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Pipe profilingmachine

Operators manualOfficial manual of the Pipe profiling machine

Includes Type: SPC/TPC 330, 500, 600, 800, 1000, 1200, 1500, 2000, 3000MPC350

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Operators ManualV3.0

2

Operators Manual Pipe profiling machine

This manual belongs to the Pipe profiling machine. For any questions or comments you cancontact:

Manufacturer: HGG Profiling Equipment b.v.

Address: Zuidrak 21771 SW, Wieringerwerf

Country: the Netherlands

Phone: +31 (0) 227 50 40 30

Release date: 16-03-2011

Version: 3.0

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Table of contents

Operators Manual Pipe profiling machine .......................................................................................... 2Preface .................................................................................................................................................... 3Table of contents ................................................................................................................................... 41. Introduction .................................................................................................................................... 4

1.1 INTENDENT USE OF THE MACHINE ............................................................................................................ 41.2 NON-INTENDED USE OF THE MACHINE ..................................................................................................... 51.3 QUALIFICATION OF PERSONNEL ............................................................................................................... 5

2. Safety ............................................................................................................................................... 62.1 QUALIFICATION OF PERSONNEL ............................................................................................................... 62.2 PERONAL SAFETY INSTRUCTIONS ............................................................................................................. 62.3 SAFETY LABELS ....................................................................................................................................... 7

3. Description of the machine ........................................................................................................... 83.1 INTRODUCTION ........................................................................................................................................ 83.2 LAY-OUT.................................................................................................................................................. 9

3.2.1 Machine style ................... .............. ............. ............. ............. .............. ............. ............ .............. ..... 94. Operating the machine ................................................................................................................ 10

4.1 MAIN DRIVE........................................................................................................................................... 104.2 REMOTE CONTROL ................................................................................................................................. 114.3 USING THE REMOTE CONTROL................................................................................................................ 13

4.3.1 Control buttons.............................................................................................................................. 144.3.2 Display ............ ............. .............. ............ .............. ............. ............ .............. ............. .............. ....... 154.3.3 Navigation bar .................... ............ .............. ............. .............. ............ ............. .............. .............. 16

4.4 INFORMATION WINDOW ......................................................................................................................... 185 To start and to stop the machine ................................................................................................ 20

Before starting the machine ............. .............. ............. ............. ............. .............. ............. ............ .............. ... 205.2 USING THE MAIN DRIVE.......................................................................................................................... 215.3 USING THE PIPE SUPPORT ....................................................................................................................... 235.4 LOADING AND UNLOADING THE MACHINE ............................................................................................. 255.5 TO START CUTTING ................................................................................................................................ 265.6 TO CUT NEAR THE MAIN DRIVE............................................................................................................... 275.7 TO CUT BEHIND THE MAIN DRIVE (OPTION) ............................................................................................ 275.8 EMERGENCY STOP.................................................................................................................................. 28

6 Settings ......................................................................................................................................... 296.2 OPERATOR SETTINGS ............................................................................................................................. 296.3 TORCH SETTINGS ................................................................................................................................... 30

7 Maintenance .................................................................................................................................. 318 Service ........................................................................................................................................... 32Appendix A: Terminology ................................................................................................................... 331. Introduction

1.1 Intendent use of the machine

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This machine is a Pioxygas cutting proceprocesses, see appapplications only. ThTechnical specificatio

the main drive unit. AYou should always ke

Figure 1: Nameplate Pipe profiling mac

1.2 Non-intended use of the mac

This machine should

Non-intende

Cause injury

Damage the

Reduce the

1.3 Qualification of personnel

Operator

Operators are instrumachine may creatconditions and emerprogram and clean th

Mechanic

Mechanics have tecdangers which electripersons who maintain

e profiling machine and should be used for profiling stes (oxyfuel) or plasma cutting process. For the explainat

endix A Terminology. The machine should be usee machine is suitable for cutting the pipe range asns or the nameplate. A nameplate like Figure 1 is locate

nameplate like Figure 2 is located on the front side ofep these nameplates clean and in legible condition.

ine Figure 2: Nameplate Pipe trolley

ine

ot be used for cutting or igniting flammable material.

use of the machine can

to personnel

machine or other equipment

achine reliability and the machine performance

ted persons who are adequately advised to avoid t. Instruction should include instructions in operatioency situations. Operators are persons who start, stomachine.

nical knowledge or sufficient experience to enable thcity, pneumatics, hydraulics and mechanics may createand clean the machine.

