6.

OPERATION OF THE MACHINE

6.1 DESCRIPTION OF THE CONTROL

The machine is controlled with the following parts:

Main switch
C7 PLC with operator panel

6.1.1 MAIN SWITCH

Main voltage is switched on and off by means of the main switch. The entire
equipment is dead when switched of at the main switch.

Attention : Power supply to the cabinet plug is independent of from the main
switch. Attention, high voltage!

6.1.2 OPERATION OF THE PLC-CONTROL

For the operation of the machine, no prior knowledge is required as all
inputs are done by software menus.
The machine is operated by the SIEMENS OP7 operator panel:

SIEMENS SIMATIC OP7

F1 F2 F3 F4

K1 K2 K3 K4

7 8 9
ESC
4 5 6
ACK
1 2 3

INS
. 0 +/- SHIFT
DEL
HELP ENTER

The following description always refers to the sketch shown above.

7. DESCRIPTION OF THE MENUES

7.1 STARTING MENU; BASIC MENU

When the operator turns on the main switch of the machine, the following text will
appear:

KISTLER
SADDLE CUTTING MACHINE
SCM

The K-function buttons are preprogrammed with the following functions:

K1: pipe turn left

K2: pipe turn right
K3: torch move left
K 4: torch move right

By pressing the F1-button, we will enter the selection menu:

11 MITER END CUT

12 JOINT END CUT
13 JOINT HOLE CUT
14 SLIT CUT
15 HELP

By pressing the  and  buttons, he can change the lines displayed.

By pressing the ENTER-button, he can choose the desired cutting shape.

Every programmed cut can be tested by pressing the F1-button or be cut by

pressing the F2-button.
7.2 CUT OFF PIPES (MITER END CUT)

DIAMETER : XXX
THICKNESS : XX
INTERSECT. ANGLE : XXX
PIERCING DIST. X : XX
PIERCING DIST. Y : XX
CUTTING SPEED : XXXX

<F1> TEST; <F2> CUT

With this menu, pipe can be cut off at a certain angle.

The pipe diameter, the wall thickness and the piercing distances are to be entered in
mm, the cutting speed in mm per min. and the angle between the pipes in degrees.

After the movement has been started, the torch is being moved to the hole piercing
point. The control will then give a start sign to the plasma power source, after having
received the signal „arc is ok“ from the plasma power source, the torch will cut to the
actual cutting path and cut the desired path.
7.3 JOINT END CUT

DIAMETER 1 : XXX
THICKNESS 1 : XX
DIAMETER 2 : XXX
THICKNESS 2 : XX
INTERSECT. ANGLE : XXX
OFFSET : XXX
PIERCING DIST. X : XX
PIERCING DIST. Y : XX
CUTTING SPEED : XXXX
METHOD (1=IN; 2=ON) :X

<F1> TEST; <F2> CUT

With this menu, a branch pipe can be cut.

The pipe diameters of the main pipe and the branch pipe, the wall thicknesses and the
piercing distances are to be entered in mm, the cutting speed in mm per min. and the
angle between the pipes in degrees.

After the movement has been started, the torch is being moved to the hole piercing
point. The control will then give a start sign to the plasma power source, after having
received the signal „arc is ok“ from the plasma power source, the torch will cut to the
actual cutting path and cut the desired path.

The operator can choose between the different types of welding methods:

1.) branch pipe will be welded inside the main pipe

2.) branch pipe will sit on the main pipe
7.4 JOINT HOLE CUT
JOINT HOLE CUT:

DIAMETER 1 : XXX
THICKNESS 1 : XX
DIAMETER 2 : XXX
THICKNESS 2 : XX
INTERSECT. ANGLE : XXX
OFFSET : XXX
PIERCING DIST. X : XX
PIERCING DIST. Y : XX
CUTTING SPEED : XXXX
METHOD (1=IN; 2=ON) :X

<F1> TEST; <F2> CUT

With this menu, the hole for a branch pipe can be cut.

The pipe diameters of the main pipe and the branch pipe, the wall thicknesses and the
piercing distances are to be entered in mm, the cutting speed in mm per min. and the
angle between the pipes in degrees.

After the movement has been started, the torch is being moved to the hole piercing
point. The control will then give a start sign to the plasma power source, after having
received the signal „arc is ok“ from the plasma power source, the torch will cut to the
actual cutting path and cut the desired path.

The operator can choose between the different types of welding methods:

1.) branch pipe will be welded inside the main pipe

2.) branch pipe will sit on the main pipe
7.5 SLIT CUT
DIAMETER : XXX
THICKNESS : XXX
SLIT LENGHT : XXX
SLIT WIDTH : XXX
RADIUS (YES=1, NO=0) :X
CUTTING SPEED : XXXX

<F1> TEST; <F2> CUT

With this menu, a rectangular hole can be cut.

