PRO-40PBS User Manual.indd
Contents
1. 17 Figure 5 Milling unit design 1 motor 2 milling head 3 milling unit lock lever 4 bolt securing milling head 5 spindle rotation lock button 6 angular pitch 7 X axis milling unit travel crank 8 X axis milling unit travel lock lever 9 Y axis milling unit travel crank 10 Y axis travel meter 11 Y axis milling unit travel lock knob GENERAL INFORMATION 1 4 Equipment included PRO 40PBS stationary pipe bevelling machine is supplied with complete standard equipment The included equipment consists of e stationary pipe bevelling machine active support with plastic rollers 1 unit passive support with steel rollers 1 unit e pipe clamp 1 unit e guiding chain 1 unit e size 10 Allen key 1 unit e size 8 Allen key 1 unit e size 5 Allen key 1 unit e size 16 flat key 1 unit e torx T15P screwdriver 1 unit e Operator s Manual 1 unit The machine active and passive support contains holes for transportation by forklifts Figure 6 Item 1 or cranes Figure 6 Item 2 0 0 0 0 00 000 Figure 6 Transportation holes active support 1 for forklift 2 for crane 10 GENERAL INFORMATION 1 5 Op2. Figure 9 Placing pipe longer than 830 mm with maximum diameter of 01000 mm STARTUP AND OPERATION 3 3 1 Using clamp Use clamp Figure 10 if pipe is short and light or not balanced during machining For this purpose place the pipe on the machine and mount clamp catching it by hooks Figure 11 Item 2 at both sides of the machine Then slightly tighten the nut Figure 10 Item 1 using size 16 flat key Figure 11 Using clamp 1 clamp 2 hook 3 3 2 Using guide chain If pipe moves along its axis during milling use guiding chain to provide balance To create the chain for the pipe of specific external diameter use basic B segment Figure 12 and 3 6 9 18 36 72 link additional segments Figure 13 Their proper interconnection sequence to form a single chain is shown in Table 1 columns from left to right while basic B segment 15 STARTUP AND OPERATION is necessary in all cases Because the 3 segment can not be last for pipes in 223 251 mm 8 78 9 88 diameter range place it within B segment after dismounting links Figure 12 Item 4 from connector Figure 12 Item 3 Figure 13 Additional segments design 1 connector 2 links 3 3 3 Guide chain usage example To create guiding chain for pipe with ex
3. 1 3 Design li 1 fe li man il ay cl El B j ES pi o a o H E AV Ei 7 E Hi iin Ul re pa af S BS Da G Figure 2 Machine design 1 active support 2 passive support GENERAL INFORMATION 6 9 LE NG TS ye o OOOO E O 11 l 10 7 5 2 8 gt li TABON NE 4 1 Lg Li mi i Ch NG 7 Figure 3 Active support design 1 body 2 control cabinet 3 fixed driving roller 4 movable driving roller 5 scale 6 rollers travel lever 7 movable roller pivot 8 chain guide 9 milling unit cover 10 emergency button 11 line indicating pipe position GENERAL INFORMATION START D a SPINDLE eo NI OPERATING d MODE v ROTATOR OVERLOAD LEFT lo RIGHI aise 1f Figure 4 Control panel design 1 main switch 2 control button 3 operating mode lever 4 emergency button 5 work area light 6 spindle start stop button 7 lamp indicating spindle overload 8 rotator start stop button 9 rotation direction switch 10 rotator speed adjusting knob GENERAL INFORMATION
4. bolt securing cutting insert 2 cutting insert 3 spindle rotation lock button 4 bolt securing milling head 3 6 Replacing milling head To replace milling head unplug power cord from power socket Then lock spindle rotation with button Figure 16 Item 3 unscrew bolt securing milling head Figure 16 Item 4 using Allen key of size dependent on the type of mounted head 19
5. and result in electric shock Bystanders can not be present in immediate vicinity of machine Before start check condition of machine and electrical installation including power cord plug control panel components and milling tools Before every use inspect machine to ensure it is not damaged Check whether any part is cracked or improperly fitted Make sure to maintain proper conditions that may affect machine operation Keep machine dry Exposing it to rain or snow is prohibited Ensure proper lighting in your worksite Never use machine in vicinity of combustible fluids or gases or in explosive environments Always use safety goggles hearing protection gloves and protective clothing during operation Do not wear loose clothing Never use blunt or damaged tools Do not touch spindle or machined pipe during motion Do not put hands into work area of driving rollers Mount cutting inserts and milling head securely Remove keys and tools used for replacement If cutting edge of insert is worn out rotate insert in socket by 90 or if all edges are worn out replace with new insert specified in Operator s Manual Maintain machine and tools with care Cover steel parts with thin grease layer to protect them against rust when not in use for a longer period After every use remove metal chips from machine particularly from milling head Never remove chips with bare hands Use only parts recommended by manufacturer and specified in Ope