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el pipes with anion of these twod for industrialescribed in thed on the side of

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6

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 1Introduction.

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 themachine.

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 onthe 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 ormaintaining this machine.

Read and understand the Instructions manual plasma machine, when plasma cutting isused.

Read and understand the Installation and operation manual dust collector, when a dustcollector is used.

Keep these manuals to hand at all times and read it as many times as necessary for acomplete understanding.

Only instructed operators are permitted to operate this machine. Instruction should includeinstructions 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 themachine 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 shutdownswitches.

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 keepsafety in mind.

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Never look directl

safety glasses. Thshield. Use this to

For safety reasons Safety shoes.

Flame proof ov Flame proof gl Ear protection. Safety glasses

2.3 Safety labels

The residual riskslabels are placed:

Label Descripti

Fire, nakprohibited

Warning!

Warning!

Warning!

Wear flam

Wear flam

Wear safe

Wear eye

Read anmanualmachine.

into the flame, the bright light could damage your eyese cutting device on the machine is also applied with a UVprotect your eyes.

operators have to wear:

erall or flame proof clothing.ves.

.

f the PPM are expressed by safety labels. The f

n Locationed flame and smoking.

Front side Main Drive U

anger! Front side of Cutting troll

otating parts. Front side Pipe trolleys.

ot surface inside. Right and left side Cuttin

e proof clothing. Front side Main Drive U

e proof safety gloves. Front side Main Drive U

ty shoes. Front side Main Drive U

and ear protection. Front side Main Drive U

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3. Description of the machine

3.1 IntroductionThe Pipe profiling machines are used to cut pipe-to-pipe and pipe-to-plate connections withconstant welding preparations over the entire pipe length. The SPC/TPC machine range andMPC can be used for several industries. The various shapes are cut by moving multiplecomputer 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 inSHS- 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 atte 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 afoundation frame which is positioned within the concrete flooring.

The TPC stands for Transportable Pipe Cutting machine. This type of machine is anchored on aspecially 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 containerframe needs to be leveled again.

The MPC stands for Multiple Profile Cutting machine. This type of machine is ancored on afoundation frame which is positioned within the concrete flooring.

SPC330

Figure 4: Layout SPC 330 machine range

SPC500-1200

Figure 5: Layout SPC 500-1200 machine range

SPC1200-3000

Figure 6: Layout SPC 1000-3000 machine range

Cutting trolley

Main drive

Cutting trolley

Remote control

Gas pressure controls

Cutting trolley

Main driveGas pressure controls

Remote control


Pipe trolley

Dust collector(optional)


Main drive


Remote control Roller ball gutter

Chuck

Chuck

Chuck

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MPC 350

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 onthe type of machine it is also possible to control the cutting trolley from controls located at themain 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 forthe cutting trolley and a reset button which has the same function as the clear error button onthe 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 clampforce.

Open chuck (SPC15003000)Pressing this button will open the chuck

Emergency switchIn 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 buttonon the touch screen in case of an error.

Power key switchThe key switch can be used to shut on/off the machine.

Main powerThis 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 cuttingtrolley is also turned off. HGG advises to keep the main power set to 1 and to shut the machinedown by using the key switch.

NOTE! By using the Reset and/or Emergency switch no dangerous situations will appear because allmachine axis keeps their actual position. The SPC150-3000 machine resets the H-axis.


Main drive

Cutting trolley


Remote controlPipe trolley Chuck

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Main drive (SPC330 SPC1200 and MPC350)

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

Main drive (SPC1500 SPC3000)

Figure 9: Control panel at Main drive SPC1500SPC3000

4.2 Remote control

The machine is controlled by the control unit at the rearside of the cutting trolley. The controlunit consists of a industrial computer which runs the machine software and several otherelectronics for controlling the machine. The control unit has a built-in climate control unit toprotect the unit against low temperatures and moisture.

The remote control is the interface between the operator and machine. The entire machine iscontrollable by this interface.

