PT-102 PT-202 CB-001D CB-001DV CB002D

Transcription

1 Operating instructions EN Positioner PT-102 PT-202 CB-001D CB-001DV CB002D Observe additional system documents!

2 General instructions CAUTION Read the operating instructions! The operating instructions provide an introduction to the safe use of the products. Read the operating instructions for all system components! Observe accident prevention regulations! Observe all local regulations! Confirm with a signature where appropriate. In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service department on A list of authorised sales partners can be found at Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the user on commissioning the equipment. The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation, operation, usage and maintenance of the equipment. An incorrectly performed installation can result in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way. EWM AG Dr. Günter-Henle-Str. 8 D Mündersbach, Germany The copyright to this document remains the property of the manufacturer. Reprinting, including extracts, only permitted with written approval. The content of this document has been prepared and reviewed with all reasonable care. The information provided is subject to change, errors excepted.

3 Contents Notes on the use of these operating instructions 1 Contents 1 Contents Safety instructions Notes on the use of these operating instructions Explanation of icons General Transport and installation Ambient conditions In operation Transport and storage Intended use Applications Use and operation solely with the following machines Documents which also apply Warranty Declaration of Conformity Service documents (spare parts) Machine description quick overview PT-102, PT Front view Machine control Operating elements CB-001D Front view Rear view CB-001DV Front view Rear view CB-002D Front view Rear view Design and function General Installation Swivel range setting PT PT Securing the machine control Connection for workpiece lead Machine control connection CB-001D CB-001DV / CB-002D Power source connection Sensor fixing (except for control CB-002D) Pin assignment Sensor setting (except for control CB-002 D) Mains connection Switching the machine on/off Changing the mains fuse Changing the gear box Machine configuration menu Remote control Compatibility list for remote controls/controls Foot-operated switch FR Function sequence PT-102, PT-202, FR

4 Contents Notes on the use of these operating instructions 6 Maintenance, care and disposal General Servicing and lubrication instructions for geared motors Mechanics Electrical components Technical data PT-102, PT Accessories General accessories Circumferential welding machine Typ S Typ R Typ L Typ U Appendix A Overview of EWM branches... 3

5 2 Safety instructions 2.1 Notes on the use of these operating instructions DANGER Safety instructions Notes on the use of these operating instructions Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. Safety notes include the "DANGER" keyword in the heading with a general warning symbol. The hazard is also highlighted using a symbol on the edge of the page. WARNING Working or operating procedures which must be closely observed to prevent serious and even fatal injuries. Safety notes include the "WARNING" keyword in the heading with a general warning symbol. The hazard is also highlighted using a symbol in the page margin. CAUTION Working or operating procedures which must be closely observed to prevent possible minor personal injury. The safety information includes the "CAUTION" keyword in its heading with a general warning symbol. The risk is explained using a symbol on the edge of the page. CAUTION Working and operating procedures which must be followed precisely to avoid damaging or destroying the product. The safety information includes the "CAUTION" keyword in its heading without a general warning symbol. The hazard is explained using a symbol at the edge of the page. Special technical points which users must observe. Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.: Insert the welding current lead socket into the relevant socket and lock. 5

6 Safety instructions Explanation of icons 2.2 Explanation of icons Symbol Description Special technical points which users must observe. Correct Wrong Press Do not press Press and keep pressed Turn Switch 0 l Switch off machine 0 l Switch on machine ENTER enter the menu NAVIGATION Navigating in the menu EXIT Exit the menu Time display (example: wait s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use 6

7 Safety instructions General 2.3 General WARNING Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! Carefully read the safety instructions in this manual! Observe the accident prevention regulations and any regional regulations! Inform persons in the working area that they must comply with the regulations! CAUTION Noise exposure! Noise exceeding 70 dba can cause permanent hearing damage! Wear suitable ear protection! Persons located within the working area must wear suitable ear protection! Risk of injury in the hazard area! Rotating movements carried out by the machine can injure people! The hazard area is the immediate area around the machine and the workpiece, plus a safety area of 1 m. Before switching on the machine and during operation, ensure that nobody is standing in the hazard area! Wear appropriate protective clothing (no loose clothing)! In the event of an emergency, press the emergency stop switch or disconnect from the power supply (remove the plug from the mains)! CAUTION Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! National implementation of the framework directive (89/391/EWG), as well as the associated individual directives. In particular, directive (89/655/EWG), on the minimum regulations for safety and health protection when staff members use equipment during work. The regulations regarding work safety and accident prevention for the respective country. Setting up and operating the machine according to IEC Check at regular intervals that users are working in a safety-conscious way. Regular checks of the machine according to IEC Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! Only insert and lock accessory components into the relevant connection socket when the machine is switched off. 7

