Manual Müller

OPERATING MANUAL
FOR THE
PIPE PROFILE CUTTING
MACHINE
Type:
RB 650/1200 EL AGD
MÜLLER OPLADEN GmbH
Stauffenbergstrasse 14-20
51379 Leverkusen-OPLADEN
GERMANY
1
1 . Overview of the Operation Manual
1.
Overview of the Operating Manual
1.1.
Operating instructions
2.
General safety instructions
3.
Machine description
4.
Transport and storage
5.
Installation and commissioning, disassembly
6.
Operating instructions
7.
Functions of operation control keys of the computer
8.
Examples of pipe cuts
9.
Programming of user cuts
10.
Operation commands of the machine
11.
Setting and checking the pendulation axis
12.
Test program
13.
Loading of additional cutting programs
14.
Cutting equipment of the machines
1.2.
Documentation of the machine
15.
Maintenance
16.
Spare Parts
17.
Technical drawings
18.
Instruction manuals subcontractors
2
1 . Overview of the Operation Manual
1.
Overview of the documentation
1.1.
Operating instructions
1.2.
Documentation of the machine
3
1 . Overview of the Operation Manual
1.
Overview of the Operation Manual
The documentation on the pipe cutting machine consists of two parts
• Operating instructions
• Machine documentation
1.1. Operating instructions
The operating instructions provide you with all information necessary
for operation of the machine.
The operating instructions are directed at:
• the owner of the pipe cutting machine and those responsible to him.
• the operating personnel who operate and service the pipe
cutting machine.
Read these operating instructions before you carry out any work on or
with the machine.
These operating instructions contain important instructions for you for
the safe operation of the pipe cutting machine. Read and follow these
safety instructions.
Should you have any questions concerning these operating instructions
or the pipe cutting machine, please contact the following address:
MÜLLER OPLADEN GmbH
Stauffenbergstr. 14-20
51379 Leverkusen-OPLADEN
Tel. 02171-766230
Fax 02171-766255
4
1 . Overview of the Operation Manual
Symbols used in these instructions
In these operating instructions some symbols are used which will
help you to find information in the instructions more quickly.
Important: Indicates texts which are particularly important
• for understanding of the installation
• for optimum operation of the installation.
Î
Indicates activities to be performed (instructions for action).
In addition, you will find warning and safety symbols at many points.
They are described in Chapter 2 in the paragraph entitled ?Safety symbols?.
Reference to the installation documentation
At many points in the operating instructions reference is made to instructions and information for manufacturers of components for the
pipe cutting installation. You will find these documents in the installation documentation.
1.2.
Documentation of the machine
The machine documentation is intended for specially trained and
qualified personnel only (maintenance and service personnel, programmers). The machine documentation contains detailed technical
information:
• circuit and function diagrams for the electrical equipment;
• documentation on programming of the pipe cutting machine
• technical drawings and parts lists for assemblies and
individual parts are included in the machine
documentation book
5
1.1. Operating instructions
1.1.
OPERATING INSTRUCTIONS
6
1.1. Operating instructions
1.1.
Operating instructions
2. General safety instructions
3. Machine description
4. Transport and storage
5. Installation and commissioning, disassembly
6. Operating instructions
7. Functions of operation control keys of the computer
8. Examples of pipe cuts
9. Programming of user cuts
10. Control panels
11. Setting and checking the pendulation axis
12. Test program
13. Loading of additional cutting programs
14. Cutting equipment of the machines
.
7
2 . General safety instructions
2.
General safety instructions
2.1.
Warning instructions and symbols
2.2.
Principle; appropriate use
2.3.
Organisational measures
2.4.
Personnel selection and qualification, basic obligations
2.5.
Safety instructions for particular operating phases
2.5.1. Normal operation
2.5.2. Special work
2.5.3. Maintenance activities
Fault elimination during work sequence/disposal
2.6.
Instructions regarding special types of hazards
2.6.1. Electrical energy
2.6.2. Gas, dust, steam, smoke
2.6.3. Hydraulic and pneumatic equipment
2.6.4. Noise
2.6.5. Oil, grease and other chemical substances
2.7.
Safety facilities
2.8.
Exclusion of liability
8
2 . General safety instructions
2. General safety instructions
2.1. Warning instructions and symbols
In the operating instructions the following designations or signs are used for
particularly important information:
IMPORTANT Special information regarding the economic use of the
machine/installation.
WARNING Special information or orders/prohibitions for the
prevention of damage.
DANGER Information or orders/prohibitions for the prevention
of injury to persons or extensive damage to property.
2.2.
Principle; appropriate use
•
The machine/installation is constructed using state of the art technology and in accordance with recognized safety regulations. Nevertheless,
use of the machine/installation may result in danger to life and limb of
the user or of a third party, or in impairment of the machine or other
physical assets.
•
Use the machine/installation in perfect working order only, appropriately and in a safety and hazard-conscious manner, and in compliance
with the operating instructions! In particular, eliminate immediately any
malfunctions which may impair safety (or have them eliminated)!
9
2. General safety instructions
2.3. Organisational measures
•
The operating instructions must be kept available (in the tool box or in
the specially provided container) at all times at the place where the machine/installation is in use !
•
Observe and instruct others to observe general statutory and other
obligatory regulations relating to accident prevention and environmental
protection in addition to those included in these operating instructions!
•
Such obligations may relate, for example, to the handling of hazardous
materials or the provision/wearing of personal protection equipment or
to road traffic regulations.
•
Supplement the operating instructions with instructions and information,
including supervising and reporting obligations, in order to take special
operating conditions into consideration, e.g. relating to organization of
work, working procedures, operating personnel.
•
Personnel assigned to working with the machine must have read the operating instructions, and in particular the Chapter „Safety instructions“,
before taking up work. It is too late to do so when actually carrying out
the work. This applies in particular to personnel who work only occasionally on/with the machine, e.g. doing setting-up or maintenance work.
•
Check at least occasionally that personnel work in a safety and hazardconscious manner and in compliance with the operating instructions!
•
Personnel must not wear loose clothing, jewellery including rings or long
hair loose. Injury may occur, for example, by being caught or drawn into
the mechanism.
•
Personal protective clothing must be worn as necessary or as required by
regulations!
•
Observe all safety and hazard information on the machine/installation!
10
2. General safety instructions
•
All safety and hazard information at/on the machine/installation must
be kept complete and legible!
•
In the event of changes in the machine/installation or in its operating
behaviour, which are relevant to safety, stop the machine/installation
immediately and report the malfunction to the authority/person responsible!
•
Modifications, additions to and conversions of the machine/installation
which may impair safety in any way must not be carried out without the
consent of the supplier! This also applies to the installation and adjustment of safety devices and valves as well as to the performing of welds
on load bearing parts.
•
Spare parts must comply with the technical requirements specified by the
manufacturers. This is always ensured when genuine spare parts are used.
•
Do not carry out any program changes (software) to the programmable
control systems!
•
Replace gas tubing at the specified or appropriate intervals even if no defects relevant to safety are visible!
•
Observe prescribed deadlines or those specified in the operating instructions for routine checks/inspections!
•
Suitable workshop equipment and tools are essential for carrying out
servicing work!
•
Make known the location of fire extinguishers and how to operate them!
•
Note fire alarms and fire fighting possibilities!
11
2. General safety instructions
2.4. Personal selection and qualifications; basic obligations
• Work on/with the machine/installation may be carried out by reliable personnel only. The minimum, legally permissible age must be observed!
• Assign only trained or instructed personnel. Clearly establish the responsibilities of the assigned personnel for operating, setting-up, maintenance
and servicing!
• Ensure that assigned personnel only work on/with the machine!
• Appoint the machinist and establish his responsibilities, also with respect
to traffic regulations, and permit him to refuse any instructions from third
parties which are detrimental to safety!
• Trainees, apprentices and personnel still receiving instruction or general
schooling are only allowed to work on the machine/installation under the
constant supervision of an experienced person!
• Work on the electrical equipment of the machine/installation may only be
carried out by qualified electricians or by instructed persons under the
guidance and supervision of a qualified electrician and in compliance with
electronic regulations!
• Work on gas equipment (gas consuming facilities) may only be carried out
by suitably qualified personnel!
• Work on hydraulic equipment may only be carried out by experienced personnel with specialist knowledge of hydraulic systems.!
12
2. General safety instructions
2.5.
Safety instructions for particular operating phases
2.5.1. Normal operation
• Avoid any mode of operation which could be detrimental to safety!
• Take measures to ensure that the machine is only operated in a safe and
operational condition!
Only operate the machine when all protective devices and safety-relevant
equipment, e.g. movable protective devices, emergency-stop devices,
sound absorbers and exhausting devices are fitted and operational!
• Check the machine/installation at least once per shift for externally visible
damage and defects! Report any changes (including any changes in operating behaviour) to the responsible authority/person immediately! If necessary, shut down the machine immediately and secure it!
• If malfunctions occur, shut down the machine/installation immediately
and secure! Eliminate malfunctions immediately (or have them eliminated)!
• Observe starting and shutdown cycles and control displays in accordance
with the operating instructions!
• Before starting up the machine/installation or putting it into operation, ensure that the machine start-up cannot endanger anyone!
• The selector switch must be in the „Normal operation“ position and
locked!
• Do not switch off or remove exhausting or venting devices while the machine/installation is running!
13
2. General safety instructions
2.5.2. Special work related to use of the machine/installation
• Adjustment, maintenance and inspection activities and inspection deadlines including specifications concerning replacement of parts/assemblies prescribed in
the operating instructions must be observed! Such activities may only be carried
out by trained personnel.
• Inform operating personnel before carrying out any special or maintenance
work! Appoint a supervisor!
• For all work concerning the operation, production adjustment, modification or
setting of the machine/installation and its safety-relevant devices as well as inspection, maintenance and repair, observe the starting and shutdown cycles in
accordance with the operating instructions and the instructions relating to maintenance work!
2.5.3. Maintenance activities and fault elimination during the work sequence; disposal
• If necessary, make safe a wide area around the maintenance zone!
• If the machine/installation is completely shut down to carry out maintenance
and repair work, it must be secured against unintentional restarting: lock the
main command facilities and withdraw the key and/or affix a warning sign to
the main switch.
• Individual parts and larger assemblies must be carefully fastened to lifting
equipment and secured when being replaced, so that they will not present any
danger. Use only suitable and technically perfect lifting equipment as well as
load handling attachments with sufficient working load! Do not work or stay
under suspended loads!
• Assign only experienced personnel to sling loads and wave instructions to the
crane drivers! The banks man must remain within view of the operator and be
in vocal contact with him.
14
2. General safety instructions
• For overhead erection work, use only the climbing aids and work platforms
provided or other suitably safe ones.
• Do not use machine parts as climbing aids! When carrying out maintenance
work at a great height, wear fall protection devices! Keep all handles, steps,
handrails, platforms and ladders free of dirt, snow and ice!
• Clean the machine/installation, and in particular the connections and screwed
joints, of oil, fuel or preserving agents when starting maintenance/repair work!
No not use aggressive cleaning agents! Use non-fibrous cleaning cloths!
• After cleaning, remove all covers/adhesives completely!
• After cleaning, check all fuel, motor oil and hydraulic oil lines for leaks, loose
connections, chafing and other damage! Eliminate any defects immediately!
• When carrying out maintenance and servicing work, always tighten any loose
screwed joints!
• If it is necessary to disassemble safety devices during setting-up, maintenance or
cleaning work, they must be reassembled and checked immediately after the
maintenance and repair work has been completed.!
• Ensure that operating and auxiliary materials as well as spare parts are disposed
of in a safe and environmentally sound way!
15
2. General safety instructions
2.6.
Instructions regarding special kinds of hazards
2.6.1. Electrical energy
• Use only genuine fuse links with specified amperage! Shut down the machine/installation immediately if there is a fault in the electrical power supply!
• Work on electrical installation or equipment may only be carried out by a qualified electrician or by instructed persons under the guidance and supervision of
a qualified electrician and in compliance with electronic regulations.
• If inspection, maintenance and repair work is to be carried out on machine and
installation parts, these must be isolated (if prescribed by regulations). First verify the safe isolation of the parts from the supply, then earth and short-circuit
and isolate other neighbouring, live parts.
• Carry out regular inspections/checks on the electrical equipment of the machine/installation! Any defects such as loose connections or scorched cables
must be eliminated immediately.
• If work has to be carried out on live parts, a second person must be available in
order to actuate the emergency-stop button or mains switch for voltage disconnection in an emergency. Cordon off the work area with a red-and-white safety
chain and warning sign. Use only insulated tools!
• For work on high-voltage assemblies, after isolating the voltage connect the
supply cable to ground and, with an earth rod, short-circuit the components,
e.g. the capacitors!
16
2. General safety instructions
2.6.2. Gas, dust, steam, smoke
•
Welding, cutting and grinding work on the machine/installation may only be
carried out if explicitly approved, e.g. there may be a risk of fire or explosion!
•
Before doing any welding, cutting or grinding work, clean the machine/installation and its surroundings of dust and combustible materials
and ensure there is sufficient ventilation (danger of explosion)!
•
For work in confined spaces, observe relevant national regulations, if any!
2.6.3. Hydraulic and pneumatic equipment
•
Work on hydraulic equipment may only be carried out by persons with
specialist knowledge and experience of hydraulic systems!
•
Check all lines, hose lines and screwed joints regularly for leaks and externally visible damage! Eliminate any damage immediately! Squirting oil may
cause injuries and fires.
•
Before commencing the repair work, depressurise any sections of the system
and pressure lines to be opened (hydraulic lines, compressed air lines) in accordance with the system descriptions.!
•
Hydraulic and compressed air lines must be properly laid and fitted.! Do not
confuse connections! Valves and fittings as well as length and quality of the
hose lines must meet the requirements.
2.6.4. Noise
•
The prescribed personal ear muffs must be worn!
17
2. General safety instructions
2.6.5. Oil, grease and other chemical substances
•
When handling oil, grease and other chemical substances, the safety regulations applying to the product must be observed!
•
Exercise caution when handling hot operating and auxiliary materials (danger
of burns and scalds)!
2.7.
Safety facilities
•
The safety facilities are for your protection. Do not work with the pipe cutting machine unless all safety facilities are in proper working order.
If you notice any damage to, or malfunctioning of, the safety facilities, have
these eliminated immediately by qualified personnel.
•
EMERGENCY STOP switch
Each EMERGENCY STOP switch shuts down the installation
(see „EMERGENCY STOP switch“ section)
The installation is not, however, de-energized!
•
Fence along the longitudinal feed facility
•
Covers for the drives
2.8.
Exclusion of liability
•
Messrs. Müller assume no liability for damage caused as a result of:
- Improper handling of the installation or sections thereof during
transport, warehousing, erection, operation, maintenance etc.
- Inappropriate operation of the installation.
- Non-observance of the safety instructions.
- The use of spare parts and accessories which had not been explicitly
approved and supplied by Messrs. Müller.
18
3. Machine description
3.
Machine description
3.1.
Description of the machines
3.2.
Technical data
19
3. Machine description
3.1. Description of the machines
The pipe cutting machines comprise:
I
Pipe chuck with
a) Main drive
b) Pneumatic clamping mechanism
(supplied on request)
II
Torch carriage guide with
a) Energy crawler
III
Torch carriage with
a) Drive
b) Control panel
c) Azimuth pendulation
(option)
d) Electromotive pendulation point adjustment
e) Electromotive torch vertical adjustment
f) Sensor control (height control)
(supplied as an extra)
IV
Rail for pipe support carriage
V
Pipe support carriage
20
3. Machine description
VI
Control cabinet with
a) Amplifiers
b) Electronic controls
c) Length measuring attachment
21
3. Machine description
3.2.