Motion controller

Move chuck up Close chuck

O en chuckMove chuck down

Reset / Clear errorEmergency switch

Control lightPower key switch

Power key switchControl lightMain power

Main power

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

Emergency switch

USB-connection

Key-board

Touch screen

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4.3 Using the remote control

The remote control is used to operate the machine. The remote control consists of anemergency stop, control buttons, keyboard and a touch screen. Important parameters of thecutting process are shown on the display. The operator will be guided through the differentsteps for starting the cutting process by blinking buttons. These blinking buttons are indicating

the next steps of the cutting process.

Figure 11: Screen shot of the remote control

Navigationbar

Display

Menu bar

Informationwindow

Controlbuttons

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

Figure 13: Control buttons

49. CT B+: move cutting trolley towards operater50. I+: positive rotation (I-axis) of cutting head51. CT B-: move cutting trolley away from operater52. Home I: Initialization of the I-axis of the cutting head. This can be used for calibrating the

cutting head53. Auto +: Increase preheat time before piercing at automatic cutting (option)54. Z-: negative tilting of Z-axis cutting head55. Z+: positive tilting of Z-axis cutting head56. Free: release I and Z axis57. Auto -: Decrease preheat time before piercing at automatic cutting (option)58. Home Z: Home Z axis of cutting head59. 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 foroperating.

The extended parameters are displayed when the Shift button is activated and contain thestandard parameters and additional maintenance data.

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

Status DescriptionReady Machine is finished cuttingProgram Machine ready for programmingInit Machine is initializingHold Machine is in hold mode. The cutting process can now be started.Heating Machine is busy heatingCutting Machine is busy cuttingMarking Machine is busy markingMove to 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. Therotation 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 beread. The covered distance is reset when the Y=0 button on the remote control is pressed.

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Figure 157: Select cut window

SettingsTo acces the most commonly used machine settings.

(See chapter 6 for more information about settings.) On the Navigation bar, click Settings.

DesignWith the Design button you start ProCAM. With ProCAM you can create, modify, nest and viewdata files.

On the Navigation bar, click Design.

NOTE! Consult the ProCAM course manual and ProCAM framework and ProGRAM user manual formore information about ProCAM.

StopWith this button the operator stops the cutting proces

On the Navigation bar, click Stop.

ATTENTION! When pressing the stop button (at the navigator bar). The machine will lose its initializing point.

JobThe 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.

Figure 16: Current Job window

OperatorBefore a operator starts a cutting project he can enter his name. This can provide theworkpreperation 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 themachine.

Figure 8: Cut position box

Position Output DescriptionX-axis [deg] Displacement rotator

Y-axis [mm] Displacement cutting trolley (longitudinal)I-axis [deg] Rotation of the cutting headZ-axis [deg] Tilting of the cutting headH-axis [mm] Elevation of the cutting trolleyCH [mm] Chuck height (option)

Tool

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

Figure 98: Tool box

Tool DescriptionOxy fuel Tool for making cutsMarking tool Tool for markingPierce tool Tool for piercing trough the materialPlasma Tool for plasma cutting

Time/date

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 Program DescriptionStatus Ready Machine is finished cutting

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5 To start and to stop the machine

Before starting the machine

Make sure the machine and the area surrounding the machine is clean and free of toolsand other obstacles.

Make sure you wear the correct personal protection equipment (PPE) as described inchapter 2.2 Personal safety instructions.

Make sure all gasses for the cutting process are available and connected to the machine inthe right order.

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 aruntime 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 (defaultpassword: operator).

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. Thegenerated information will be stored and during the cutting process.

SPC/TPC250 On the Remote control:

o Press Home chuck diameter + Home CT + Home height chucko 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 homebuttons. 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 startand shut down to close Windows. Wait until the message its now safe to turn off yourcomputerappears.

On the Control unit, put the Power key-switch in the OFF or 0 position to shutdown themachine.

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 fromthe 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 byusing the valve knob at the side of the main drive unit. The clamping force can be read from thepressure 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 adjustedelectrically 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. Use a adjustable pin wrench and a wrench to demount the M6 bolt from the jaw, thenremove the spike from the jaw. The spike contains spring collars. These spring collarsmust stay in this exact position.

