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.
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. 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-
Metric standard -2- Frequency/Volt age(kw/v) speed(rpm ) ISD-80 φ16-80 3~25 20 31 43 ISD-150 φ65-150 3~25 16 43 55 ISD-300 φ150-300 3~25 13 73 97 ISD-450 φ300-450 3~25 1.2-2.2 10 91 118 ISD-600 φ450-600 3~25 8 122 158 ISD-750 φ600-750 3~25 7 160 192 ISD-900 φ700-900 3~25 6 197 233 ISD-1050 φ850-1050 3~25 5 238 282 Rated pressure Air speed(rpm) GPD-80 φ16-80 3~25 20 31 43 GPD-150 φ65-150 3~25 16 43 55 GPD-300 φ150-300 3~25 13 73 97 GPD-450 φ300-450 3~25 0.6mpa~ 10 91 118 GPD-600 φ450-600 3~25 1.5mpa 8 122 158 GPD-750 φ600-750 3~25 7 160 192 GPD-900 φ700-900 3~25 6 197 233 GPD-1050 φ850-1050 3~25 5 238 282 Frequency/Vo ltage(kw/v) speed(rpm) SKD-80 φ16-80 3~50 20 51 63 SKD-150 φ65-150 3~50 16 63 75 SKD-300 φ150-300 3~50 13 93 117 SKD-450 φ300-450 3~50 10 111 138 2.5/220 SKD-600 φ450-600 3~50 8 142 178 SKD-750 φ600-750 3~50 7 180 212 SKD-900 φ700-900 3~50 6 217 253 SKD-1050 φ850-1050 3~50 5 258 302 Frequency/Vo ltage(kw/v) speed(rpm) HYD-80 φ16-80 3~25/50 0~20 341 383 HYD-150 φ65-150 3~25/50 0~16 353 395 HYD-300 φ150-300 3~25/50 0~13 383 435 HYD-450 φ300-450 3~25/50 0~10 401 467 7.5/380 HYD-600 φ450-600 3~25/50 0~10 432 500 HYD-750 φ600-750 3~25/50 0~10 470 540 HYD-900 φ750-900 3~25/50 0~10 507 583 HYD-1050 φ900-1050 3~25/50 0~10 548 632 British system standard Frequency/Vol tage(kw/v) speed(rpm) ISD-168 Φ78-168 3~25 16 47 59 1.2~2.5 ISD-219 Φ89-219 3~25 15 54 74 220V ISD-273 Φ130-273 3~25 14 63 84
ISD-305 Φ150-305 3~25 14 71 95 ISD-323 Φ180-323 3~25 13 78 106 ISD-406 Φ265-406 3~25 11 85 112 ISD-457 Φ300-457 3~25 10 93 120 ISD-508 Φ355-508 3~25 9 104 133 ISD-560 Φ400-560 3~25 9 118 148 ISD-610 Φ460-610 3~25 8 128 164 ISD-715 Φ560-715 3~25 8 146 182 ISD-762 Φ610-762 3~25 7 170 202 ISD-930 Φ780-930 3~25 6 210 246 ISD-1016 Φ860-1016 3~25 5 228 272 ISD-1160 Φ1020-1160 3~25 5 288 332 Frequency/Vo ltage(kw/v) speed(rpm) GPD-168 Φ78-168 3~25 16 47 59 GPD-219 Φ89-219 3~25 15 54 74 GPD-273 Φ130-273 3~25 14 63 84 GPD-305 Φ150-305 3~25 14 71 95 GPD-323 Φ180-323 3~25 13 78 106 GPD-406 Φ265-406 3~25 11 85 112 GPD-457 Φ300-457 3~25 10 93 120 GPD-508 Φ355-508 3~25 More than 0.6 9 104 133 GPD-560 Φ400-560 3~25 9 118 148 GPD-610 Φ460-610 3~25 8 128 164 GPD-715 Φ560-715 3~25 8 146 182 GPD-762 Φ610-762 3~25 7 170 202 GPD-930 Φ780-930 3~25 6 210 246 GPD-1016 Φ860-1016 3~25 5 228 272 GPD-1160 Φ1020-1160 3~25 5 288 332-3- Frequency/Vol tage(kw/v) speed(rpm) SKD-168 Φ78-168 3~25/50 0~16 67 79 SKD-219 Φ89-219 3~25/50 0~15 74 94 SKD-273 Φ130-273 3~25/50 0~14 83 104 SKD-305 Φ150-305 3~25/50 0~14 91 115 SKD-323 Φ180-323 3~25/50 0~13 98 126 SKD-406 Φ265-406 3~25/50 0~11 105 132 SKD-457 Φ300-457 3~25/50 0~10 113 140 2.5/220 SKD-508 Φ355-508 3~25/50 0~10 130 157 SKD-560 Φ400-560 3~25/50 0~10 138 165 SKD-610 Φ460-610 3~25/50 0~10 148 184 SKD-715 Φ560-715 3~25/50 0~10 166 202 SKD-762 Φ610-762 3~25/50 0~10 190 222 SKD-930 Φ780-930 3~25/50 0~10 230 266 SKD-1016 Φ860-1016 3~25/50 0~10 248 292
