HGG SPC 500 User manual

Pipe Profiling Machine
Operators Manual
Original manual for the Pipe Profiling Machine
MAINTENANCE CALIBRATION MESSAGES RESTORE QUALITY TERMINOLOGY
SPC 500-1200

Operators Manual
Pipe Profiling Machine | SPC 500 - 1200
I
Operators Manual - Pipe profiling machine
This is the pipe profiling machine operator’s manual. For any questions or comments please contact:
Manufacturer: HGG Profiling Equipment b.v.
Address: Zuidrak 2
1771 SW Wieringerwerf
Country: The Netherlands
Phone: [phone]
Release date: 01-06-2018
Version: 2018 version 1
Service
Spare parts and consumables are available and can be ordered from the HGG service department.
Questions or information can be sent to the service department by e-mail or fax 24 hours a day. During
local office hours your questions will be handled with dedication and care.
HGG opening hours Monday to Friday from 8:00 am - 17:00 pm (local time).
Phone: [phone]
Fax: [phone]
E-mail: [email protected]

Operators Manual
Pipe Profiling Machine | SPC 500 - 1200
II
Preface
This is the operators manual providing information regarding the operation and safe use of the pipe
profiling machines. The machine types SPC (stationary pipe cutter) 500-1200 are covered by this manual.
This manual is part of a set of manuals supplied with the pipe profiling machines.
Manual sets
This manual describes the operating procedure of the pipe profiling machine. This
manual also contains important information regarding safe use of the machine.
In the appendices you will find the periodic maintenance and grease schedule,
the calibration procedure for the cutting head and instructions for cutting
test pieces. Also included in the appendices is the procedure for restoring the
software and a list of error codes in numerical order. For reference purposes you
will also find definitions of the terminology used in this manual and a quick guide
to the oxyfuel cutting process.
Technical Manual This manual contains an installation checklist for the assembly and installation
of the machine, a list of spare parts and wear and tear parts for the machine
configuration. Also included in the technical manual are the main assembly
drawings, electrical diagrams and connection lists and pneumatic and hydraulic
diagrams. Detailed technical specifications and sub-assembly and individual part
drawings form part of the technical dossier which is stored at HGG.
Software Manual In this manual you will find instructions for using the ProCAM software for
online and offline programming of the profiles that can be cut on the machine.
This manual also describes the nesting of parts in raw materials and all the
other features of ProCAM. There is also a course book which includes exercises
providing a step for step guide to using the software. Manuals for the optional
ProCAD connections for AutoCAD and Tekla will also be included if applicable.
Options In the options you will find manuals for any other optional features delivered with
the machine, such as a plasma unit, dust collector, marking unit etc.
For safe operation and to ensure the reliability of the pipe profiling machine it is important that all the
above manuals are available to all the people who work with the machine and to those who are involved
with the machine such as supervisors, maintenance engineers, service engineers and work preparation
personnel.
Operators Manual

Operators Manual
Pipe Profiling Machine | SPC 500 - 1200
III
Safety
It is important that everybody who works with the profiling machine is aware of the safety notes as
described in the chapter ‘Safety’ in the operator’s manual. Use the machine only after you have read and
completely understood the contents of this manual. Operators and everybody involved with the machine
must always keep safety in mind.
Maintenance
For reliability and safe operation of the machine it is necessary that the maintenance is carried out as
described in the Appendix A: Maintenance & Grease Schedule.
Special notations
There are four levels of special notation used in this manual.
WARNING!
A warning statement will typically describe 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 of potential problems.
NOTE!
Provides information or gives a tip for easier operation.

