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BEAM STRAIGHTENING MACHINE

INSTALLATION, OPERATING AND

MAINTENANCE MANUAL
FOR KTS-6080S
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CONTENTS

A GENERAL ------------------------------------------------------------------------------------------------------- Page 4

B SAFETY INSTRUCTIONS ---------------------------------------------------------------------------------- Page 4
1. Electrical security ---------------------------------------------------------------------------------------------- Page 4
C SPECIFICATIONS -------------------------------------------------------------------------------------------- Page 6
1. Workpiece capacity required -------------------------------------------------------------------------------- Page 6
2. Application ------------------------------------------------------------------------------------------------------- Page 6
3. Specifications for machine and other apparatus ------------------------------------------------------- Page 6
4. Specifications for electric control system ---------------------------------------------------------------- Page 8
5. Accuracy --------------------------------------------------------------------------------------------------------- Page 8
D HANDLING & INSTALLATION --------------------------------------------------------------------------- Page 8
1. Unloading from container ----------------------------------------------------------------------------------- Page 8
2. Unpacking ------------------------------------------------------------------------------------------------------- Page 9
3. Installation ------------------------------------------------------------------------------------------------------- Page 9
E- OPERATION ---------------------------------------------------------------------------------------------------- Page 10
1. Warming-up of hydraulic unit ------------------------------------------------------------------------------- Page 10
2. How to control hydraulic cylinder -------------------------------------------------------------------------- Page 10
3. How to control drive motor for straightening ------------------------------------------------------------ Page 10
4. Straightening ---------------------------------------------------------------------------------------------------- Page 10
5. How to control powered roller & conveyor -------------------------------------------------------------- Page 12
F - MAINTENANCE ----------------------------------------------------------------------------------------------- Page 12
1. Daily inspection ------------------------------------------------------------------------------------------------ Page 12
2. Periodical inspection ----------------------------------------------------------------------------------------- Page 12
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KUMKWANG TECH CO.,LTD. thanks you for your confidence in purchasing this beam straightening machine in
connection with built-up beam fabrication. The equipment will give you complete satisfaction provided that you follow:

the operating and maintenance instructions and

the important safety and environmental information hereafter

This beam straightening machine has been built in strict conformity with the following standards:

European Directive 98/37/EC

by application of the respective harmonized standards

EN ISO 12100-2:2003 (Safety of machinery Basic concepts, general principles for design Part 2 :
Technical principles)
EN 60204-1 : 1997 (Safety of machinery. Electrical equipment of machines. General requirements)

KUMKWANG TECH CO.,LTD. accepts no responsibility in the event of

modification, addition of components or sub-units or any conversion of the
beam welding & straightening machine, carried out by the customer or a third
party, without prior written agreement from KUMKWANG TECH CO.,LTD.
This machine must satisfy the essential requirements of the European Directive.
KUMKWANG TECH CO.,LTD. cannot accept responsibility for combinations
of equipment not defined by them.

For your safety, there follows a non-restrictive list of recommendations or

requirements, many of which appear in the employment code.

Finally we would ask you kindly to inform your supplier of any error which you
may find in this instruction manual.

Please contact our regional distributor in case you need any technical support or if you
want to order consumables.

A GENERAL
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This equipment is totally designed, manufactured, installed and first commissioned by KUMKWANG TECH CO.,LTD,
which it is specially designed to straighten warped built-up H-beam, camber beam (option) and tapered beam (option)
after welding.

Special model KTS-6080S integrated with own experience, know-how and technique makes the customers fully
satisfied with the following features.

Strong and rigid design

This equipment is designed to straighten warped flange caused by stress after welding. Continuous straightening of
horizontal and vertical deformation, which takes place during welding, is carried out by hydraulic rolling press. The
max. rigidity materials it can cover is SM-570.

User friendly operation

Any special skill or technique is not required to operate the equipment; it can be easily handled by pressing the push
buttons or the mono levers on the operation panel. Furthermore, image label of each mono lever switch add more
convenience in handling the machine.

Designed for durability

This equipment is our fruitful outcome from long experience in the structural steel industry. Main components are
specially selected and combined to have high rigidity in order to maintain its permanent accuracy in spite of
applications of long standing.

