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Operators Manual

Pipe Profiling Machine | SPC 500 - 1200

V

4 

The controls 

17

4.1  Main drive  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    17

4.1.1  Power key switch    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    17
4.1.2  Clamping pressure.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    17

4.2  Remote control.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    18
4.3  Manual Data Input (MDI) with ProCAM    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    18
4.4  Using the remote control .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    19

4.4.1  The display    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    19
4.4.2  The menu bar  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    19
4.4.3  The quick action buttons.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    20
4.4.4  The ‘Mode selection’ button    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    20
4.4.5  Material handling mode  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    20
4.4.6  Profiling mode.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    21
4.4.7  Automatic mode.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    21

4.5  Material Handling screen  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    22

4.5.1  The cutting trolley .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    23
4.5.2  The main drive.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    23

4.6  Profiling screen.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    24

4.6.1  Selecting a data file or set   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    25

4.7  Advanced profiling screen    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    26
4.8  Action progress    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    27
4.9  Settings screen .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    29
4.10 Settings   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    30
4.11 Diagnostics screen  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    32

4.11.1  Tab bar   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    32
4.11.2  Machine status    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    32
4.11.3  Cutting tools    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    33
4.11.4  MARKING  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    34
4.11.5  Cutting trolley .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    35
4.11.6  Main drive .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    36
4.11.7  Cutting Head    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    37
4.11.8  Calibrating the cutting head  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    37
4.11.9  Profiling tool calibration  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    37
4.11.10  Support    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    38
4.11.11  Generate error report  .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    39
4.11.12  Team viewer    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    39
4.11.13  HGG   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    39

5 

Operating the machine 

40

5.1  Control elements .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    40
5.2  Before starting the machine.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    41
5.3  To start the machine   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    41
5.4  To home the machine    .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    41

5.4.1  On the remote control:.   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    41

5.5  To stop the machine   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    42

Содержание SPC 1000

Страница 1: ...Pipe Profiling Machine Operators Manual Original manual for the Pipe Profiling Machine MAINTENANCE CALIBRATION MESSAGES RESTORE QUALITY TERMINOLOGY SPC 500 1200...

Страница 2: ...herlands Phone 31 0 227 50 40 30 Release date 01 06 2018 Version 2018 version 1 Service Spare parts and consumables are available and can be ordered from the HGG service department Questions or inform...

Страница 3: ...parts for the machine configuration Also included in the technical manual are the main assembly drawings electrical diagrams and connection lists and pneumatic and hydraulic diagrams Detailed technic...

Страница 4: ...ity and safe operation of the machine it is necessary that the maintenance is carried out as described in the Appendix A Maintenance Grease Schedule Special notations There are four levels of special...

Страница 5: ...ma Hypertherm 4 1 7 Heat smoke and fumes 5 1 8 Fire risk when clamping pipes 5 1 9 Definitions of qualification of personnel 6 2 Safety 7 2 1 Machine safety 7 2 2 Personal safety instructions 8 2 3 Re...

Страница 6: ...ve 23 4 6 Profiling screen 24 4 6 1 Selecting a data file or set 25 4 7 Advanced profiling screen 26 4 8 Action progress 27 4 9 Settings screen 29 4 10 Settings 30 4 11 Diagnostics screen 32 4 11 1 Ta...

Страница 7: ...50 6 4 To start profiling 50 6 4 1 Oxyfuel 50 6 4 2 Plasma 51 6 5 Switching from oxyfuel to plasma 52 6 6 Adjusting the height of the plasma torch 52 6 6 1 Pause 53 6 6 2 Displace profile 53 6 6 3 Sto...

Страница 8: ...re Messages Notifications and Errors 92 130 Remote control on screen messages in table form numerically sorted with description explanation and suggested solution or referral to the detailed explanati...

Страница 9: ...Oxyfuel 3 mm 150 mm 70 tot 70 Plasma 3 mm 38 mm 30 mm quality cut 45 to 45 Intended use of the machine This machine is a thermal profiling machine and should be used for profiling steel pipes with an...

Страница 10: ...ers hermetically sealed containers or objects other than described in chapter 1 1 The machine should not be used for cutting flammable or explosive material Do not use tools other than those specified...

