HGG PCL 600 Manuel utilisateur

Profile Cutting Line

Operators Manual

Official manual of the Profile Cutting Line

Includes types: PCL 600

PCL 600

Operators Manual

v 2.0

Operators manual Profile Cutting Line

This is the operator’s manual for the PCL 600 profile cutting line.

For any questions or comments please contact:

Manufacturer: HGG Profiling Equipment b.v.

Address: Zuidrak 2

1771 SW Wieringerwerf

Country: The Netherlands

Phone: +31 (0) 227 50 40 30

Release date: 13-09-2013

Version: 2.0

PCL 600

Operators Manual

v 2.0

Preface

This manual is part of a set of manuals for the PCL 600 robotic cutting machine. In this manual you will find

the operating instructions. The complete set of manuals consist of the following manuals:

Operator’s manual Contains information concerning the safe operation of the machine. Includes

a list of screen messages with explanations.

Maintenance and

Grease Schedule Contains information about periodic maintenance and the lubrication

programme for the machine and it’s parts.

Software Restore Contains instructions on how to restore the machine software in the event of

a computer crash.

Robot control manual A short overview of the information needed to safely operate the Staubli

TX60L robot. Full details of the robot and controller can be found in the

Staubli manuals delivered with this manual set.

Plasma Unit

User’s Manual Contains operating instructions and cutting information for the plasma unit.

ProCAM Manual –

Framework and ProGRAM Contains instructions and description of the ProCAM software including

programming instructions and nesting.

Course Book ProCAM

Framework Course book for the ProCAM software with exercises demonstrating the use

of ProCAM.

Technical Manual Contains mechanical and electrical drawings and connection list for all

cables.

For safe operation and to ensure the reliability of the cutting machine it is necessary that all the above

manuals are available to all the people who work with the machine and to those who are related to the

machine, such as maintenance and service engineers and the work preparation engineers.

Document conventions

There are four levels of special notation used in this manual:

WARNING!

A warning statement typically describes the potential hazard, it’s possible effect and the

measures that must be taken to reduce the hazard.

CAUTION!

Damage to the equipment or products could result if the specified action is not complied

with.

ATTENTION!

Provides extra information to notify the user for potential problems.

NOTE.

Provides information or gives a tip for easier operation.

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Operators Manual

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Contents

1INTRODUCTION...........................................................................................................................................7

1.1INTENDED USE OF THE MACHINE...............................................................................................................7

1.2RANGE......................................................................................................................................................7

1.3MATERIAL SPECIFICATIONS......................................................................................................................7

1.4CONDITIONS FOR USE AND INSTALLATION................................................................................................8

1.5NOISE EMISSIONS......................................................................................................................................8

1.6GAS SUPPLIES ...........................................................................................................................................8

1.7NON-INTENDED USE OF THE MACHINE ......................................................................................................9

1.8DEFINITIONS OF QUALIFICATION OF PERSONNEL ......................................................................................9

2SAFETY........................................................................................................................................................10

2.1QUALIFICATION OF PERSONNEL..............................................................................................................10

2.2PERSONAL SAFETY INSTRUCTIONS..........................................................................................................11

2.3PERSONAL PROTECTION EQUIPMENT.......................................................................................................11

2.4RESIDUAL RISKS .....................................................................................................................................12

2.5SAFETY LABELS......................................................................................................................................13

2.6EMERGENCY STOP ..................................................................................................................................14

3MACHINE DESCRIPTION..........................................................................................................................15

3.1LAY OUT PCL 600..................................................................................................................................15

3.2MACHINE COMPONENTS .........................................................................................................................16

4CONTROLS..................................................................................................................................................18

4.1MACHINE CONTROLLER..........................................................................................................................18

4.2ROBOT CONTROLLER ..............................................................................................................................18

4.3USING THE TOUCH SCREEN CONTROLS....................................................................................................19

4.3.1GENERAL ...................................................................................................................................19