Reduced manpower required

Only, 1 operator is required to handle this machine because of convenient operation system.

Improvement in working efficiency

Fast straightening speed of max. 6~6.5m/min enables the productivity to be increased and the working hours to be
diminished to the minimum.

Customized solution

As an option, special functions to make tapered and camber beam are guaranteed within the parameters the maker
can accept. Optional elements like spare roll housing for small workpiece can be customized as per customer
requirements.

B SAFETY INSTRUCTIONS

1. ELECTRICAL SECURITY

1.1 CONNECTION OF MACHINE & WELDING POWER SOURCES TO MAIN POWER

Before connecting up your equipment, you must check that:

- The meter, the system for protection against over-currents and the electrical

installation are compatible with its maximum power and its power voltage (cf.instruction plates).
- The single-phase or three-phase connection with earth can be effected by way of a
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socket compatible with the plug of its connecting cable.

- If the cable is connected to a fixed station, the earth, if it is provided, is never to be cut
by the protective system against electrical shocks.
- Its switch, if there is one, is turned to be OFF setting..

1.2 WORK STATION

The use of cutting implies a strict respect of safety conditions with regard to electrical currents.
It is necessary to check that no metal piece accessible to the operators and to their assistants can come into
direct or indirect contact with a phase conductor and the neutral of the supply network.
Connect all the metal earths of the welding set that are within reach of the user to a single point.
This point is grounded. All connections must be made with cables whose section is at least equal to that of
the largest phase cable.
Connect the earth cable to the piece as close as possible to the area of welding to avoid a long current path,
to reach uncontrollable places and to cause electric shocks or fires. Remove inflammable products or
equipment from the area of spatter coming from the arc, or protect them.

1.3 SERVICING

Before carrying out any checks and repairs inside the machine, check that the equipment has been
separated from the electrical installation by padlocked lock-out devices.

The power supply plug has been removed. Provisions are taken to prevent the accidental connection of the
plug in a socket.
The accidental connection of the cable of a fixed installation is made impossible.
Cutout by way of a fixed connecting system is single pole (phases and neutral). It is in the OFF position,
and cannot be accidentally put into operation.

Maintenance work on electrical equipment must be entrusted to persons qualified to do such work.

1.4 MAINTENANCE

Regularly check the insulation of equipment and electrical accessories is in good condition. This
concerns plugs, flexible cables, sheaths, connectors, extension cords, workpiece clamps, electrode
holders or torches Maintenance and repair work on insulating sheaths and covers should never be
done in a makeshift manner.

As required have a specialist repair, or even better, replace defective accessories.

Check periodically that electrical connections are properly tightened and do not overheat. In the Maintenance
and Operating Manual, see the Section devoted to the type of equipment supplied.

C SPECIFICATIONS

1. WORKPIECE CAPACITY REQUIRED

Flange width (B): 200 ~ 800mm

Flange thickness (t2): 16 ~ 60mm
Web height (A): Min. 312mm
Web thickness (t1): 6 ~ 50mm
Workpiece length: 6,000 ~ 15,000mm
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Max. rigidity materials : SM-570

2. APPLICATION

a. Warped beam straightening

3. SPECIFICATIONS FOR MACHINE AND OTHER APPARATUS

a. Overall dimension: 4,500 x 1,850 x 1,900mm (W x L x H)

b. Weight: Approx. 13.6 ton

c. Upper roller 2 sets

This device pressurizes to fix flange with bottom roller for straightening.
Transfer cylinder: FA50B400stroke (140kgf/cm)
Fixed cylinder: 80 x 50 stroke (140kgf/cm)
Transfer cylinder speed: Approx. 50mm/sec (Adjustable in line with working conditions)
Fixed cylinder speed: Approx. 50mm/sec (Adjustable in line with working conditions)
Upper roll: 280 x 140L

d. Flange guide roller 2 sets (One is controlled by hyd. cylinder, the other is controlled by handle)
Cylinder: FA80B80stroke (140kgf/cm)
Cylinder speed: 70mm/sec
Handle screw: TM50 x 60pc
Guide roller: 176 x 220L

