Related Manuals for HGG SPC 1200
Summarization of Contents
Introduction
Machine Overview and Specifications
Covers intended use, pipe range, conditions, noise, gas, and hazards.
Safety
Machine and Personal Safety
Details machine safety, personal instructions, residual risks, and safety labels.
Machine Description
3.1 Introduction
Provides an overview of the SPC machines and their capabilities.
3.2 Axis Definition
Defines the different axes and movements of the machine.
3.3 Lay Out
Illustrates the main components and their arrangement on the machine.
Machine Frame
Describes the foundation frame essential for machine function and stability.
Main Drive
Details the main drive unit, including its chuck, motor, and clamping system.
Cutting Trolley
Explains the cutting trolley's function, movement, and integrated cutting head.
Cutting Head
Describes the biaxial cutting head, its torch, and rotation/tilt capabilities.
Spark and Fume Reversal Kit
Details the function of the spark and fume reversal kit for safety and fume management.
Remote Control
Explains the remote control interface for operating the machine.
Pipe Support: Pipe Trolleys
Describes the height-adjustable pipe trolleys used for supporting pipes.
Pipe Support: Rollerball Gutter
Details the rollerball gutter as an alternative pipe support system.
Fume Extraction (Optional)
Explains the optional fume extraction system for removing smoke and fumes.
Marking Unit (Optional)
Describes the optional marking units for applying marks on pipes.
The Controls
Main Drive Controls
Details the power key switch and clamping pressure adjustment for the main drive.
Remote Control Interface and Operation
Explains the remote control panel, its use, display, menus, and action buttons.
Screen-Based Operations
Covers Material Handling, Profiling, Settings, and Diagnostics screens for machine operation.
Component Controls
Details controls for the cutting trolley and main drive, covering movement and adjustment functions.
Profiling and Marking Controls
Covers settings, diagnostics, cutting tools, and marking controls for machine operation.
Operating the Machine
Control Elements Overview
Identifies and describes the main control elements of the SPC 500-1200 machine.
Pre-Operation Checks
Lists pre-operation checks and safety measures before starting the machine.
Starting and Homing the Machine
Provides steps for starting the machine and homing its axes for accurate positioning.
Stopping the Machine
Outlines procedures for safely stopping the machine and its associated systems.
Using the Main Drive
Details how to control the main drive for clamping, rotation, and height adjustments.
Pipe Handling Procedures
Provides safety instructions and procedures for loading and unloading pipes from the machine.
Profiling Process
Guides on initiating profiling, adjusting cutting parameters, and managing the cutting process.
Starting Oxyfuel Profiling
Provides detailed steps for starting the oxyfuel cutting profiling process.
Starting Plasma Profiling
Provides detailed steps for starting the plasma cutting profiling process.
Switching Cutting Torches
Explains how to switch between oxyfuel and plasma torches and adjust the plasma torch height.
Stopping and Resuming Profiling
Outlines procedures for stopping, pausing, resuming, and displacing the profiling process.
Cutting Near Main Drive and Behind Main Drive
Warns about cutting near the main drive and explains optional cutting behind it.
Emergency Stop and Safety Features
Explains the emergency stop system and safety features during operation.
Appendix A Maintenance and Grease Schedule
Periodic Maintenance Overview
Details the importance of periodic maintenance for machine reliability and safe operation.
Safety During Maintenance
Outlines safety precautions to be taken during maintenance procedures.
Replacing the Cutting Torch Nozzle
Details the procedure for replacing the cutting torch and preheat torch nozzles.
Weekly Maintenance Tasks
Outlines essential weekly checks for optimal machine performance and cutting quality.
Three-monthly Maintenance Tasks
Details maintenance procedures to be performed every three months.
Grease Types
Lists the types of grease, lubrication, and cleaning fluids used for machine maintenance.
Main Drive Unit Lubrication and Maintenance
Details greasing points and maintenance tasks for the main drive unit.
Cutting Trolley Lubrication and Maintenance
Details greasing points and maintenance tasks for the cutting trolley.
Cutting Head Lubrication and Maintenance
Details greasing points and maintenance tasks for the cutting head.
Pipe Trolley Lubrication and Maintenance
Details greasing points and maintenance tasks for the pipe trolleys.
Rollerball Gutter Lubrication and Maintenance
Details cleaning and greasing tasks for the rollerball gutter.
Machine Frame Cleaning
Details cleaning procedures for the machine frame's horizontal rails and pipe trolley rails.
Appendix B Calibration and Cutting Test Pieces
Calibration and Alignment Overview
Explains the importance of alignment and the process of calibrating machine components.
Cutting Test Pieces Procedure
Guides on cutting and evaluating test pieces for software offset calculation.
Safety During Calibration
Outlines safety precautions to be taken during calibration procedures.