Technical ca. data of the machine RB 650/1200 EL AGD
installation space in length, width, height:................................ mm............................about 12,000 x 4,000 x 2,500
inch ...........................about 551 x 157 x 98
gross weight:.................................................................................. kg ..............................about 8,000
clamping through the chuck: ..................................................... mm (inch) ................80 (3.15“) - 650 (25.6“)
clamping on the chuck: .............................................................. mm (inch) ................650 (25.6“)- 1,220 (48“)
diameter range of pendulation:................................................... mm (inch) ................80 (3.15“)- 1,220 (48“)
inclination of the pendulation for the weld bevel: .................. degrees .....................+ 70o up to – 70o
torch rotation: ............................................................................... degrees .....................360o
min. cutting range in front of the chuck:* ............................... mm (inch) ................700 (27.6“)
max. cutting range in front of the chuck:* .............................. mm (inch) ................8,000 (315“)
min. cutting range behind the chuck:* ..................................... mm (inch) ................1,350 (53.15“)
max. cutting range behind the chuck:* .................................... mm (inch) ................2,300 (90.5“)
measuring point starts in front of the chuck jaws
min. wall thickness for flame cutting:*...................................... mm (inch) ................5 (0.19”)
max. wall thickness for flame cutting:* ..................................... mm (inch) ................90 (3.5”)
chuck rotation speed in position 'manual': .............................. r.p.m .........................0 - 4.0
torch carriage speed in position 'manual': ............................... mm/min. .................0 - 1,400
inch/min..................0 - 55.12
max. static radial load in the chuck: .......................................... N ...............................20,000
max. litting torque in the chuck: ............................................... Nm............................20,000
max. torque in the chuck: ........................................................... Nm............................6,000
max. radial load of the pipe support carriage
for ∅ 80 (3.15“) - 1,220 (48“)mm: ............................................ N ...............................75,000
power supply in accordance with DIN IEC 38:...................... volts ..........................400
other power supply alternatives on request
hertz..........................50
phase.........................3, AC
kVA ..........................7,5
main voltage fluctuations in accordance with DIN IEC 38:. % ..............................+ 6/- 10
main frequency fluctuations........................................................ hertz: .......................+ 1.5
admissible temperature range: ................................................................................ oC (°F) ......................5 up to 40 (41 up to 104)
computer:....................................................................................... PC .............................IBM compatible
gases: .............................................................................................. oxygen/acetylene, other gases on request
oxygen: ........................................................................................... 8-8.2 kg/cm2, purity 99.4% - 18,000 l/h
propane: ......................................................................................... 0.2-0.25 kg/cm2, purity 98% - 1,700 l/h
*: at vertical position of the torch
22
4. Transport and storage
4.
Transport and storage
4.1.
Transport
4.2.
Storage
23
4. Transport and storage
4.
Transport and storage
4.1.
Transport
Damage to parts of the installation
Improper transport and improper storage may cause damage to the installation parts.
• Transport the parts only in compliance with the instructions given by MÜLLER
OPLADEN personnel.
• Observe the transport and storage instructions on the transport cases.
Lifting of installation parts
Many parts of the installation are very heavy. Always use suitable transport and load
lifting equipment.
Always lift the parts or cases at the anchoring points or by the suspension lugs provided.
Observe markings indicating the centre of gravity.
Secure the parts carefully against slipping or falling.
4.2. Storage
Storage location specifications
All installation parts and components must be stored in compliance with the regulations and specifications of MÜLLER OPLADEN.
For these specifications, please see the technical description of your installation.
In particular, the storage location must fulfil the following requirements:
• Dry
• Level floor
• Temperature: 0 to 40 °C
• Relative humidity: 10% to 90%
24
5. Installation and commissioning, disassembly
5.
Installation and commissioning, disassembly
5.1.
Ambient conditions
5.2.
Disassembly
25
5. Installation and commissioning, disassembly
5. Installation and commissioning, disassembly
Installation and initial commissioning of the pipe cutting machine require specialist
knowledge and know-how. The pipe cutting machine may therefore only be installed and commissioned under the supervision of and on the instructions of
MÜLLER OPLADEN personnel.
Do not attempt to install or fit parts of the machine without the relevant instructions.
5.1. Ambient conditions
See Chapter 3.2. „ Technical Data “
5.2. Disassembly
The profile cutting machine is designed for stationary operation at the original
place of installation.
To disassemble the machine, specialists from MÜLLER OPLADEN must be
called in.
26
6. Operating instructions
6. Operating instructions
6.1.
Starting / Switching off
6.2.
Pipe clamping
6.2.1. Pneumatic chuck clamping device
6.3.
Adjusting the variable bevelling point
6.4.
Program selection
6.4.1. Loading the program
6.4.2. Cutting parameter input
6.5.
Torch carriage positioning
6.6.
Chuck positioning
6.7.
Changing the cutting speed
6.8.
Operating the machine when standard cuts are being carried out
6.9.
Operating the machine when offshore cuts are being carried out
6.10.
End of cut
6.11.
Reset
27
6. Operating instructions
6.1.
Starting
Put the mains switch (of mains supply) on
Switch on control voltage
(18)
Switching off the machine
Activate the push button ‚EMERGENCY OFF‘ (14), (94)
When using heating or cooling devices, the main switch
of the line must not be turned off!
28
6. Operating instructions
6.2. Pipe clamping
Set height of roller carriage according to the scale.
Move the diameter adjustment on the torch carriage sufficiently far
upwards or push the torch carriage out of the working area (by means
of the switches (107) or (77) and push-button switch Ø (78) to the
left respectively).
Manual clamping:
Set switch (92) (on the chuck) to position “manual” (right), clamping
can now be carried out with the key.
Pneumatic clamping:
(supplied on request)
Set switch (92) (on the chuck) to position “automatic” (left).
For the remaining operation sequence see 6.2.1.
After clamping, move the lever and the switch (92) into the central position, since the activation of the chuck is otherwise blocked. Switching
on is subject to a time delay.
Operation sequence:
Regulator lock, coupling interlock, compressed air input.
An indicator lamp (65) and (93) is lit on the control panel and respectively on the chuck while the switch (92) is activated.
29
6. Operating instructions
6.2.1. Pneumatic chuck clamping device (option)
30
6. Operating instructions
Operating instruction:
Open compressed-air connection at the machine.
Check maintenance unit for prescribed working pressure which has to
be set at 6 bar max.
1.
Clamping through the chuck
Clamping: pressure regulator I has to be adjusted at 3 bar working pressure
Releasing: pressure regulator II has to be adjusted at 5 bar working pressure
2.
Clamping on the chuck
Clamping: pressure regulator I has to be adjusted at 5 bar working pressure
Releasing: pressure regulator II has to be adjusted at 3 bar working pressure
Note: alteration or exchange of the values can lead to jamming
the chuck
31
6. Operating instructions
6.3. Adjusting the variable bevelling point
Move the switch (77) into the neutral position.
Next activate the switch Ø (78) according to the direction ↑↓
Version with height adjustment
The machine is set to the respective pipe as follows:
The pointer of the scale at the column is manually set to the value di/2.
After that the wall thickness (depending on the application – see cutting examples in chapter 5) is set at the scale of the height adjustment
device by means of the hand wheel. The height adjustment arm is put
onto the pipe and the automatic height adjustment is switched on by
means of switch (77) on the control panel. Now the pendulation point
is automatically adjusted to the inside diameter of the pipe, i.e. although
during the cutting process the outer surface of the pipe is controlled by
means of the height adjustment, the reference point for the bevel pendulation remains unchanged.
The vertical sensor can however not detect differences in height due to
increased wall thickness at weld seams. In order to avoid incorrect cuts
here the sensor must be switched off in the vicinity of the weld seam.
This is achieved with the machine as follows:
When the values of the parameters are being entered, the maximum
width of the weld seam must be entered when ‚SW‘ is prompted. Before cutting starts, the pipe is turned so that the centre of the longitudinal seam is under the torch.
When switch (75) is operated and this button lights up, this position is
programmed. During the flame cutting the sensor then switches off in
this area i.e. the last diameter sensored is retained until the sensor
switches on again after the weld seam has been passed. (Lamp (75) on,
via „INS“ the area can also be indicated: „DEL“ = off)
32
6. Operating instructions
It is possible to lower or raise the sensor arm partly automatically
(switch (77) in the left position), activation of switch (78) depending on
the direction of the movement to the left or right respectively. (Interruption of this process by switch (77) in neutral position). The red signal lamp (76) comes on. It indicates to the operator that the sensor arm
is not in the correct position. It is then necessary to turn switch (77) to
automatic after moving the arm. The vertical sensor is now switched
off as for a hole.
Note: Lowering only with sensor arm in operating position, because otherwise a collision between the torch arm and the pipe
might occur.
33
6. Operating instructions
6.4.
Program selection
The following cuts are available:
(* = supplied as standard)
1. Saddle cuts
* Concentric, constant kappa
* Eccentric, constant kappa
Concentric, kappa = ½ dihedral angle
Eccentric, kappa = ½ dihedral angle
Concentric, variable kappa
Eccentric, variable kappa
Concentric, constant volume
Eccentric, constant volume
2. Cut-outs
* Concentric, constant kappa
* Eccentric, constant kappa
Concentric, constant volume
Eccentric, constant volume
double mitre (cut-out)
double mitre with radius
double mitre (Hamacher)
3. Mitre cuts
* single, constant kappa
double, constant kappa
single, with constant height
double, with constant height
double with radius
double (Hamacher)
34
6. Operating instructions
4. Offshore cuts (saddles)
Concentric, High. Fab.
Eccentric, High. Fab.
Concentric, UK
Eccentric, UK
Concentric, Norway
Eccentric, Norway
Concentric, Belleli (flexible contact line and variable
welding bevel opening angle)
Eccentric, Belleli
(flexible contact line and variable
welding bevel opening angle)
on plate, UK
5. Special cuts
Slot with radius
Slot without radius
Slot with angle (α to centre line) and radius
Slot with angle (α to centre line) and without radius
Elbow, concentric
Elbow, eccentric
Saddle cut on cone
35
6. Operating instructions
6.4.1. Loading of the program
All switches „S“, „X“, „Y“, „<)“ (37, 47, 57, 67)
Into „0“ position.
After switching on the machine the main menu is automatically loaded.
Main menu 1 = cuts:
saddle
cut-out
mitre
saddle (offshore cuts)
help
Via „F6“ the main menu 2 is reached
Main menu 2 =
single cut
files
test programs
special cuts
help
Via the keys
a) „ALT“ and cursor →←
or
b) „ALT“ and coloured letter
the corresponding range is presented.
Via the cursor keys ↓↑ the desired program is selected and confirmed
by „CR“.
(The √ in front of the cut description means the availability of the cuts).
36
6. Operating instructions
F1 (HELP)
By means of „F1“ help masks are displayed:
1. Main menu
2. Program application
3. File (following cuts)
4. Test program
5. Test program contact line
F2 (COL)
By means of „CTRL F2“ the background colour of the main menu
can be changed
By means of „ALT F2“ the colour of the pull-down menu can be
changed
Storage of colours by means of „HELP“; „STORE OPTIONS“
F3 (DIR)
Call list of cutting sequences:
Only files in the form of „PROG *.*“ can be deleted by means of
[DEL]
(see 9.3.)
F4 (SERIES)
Start of a cutting sequence (1st cut)
(see 9.2.)
F5 (LAST)
Call of the cut last used:
This key is of advantage if the same cuts are to be done again and again.
37
6. Operating instructions
F6 (CHANGE)
Change over between the two menus
F 10/ALT
Activate entry via pull-down menu
ESC = Exit
38
6. Operating instructions
6.4.2.
Cutting parameter input
With the corresponding selection from the menu the required program
can now be called.
Via „CR“ the program is read in and started. It announces itself with its
type and designation, e.g. = saddle cut, conc. (VI.0.)
After the „CR“ key has been pressed, the computer is interrogated regarding the individual cut parameter. The computer shows the respective value contained in the memory. Via the keyboard the value is entered and confirmed with the „CR“ key.
Should a false value have been erroneously fed in, the cursor is placed
on the corresponding line and can be corrected with the input of the
new value.
After the last input (start = 1) the computer goes into the preliminary
circulation cycle. Now: chuck, torch carriage and pendulation are positioned in accordance with the values that have been fed in. Should the
values for the path „ S “ , the angle of twist „gamma“ and the initial position of the cut „phi“ are still not correct, via function key „F5“ the
positioning menu can be called and then the corresponding repositioning can be carried out.
IMPORTANT!: For positioning all switches of the control panel
must be in automatic (37, 47, 57, 67).
For record purposes the pipe and cut data can be printed out. (Activation of „F2“, „F3“). This printout is used for the computational monitoring of the cut.
To exit the program press „ESC“.
39
6. Operating instructions
6.5.
Torch carriage positioning
a) Manually
For the first cut it is recommended to position the chuck and the torch
carriage manually. To do this set switch „S“ (37) to zero. With the
switch (36) activated the carriage can be moved by hand as required. If
the displayed data for chuck and path correspond to the requirements,
the key (87) can be activated until the pilot lamp goes on, „TEACH
IN“ or „END“ key. Now the switch „S“ (37) can be set back to the
right hand position
IMPORTANT!: This manual positioning of the torch carriage is
only possible with the computer being in the cycle.
By means of the switch „0“ (34) the display „S“ (31) can be set to
„20000“ or
„30000“ (option)
b) With the computer in the positioning menu (F5)
During the message „MACHINE OK!“ it is possible either to pre-select
the position of the torch carriage after entering „S“ (path of the torch
carriage) as an absolute dimension in mm and pressing „CR“, or alternatively to pre-select the relative movement of the torch carriage referred
to the actual value of „gamma“ after entering „S - gamma“ as a relative
dimension in mm and pressing „CR“. Positive and negative values are
possible here.
40
6. Operating instructions
6.6.
Chuck positioning
a) Manually
The chuck can be adjusted with the switch “<)” (67).
After completion of the positioning, bring this switch (67) into zero
position.
The push button “0” (64) enables the setting of the display “<)” (61)
to zero.
b) With the computer in the positioning menu (F5)
During the running program and after having entered “gamma” in
degrees, the tube can be rotated by the corresponding angle in relation to
the zero line.
Enter “γ“ (gamma) in degrees and press “CR”.
Chuck blocking control
The chuck blocking control system protects the chuck drive in the case
of overloads in stop position and during low running speeds.
If this control device is activated, the propulsion of the chuck is cut off
and the red signal lamp of the push button (66) illuminates.
For release, press this push button (66) on the control panel.
41
6. Operating instructions
6.7.
Changing the cutting speed
The pre-selected speed can be changed by means of the potentiometer
„ → % “ (108).
The speed can be changed in the positioning menu (F5) by entering a
factor from 0 to 20. (Between the indicators of the control panel and the
computer display a factor 10 is contained in the program).
42
6. Operating instructions
6.8.
Operating the machine when standard cuts are being carried out
Set switch (106) to zero.
To simplify the start of the cut, hold the key (87) down until the corresponding lamp goes out. The torch carriage is now automatically moved
out of the contour by 10 mm (cut in) or press the keys „CTRL“
„END“.
If the key (87) is activated just briefly, the values which are in the
indicator „S“ will be taken over by the computer as new starting
position (TEACH IN) or the key „END“.