Operators Manual
Pipe Profiling Machine | SPC 500 - 1200
IV
Table of contents
1 Introduction 1
1.1 Intended use of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Pipe range SPC 500 - 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Conditions for use and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Non-intended use of the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.1 Smart Focus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.2 High Focus 440i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5.3 Hypertherm HPR400XD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Gas supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6.1 Oxyfuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6.2 Plasma Kjellberg Smart Focus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6.3 Plasma Kjellberg High Focus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6.4 Plasma Hypertherm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Heat, smoke and fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.8 Fire risk when clamping pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.9 Definitions of qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety 7
2.1 Machine safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Personal safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Machine Description 11
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Axis definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Lay out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 SPC 500 - 1200 main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.1 Machine frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.2 Main drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.3 Cutting trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4.4 Cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4.5 Spark and fume reversal kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.6 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.7 Pipe support: pipe trolleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.8 Pipe support: rollerball gutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4.9 Fume extraction (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4.10 Marking unit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operators Manual
Pipe Profiling Machine | SPC 500 - 1200
V
4 The controls 17
4.1 Main drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.1 Power key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1.2 Clamping pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Remote control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Manual Data Input (MDI) with ProCAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Using the remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4.1 The display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4.2 The menu bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4.3 The quick action buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.4 The ‘Mode selection’button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.5 Material handling mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.6 Profiling mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.4.7 Automatic mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Material Handling screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5.1 The cutting trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.2 The main drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Profiling screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.1 Selecting a data file or set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7 Advanced profiling screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.8 Action progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.9 Settings screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.10 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.11 Diagnostics screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11.1 Tab bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11.2 Machine status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11.3 Cutting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.11.4 MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.11.5 Cutting trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.6 Main drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.11.7 Cutting Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11.8 Calibrating the cutting head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11.9 Profiling tool calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11.10 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.11.11 Generate error report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.11.12 Team viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.11.13 HGG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5 Operating the machine 40
5.1 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2 Before starting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 To start the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 To home the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4.1 On the remote control:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5 To stop the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operators Manual
Pipe Profiling Machine | SPC 500 - 1200
VI
5.6 Using the main drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6.1 Clamping a pipe in the chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6.2 To turn the jaws of the chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.6.3 To adjust the clamping force of the chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.7 Using the spark and fume reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.7.1 Positioning the spark and fume reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.8 Roller ball gutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.9 Using the pipe support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.9.1 Pipe trolley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.9.2 Adjusting the wheel distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.9.3 Pipe trolley positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.10 Loading and unloading pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.10.1 Loading pipes on to the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.10.2 Unloading pipes from the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 Profiling 49
6.1 Cutting speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.2 The preheat flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 The cutting flame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 To start profiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4.1 Oxyfuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4.2 Plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.5 Switching from oxyfuel to plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.6 Adjusting the height of the plasma torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.6.1 Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.6.2 Displace profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.6.3 Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.7 The ‘Reverse’ button - moving back in the cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.8 The ‘Displace profile’button – continuing from a new position . . . . . . . . . . . . . . . . . . . . . 54
6.9 To cut near the main drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.10 To cut behind the main drive (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.11 Using the preheat (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.12 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.13 To reset from emergency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 Marking options 56
7.1 Using the marking option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1.1 Ink jet printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1.2 Printer offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1.3 Marking speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1.4 Hardware settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1.5 Cleaning and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1.6 Punch marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1.7 Replacing the marking needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1.8 Line marking options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1.9 Text marking options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.1.10 Footprints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.2 Programming marking in ProCAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Operators Manual
Pipe Profiling Machine | SPC 500 - 1200
VII
Appendices
Appendix A Maintenance and Grease Schedule 63 - 72
Periodic and preventive maintenance. Lubrication points and frequencies.
Appendix B Calibration and Cutting Test Pieces 73 - 91
Calibration and alignment of the machine. Instructions for programming,
cutting and evaluating test pieces.
Appendix C Software Messages, Notications and Errors 92 - 130
Remote control on-screen messages in table form, numerically sorted with
description, explanation and suggested solution or referral to the detailed explanation.
Appendix D Software Restore 131 - 154
Instructions on how to reinstall the software in the event of a computer crash.
Appendix E Cutting Quality 155 - 157
Instructions and tips on how to evaluate and improve the cutting quality for
oxyfuel and plasma cutting.
Appendix F Terminology 158- 160
A list of terms and words as used in this document with a short explanation.