The pipe diameter and the wall thickness are to be entered in mm, the cutting speed
in mm per min. and the slit data (slit lenght and slit width) are to be entered in mm.

After the movement has been started, the torch is being moved to the hole piercing
point. The control will then give a start sign to the plasma power source, after having
received the signal „arc is ok“ from the plasma power source, the torch will cut to the
actual cutting path and cut the desired path.

The operator can choose between the different types of holes:

1.) rectangular hole without radius

2.) rectangular hole with radius
8. INSPECTION, GENERAL CARE AND MAINTENANCE
Always use extreme care to avoid physical harm to yourself when performing inspection,
service and maintenance operation.

WARNING! Disconnect all electrical power to unit prior to performing any inspection or
maintenance!

KISTLER suggests a program of preventative maintenance with initial intervals of 6

months.
A maintenance program will add to the reliability, accuracy and over-all life of the
machine.

Welding equipment is subjected to adverse environmental conditions caused mainly by

the welding process itself.

UNDER NO CIRCUMSTANCES SHOULD A MACHINE BE LOADED BEYOND ITS

RATED CAPACITY.

o Store and operate the machine in a dry place.

o Be sure ladders and service platforms are securely anchored and not obstructing
machine movements or causing interference.

o When lifting an entire machine (or component parts) be sure chain slings are
properly secured.

o Replace any parts suspected of being worn or damaged.

o Keep floors in the immediate area of the machine clean to minimize dirt being
drawn into the motor and drive mechanism.

o Use only factory approved repair parts when servicing machine.

o If drive covers are removed for servicing, be sure they are replaced before resuming
operation.

o In the event of an accident, for example: an overhead crane hook strikes a work-
piece or fixture, shut the machine down immediately. Thoroughly inspect all parts
for integrity before resuming operation.

o If you hear any unusual noises such as grinding, squealing, etc., shut the machine
down and have a qualified serviceman investigate.
8.1 ELECTRICAL
Be sure that only qualified, well trained electricians are allowed to service the machine.
Electricians should always practice the safety regulations as set forth in the various
applicable local codes.

o The life of electrical equipment cannot be predicted with any degree of success,
so a program of inspection of contact points, motor brushes and cables should
be established.

o Periodically inspect electrical cables to check their insulation integrity and there-
by prevent possible dangerous short circuiting.

o Refer to the electrical wiring diagram for the specific machine that accompanies
this manual.

o Visually check the contact points of contactors and relays periodically. Replace
when they show signs of discoloration or pitting. Keep electrical enclosures clean.
Use a vacuum cleaner if possible. It is a good idea to have spare electrical
components available, to minimize downtime.

8.2 LUBRICATION
WARNING: Never attempt to clean, oil or adjust a machine while it is in motion.

Keep the machine well lubricated at all times. Follow the lubricating instructions included
in section 10 of this manual.

8.3 CLEANLINESS, GENERAL

Keep the machine as clean possible at all times. It is highly recommended that a
continuing program of cleanliness be employed. Dirty ambient conditions, especially
where flux is utilized, can cause much trouble and accelerated wear. Do not allow
debris to fall into or accumulate on or near machinery mechanisms.

To protect the rollers from welding spatter, they should be sprayed or pasted with anti-
spatter from time to time.

Observation of the machine will show parts that should be wiped off, scraped off, blown
out, etc., at frequent intervals. Some representative parts are listed below:

DRIVE CHAINS ROLLERS

GEARING COLUMN WAYS
GRIPPERS SLIDE SCREWS & WAYS
8.4 BOLTS AND NUTS
It is a good idea to periodically go over the entire machine and re-tighten all the bolts
and nuts, some of which may have worked loose over a period of time or were not
retreated with locking fluid after removal.

KISTLER recommends use of Loctite Removable Threadlocker 242 for securing

attachments against vibration.

8.5 DRIVE MECHANISMS

Periodically, inspect the chain drives from the motors to insure proper tightness and
alignment is being maintained and that there are no signs of accelerated wear. After
extended service, the worm shaft of the drive may show axial play causing a jerky
movement of the workpiece. This can be corrected by putting suitable washers on
the pivot of the worm shaft.

WARNING: Never attempt to dismantle any machine or part thereof while a workpiece
is resting on the rolls.

o Do not allow the roller box, or other components, to fill with flux, rod stubs, or
other foreign material, which could impede operation.

o When lifting an entire machine (or component parts) be sure chain slings are
properly secured. Be sure the roll stand is properly supported to avoid undue
twist or bending strains. Lift slowly and gently.

o Clean out openings in the frame provided for inspection and removal of accumulated
foreign material.