8 Safety instructions Transport and installation 2. Transport and installation 2..1 Ambient conditions CAUTION Damage due to supply lines not being disconnected! During transport, supply lines which have not been disconnected (mains supply leads, control leads, etc.) may cause hazards such as connected equipment tipping over and injuring persons! Disconnect supply lines! CAUTION Equipment damage due to dirt accumulation! Unusually high quantities of dust, acid, corrosive gases or substances may damage the equipment. Avoid high volumes of smoke, vapour, oil vapour and grinding dust! Avoid ambient air containing salt (sea air)! Non-permissible ambient conditions! Insufficient ventilation results in a reduction in performance and equipment damage. Observe the ambient conditions! Keep the cooling air inlet and outlet clear! Observe the minimum distance of 0.5 m from obstacles! In operation Temperature range of the ambient air: -20 C to +0 C Relative air humidity: Up to 50% at 0 C Up to 90% at 20 C Transport and storage Storage in an enclosed space, temperature range of the ambient air: -30 C to +70 C Relative air humidity Up to 90% at 20 C 8

9 Intended use Applications 3 Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! The equipment must only be used in line with proper usage and by trained or expert staff! Do not modify or convert the equipment improperly! 3.1 Applications Using the positioners you can move the workpiece to a position convenient for welding. The workpieces secured on the turn table can be infinitely tilted and rotated during welding with the help of a gear mechanism. 3.2 Use and operation solely with the following machines Only the combinations of turn table and machine control specified may be used together. Older machines are not permitted! CB-001D CB-001DV CB-002D PT-102 PT-202 FR 001 possible not possible 9

10 Intended use Documents which also apply 3.3 Documents which also apply Warranty For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at Declaration of Conformity The designated machine conforms to EC Directives and standards in terms of its design and construction: EC Low Voltage Directive (2006/95/EC), EC EMC Directive (200/108/EC), This declaration shall become null and void in the event of unauthorised modifications, improperly conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted conversion work not specifically authorised by the manufacturer. The original copy of the declaration of conformity is enclosed with the unit Service documents (spare parts) DANGER Do not carry out any unauthorised repairs or modifications! To avoid injury and equipment damage, the unit must only be repaired or modified by specialist, skilled persons! The warranty becomes null and void in the event of unauthorised interference. Appoint only skilled persons for repair work (trained service personnel)! Spare parts can be obtained from the relevant authorised dealer. 10

11 Machine description quick overview.1 PT-102, PT Front view Machine description quick overview PT-102, PT Item Symbol Description 0 1 Rotary plate Figure -1 2 Machine control- See.2 Machine control Operating elements chapter 3 Warehouse Hollow shaft = 38.5mm, e.g. for forming gas, compressed air, etc. 5 Handwheel (PT-202) To set the tilting angle Locking lever (PT-102) To fix the tilting angle 6 Gears, rotary plate speed Gear A = 0,15 to 5 rpm Gear B = 0,3 to 10 rpm Gear C = 0, to 15 rpm Gear D = 0,55 to 20 rpm 11

12 Machine description quick overview Machine control Operating elements.2 Machine control Operating elements.2.1 CB-001D Front view AUTO WELD WELD 6 MANU RAPID TEST WELD SPEED TIMER Figure -2 Item Symbol Description 0 1 Display 2 Idle/stand by mode push-button with signal light Signal light off: Machine is switched off or in idle mode Signal light on: Machine is operational 3 Changeover switch, surface plate rotational direction position = surface plate turning right clockwise position = surface plate turning left anti-clockwise Changeover switch, automated/manual AUTO position = welding with time-controlled rotation MANU position = manual welding without time-controlled rotation 5 Changeover switch, WELD/RAPID rotation speed WELD position = welding mode with rotation speed set RAPID position = positioning, rotary plate with maximum speed regardless of the set rotation speed. There is no start signal for the welding machine. 6 Changeover switch, welding mode/test mode WELD position = welding mode, start signal for welding machine is issued TEST position = test mode, there is no start signal for the welding machine 7 Rotary dial, WELD SPEED rotation speed Infinite adjustment of the rotation speed (gear-dependent) 8 Rotary dial, TIMER time-controlled rotation Infinite adjustment of the rotation time (approx. 1 sec. up to 60 sec.) 9 Emergency stop switch 12