2. Use a socket wrench to demount bolt A.3. 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.4. Turn the jaw 180, place it on the chuck and tighten it with bolt A and B.5. Replace the spike with spring collars. Use a adjustable pin wrench and wrench to tighten it.6. Repeat these steps for all the jaws.

NOTE! For all other chucks the operator can just unscrew the bolts of the jaws. Turn the jaws andrebolt them. Dont forget to select the outer/ inner clamping direction in the setting. (see chapter6)

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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 thepipe in line with the machine centerline . The distance between the wheel units have to be setaccordingly to the diameter of the pipe. The pipe trolleys can be manually transported over itsrail. 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 wheelunits, make sure to position the pipe trolleys in such a manner that programmed cuts do not runover 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 atleast 50

o.

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. Make sure the release valve (red knob) is closed by turning it clockwise.2. Pump the handle up and down to raise the wheel units until the wheel distance is correct.3. Pull the safety lever to close the hydraulic circuit.4. To lower the wheel units, push the safety lever, then turn the release valve slowly counter-

clockwise until the wheel units come down.

Figure 26: Advised wheel distance Figure 12: Layout pipe trolley

Minimal 50

Center of pipe

Center of wheel

M6 bolt

Spring collars

Spike

Location bolt B

Location bolt A

Handle

Release valve

Safety lever

Wheel units

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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 orwedged. Make sure no people or objects are located on or near the machine before and duringloading 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 5.3.2. 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.3. When the material is loaded, it can be pushed to the jaws of the chuck.4. Adjust the height/wheel distance of the pipe trolleys until the pipe is leveled5. 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.

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.

2. On the Remote control use the Clamp in or Clamp out button to unclamp the pipe.3. The material can now be pushed out of the jaws.4. 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.

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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 laserpointer integrated in the cutting head. Move the cutting head in longitudinal direction in order tomove 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 thelocation of the first profile, then press the INI button. The position of other possible profilesfrom the same data-file is automatically calculated from this location.

After initialization the machine enters Hold mode.

Hold modeHold mode is entered before the start of each cut and if cuts are interrupted by the pressing theStop button during cutting. If Stop is pressed, the gas and oxygen valves will be closed, and themachine 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 showsthe error on the control unit and the display. Hold mode is active if the hold button on the remotecontrol is illuminated and the status row on the display shows HOLD. The Heat button isblinking to indicate that pressing this button starts/continues the cutting process.

To start cuttingOxygas cutting1. Instal the right pit2. Check the velocity which is set for the cutting proces3. 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 cutting1. Instal the right nozzle2. Check the velocity which is set for the cutting process.3. Adjust the right current4. Position the nozzle to the pipe5. Pres the heat button6. When the cutting process is finished, the status of the machine changes to Ready7. 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 cuttingprocess. The cutting head is applied with a laser which checks the four surfaces of theSHS/RHS-profile to be cut.After that the cutting process can be started according the mentioned steps above.

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Figure 31: Gas control knobs and pressure gaugesTo move back in cut

In Hold mode it is possible to follow the cutting job in opposite direction. This is very usefulwhen the machine missed a cut because of wrong settings and a particular part needs to bedone over again.

1. On the Remote control, press the Stop button to interrupt the cutting process.2. Press the Back button to move automatically back in cut.3. Press the Stop button when the preferred cutting position is reached.4. 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 cuttinghead is moved the Move cut button starts blinking. This means that the cutting head is not incutting position anymore. To proceed do one of the following:

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 newposition.

ATTENTION! Changing the cutting position will affect the whole cutting job! All remaining profiles arecalculated 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 possibleto move the cutting trolley at full speeds towards the main drive. When the limit switch isreached the cutting head stops only a few centimeters from the main drive. This distancecauses 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 itsmaximum speed. If the DIS LIM button is pressed during cutting the cutting process will not bestopped when reaching the end switch and continues in slow speed. In all other cases themachine will be stopped, and continuation is possible after activating the DIS LIM button. Whenthe machine is in auto mode the DIS LIM function will be disabled. This means that the operatorhas 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 theoperator 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 themain drive. Material can be positioned trough the main drive. The conditions are that thefoundation frame and rear beam must be extended at the backside of the main drive. To

Pre heat gas

Burner gas

Pre heat oxygen

Burner oxygen

Cutting oxygen

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transport the cutting trolley over the main drive, the main drive must be in home position and thecutting 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 valveswill close and the buttons on the remote control start flashing. The following text appears on thescreen: Emergency stop active, press Reset to continue!Follow the internal procedures of yourcompany or organization for an emergency situation.