Operators Manual
Pipe Profiling Machine | SPC 500-1200
1
SPC
Figure 1: Nameplate pipe profiling machine Figure 2: Nameplate pipe trolley
Introduction
Profile Machine Minimum and maximum
outer diameter
Maximum
weight
Minimum
length
Maximum
length
CHS
(Circular
Hollow
Section)
SPC 500 48 mm 510 mm 4000 kg 300 mm 6000 mm
SPC 600 48 mm 610 mm 4000 kg 300 mm 6000 mm
SPC 800 60 mm 815 mm 6000 kg 300 mm 6000 mm
SPC 1000 75 mm 1020 mm 8000 kg 300 mm 8000 mm
SPC 1200 75 mm 1225 mm 8000 kg 300 mm 12000 mm
SPC 1200 75 mm 1225 mm 12000 kg 300 mm 12000 mm
Cutting
process Minimum wall thickness Maximum wall thickness Cutting angle range
Oxyfuel 3 mm 150 mm -70° tot 70 °
Plasma 3 mm 38 mm (30 mm quality cut) -45° to 45°
Intended use of the machine
This machine is a thermal profiling machine and should be used for profiling steel pipes with an oxygas
cutting process (oxyfuel) or plasma cutting process. For the explanation of these two processes, see
the ‘Terminology’ appendix. The machine should be used for industrial applications only. The machine
is suitable for cutting the pipe range as described in the technical specifications or the nameplate. An
overview of the pipe ranges is shown in the table below.
A nameplate like the one shown in Figure 1 is located on the side of the main drive unit. A nameplate like
the one shown in Figure 2 is located on the front side of each pipe trolley. You should always keep these
nameplates clean and legible.
Pipe range SPC 500 - 1200

Operators Manual
Pipe Profiling Machine | SPC 500-1200
2
SPC
Conditions for use and installation
The SPC 500 - 1200 range 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 +45º C;
●maximum atmospheric humidity of 95% non-condensing;
●minimum illumination intensity of 500 lux.
Non-intended use of the machine
The SPC 500 - 1200 range 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.
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!
Due to the plasma cutting process hazardous substances may
be created. Consult the instruction manual of the plasma unit
for more information.
WARNING!
The plasma cutting process generates high temperatures and
sparks. The machine should never be used in a flammable or
explosive environment!

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Pipe Profiling Machine | SPC 500-1200
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Noise emissions
There are no harmful noise emissions when profiling using the oxyfuel cutting process,
the noise emissions are less than 70 dB(A). The plasma cutting process causes higher
noise emissions which increase slightly with higher currents. Please refer to the plasma
instruction manual for details. The tables below gives a general indication of the
expected noise emissions for commonly used plasma units. Ear protection must be
worn when using the plasma cutting process.
Smart Focus
High Focus 440i
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.
Hypertherm HPR400XD
Source: Hypertherm HPR 400XD Acoustic Noise Level Measurements (16-12-2004).
* MaxP = peak C-weighted instantaneous sound pressure (LpCpeak in dB).
** Lav5 = A-weighted sound pressure (LpA in dB).
Cutting
current Material thickness Maximum noise level at a distance of: Cutting pressure
1 meter 3 meters 6 meters
90 Amps 6 mm 96 dB(A) 86 dB(A) 83 dB(A) 9.9 bar
130 Amps 6 mm 100 dB(A) 91 dB(A) 86 dB(A) 9.9 bar
280 Amps 20 mm 104 dB(A) 98 dB(A) 93 dB(A) 5.5 bar
400 Amps 40 mm 112 dB(A) 99 dB(A) 96 dB(A) 7.0 bar
Cutting
current Material thickness Distance from source Distance above arc MaxP* Lav5**
130 Amps 25.4 mm
3000 mm 340 mm
111.0 97.7
260 Amps 38.1 mm 118.4 103.8
400 Amps 50.8 mm 123.4 107.8
Cutting
current Material thickness Maximum noise level at a distance of: Cutting pressure
1 meter 3 meters 6 meters
90 Amps 6 mm 96 dB(A) 86 dB(A) 83 dB(A) 9.9 bar
130 Amps 6 mm 100 dB(A) 91 dB(A) 86 dB(A) 9.9 bar
160 Amps 25 mm 105 dB(A) 93 dB(A) 91 dB(A) 9.9 bar
280 Amps 20 mm 104 dB(A) 98 dB(A) 93 dB(A) 5.5 bar
360 Amps 25 mm 104 dB(A) 95 dB(A) 91 dB(A) 7.0 bar
400 Amps 40 mm 112 dB(A) 99 dB(A) 96 dB(A) 7.0 bar