13 Machine description quick overview Machine control Operating elements Rear view FUSE Item Symbol Description 0 1 Mounting holes Figure pole connection socket, motor connection 3 3-pole connection socket Foot-operated switch connection (start/stop) Connection screw for dynamic earth cable 5 Main switch, machine on/off 6 Fuse holder 7 Connection socket mains cable 8 -pole connection socket, welding machine start/stop 13

14 Machine description quick overview Machine control Operating elements.2.2 CB-001DV Front view 1 2 EXTERN 10 3 AUTO 5 INTERN WELD WELD 6 MANU RAPID TEST WELD SPEED TIMER Figure - Item Symbol Description 0 1 Display 2 Idle/stand by mode push-button with signal light Signal light off: Machine is switched off or in idle mode Signal light on: Machine is operational 3 Changeover switch, surface plate rotational direction position = surface plate turning right clockwise position = surface plate turning left anti-clockwise Changeover switch, automated/manual AUTO position = welding with time-controlled rotation MANU position = manual welding without time-controlled rotation 5 Changeover switch, WELD/RAPID rotation speed WELD position = welding mode with rotation speed set RAPID position = positioning, rotary plate with maximum speed regardless of the set rotation speed. There is no start signal for the welding machine. 6 Changeover switch, welding mode/test mode WELD position = welding mode, start signal for welding machine is issued TEST position = test mode, there is no start signal for the welding machine 7 Rotary dial, WELD SPEED rotation speed Infinite adjustment of the rotation speed (gear-dependent) 8 Rotary dial, TIMER time-controlled rotation Infinite adjustment of the rotation time (approx. 1 sec. up to 60 sec.) 9 Emergency stop switch 10 Changeover switch for rotational speed, foot-operated switch "External/Internal" "External position = rotational speed control via foot-operated remote control "Internal position = rotational speed control via rotary knob 1

15 Machine description quick overview Machine control Operating elements Rear view FUSE 6 9 Figure Item Symbol Description 0 1 Mounting holes 2 7-pole connection socket, motor connection 3 3-pole connection socket Foot-operated switch connection (start/stop) Connection screw for dynamic earth cable 5 Main switch, machine on/off 6 Fuse holder 7 Connection socket mains cable 8 -pole connection socket, welding machine start/stop 9 5-pole connection socket CB 001DV control: Foot-operated remote control connection CB 002D control: Welding position sensor connection 15

16 Machine description quick overview Machine control Operating elements.2.3 CB-002D Front view AUTO WELD WELD MANU RAPID TEST START DELAY WELD SPEED OVERLAP 8 9 Figure -6 Item Symbol Description 0 1 Display 2 Idle/stand by mode push-button with signal light Signal light off: Machine is switched off or in idle mode Signal light on: Machine is operational 3 Changeover switch, surface plate rotational direction position = surface plate turning right clockwise position = surface plate turning left anti-clockwise Changeover switch, Automated/Manual "AUTO" position = welding with preset start delay and weld seam overlap. Start via foot-operated switch, stop after completion of the preset weld seam overlap "MANU" position = start/stop via foot-operated switch 5 Changeover switch, WELD/RAPID rotation speed WELD position = welding mode with rotation speed set RAPID position = positioning, rotary plate with maximum speed regardless of the set rotation speed. There is no start signal for the welding machine. 6 Changeover switch, welding mode/test mode WELD position = welding mode, start signal for welding machine is issued TEST position = test mode, there is no start signal for the welding machine 7 Rotary dial, START DELAY rotation delay Time before the surface plate starts to rotate after the start signal (approx. 0 sec. to 5 sec.) 8 Rotary dial, WELD SPEED rotation speed Infinite adjustment of the rotation speed (gear-dependent) 9 Rotary dial, OVERLAP overlap weld seam Time to reach the end of the weld to the overlap (approx. 0 sec. to 15 sec.). Sensor required to detect the rotation position- See 8 Accessories chapter. 10 Emergency stop switch 16