9. LUBRICATION INSTRUCTIONS
Proper lubrication practices should be adhered to in caring for positioning equipment,
exactly the same as for any other high quality tool. In as much as most positioning
equipment is intermittent duty in nature and usually operates at slow speeds, heat is
seldom a factor as it relates to lubrication.

The instructions outlined in this manual are intended to cover the large majority of
normal installations. Of necessity, these instructions must pertain to average conditions.
The infinite number of variables affecting lubrication, such as speed, temperature en-
vironment, etc., make it nearly impossible to cover every application.

Cutting equipment is often located in dirty, damp environments that impose severe
service on the various machine elements. Under these conditions, extraordinary
emphasis should be placed on proper lubrication practices. Long life is directly
related to clean, well lubricated components.
Welding and flux equipment on welding positioning equipment should be maintained
in keeping with the manufacturer's recommendations.

There is a multiplicity of items often affixed to welding positioning equipment, such as

slides, pivots, wire loading jibs, wire reels, flux conveyors, etc. Careful observation of
these miscellaneous items will usually indicate the type and frequency of lubrication
required.

Lubrication must be done with a low pressure hand type grease gun or a high pressure
gun with a low pressure adapter only.

KISTLER suggests the use of the lubricants listed in paragraph 10.1. It is not necessary
that these particular products be used. All major oil companies usually have equivalent
products that can be employed. Many shops have standardized lubricants for industrial
machinery, and these may be used wherever they are being used for comparable com-
ponents and services. When in doubt, any KISTLER representative will gladly arrange
direct factory assistance in solving your specific lubrication problem.

To obtain maximum benefit from positioning equipment, KISTLER highly recommends

the installation of a preventative maintenance program. Lubrication should be a key
activity in this program. At installation we recommend an initial maintenance interval
of one month to insure sure that no abnormal wear patterns exist. When confidence
that the machine is operating normally based on the maintenance records resulting from
previous inspections, it is acceptable to extend the maintenance interval. It is KISTLERS'
position that maintenance intervals not exceed six months.

9.1 APPROVED LUBRICANTS

CAUTION: All greases are not created equal. Special attention should be exercised to
insure compatibility to bearing seals, gear materials, temperature, operating speed and
loading.

As a general guide and under normal conditions, the following lubricants are
recommended. When a device has a nameplate with lubricating instructions that
differs from the information in this manual, the nameplate instructions shall take
precedence.

I Chevron Ultra Duty Grease - Grade 2

Used for sliding applications that are enclosed or protected, such as "Screw and
Nut", Kingpin Housing - Timken Bearings, etc.
For Technical assistance, contact Chevron at 1-800-582-3835.

II Chevron Cylinder Oil W-ISO Grade 460, 680 and 1000 - Does not have
SULFUR-PHOSPHORUS additives. Used for worm gear reducers and other
enclosed gear-train applications. Meets AGMA 7 Comp., 8 Comp. and AGMA 8A
comp. respectively, and has a minimum viscosity index of 90.
III McLube #108 - Moly Sulphide Aerosol Spray
Used for general external usage where lubrication is desired without having oily
surfaces, that trap airborne dirt.
McGee Chemical Company
8000 West Chester Pike
Upper Darby, Pennsylvania

IV Chevron Turbine Oil GST, Grade 32, 46 and 100

Industrial Single viscosity, Non- Detergent Oil, Used for any application calling
for 10W, 20W and 30W oil respectively.

V Chevron GEAR Compound - Grade 68, 150, 220, and 460. An extreme pressure
gear lubricant containing a SULPHUR-PHOSPHORUS additive. Used for parallel
and bevel gear reducers. Not recommended for bronze worm gearing.

VI Keystone Moly 29 Grease - Grade 2

An extremely tacky lubricant used for open heavy duty spur gearing.

9.2 GEARMOTORS
All gear-motors have been shipped pre-lubricated. The fill port is furnished with a solid
pipe plug. A drilled breather plug is taped to the motor and should be installed in the fill
port whenever the motor mounting position permits. Remove the oil level plug and check
the level before beginning operation, and every four months thereafter. Flush and drain
the gear case after ever two years of normal operation.

Motor bearings are grease lubricated, and do not require re-lubrication for a period of
five years, or 10,000 hours of operation, when operated in normal ambient temperatures.

Lubricating oils for use in gearmotors should be high quality well refined petroleum oil.
They must not be corrosive to gears or bearings; they must be neutral in reaction; free
from grit or abrasive; and have good de-foaming properties. As they may be subjected
to high operating temperatures, they must have good resistance to oxidation. Consult
the gear-motor manufacturer for the proper lubricant.

