Operation Instruction

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Tamsin Harriet Hall
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instruction In order to assure safety, please let the qualified personal or person who has a deep understanding of beveling machine to install, maintain, check and

1 Shanghai Zhengte Welding Equipments & Consumables Manufacture CO., LTD. Enterprise of ISO-9001 Quality System Certification Operation Instruction Pipe Cutting and Machine Please use this machine after carefully read this operation instruction In order to assure safety, please let the qualified personal or person who has a deep understanding of beveling machine to install, maintain, check and repair. In order to assure safety, please operate this machine after fully understanding the contents in this instruction. After read this instruction, please put it at an easy available place to related personnel and keep it well. Please read it again if needed.

2 Contents Special tips for operation Title page 1.Product performance and features 1 2.Main structure and function 1 3.s and technical parameters 1 4.Reference table for clamp rib applied for pipe O.D 4 5.Operation procedure for manual blade feed beveling machine 5 6. blade 6 7.Repair and maintenance 6 8.Common troubles and settlement 7 9.Transportation and movement 7 10.Quality guarantee and after sales service 8 11.Attached documents 8 12.Product structure diagram 8

During beveling,please keep a certain distance from the rotating cutter head,be sure your arm are 10cm at least from the turn units except start and stop.

3 During beveling,please keep a certain distance from the rotating cutter head,be sure your arm are 10cm at least from the turn units except start and stop. Warning Please do wear safety goggles when work close to the machine. Caution Please do wear hearing protector or other sound insulation device when work close to the machine. Caution Please do not wear the gloves during operation because they cannot help protection.please use the broom and dustpan to clean up the beveling chips so that can avoid injury to hands. 1.Product performance and features Electric pipe cutting and beveling machine is a portable pipe beveling equipment, designed and manufactured based on high standard requirement with an eye on advanced international level through our company s many years hard work. Adopting machining process method, this machine can bevel different metal such as carbon steel, stainless steel, alloy steel, casting iron etc, under cooling circumstance, with different bevel shape to meet welding requirement. The portable design can make the bevel work under any environment with electric power, indoors and outdoors. It can be widely used in petroleum, chemical industry, electric power, water transportation, boiler etc, for their pipeline construction and maintenance operations. Features: 1.Many models, each one can work on pipes with any different diameter in its applicable range just by changing the different clamp rib; 2.Compact, lightweight, allow use in narrow space and headroom in any orientation, without need of other tools. 3.The installation is simple and convenient, beveling speed is fast; 4.As it adopts mechanical cutting beveling method, it can maintain well mechanical properties of the material quality so as to avoid burning by using gas cutting method. 5.Automatic knife feeding beveling machine can do many beveling shapes, such as flat, V shape, X shape, U shape and so on, which can meet the technological requirements for butt welding. 2.Main structure and function Pipe cutting and beveling machine consists of following 6 parts: motor (includes speed reducer), deceleration system compounded from three planetary gear reducers, clamping system, feeding device, blade and clamp rib. Through the motor s high-speed rotating, multilevel and various forms gear speed change drive system and rotating cutterhead around the mandrel, finally the machine outputs the needed rotate speed of the cutterhead and cutting force for beveling work. Rotate the draw rod, make the clamp rib clamp and shrink radially, let the machine rigidly mount to pipe I.D.or release. The feeding device including outgoing feed and radial feed, consists of two parts, cutting and beveling device. Automatic feed device can deliver a even feed schedule by rotating the ratchet wheel on the end of the holder. 3. and technical parameter -1-