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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:
Oxyfuel
●Compressed air. Non-greased, non-condensed, filtered for particles <5 μm. Pressure 6-8 bar.
●Acetylene. Non-greased, non-condensed, filtered for particles <5 μm. Pressure 1.2-1.5 bar.
●Propane. Non-greased, non-condensed, filtered for particles <5 μm. Pressure 1.5-1.8 bar.
●Oxygen. Non-greased, non-condensed, purity 99.8%, filtered for particles <5 μm. Pressure 8-10 bar.
Plasma Kjellberg Smart Focus
●Compressed air. Non-greased, non-condensed, filtered for particles according to ISO 8573-1 Class
1.4.1. Pressure 10 bar.
●Argon. Purity 99.996%. Pressure 10 bar.
●Hydrogen. Purity 99.95%. Pressure 12 bar.
●Nitrogen. Purity 99.9%. Pressure 10 bar.
●Oxygen. Non-condensed, purity 99.5%, filtered for particles <5 μm. Pressure 10 bar.
Plasma Kjellberg High Focus
●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.
Plasma Hypertherm
●Compressed air. Non-greased, non-condensed, filtered for particles according to ISO 8573-1 Class
1.4.2. Pressure 8 bar.
●Argon. 99.990% pure. Non-greased, non-condensed. Pressure 8 bar.
●H35 (65% Argon 35% Hydrogen). 99.995% pure.Non-greased, non-condensed. Pressure 8 bar.
●Nitrogen. 99.990% pure. Non-greased, non-condensed. Pressure 8 bar.
●Oxygen. 99.500% pure. Non-greased, non-condensed. Pressure 8 bar.

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Pipe Profiling Machine | SPC 500-1200
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WARNING!
The exhaust gases from the fume extraction and dust collection
systems must be removed from the work floor according to local
health and safety regulations. HGG recommends these gases
be released to the exterior. When cutting stainless steel HGG
STRONGLY advises that fumes are ALWAYS released outside.*
Heat, smoke and fumes
The exhaust system creates an air
flow which removes smoke and fumes
from the cutting area and also cools
the cutting trolley which can reach
high temperatures during the cutting
process. It is essential that the exhaust
system is switched on and active during
cutting. Failure to do so could result in
damage to the machine and in extreme
cases melting of components. The
plasma cutting process may also result
in the release of hazardous substances,
especially when cutting stainless steel
and aluminium. The fume extraction and
dust collection system removes smoke
and fumes from the immediate cutting
area. However, these units filter particles
from the exhaust, they do not purify or
filter the gases. The exhaust gases from
the dust collector must be extracted
and removed from the area according to
local health and safety regulations. HGG
recommends that these gases are always
released to the exterior
* HGG’s advice is based on international research and European Health and Safety Regulations.
WARNING!
Clamping pipes through the chuck and up against the spark arrestor will
increase the risk of fire in the dust collector. All pipes should be checked for
residue and cleaned if necessary before starting to cut.
Fire risk when clamping pipes
The main drive is equipped with a spark
arrestor and dust bin behind the chuck.
This is connected to the extraction or
exhaust system, extracting fumes and
sparks through the pipe. Because of
this air flow through the spark arrestor,
caution must be taken when clamping
the pipe to minimise the risk of fire
caused by sparks and residue being
sucked through into the dust collector.
Do not clamp pipes through the chuck
and into the main drive. This will cause
greater suction and higher temperatures
and increase the risk of fire. Larger pipes
can be clamped right up to the face of
the chuck because in the larger area
inside the pipe the temperature does not
reach dangerous levels and the flow rate
is lower. However, to further minimise the
risk, operators must always check that
the inside of all pipes are clean and free
from dust, cardboard, wood, paper and
any other residue that could increase the
risk of fire.