6. personnel will void all warranty Consumable items such as cutting tools pilot pins saw blades grinding wheels etc are NOT covered by warranty Our goods come with guarantees which cannot be excluded under the Australian Consumer Law You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure TABLE OF CONTENTS General Information 2 Technical Data 3 Design 4 5 Saftey Precautions 6 7 Startup and Operation 8 11 Wiring Diagram 12 Parts Lists amp Exploded Views General Assembly 13 14 Drive System Assembly 15 Drive System 16 17 Controller Housing Complete 18 Panel Assembly 19 Torch Holding amp Low Torch Holding Assembly 20 GENERAL INFORMATION 1 GENERAL INFORMATION 1 1 Application The PRO 40PBS Stationary Pipe Bevelling Machine is designed for milling pipe edges of diameters from 200 mm 8 to 1016 mm 40 made of carbon steel It performs bevelling in 0 60 angular range bevels internal edges at 45 with maximum bevel depth of 5 mm 0 20 and enables facing When equipped with one of the optional milling heads available on request the machine enables performing J bevels with radius of 6 mm 0 24 or 8 mm 0 31 as well as bevelling internal edges in 0 60 range with maximum bevel widt
7. pivots Proceed as described for passive support as well Figure 2 Item 2 Item 9 and use crank Figure 5 Item 7 to lower X axis milling unit to prevent its damage caused by collision with the pipe 1 WARNING Before you place the pipe raise cover Figure 3 Place the pipe on the rotator to maintain a 160 260 mm 6 10 distance between pipe face and side surface of the rollers on the active support as in Figure 9 Because position of machining differs from position of the support any pipe shape tolerance deviation will cause inconsistency in the bevel or threshold To diminish these errors place the pipe as close to the rollers as permitted 160 mm 6 Additionally you may need to use clamp guiding chain or both 13 14 STARTUP AND OPERATION 830 mm 32 7 400 mm 15 7 O600 mm 23 6 KOH O200 mm 7 9 Figure 8 Placing pipe with the length of 400 830 mm and maximum diameter of 0600 mm over 830 mm 32 7 160 260 mm 6 10 Y D pad O E E Q S O 7 o A O
8. 4 Then place the pipe and hook up the chain on pipe perimeter as shown in Figure 15 17 18 STARTUP AND OPERATION Figure 15 Installing guiding chain 1 guiding chain 2 catch 3 tightener Hook the catch on the last link second or third from the end and put free links upwards Figure 15a Tighten guiding chain slightly to maintain minimum clearance using tightener Figure 15 Item 3 with the help of size 10 Allen key Then turn on the power with main switch Figure 4 Item 1 and press control button Figure 4 Item 2 what will be indicated by illuminating lamp after about 5 seconds Set lever Figure 4 Item 3 to rotator position start rotation using green button Figure 4 Item 8 and perform one complete rotation to ensure good arrangement of the guiding chain Then stop rotator with red button Figure 4 Item 8 and tighten guiding chain completely 3 4 Spindle setup and machine startup To perform a bevel open milling unit cover Figure 3 Item 9 Then after loosening levers Figure 5 Item 3 set milling unit to required angle on the pitch Figure 5 Item 6 and lock its rotation with the button Figure 5 Item 5 Unlock X axis milling unit travel lever Figure 5 Item 8 move milling unit to proper height using crank Figure 5 Item 7 and lock again Figure 5 Item 8 Set crank in horizontal position and fold its handle to prevent collision with the cover Then close the STARTUP AND OPERATION cov