17 Machine description quick overview Machine control Operating elements Rear view FUSE 6 9 Figure Item Symbol Description 0 1 Mounting holes 2 7-pole connection socket, motor connection 3 3-pole connection socket Foot-operated switch connection (start/stop) Connection screw for dynamic earth cable 5 Main switch, machine on/off 6 Fuse holder 7 Connection socket mains cable 8 -pole connection socket, welding machine start/stop 9 5-pole connection socket CB 001DV control: Foot-operated remote control connection CB 002D control: Welding position sensor connection 17

18 Design and function General 5 Design and function 5.1 General WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! Follow safety instructions on the opening pages of the operating instructions. Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! Connection and welding leads (e.g. electrode holder, welding torch, workpiece lead, interfaces) may only be connected when the machine is switched off! CAUTION Risk of injury in the hazard area! Rotating movements carried out by the machine can injure people! The hazard area is the immediate area around the machine and the workpiece, plus a safety area of 1 m. Before switching on the machine and during operation, ensure that nobody is standing in the hazard area! Wear appropriate protective clothing (no loose clothing)! In the event of an emergency, press the emergency stop switch or disconnect from the power supply (remove the plug from the mains)! Risk of burns on the welding current connection! If the welding current connections are not locked, connections and leads heat up and can cause burns, if touched! Check the welding current connections every day and lock by turning in clockwise direction, if necessary. Risk of injury due to moving parts! The wire feeders are equipped with moving parts, which can trap hands, hair, clothing or tools and thus injure persons! Do not reach into rotating or moving parts or drive components! Keep casing covers or protective caps closed during operation! CAUTION Damage to the machine due to improper connection! Incorrect connection assignments result in equipment damage! All connections must be made by a qualified electrician in compliance with the laws and regulations applying in that country. 18

19 Design and function Installation 5.2 Installation WARNING Risk of accident due to improper transport of machines that may not be lifted! Do not lift or suspend the machine! The machine can fall down and cause injuries! The handles and brackets are suitable for transport by hand only! The machine may not be lifted by crane or suspended! CAUTION Risk of accidents due to tripping over and unsuitable installation site! Persons can be injured due to the machine being installed on an incorrect site! Improperly laid cables or tube packages are trip hazards and can cause accidents! Set up the machine so that there is sufficient space for setting the operating elements! Do not block any escape routes! Do not place cables or tube packages in the hazard area around the machine! Lay cables or tube packages straight and in bundles (where appropriate, use cable ducts or other tools)! Item Symbol Description 0 1 Fixing holes Securing the rotary table 1 1 Figure 5-1 Secure the turntable through the fixing holes on a suitable stable and level base. 19

20 Design and function Swivel range setting 5.3 Swivel range setting PT-102 CAUTION Risk of injury when releasing the locking lever! When releasing the locking lever, the rotary table can drop down, injure people and cause damage! Switch off the machine before each change of position! Before releasing the locking lever, check the workpiece fastening! Carry out position changes with the workpiece attached with the help of a second person! Release the locking lever and set the rotary table slewing range PT-202 Set the slewing range of the rotary table infinitely (self-locking gears) using the handwheel. 20

21 Design and function Securing the machine control 5. Securing the machine control Mounting process using an example. Procedure is similar for other models as appropriate. 1 2 FUSE 3 Item Symbol Description 0 1 Mounting holes Figure Fixing pin To fasten the machine control 3 Dynamic earth cable Connection screw for dynamic earth cable Position the machine control on the mounting bolts using the mounting holes. Unscrew the nut from the earth cable, install the eyelet of the dynamic earth cable and reattach the nut. 21