Страница 11: ...rements 16 12 2004 MaxP peak C weighted instantaneous sound pressure LpCpeak in dB Lav5 A weighted sound pressure LpA in dB Cutting current Material thickness Maximum noise level at a distance of Cutt...

Страница 12: ...ensed filtered for particles according to ISO 8573 1 Class 1 4 1 Pressure 10 bar Argon Purity 99 996 Pressure 10 bar Hydrogen Purity 99 95 Pressure 12 bar Nitrogen Purity 99 9 Pressure 10 bar Oxygen N...

Страница 13: ...area according to local health and safety regulations HGG recommends that these gases are always released to the exterior HGG s advice is based on international research and European Health and Safety...

Страница 14: ...ucted persons are adequately advised or supervised by skilled persons to enable them to avoid the dangers which electricity pneumatics hydraulics and mechanics may create operating cleaning and mainte...

Страница 15: ...more than one person is working on the machine at the same time The machine can ONLY be operated by instructed operators and mechanics Risks can especially be caused when the machine is operated maint...

Страница 16: ...ped in such a way that another worker can start the machine while you are working on it To avoid injury the operator should Never reach into the machine for any reason unless the machine is at a compl...

Страница 17: ...uck when it is rotating you could get wedged or hit by moving parts WARNING Pipe trolleys The pipe trolley wheels provide support for the pipe Keep your hands and body away from the pipe trolleys when...

Страница 18: ...te control Front side of the main drive Read and understand the operator s manual before operating the machine Front side of the remote control Front side of the main drive Warning Hot surfaces Right...

Страница 19: ...ial cutting head can rotate and tilt Pipes are rotated by the main drive This flexibilty of movement combined with computer numeric control of the axes produces a versatile machine capable of high pre...

Страница 20: ...concrete flooring optional CTL MDR CTH MDH MDC CHT CHR 1 Main drive 2 Cutting trolley 1 5 2 3 9 8 10 6 7 4 3 Gas controls 4 Remote control 5 Spark reversal kit 6 Pipe trolley 7 Rear frame 8 Dust coll...

Страница 21: ...olley at high speed 20 m min To guarantee perfect and smooth movement high precision hardened linear guides are used As the foundation frame is solidly constructed in a concrete floor vibrations cause...

Страница 22: ...nt is controlled by a servo motor Two heavy duty rollerball arms at each side of the cutting torch apply pressure to the pipe in its support with a pre set weight of 250 N The pre set weight is adjust...

Страница 23: ...can be controlled from this point The intuitive graphic interface can be operated using the touch screen The most common actions can also be controlled using stainless steel buttons on the right and...

Страница 24: ...ctor connected to a dust tray which allows easy collection and emptying The spark collector should be connected to a separate fume extraction system on site A ventilator can be connected to the spark...

Страница 25: ...switch The key switch can be used to turn the machine on and off Clamping pressure The knob to the left of the key switch can be used to adjust the clamping pressure of the chuck NOTE When the main po...

Страница 26: ...roCAM multiple macros cuts can be programmed in order to create a production piece The parts can be nested into raw materials and data files generated which can then be directly opened and profiled on...

Страница 27: ...am for on line creation of parts The settings screen is for entering choices and preferences Also for machine settings and offsets The material handling screen prepares the machine and material for pr...

Страница 28: ...e Mode selection button The Mode selection button at the bottom right of the screen toggles between Material handling and Profiling modes The quick action buttons in the side bar on the right of your...

Страница 29: ...the left for plasma If the pipe is rotated while profiling is paused this button resumes from the new position pressing play will resume from where profiling was paused When profiling using oxyfuel th...

Страница 30: ...be manually controlled from here The material handling screen clicking on a machine part will open the control box The pipe diameter can be entered in this field the speeds of some of the machine par...

Страница 31: ...g trolley to Pipe Bottom Move cutting trolley to Float Bottom Move cutting trolley to Top Bottom Close window Bottom The main drive Button Action Position Rotate the chuck counter clockwise Top Rotate...