Switching on the gas supply
Basically when there is a voltage failure due to:
a) an “emergency stop” or a “control system off”
b) an activation of the interrupter for the limits of the movement of the
carriage on the guide way.
The valves are turned off and can only, after having been released
(move button (97) to the left), be turned on again with the switches
(97), (98) and (96) to the right hand position.
Functions of the buttons/switches
(97) Release (ignition –special type)
(97) Fuel gas / oxygen
(98) Preheating torch “ON” (special type)
(96) Plasma cutting - start
(96) Cutting oxygen
Select the required direction of cutting with the switch (106)
(start of cut)
The cut ins now executed, the torch simultaneously moving back to the
required contour. The flame cutting speed can, if required, be corrected
with the potentiometer % → (108). Observe the torch distance while
cutting (can be adjusted with switch (107) ).
43
6. Operating instructions
6.9.
Operating the machine when offshore cuts are being carried out
In the beginning proceed as described under 6.4.:
Put in the individual parameter values and effect the first cut.
After that proceed as follows:
Put the switch „automatic start – right – left“ (106) into „0“ position.
Activate push button (88) or the key „POS“.
Switching-over „a/b“ via „F6“ to cut „b“ (automatic starting of the second cut), by means of „CTRL F6“ the second cut can be started manually.
Starting is effected by means of switch (106) „right“.
The torch is now automatically executing the second chamfer cut according to AWS prescriptions Fig. 10.13 1 A detail D.
After completion of the cut reset switch (106) to „0“.
By means of „F6“ switching-over to the first cut (cut „a“) (CTRL F6“)
respectively.
By actuating push button (88) or the key „POS“ the torch is returned to
its initial position.
44
6. Operating instructions
6.10.
End of cut
Extinguish flame with switch (97), switch (96) and switch (98).
Set switch (106) into the central position.
End of cut with plasma units
Set switch (96) into central position
Set Switch (106) into central position
Switch off supply of plasma unit by means of push button (27) or direct
at plasma unit.
45
6. Operating instructions
6.11.
Reset
When activating the switch (88) or the key „POS“, the system is after
the end of the cut returned to the initial starting position.
To allow this, the switch (106) must previously be set to the position
zero.
46
7. Functions of operation control keys of computer
7. Functions of operation control keys of computer
Computer function key assignment
The function of the keys „F1“ to F12“ are listed below:
F1
Restart
New input of pipe parameters
F2
Print parameters
Printout of the most important data of the selected cut
Note:
F3
Do not run a printout while a cut is in progress, the pipe
profile cutting machine will operate out off control.
Print data
Printout of cutting coordinates (S, beta (X), chi (Y), gamma, phi
(gamma).
F4 Display of speed
The actual speed of the drives „S“ and „gamma“ is displayed.
F5 POS ON/OFF
The positioning menu is called.
Positioning is possible as follows:
S abs (absolute)
During the course of the program the position of the torch carriage can
be pre-selected after the input of „S abs“ (path of the torch carriage) in
mm and the pressing of „CR“
S rel (relative)
During the course of the program the relative movement of the torch
carriage referred to the actual value of „S“ can be pre-selected after the
input of „S rel“ in mm and the pressing of „CR“.
47
7. Functions of operation control keys of computer
Gamma γ
During the course of the program and after the input of gamma in degrees the pipe can be turned through the relevant angle in relation to the
zero line. Enter “ γ “ in degrees and press „CR“.
Phi φ
During the course of the program the pipe can be positioned corresponding to the path line after the input of phi in degrees.
Enter “ φ “ in degrees and press „CR“.
Note:
When changing “phi” the “gamma” value changes automatically. The new “phi” coordinate is not approached on
the pipe profile.
Cut-in (mm)
Possible cut-in range into the scrap part is 10 to 50 mm!
Factor v (speed)
By keying in a factor of 0 to 20 and pressing „CR“ the cutting speed can
be changed.
F6 a/b (AWS) for offshore cuts
By activation of this key a switch-over from cut „a“ to cut „b“ or vice
versa will be effected.
F7 RECORD
Storage of the called cut (pipe no. / cut no.) (See chapter 9.1.).
48
7. Functions of operation control keys of computer
F8 LOAD
Loading of a certain user program into the system (pipe no./cut no.)
(see chapter 9.2.).
Note:
After exit of the positioning menu via „ESC“ the changed parameters will only be transferred if the key (87) „TEACH IN“
or the key „END“ is activated.
49
8. Examples of pipe cuts
8.
Examples of pipe cuts
8.1.0.
Saddle cuts
8.1.0.0./0.0.0. Saddle cut placed on top
8.1.0.0./0.0.1. Saddle cut inserted
8.1.0.0./0.1.
Saddle cut, concentric, eccentric
8.1.0.0./1.0.
Saddle cut, concentric, 90°
8.1.0.0./1.1.
Saddle cut, eccentric, α = 90°
8.1.0.0./1.2.
Saddle cut, concentric, α < 90°
8.1.0.0./1.3.
Saddle cut, eccentric, α < 90°, in front of the main
pipe axis
8.1.0.0./1.4.
Saddle cut, eccentric, α < 90°, behind the main pipe
axis
8.1.0.1./0.0.
Saddle cut, AWS, U.K. cut (option)
8.1.0.1./0.1.
Saddle cut, AWS, Norway cut (option)
8.1.0.1./0.2.
Saddle cut, AWS, High Fab. Cut (option)
8.1.0.1/1.0.
Saddle cut, concentric α < 45°
8.1.0.1/1.1.
Saddle cut, eccentric α < 45°, in front of the main
pipe axis
8.1.1./0.0.
Mitre cut
8.1.1./0.1.
Double mitre (option)
50
8. Examples of pipe cuts
8.1.1./0.2.
Double mitre with constant height
8.1.1./0.3.
Double mitre cut-out
8.2.0.
Cut-outs
8.2.0./0.0.
Cut-out, eccentric (penetrating pipe inserted)
8.2.0./0.1.
Cut-out, eccentric (penetrating pipe placed on top)
8.2.0./0.2.
Cut-out, concentric, eccentric
8.2.0./0.3.
Cut-out, concentric α = 90° (pendulation point
adjustment)
8.2.0/1.0.
Cut-out, concentric
8.3.0.
Slots
8.3.0./0.0.
Slot with radius
8.3.0./0.1.
Slot without radius
51
8. Examples of pipe cuts
8.1.0. Saddle cuts
8.1.0.0./0.0.0. Saddle cut placed on top
λ
β
ϕ
ϕ
λ
β
α
The maximum angle of oscillation b max. and b min. is set to 70 degrees
during all saddle cuts.
A limit is effective if the value calculated by the computer is higher than
70 degrees
In case of saddle cuts placed on top:
Input in the computer:
Do = Do
D = Do
do = do
d = di
The oscillation point setting should be “di/2”.
a) By hand (manual)
b) automatically with height control sensor
The wall thickness is set:
a) on the scale for height scanning by hand
b) on the digital display by motor (option) to „(do-di) / 2“
52
8. Examples of pipe cuts
8.1.0.0./0.0.1.
Saddle cut inserted
β
ϕ
ϕ
α
The maximum angle of oscillation b max. an b min. is set to 70 degrees
during all saddle cuts.
A limit is effective if the value calculated by the computer is higher than
70 degrees.
In case of saddle cuts for inserted pipes:
Input in the computer:
Do = Do
D = Di
do = do
d = do
The oscillation point setting should be “do/2”.
a) by hand (manual)
b) automatically with height control sensor
The wall thickness is set:
a) on the scale for height scanning by hand
b) on the digital display by motor (option) to „0“.
53
8. Examples of pipe cuts
8.1.0.0./0.1. Saddle cut concentric, eccentric
The following formula apply
max. (ß max. = 70°)
I ψ – 90 + ß max. =
=0
II ψ – 90 + ß max. = 0;
III ψ – 90 + ß max. < 0; limit. The bevel must be finished by grinding
= local dihedral angle
ψ
ψ
Η
β
ψ
54
8. Examples of pipe cuts
8.1.0.0./0.2. Saddle cut concentric, eccentric
Possible opening angle <) k
RB Elektron with azimuth pendulation ß max. = +/- 70°
Example: with ψ = 90° and ß 0 45° is k = 45°
General formula: ψ - 90 + ß = k
180°
χ
100°+
110°+
120°+
130°+
140°+
150°+
160°+
160°
80+
90+
100+
110+
120+
130+
140+
140°
60+
70+
80+
90+
100+
110+
120+
120°
40+
50+
60+
70+
80+
90+
100+
100°
20+
30+
40+
50+
60+
70+
80+
χ45
90°
80°
0+
10+
60°
20+
30+
40+
50+
60+
0+
10+
20+
30+
40+
0+
10+
20+
50°
60°
70°
40°
20°
10°
20°
30°
40°
45°
55
8. Examples of pipe cuts
8.1.0.0./1.0. Saddle cut, concentric 90°
L = S. rel.
x = x (phi)
cut
Program
Gamma
Phi
touch
1
Alt
0°
0°
0
0°
0°
1
2
cursor→↓←↑
CR
Parameters
s,
Do,
do,
di,
α,
k,
b max.,
b min.,
sw
56
8. Examples of pipe cuts
8.1.0.0./1.1. Saddle cut, eccentric α = 90° in front of the main pipe axis
Saddle cut, eccentric α = 90° in front of the main pipe axis
Cut
1
2
Program
Alt
Cursor →↓←↑
CR
Gamma Phi
0°
0°
0°
0°
touch Parameters
0
S,
Do, do, di,α, k,
1
b max, b min, sw
-f
-f
Saddle cut, eccentric α = 90° behind the main pipe axis
Cut
1
2
Program
Alt
Cursor →↓←↑
CR
Gamma Phi
0°
0°
0°
0°
touch Parameters
0
S,
Do, do, di,α, k,
1
b max, b min, sw
+f
+f
57
8. Examples of pipe cuts
8.1.0.0./1.2. Saddle cut, concentric α < 90°
L = S. rel.
x = x (phi)
Cut
1
Program
gamma phi
180°
0°
touch
0
0°
180°
1
0°
0°
0
0°
0°
1
5
0°
180°
0
6
0°
180°
1
2
Alt
3
Cursor→↓←↑
4
CR
parameters
s,
Do,
do,
di,
α,
k,
b max
b min,
sw
58
8. Examples of pipe cuts
8.1.0.0./1.3. Saddle cut, eccentric α < 90° in front of the main pipe
axis
L = S. rel.
x = x (phi)
cut
Program
Gamma
phi
touch
Parameters
s,
+f
Do,
+f
1
0°
180°
0
2
0°
180°
1
0°
0°
0
0°
0°
1
α,
-f
0°
180°
0
k,
+f
b max.,
+f
3
4
Alt
cursor→↓←↑
5
CR
6
0°
180°
1
do,
di,
-f
b min.,
sw
59
8. Examples of pipe cuts
8.1.0.0./1.4. Saddle cut, eccentric α < 90° behind the main pipe axis
L = S. rel.
x = x (phi)
Cut
1
Program
gamma phi
180°
0°
touch
0
0°
180°
1
0°
0°
0
0°
0°
1
5
0°
180°
0
6
0°
180°
1
2
Alt
3
Cursor→↓←↑
4
CR
parameters
+f
s,
Do,
do,
di,
α,
k,
b max
b min,
sw
+f
-f
-f
+f
+f
60
8. Examples of pipe cuts
8.1.0.1/0.0. Saddle cut, AWS / U.K. cut
β
χ
β
ϕ
ϕ
α
61
8. Examples of pipe cuts
8.1.0.1./0.1. Saddle cut, AWS / Norway cut
β
χ
β
90
°
ϕ
ϕ
α
β
β
62
8. Examples of pipe cuts
8.1.0.1./0.2. Offshore cut AWS / High Fab. Cut
α < 90°
β
90°
χ
β
ϕ
ϕ
α
α
α
β
β
63
8. Examples of pipe cuts
8.1.0.1. /1.0. Saddle cut concentric α < 45°
L = S. rel.
x = x (phi)
Cut
1
Program
gamma
0°
2
phi
180°
touch
0
0°
180°
1
0°
0°
0
0°
0°
1
5
0°
180°
0
6
0°
180°
1
Alt
3
Cursor→↓←↑
4
CR
parameters
s,
Do,
do,
di,
α,
k, (ko, ki)
sw
64
8. Examples of pipe cuts
8.1.0.1./1.1. Saddle cut eccentric α < 45° in front of the main pipe axis
(offshore cut)
L = S. rel.
x = x (phi)
Cut
1
Program
gamma
0°
2
phi
180°
touch
0
parameters
+f
s,
Do,
do,
di,
α,
k, (ko, ki)
sw
0°
180°
1
180°
0°
0
180°
0°
1
5
0°
180°
0
+f
6
0°
180°
1
+f
Alt
3
Cursor→↓←↑
4
CR
+f
-f
-f
65
8. Examples of pipe cuts
8.1.1./0.0. Mitre cut
Starting point of cut
Cut
1
2
Program
Gamma Phi
0°
180°
Alt
Cursor →↓←↑
0°
180°
CR
touch Parameters
0
S,
Do, do, di,α, k,
1
b max, b min, sw
β
β
Starting point of cut
Cut
1
2
Program
Alt
Cursor →↓←↑
CR
Gamma Phi
0°
0°
0°
0°
touch Parameters
0
S,
Do, do, di,α, k,
1
b max, b min, sw
66
8. Examples of pipe cuts
8.1.1./0.1.
Double mitre (option)
Pendulation points: setting di
2
Double mitre: Welding face formation phi = 90°; phi = 270°
Can be influenced by ß min / ß max
°
±70
α
67
8. Examples of pipe cuts
8.1.1./0.1. Double mitre
α
cut
Program
Gamma
Phi
touch
1
0°
0°
0
2
0°
0°
1
Parameter
s,
Do, di,
α,h,
bmax., bmin.,
sw
68
8. Examples of pipe cuts
8.1.1./0.2. Double mitre with constant height
h = const.
−
β
Pendulation point: setting di
2
Parallel cutting angles
+
β
α
69
8. Examples of pipe cuts
8.1.1./0.3. Double mitre cut-out
cut
1
Program
Gamma
Phi
touch
0°
0°
0
Parameter
s,
Do, di,
α,h,
b max., b min., sw
70
8. Examples of pipe cuts
8.1.1./0.3. Double mitre cut-out
with cross pendulation for “ky”
Pendulation point: setting di
2
α
71
8. Examples of pipe cuts
8.2.0. Cut-outs
8.2.0./.0.0. Cut out, eccentric
(Penetrating pipe inserted)
α
The maximum angle of oscillation b max. and b min. is set to 70 degree during all saddle cuts.
A limit is effective if the value calculated by the computer is higher than 70 degrees.
In case of cut-outs for inserted pipes:
Input in the computer:
Do = Do
D = Di
do = do
d = do
The oscillation point setting should be “Di/2”
a) by hand
b) automatically with height control sensor
The wall thickness is set:
a) on the scale for height scanning by hand
b) on the digital display by motor (option) to „(Do-Di)/2“.
72
8. Examples of pipe cuts
8.2.0./0.1. Cut-out, eccentric
(Penetrating pipe placed on top)
In the case of cut-outs for pipe placed on the top the pendulation point setting is
Do;
2
This diameter “Do” is also fed into the computer (The computer interrogation is
for „0“).
The wall thickness is to be adjusted to „0“!
α
The maximum angle of oscillation b max. and b min. is set to 70 degree during all
saddle cuts.