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Pipe Profiling Machine | SPC 500-1200
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Definitions of qualification of personnel
User
A user is a person or organization who is responsible for the machine.
Authorized person
An authorized person is someone who is authorized by the user to carry out certain
activities on the machine.
Skilled person
Skilled persons have technical knowledge or sufficient experience to enable them to
avoid the dangers which electricity, pneumatics, hydraulics and mechanics may create
(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 (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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Safety
Machine safety
The machine is designed to be controlled by a single operator. The location of the
control elements ensures that the person controlling the machine is not exposed to
hazards generated by machine movements or the cutting process. The touch screen
interface is also designed with safety in mind. Many machine actions require operator
confirmation in order to continue. This guarantees that the operator is in position
at the remote control and ensures that he is aware of what is about to happen.
Dangerous situations can arise if more than one person is working on the machine at
the same time!
CAUTION!
Before operating the machine check that there is no oil leakage
from the pipe trolleys or main drive, this may cause a slipping
hazard. Remove all materials from the vicinity of the machine
that could cause a tripping hazard.
WARNING!
The machine is designed to be operated by a single operator.
There is a danger of unexpected movement, crushing, wedging
or drawing in if more than one person is working on the machine
at the same time.
The machine can ONLY be operated by instructed operators and 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 location 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 could be dangerous to the health.
●avoid all activities that could 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 protective covers are correctly installed at
the correct locations.

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Pipe Profiling Machine | SPC 500-1200
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Personal safety instructions
An operator has to keep the following
safety instructions in mind:
●Do not use the machine without
following the instructions in the
manuals.
●Read and understand the Operators
Manual and all safety labels before
operating or maintaining this machine.
●Read and understand the ‘Plasma
Unit Instruction Manual’ when plasma
cutting is used.
●Read and understand the dust
collector ‘Installation and Operation
Manual’, when a dust collector is used.
●Keep these manuals at hand at
all times and read it as many
times as necessary for a complete
understanding.
●Only instructed operators are
permitted to operate this machine.
Instruction should include instructions
for operation under normal conditions
and emergency situations.
Before starting this machine, the operator
must check that:
●All persons are clear of the machine.
●No maintenance work is being
performed on the machine.
●All guards are in place.
●The machine is free of jams and other
obstacles.
●The machine has not been stopped
in such a way that another worker
can start the machine while you are
working on it.
To avoid injury the operator should:
●Never reach into the machine for any
reason unless the machine is at a
complete stop.
●Never change or disable the function
of electrical interlocks or other
machine shutdown switches.
●Never modify the machinery in any
way.
●Never exceed the maximum pipe load.
●Never approach the pipe trolley
wheel units, pipe trolley rails, cutting
trolley track when the machine is in
operation or when maintenance is
being carried out due to the risk of
crushing.
●Never approach the cutting torch,
flames from the torch will burn skin!
Always maintain a safe distance.
●Never look directly into the flame,
the bright light could damage your
eyesight. Always use safety glasses
and make sure the glass UV protection
shield supplied with the cutting device
on the machine is in place before any
cutting is done.
For safety reasons operators have to wear
the following protective equipment:
●Safety shoes.
●Flame proof overalls or flame proof
clothing.
●Flame proof gloves.
●Safety helmet.
●Ear protection.
●Safety glasses.
ATTENTION!
Consult the plasma unit instruction manual for more information about
risks and endangerments of the plasma unit and its accessories.