When the machine is in the emergency mode the machine cannot be operated unless themachine is reset from emergency mode. The emergency stops are located on the Main driveand Remote control.

To reset from emergency mode

1. Pull the emergency stop to reset the emergency-stop button.2. 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 If checked the machine will automatically cut a connectionbetween positions in a TAF file.

Connection method The connection method can be set as Ini Inline where theinitialization points are in line, Normal or Optimal scrap wherethere is produced as less wasted material as possible.

Combined cuts All saddle and chamfer cuts on one side will be cut in onesequence if this option is turned on.

Negative cutting Machine will cut backwards all cuts.Start point opti If this option is enabled, the software will search for the most

optimal pierce point for each cut. The most optimal point isdetermined by the point with the smallest cutting angle.

Language Change the language of the user interface (option).

Chuck rotating speed Manual rotating speed of the chuck. Value adjustable from 0 to100% of maximum speed.

Inside/Outside Clamping side of the pipe. If the pipe is clamped from the outsidethe machine setting must be outside.

Clamping force This is the default clamping force. Every time the machine isswitched on, this force is used as default. During operating, theclamping force could be changed using the remote control

Pointer As profile zero pointer a selection can be made between thetorch and the laser pointer.

Units Determines if the units are set in metric or inch system.Block hole rot. Determines the diameter from where the rotation of the i-axis is

blocked.Speed correction Special oblong hole speed correction.Depth correction Set as a value between 0 and 1. Where 0 represents the inner fit

and 1 represents the outer fit.Lead-in The lead-in is selectable between straight and circular lead-in.

Lead-out Lead-out can be switched on. The lead-out is always circular.

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6.3 Torch settings

Figure 33: Torch settings tab

Cutting process Gas cutting or plasma cutting can be selected as cutting process.Kerf width The kerf width of gas cutting can be programmed.Gas settings The minimal and maximal burner angle can be programmed.Plasma settings The minimal and maximal burner angle can be programmed and

a default current can be given.Speed Fault factorcorrection

The percentage the true speed may differ from the set speedbefore a fault is given.

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7 MaintenanceFor reliability and safe operation of the machine maintenance is necessary. Maintenance isimportant 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 manualandChecklist.

Replacing the tip

The following procedure can be used for replacing the tip of the cutting torch, pierce torch andpreheat torch.

WARNING! The torch and the tip can be hot due to the cutting process! Allow the torch and the tip to cooldown. Always wear flame proof gloves and flame proof clothing when replacing the tip.

1. Use a wrench and a additional counter wrench to demount the nut from the torch. The tipcan now be removed from the torch.

2. Select a proper tip according to the wall thickness and cutting angle and attach it to thetorch.

3. Use a wrench to tighten the nut.

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

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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 850C 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 jetof oxygen pierces through the wall thickness of the metal. The oxygen causes a chemicalreaction known as oxidation to take place rapidly. When oxidation occurs rapidly, it is calledcombustion or burn. Due to the chemical reaction, various shapes can be cut by moving thematerial.

Plasma cuttingPlasma cutting is a process that is used to cut steel and other metals (or sometimes othermaterials) using a plasma torch. In this process, an inert gas (in some units, compressed air) isblown at high speed out of a nozzle. at the same time an electrical arc is formed through thatgas from the nozzle to the surface being cut, turning some of that gas to plasma. The plasma issufficiently hot to melt the metal being cut and moves sufficiently fast to blow molten metal awayfrom the cut.

Leadin/leadoutThe leadin is a distance the machine needs to pierce trough the material and accelerate tocutting speed. Before the machine starts to cut the programmed profile, the chemical process ofcutting 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 thiscrater can decrease the quality of the cut, it is necessary to pierce at a certain distance. Thisdistance is referred as a leadin. When the cutting process ends in the middle of a profile cut itcan also decrease the quality, therefore a leadout distance can be programmed. The leadin andthe leadout are always made on the scrap side of the material.

Documents

STD_PPM_330-3000_opl_v3_EN