4.3.2CONTROLS..................................................................................................................................20

4.3.3INFORMATION ............................................................................................................................24

4.3.4PROFILING..................................................................................................................................24

5OPERATING THE MACHINE ....................................................................................................................25

5.1BEFORE STARTING THE MACHINE ...........................................................................................................25

5.2STARTING UP THE MACHINE....................................................................................................................25

6PROFILING ..................................................................................................................................................26

6.1MANUAL SELECTION OF CUTTING DATA .................................................................................................26

6.2DEFAULT PROJECT SETTING....................................................................................................................27

6.3USING THE AUTO CUT LIST....................................................................................................................27

6.4STATUS...................................................................................................................................................28

6.5THE CUTTING SEQUENCE FOR A SINGLE BAR...........................................................................................29

6.5.1CUTTING PROGRESS –PRODUCTION GRAPHIC............................................................................31

6.5.2MATERIAL SPECIFICATIONS........................................................................................................31

6.6AUTOMATIC CUTTING.............................................................................................................................32

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7MENU BAR AND SETTINGS.....................................................................................................................33

7.1SERVICE .................................................................................................................................................33

7.2LIST........................................................................................................................................................33

7.3TOOLS ....................................................................................................................................................34

7.4CUTTING.................................................................................................................................................34

7.5SERVICE MENU ITEMS:SETTINGS............................................................................................................34

7.5.1MAINTENANCE...........................................................................................................................36

7.5.2COLLECT DATA ..........................................................................................................................36

7.5.3PRINT LAST CUT PARTS...............................................................................................................36

7.5.4CUTTING SETTINGS EDITOR ........................................................................................................36

7.6TOOLS MENU ITEMS:PLASMA SERVICE INFO...........................................................................................37

7.6.1MAINTENANCE AND DATA MONITORS.......................................................................................37

8CALIBRATION............................................................................................................................................38

8.1TOOLS AND MATERIAL............................................................................................................................38

8.2CALIBRATE CLAMPS ...............................................................................................................................39

8.3CALIBRATE ACTIVE FRAME.....................................................................................................................40

8.4CALIBRATE TOOL....................................................................................................................................43

8.4.1CREATE A CUTTING FILE.............................................................................................................43

8.4.2CUT THE ‘TOOLCALMID’CALIBRATION PIECE...........................................................................46

8.4.3ENTER THE ‘CALIBRATE TOOL’MEASUREMENTS .......................................................................47

8.5CUTTING COMPENSATION.......................................................................................................................48

8.5.1PROFILE SELECTION ...................................................................................................................48

8.5.2SHIFT DIRECTION........................................................................................................................48

8.5.3ADJUSTMENTS............................................................................................................................48

9CUTTING TABLES......................................................................................................................................49

9.1EDITING THE CUTTING TABLE .................................................................................................................49

9.2COLUMNS IN THE CUTTING TABLE ..........................................................................................................50

10TRANSPORT AND STORAGE...................................................................................................................52

10.1PREPARATION.........................................................................................................................................52

10.1.1STORAGE ENVIRONMENT............................................................................................................52

10.1.2MOVING THE MACHINE...............................................................................................................52

10.1.3TRANSPORTING THE MACHINE....................................................................................................52

10.2STORAGE................................................................................................................................................53

10.2.1MAIN FRAME AND GRIPPER RAIL ................................................................................................53

10.2.2OUTFEED BELT,PUSHER AND TABLE ..........................................................................................53

10.2.3CONVEYORS AND PASSIVE SUPPORT LEGS ..................................................................................54

10.2.4SIDEWAYS LOADING CHAINS ......................................................................................................54

10.2.5INFEED AND OUTFEED BUFFER CHAINS.......................................................................................54

10.2.6CUTTING CELL............................................................................................................................55

10.2.7CONTROL UNIT CABINET ............................................................................................................55

10.2.8DUST COLLECTOR.......................................................................................................................56