22 Design and function Connection for workpiece lead 5.5 Connection for workpiece lead DANGER Electric shock! In order to avoid injuries, make sure that the cables and hoses are fitted correctly when connecting and working with the machine. Connect all cables and hoses in such a way as to prevent them being crushed or getting caught when using the turntable! After installation or conversion, all mechanical and electrical connections must be tested for correct installation! CAUTION Risk of burns due to incorrect connection of the workpiece lead! Paint, rust and dirt on the connection restrict the power flow and may lead to stray welding currents. Stray welding currents may cause fires and injuries! Clean the connections! Fix the workpiece lead securely! Do not use structural parts of the workpiece as a return lead for the welding current! Take care to ensure faultless power connections! Risk of accidents due to tripping over and unsuitable installation site! Persons can be injured due to the machine being installed on an incorrect site! Improperly laid cables or tube packages are trip hazards and can cause accidents! Set up the machine so that there is sufficient space for setting the operating elements! Do not block any escape routes! Do not place cables or tube packages in the hazard area around the machine! Lay cables or tube packages straight and in bundles (where appropriate, use cable ducts or other tools)! Mounting process using an example. Procedure is similar for other models as appropriate. 1 Item Symbol Description 0 1 M8 threaded pin Connection for workpiece lead Figure 5-3 Fasten workpiece lead to Workpiece lead connection M8 threaded pin. 22

23 Design and function Machine control connection 5.6 Machine control connection CB-001D FUSE Item Symbol Description 0 1 Mounting holes Figure pole connection socket, motor connection 3 3-pole connection socket Foot-operated switch connection (start/stop) Connection screw for dynamic earth cable 5 Main switch, machine on/off 6 Fuse holder 7 Connection socket mains cable 8 -pole connection socket, welding machine start/stop 23

24 Design and function Machine control connection CB-001DV / CB-002D FUSE 6 9 Figure Item Symbol Description 0 1 Mounting holes 2 7-pole connection socket, motor connection 3 3-pole connection socket Foot-operated switch connection (start/stop) Connection screw for dynamic earth cable 5 Main switch, machine on/off 6 Fuse holder 7 Connection socket mains cable 8 -pole connection socket, welding machine start/stop 9 5-pole connection socket CB 001DV control: Foot-operated remote control connection CB 002D control: Welding position sensor connection 2

25 Design and function Power source connection 5.7 Power source connection CAUTION Damage to the machine due to improper connection! Incorrect connection assignments result in equipment damage! All connections must be made by a qualified electrician in compliance with the laws and regulations applying in that country. The max. load of the potential-free contact is: 0.5A, 125V AC or 2A, 30V DC Pin 1 FUSE 1 Pin 2 Figure Item Symbol Description 0 1 -pole connection socket, welding machine start/stop 2 Connector plug, -pole Start/stop signal from the machine control to the welding machine Unscrew and take apart -pole connection plug and solder to pin 1 and pin 2 using a suitable 2-pole cable. Screw together the -pole connection plug and insert and screw into -pole connection socket, start/stop welding machine. 25

26 Design and function Sensor fixing (except for control CB-002D) 5.8 Sensor fixing (except for control CB-002D) Item Symbol Description 0 1 Arrow plate Figure Hollow shaft = 38.5mm, e.g. for forming gas, compressed air, etc. 3 M x 8mm hexagonal screw Welding position sensor 5 Sensor holder 6 Sensor fixing screw 7 hexagonal screw M x 20 mm Attach the indicator plate to the hollow shaft using two M x 8 mm hexagonal socket screws. Remove any mounting material such as nuts or toothed lock washers from the sensor thread. Push the sensor into the sensor holder as far as it will go. Secure the sensor with the dedicated mounting screw in the sensor holder. Attach the sensor holder to the relevant mounting holes using to M x 20 mm hexagonal socket screws Pin assignment Sensor pin assignment: Pin 1 -> brown Pin 2 -> blue Pin 3 -> black 26

27 Design and function Sensor fixing (except for control CB-002D) Sensor setting (except for control CB-002 D) CAUTION Risk of injury when setting the sensors! The sensor setting work is carried out in the hazard area when the machine is switched on. Persons can be injured during this process! Before switching on, ensure that there are no other persons standing in the hazard area! 2 mm Item Symbol Description 0 1 hexagonal screw M x 20 mm 2 Sensor holder 3 Arrow plate Sensor signal light On if the arrow plate is detected Figure 5-8 Unfasten M x 20 mm hexagon screws, move sensor holder to the right and refasten the screws. On the machine control, switch the "Automated / manual changeover switch" to the "Manual" position. Switch on the machine control on the main switch (rotary table is not turning). Activate the foot-operated switch and rotate arrow plate with the indicator tip parallel to the sensor holder (see diagram). Unfasten M x 20 mm hexagon screws and move the sensor holder to approx. 2 mm away from the indicator tip. The Sensor signal light will light up in red. Secure the sensor holder using M x 20 mm hexagon screws. 27