Operators Manual
Pipe Profiling Machine | SPC 500-1200
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SPC
Residual risks
The pipe profiling machine is designed
to be safe. Despite all risk reduction
measures, care must always be taken
when operating the machine. Some
risks cannot be entirely eliminated, the
greatest potential residual risks of the
SPC 500-1200 range are:
●Wedging/crushing
●Burning (skin injury)
●Falling material
Operators should pay special attention to the following residual risks:
WARNING! Main drive
The chuck rotates and the jaws may stick out. Keep your body
and hands away from the chuck when it is rotating, you could
get wedged or hit by moving parts.
WARNING! Pipe trolleys
The pipe trolley wheels provide support for the pipe. Keep your
hands and body away from the pipe trolleys when the pipe is
rotating, you could wedged between the pipe and wheels!
WARNING! Cutting trolley and torch
Flames from the torch will burn skin! The cutting arm and torch
can be hot during the cutting process! Always wear flame proof
gloves when replacing the tip.
WARNING! Pipes and scrap pieces
Pipe and scrap pieces can be hot due to the cutting process!
Always wear flame proof gloves and clothes and wait until
the machine has stopped before cleaning or removing pieces.
Beware of pipes and scrap pieces falling after cutting, wear
safety boots to avoid injury.

Operators Manual
Pipe Profiling Machine | SPC 500-1200
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Safety labels
The residual risks of the SPC are expressed by safety labels. The following safety labels can be found on
the machine:
Label Description Location
Fire, naked flame and smoking prohibited. Front side of the remote control.
Front side of the main drive.
Wear flame proof clothing. Front side of the remote control.
Front side of the main drive.
Wear flame proof safety gloves. Front side of the remote control.
Front side of the main drive.
Wear safety shoes. Front side of the remote control.
Front side of the main drive.
Wear head, eye and ear protection. Front side of the remote control.
Front side of the main drive.
Read and understand the operator’s
manual before operating the machine.
Front side of the remote control.
Front side of the main drive.
Warning! Hot surfaces. Right and left sides of the cutting trolley.
Warning! Laser. Right and left sides of the cutting trolley.
Warning! Hazardous substances. Right and left sides of the cutting trolley.
Warning! Suffocation hazard. Right and left sides of the cutting trolley.
Warning! Moving parts.
Right and left sides of the cutting trolley.
Front side of the main drive.
Front side of the pipe trolleys.
Next to the marking unit (optional).
Warning! Electric shock hazard.
Right and left sides of the cutting trolley.
Back side of the remote control.
Front side of the main drive.
Side of the control unit cabinet.
Next to the marking unit (optional).
Front of the exhaust unit (optional).

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Machine Description
Introduction
The SPC machines are thermal profiling
machines designed to cut connections
on steel and stainless steel pipes, with
constant welding preparations over the
entire profile length. Pipes are clamped
in the main drive and supported by
pipe trolleys. The machines are capable
of cutting with oxyfuel and plasma
(optional). The cutting trolley moves
along the length of the profile and the
bi-axial cutting head can rotate and tilt.
Pipes are rotated by the main drive. This
flexibilty of movement combined with
computer numeric control of the axes
produces a versatile machine capable
of high precision profiling. The SPC
machines can be used for applications
from a variety of industries.
The SPC machine range is capable of
profiling the following connections and
shapes:
●Chamfer
●Saddle
●Hole set in
●Hole set on
●Mitre saddle
●Mitre hole
●Saddle set in
●Oblong hole
●PJP chamfer (offshore)
●PJP saddle (offshore)
A range of additional profiles including
offshore profiles and other industry
specific profiles is also available, for more
details or further information please
contact HGG.

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Pipe Profiling Machine | SPC 500-1200
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Axis definition
Lay out
The SPC stands for Stationary Pipe Cutting machine. This type of machine is anchored
to a foundation frame which is embedded in the concrete flooring.
* optional
CTL
MDR
CTH
MDH MDC CHT
CHR
1Main drive
2Cutting trolley
1 52 3
9
8
10
67 4
3Gas controls
4Remote control
5Spark reversal kit
6Pipe trolley
7Rear frame
8Dust collector
9Marking unit*
10 Plasma unit*
*
●MDR Main drive rotation
●MDH Main drive height
●MDC Main drive clamping
●CTL Cutting trolley longitudinal
●CTH Cutting trolley height
●CHT Cutting head tilt
●CHR Cutting head rotation