Страница 32: ...f the currently selected part and set The target button on the left hand side of the screen can be used to view all the sets in a file use the hand to select a specific set with which to begin Dependi...

Страница 33: ...gress The boxes here will be coloured orange when active light blue pending dark blue done The larger boxes at the bottom show a green blinking arrow to inform the operator of the next step in the pro...

Страница 34: ...en quick action buttons The advanced profiling screen gives the operator extra control over the profiling process This is particularly useful for large pipes and especially thick walled pipes The firs...

Страница 35: ...new position where it has a clear run in to the starting point Attention the starting point will not change Press the button to set the new point as the start of the lead in Action progress Once an ac...

Страница 36: ...the pierce tool this occurs automatically with plasma cutting When piercing is complete profiling begins automatically The progress bar in the Profiling box shows the progress When the machine has fi...

Страница 37: ...e right For more information and details of the settings see the table in this chapter Touch control Description This button changes access to the controls a window will open asking the new operator t...

Страница 38: ...a fast moving cutting head Reducing the lead in speed will reduce vibration in the cutting trolley It can also help to solve following errors during the lead in The default value is 0 no speed reduct...

Страница 39: ...ngs enabled Check the box to enable all marking If the box is not checked no marking will be done see page 50 Marking Tool Marking HiFocus plasma REA ink jet or Punch marker Line marking tool If you h...

Страница 40: ...s a quick diagnostic check when there is a problem with the machine The operator can see at a glance if there is a problem The green lights show the device connections assisting remote assistance and...

Страница 41: ...urn the cutting gas on or off This can be used to check the cutting flame and make adjustments as necessary The third button stops the tool The button underneath is used to enable or disable the fast...

Страница 42: ...e bottom light indicates that the printer is connected and communicating with the software The right hand button is the Test button This is used to test the printer and clean the nozzle and should be...

Страница 43: ...STATUS SWITCH INDICATORS INFORMATION WINDOW TOUCH CONTROLS Touch control Description These buttons move the cutting trolley in positive and negative directions along the length of the pipe the CTL ax...

Страница 44: ...he home position The light will be red while the chuck is rotating and will turn yellow when the home position is reached The status will change from idle to homing The zero button will change the pos...

Страница 45: ...alibration and storage of the offsets can be done here The procedure is explained in detail in chapter 8 Calibration Profiling tool calibration To the right of the calibration dialog you will find the...

Страница 46: ...for diagnostics and troubleshooting The Service tab has 4 buttons The settings buttons provide the opportunity to make a copy of the settings It is advisable to do this once all the settings have bee...

Страница 47: ...rectly during diagnosis For optimal use of this service it is important that both parties use the same version you can find the current HGG version at this location https get teamviewer com hggservice...

Страница 48: ...st the clamping force of the chuck 5 The remote control is used to control the SPC 500 1200 range The remote control consists of a touch screen manual control buttons a keyboard with trackball and an...

Страница 49: ...ive for any amount of time it may have been switched off at the main power switch On the main drive control panel turn the power key switch to the ON or 1 position Use the remote control to log on Log...

Страница 50: ...e or outside of the pipe and check that the jaws are correctly mounted for the selected clamping to turn the jaws see the description below Move the main drive to a suitable height to clamp the pipe a...

Страница 51: ...force of the SPC 500 1200 range can be adjusted manually by using the valve knob next to the main drive control panel The clamping force can be read from the pressure gauge The set clamping force is...

Страница 52: ...ls is at least 50 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...

Страница 53: ...be cut and the type of cut Normal use In normal use distribute the available pipe trolleys evenly over the length of the pipe In the example below three different pipe trolleys are present 5 tons 10...

Страница 54: ...he pipe trolley rails before cutting Long parts When cutting longer parts always make sure that the cut part has sufficient support see diagram Remember that the pipe trolleys have a maximum weight ca...

Страница 55: ...nd of the pipe move too much during rotation This can be compensated by placing the pipe trolleys at the ends of the pipe and not in the middle In the diagram above the middle pipe trolley has been lo...

Страница 56: ...that the pipe is correctly clamped Adjust if necessary Unloading pipes from the machine To avoid injuries or damage to the equipment make sure that before unloading the cutting trolley is in its home...