28 Design and function Mains connection 5.9 Mains connection Switching the machine on/off CAUTION Risk of injury in the hazard area! Rotating movements carried out by the machine can injure people! The hazard area is the immediate area around the machine and the workpiece, plus a safety area of 1 m. Before switching on the machine and during operation, ensure that nobody is standing in the hazard area! Wear appropriate protective clothing (no loose clothing)! In the event of an emergency, press the emergency stop switch or disconnect from the power supply (remove the plug from the mains)! Switch the machine on or off at the main switch Changing the mains fuse DANGER Electric shock due to live parts! The machine carries voltage during operation! Working on the machine during operation can result in fatal injuries! Before all work, switch off the main switch! Remove the mains connection cable! Item Symbol Description 0 1 Main switch, machine on/off Figure Fuse holder 3 Connection socket mains cable Replacement fuse (1A) 5 Machine fuse (1A) Switch off machine at the main switch. Remove the mains connection cable. Fold down the fuse holder. Remove faulty machine fuse. Fit the replacement fuse. Fold the fuse holder back into position. Plug in the mains connection cable and switch on at the main switch. 28

29 Design and function Changing the gear box 5.10 Changing the gear box The rotation speed of the surface plate is determined to a great extent by the gear being used. The user can choose between four different gear variants for the rotary tables described: Variant A (0,15 to 5 rpm) Variant B (0,3 to 10 rpm) Variant C (0, to 15 rpm) Variant D (0,55 to 20 rpm) Before starting conversion work Remove the workpiece. Disconnect the power supply by removing the mains plug! Allow the turntable to cool down! Figure 5-10 Item Symbol Description 0 1 Motor, rotary plate drive unit 2 Fixing screws (x ) 3 Gears, rotary plate speed Gear A = 0,15 to 5 rpm Gear B = 0,3 to 10 rpm Gear C = 0, to 15 rpm Gear D = 0,55 to 20 rpm Rotary plate 5 Protective fleece Prevents lubricants escaping 6 Drive shaft with slot wedge 7 Slot wedge 8 Hollow shaft = 38.5mm, e.g. for forming gas, compressed air, etc. 29

30 Design and function Changing the gear box Move the turntable to the vertical position and secure (motor at top). Remove the plug (2-pole) from the motor connection cable. Remove all fixing screws and take off the drive motor. Leave the protective fleece on the motor (replace if defective). Remove the gear unit carefully. Remove the slot wedge from the slot on the drive shaft. Place the slot wedge into the groove on the gear unit required. Place the gear unit with drive shaft back into the hollow shaft on the turntable. Place the drive motor onto the gear unit and fasten using all fixing screws. Re-insert the plug (2-pole) on the motor connection cable. As the gears are at different heights, the mounting screws supplied with the gears must be used. 30

31 Design and function Machine configuration menu 5.11 Machine configuration menu CAUTION Trained personnel! Commissioning is reserved for persons who have the relevant expertise of working with arc welding machines. Before you can adjust the control to the relevant drive type, the outer cover has to be removed. Drive type Drive code A 3800 B C 1600 D Figure Item Symbol Description 0 1 Display cover 2 Display switching push button 3 Decimals selection Changeover switch Up 5 Changeover switch Down 31

32 Design and function Machine configuration menu Remove the display cover. Press the display switching push button until the parameter "PPR" is shown on the display. Select the relevant place on the display using the Decimals push button. Set the correct drive code (see table above) using the Up/Down push buttons. Exit the menu by pressing the Display switching push button. Reinstall the cover. The other parameters must not be changed. 32

33 Design and function Remote control 5.12 Remote control CAUTION Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! Only insert and lock accessory components into the relevant connection socket when the machine is switched off Compatibility list for remote controls/controls CB-001D CB-001DV CB-002D Foot-operated switch not possible possible Foot-operated switch FR-1 Functions Start / Stop. It is connected to the 3-pole remote control connection socket. 33