4 Metric standard -2- Frequency/Volt age(kw/v) speed(rpm ) ISD-80 φ ~ ISD-150 φ ~ ISD-300 φ ~ ISD-450 φ ~ ISD-600 φ ~ ISD-750 φ ~ ISD-900 φ ~ ISD-1050 φ ~ Rated pressure Air speed(rpm) GPD-80 φ ~ GPD-150 φ ~ GPD-300 φ ~ GPD-450 φ ~25 0.6mpa~ GPD-600 φ ~25 1.5mpa GPD-750 φ ~ GPD-900 φ ~ GPD-1050 φ ~ Frequency/Vo ltage(kw/v) speed(rpm) SKD-80 φ ~ SKD-150 φ ~ SKD-300 φ ~ SKD-450 φ ~ /220 SKD-600 φ ~ SKD-750 φ ~ SKD-900 φ ~ SKD-1050 φ ~ Frequency/Vo ltage(kw/v) speed(rpm) HYD-80 φ ~25/50 0~ HYD-150 φ ~25/50 0~ HYD-300 φ ~25/50 0~ HYD-450 φ ~25/50 0~ /380 HYD-600 φ ~25/50 0~ HYD-750 φ ~25/50 0~ HYD-900 φ ~25/50 0~ HYD-1050 φ ~25/50 0~ British system standard Frequency/Vol tage(kw/v) speed(rpm) ISD-168 Φ ~ ~2.5 ISD-219 Φ ~ V ISD-273 Φ ~

5 ISD-305 Φ ~ ISD-323 Φ ~ ISD-406 Φ ~ ISD-457 Φ ~ ISD-508 Φ ~ ISD-560 Φ ~ ISD-610 Φ ~ ISD-715 Φ ~ ISD-762 Φ ~ ISD-930 Φ ~ ISD-1016 Φ ~ ISD-1160 Φ ~ Frequency/Vo ltage(kw/v) speed(rpm) GPD-168 Φ ~ GPD-219 Φ ~ GPD-273 Φ ~ GPD-305 Φ ~ GPD-323 Φ ~ GPD-406 Φ ~ GPD-457 Φ ~ GPD-508 Φ ~25 More than GPD-560 Φ ~ GPD-610 Φ ~ GPD-715 Φ ~ GPD-762 Φ ~ GPD-930 Φ ~ GPD-1016 Φ ~ GPD-1160 Φ ~ Frequency/Vol tage(kw/v) speed(rpm) SKD-168 Φ ~25/50 0~ SKD-219 Φ ~25/50 0~ SKD-273 Φ ~25/50 0~ SKD-305 Φ ~25/50 0~ SKD-323 Φ ~25/50 0~ SKD-406 Φ ~25/50 0~ SKD-457 Φ ~25/50 0~ /220 SKD-508 Φ ~25/50 0~ SKD-560 Φ ~25/50 0~ SKD-610 Φ ~25/50 0~ SKD-715 Φ ~25/50 0~ SKD-762 Φ ~25/50 0~ SKD-930 Φ ~25/50 0~ SKD-1016 Φ ~25/50 0~

6 SKD-1160 Φ ~25/50 0~ Frequency/Vol tage(kw/v) speed(rpm) HYD-168 Φ ~25/50 0~ HYD-219 Φ ~25/50 0~ HYD-273 Φ ~25/50 0~ HYD-305 Φ ~25/50 0~ HYD-323 Φ ~25/50 0~ HYD-406 Φ ~25/50 0~ HYD-457 Φ ~25/50 0~ HYD-508 Φ ~25/50 0~ HYD-560 Φ ~25/50 7.5/380 0~ HYD-610 Φ ~25/50 0~ HYD-715 Φ ~25/50 0~ HYD-762 Φ ~25/50 0~ HYD-930 Φ ~25/50 0~ HYD-101 Φ ~25/50 0~ HYD Φ ~25/50 0~ Note: 1. The single weight does not contain accessories. 2. The datas of wall thickness in the chart above are for plain carbon steel. 4. Reference table for clamp rib applied for pipe O.D.(mm) Metric standard Clamp rib No Clamp rib 1# Clamp rib 2# Clamp rib 3# Clamp rib 4# Clamp rib Range Height Range Height Range Height Range Height Range 80 φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ British system standard -4-