e. Web guide roller 2 sets (One is controlled by hyd. cylinder, the other is controlled by handle)
Cylinder: FA80B400stroke (140kgf/cm)
Cylinder speed: 70mm/sec
Handle screw: TM50 x 6pc
Guide roller: 176 x 220L

f. Straightening roller 1 set

Cylinder: 300 x 90stroke (210kgf/cm) produced by KOTEC
Cylinder speed: 39.63mm/min
Straightening roller: 400 x 220stroke
Drive motor: 11kW / 289:1
Drive speed: 7.6mm/min
Driven chain: RS#80 double
Driven sprocket: RS#80 x 35NT

g. Hydraulic elements
Max. pressure: 250kg/cm2
Hydraulic pump: 1 set
Hydraulic motor with 11kW / 380V / 50Hz (Reduction ratio 273:1) 1 set
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h. Screw jack 4 sets (Option)

For cambering job, 2 sets of screw jack pushes up the machine like below figure.
Pressing capacity: 80 ton
Screw jack: 300 stroke
Motor: 5.5kW (Reduction ratio 11:1)
Gear box: Model ES 8M/B II LR or equivalent component

Before pushing up After pushing up

i. Drive motor
1 set of drive motor with 380V / 3P / 15kW / 50Hz
Reduction ratio : 273:1
1 set of control & operation panel

j. Loading & unloading powered rollers

4 sets of drive motor with 380V / 1.5kW / 50Hz
Hydraulic up & down stroke: 50mm
Hydraulic pressure: Max. 140kg/cm2
Lifting power: 4,000kg per set
Feeding speed: Max. 7,800mm/min

4. SPECIFICATIONS FOR ELECTRIC CONTROL SYSTEM

a. Straightening part
Hydraulic system: 3P / 3W / 380V / 50Hz / 11kW 1 set
Control device: CP-01 operating panel (PBL-01, PBL-02) 1 set

b. Drive part for straightening

Drive motor: 3P / 3W / 380V / 15kW 1 set
Inverter drive: TOSHIBA VFS11-2110PM 1 set
Operating system: Operating panel, Jog travelling (Forward & backward), straightening travelling (Forward &
backward), straightening speed regulator
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5. ACCURACY

Straightening (for warped flange): Within 2mm from the width of flange (300mm).

D - HANDLING & INSTALLATION

1. Unloading from container

Use forklift to unload

Most of the users choose this method to load or unload. At least,

the capacity to lift 30 ton is required to handle heavy equipments
like beam welding & straightening machine.

A forklift driver who possesses the qualified license is

indispensable.

Use portable crane to unload

Carry the machine to its location by using a crane and a wire rope
sling that can fully withstand the weight of the machine

A crane driver who possesses the qualified license is indispensable.

Moving to installation spot

Use proper tools like sling belts, wire ropes and chains to move
the machine. Shackles are basic and indispensable tool.

Select wire ropes or chains to move, so that it can lift and sustain the machine. Beam welding & straightening
machine is too heavy to carry by means of sling belts.
Apply chains (or wire ropes) to shackles or lifting hooks, and connect to 4 holes of the main frame. After
complete connection, lift the machine using overhead crane. (In case that overhead crane is not enough to
lift, you have to rent a portable crane with the capacity of over 15 ton.)
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Slowly lift and carry the machine while taking care, so that the machine is protected by any shock or damage.

2. Unpacking

After the machine has been properly positioned, remove the shipping bracket or nail.
Unpack your machine carefully. Do not damage painted surface and any components of the machine.
Remember to remove the bracket and be sure to retain this bracket, so that it can be used again in the event
that your machine is relocated.

3. Installation

This equipment is composed of infeeding (input) conveyor with centering devices, assembling & straightening
machine and outfeeding (output) conveyor with pass line of floor 770mm and adjustment width 30mm.
Install by extending piano wire according to punch mark, so that the direction of line between the center of
beam welding & straightening machine and that of infeeding & outfeeding conveyors can be straight line.
Install in order that height of the top of drive (bottom) roller and infeeding & outfeeding conveyor can be even
as 800mm from ground. Measure four points (front-rear-left-right), so
that the height difference can be minimum 0.5mm.
Foundation (anchor) bolt is welded with beam welding & straightening machine after being
fixed by bracket.