A limit is effective if the value calculated by the computer is higher than 70 degrees.
In case of cut-outs for pipes placed on top:
Input in the computer: Do = Do
D = Do
do = do
d = di
The oscillation point setting should be “Do/2”
c) by hand (manual)
d) automatically with height control sensor
The wall thickness is set:
c) on the scale for height scanning by hand
d) on the digital display by motor (option) to „0“.
73
8. Examples of pipe cuts
8.2.0./0.2. Cut-out, concentric, eccentric
The following formula apply:
I
II
III
ψ
ψ
ψ
-90 + ß max. =
max. (ß max. = 70°)
-90 + ß max. = 0;
=0
-90 + ß max. < 0; limit; the bevel must be finished by grinding
ψ = local dihedral angle
ψ
ψ
β
χ
74
8. Examples of pipe cuts
8.2.0./0.3. Pendulation point adjustment
Example: cut-out, concentric α = 90°; K = o°
Di: do ≈ 1:1
β
β
γ
ϕ
Input computer:
D = 1000
d = 100
Example:
Do = 1000 mm
Di = 700 mm
do = 700 mm
α = 90°
κ =
0°
I.e. if Ri:ro ≈ 1 is to be cut, the pendulation point (normally = inside diameter) must
be shifted in such a way that the distance of the pendulation point from the centre of
the pipe will be: p = __ ro___
sin ß max.
In this example 350 mm = 372,4622 mm is to be set.
Sin 70°
In order to avoid cutting into the wall, ß is limited the highest value.
75
8. Examples of pipe cuts
8.2.0./1.0. Cut-out, concentric
Cut
1
Program
Alt
2
Cursor→↓←↑
3
CR
gamma phi
0°
touch
0
0-360°
0
1
parameters
s,
Do, d,
α, k,
b max, b min,
sw
76
8. Examples of pipe cuts
8.3.0. Slots
8.3.0./0.0. Slot with radius
ϕ
ϕ
ϕ
ϕ
77
8. Examples of pipe cuts
8.3.0./0.1. Slot without radius
ϕ
ϕ
ϕ
ϕ
78
9. Programming of user cuts
9.
Programming of user cuts
9.1.
Storage of user cuts
9.2.
Loading of user cuts
9.2.1.
Calling of the first cutting sequence from the level of
the main menu
9.2.2.
Calling of the further cuts of the cutting sequence
9.2.3.
Calling of the first cut starting from the parameter input
9.3.
Listing of files
9.4.
Copying user cuts
79
9. Programming of user cuts
9.1.
Storage of user cuts
The required type of cut is called, the parameters of the cut are fed in and
calculated.
Via key „F7“ it is possible to store the cut.
→ PROG XXXX. YYY
appears on the monitor,
XXXX representing the pipe number 0000 to 9999
YYY representing the cut number of the pipe 000 to 999
First enter the pipe number and press „CR“
Then enter the cut number, press „CR“ for confirmation and storage if this
designation does not yet exist.
If it does already exist the system will ask:
→ REPLACE?
By means of the key „CR“ the already existing cut number would be overwritten with the new parameters.
By means of the key „ESC“ the process is interrupted and there is the possibility of storing the cut under another number.
Press „ESC“ to return to the main menu.
(See also table 3 [ function key „F1“] ).
80
9. Programming of user cuts
9.2.
Loading of user programs
9.2.1.
Call of first cut of the cutting sequence from the level of the main menu
Via function key „F4“ (series) it is possible to call the cut
→ PROG XXXX. YYY
appears on the monitor,
XXXX representing the pipe number 0000 to 9999
YYY representing the cut number of the pipe 000 to 999
First enter the pipe number and press „CR“.
Then enter the cut number, press „CR“, the cut is now called and calculated.
After having been calculated, this cut is available.
Should the cut not exist under the given number, an error message will appear.
Example:“ PROG 0000.000“
Press „ESC“ to return to the main menu.
(See also help table 3 [function key „F1“] ).
81
9. Programming of user cuts
9.2.2.
Call of further cuts of the cutting sequence
After finishing the cut, by means of the function key „F8“ the next cut of the
cutting sequence can be called.
Example:
„Loading
PROG 000.001“
The selected cut can be confirmed by means of „F8“ (subsequent calculation)
or
A new pipe number or/and cut number can be pre-selected (confirm by
„CR“).
To exit or to return to the main menu respectively press „ESC“.
82
9. Programming of user cuts
9.2.3.
Call of the first cut starting from the parameter input
Any cut has been called and calculated. Now a cutting sequence is to be carried out.
Via function key „F8“ it is possible to call the cut
→ PROG XXXX. YYY
appears on the monitor,
XXXX representing the pipe number 0000 to 9999
YYY representing the cut number of the pipe 000 to 999
First enter the pipe number and press „CR“.
Then enter the cut number, press „CR“. The cut is now called and calculated.
After having been calculated, this cut is available.
Should the cut not exist under the given number, an error message will appear.
After completion of the cut by means of „F8“ the next pipe number/cut
number is pre-selected and confirmed by „F8“ (see 9.2.2.).
Press „ESC“ to exit or to return to the main menu respectively.
83
9. Programming of user cuts
9.3.
Listing of files
Call „FILES“ from the main menu
Call „LISTING OF FILES“
or press the function key „F3“ (DIR).
→ PROG XXXX. ***
appears on the monitor,
XXXX representing the pipe number 0000 to 9999
*** representing all the cut numbers under the above pipe number
Enter pipe number, press „CR“ to confirm.
Via „CR“ the cut numbers of the above mentioned pipe number are listed.
e.g.
PROG 0000.000
PROG 0000.001
PROG 0000.002
first cut
second cut
third cut
It is possible to delete individual cuts.
Call the corresponding cut by means of „CR“
Press „DEL“ key
The system asks: „DELETE?“
By entering „DEL“ the cut is deleted
By entering „CR“ instead, the process is interrupted the cut is retained.
Press „ESC“ to return to the main menu.
84
9. Programming of user cuts
9.4.
Copying user cuts
Selecting „FILES“ from the menu accesses the function for copying cutting
sequences. The „FILES“ menu can be displayed with „ALT + D“ or „ALT
+ Curs“ or „F10 + Curs“. Call copying of cutting sequences with „k“ or
„Curs CR“ in the menu window.
The window „Copying cutting sequences“ will appear. The copying direction with the associated drives and directories is displayed in the top lefthand corner.
File :prog*
appears in the middle
At this point a list of the cutting sequences available on the source drive can
be displayed by pressing „CR“. Pressing „C“ then confirms that the last
cutting sequence displayed is to be copied.
Once copying is finished the next cutting sequence can be copied by confirming the question „[Cont]?“ by pressing „CR“.
Once there are no more cutting sequences available the display jumps back
to the prompt to enter the cut number „prog*“. It is also possible to enter
the pipe number directly at this point.
The direct entry is concluded by pressing „CR“. The cutting sequence with
the number of individual cuts will be displayed and you will be prompted to
copy it with „Copy?“. Pressing „C“ or „F10“ will start the copying operation.
All of the above functions can be aborted by pressing „ESC“.
85
10. Operation of the machine
10. Operation of the machine
10.1. Operation
10.1.1. Safety devices
10.1.2. Operation and control elements
10.1.3. Operation
10.2. Control panels
10.2.1 Diagrams of the control panels
10.2.2. Explanations for the control panels
10.2.2.1.
On the control cabinet
10.2.2.2.
On the chuck
10.2.2.3.
On the remote control
86
10. Operation of the machine
10.1.
Operation
10.1.1. Safety devices
EMERGENCY OFF
On the operator's side on the control panel of the torch carriage
and on the remote control there is an EMERGENCY OFF button
(red button on a yellow disc).
EMERGENCY OFF BUTTON
(Remote control)
EMERGENCY OFF BUTTON
(Control panel)
EMERGENCY OFF BUTTONS on the torch carriage
87
10. Operation of the machine
Another EMERGENCY OFF BUTTON is situated on the operator's
side of the pipe chuck.
EMERGENCY OFF BUTTON
EMERGENCY OFF BUTTON on the pipe chuck
When the EMERGENCY OFF BUTTON is pressed, the machine
is immediately braked to a standstill.
The power supply is interrupted.
The machine is locked to prevent it being switched back on again.
To unlock the EMERGENCY OFF BUTTON, turn it clockwise.
Regularly check the EMERGENCY OFF BUTTON to make sure
it is working correctly (daily if possible).
Never use the machine if the button is not working properly.
88
10. Operation of the machine
When the machine is braked through actuation of the EMERGENCY OFF BUTTON, the machine is subjected to extreme jolting.
The EMERGENCY OFF BUTTON should therefore only be
pressed to check its function and in genuine emergencies.
In all other cases, stop the machine by pressing the MACHINE
OFF key on the operator's panel.
Protective panels
All moving and rotating parts are housed behind detachable protective panels.
Only open or remove these protective panels for maintenance
or repair work when the machine is stationary.
89
10. Operation of the machine
10.1.2.
Operation and control elements
Control panel on the torch carriage
Remote control (horizontal surface on the torch carriage)
90
10. Operation of the machine
Control on the pipe chuck
Measurement scale
Square connector for
SW 19 shifting
ratchet
Pipe carriage height adjustment
SW 19 ratchet switch
91
10. Operation of the machine
Control for oxyacetylene equipment
Torch carriage
Flow rate control
6
5
4
1
2
3
1. Flame cutter cutting oxygen
2. Flame cutter heating oxygen
3. Flame cutter heating gas
4. Preheating torch heating gas
5. Preheating torch heating oxygen
6. Ignition torch fuel gas
92
10. Operation of the machine
Pressure control
4
3
1
2
1. Cutting oxygen control
2. Heating oxygen control
3. Heating gas control
4. Ignition gas control
93
10. Operation of the machine
Valve block
2
1
1. 2/2-way shut-off valve (5 units)
2. Relief valve
94
10. Operation of the machine
Compressed air control, pipe chuck
2
1
4
3
1. Pressure control valve I
2. Pressure control valve II
3. 4/3-way manual control slide
4. Position interrogation
95
10. Operation of the machine
Compressed air maintenance unit, pipe chuck
3
2
1
1. Filter
2. Pressure controller
3. Water separator
96
10. Operation of the machine
10.1.3. Operation
Before starting work (start of shift) check that the EMERGENCY OFF BUTTON is working properly.
Make sure that there are no foreign objects, e.g. tools or remains of pipes, lying around within the pipe profile cutting
machine's working radius.
This applies particularly to the areas travelled by the torch and
pipe carriages.
Any foreign bodies must be removed.
During operation of the machine, its movements may be dangerous.
If faults have to be remedied, always switch the machine/line
off.
Always make sure that the area around the machine is kept
clean.
Further information on the operation of the pipe profile cutting machine can be found in the separate operator's manual and operator's manual for the electrics of the pipe profile cutting machine.
97
10. Operation of the machine
Operating data for Torch Cutting Nozzle GRICUT 1230 - PM, fuelgas propane
Workpiece
thickness
[mm]
3
4
5
6
8
10
7
8
10
12
15
15
20
25
25
30
35
40
40
50
60
60
80
100
Cutting
nozzle
Heating
nozzle
Propane
pressure
[bar]
3 - 10
7 - 15
15 - 25
25 - 40
40 - 60
60 - 100
3 - 100
0.2
Heating
oxygen
pressure
[bar]
1.5
1.5
1.5
2.0
2.0
2.0
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
Cutting
oxygen
pressure
[bar]
1.0
1.5
2.0
2.5
3.5
5.0
5.0
5.5
6.0
6.5
7.0
6.0
6.5
7.0
6.0
7.0
7.5
7.5
5.5
6.5
7.5
6.0
7.5
8.5
Cutting
speed
Nozzle
clearance
[mm/min]
780
740
720
700
650
600
670
650
630
590
560
560
510
460
460
440
420
400
400
360
340
340
300
270
[mm]
2–4
2–4
2–4
2–4
4–5
4–5
4–5
4–5
5–8
5–8
5–8
5–8
5 – 10
5 – 10
5 – 10
5 – 10
5 – 10
5 – 10
5 – 10
5 – 10
5 – 10
6 – 10
6 – 10
6 – 10
Cutting
kerf
width
[mm]
0.9
0.9
1.0
1.1
1.3
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.9
3.4
3.5
3.5
Propane
consumpt.
[m3/h]
0.28
0.28
0.28
0.33
0.33
0.33
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
0.38
Heating
oxygen
consumpt.
3
[m /h]
1.1
1.1
1.1
1.3
1.3
1.3
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
Cutting
oxygen
consumpt.
3
[m /h]
0.6
0.8
1.0
1.2
1.6
2.2
1.8
1.9
2.0
2.2
2.3
2.5
2.8
3.1
3.8
4.3
4.5
4.5
4.2
4.9
5.6
7.6
9.4
10.6
Total
oxygen
consumpt.
3
[m /h]
1.7
1.9
2.1
2.5
2.9
3.5
3.3
3.4
3.5
3.7
3.8
4.0
4.3
4.6
5.3
5.8
6.0
6.0
5.7
6.4
7.1
9.1
10.9
12.1
The table indicates standard values based on the use of plain steel with a carbon content of up to 0.3 % and oxygen with a minimum purity of 99.5 %.
Satisfactory cuts on clean and non-primed plates, sheets and pipes can only be achieved with undamaged nozzles.
The cutting speeds stated are to be reduced as follows: for shape cutting radii involving small radii by 10 % approx., for bevel cuts of 30°
of 30° by 25 % approx., for bevel cuts of 45° by 45 % approx.
Nozzle size and corresponding adjusting values are to be selected acc. to the real cutting thickness.
The pressures stated are excess pressures measured at the torch inlet.
The consumption data indicated in m3/h apply to the standard condition as per DIN 1343.
98
10. Operation of the machine
Pipe carriage
Adjusting the height to the pipe diameter employed
Examples:
1. Pipe diameter 1200 mm
2. Pipe diameter 650 mm
99
10. Operation of the machine
3. Pipe diameter 80 mm
100
10. Operation of the machine
Needle position indicates the pipe diameter:
Pipe diameter 1200 mm
Pipe diameter 650 mm
Pipe diameter 80 mm
101
10. Operation of the machine
Pipe chuck
Pneumatic clamping device
The clamping cheeks of the pipe chuck enable the pipe to be
clamped by both its inner and outer diameter, depending on pipe
diameter.
The clamping process is controlled by means of the pressure
valves I and II and the manual control slide (see below).
The specified operating pressure is max. 6 bar.
1. Clamping the pipe by its outer diameter
Shift the manual control slide to its left position.
To clamp the pipe, set pressure valve I to operating pressure
of 3 bar.
To release the pipe, set pressure valve II to operating
pressure of 5 bar.
2. Clamping pipe by its inner diameter
Shift the manual control slide to its right position.
To clamp the pipe, set pressure valve II to operating pressure
of 3 bar.
To release the pipe, set pressure valve I to operating
pressure 5 bar.
1.
2.
Caution: Modifying or interchanging the given values may
lock the pipe chuck.