7 Clamp rib No Clamp rib 1# Clamp rib 2# Clamp rib 3# Clamp rib 4# Clamp rib Range Height Range Height Range Height Range Height Range 168 φ φ φ φ φ φ Φ φ φ φ φ φ φ φ φ Φ Φ φ Φ φ φ φ φ φ φ φ φ φ φ Φ φ φ φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ φ φ φ φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Φ Operation procedure for manual blade feed beveling machine This operational program is applicable for ISD series beveling machines. No. Operational program 1 Preparation 2 3 Operation steps and contents 1.Clear up the circumstance round the pipe to be beveled. 2.Clean up the pipe end. 1.Measure the pipe O.D. Installation 2.Select suitable clamp rib for O.D. according to the chart. of clamp rib 3.Test if the clamp and shrink range meet the requirement. Adjust the cutterhead pipe (backward adjusting) Notice To avoid accident caused when the turn plate scrap the circumstances. The pipe head for beveling needs to be grinded if the pipe end is gas cut or has weld bead to avoid blade damage. 1.To ensure that the max swelling diameter is 10mm above more than the pipe O.D. 2. the tighting diameter should be at least 5mm less than the O.D. 3. the below flat surface should be quite close to the oblique surface of the swelling strip to assure firm and stable. Enough feed space should be allowed for installation in one step according to radial length needed. 4 Clamp and location 1.Mount the machine body on the pipe O.D.and fix it well. 2.Tighten the bilge screw well with a inner hexagon spanner. When do the location, please avoid slope by adjusting the vertical degree between clamp rib and pipe outside wall, and center well according to the scale Make sure the clamp are reliable to avoid movement during working. 5 6 Blade installation Power connection Let the blade center locate at the pipe center and screw it Fix the beveling blade with defined angle on the knifeup by the fastening screw on the knife plate. The end turnplate. surface should be reliably close to the bottom surface of knife plate. Get the power cable and insert it into power socket. The power cable direction should be kept far from the machine body to avoid accident because of twisting during work. -5-

8 7 8 Release 1. Turn on the power switch on the motor, then the cutterhead1. Please note the blade cannot touch the pipe. is rotating. 2. Because the pipe head is accidented, please start 2.Drive handwheel or handle slowly to the pipe bevel end. beveling slowly. 3. The feeding speed can be adjusted based on the cut3. First feed the cutting blade, then beveling blade. thickness when the knife is quite close to the bevel area. 4. If bevel the thick pipe, please try to use the coolant to 4. When finish beveling, please firstly shut down the motor prolong blade life. and then turn the knife back to safe area. 1.Cut off the power 1. Please avoid the blade damaged when it bumps at the 2.Use the hex wrench to release clamp screw pipe during loosening. 2. If all the bevel work are finished, please unload the 3. Pull out the bevel machine from the pipe and put it at a beveling knife and make maintenance according to the fixed place. relevant chapters 6. blade blade is the most important part for beveling process. Correct selection and use can realize high efficient and quality bevel work: 1).For external installed pipe beveling and cutting machine, all kinds of beveling shape of pipe end such as flat, V shape, X shape and U shape, is formed due to different blade shape of beveling blade. 2). To choose what material of blade is determined by the processing pipe material. Usually, please choose the blade as following. *If bevel carbon steel pipe (such as 235,10#,20# pipe), please use high speed steel material blade *If bevel stainless steel pipe, high strength alloy steel pipe and casting iron, please use the coated blade 3).Keep blade sharp, and resharpen it if it wears before use. The beveling machine is delivered from the factory with 4 high speed tool steel blades that can realize bevel on the carbon steel pipe for maximum wall thickness. Please refer to the common beveling diagram for blade shape and quantity. User can also choose it according to your own need and order other one when the listed blade below can t meet your requirement. Please tell us the processed pipe material and wall thickness when order beveling machine or blade from us so that we can suggest what is the suitable machines and knife for you. Our company s blade is made with good quality material through optimized design, with the characteristic of good blade and long life. Please do use our beveling knife for the best benefits and beveling performance. Specification for common bevel blade Drawing Name No. Quantity Description Severing blade Severing Upright beveling angle beveling blade beveling angle Reverse beveling blade beveling angle 7. Repair and maintenance 1). Check the power cable and socket regularly and keep it at good insulation condition. 2). Every time after beveling, please clean up the metal scraps and wash the machine body with coal oil or diesel oil for rust -6-