9. Figure 4 Item 8 and to adjust rotational speed using knob Figure 4 Item 10 Spindle rotation is inactive in this mode Beveller mode enables after closing cover Figure 3 Item 9 to start the spindle using green button Figure 4 Item 6 and then to start rollers Figure 4 Item 8 If the spindle gets overloaded during operation red light will illuminate Figure 4 Item 7 In such case immediately decrease either milling depth or rotational speed of rollers To decrease milling head penetration in the working material retract Y axis milling unit using crank Figure 5 Item 9 Further spindle load increasing will trigger safety circuit and shut down the rotator spindle rotation will not stop In such case before you start rollers again retract Y axis milling unit and press rotator stop red button Figure 4 Item 8 This will turn off the red lamp and enable to start rotator with green start button Figure 4 Item 8 If the cover becomes open during bevelling spindle and rotator will immediately stop operation 3 3 Placing pipe Before you place the pipe on the machine set movable driving rollers Figure 3 Item 4 to match the red line Figure 3 Item 11 with machined pipe diameter on the scale Figure 3 Item 5 For this purpose remove pivots Figure 3 Item 7 maximally lower rollers travel lever Figure 3 Item 6 and use it to manually move rollers forwards or backwards Once setting in proper position raise lever and reinsert
10. TRADEMASTER INDUSTRIAL TOOLS PRO 40PBS STATIONARY PIPE BEVELLING MACHINE OPERATOR S MANUAL BEFORE USE ENSURE EVERYONE USING THIS MACHINE READS AND UNDERSTANDS ALL SAFETY AND OPERATING INSTRUCTIONS IN THIS MANUAL senal Heche a cece eee eee Date of Purchase TRADEMASTER PRO 40PBS STATIONARY PIPE BEVELLING MACHINE IMPORTED amp DISTRIBUTED BY A r AA INDUSTRIAL TOOL amp MACHINERY SALES 18 BUSINESS ST mu wa YATALA QLD 4207 AUSTRALIA T 07 3287 1114 F 07 3287 1115 E sales industrialtool com au W www industrialtool com au WARRANTY TERMS In addition to any warranties or conditions implied by applicable Statute or Regulations Industrial Tool amp Machinery Sales warrants all of it s products against defective workmanship and faulty materials for a period of twelve 12 months from the date of purchase unless otherwise stated At our option we will repair or replace free of charge any item on the condition that e The complete machine or tool is returned freight prepaid to ITM or one of it s authorised service agents as directed by ITM and is found to have a material or constructional defect The machine or tool has not been subject to misuse neglect or damage by accident The fault is not a result of normal wear and tear Written permission has been received from ITM prior to commencement of repair Repairs tampering or modification carried out by unauthorised
11. er and move it two inches away from pipe face Use switch Figure 4 Item 9 to choose between left recommended and right rotator direction and set required rotational speed with knob Figure 4 Item 10 Then use green button to start spindle Figure 4 Item 6 and rotator Figure 4 Item 8 Unlock Y axis milling unit travel using knob Figure 5 Item 11 Rotating crank Figure 5 Item 9 bring the tool close to working material then start milling process and lock Y axis travel again The bevel will be finished after one complete rotation To increase the width of achieved bevel set higher Y axis milling unit penetration in the working material In case of emergency press one of the emergency buttons either located on the machine body Figure 3 Item 10 or on the control panel Figure 4 Item 4 what will shut down the power 3 5 Replacing cutting inserts PRO 40PBS Stationary Pipe Bevelling Machine is equipped with the milling head containing 7 cutting inserts made of carbide that wear during operation Inserts can be replaced or rotated To replace or rotate the insert unplug power cord from power socket and using supplied torx T15P screwdriver unscrew bolt Figure 16 Item 1 then remove insert Figure 16 Item 2 and clean the socket Place rotated insert again or replace with new one if all four edges are worn out socket Place rotated insert again or replace with new one if all four edges are worn out Figure 16 Milling tool 1
12. h of 20 mm 0 79 Using optional steel rollers the carrying capacity is increased 5000 kg 11 000 Ibs per support max 5 mm 0 20 The value of the attained threshold will be variable for pipe of variable thickness threshold i GENERAL INFORMATION 1 2 Technical data Voltage 1 208 230 V 50 60 Hz Total power 2000 W Spindle power 1500 W External pipe diameter range for pipes 200 600 mm 7 87 23 62 of 400 830 mm length 15 7 32 7 External pipe diameter range for pipes 200 1016 mm 7 87 40 longer that 830 mm 32 7 b 45 mm 1 77 Figure 1 5 mm 0 20 Maximum allowed pipe weight For steel rollers of active support not included in standard equipment For plastic rollers of active support standard carrying capacity of each support is 3000 kg 6600 Ibs and maximum allowed pipe weight equals 6000 kg 13 200 Ibs Figure 1 Bevel dimensions GENERAL INFORMATION
