer guiding rolls of the pipe trolley (special for MPC). At the center of the rotator is two piece clamping device. To install and clamp a SHS/RHS- profile in the rotator the rotator can be opened by unlatching two doors which are situated in the main rings.

Figure 149: Doors opened

Figure 30: A clamped SHS profile

Each clamping device has two rotating jaws. These jaws can be set according to the SHS/RHS profile. The SHS/RHS profile fits by clamping it diagonal in the rotator. Clamping the profile occurs by the use of a spindle which fits at the end of the spiral. WARNING! Pay attention to the balance of the rotator by opening the two doors. Opening these doors causes an unbalanced situation which may result in rotation of the rotators on the pipe trolleys and unexpected closing of these two doors. Dont forget to put the spindle safe after you finished clamping.

WARNING!

Roller ball gutter Instead of pipe trolleys the machine can be equipped with a roller ball gutter. A roller ball gutter has the same function as the pipe trolleys. A roller ball gutter becomes handy when relative many short positions have to be cut from a pipe length. The roller ball gutter can be installed on the pipe trolley rail. The SPC/TPC330 comes with a fixed roller ball gutter.

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5.4 Loading and unloading the machine

WARNING! Serious injuries could occur when loading or unloading the machine. People can get hit or wedged. Make sure no people or objects are located on or near the machine before and during loading or unloading the machine. Always keep safety in mind!

Loading the machine 1. To avoid injuries or damage to the equipment, make sure that before loading: a. the chuck is in the home position. b. the cutting trolley is in the home position. c. the jaws of the chuck are correctly positioned to handle the pipe diameter. d. the machine and pipe trolleys are not operated. e. no people or objects are located near the machine. f. the pipe trolleys are positioned in such a manner that loaded material cannot collapse by force of gravity. g. the wheel distance of the pipe trolleys are correctly adjusted as described in chapter 5.3. Make sure to load the material slowly on the pipe trolleys or roller ball gutter. A overhead crane can be used to load the material. When the material is loaded, it can be pushed to the jaws of the chuck. Adjust the height/wheel distance of the pipe trolleys until the pipe is leveled On the Remote control use the Clamp in or Clamp out button to clamp the pipe, then check if pipe is correctly clamped. Adjust if necessary.

2. 3. 4. 5. NOTE!

The numbers: 1f, 1g and 4 only in case of using pipe trolleys.

Unloading the machine 1. To avoid injuries or damage to the equipment, make sure that before unloading: a. the cutting trolley is in its home position. b. the machine and pipe trolleys are not operated. c. no people or objects are located near the machine. d. all the loose scarp pieces are removed from the material. On the Remote control use the Clamp in or Clamp out button to unclamp the pipe. The material can now be pushed out of the jaws. Make sure to unload the material slowly from the pipe trolleys or roller ball gutter. A overhead crane can be used to unload the material.

2. 3. 4.

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5.5 To start cutting

To initialize the machine Before cutting material the machine needs to be initialized. Initializing is done by use of a laser pointer integrated in the cutting head. Move the cutting head in longitudinal direction in order to move the laser pointer / torch to the location of the first cut. The blinking INI button on the Remote control indicates that the machine is not initialized. On the Remote control, use the X+, X-, Y+, Y- buttons to move the laser pointer to the location of the first profile, then press the INI button. The position of other possible profiles from the same data-file is automatically calculated from this location. After initialization the machine enters Hold mode.