9.3 WORM GEAR REDUCERS, GENERAL PURPOSE

Be sure to check the oil level before putting the machine in service. Some worm gear
units have oil level plugs in the side of the housing, while others are equipped with a
breather dip-stick plug on top or a sight gauge.

o During the first few days of operation, a worm gear unit may run hot. Unless
the temperature exceeds 200o F., there is no cause for alarm. Keep the oil level
up to the check plug at all times. The oil level must be checked while the unit is
not running.
o The oil in a new unit should be drained at the end of two weeks operation, and
at yearly intervals thereafter. The case should be thoroughly flushed with light
flushing oil prior to refilling. The original oil can be used for refilling if it has been
filtered; otherwise, new oil must be used. After this, a change of oil every 2500
hours of operation, or every six months, whichever occurs first, is recommended
for units operating under favorable conditions.

o Units which run at very slow speeds should carry an extra high oil level. Units
which run at high speed should have the oil level maintained at the normal
proper level. Overfilling causes churning losses and may result in overheating.

9.4 PILLOW BLOCK BEARINGS, BALL AND ROLLER

All anti-friction pillow blocks and cartridge type bearings should be lubricated with
Chevron Ultra Duty Grease - Grade 2 or equivalent. The recommended interval is
two to three months. Grease must be free of any impurities, such as free acid or
alkali, dust, rust, metal particles or abrasive.

o Grease should be pumped in slowly until a slight bead forms around the seals.
This bead in addition to acting as an indicator of adequate lubrication, provides
additional protection against the ingress of dirt.

o Pressure gun grease fittings are typically furnished on pillow blocks.

o When equipment will be idle for sometime, addition of fresh grease before shutting
down will assure maximum protection for the bearing races. This is particularly
important for equipment exposed to the weather.

9.5 BRONZE BUSHINGS

For bronze bushings that are furnished with grease fittings, pump Grade 2 grease into
the bearing until clean grease is observed emerging from the bushing.

Since applications can be diverse, the frequency of lubrication is not specified.

Experience with the machine must dictate the time between re-lubrications.

Bronze bushings that are used to mount a slide screw are Oilite brand and require no
lubrication.

9.6 CHAIN DRIVES

A properly lubricated chain drive will last many times as long as a poorly or unlubricated
chain.

A good grade of clean petroleum oil, either with or without additives, should be used.
The highest viscosity oil, which will flow between the link plates, and fill the pin bushing
areas, will provide the best wear life. For normal temperatures of 40o to 100o F., the
recommended lubricant is Chevron Turbine Oil GST, Grade 46.
Chains should be lubricated when they are not running. Manually lubricate with a brush,
or spout. Oil should be directed to the inside of the lower span, so it will not be thrown
off by centrifugal force before it penetrates the chain joints.

To protect the drive chain from spatter, it should be lubricated from time to time.

9.7 OPEN SPUR GEARS

Opinion is about equally divided on whether open spur gears should be greased. If they
are greased, frictional rubbing at the tooth flanks is improved, but there is also the
disadvantage that an abrasive sludge quickly forms due to air-borne dirt being trapped
in the grease. Conversely, if they are not greased, the dirt will fall off but the teeth will
operate under a dry rubbing condition.

Long experience has indicated that either method is acceptable for normal life in low
load, low cycle conditions.

9.8 SCREW AND NUT, ACME & BALL SCREW

Two versions are employed. They are the Acme screw and nut and the ball screw
and nut. Lubrication of either type is identical.

Environment conditions dictate the frequency and type of lubrication. The screw should
be inspected frequently and lubricated as required. As a general rule for exposed in-
stallations in a non-hostile environment, use Chevron Turbine Oil GST Grade 68 (20 wt)
wiped on with a soaked rag or applied by oil can. For exposed applications where oil or
grease attracts excessive dirt, McLube #108 is recommended.

o Avoid over-oiling since too much oil will only catch air borne dirt and form sludge.

o Clean dirt and sludge from the screw as often as is necessary.

9.9 COLUMN AND BOOM WAYS

It is recommended that column and boom ways be operated without any lubricant over
and above that required to prevent rusting. Always wipe dry after spreading a thin film.
Excessive lubricant tends to catch and hold dirt and grit.

Light oil film or a moly sulphide dry film lubricant is recommended.

10. SPARE PARTS

11.1 turning drive R42 DT71

11.2 set of toothed wheels
11.3 ball bearing
11.4 torch drive W20 DT71
11.5 toothed wheel
11.6 toothed rack
11.7 linear bearing