Страница 57: ...on material qualities like wall thickness and temperature For a thicker walls and lower material temperatures a lower cutting speed is recommended Smudged or coated material can also reduce the cuttin...

Страница 58: ...screen select a data file 7 Choose oxyfuel cutting tool Use the profiling table for default cutting speed for the wall thickness of the pipe If you wish to change the cutting speed disable the profili...

Страница 59: ...rs click on OK 5 Set the initialisation point for the file the point where profiling will begin and press Play 6 Measuring is only applicable to roller bed machines and will be automatically skipped P...

Страница 60: ...xyfuel torch in the bracket and close the bracket 7 Place the plasma torch in the holder so that the nozzle is just showing and replace the cap securely but not too tightly 8 With a tube clamped in th...

Страница 61: ...ll automatically activate the Displace profile button in the right quick action buttons see below for a description of cutting from a new position Stop The quick action Stop button at the bottom of th...

Страница 62: ...the Play button to resume profiling WARNING Changing the cutting position will affect the whole job All remaining profiles are calculated from the new position To cut near the main drive When the cutt...

Страница 63: ...ut at steeper angles a preheat torch can be used to help preheating the material Activate the preheat option using the quick action button on the right of the profiling screen Emergency stop In case o...

Страница 64: ...ipe is being cut on the machine and later aligned to ensure easy and accurate An SPC equipped with an ink jet printer left and a punch marker right Ink reference lines and footprints Ink alphanumeric...

Страница 65: ...y be half of the entered printer height The tilde sign itself is never printed Printer offsets The printer is mounted on the side of the cutting trolley For line marking dot number 8 is used this dot...

Страница 66: ...essure from the gauge Increase or decrease the dot size to achieve the desired printing result Always check the ink level in the reservoir before printing Always keep the level between the minimum and...

Страница 67: ...leaning fluid and let it work in for a while then empty out the cleaning fluid 5 Refill the chamber with fresh cleaning fluid Continue to repeat the process until the chamber is clean 6 If the nozzles...

Страница 68: ...on the pipe can be programmed in ProCAM s MDI module Manual Data Input which is explained in detail later in this chapter There are also several other automatic line marking options available If one o...

Страница 69: ...g part profile next to the hole or slot Part name automatically marks the part name on each part Text enable automatically marks the connecting part name next to each cut Footprints A footprint is a c...

Страница 70: ...ers The Text parameter is the field in which to type your text Remember for two lines of text enter a tilde sign at the end of the first line If you choose two lines of text each line of text will be...

Страница 71: ...Appendix A Maintenance and Grease Schedule Grease Schedule...

Страница 72: ...ts A person could be hit by the moving cutting head A person could be injured by a rotating pipe A person could get an electric shock Replacing the cutting torch nozzle Always make sure the cutting pr...

Страница 73: ...sk check Cut and evaluate this See Appendix B Calibration for more information If necessary adjust the cutting head CONTROL UNIT Remove the ventilator cover of the air conditioning unit and clean the...

Страница 74: ...III 08 00 008 Hydraulic oil HV A 32 5 litre IV 08 00 020 Total Carter SG 680 5 litre V 08 00 013 Cleaning fluid Number HGG part number Cleaner TKDK VI 01 08 206 Plasma coolant HGG part number Kjellfro...

Страница 75: ...e grease is spread over the whole surface to prevent friction and vibration 3 III 500 3 months 1 2 Open the jaws fully clean and apply new grease Close the jaws and clean and grease the remaining part...

Страница 76: ...low 4 II 1000 6 months 2 3 Clean the vertical spindle and nut Pump a small amount of new grease into the grease nipples colour coded red the middle position 1 III 1000 6 months 2 4 Pump a small amount...

Страница 77: ...Cutting head Grease point Description No Type Operating hours Maint schedule 3 1 Clean the rotation gear 2 500 3 months 3 2 Remove excess dirt and grease from the tilting system 4 500 3 months 3 1 3...

Страница 78: ...g hours Maint schedule 4 1 Set the pipe trolley to the top position clean and lubricate the vertical guide system 2 I 200 1 month 4 2 Set the pipe trolley to the bottom position check the oil level in...