34 Design and function Function sequence 5.13 Function sequence PT-102, PT-202, FR-1 The start of the welding process is initiated by the foot-operated switch FR-1, which is connected to the control. The machine control forwards the start signal to the power source being used via the "Connection socket, -pole, start/stop welding machine". The power source connection to the "Connection socket, -pole, start/stop welding machine" is created using a cable provided by the customer- See 5.7 Power source connection chapter. Depending on the control, different parameters can be controlled with the FR-1 foot-operated switch. CB-001D control When using the CB-001D or CB-001DV control, the following parameters can be infinitely adjusted: rotational speed welding time CB-002D control When using the CB-002D control, the following parameters can be infinitely adjusted: rotational speed start delay overlap time The functional sequence shows the combination of the FR-1 foot-operated switch and the CB- 002D control. The CB-001D control does not support the START DELAY and OVERLAP functions! WELD SPEED t I t START DELAY Figure 5-12 OVERLAP 3

35 Design and function Function sequence Symbol I t START DELAY OVERLAP WELD SPEED Meaning Welding current Welding process time Start delay Ignition current Rotary plate rotation speed Rotary plate turns to the right, clockwise Rotary plate turns left, anti-clockwise 35

36 Maintenance, care and disposal General 6 Maintenance, care and disposal 6.1 General DANGER Electric shock due to live parts! The machine carries voltage during operation! Working on the machine during operation can result in fatal injuries! Before all work, switch off the main switch! Remove the mains connection cable! WARNING Risk of injury due to high temperatures! The rotary table can heat up during operation! Injuries can be caused if touched! Allow the rotary table to cool down after use! 6.2 Servicing and lubrication instructions for geared motors All moving components in the system must be kept clean at all times and greased when appropriate. The system must be serviced at regular intervals and tested for faults depending on the operating conditions. Keep moving parts clean. Service at regular intervals and check for errors. 6.3 Mechanics Check that the machine is anchored. Check bearings for damage. Tighten the screw connections. Keep moving parts clean. 6. Electrical components Check the cables and operating elements for external damage. Thoroughly remove dust and foreign bodies at regular intervals. 36

37 Technical data PT-102, PT Technical data 7.1 PT-102, PT-202 Positioner PT-102 PT-202 Mains voltage 1 x 230 V Frequency 50/60 Hz Mains fuse Turn table ultimate load (horizontal/vertical) Power transmission Speed (gear mechanism A) Speed (gear mechanism B) Speed (gear mechanism C) Speed (gear mechanism D) 10 A 100/60 kg 200/130 kg max. 300 A 0.15 to 5 rpm 0.3 to 10 rpm 0. to 15 rpm 0.55 to 20 rpm Tilting angle Weight 31,5 kg 32,5 kg Length (1) 20 mm Width (2) 35 mm Height (3) 30 mm Turn table () Ø 320 mm Height (5) 250 mm Figure

38 Accessories General accessories 8 Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. 8.1 General accessories Type Designation Item no. 3BS 3-jaw welding chuck (mm - 150mm) BS 3-jaw welding chuck (mm - 50mm) BS 3-jaw welding chuck (mm - 500mm) PNEUMATISCHER Pneumatic welding torch positioner, BRENNERLIFT S PNEUMATISCHE Pneumatic welding torch positioner, mm BRENNERVERSTELL S BRENNERHALTER Torch holder SUPPORT VERSTELLWEG Linear adjustment 75 mm MM MITLAEUFER TYP R S Idler unit, mm GRUNDRAHMEN 1500MM Basic frame, 1500 mm GRUNDRAHMEN 1800MM Basic frame, 1800 mm CB-001D Standard controller incl. foot-operated switch CB-001DV Control for foot-operated remote control CB-002D Sensor sequence control including foot-operated switch FR-001 Foot-operated remote control

39 Accessories Circumferential welding machine 8.2 Circumferential welding machine Typ S Figure Item 0 Quantity Description Item number 1 1 Linear adjustment, 50mm V-block torch holder Stand, Y-axis, 00mm Stand torch, 750mm Holder, Y-axis Retainer clip, Y-axis holder Flange for stand Positioners, gear mechanism A Basic frame, 600 mm Assembly stand, 500 mm