102
10. Operation of the machine
Pressure valve:
I
II
Manual control slide
1. Closed
Open
2. Open
Closed
103
10. Operation of the machine
10.2.1. Diagrams of the control panels
On the control cabinet
Display
Control Panel
104
10. Operation of the machine
Diagrams of the control panels
On the chuck
EMERGENCY OFF
push button
Signal Lamp
aut. / man
ON
93
91
automatic
manual
switch
92
On the remote control
105
10. Operation of the machine
10.2.2. Explanations for the control panels
10.2.2.1. On the control cabinet
11
Display of cutting speed in %
14
Emergency OFF
16
Over current fans of control cabinet (signal lamp)
17
Control on (signal lamp)
18
Control on (switch)
25
(reserve)
26
(reserve)
27
(reserve)
28
(reserve)
31
Display carriage
34
Reset: values of display carriage („31“)
35
Manual release of torch carriage (signal lamp)
36
Manual release of torch carriage (switch)
106
10. Operation of the machine
Explanations for the control panel
On the control cabinet
37
Manual – 0 – automatic: torch carriage (S)
38
Manual nominal values for S
47
Manual – 0 – automatic: X-pendulation (beta)
48
Manual nominal values for X (beta)
55
(reserve)
56
(reserve)
57
Manual – 0 – automatic: Y-pendulation (chi)
58
Manual nominal values for Y (chi)
61
Display angle (chuck)
64
Reset: values of display angle (chuck) „61“
65
Chuck clamping (signal lamp)
66
Chuck blocking control
107
10. Operation of the machine
Explanations for the control panel
On the control cabinet
67
Manual – 0 – automatic: chuck (gamma)
68
Manual nominal values for gamma (chuck)
71
(reserve)
75
Welding seam width (illuminated push button)
76
Sensor arm not in correct position or partial automatic (signal lamp)
77
Height control
• to the left:
partial automatic
(sensor arm lowering or raising)
pre-selection via (78)
• zero position:
manual (78) (partial automatic off)
• to the right:
automatic
78
Manual torch arm adjustment ( up or down)
84
Readiness of cutting programming (signal lamp)
85
(reserve)
86
(reserve)
108
10. Operation of the machine
Explanations for the control panel
On the control cabinet
87 Transfer torch carriage position
“TEACH IN”
“ CUT-IN”
(activate shortly)
(activate long)
88 Reset: move machine into start position
(106) must be in „0“ position
10.2.2.2. On the chuck
91 Clamping function: green signal lamp
92 Clamping (switch):
- automatically (to the left)
- manually
(to the right)
93 Emergency OFF
109
10. Operation of the machine
Explanations for the control panel
10.2.2.3.
On the remote control
94 Emergency OFF
95 Display of cutting speed in %
96 Plasma cutting – start
Cutting oxygen – start
97 Release (ignition)
(to the left)
(to the right)
(to the right)
fuel gas/oxygen
98 Preheating torch (switch)
106 Working direction (left or right)
107 Torch distance (up/down)
108 Cutting speed setting
110
11. Setting and checking the pendulation axis
11.
Setting and checking the pendulation axis
11.1. Setting and checking the pendulation axis for variable
bevelling
11.1.1.
Manually
11.1.2.
With the aid of the computer
11.1.3.
Results
111
11. Setting and checking the pendulation axis
11.1. Setting and checking the pendulation axis for variable bevelling
1. Clamp the pipe and align exactly. The pipe must be perfectly round and
must run true.
2. The cutting jet must be perfectly straight.
3. Set the torch arm to the inside radius of the pipe (di )
2
The corresponding scale is arranged on the column.
( When setting is correct, the pendulation axis and the inside radius will
form a straight line).
4. Set the wall thickness to
do-di
2
by means of the hand wheel.
11.1.1.
Manually
Now make a round cut on the pipe as a test.
During the cutting, the torch must be swivelled to the left around the pendulation axis. After a cut of about 4 cm set the torch upright again and cut
upright for 4 cm and then again at an angle, and so on until the end.
112
11. Setting and checking the pendulation axis
11.1.2.
With the aid of the computer
(Test of the contact line)
Call of test of the contact line (pendulation point) by means of
„TEST PROGRAMS“ and „TEST OF THE CONTACT LINE“
A simple round cut with fixed „S“ value and „chi = 180°“ is made.
The pendulation angle is abruptly changed over from „beta 1“ to „beta 2“.
The changing distance on the pipe surface (sequence q) is entered by the
operator during parameter input.
Depending on the respective pipe diameter, „q“ is calculated and displayed.
(See also help menu 5 [function key „F1“] ).
The values for the wall thickness setting and the scale at the column are
shown.
113
11. Setting and checking the pendulation axis
11.1.3.
Results
The inner edge of the pipe must be a flat surface; to check put it on a
straight and even plate.
If a sharp edge (drawing “ a ”) projects on the inclined cut, then the pendulation axis has been set too high.
⇒ Move height control downwards (by some millimetres), cut anew and
check!
If the sharp edge (drawing “ b “) is set back, the pendulation axis is too
low.
⇒ Move height control upwards (by some millimetres), cut anew and
check!
If the pendulation point is correct, the pointer at the scale of the column
must be readjusted to the value
di
2
If on one half of the bevel, projecting edges are found and recessed edges
on the other half, this indicates that the pipe is not quite round or did not
run quite true.
114
12. Test program
12.
Test program
The control electronics can be tested by means of the test program.
Call the test program from the main menu.
1. Nominal value input of main drives via function key „F3“ or:
To confirm input press „CR“
Select drive by means of cursor
Exit data input by means of „F2“ or „ESC“
2. Function key „F2“ sets all signals into starting position of the test
program.
3. Input
Output
- (operation from the machine)
- digital signals: function keys „F6“, „F7“, „F8“
Port I/O – this test requires a special plug
4. Exit test program by means of „F1“ or „ESC“
Example:
By slowly moving the chuck or the torch carriage the correct display of the
angle transmitter or the path transmitter can be checked and compared
with the displayed values at the torch carriage (panel).
(See also help menu 4 [function key F1] ).
115
13. Loading of additional cutting programs
13.
Loading of additional cutting programs
You quit the RB program with „HELP“ and „END PROGRAM“
(main menu).
→ C:\TCP\RB >
appears on the screen.
Insert a new program disk into the computer.
Enter on the keyboard:
COPY A: *.* C:
Press „CR“
The program will be copied: then press
„CTRL“, „ALT“ and „DEL“ simultaneously
The RB program will be loaded.
Display all the cuts once, have the calculations carried out, call „Help“
from the menu and select and perform „Store options“. This ensures
that the new cuts are available, as indicated by the „√“ with which they
are marked.
116
14. Cutting equipment of the machines
14.
Cutting equipment of the machines
14.1. Gas supply to the machines
14.2. Setting of the gas pressure values
14.3. Ignition of the pilot flame
14.4. Ignition of the heating flame
14.5. Maintenance of the torches, nozzles and backflow safety devices
14.6. Tubing and connections
14.7. Safety instructions
117
14. Cutting equipment of the machines
14.1. Gas supply to the machines
Depending on the requirements, cylinder batteries, cylinder bundles or
cold gasifiers can be used. Depending on operating conditions, the pipe
cutting machine can be fed either via the factory supply network or
straight from the gas source.
For the pipe cutting machine, the pressure control valves must be located at the discharge point and must permit the required gas throughput
rates. The pressure control valves are not included in the machine scope
of supply.
To protect the hoses and the gas supply in the pipe cutting machine,
backflow safety devices are fitted between the tubing and the torch setting valves.
The pressure control valves at the discharge point also have to be
equipped with backflow safety devices.
14.2.
Setting of the gas pressure values
When the valves are open, set the gas pressure for fuel gas, heating gas
and cutting oxygen by turning the setting screw on the pressure control
valve in compliance with the specifications of the torch and cutting nozzle suppliers.
After completion of the setting and cutting work, the pressure control
valves should by relieved by turning down the setting screws.
14.3.
Ignition of the pilot flame
The pipe cutting machine is equipped with a pilot burner for automatic
ignition of the heating flame of the cutting torch.
Switching on the control system and actuating the "Pilot flame ON" key
opens the valve for fuel gas flow to the pilot burner. Allow escaping fuel
gas to escape for a few seconds, then manually ignite using a suitable
lighter.
118
14. Cutting equipment of the machines
This procedure then has to be acknowledged on the control desk by operating "Pilot flame ON " key, otherwise the control system will switch off the
pilot flame again after a few seconds.
Use "Emergency Stop" or "Control System Off " to close
the valve immediately.
14.4.
Ignition of the heating flame
Set switch (97) on the remote control unit to the right position (heating
flame). The electrically operated valves for the heating oxygen and - with a
time-lag - for fuel gas are opened. The pilot flame ignites the escaping gas
mixture.
With the heating oxygen valve open, first set the heating gas surplus using
the fuel gas valve, then throttle the fuel gas and heating oxygen until the
flame presents a clearly defined cone-shaped form. If the heating flame is
too big, this has a negative effect on the required sharpness of the cutting
edge.
Now check the cutting oxygen jet again. Set the switch (96) on the remote
control unit to the right.
The oxygen jet flowing out of the nozzle must be straight and cylindrical
and must not waver. The heating flame must surround the oxygen jet in a
concentric manner.
14.5.
vices
Maintenance of the torches, nozzles and backflow safety de-
Protect the torches from damage. Always keep the nozzles clean. When
contaminated, use only suitable nozzle cleaners, brushes to clean them.
The backflow safety devices are of sintered metal and become dirty in the
course of time, either through soot from the back flashes or dirt from the
lines. As a result, the pressure loss becomes greater and greater and the
function of the torch is impaired.
Depending on dirt accumulation, replace the backflow safety devices.
119
14. Cutting equipment of the machines
14.6.
Tubing and connections
Use tubing in compliance with DIN 8541 standard.
Colour code:
• Oxygen :
• Fuel gas:
blue
red
Use suitable hose clamps to secure the tubes.
14.7.
Safety instructions
Check the hose connections regularly. Unnoticed escaping gas may cause
fire or an explosion.
Carry out a gas pressure test weekly.
Ensure that all components which come into contact with oxygen
(O2) are free of oil and grease, as otherwise there is a danger of
explosion.
120
1.2. Documentation of the machine
1.2.
DOCUMENTATION
of the machine
121
1.2. Documentation of the machine
1.2.
Documentation of the machine
15. Maintenance
16. Spare Parts
17. Technical drawings
18. Sub-Supplier manuals
122
15. Maintenance
15.
Maintenance
15.1.
Generalities
15.2.
Maintenance Schedule
15.3.
Lubrication recommendation
15.4.
Lubrication instructions
123
15. Maintenance
15.1
Generalities
Periodical maintenance can contribute to the dependable and safe
operation of the machine/equipment.
The component’s life will be increased!
The absolute necessary maintenance- and testing work and the respective intervals can be taken from the following maintenance
plans.
The statutory regulations, especially those for industrial
power current, are to be observed during maintenance work.
Wear protective equipment!
For the care and maintenance of the individual units, observe the
operating manuals of the sub-supplier in the appendix.
Check:
 Only authorized personnel may adjust the torch cutting
adjustments.
 Visual inspections are to be periodically carried out.
 The proper cutting process and the form of the torch cut are to
be constantly observed and controlled.
 Watch particularly for leakage in the gas pipe lines.
 Watch for leakage in the gear units.
 Listen for unusual running noises in the motors and gear units,
the chain drives, the shafts, and the bearings.
 Watch for an increase in temperature of the gear units and
bearings.
Gear Unit Oil Change:
In order to withdraw oil samples and analyse its quality, absolutely
observe the manufacturer’s specifications.
Used oil is to be stored, and later disposed of, in appropriate
receptacles in compliance with the respective regulations.
124
15. Maintenance
Lubrication:
The usage of appropriate lubricants serve to increase performance
and durability of the machine parts and helps to prevent damage.
An appropriate and thorough lubrication is of great importance!
Varying grease types are not to be mixed together!
For example, a lithium-base grease according to DIN 51502 K-P2K
cannot be mixed together with a calcium-saponified grease according to DIN 51502 K-P2K.
There is danger of coagulation!
The lubrication instructions are recommendations based on theoretically assumed working conditions.
Management is obliged to adapt these recommendation if necessary to current working conditions.
The recommendations of the supplier must be observed.
The lubrication of the parts, which occur by means of lube nipples,
should be carried out using a manually operated grease gun with
armoured hose, in accordance with DIN 1283, and gripper mouth
reel piece liner proportionate to the size of the nipple.
Generally are distinguished:
Button head lube nipple
Hydraulic-type lube nipple
Funnel-shaped lube nipple
Domed-head lube nipple
DIN 3404
DIN 71412
DIN 3405
DIN 3402
Points of lubrication which are not listed in the corresponding lubrication chart:
In this case, it deals exclusively with antifriction bearings that are
initially grease filled by the manufacturer according to the expected
life of the bearing.
A re-lubrication is usually not necessary.
Within the scope of the usual maintenance intervals, the condition
of the bearing is nevertheless to checked and, if necessary, relubricated
125
15. Maintenance
Dry Solid Film Lubrication:
Should a dry solid firm lubrication be required on the parts, then the
therefore appropriate lubricant should be used.