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10.2.9PLASMA UNIT .............................................................................................................................56

10.3SMALLER COMPONENTS..........................................................................................................................56

APPENDIX A: TERMINOLOGY ........................................................................................................................57

APPENDIX B: NOTIFICATIONS, WARNINGS AND ERRORS......................................................................58

APPENDIX C: CE CERTIFICATE......................................................................................................................69

PCL 600

Operators Manual

v 2.0

1 Introduction

1.1 Intended use of the machine

This machine is a stationary, computer controlled,

programmable cutting machine. It should be used

for the cutting of metal profiles such as angles, flat

bars, bulbs, T-bars etc. using a plasma cutting

process. For an explanation of this process please

refer to Appendix A: Terminology. This machine

should be used for industrial applications only. A

nameplate, as shown on the right, is located on the

right hand door of the cutting cell on the operator’s

side. Do not exceed the maximum values indicated

on the name plate. You should always keep this

nameplate clean and in legible condition.

1.2 Range

Material profile Minimum

thickness Maximum

weight Minimum

length Maximum length

Raw bar 5 mm 60 mm 2,500 kg 2000 mm 12000 mm

Cutting process Minimum wall thickness Maximum wall thickness Cutting angle range

Plasma 5 mm 60 mm (35 mm quality cut) -45° to 45°

1.3 Material specifications

Material profile Minimum

thickness Maximum

weight Minimum

size Maximum size

Flat bar 5 mm 60 mm* 160 kg/m 100 x 5 mm 550 x 60 mm

Holland profile 5 mm 15 mm 160 kg/m 100 x 5 mm 550 x 15 mm

Equal angle 160 kg/m 75 x 75 mm 150 x150 mm

Unequal angle 160 kg/m 100 x 75 mm 550 x 150 mm

T-bar 160 kg/m 100 x 75 mm 500 x 200 mm

* Material with a thickness of 60 mm cannot be pierced by the plasma torch. It can be cut, starting from the

outside edge. The maximum thickness that can be pierced is approximately 40 mm.

Maximum deviation/deformation of material Deflection:

Maximum deflection (over 12 m) = ±30 mm

Maximum longitudinal deflection = 3 mm/m

Web and flange angle = 90° ±3° Twist:

Overall maximum twist = ±5°

Maximum twist per meter = ±1°

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1.4 Conditions for use and installation

The PCL 600 is suitable for installation and use in an environment with the following specifications:

Ventilated, wind- and rainproof environment.

Admissible ambient temperature of 0º C to +35º C.

Maximum atmospheric humidity of 90% non-condensing.

Minimum illumination intensity of 500 lux.

WARNING!

Due to the plasma cutting process hazardous substances may be

created. Consult the instruction manual of the plasma unit for more

information.

1.5 Noise emissions

The plasma cutting process causes noise emissions which increase with higher currents and thicker

material. Please refer to the plasma instruction manual for detailed information. The table below gives a

general indication of the expected noise emissions. Emissions above 70 dB(A) for extended periods can

cause damage to the hearing. Ear protection must be worn when using the plasma cutting process.

Fine Focus 800

Cutting current Material thickness Maximum noise level measured at a distance of:

1 meter 3 meter

No load - 70 dB(A) -

Pilot arc (24 Amp) - 96 dB(A) 88 dB(A)

250 Amps 10 mm 103 dB(A) 93 dB(A)

250 Amps 40 mm 105 dB(A) 99 dB(A)

* Source: Kjellberg Finsterwalde Plasma Instruction Manuals

WARNING!

The plasma cutting process generates noise emissions above 70 dB(A), ear

protection must be worn at all times.

1.6 Gas supplies

The cylinders must always be placed upright and in a secured position.

Do not use damaged cylinders, pressure reducers or armatures.

Use pressure reducers only for the gas for which they are intended.

Do not lubricate pressure reducers with grease or oil.