9 prevention. 3). Please lubricate the screws of feed and clamp device, driven parts, exposed parts in center mandrel, oblique parts in clamp rib and so on to keep the machine under a good lubrication condition. 4) Please put the machine in package box or fixed support and keep drying. 5). Please do maintenance as following when the machine is used as long as half a year. a. check the gear and bearing on the driven system. Change them if they are worn. b. clean up the gear and bearing parts in driven system with lubrication as following requirements. * The gear and bearing on motor and panel reducer should be lubricated with 4# supramoly. * In machine head, the bearing should be lubricated with 4# supramoly and the gear with 9# supramoly. c. Adjust well the intervals reserved when reassemble the machine to avoid too loose or too tight. For other parts, please keep the same precision as original assembly. 8.Common trouble and settlement No. Common trouble Possible cause Settlement 1 The blade edge is broken. The pipe head is accidented surface. Feed blade slowly and speed up when the surface is even. There is gas cutting bump or weld bead on processed pipe Use the grinder to make it even before beveling. 2 The knife wasn t pressed well when do Increase the strength to stabilize it down and feed The blade is quake, bevel. the blade slowly. which causes accidented The inner pipe hole is irregular or the bevel surface. Release the machine and re-fix it for center location machine was not fixed in center. 3 Rough bevel surface. The blade is dull or default. Change or regrind the blade. The cutterhead rotation is 4 slow down obviously Feed the blade slowly or draw back and feed it Too much blade feeding. when beveling, with again. abnormal motor sound. 5 The machine moves or The clamp is not tight enough or the Clamp again or change suitable clamp rib and wobbles when bevel. clamp ribs are unsuitable. clamp them again. 6 The clamp or feeding structure lacks Clamp or feed is not lubricating or there is additional thing flexible. in this structure. Clean up the additional thing and lubricate it. Judge by your hand: If it can be hold by hand, the temperature is 7 supposed to be 50 degree below so it can be used The motor and planetary Cause by high speed rotation. continuously. gearbox get hot. If it is too hot for your hand, please stop working immediately and rework when it is cool naturally. Or check if there is any other cause. 8 The journey of blade support is beyond Move out the blade support with your hand and at Can t draw back the the adjustment range, and the screw is the same time turn the clutch hand wheel to let the blade. off the driven rod. screw fixing well on the rod. 9. Transportation and movement When move the bevel machine, please put it in the package box with the quake prevention foam under the motor and the power cable should be bundled at a free of pressing place. Avoid to be rainy and moisture and avoid serious shake during transportation. -7-

10 10. Quality warranty and after sales service Our machine is tested strictly according to the technical requirement for following items: a. electric insulation performance testing b. no load running testing c. beveling testing based on work condition d. the intervals among driven system are adjusted at the best condition Our after sales service will be offered to you under the following clauses: a. have 1 year warranty since the purchasing day b. if the machine is in trouble due to our quality problem within warranty period, we will serve for you free of charge. c. If the machine is damaged due to user s problem within our warranty period, the damaged parts will be charged as cost and no charge for repair. Any items below are beyond warranty range: a. Within warranty period, user dismantles the driven system or change the machine structure by yourself. b. The machine performance is badly influenced due to serious and obvious crash of the machine. c. No bevel machine s name card and no effective documents. We offer lifelong maintenance service for our machine. 11. Attached documents a. operation instructions (this document) b. product qualification card c. attached components list 12. Product structure diagram -8-

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14 Shanghai Zhengte Welding Equipments & Consumables Manufacture Co., Ltd. Add: No.305, South Shengxin Rd., Nanxiang Town, Jiading District, Shanghai, China Tel: , , , Fax: P.C.: Website:

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