SKD-1160 Φ1020-1160 3~25/50 0~10 308 352 Frequency/Vol tage(kw/v) speed(rpm) HYD-168 Φ78-168 3~25/50 0~16 357 399 HYD-219 Φ80-219 3~25/50 0~15 364 406 HYD-273 Φ130-273 3~25/50 0~14 373 425 HYD-305 Φ150-305 3~25/50 0~10 381 433 HYD-323 Φ180-323 3~25/50 0~13 388 450 HYD-406 Φ265-406 3~25/50 0~11 395 461 HYD-457 Φ320-457 3~25/50 0~10 403 472 HYD-508 Φ355-508 3~25/50 0~10 420 490 HYD-560 Φ400-560 3~25/50 7.5/380 0~10 428 518 HYD-610 Φ470-610 3~25/50 0~10 438 526 HYD-715 Φ560-715 3~25/50 0~10 456 534 HYD-762 Φ620-762 3~25/50 0~10 480 550 HYD-930 Φ790-930 3~25/50 0~10 520 595 HYD-101 Φ860-1016 3~25/50 0~10 538 622 6 HYD-116 0 Φ1020-1160 3~25/50 0~10 598 687 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 φ46-80 15 φ16-46 30 150 φ120-150 15 φ90-120 30 φ60-90 300 φ270-300 15 φ240-270 30 φ210-240 45 φ180-210 60 φ150-180 450 φ420-450 15 φ390-420 30 φ360-390 45 φ330-360 60 φ300-330 600 φ570-600 15 φ540-570 30 φ510-540 45 φ480-510 60 φ450-600 750 φ720-750 15 φ690-720 30 φ660-690 45 φ630-660 60 φ600-630 900 φ900-860 20 φ820-860 40 φ780-820 60 φ740-780 80 φ700-740 1050 φ1050-1010 20 φ970-1010 40 φ930-970 60 φ890-930 80 φ850-890 British system standard -4-
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 φ138-168 15 φ108-138 30 φ78-108 219 φ199-219 15 φ169-199 30 φ139-169 45 Φ109-139 60 φ80-109 273 φ253-273 15 φ223-253 30 φ193-223 45 φ163-193 60 φ130-163 305 φ275-305 15 φ245-275 30 Φ215-245 45 Φ185-215 60 φ150-185 323 Φ303-323 15 φ273-303 30 φ243-273 45 φ213-243 60 φ180-213 406 φ386-406 15 φ356-386 30 φ326-356 45 φ296-326 60 φ265-296 457 φ437-457 15 Φ407-437 30 φ377-407 45 φ347-377 60 φ320-347 508 Φ478-508 15 Φ448-478 30 Φ418-448 45 Φ388-418 60 Φ350-388 560 Φ530-560 15 Φ500-530 30 Φ470-500 45 Φ470-440 60 Φ440-400 610 Φ590-610 15 Φ560-590 30 Φ530-560 45 Φ500-530 60 Φ470-500 715 Φ685-715 15 Φ655-685 30 Φ625-655 45 Φ595-625 60 Φ560-595 762 Φ742-762 15 φ970-1010 30 φ930-970 45 φ890-930 60 φ850-890 930 Φ900-930 15 Φ870-900 30 Φ840-870 45 Φ810-840 60 Φ810-790 1016 Φ986-1016 15 Φ956-986 30 Φ926-956 45 Φ896-926 60 Φ860-896 1160 Φ1130-1160 15 Φ1100-1130 30 Φ1070-1100 45 Φ1040-1070 60 Φ1010-1040 5. 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-
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 43-702-01 2 Severing Upright 43-703-02 1 30 beveling angle beveling blade 43-704-02 1 37.5 beveling angle Reverse beveling blade 43-705-03 1 37.5 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-
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. 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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Shanghai Zhengte Welding Equipments & Consumables Manufacture Co., Ltd. Add: No.305, South Shengxin Rd., Nanxiang Town, Jiading District, Shanghai, China Tel: +86-21-69176478, 69176479, 69176480, 69171792 Fax: +86-21-69179932 P.C.: 201802 Website: www.chdwelding.com E-mail:joe@chdwelding.com -12-