Rear Frame Alignment
Provides detailed steps for ensuring the rear frame is correctly aligned horizontally and vertically.
Main Drive Alignment
Guides on aligning the main drive unit vertically and perpendicular to the machine centerline.
Pipe Trolley Adjustment
Details how to adjust pipe trolleys to align with the machine centerline and ensure proper fit.
Roller Ball Gutter Adjustment
Explains how to adjust roller ball gutter units for horizontal level and centerline alignment.
Mechanical Alignment of the Cutting Head
Guides on the mechanical alignment of the cutting head using pull and push bolts.
Cutting Head Rotation Alignment
Describes how to position the cutting arm and check its rotation axis for vertical level.
Software Calibration of the Cutting Head
Guides on performing software calibration for the cutting head, including tilt and torch angle adjustments.
Setting the Torch in the Centre of the Cutting Head
Explains how to mechanically center the torch within the cutting head.
Oxyfuel Cutting Test Pieces
Guides on cutting test pieces for oxyfuel profiling and evaluating results.
Cutting the First Test Piece
Provides instructions for cutting the first test piece for calibration.
Calculating Oscillation Offsets
Explains how to calculate oscillation offsets based on measurements from test pieces.
Cutting the Second Test Piece
Guides on cutting the second test piece, including bevel adjustments.
Calculating Virtual Burner Height
Explains how to calculate the virtual burner height based on test piece results.
Setting Kerf Width and Virtual Burner Height
Guides on setting kerf width and virtual burner height using caliper measurements.
Kerf Width Correction
Details how to correct kerf width based on test piece measurements for accurate cuts.
Virtual Burner Height Correction
Explains how to correct the virtual burner height based on test piece results for precise cutting.
Plasma Cutting Test Pieces
Guides on cutting test pieces for plasma profiling and evaluating results.
Plasma Angle Correction
Explains how to perform plasma angle correction based on ring measurements.
Calibrating the Marking Tool
Guides on calibrating the marking tool using test pieces and calculating offsets.
Appendix C Software Messages, Notifications and Errors
IO Director and Pmac Errors
Lists and explains errors related to IO Director and Pmac motion controller systems.
Max Controller Errors
Lists and explains errors related to the Max Controller system.
Axes and Safety Overrule
Describes software problems with axes and notifications for safety setting overrides.
Laser Measurement System Errors
Lists and explains messages and errors related to the Keyence laser measurement system.
Data Collector Messages
Explains messages related to the data collector's activity recording.
Digitax Drive Errors
Lists and explains errors related to the Digitax servo motor drive.
Plasma Service Counter Notifications
Explains notifications related to the plasma service counter for consumables.
HiFocus Plasma Unit Errors
Lists and explains messages and errors related to the HiFocus plasma unit.
REA Inkjet Printer Errors
Lists and explains communication problems with the REA Inkjet Printer driver.
Default Settings and General Errors
Explains default setting issues and general timeout/configuration errors.
General Notifications
Lists general notifications for the operator during machine startup and shutdown.
ProCAM Software Errors
Lists and explains errors related to starting ProCAM and its licensing.
Control Unit Errors
Lists and explains errors related to the control unit, including emergency stop and overheating.
Main Drive Rotation Errors
Lists and explains errors related to main drive rotation during profiling or automatic mode.
Main Drive Height Errors
Lists notifications for the operator regarding main drive height encoder status.
Main Drive CNC Clamping Errors
Lists and explains errors related to CNC clamping on the SPC 330 main drive.
Cutting Trolley Errors
Lists and explains errors related to cutting trolley longitudinal movement and conditions.
Main Drive Hydraulic Motor Errors
Explains errors related to the main drive hydraulic motor overload.
Cutting Trolley Height Errors
Lists and explains timeout errors for cutting trolley height systems.
Cutting Trolley Height Sensor Errors
Lists and explains errors related to the cutting trolley height sensor.
Gas Cutting Errors
Lists and explains timeout errors related to gas cutting operations like piercing.
Plasma Cutting Errors
Lists and explains timeout errors related to plasma cutting operations.
Software Errors
Lists and explains general software configuration errors.
Fume Extraction Unit Notifications
Lists notifications for the operator regarding fume extraction status.
Profiling Errors
Lists and explains errors related to data file calculation, loading, and profiling parameters.
Cutting Head Rotation Errors
Lists and explains notifications related to cutting head rotation calibration.
Cutting Head Pitch Errors
Lists and explains notifications related to cutting head pitch calibration.
Cutting Head Tilt Errors
Lists and explains notifications related to cutting head tilt calibration.
Main Drive Longitudinal Errors
Lists and explains notifications for main drive longitudinal movement limits.
Main Drive Transversal Errors
Lists and explains errors and notifications for main drive transversal movement.