Graphite up to +600°C (high load-carrying capacity)
Molybdenum disulphide (MoS2) up to +450°C (very high loadcarrying capacity)
Polytetrafluorethylene (PTFE) from –200°C up to +260°C (low
load-carrying capacity, reinforcing components are necessary)
126
15. Maintenance
15.2. Maintenance Schedule
Code Word/Order
Maintenance Schedule
Pipe Profile Cutting Machine
Product:
Assembly:
Page: 8.2-1/7
Com.-No.:
4.3.1 Torch Carriage
all Bolted Connections
X
X
X
X
X
Yearly
Semi-annually
Quarterly
Monthly
Weekly
Daily
Remark
X
X
X
X
Standstill
Operation
Lubrication
Leakage
X
Torch Carriage, general
all Gas Supply Lines
Maintenance Interval
Damage
X
Clean
X
Adjust
Wear and Tear
X
Force Fit
Noise
X
Clearance
Visual Check
Torch Carriage, general
Function
Name of maintained
component
Gear-Contact Pattern
Type of Maintenance/Check
Point of Maintenance
RB 650/1200 EL AGD
X
X
X
X
X
127
15. Maintenance
Code Word/Order
Maintenance Schedule
Pipe Profile Cutting Machine
Product:
Assembly:
Page: 8.2-2/7
Com.-No.:
4.3.1 Torch Carriage
Traversing Drive, Gear Unit
Guide Roller (Cam Roller) eccentric
X
X
X
X
X
X
X
X
X
X
Yearly
Semi-annually
Remark
Oil-Level Indicator
Guide Roller (Cam Roller)
X
X
X
Track Wheel
X
X
X
Gear Track, Traversing Drive
X
X
X
X
X
X
X
X
X
Gear, Transducer
X
X
X
X
X
X
X
X
X
Chain Drive, Traversing Drive
X
X
X
X
X
X
X
X
X
X
Chain Drives, Transducer
X
X
X
X
X
X
X
X
X
X
Chain Drive, Azimuth-Pendulation
X
X
X
X
X
X
X
X
X
X
Gear Drive, Azimuth-Pendulation
X
X
X
X
X
X
X
X
X
X
Brush, Rail Cleaner
X
X
X
X
X
Quarterly
Monthly
Weekly
Daily
Standstill
Operation
Lubrication
Leakage
Maintenance Interval
Damage
Clean
Adjust
Force Fit
Clearance
Gear-Contact Pattern
Wear and Tear
Noise
Function
Name of maintained
component
Visual Check
Type of Maintenance/Check
Point of Maintenance
RB 650/1200 EL AGD
128
15. Maintenance
Code Word/Order
Maintenance Schedule
Pipe Profile Cutting Machine
Product:
Assembly:
Page: 8.2-3/7
Com.-No.:
4.3.1 Torch Carriage
X
X
Remark
Yearly
Semi-annually
Quarterly
Monthly
Weekly
Daily
X
Standstill
X
Operation
Damage
Clean
Adjust
Force Fit
Clearance
Gear-Contact Pattern
Wear and Tear
Lubrication
X
Maintenance Interval
Leakage
Gear Unit, Lifting Drive
Noise
Name of maintained
component
Visual Check
Type of Maintenance/Check
Function
Point of Maintenance
RB 650/1200 EL AGD
Gear Unit Grease CENTOPLEX HO
Firm Klüber
129
15. Maintenance
Code Word/Order
Maintenance Schedule
Pipe Profile Cutting Machine
Product:
Assembly
Page: 8.2-4/7
Com.-No.:
4.3.2. Torch Carriage Track
Remark
Yearly
Semi-annually
Quarterly
X
Monthly
Daily
X
Weekly
Standstill
Operation
X
Lubrication
X
Leakage
Adjust
Force Fit
Clearance
Gear-Contact Pattern
Wear and Tear
Damage
X
Maintenance Interval
Clean
Track, general
Noise
Function
Name of maintained
component
Visual Check
Type of Maintenance/Check
Point of Maintenance
RB 650/1200 EL AGD
130
15. Maintenance
Code Word/Order
Maintenance Schedule
Pipe Profile Cutting Machine
Product:
Assembly:
Page: 8.2-5/7
Com.-No.:
4.3.3 Pipe Chuck
X
X
X
X
X
Clamping Jaw
X
X
Rotating Drive, Gear Unit
X
X
Rotating Drive, Chain Drives
X
X
Rotating Drive, Gear Drives
X
X
X
X
X
X
X
X
X
X
Yearly
Semi-annually
acc.to sub-supplier instructions
Oil lubricate
X
X
Oil-Level Indicator
X
X
X
6x Hydr. Type Lube Nipple
X
X
X
X
X
X
X
X
X
X
X
Quarterly
Monthly
Weekly
Daily
X
X
X
Roller Slewing Ring
Remark
X
X
X
X
Standstill
Operation
Lubrication
X
X
Compr.-Air Condition Unit
all Bolted Connections
Leakage
Damage
Maintenance Interval
X
Pipe Chuck, general
Compressed-Air Supply, general
Clean
Adjust
X
Force Fit
X
Clearance
X
Gear-Contact Pattern
Wear and Tear
Pipe Chuck, general
Noise
Function
Name of maintained
component
Visual Check
Type of Maintenance/Check
Point of Maintenance
RB 650/1200 EL AGD
X
X
131
15. Maintenance
Code Word/Order
Maintenance Schedule
Pipe Profile Cutting Machine
Product:
Assembly:
Page: 8.2-6/7
Com.-No.:
4.3.4 Pipe Carriage
X
X
X
Track Wheels
X
X
X
X
Yearly
Semi-annually
Quarterly
Monthly
Weekly
Remark
X
ACME-Threaded Spindles
all Bolted Connections
Daily
Standstill
Operation
X
Lubrication
X
Leakage
Damage
X
Maintenance Interval
Clean
X
Adjust
X
Force Fit
Wear and Tear
X
Clearance
Noise
Pipe Carriage, general
Visual Check
Name of maintained
component
Gear-Contact Pattern
Type of Maintenance/Check
Function
Point of Maintenance
RB 650/1200 EL AGD
X
Oil lubricate
X
X
X
132
15. Maintenance
Code Word/Order
Maintenance Schedule
Pipe Profile Cutting Machine
Product:
Assembly:
Page: 8.2-7/7
Com.-No.:
4.3.6 Torch Cutting Equipment, oxy-acetylene
X
X
Remark
Yearly
Semi-annually
Quarterly
Monthly
Weekly
Daily
Standstill
Operation
Lubrication
Leakage
Maintenance Interval
Damage
Clean
Adjust
X
Force Fit
X
Clearance
X
Gear-Contact Pattern
Wear and Tear
Refer to the Maintenance Instructions of the Sub-Supplier !
Noise
Name of maintained
component
Visual Check
Type of Maintenance/Check
Function
Point of Maintenance
RB 650/1200 EL AGD
X
133
15. Maintenance
15.3.
Lubrication recommendation
Lubrication recommendation - GREASE
Types of grease in compliance with the supplier’s recommendations
DIN
51502
MOBIL
SHELL
Typical
field of
application
ESSO
TEXACO
BP
DEA
NEVER
SEEZ
TivelaFibrax
KP0K-20 Mobiplex
44
Compound EP 370
KP00KA
20
EP
ou
Grease
similaire
350
Multifac
EP 0
Energrease
HT-EP 00
Glissando
EP 0
Gear Coupling
Multifac
EP2
Energrease
LS-EP 2
Glissando
EP 2
Antifriction- and
Plain Bearing
Spectron
FO 20
Antifriction- and
Plain Bearing
max. 260°C.
With frequent
automatic re- lubrication
Sliding Surface
and Gear Rack
Liquid
grease
S 420
KP2K-20
K2N-30
Mobilux
EP 2
Alvania
EP 2
Beacon
EP 2
Texando
FO 20
NS
135
15. Maintenance
Lubrication recommendation - OIL
Types of oil in compliance with the supplier’s recommendations
DIN
51502
MOBIL
SHELL
ESSO
TEXACO BP
DEA
Typical
field of
application
DOW
Corning
CLP 100
CLP 150
CLP 220
Mobilgear
627
Mobilgear
629
Mobilgear
630
Omala
100
Spartan
EP 100
Meropa
100
Omala
150
Spartan
EP 150
Meropa
150
Spartan
EP 220
Meropa
220
Omala
220
Gear Unit
Energol
GR-XP
100
Energol
GR-XP
150
Energol
GR-XP
220
Falcon
CLP
100
Falcon
CLP
150
Falcon
CLP
220
Central Oil Circulating Lubrication
System, Gear Unit
Gear Unit
CLP 320
Mobilgear
632
Omala
320
Spartan
EP 320
Meropa
320
Energol
GR-XP
320
Falcon
CLP
320
Central Oil Circulating Lubrication
System, Gear Unit
CLP 460
460
Mobilgear
634
Omala
460
Spartan
EP 460
Meropa
460
Energol
GR-XP
460
Falcon
CLP
460
CLP 680
Mobilgear
636
Omala
680
Spartan
EP 680
Meropa
680
Energol
GR-XP
680
Falcon
CLP
680
Central Oil Circulating Lubrication
System, Gear Unit,
Gear Couplings
Worm Gear Unit,
Gear Couplings
VDL 100
DIN
51506
Rarus
427
Corena
H 100 D
Compressor
oil
3021 N
Energol
RC 100
Actro
VDL
100
High-Pressure Compressors
Kutwell
40
Compressor
oil
EP VDL
100
Texsol
D
Fedaro
M
Targon
D
5% Oil-in-Water
Emulsion
Nuto
H 46
Rando Oil
HDB 46
Energol
HLP 46
Astron
HLP 46
Hydraulic System
SE
Solvac
1535
GD
HLP 46
DIN
51524/2
DTE 25
ISO
VG 100
Valculine
525
Glygoyle
HE 220
PGLP
220
Corena
P 100
Dromus
B
Tellus 46
Tivela
oil
WB
Recirculation oil
S 220
Synlube
CLP 220
Energol
SG-XP
220
Central Oil Circulating
Lubrication System
Pedestal Bearing
Polydea
PGLP
220
MOS 2
Spray
Chains
136
15. Maintenance
Lubrication recommendation - OIL
Types of oil in compliance with the supplier’s recommendations
DIN
ARAL
ICI
OPTIMOL
KLÜBER CASTROL
TRIBOL
51502
Typical
field of
application
WINTERSHALL
CLP 100
Gear Unit
Gear Unit
CLP 150
CLP 220
Degol
BG 220
Tribol
1100/220
Optigear
BM 220
Klüberoil
GEM 1220
Alpha
MW 220
SP 220
Ersolan
220
CLP 320
Degol
BG 320
Tribol
1100/320
Optigear
BM 320
Klüberoil
GEM 1320
Alpha
MW 320
SP 320
Ersolan
320
CLP 460
Degol
BG 460
Tribol
1100/460
Optigear
1100/460
Klüberoil
GEM 1460
Alpha
MW 460
SP 460
Ersolan
460
CLP 680
Degol
BG 680
Tribol
1100/680
Optigear
1100/680
Klüberoil
GEM 1680
Alpha
MW 680
SP 680
Ersolan
680
Central Oil Circulating Lubrication
System, Gear
Unit
Central Oil Circulating Lubrication
System, Gear
Unit
Central Oil Circulating Lubrication
System, Gear
Unit,
Gear Couplings
Worm Gear Unit,
Gear Couplings
VDL 100
DIN
51506
High-Pressure
Compressors
SE
5% Oil-in-Water
Emulsion
HLP 46
DIN
51524/2
Hydraulic System
ISO
VG 100
Central Oil Circulating
Lubrication System
Pedestal Bearing
PGLP
220
Degol
GS 220
Tribol
800/220
Syntheso
D 220 EP
Alpha
PG 220
Wintax
SGW 220
Chains
137
15. Maintenance
Lubrication recommendation - OIL
Types of oil in compliance with the supplier’s recommendations
DIN
51502
MOBIL
Energol
WRL
Tellus
22/32
Nuto
H 22/32
Mobil
DTE
Tellus
C 22/32
Spinesso
22/32
Rando Oil
Energol
HDA 22/32 HLP 22/32
Aries
HLP
32
D22/32
HL 32
Mobil
DTE 25
Tellus
C 46
Nuto
46
Terre-sso
32
HFC 46
BP
Surett
Fluid 4K
Mobil
CL 46
TEXACO
Cardlum
Fluid C
HL/HLP DTE 22
CL/CLP
22, 32
ESSO
DEA
DOW
Corning
BC-V
22, 32
SHELL
Typical
field of
application
Hydro- Hydraulic
fluid
fluid
HFC 46 HFC 46
Rando Oil
46
Energol
HL 46
Gear Rack
Astron
HLP
22/32
Compressed Air Treatment Unit
Arkas
DLP 32
Astron
HL 46
Flushing Oil for
Central Oil Circulating
Lubrication System
Hydraulic System
Water-Glykol Basis
138
15. Maintenance
15.4.
Lubrication instructions
Code Word/Order
Lubrication Instructions
RB 650/1200 EL AGD
Product:
Pipe Profile Cutting Machine
Page: 15.4-1/3
Assembly:
3.1.1
Com.-No.:
Torch Carriage
Bearing Seat
Component
Lube Nipples per
Bearing
Seat
Identification
Initial Fill
Lubrication
Amount/Pos.
Re-lubrication
Lubrication
Interval
Lubrication
Type of Lubrication
Automatic
By Hand
Identification
Remark
No.
Amount
Track Wheel
1
4
1
monthly
X
Observe Manufact. adwise
Guide Roller, centric
2
2
1
monthly
X
Observe Manufact. adwise
Giude Roller, excentric
3
2
1
monthly
X
Observe Manufact. adwise
Chain Drive, Traversing Drive
4
1
quarterly
X
Chain Drive, Transducer
5
2
quarterly
X
Gear Drive, Traversing Drive
6
1
monthly
X
Gear Drive, Transducer
7
3
monthly
X
Lifting Spindle, Lifting Column
8
1
1
half-yearly
X
Hydr.-type lube nipple
Line. Guide Carriage, L. Column
9
4
1
half-yearly
X
Hydr.-type lube nipple
Chain Drive, Cantilever
10
1
quarterly
X
Chain Drive, Azimuth
11
1
quarterly
X
Chain Drive, Transducer
12
1
quarterly
X
Gear Drive, Azimuth
13
1
monthly
X
Amount
incl. Gear rack, Trav. track
This lubrication requirement applies only in conjunction with the lube chart: Drg.-No. 65.120.18.0009
139
15. Maintenance
Code Word/Order
Lubrication Instructions
RB 650/1200 EL AGD
Product:
Pipe Profile Cutting Machine
Page: 15.4-2/3
Assembly:
3.1.3
Com.-No.:
Pipe Chuck
Bearing Seat
Component
Lube Nipples per
Bearing
Seat
Re-lubrication
Identification
Initial Fill
Lubrication
Amount/Pos.
Lubrication
Interval
Lubrication
Amount
Type of Lubrication
Automatic
Identification
Remark
No.
Amount
Chain Drive, Rotating Device
1
1
quarterly
X
Chain Drive, Transducer
2
1
quarterly
X
Clamping Jaw
3
3
weekly
X
Anti-Seez
Tension Nut
4
3
monthly
X
Ball-type lube nipple
Bevel Gear, Tension nut
5
1
weekly
X
Roller Slewing Ring
6
3
half-yearly
X
Hydr.-type lube nipple
Spiral Bevel Gear Box
7
1
X
Observe Manufact. adwise
1
1
0,4 l
as required
as required
By Hand
Duplex-Chain
This lubrication requirement applies only in conjunction with the lube chart: Drg.-No. 65.120.18.0010
140
15. Maintenance
Code Word/Order
Lubrication Instructions
RB 650/1200 EL AGD
Produkt:
Pipe Profile Cutting Machine
Page: 15.4-3/3
Assembly:
3.1.4
Com.-No.:
Pipe Support Carriage
Re-lubrication
Type of Lubrication
No.
Amount
Lube Nipples per
Bearing
Seat
Track Wheel
1
4
1
monthly
X
Button head lube nipple
Roller
2
2
1
monthly
X
Cupped-type lube nipple
ACME-Threaded Spindle
3
2
weekly
X
Slideway, Roller Bracket
4
2
monthly
X
Chain Drive
5
1
quarterly
X
Bearing Seat
Component
Identification
Initial Fill
Lubrication
Amount/Pos.
Lubrication
Interval
Lubrication
Amount
Automatic
Identification
Remark
By Hand
This lubrication requirement applies only in conjunction with the lube chart: Drg.-No. 65.120.18.0011
141
16. Spare Parts
16.
Spare Parts
16.1.
Spare Parts: mechanical
16.1.1. List of Spare Parts
16.1.2. List of Antifriction Bearings
16.2.
Spare Parts: electrical
142
16. Spare Parts
16.1.1. List of Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Pipe Profile Cutting Machine
Page:
Assembly:
4.3.1
Com.-No.:
No.
Drawing-No.
Item
Torch Carriage
Description
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
1.
65.120.18.0621
Strip-Off Plate
St 1203
2.
65.120.18.0625
Brush
3.
65.120.18.0605
39
4.
65.120.18.0605
5.
6.
0,01
16.1.1-1/23
II
III
4
16
PP/Al
4
16
Power Chain
St
1
1
40
Track Wheel (Cam Roller)
St
4
4
65.120.18.0605
41
Guide Roller (Cam Roller)
St
2
2
65.120.18.0605
42
Guide Roller (Cam Roller, exc.)
St
2
2
7.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
143
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
16.1.1-2/23
Material
Amount of Spare Parts
Weight
kg/Piece
I
II
III
8.
65.120.18.0633
Gear Wheel
9 SMn 28 K
0,2
1
1
9.
65.120.18.0634
Chain Wheel
C 45
0,2
1
1
10.
65.120.18.0635
Chain Wheel
C 45
0,2
1
1
11.
65.120.18.0608
37
Deep Groove Ball Bearing
St
2
2
12.
65.120.18.0608
38
Deep Groove Ball Bearing
St
2
2
13.
65.120.18.0608
43
Chain Tensioning Wheel
St
1
1
14.