Страница 79: ...gutter Grease point Description No Type Operating hours Maint schedule 5 1 Clean and grease the roller balls in the gutter II 50 1 week 5 2 Remove any excess dirt and or residue from the gutter 50 1...

Страница 80: ...le 6 Machine frame Grease point Description No Type Operating hours Maint schedule 6 1 Clean the horizontal rails and the tooth gears 2 10 1 day 6 2 Clean the pipe trolley rails 2 10 1 day 6 1 6 2 GRE...

Страница 81: ...Appendix B Calibration and Cutting Test Pieces Calibration...

Страница 82: ...ndix It is recommended that these test pieces are cut at least once a week Safety Always take great care when calibrating the machine Follow the safety instructions as outlined in chapter 2 of this ma...

Страница 83: ...n the vertical rails of the cutting trolley to check the vertical alignment Move the cutting trolley along the rear frame to the next pole Check the that the rear frame is horizontally level and the c...

Страница 84: ...t side of the chuck must be perpendicular to the machine centreline 3 The centre of the chuck must be aligned to the machine centreline Vertical For the vertical alignment use a spirit level on the ve...

Страница 85: ...Centreline For the alignment of the centre of the chuck hang a plumb line over the chuck and measure the distance to the pipe trolley rails Move the chuck to its bottom position and measure again A B...

Страница 86: ...pe on the pipe trolley which you know is absolutely straight For accurate measurements it should be at least 1 metre long Measure the distance between the bar or pipe and the rails at the 4 points as...

Страница 87: ...ure the distance between the top of the pipe trolley rails and the bottom of the spirit level to check the height of the roller ball gutter The height must be the same at each unit to ensure that the...

Страница 88: ...ate is level 0 5mm m see diagrams and photo for exact location Centreline Set the cutting head in the centre of the machine by aligning the torch with the centreline of the machine To do this clamp a...

Страница 89: ...plate The cutting arm should now be parallel to the rotation axis Check this by placing a small spirit level on the machined edge on the right hand side of the arm Rotate the arm clockwise in steps of...

Страница 90: ...appear on screen Cutting head tilt axis is free Please position the axis at its home position Manually move the cutting head so that the top calibration pin can be inserted Store the offset by pressin...

Страница 91: ...rotated with both calibration pins inserted the nozzle should not move it should only rotate around its own axis You can check this by placing a small fixed reference block on the pipe close to the no...

Страница 92: ...imensions as the production pieces you will subsequently be cutting If this is not possible choose a pipe with a relatively thick wall this will make measurement easier when evaluating the pieces afte...

Страница 93: ...s of the test piece have to be smooth and straight If they are not refer to the cutting quality appendix in this manual Calculating the oscillation offsets The result of the test piece should be as sh...

Страница 94: ...t The more the torch is tilted the further the arm moves but the tip of the torch always points directly at the same point in space see diagram below The torch height is the distance from the torch ti...

Страница 95: ...must be decreased If all the mechanical and software calibration has been carried out as described in this appendix the deviation shown in example 2 above should not happen If the two halves are out o...

Страница 96: ...rings that are to be cut from the pipe Cutting direction The cutting direction is important The right hand side of the cut relative to the forward motion of the torch is always the good side Depending...

Страница 97: ...meter for a perpendicular cut is 90 In ProCAM the part will look like the image below When the part has cooled use a pair of calipers to measure the width of the ring at the outer wall and at the inne...

Страница 98: ...er compensated So if the width is 22 mm the difference is 2 mm decrease the kerf width in the settings by 1 mm Virtual Burner Height correction When cutting a bevelled chamfer the cutting head will mo...

Страница 99: ...ll be printed or punched by the marking unit It is also important that the oscillation correction has already been carried out for htis cutting process If this has not been done it will affect the mea...

Страница 100: ...Appendix C Software Messages Notifications and Errors Software Messages i i i i i...

Страница 101: ...tor error check the other errors if this error appears again contact HGG 003 000 006 Invalid Pmac motor status received for motor named named status Check the named motor see chapter 10 of this append...