Diabolo Conveyor Controller Errors
Lists and explains errors and notifications for the Diabolo Conveyor controller.
Plasma Fine Marker Errors
Lists and explains timeout errors for the plasma fine marker.
Punch Marker Errors
Lists and explains timeout errors for the punch marker.
HiFocus Plasma Unit Errors
Lists and explains timeout errors for the HiFocus plasma unit.
REA Inkjet Printer Errors
Lists and explains timeout errors for the REA inkjet printer.
Main Drive Clamping Errors
Explains errors related to main drive clamping on SPC 1500-3000 machines.
Control Unit Errors
Lists and explains errors related to the control unit, specifically emergency stop fuses.
Approach Errors (Prior to Profiling)
Lists errors that occur before profiling, related to approaching sets or main drive areas.
REA Inkjet Printer Controller Errors
Lists and explains communication errors with the REA inkjet printer controller.
Diabolo Conveyor Errors
Explains errors related to the Diabolo conveyor motor overload.
Conveyor Lever Height Errors
Lists notifications for conveyor lever height status.
Roller Bed Bogie Errors
Lists notifications for roller bed bogie height status.
Roller Bed Hydraulic Motor Errors
Explains errors related to roller bed hydraulic motor overload.
Frequency Regulator Faults
Describes faults related to frequency regulators and emergency stop procedures.
Diameter Check Errors (RBPC Machines)
Lists and explains timeout errors during diameter checks on RBPC machines.
Transversal Platform Errors (SPC-RB Machines)
Lists and explains timeout errors for the transversal platform movement.
Diabolo Conveyor Height Errors
Lists notifications for diabolo conveyor height status.
Settings Errors
Covers errors encountered when opening, creating, or modifying settings files and parameters.
Axis Definition
Axis Labels and Diagrams
Defines the machine's axes and their corresponding labels with visual diagrams.
Amplifier Errors
Checking the Amplifier
Provides guidance on checking the amplifier status and potential causes of errors.
Amplifier Errors for MDR, CTL, CTH, MDH Motors
Describes the status LEDs and display modes of M'Ax drives used for these motors.
Amplifier Checks for CHT and CHR Motors
Details amplifier checks for CHT and CHR motors, including power and LED status.
Amplifier Checks for MDC Motor (SPC 1500-2500)
Describes amplifier checks for the MDC motor, including status LEDs and power issues.
Following Errors
Motor Position Display Issues
Addresses issues where motor position display doesn't update despite motor movement.
Motor Does Not Move
Covers scenarios where the motor fails to move, indicating mechanical blockage or defects.
Motor Overload Errors
Discusses errors occurring when the motor cannot keep up with commanded speed or acceleration.
Troubleshooting Unlocated Errors
Provides further troubleshooting steps when initial checks fail to identify the error cause.
Height Sensor Following Errors
Addresses following errors related to the height sensor and pipe surface following.
End Switch Errors
Software End Switches
Explains software-defined end positions and their role in error reporting.
CHT Motor End Switch Errors
Discusses end switch errors for the CHT motor, noting the absence of physical switches.
CHR Motor End Switch Errors
Covers end switch errors for the CHR motor, including hardware and software aspects.
CTL Motor End Switch Errors
Details end switch errors for the CTL axis, including safety features related to the main drive.
False End Switch Error Messages
Guides on identifying and troubleshooting false end switch error messages.
Missing End Switch Error Messages
Addresses situations where the machine hits a mechanical stop without an end switch error.
Double End Switch Errors
Discusses troubleshooting double end switch errors possibly caused by power supply issues.
Homing Errors
CTL Axis Home Error
Explains home errors for the CTL axis and checks for its functioning.
Cutting Head Home Errors
Covers general home errors for the cutting head axes and troubleshooting steps.
CHT Axis Home Error
Details home errors for the CHT axis and checks for its home switch functionality.
CHR Axis Home Error
Explains home errors for the CHR axis and checks for its home and limit switches.
General Home Search Errors
Addresses general home search timeout errors and checks for other motor errors.
Sensor System Errors
General Sensor Check
Guides on performing a general check of the sensor system and its components.
Sensor Value Not Changing
Provides troubleshooting steps when the sensor value does not change during operation.
Height Sensor Blocked
Addresses issues where the height sensor system becomes mechanically blocked.
Floating Mode and Deviation Errors
Explains errors occurring during floating mode and deviation issues related to the sensor system.
Emergency Stop
False Emergency Stop Message
Discusses potential causes and checks for false emergency stop messages.
Main Drive Unit Errors
SPC 330 Main Drive Unit Errors
Details errors specific to the SPC 330 main drive unit, including clamping and rotation.
Clamping Errors SPC 330
Covers clamping errors for the SPC 330, including cylinder and switch checks.
SPC 500-1200 Main Drive Unit Errors
Explains errors related to the SPC 500-1200 main drive unit, including hydraulic height and clamping.