65.120.18.0608
44
Single Roller Chain
St
1
1
I = Installed piece
II = Recommended spare parts for start-up
III =
Price/Amount for 1 Year Operation
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
144
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Pipe Profile Cutting Machine
Assembly:
No.
Page:
Drawing-No.
4.3.1
Item
Com.-No.:
Torch Carriage
Description
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
15.
65.120.18.0608
16.
65.120.18.0649
17.
65.120.18.0608
45
49
16.1.1-3/23
Connection Link
St
II
III
1
1
Pulley Drive Heared Motor
1
1
Holder with Carbon Brush
1
2
18.
19.
20.
21.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
145
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
16.1.1-4/23
Material
Amount of Spare Parts
Weight
kg/Piece
I
II
III
22.
65.120.18.0643
Gear Wheel
C 45
0,6
1
1
23.
65.120.18.0644
Gear Wheel
C 45
0,3
1
1
24.
65.120.18.0645
Gear Wheel
9 SMn 28 K
0,3
1
1
25.
65.120.18.0646
Chain Wheel
C 45
0,3
1
1
26.
65.120.18.0647
Chain Wheel
C 45
0,3
1
1
27.
65.120.18.0609
44
Chain Tensioning Wheel
St
1
1
28.
65.120.18.0609
45
Single Roller Chain
St
1
1
I = Installed piece
II = Recommended spare parts for start-up
III =
Price/Amount for 1 Year Operation
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
146
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Item
Com.-No.:
Torch Carriage
Description
16.1.1-5/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
29.
65.120.18.0609
46
Connection Link
St
1
1
30.
65.120.18.0609
48
Deep Groove Ball Bearing
St
2
2
31.
65.120.18.0609
49
Deep Groove Ball Bearing
St
4
4
32.
65.120.18.0609
56
Clutch
1
1
33.
34.
35.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
147
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
16.1.1-6/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
36.
65.120.18.0930
Ball Screw Unit
1
1
37.
65.120.18.0932
Extension Below
2
2
38.
65.120.18.0934
Gear Drive
1
1
39.
65.120.18.0920
21
Linear Guide Set
1
1
40.
65.120.18.0920
22
Angular-Contact Ball Bearing
1
1
41.
65.120.18.0920
23
Steel Wire Rope
1
1
42.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
148
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Item
Com.-No.:
Torch Carriage
Description
16.1.1-7/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
43.
44.
45.
46.
47.
48.
49.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
149
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Item
Com.-No.:
Torch Carriage
Description
16.1.1-8/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
50.
65.120.18.0675
56
WIG-Electrode
Wolfram
1
1
51.
65.120.18.0675
60
Rolling Guide
Al
1
1
52.
65.120.18.0675
63
Roller, concentric
2
2
53.
65.120.18.0675
64
Roller, eccentric
2
2
54.
65.120.18.0675
65
Set of Wipers
1
1
55.
56.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
150
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
57.
65.120.18.0705
Chain Wheel
58.
65.120.18.0706
Gear Drive
59.
65.120.18.0707
Chain Wheel
60.
65.120.18.0708
61.
65.120.18.0700
62.
63.
16.1.1-9/23
III
1
1
1
1
C 45
1
1
Chain Wheel
C 45
1
1
21
Single Roller Chain
St
1
1
65.120.18.0700
22
Connection Link
St
1
1
65.120.18.0700
23
Deep Groove Ball Bearing
St
2
2
I = Installed piece
II = Recommended spare parts for start-up
C 45
II
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
151
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Item
Com.-No.:
Torch Carriage
Description
16.1.1-10/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
64.
65.120.18.0700
24
Deep Groove Ball Bearing
St
2
2
65.
65.120.18.0700
25
Deep Groove Ball Bearing
St
1
1
66.
65.120.18.0700
26
Expansion Bellow Clutch
1
1
67.
68.
69.
70.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
152
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
71.
65.120.18.0758
Chain Wheel
72.
65.120.18.0762
73.
16.1.1-11/23
II
III
C 45
2
2
Roller
16 MnCr 5
3
1
65.120.18.0768
Drive Shaft
9 SMn 68 K
1
1
74.
65.120.18.0771
Gear Drive
1
1
75.
65.120.18.0775
Gear Rack
St 60
1
1
76.
65.120.18.0778
Clamping Bush
St 35 BK
1
1
77.
65.120.18.0786
Chain Wheel
C 45
1
1
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
153
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
78.
65.120.18.0787
Chain Wheel
79.
65.120.18.0788
Gear Drive
80.
65.120.18.0795
Driving Dog
81.
65.120.18.0789
82.
65.120.18.0750
83.
84.
16.1.1-12/23
III
1
1
1
1
45 H
1
1
Chain Wheel
C 45
1
1
51
Single Roller Chain
St
1
1
65.120.18.0750
52
Connection Link
St
1
1
65.120.18.0750
53
Single Roller Chain
St
1
1
I = Installed piece
II = Recommended spare parts for start-up
C 45
II
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
154
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
85.
65.120.18.0750
54
Connection Link
86.
65.120.180750
55
Expansion Bellow Clutch
87.
65.120.18.0750
56
Angular-Contact Ball Bearing
88.
65.120.18.0750
57
89.
65.120.18.0750
90.
91.
16.1.1-13/23
III
1
1
1
1
St
3
3
Deep Groove Ball Bearing
St
4
4
58
Deep Groove Ball Bearing
St
2
2
65.120.18.0750
59
Deep Groove Ball Bearing
St
2
2
65.120.18.0750
60
DU-Sleeve
2
2
I = Installed piece
II = Recommended spare parts for start-up
III =
St
II
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
155
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Pipe Profile Cutting Machine
Assembly:
No.
Page:
Drawing-No.
4.3.1
Com.-No.:
Torch Carriage
Item
Description
16.1.1-14/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
92.
65.120.18.0750
61
Backing Roller
St
2
2
93.
65.120.18.0750
62
Disk Spring
F-St
4
4
94.
95.
96.
97.
98.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
156
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.3
Com.-No.:
Pipe Chuck
Item
Description
16.1.1-15/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
1.
65.120.18.0215
Chain Wheel
C 45
1,0
1
1
2.
65.120.18.0216
Chain Wheel
C 45
0,1
1
1
3.
65.120.18.0220
Chain Wheel
C 45
0,15
1
1
4.
65.120.18.0224
Chain Wheel
C 45
36,0
1
1
5.
65.120.18.0229
Chain Wheel
C 45
0,5
1
1
6.
65.120.18.0210
Gear Drive
1
1
7.
65.120.18.0225
Roller Bearing Slewing Ring
1
1
I = Installed piece
II = Recommended spare parts for start-up
III =
St
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
157
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.3
Item
Com.-No.:
Pipe Chuck
Description
16.1.1-16/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
8.
65.120.18.0201
37
Angular-Contact Ball Bearing
St
1
1
9.
65.120.18.0201
38
Deep Groove Ball Bearing
St
1
1
10.
65.120.18.0201
39
Deep Groove Ball Bearing
St
2
2
11.
65.120.18.0201
40
Ball
St
58
58
12.
65.120.18.0201
41
Ball
St
58
58
13.
65.120.18.0201
42
Two-Strand Roller Chain
St
1
1
14.
65.120.18.0201
43
Connection Link
St
2
2
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
158
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.3
Item
Com.-No.:
Pipe Chuck
Description
16.1.1-17/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
15.
65.120.18.0201
44
Offset Double Link
St
1
1
16.
65.120.18.0201
45
Single Roller Chain
St
1
1
17.
65.120.18.0201
46
Connection Link
St
1
1
18.
65.120.18.0201
47
Clutch
1
1
19.
65.120.18.0201
80
Hydr.-Type Lube Nipple
3
3
St
20.
21.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
159
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.3
Com.-No.:
Pipe Chuck
Item
Description
16.1.1-18/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
22.
65.120.18.0302
Tension Nut
C 45 V
82,0
1
1
23.
65.120.18.0303
Clamping Jaw
42 CrMo 4 V
16,0
1
1
24.
65.120.18.0304
Clamping Jaw
42 CrMo 4 V
16,0
1
1
25.
65.120.18.0305
Clamping Jaw
42 CrMo 4 V
16,0
1
1
26.
65.120.18.0306
Clamping Chuck
16 MnCr 5
8,5
6
6
27.
65.120.18.0309
Bevel Gear
C 45 V
2,5
1
1
28.
65.120.18.0320
Socket French
St
4,5
1
1
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
160
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.3
Item
Com.-No.:
Pipe Chuck
Description
16.1.1-19/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
29.
65.120.18.0310
Spiral Bevel Gear Box
13,0
1
1
30.
65.120.18.0315
E-Magnetic Gear Coupling
2,6
1
1
31.
65.120.18.0318
Compr.-Air Geared Motor
12,0
1
1
32.
65.120.18.0300
29
Carbon Brush
2
4
33.
65.120.18.0300
30
Deep Groove Ball Bearing
St
2
2
34.
65.120.18.0300
31
Ball-Type Lube Nipple
St
3
3
35.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
161
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.3
Item
Com.-No.:
Pipe Chuck
Description
16.1.1-20/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
36.
65.120.18.0008
1
Comp.-Air Conditioning Unit
1
1
37.
65.120.18.0008
2
2/2-Directional Control Valve
1
1
38.
65.120.18.0008
3
Sound Absorber
2
2
39.
65.120.18.0008
4
4/3-Direct. Manual Control Valve
1
1
40.
65.120.18.0008
5
Pressure Control Valve
2
2
41.
65.120.18.0008
6
Autom. Drain Valve
1
1
42.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
162
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.4
Com.-No.:
Pipe Support Carriage
Item
Description
16.1.1-21/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
1.
65.120.18.0416
Spindle Nut
RG 7
1,0
1
1
2.
65.120.18.0417
Spindle Nut
RG 7
1,0
1
1
3.
65.120.18.0423
Chain Wheel
C 45
1,0
1
1
4.
65.120.18.0400
33
Tensioning Element
St
2
2
5.
65.120.18.0400
38
Roller Chain
St
1
1
6.
65.120.18.0400
39
Connection Link
St
1
1
7.
65.120.18.0400
34
Deep Groove Ball Bearing
St
2
2
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
163
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.4
Com.-No.:
Pipe Support Carriage
Item
Description
16.1.1-22/23
Material
Amount of Spare Parts
Weight
kg/Piece
Price/Amount for 1 Year Operation
I
II
III
8.
65.120.18.0400
35
Deep Groove Ball Bearing
St
4
4
9.
65.120.18.0400
68
Deep Groove Ball Bearing
St
8
8
10.
65.120.18.0400
66
Button Head Lube Nipple
St
6
6
11.
65.120.18.0400
69
Backing Disk
St
24
24
12.
65.120.18.0400
70
Fitting Disk
St
8
8
13.
65.120.18.0400
71
Fitting Disk
St
8
8
14.
65.120.18.0400
67
Universal Ratchet
1
1
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
164
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Product:
Page:
Pipe Profile Cutting Machine
Assembly:
4.3.6
Cutting Torch Equipment,
16.1.1-23/23
Com.-No.:
oxy-acetylene
No.
Drawing-No.
Item
Description
Material
Amount of Spare Parts
Weight
kg/Piece
I
II
Price/Amount for 1 Year Operation
III
refer separate Spare parts lists
annexed
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
165
16. Spare Parts
Code Word/Order
List of Spare Parts
RB 650/1200 EL AGD
Machine cutting torch Type MS 832
Propane/Mapp gas/Methane/Town gas
Acetylene
Item
Description
MS 832/110-A
MS 832/1160-A
MS 832/250-A
MS 832/110-PMYF
MS 832/160-PMYF
MS 832/250-PMYF
MG.-No.
MG.-No.
MG.-No.
MG.-No.
MG.-No.
MG.-No.
716.11147
716.11149
716.11127
716.11148
716.11150
716.11142
1
Valve body
716.11119
716.11119
716.11119
716.11149
716.11149
716.11149
2
Torch head
716.51204
716.51204
716.51204
716.51204
716.51204
716.51204
3
Mixing nozzle
716.11120
716.11120
716.11120
716.11120
716.11120
716.11120
4
Mixing tube
716.11151
716.11152
716.11121
716.11151
716.11152
716.11121
5
Cutting oxygen pipe
716.11153
716.11154
716.11126
716.11153
716.11154
716.11126
6
Guide pipe
716.11155
716.11156
716.11125
716.11155
716.11156
716.11125
7
Threaded socket G 3/8
677.01963
677.01963
677.01963
677.01963
677.01963
677.01963
8
Threaded socket G 1/4
677.51426
677.51426
677.51426
677.51426
677.51426
677.51426
9
Threaded socket G 3/8-LH
677.01964
677.01964
677.01964
677.01964
677.01964
677.01964
10
Pressure nozzle
716.11163
716.11163
716.11163
716.05159
716.05159
716.05159
11
O-Ring 5x1,5
0.329.392
0.329.392
0.329.392
0.329.392
0.329.392
0.329.392
12
O-Ring 3x1,5
770.20048
770.20048
770.20048
770.20048
770.20048
770.20048
13
Locking screw
540.11180
540.11180
540.11180
540.11180
540.11180
540.11180
14
Countersunk screw
0.233.730
0.233.730
0.233.730
0.233.730
0.233.730
0.233.730
Heating oxygen
Cutting oxygen
Fuel gas
G 1/4
G 3/8
G 3/8 - LH
Adjusting valve
718.00500
718.00501
718.00502
Non-return valves
0.647.583
0.647.584
0.346.364
Accessories:
Tool for pressure nozzle
540.11250
Page : x.x-xx/xx
166
16. Spare Parts
Machine Cutting Torch:
168
16. Spare Parts
Quick cutting nozzle
1. Cutting nozzle
Designation: GRICUT 1230 - PMYF
Cutting range
Cutting-O2 Pressure
MG.-No.
3 – 10 mm
7 – 15 mm
15 – 25 mm
25 – 40 mm
40 – 60 mm
60 – 100 mm
1.0 – 5.0 bar
5.0 – 7.0 bar
6.0 – 7.0 bar
6.0 – 7.5 bar
5.5 – 7.5 bar
6.0 – 8.5 bar
716.15901
716.15902
716.15903
716.15904
716.15905
716.15906
2. Heating nozzle, Propane/Natural Gas/MAPP/GRIESON/TETRENE:
3 – 100 mm
716.15900
2
1
169
16. Spare Parts
Ignition unit with Pilot torch
Item
Description
MG.-No.
1
Pilot torch, Acetylene
Pilot torch, Propane/
MAPP Gas/GRIESON
Ignition control device
Ignition cable
Sparking plug connector
Connection box
Spacer pin
723.17309
723.17310
2
3
4
5
6
0471.008
0.570.199
0.462.419
0.550.117
0.281.427
3
1
Cutting torch arrangement
170
16. Spare Parts
Item
Description
MG.-No.
1
Pilot torch, Acetylene
Pilot torch, Propane/
MAPP Gas/GRIESON
Ignition control device
Ignition cable
Sparking plug connector
Connection box
Spacer pin
0.281.427
723.17309
723.17310
2
3
4
5
6
0471.008
0.570.199
0.462.419
0.550.117
5
6
2
4
3
Ignition unit
171
16. Spare Parts
Installation of ignition cable:
1. Ignition cable manually tapped into cable sleeve and cut compactly.
2. Ignition cable tapped another 1.5 mm and insulation removed so that
wire just out at the max. of 1.5 mm.
1
Ignition cable
2
Insulation
3
Wire
4
Cable sleeve
172
16. Spare Parts
List of spare parts for Pilot torch:
Acetylene
Item
Description
Gas
MG.-No.