All parts coming into contact with oxygen must be protected from grease and oil.

The following gas supplies must be available where the machine is installed:

Compressed air. Non-greased, non-condensed, filtered for particles < 40 µm. Pressure 12 bar.

Argon. Non-greased, non-condensed, filtered for particles < 5 µm. Pressure 12 bar.

Hydrogen. Non-greased, non-condensed, filtered for particles < 5 µm. Pressure 12 bar.

Nitrogen. Non-greased, non-condensed, filtered for particles < 5 µm. Pressure 12 bar.

Oxygen. Non-greased, non-condensed, purity 99.5%, filtered for particles < 5 µm. Pressure 12 bar.

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1.7 Non-intended use of the machine

The PCL 600 should not be used for clamping or cutting pressurized cylinders, hermetically sealed

containers or objects other than described in chapter 1.1. The machine should not be used for cutting

flammable or explosive material. The machine should not be used for cutting coated materials that cause the

formation of noxious gasses during cutting. Do not use tools other than those specified in this manual in

combination with the machine.

Non-intended use of the machine can:

cause injury to personnel

damage the machine or other equipment

reduce the machine reliability and the machine performance.

WARNING!

The plasma cutting process generates high temperatures and

sparks. The machine should never be used in a flammable or

explosive environment! Remove containers with flammable

substances from the vicinity of the machine (e.g. paint, grease etc.).

1.8 Definitions of qualification of personnel

User

A user is a person or organisation who is responsible for the machine.

Authorised person

An authorised person is someone who is authorised by the user to carry out certain activities on the

machine.

Skilled person

Skilled persons heave technical knowledge or sufficient experience to enable them to avoid the dangers

which electricity, pneumatics, hydraulics and mechanics may create (e.g. engineers and technicians).

Instructed person

Instructed persons are adequately advised or supervised by skilled persons to enable them to avoid the

dangers which electricity, pneumatics, hydraulics and mechanics may create (e.g. operating, cleaning and

maintenance staff).

Operator

Operators are instructed persons who are adequately advised to avoid the dangers this machine may create.

Instruction should include instructions in operation under normal conditions and emergency situations.

Operators are persons who start, stop, load, unload, program and clean the machine.

Mechanic

Mechanics have technical knowledge or sufficient experience to enable them to avoid the dangers which

electricity, pneumatics, hydraulics and mechanics may create. Mechanics are persons who maintain and

clean the machine.

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Operators Manual

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2 Safety

The machine is designed to cut metal profiles using a plasma torch. The machine should only be used for

industrial applications as outlined in chapter 1.1: Intended use of the machine. Care must be taken when

loading material on to the machine. Always place the robot in the ‘safe’ position before moving material into

or out of the cutting area.

2.1 Qualification of personnel

The machine must only be operated by instructed operators and repaired or maintained by instructed

mechanics.

Risks can especially be caused when the machine:

is operated, maintained or cleaned by inexperienced or non-instructed personnel.

is operated, cleaned or maintained insufficiently.

is used for purposes other than described in chapter 1 Introduction.

Operators and mechanics must:

read and understand chapter 2 of this manual: Safety.

have sufficient knowledge to carry out the activities on the machine.

have knowledge of the presence and working of the emergency stop mechanism of the machine.

have knowledge of the presence and working of all other safety facilities of the machine.

have knowledge of their specific tasks and authorizations.

avoid all activities that are dangerous to the health.

avoid all activities that can cause damage to the machine and the products of the machine.

Operators and mechanics have to make sure that:

the area surrounding the machine is clean and free of persons, tools and other (flammable) objects or

liquids.

the machine is only operated when the machine is in good condition.

the machine is only operated when the provided protective covers are correctly installed at the correct

locations.

CAUTION!

Before operating the machine check that there is no oil leakage in

the vicinity, this may cause a slipping hazard. Remove all materials

from the vicinity of the machine that could cause a tripping hazard.

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