Hold mode

Hold mode is entered before the start of each cut and if cuts are interrupted by the pressing the Stop button during cutting. If Stop is pressed, the gas and oxygen valves will be closed, and the machine stops moving. The last cutting position will be stored. After proceeding, the cutting process starts at this position. An error can cause that the machine will be forced to Hold mode. This is possible when the cutting head runs into a end switch. In this case the machine shows the error on the control unit and the display. Hold mode is active if the hold button on the remote control is illuminated and the status row on the display shows HOLD. The Heat button is blinking to indicate that pressing this button starts/continues the cutting process. To start cutting Oxygas cutting 1. Instal the right pit 2. Check the velocity which is set for the cutting proces 3. On the Remote control, press the Heat button to ignite the cutting torch. 4. Use the pressure controls on the front side of the cutting trolley to adjust the heating flame. 5. Press the Test button to open the cutting oxygen valve. 6. Use the pressure controls on the front side of the cutting trolley to adjust the cutting flame. 7. Press the Test button again to close the cutting oxygen valve. The heating flame appears. 8. Press the Pipe button to lower the cutting head towards the pipe. The heating flame keeps burning. 9. Press the Go button to start the cutting process when the pipe is sufficiently heated. 10. When the cutting process is finished, the status of the machine changes to Ready. 11. Press the Go button to start the next cut if necessary. 12. To interrupt the cutting process, press the Stop button. Plasma cutting 1. Instal the right nozzle 2. Check the velocity which is set for the cutting process. 3. Adjust the right current 4. Position the nozzle to the pipe 5. Pres the heat button 6. When the cutting process is finished, the status of the machine changes to Ready 7. Press the Go button to start the next cut if necessary. 8. To interrupt the cutting process, press the Stop button. MPC: The MPC starts with a geometrical check of the cutting material before it starts the cutting process. The cutting head is applied with a laser which checks the four surfaces of the SHS/RHS-profile to be cut. After that the cutting process can be started according the mentioned steps above.

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Pre heat oxygen

Pre heat gas

Burner gas Burner oxygen Figure 31: Gas control knobs and pressure gauges To move back in cut In Hold mode it is possible to follow the cutting job in opposite direction. This is very useful Cutting oxygen when the machine missed a cut because of wrong settings and a particular part needs to be done over again. 1. 2. 3. 4. On the Remote control, press the Stop button to interrupt the cutting process. Press the Back button to move automatically back in cut. Press the Stop button when the preferred cutting position is reached. To resume cutting see To start cutting.

Moving the cutting head in Hold mode In Hold mode it is possible to move the cutting head to a new cutting position. When the cutting head is moved the Move cut button starts blinking. This means that the cutting head is not in cutting position anymore. To proceed do one of the following: ATTENTION! On the Remote control, press the Go button to return to the previous cutting position. On the Remote control, press the Move cut button to proceed cutting from this new position.

Changing the cutting position will affect the whole cutting job! All remaining profiles are calculated from the new cutting position.

Using the preheat (option) To increase cutting speed, a preheat torch can be used to help preheating the material. On the Remote control, press the Preheat button to (de)activate automatic preheating.

5.6 To cut near the main drive

A limit switch prevents the cutting head from running into the main drive and making it possible to move the cutting trolley at full speeds towards the main drive. When the limit switch is reached the cutting head stops only a few centimeters from the main drive. This distance causes a loss of cutting length. Therefore it is possible to disable the main drive limit switch. When the main drive limit switch is disabled, all machine movements are reduced to 1/8 of its maximum speed. If the DIS LIM button is pressed during cutting the cutting process will not be stopped when reaching the end switch and continues in slow speed. In all other cases the machine will be stopped, and continuation is possible after activating the DIS LIM button. When the machine is in auto mode the DIS LIM function will be disabled. This means that the operator has to press the DIS LIM button every time the cutting head reaches the main drive. CAUTION! When the limit switch is disabled and the machine moves at slow speeds, it is still possible to run the cutting head into the main drive. This can and will cause damage to the cutting head! Operators must keep safety in mind!

On the Remote control, press the DIS LIM button. The DIS LIM button lights up to let the operator know that the limit switch is disabled.

5.7 To cut behind the main drive (option)

To gain cutting length and to reduce scrap, it is possible for some machines to cut behind the main drive. Material can be positioned trough the main drive. The conditions are that the foundation frame and rear beam must be extended at the backside of the main drive. To

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transport the cutting trolley over the main drive, the main drive must be in home position and the cutting trolley must be in the most upper position.

5.8 Emergency stop

In case of a emergency situation the emergency switch must be operated. A emergency stop will cause all machine movements to stop immediately. The cutting gas, oxygen and air valves will close and the buttons on the remote control start flashing. The following text appears on the screen: Emergency stop active, press Reset to continue! Follow the internal procedures of your company or organization for an emergency situation. When the machine is in the emergency mode the machine cannot be operated unless the machine is reset from emergency mode. The emergency stops are located on the Main drive and Remote control. To reset from emergency mode 1. 2. Pull the emergency stop to reset the emergency-stop button. On the Remot control, click the Reset button or use the reset button on the main drive (SPC1500-3000) to continue.