13. rator s Manual Perform all maintenance work only with power cord unplugged from power socket Perform all repairs only in service centre appointed by seller If machine is wet or has other damage that could affect technical state of machine stop operation and immediately send machine to service centre for inspection N WARNING Safety rules must be closely observed 11 12 STARTUP AND OPERATION 3 STARTUP AND OPERATION N WARNING Read safety precautions before starting 3 1 Supports arrangement and machine connection Place machine on foundations that ensure balance and can transmit forces exerted by machine and working material Use active support for machining pipes in 400 830 mm 15 7 32 7 length range For pipes longer than 830 mm 32 7 use also passive support positioning it in relation to active support in a manner that prevents pipe from moving during rotation This can be done either by ensuring equality of diagonals formed between supports or by using 55x15 drawing flat bar Figure 7 Every support contains holes for fastening to foundations We recommend to connect the machine into mains using 3G2 5 mm power cord 55x15 drawing flat bar Figure 7 Supports arrangement for bevelling pipes longer than 830 mm 32 7 STARTUP AND OPERATION 3 2 Operating modes The machine can operate in rotator or beveller mode set by lever Figure 4 Item 3 Rotator mode enables to start rollers with green button
14. ternal diameter of 390 mm 15 35 connect basic B segment to additional 18 and 3 segments using connectors Figure 13 Item 1 with the help of size 5 Allen key Proper interconnection sequence should be as follows B 3 18 Figure 14 Figure 14 Guiding chain design for pipe with external diameter of 390 mm 15 35 1 basic segment 2 3 link segment 3 18 link segment 16 STARTUP AND OPERATION Basic Additional segments Pipe external Pipe external segment diameter diameter range mm range in 199 227 7 83 8 94 223 251 8 78 9 88 248 275 9 76 10 83 272 300 10 71 11 81 296 324 11 65 12 76 320 348 12 60 13 70 345 372 13 58 14 65 369 397 14 53 15 63 393 421 15 47 16 57 417 445 16 42 17 52 442 469 17 40 18 46 466 494 18 35 19 45 490 518 19 29 20 39 514 542 20 24 21 34 539 566 21 22 22 28 563 591 22 17 23 27 587 615 23 11 24 21 611 639 24 06 25 16 636 663 25 04 26 10 660 688 25 98 27 09 684 712 26 93 28 03 708 736 27 87 28 98 733 760 28 86 29 92 757 785 29 80 30 91 781 809 30 75 31 85 805 833 31 69 32 80 830 858 32 68 33 78 854 882 33 62 34 72 878 906 34 57 35 67 903 930 35 55 36 61 927 955 36 50 37 60 951 979 37 44 38 54 975 1003 38 39 39 49 1000 1027 39 37 40 43 Table 1 Proper segments interconnecting sequence for specific pipe diameters Before placing pipe on the machine place guiding chain between driving rollers Figure 3 Item
15. tional equipment You can optionally order milling heads for performing J bevels with the radius of 6 mm 0 24 or 8 mm 0 31 and for bevelling internal edges in 0 60 range with maximum bevel width of 20 mm 0 79 Additionally available steel rollers provide 5000 kg 11 000 Ibs carrying capacity per support The optional equipment consists of e milling head for R6 round cutting inserts e milling head for R8 round cutting inserts e milling head for bevelling internal edges e steel rollers threshold J Bevelling Internal Bevelling in 0 60 SAFETY PRECAUTION 2 SAFETY PRECAUTION 1 DAAN 11 12 13 14 15 16 17 18 19 20 Zi 22 23 24 25 Before start read Operators Manual and complete proper occupational safety and health training Machine must be used only in applications stated in Operator s Manual Machine must be complete and all parts must be genuine Power supply specifications must conform to those stated on rating plate Transport and operate machine only in vertical position Install machine on flat foundations with maximum 5 mm 2 deviation from level over length Improperly prepared surface may lead to damage incorrect machine operation and may Cause injuries to people in vicinity Connect machine to installation equipped with safety circuit earthing Never yank power cord to disconnect plug from socket It may cause power cord to break
Download Pdf Manuals
Related Search