40 Accessories Circumferential welding machine Typ R Item 0 Quantity Description Item number 1 1 V-block torch holder Linear adjustment, 50mm Stand, Y-axis, 00mm Stand torch, 750mm Holder, Y-axis Retainer clip, Y-axis holder Flange for stand Positioners, gear mechanism A Basic frame, 1200 mm Assembly stand, 500 mm

41 Accessories Circumferential welding machine Typ L Item 0 Quantity Description Item number 1 1 V-block torch holder Linear adjustment, 50mm Stand, Y-axis, 00mm Stand torch, 750mm Holder, Y-axis Retainer clip, Y-axis holder Flange for stand Positioners, gear mechanism A Basic frame, 1200 mm Assembly stand, 500 mm Pneumatic tailstock, 75 mm

42 Accessories Circumferential welding machine 8.2. Typ U Item 0 Quantity Description Item number 1 1 V-block torch holder Linear adjustment, 50mm Stand, Y-axis, 00mm Holder, Y-axis Pneumatic tailstock, 75 mm Retainer clip, Y-axis holder torch stand, 600 mm x 00 mm Positioners, gear mechanism B Holder Flange for stand Assembly stand, 650 mm

43 Appendix A Overview of EWM branches 9 Appendix A 9.1 Overview of EWM branches Headquarters EWM AG Dr. Günter-Henle-Straße Mündersbach Germany Tel: Fax: -2 info@ewm-group.com Technology centre EWM AG Forststraße Mündersbach Germany Tel: Fax: -1 info@ewm-group.com Production, Sales and Service EWM AG Dr. Günter-Henle-Straße Mündersbach Germany Tel: Fax: -2 info@ewm-group.com EWM HIGHTEC WELDING s.r.o. 9. května 718 / Jiříkov Czech Republic Tel.: Fax: info@ewm-jirikov.cz EWM HIGH TECHNOLOGY (Kunshan) Ltd. 10 Yuanshan Road, Kunshan New & Hi-tech Industry Development Zone Kunshan City Jiangsu Post code People s Republic of China Tel: Fax: info@ewm.cn info@ewm-group.cn Sales and Service Germany EWM AG Sales and Technology Centre Grünauer Fenn 1712 Rathenow Tel: Fax: info@ewm-rathenow.de EWM AG Rudolf-Winkel-Straße Göttingen Tel: Fax: info@ewm-goettingen.de EWM AG Sachsstraße Pulheim Tel: Fax: info@ewm-pulheim.de EWM HIGHTEC WELDING GmbH Sales and Technology Centre Draisstraße 2a 6969 Weinheim Tel: Fax: info@ewm-weinheim.de EWM Schweißtechnik Handels GmbH Karlsdorfer Straße Tettnang Tel: Fax: info@ewm-tettnang.de EWM Schweißtechnik Handels GmbH Heinkelstraße Neu-Ulm Tel: Fax: info@ewm-neu-ulm.de EWM AG August-Horch-Straße 13a Koblenz Tel: Fax: info@ewm-koblenz.de EWM AG Eiserfelder Straße Siegen Tel: Fax: -9 info@ewm-siegen.de Sales and Service International EWM HIGH TECHNOLOGY (Kunshan) Ltd. 10 Yuanshan Road, Kunshan New & Hi-tech Industry Development Zone Kunshan City Jiangsu Post code People s Republic of China Tel: Fax: info@ewm.cn info@ewm-group.cn EWM HIGHTEC WELDING GmbH Wiesenstraße 27b 812 Pinsdorf Austria Tel: Fax: info@ewm-austria.at EWM HIGHTEC WELDING UK Ltd. Unit 2B Coopies Way Coopies Lane Industrial Estate Morpeth Northumberland NE61 6JN Great Britain Tel: Fax: info@ewm-morpeth.co.uk EWM HIGHTEC WELDING Sales s.r.o. / Prodejní a poradenské centrum Tyršova Benešov u Prahy Czech Republic Tel: Fax: info@ewm-benesov.cz Liaison office Turkey EWM AG Türkiye İrtibat Bürosu İkitelli OSB Mah. Marmara Sanayi Sitesi P Blok Apt. No: Küçükçekmece / İstanbul Türkiye Tel.: info@ewm-istanbul.com.tr Plants Branches Liaison office More than 00 EWM sales partners worldwide 3