Страница 102: ...4 bit addresses 48 bit address starts with 4 or C 003 000 034 Pmac error aborting gather 003 000 035 Invalid Pmac motor speed count received named 003 000 036 Home offset named out of bounds 8388608 8...

Страница 103: ...l 003 003 003 Overrule safety disabled automatic Laser Measurement System 003 017 001 Keyence settings loaded Messages marked with are notifications not errors Messages marked with are connection erro...

Страница 104: ...t module error code code 003 029 010 named module slot 2 error SM Universal Encoder Plus module error code code 003 029 011 named module slot 3 error SM EZMotion Module error code code 003 029 012 nam...

Страница 105: ...l of com port number failed 003 033 004 ReaDriver Setting callback function for data reception on com port number failed These are communication problems between the printer controller and the driver...

Страница 106: ...not found and the default value will be used If another value is desired make a note if the setting and value named and contact HGG 005 000 002 Setting not found named setting default value also not f...

Страница 107: ...Close the door before continuing 005 003 007 Error resetting emergency stop Try again if the problem persists contact HGG 005 003 008 Emergency stop successfully reset Notification Main Drive Rotatio...

Страница 108: ...e software configuration problems which should no longer occur If they do contact HGG 005 014 009 Main Drive Clamping CNC invalid axis configuration 005 014 010 Main Drive Clamping cylinder out timeou...

Страница 109: ...a software defined region If you wish to move the trolley in this area activate the safety and be careful or first move the cutting trolley to the top position 005 018 007 Cutting Trolley Longitudinal...

Страница 110: ...et time limit This could just be the distance that must be travelled try again 005 026 002 Timeout cutting trolley height to pipe 005 026 003 Timeout cutting trolley height to float 005 026 004 Timeou...

Страница 111: ...pipe has caused the sensor arm to jump Check the pipe and try again 005 026 020 Cutting trolley height error following pipe contour positive deviation too big 005 026 021 Cutting trolley height error...

Страница 112: ...issing check path save as in the correct format 005 033 004 Error starting ProCalc2 named error Failed to calculate check path If the error persists contact HGG 005 033 005 Timeout calculating data fi...

Страница 113: ...chine is not homed Home the machine axes and try again 005 033 025 Error calculating data file diameter named value too big max named value The diameter of the pipe in the file is too big for the mach...

Страница 114: ...tact HGG 005 033 038 Error loading angle file named file 005 033 039 Incompatible angle file version V version number 005 033 040 Error loading data file information from named data file Check the dat...

Страница 115: ...es 005 049 001 Timeout moving named axis Try again 005 049 002 Unable to move named axis when infeed end switch found material Material has been detected by the sensor Movement has been blocked as a s...

Страница 116: ...timeout It took too long to ignite the main arc try again 005 052 011 Timeout moving to pipe Try again Material Length Measurement 005 053 002 Theoretical stock item length too short to do material le...

Страница 117: ...own It has taken too long for the marking unit to reach its position Check that it is not blocked try again 005 058 002 Timeout moving REA inkjet marker up Main Drive Clamping SPC 1500 3000 005 059 00...

Страница 118: ...bogie s to reach the top or bottom Check that nothing is obstructing movement and try again 005 069 005 Timeout for moving Roller Bed Bogie numbered bogie Height to bottom position Roller Bed hydrauli...

Страница 119: ...omatic functions stopped and blocked Reset light screen to resume automatic functions 005 076 011 Automatic functions can only be used when all axes have been homed Home all axes on the material handl...

Страница 120: ...r Height at bottom position 005 080 004 Timeout for moving Diabolo Conveyor Height to top position It has taken too long for the diabolo conveyor to reach its top or bottom position Check for blockage...

Страница 121: ...CHR Cutting Head Rotation CTL Cutting Trolley Longitudinal CTH Cutting Trolley Height MDR Main Drive Rotation MDL Main Drive Longitudinal MDH Main Drive Height MDT Main Drive Transversal SPC 500 1200...

Страница 122: ...s move such as the cable chains Keep in mind the disconnection or short circuit might not be present all the time Replace the motor MDR CTL CTH and MDH motors The M Ax drives have the following four s...