1-4
Pilot torch
Acetylene
723.17309
1
Mixing unit
723.17191
2
Press. nozzle
723.17206
3
Bunsen burner
4
Cable sleeve
Acetylene
723.17192
723.17188
173
16. Spare Parts
Propane/MAPP gas/GRIESON
Item
Description
Gas
MG.-No.
1-5
Pilot torch
Propane/
723.17310
MAPP gas/GRIESON
1
Mixing unit
723.17191
2
Press. nozzle
723.17206
3
Bunsen burner
Propane/
723.17187
Methane/MAPP gas
4
Cable sleeve
723.17188
5
Flame tube
723.17189
174
16. Spare Parts
Methane
Item
Description
Gas
MG.-No.
1-5
Pilot torch
Methane
723.17311
1
Mixing unit
2
Press. nozzle
share of
723.17207
methane up to 85 %
Press. nozzle
share of
methane 85 – 93 %
723.17206
Press. nozzle
share of
methane 93 – 99 %
723.21631
3
Bunsen burner
Propane/
723.17187
Methane/MAPP gas
4
Cable sleeve
723.17188
5
Flame tube
723.17189
723.17191
175
16. Spare Parts
Pre-heating torch:
1-4
Pre-heating torch
1
Cutting torch unit
2
Nozzle support (Nut, Width across Flat 24)
3
Gas connection
G 3/8 – LH (Fuel gas)
4
Gas connection
G 1/4 (Oxygen)
Pre-heating torch
176
16. Spare Parts
Pre- heating torch nozzle
3 – 100 mm
177
16. Spare Parts
16.1.2. Lists of Antifriction Bearings
Code Word/Order
List of Antifriction Bearings
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Item
16.1.2-1/4
Com.-No.:
Torch Carriage
No.
Description
Amount of Spare Parts
Manufacturer
DIN
I
II
III
1.
65.120.18.0608
37
Deep Groove Ball Bearing
6906-2Z
DIN 625
2
2
2.
65.120.18.0608
38
Deep Groove Ball Bearing
6004-2Z
DIN 625
2
2
3.
65.120.18.0609
48
Deep Groove Ball Bearing
6004-Z
DIN 625
2
2
4.
65.120.18.0609
49
Deep Groove Ball Bearing
6002-Z
DIN 625
4
4
5.
65.120.18.0920
22
Angular-Contact Ball Bearing
3204 A
DIN 628
1
1
6.
65.120.18.0700
24
Deep Groove Ball Bearing
6002-2Z
DIN 625
2
2
7.
65.120.18.0700
25
Deep Groove Ball Bearing
6001-2Z
DIN 625
1
1
I = Installed piece
II = Recommended spare parts for start-up
III =
Price/Amount for 1 year operation
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
178
16. Spare Parts
Code Word/Order
List of Antifriction Bearings
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.1
Item
16.1.2-2/4
Com.-No.:
Torch Carriage
No.
Description
Amount of Spare Parts
Manufacturer
Price/Amount for 1 year operation
DIN
I
II
III
8.
65.120.18.0750
56
Angular-Contact Ball Bearing
3200
B.TVH.2ZR
DIN 628
3
3
9.
65.120.18.0750
57
Deep Groove Ball Bearing
6000-2Z
DIN 625
4
4
10.
65.120.18.0750
58
Deep Groove Ball Bearing
6001-2Z
DIN 625
2
2
11.
65.120.18.0750
59
Deep Groove Ball Bearing
6002-2Z
DIN 625
2
2
12.
13.
14.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
179
16. Spare Parts
Code Word/Order
List of Antifriction Bearings
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.3
Item
Com.-No.:
Pipe Chuck
No.
Description
Roller Slewing Ring
16.1.2-3/4
Amount of Spare Parts
Manufacturer
Price/Amount for 1 year operation
DIN
I
001.11.1403
HoeschRotheErde
1
1
160.16.0763.
II
III
1.
65.120.18.0225
2.
65.120.18.0201
37
Angular-Contact Ball Bearing
3204
DIN 628
1
1
3.
65.120.18.0201
38
Deep Groove Ball Bearing
6207-2Z
DIN 625
1
1
4.
65.120.18.0201
39
Deep Groove Ball Bearing
6000-2Z
DIN 625
2
2
5.
65.120.18.0300
30
Deep Groove Ball Bearing
16008
DIN 628
2
2
6.
7.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
180
16. Spare Parts
Code Word/Order
List of Antifriction Bearings
RB 650/1200 EL AGD
Product:
Assembly:
No.
Page:
Pipe Profile Cutting Machine
Drawing-No.
4.3.4
Item
16.1.2-4/4
Com.-No.:
Pipe Support Carriage
No.
Description
Amount of Spare Parts
Manufacturer
Price/Amount for 1 year operation
DIN
I
II
III
1.
65.120.18.0400
34
Deep Groove Ball Bearing
6001-2Z
DIN 625
2
2
2.
65.120.18.0400
35
Deep Groove Ball Bearing
6210-Z
DIN 625
4
4
3.
65.120.18.0400
68
Deep Groove Ball Bearing
6307-Z
DIN 625
8
8
4.
5.
6.
7.
I = Installed piece
II = Recommended spare parts for start-up
III =
Recommended spare parts for 1 year operation
IV = Pieces ordered by customer
181
16. Spare Parts
16.2.
Spare Parts: electrical
Ersatzteilliste elektrisch
List of electrical Spare Parts
Pos.
Item
Art. - Nummer Artikelbezeichnung
Goods No.
Description
RB 650/1200 EL AGD
Menge*
Unit*
1
640 0275
Notausschaltgerät
Emergency OFF device
PNOZ 2/230 V
1
2
640 6640
Kammrelais N; Gr.2
Cradle relay N; Gr.2
2
3
640 8736
Sicherung 2A D01
Fuse 2A D01
10
4
640 8735
Sicherung 4A D01
Fuse 4A D01
10
5
640 8734
Sicherung 6A D01
Fuse 6A D01
10
6
640 0079
Sicherung 10A D01
Fuse 10A D01
10
7
640 6790
Sicherng 16A D01
Fuse 16A D01
10
8
640 8723
Sicherung 35A D02
Fuse 35A D02
3
9
640 6752
Sicherug 10A D01 Ultrarapid
Fuse 10A D01 ultrarapid
10
10
640 6751
Sicherung 16A D01 Ultrarapid
Fuse 16A D01 ultrarapid
10
11
640 6453
Halter für Schaltelemente
Holder for switch element
5
12
640 6454
Lampenfassung BA9s
Lamp holder BA9s
5
* = recommended spare parts for 1 year operation
182
16. Spare Parts
Ersatzteilliste elektrisch
List of electrical Spare Parts
RB 650/1200 EL AGD
13
640 4031
Glühlampen BA9s 30V, 2W
Incandescent lamp BA9s 30V,2W
10
14
640 6479
Meldeleuchte weiß
Pilot light, white
1
15
640 6460
Meldeleuchte rot
Pilot light, red
1
16
640 6478
Meldeleuchte grün
Pilot light, green
1
17
640 6461
Meldeleuchte gelb
Pilot light, yellow
1
18
640 6755
Leuchtdrucktaster rot
Illuminated push button, red
1
19
640 0063
Leuchtdrucktaster blau
Illuminated push button, blue
1
20
640 0077
Leuchtdrucktaster gelb
Illuminated push button, yellow
1
21
640 0078
Leuchtdrucktaster grün
Illuminated push button, green
1
22
640 6757
Sicherheitsschloß SSG 10
Safety lock SSG 10
1
23
640 6458
Pilzdrucktaster rot
Emergency stop switch, rot
1
24
640 6459
Knebelschalter 1x100°, rast.
Selector button 1x100°; rast.
1
* = recommended spare parts for 1 year operation
183
16. Spare Parts
Ersatzteilliste elektrisch
List of electrical Spare Parts
RB 650/1200 EL AGD
25
640 6449
Knebelschalter 2x50°, rast.
Selector button 2x50°; rast.
2
26
640 6450
Knebelschalter 2x50°, tast.
Selector button 2x50°; tast.
2
27
640 0024
Knebelschalter tast.-rast.
Toggle switch inching-locking
2
28
640 6455
Drucktaster rot
Push button, red
1
29
640 6756
Schaltelement 1Ö
Switch element 1Ö
2
30
640 6467
Schaltelement 1S+1Ö
Switch element 1S+1Ö
10
31
640 6468
Schaltelement 2S
Switch element 2S
10
32
640 5937
Endschalter Rollenstößel D
Limit switch with roller plunger D
2
33
640 5704
Endschalter Rollenhebel E
Limit switch with roller lever E
2
34
640 0262
Hilfsschütz 24V, DC 3S+1Ö
Auxiliary Contactor 24V, DC 3S+1Ö
5
35
640 0261
Hilfsschütz 24V, DC 2S+2Ö
Auxiliary Contactor 24V, DC 2S+2Ö
1
36
640 0263
Hilfsschütz 230V, AC 3S+1Ö
Auxiliary Contactor 230V, AC 3S+1Ö
1
Leistungsschütz 230V, AC 2S+2Ö
Auxiliary Contactor 230V, AC 2S+2Ö
1
37
38
640 0276
Zeitrelais Rückfallverzögert
Electric Time Relay
1
39
640 0260
Überspannungsbegrezer
Varistor
6
40
* = recommended spare parts for 1 year operation
184
16. Spare Parts
Ersatzteilliste elektrisch
List of electrical Spare Parts
41
RB 650/1200 EL AGD
Hilfsschaltblock 4S
Auxiliary circuit 4S
2
42
640 6287
Endchalter Rollenstößel E 12 R
Limit switch roller level E 12 R
2
43
640 6399
Tastkopf
Probe
1
44
640 6727
Potentiometer 10K0
Potentioneter 10K0
1
45
640 6728
Potentoimeter 5K0 Typ. 7216 10 Umbrehungen
Potentiometer 5K0 Typ. 7216
1
46
640 6724
Potentiometer 4K7, linear
Potentiometer 4K7, linear
2
47
640 6784
Potentiometer 10K0, linear
Potentiometer 10K0, linear
1
48
640 0013
7-Segment-Anzeige
7-Segment-Indicator
3
49
640 0004
7-Segment-Anzeige
7-Segment-Indicator
3
50
640 7503
Optokoppler
Optokoppler
2
51
640 6638
Inkrementalgeber 500 impulse/360°
Digital Transmiter 500 impulses/360°
1
52
640 6637
Inkrementalgeber 3600 impulse/360°
Digital Transmiter 3600 impulses/360°
1
53
640 7502
6-Q-Regler 400 VAC,50/60 Hz
Bi- directional thyristor amplifier
1
54
640 7500
4-Q-Regler 400 VAC,50/60 Hz
Bi- directional thyristor amplifier
1
55
640 6634
Scheibenläufer- Getriebemotor mit Tacho
Lamellar- conductor geared motor with tacho
1
56
640 633
Scheibenläufer-Getriebemotor mit Techo
Lamellar- conductor geared motor with tacho
1
* = recommended spare parts for 1 year operation
185
16. Spare Parts
Ersatzteilliste elektrisch
List of electrical Spare Parts
RB 650/1200 EL AGD
57
640 6517
Gleichstrom-Getriebemotor
DC Geared motor
1
58
640 6543
Gleichstrom-Getriebemotor
DC Geared motor with tacho
1
59
3.006.3178.01 E-Karte "Eingang Bedienung"
Board "Input control panel" (EB)
1
60
3.006.3179.01 E-Karte "Interface Steuerung"
Board "Interface" (IS)
1
61
3.006.3180.01 E-Karte "Eingang Weg"
Board "Input Distance" (ES)
1
62
3.006.3181.01 E-Karte "Speicher Weg"
Board "Distance Latch" (ES)
1
63
3.006.3182.01 E-Karte "Speicher Eingabe 1"
Board "Input Latch 1" (SE1)
1
64
3.006.3183.01 E-Karte "Speicher Eingabe 2"
Board "Input Latch 2" (SE2)
1
65
3.006.3184.01 E-Karte "Speicher Winkel"
Board "Angle Latch" (SW)
1
66
3.006.3185.01 E-Karte "Eingang Winkel"
Board "Input Angle" (EW)
1
67
3.006.3186.01 E-Karte "Eingang Geschwindigkeit"
Board "Input Speed" (EG)
1
68
3.006.3187.01 E-Karte "Analog Ausgabe Winkel"
Board "Output Angle" (AW)
1
69
3.006.3188.01 E-Karte "Analog Ausgabe Weg"
Board "Output Distance" (AS)
1
70
3.006.3189.01 E-Karte "Analog Ausgabe Pendelung X"
Board "Output Pendulunm X" (APX)
1
71
3.006.3190.01 E-Karte "Analog Ausgabe Pendelung Y"
Board "Output Pendulunm Y" (APY)
1
72
3.006.3191.01 E-Karte "Ausgabe Speicher 1"
Board "Output Latch 1" (AS1)
1
* = recommended spare parts for 1 year operation
186
16. Spare Parts
Ersatzteilliste elektrisch
List of electrical Spare Parts
RB 650/1200 EL AGD
73
3.006.3192.01 E-Karte "Ausgabe Speicher 2"
Board "Output Latch 2" (AS2)
1
74
3.006.3193.01 E-Karte "Ausgabe Relais"
Board "Output Relais" (AR)
1
75
3.006.3194.01 E-Karte "Regler Sperre"
Board "Control Barrier" (RS)
1
76
3.009.3177.04 E-Karte "Vorstufe Pendelung"
Board "Pendulum Controller" (VP)
1
77
640 6630
Netzteil "NT 1/NT 2"
Power supply "NT 1/NT 2"
2
* = recommended spare parts for 1 year operation
187
17. Technical drawings
17.
Technical drawings
17.1. Technical drawings: mechanical
17.2. Technical drawings: electrical
188
17. Technical drawings
17.1.
Technical drawings: mechanical
17.1.1.
Height adjustment
17.1.2.
Torch carriage
17.1.3.
Elevation column
17.1.4.
Beam
17.1.5.
Azimuth
17.1.6.
Chuck
17.1.7.
Pneumatic
17.1.8.
Pipe support carriage
17.1.9.
Traversing track
17.1.10.
Foundation plan
17.1.11.
Lubrication plans
189
17. Technical drawings
17.1.1.
Height adjustment
190
17. Technical drawings
17.1.2. Torch carriage
191
17. Technical drawings
17.1.3. Elevation column
192
17. Technical drawings
17.1.4. Beam
193
17. Technical drawings
17.1.5. Azimuth
194
17. Technical drawings
17.1.6. Chuck
195
17. Technical drawings
17.1.7. Pneumatic
196
17. Technical drawings
17.1.8. Pipe support carriage
197
17. Technical drawings
17.1.9. Traversing track
198
17. Technical drawings
17.1.10. Foundation plan
199
17. Technical drawings
17.1.11. Lubrication Plans
200
17. Technical drawings
17.2.
Technical drawings: electrical
17.2.1.
Block schematics
17.2.2.
Wiring diagrams
17.2.3.
Circuit diagrams
17.2.4.
Electro drawings
201
17. Technical drawings
17.2.1.
Block schematics
202
17. Technical drawings
17.2.2.
Wiring diagrams
203
17. Technical drawings
17.2.3.
Circuit diagrams
204
17. Technical drawings
17.2.4.
Electro drawings
205
18. Sub-Supplier manuals
18.
Sub-Supplier manuals
206