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6 Settings
6.2 Operator settings

Figure 32: Operator settings tab Connect Left/Right Connection method If checked the machine will automatically cut a connection between positions in a TAF file. The connection method can be set as Ini Inline where the initialization points are in line, Normal or Optimal scrap where there is produced as less wasted material as possible. All saddle and chamfer cuts on one side will be cut in one sequence if this option is turned on. Machine will cut backwards all cuts. If this option is enabled, the software will search for the most optimal pierce point for each cut. The most optimal point is determined by the point with the smallest cutting angle. Change the language of the user interface (option). Manual rotating speed of the chuck. Value adjustable from 0 to 100% of maximum speed. Clamping side of the pipe. If the pipe is clamped from the outside the machine setting must be outside. This is the default clamping force. Every time the machine is switched on, this force is used as default. During operating, the clamping force could be changed using the remote control As profile zero pointer a selection can be made between the torch and the laser pointer. Determines if the units are set in metric or inch system. Determines the diameter from where the rotation of the i-axis is blocked. Special oblong hole speed correction. Set as a value between 0 and 1. Where 0 represents the inner fit and 1 represents the outer fit. The lead-in is selectable between straight and circular lead-in. Lead-out can be switched on. The lead-out is always circular.

Combined cuts Negative cutting Start point opti

Language Chuck rotating speed Inside/Outside Clamping force Pointer Units Block hole rot. Speed correction Depth correction Lead-in Lead-out

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6.3 Torch settings

Figure 33: Torch settings tab Cutting process Kerf width Gas settings Plasma settings Speed Fault factor correction Gas cutting or plasma cutting can be selected as cutting process. The kerf width of gas cutting can be programmed. The minimal and maximal burner angle can be programmed. The minimal and maximal burner angle can be programmed and a default current can be given. The percentage the true speed may differ from the set speed before a fault is given.

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7 Maintenance
For reliability and safe operation of the machine maintenance is necessary. Maintenance is important to: keep the machine in a perfect condition. to have a constant high cutting quality. to reduce the down time. to ensure safe operation.

Cleaning and lubrication Make sure cleaning and lubrication is done according to the Greasing manual and Checklist. Replacing the tip The following procedure can be used for replacing the tip of the cutting torch, pierce torch and preheat torch. WARNING! The torch and the tip can be hot due to the cutting process! Allow the torch and the tip to cool down. Always wear flame proof gloves and flame proof clothing when replacing the tip. 1. 2. 3. CAUTION! Use a wrench and a additional counter wrench to demount the nut from the torch. The tip can now be removed from the torch. Select a proper tip according to the wall thickness and cutting angle and attach it to the torch. Use a wrench to tighten the nut.

If the tip is tightened excessively, it will be heated during cutting and become tighter, making it difficult to remove the tip.

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8 Service
Spare parts and consumables are available, and can be ordered from the HGG service department. Questions or information can be send to the service department by e-mail or fax 24 hours a day. During the local office hours your questions will be handled with great importance and care. HGG opening hours Monday to Friday from 8:00 AM - 17:00 PM local time. Phone: +31 227 50 40 30 Fax: +31 227 50 19 03 e-mail: service@hgg.nl

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Appendix A: Terminology
Oxygas cutting When using the oxyfuel cutting process, you heat a spot on the metal to the melting temperature (between 750C and 850 C for steel). The term used for this flame is the preheating flame. When the metal is heated sufficiently you direct a jet of pure oxygen at the heated metal. The jet of oxygen pierces through the wall thickness of the metal. The oxygen causes a chemical reaction known as oxidation to take place rapidly. When oxidation occurs rapidly, it is called combustion or burn. Due to the chemical reaction, various shapes can be cut by moving the material. Plasma cutting Plasma cutting is a process that is used to cut steel and other metals (or sometimes other materials) using a plasma torch. In this process, an inert gas (in some units, compressed air) is blown at high speed out of a nozzle. at the same time an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal away from the cut. Leadin/leadout The leadin is a distance the machine needs to pierce trough the material and accelerate to cutting speed. Before the machine starts to cut the programmed profile, the chemical process of cutting needs to be started. At first the cutting flame needs to pierce trough the material, piercing of the material results into a crater in combination with lots of cutting slag. Since this crater can decrease the quality of the cut, it is necessary to pierce at a certain distance. This distance is referred as a leadin. When the cutting process ends in the middle of a profile cut it can also decrease the quality, therefore a leadout distance can be programmed. The leadin and the leadout are always made on the scrap side of the material.

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