Страница 123: ...Green Drive healthy None of the LED s are turned on The amplifier probably has no main power Check the automatic fuse F6 below the amplifier Check the main power to the amplifier this should be 3 x 1...

Страница 124: ...ly or there is a defect in the motor or cables Check the motor as described in chapter 10 Check to see if the motor is blocked as described in chapter 11 The error occurs when the motor is running The...

Страница 125: ...e cutting head Normally the end switches detect the positions cable chain fully wound or cable chain fully unwound If the cable chain does not wind up properly you will get a CHR end switch error Cutt...

Страница 126: ...witch is not pressed Check the end switch power supply P 24V PGND Check the cabling of the end switches for short circuits Check the functioning of the end switch with a multimeter Double end switch m...

Страница 127: ...ad Tilt axis home error The CHT axis has one home switch at the back of the cutting head rotate the cutting head to the 180 position for good access to the home switch During the homing process first...

Страница 128: ...0 to 25 The home flag should change from top to bottom The system must rotate absolutely freely it may not come in contact with any parts of the cutting arm other than the sensor pin spring and beari...

Страница 129: ...y stop button pressed message The emergency system consists of an emergency relay that is activated by the computer and can be deactivated by one of the emergency buttons All emergency buttons are pla...

Страница 130: ...CNC servomotor SPC 500 1200 main drive unit These machines use a hydraulic height adjustable main drive that can be controlled using the remote control or the buttons on the main drive unit A separat...

Страница 131: ...he pipe clamped in the chuck is forced up or down during rotation because it was not clamped properly or if the pipe trolley or chuck height was not set properly the pipe might move in the jaws of the...

Страница 132: ...above is correct you may assume the encoder signal is correct Encoder failure If the encoder signal does not change when the motor moves there must be an encoder failure If you have problems with seve...

Страница 133: ...k the O 5V and OGND in the encoder box Compare the voltage on the encoder lines in the control unit and the encoder box are they the same Check the encoder signal status as described below Check the f...

Страница 134: ...the amplifier does not show a resolver break signal you may assume the resolver is okay Check the resolver on the disconnected resolver connector of the amplifier Check to see if one of the resolver s...

Страница 135: ...f a rotating coil and a fixed magnet Check the motor signals on the disconnected motor connector of the DC line driver Check to see if the motor fuses are okay Check to see if one of the motor cables...

Страница 136: ...eck the front of the main drive unit for failures while the chuck is rotating at the slider contacts Check the main bearing of the chuck Check to see if the gearbox shaft and or pinion are touching th...

Страница 137: ...see if the motor runs without the gearbox Check to see if you can easily rotate the input shaft of the gearbox CHR motor The CHR motor has a low backlash gearbox at low temperatures the grease may bec...

Страница 138: ...k in front of the clamping motor Open the gearbox and check for wear and damage Remove the MDC motor Check to see if the motor is running without the gearbox Check to see if you can manually rotate th...

Страница 139: ...Appendix D Software Restore Software Restore...

Страница 140: ...ent to make sure that all efforts have been made to restore the system without using the USB stick Software locations All the necessary software needed to configure your machine can be found in the So...

Страница 141: ...be found in the folder IM nnn W7 FPC 7300_ version the folder will be named according to the computer on your machine FPC 7100 FPC 7300 or FPC 7700 ProCAM software The latest version of ProCAM can be...

Страница 142: ...AD software for the ProCAM connections with AutoCAD and or Tekla Structures is installed on your machine there will also be a folder present with the most recent version of this software NOTE upgradin...

Страница 143: ...puters a 4Gb USB key should suffice This chapter assumes that a 16Gb key is being used the process is the same for a 4Gb key Download the latest version of the necessary software Snapshot and image fr...

Страница 144: ...he drop down menu select Restore Master Boot Record Confirm the deletion of data Yes Snapshot will confirm succesful restoration of the MBR OK Select the USB key and press Next Confirm the overwrite o...

Страница 145: ...You may see the following warning stating that the disk is not bootable You can ignore this warning Rename the USB key The USB key should now contain the data shown below Firstly rename the USB key w...