SPC 1500-2500 Main Drive Unit Errors
Details errors for the SPC 1500-2500 main drive unit, including fixed height and electric clamping.
Pipe Jammed in Chuck
Addresses issues with pipes jammed in the chuck and potential causes.
Clamping Side Setting Importance
Explains the importance of the clamping side setting for pipe release.
Jamming Due to Improper Clamping
Discusses jamming caused by improper clamping or height adjustments.
Manual Pipe Removal from Chuck
Provides methods for manually removing a pipe jammed in the chuck.
Encoder Signal Check
Checking MDR, MDH, CTH, CTL Motor Encoder Signals
Guides on checking encoder signals for MDR, MDH, CTH, and CTL motors.
Checking CHT and CHR Motor Encoder Signals
Details checking encoder signals for CHT and CHR motors.
Height Sensor Encoder Signal Check
Explains how to check the encoder signal for the height sensor system.
Encoder Failure Troubleshooting
Discusses steps to take if the encoder signal does not change during motor movement.
MDR Motor Resolver Feedback Check
Details checks for the MDR motor's resolver feedback and amplifier.
CTH, CTL, MDH Motor Checks
Explains checks for CTH, CTL, and MDH motors with resolver feedback.
Encoder Voltage and Status Check
Explains how to check encoder signal voltage and status using a multimeter.
Resolver Check
Resolver Functionality and Amplifier Diagnosis
Guides on checking the resolver's functionality and diagnosing issues with the amplifier.
Motor Check
MDR, MDH, CTL, CTH Motor Checks
Details checks for MDR, MDH, CTL, and CTH motors, including coil impedance and earthing.
CHT and CHR Motor Checks
Explains checks for CHT and CHR motors, including fuse status and coil impedance.
MDC Motor Checks (SPC 1500-2500)
Details checks for the MDC motor, including cable earthing and coil impedance.
Motors Overloaded
MDR Motor Overload Causes
Discusses potential causes of MDR motor overload and how to locate system blocks.
CTL Motor Issues
Addresses common problems with the CTL motor, sliders, and guiding rail.
CHT Motor Issues
Discusses CHT motor issues related to gearbox grease and mechanical checks.
CHR Motor Issues
Covers CHR motor problems related to gearbox grease and checks of the cutting head components.
CTH Motor Issues
Details CTH motor issues, including guide rails, spindle, and bearing checks.
MDC Motor Issues (SPC 1500-2500)
Addresses MDC motor overload, slider box, chuck, and gearbox checks.
MDH Motor Issues
Covers MDH motor checks, including gearbox, spindle, and bearing inspections.
Appendix D Software Restore
Introduction to Software Restore
Introduces the process of restoring machine software using a USB stick.
Software Locations
Identifies where to find necessary software on the HGG Customer Portal and USB drive.
Bootable USB Key Preparation
Explains how to prepare a bootable USB key with snapshot software and disk images.
Machine Image Location
Specifies the location of the latest machine images for different computer types.
ProCAM Software Location
Indicates the location of the latest ProCAM software version.
UPC Software Location
Specifies the location of the latest UPC machine software.
ProCAD Software Information
Discusses ProCAD software installation and compatibility requirements with AutoCAD/Tekla.
Creating a Bootable USB Key
Guides on preparing the USB key by starting Snapshot and selecting 'Restore disk from file'.
Copying Software to USB Key
Explains how to copy Windows images, UPC, and ProCAM software to the USB drive.
UPC Machine Configuration Copy
Guides on copying UPC machine backup files to the USB drive for settings.
ProCAD Connection and Manuals Copy
Explains how to copy ProCAD installers and manuals to the USB drive.
Restoring the Hard Disk
Details the process of installing the Windows image from the USB stick by booting from it.
Restoring UPC Machine Software
Guides on installing the UPC machine software from the USB drive.
Replacing Settings
Explains how to import settings files after installing the UPC software.
Restoring ProCAM Software
Guides on installing the ProCAM software from the USB drive.
BIOS Settings
FPC-7100 BIOS Configuration
Details BIOS setup adjustments for the FPC-7100, including power configuration.
FPC-7300 BIOS Configuration
Details BIOS setup adjustments for the FPC-7300, including SuperIO and USB configuration.
FPC-7700 BIOS Configuration
Details BIOS setup adjustments for the FPC-7700, focusing on Super IO configuration.
Appendix E Cutting Quality
Oxyfuel Cutting Quality Issues
Discusses oxyfuel cutting quality issues, their causes, and correction methods.
Plasma Cutting Quality Issues
Discusses plasma cutting quality issues, their causes, and correction methods.
Appendix F Terminology
Glossary of Technical Terms
Defines key technical terms used throughout the manual related to cutting and machine operation.
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