E - OPERATION

1. Warming-up of hydraulic unit

Before starting the machine, run the hydraulic unit first.

Push the button (PBL-01) on the control panel under the condition of
the power-supply connection and then,
the lamp lights.

2. How to control hydraulic cylinder: As Jog mode, it works only while pushing the push button switch on the control
panel. Select CS-01 of CP-01 panel in line with working process.

For straightening: If you select CS-01 as straightening mode, the red lamp turns on PBL-03 button switch of
CP-01.
Machine control

Flange guide roll (MN-01 UP) Unloading (MN-01 DW) Loading

Web guide roll
Straightening roll
Press roll
Bottom roll
Left web centering
Right web centering
Upper roll (left / right)
Upper roll clamp
Stopper
Torch (MIG / SUBMERGED)
(MN-01 LEFT) Unloading
(PBL-17) Up
(MN-02 UP) Up
(MN-02 LEFT) Up
(MN-03 LEFT) Unclamped
(MN-03 UP) Unclamped
(MN-04 LEFT) Unclamped
(MN-04 UP) Unclamped
(PBL-23) Unloading
(PBL-19 DW) Loading
(MN-01 RIGHT) Loading
(PBL-18) Down
(MN-02 DW) - Down
(MN-02 RIGHT) Down
(MN-03 RIGHT) - Clamped
(MN-03 DW) Clamped
(MN-04 RIGHT) Clamped
(MN-04 DW) - Clamped
(PBL-24) Loading
(PBL-20 UP) Unloading

3. How to control drive motor for straightening

Select C/S-01 switch of the control panel (CP-01) as straightening mode.

Push PBL-13 or PBL-14 switch to make workpiece forward and backward.
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The drive motor works if C/S-02 switch is pushed as Jog and continuous mode, and PBL-04 and PBL-05
switches. Push PBL-03 switch to stop.

4. Straightening

Put tack-welded workpiece on infeeding conveyors by overhead crane and feed into the machine.
Prior to straightening of warped flange, the measurement has to be fixed by web & flange guide rolls, and
bottom roll goes up to give required pressure and straighten continuously.
After straightening one side of flange, it is rotated 180 degrees by turning device and transferred to the
machine to be completely straightened.
Dont use press roll in straightening.
Straightening method

- Left and right rolls of flange guide rolls are to be set at a little wider than the flange width (i=b+2J) as the
above figure. Web guide roll handle side is to be set at 1/2 of web board thickness (t1).
- The gap of upper roll depends on workpiece section and type, but it is set on the location of Y=b-2p
(p=50~150), and pressed and fixed.
- Bottom roll is pushed up by hydraulic cylinder and pressurize considering flanges elasticity, but it is strongly
recommended to set first at required pressure.
- Web guide cylinder side is to be set at the point to touch web material. (Scales of pressure gauge is zero)
- By driving lower roll by drive motor, flange bending can be straightened continuously.
Follow the next steps for straightening.
- Select the straightening switch on the operating panel.
- Control workpiece to 4 directions (left-right-up-down) based on roll.
- Move workpiece forward and backward. (Controlled by the operating panel)
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5. How to control powered roller & conveyor

Powered roller is designed to move workpiece and possible to use with cambering rolls simultaneously.
There are the snap switches on CP-02 and you can operate by the mono-lever switches.

F - MAINTENANCE

1. Daily inspection

Check oil leakage from hydraulic device.

Check oil level and if there is any unusual noise.
Check the electric motor.
Check lighting condition each button on the operation panel.
Check if each hydraulic cylinder works well with normal pressure.
Check if there is any dust or particle on hydraulic elements.

2. Periodical inspection

It is strongly required that all hydraulic parts of the machine like upper roller, web guide roller and both master
column of press roller must be checked and re-greased into each nipple on the regular basis. Especially, pay
your keen attention the greasing condition of upper roller part must be checked every day because it is the
most important part on the machine.
Inject new grease into nipples per month. (For machine)
Inject new grease into nipples per 2 months. (For conveyor)
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Hydraulic oil must be changed no later than every 6 months.

- For all seasons: Hydraulic oil no.45
- For cold area: Hydraulic oil no.32
- For hot area: Hydraulic oil no.60