Страница 146: ...n that you downloaded to the 02_UPC folder on the USB drive A change log is included in the UPC folder this contains information on the changes since the last version The minimum version of the ProCAM...

Страница 147: ...e_Settings folder ProCAD connection and manuals If you have ProCAD connection software for either AutoCAD or Tekla Structures copy the installer to the the 05_CAD_Connection folder on the USB drive Fi...

Страница 148: ...SPC machines If the computer itself is replaced it will also be necessary to alter some BIOS settings before you begin The procedure for changing the BIOS settings and the order of the boot devices i...

Страница 149: ...Win7PE will now be booted wait until Windows has started up and you see this screen Double click on the Snapshot icon to start Snapshot Press Restore Disk from File Software Restore SOFTWARE RESTORE...

Страница 150: ...Next to restore the image Any existing partitions on the disk to be restored need to be deleted before restoring the image Right click on the partition and from the drop down menu select Delete Partit...

Страница 151: ...aster Boot Record Confirm that you want restore the master boot record press Yes When successful you will see the confirmation window press OK Now select the drive to which you wish to restore the ima...

Страница 152: ...sizes of the hard drives If this happens NEVER RESIZE THE PARTITION This will cause problems when using Windows 7 it will fail to boot and display the following screen If this happens follow the inst...

Страница 153: ...ware The following step is to install the UPC machine software Start the UPC installer from the USB drive in folder 02_UPC Follow the instructions Choose a language for the installation wizard Yes Sof...

Страница 154: ...Software Restore SOFTWARE RESTORE...

Страница 155: ...folder you will find a backup file of your settings see Software locations at the beginning of this appendix Alternatively you may have already made your own backup file or files previously Browse to...

Страница 156: ...tware The final step is to install the ProCAM software Start the ProCAM installer from the USB drive in folder 03_ProCAM Follow the instructions Choose a language for the installation wizard Software...

Страница 157: ...is ready to use If you experience any further problems please contact the HGG service department HGG opening hours Monday to Friday from 08 00 17 00 local time Phone 31 227 50 40 30 Fax 31 227 50 19...

Страница 158: ...ngs FPC 7100 Go to the BIOS setup and select the Advanced tab Select the Power Configuration and press Enter Change Restore on AC Power Loss to Power ON Press F10 save and exit Software Restore SOFTWA...

Страница 159: ...nd press Enter Select the USB 2 0 Controller Mode Set to HiSpeed and press F10 save and exit You can now exit the BIOS Setup and procede to restore the hard disk as described earlier in this appendix...

Страница 160: ...s and press Enter to select a sub menu When you have made the changes press F10 save and exit SuperIO Configuration Set PWRON After PWR Fail to Power ON This is to make sure the computer boots when th...

Страница 161: ...ay Device to CRT DVI This will enable video output on the VGA and DVI ports USB Configuration Set Flat Panel Type to 1280x1024 This will give the optimal screen resolution in Windows You can now exit...

Страница 162: ...d tab Select the F81866 Super IO Configuration and press Enter Change the Power On After Power Fail to Power On You can now exit the BIOS Setup and procede to restore the hard disk as described earlie...

Страница 163: ...Appendix E Cutting Quality Cutting Quality...

Страница 164: ...correct nozzle clearance the preheat flames should not be more than 2 centimeters 1 inch above the top surface of the work 5 Nozzle too near surface When the nozzle is too low part of the preheat fla...

Страница 165: ...Replace nozzle High speed dross Narrow kerf Slanted or S shaped lag lines Small hard bead or roughness along bottom edge of cut difficult to remove Speed too fast Current too low Torch too far from ma...

Страница 166: ...Appendix F Terminology Terminology...

Страница 167: ...g head or collisions which could damage parts of the machine Pipe position The Pipe position is the position of the cutting trolley prior to cutting The torch will be at the set burner height Float po...

Страница 168: ...al profile the tube diameter refers to the actual outside diameter of the cylinder Chuck Mechanical rotating ring in the main drive that contains gripping jaws Main drive Houses and controls the rotat...

Страница 169: ...SPC Operators Manual Pipe Profiling Machines SPC 500 1200 PT HGG Profiling Equipment www hgg group com...

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