Instruction Manual Form Number 0558011891 Date: 010/2012
BE SURE THIS INFORMATION REACHES THE OPERATOR. YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER. CAUTION These INSTRUCTIONS are for experienced operators; if you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read booklet Precautions and Safe Practices for Arc Welding, Cutting, and Gouging (Form 52-529). Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read Safety Precautions before installing or operating this equipment. USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! 2
Contents Safety... 5 Precautions... 5 Enclosure Class... 6 General Safety Recommendations... 7 Description... 9 Introduction... 9 Major Components - B4 Lift... 10 Technical Specifications... 10 Installation... 11 Mounting...11 Operation... 13 Cut Data/Consumable part list... 14 Maintenance... 15 Preventative Maintenance Schedule... 15 Daily... 15 Weekly... 16 Monthly... 16 Semi-Annually... 16 3
Maintenance Procedures... 17 B4-350 Lift... 18 Introduction... 18 Lift Cleaning and Lubrication... 18 B4 Lift Part Removal and Replacement...20 Basic B4 Lift Assembly Troubleshooting... 27 Yaskawa Junma Servopack Alarm Indicators... 28 Replacement Parts... 33 General... 33 Ordering... 33 Consumable and Spare Part Reference List... 34 4
Safety Precautions Users of ESAB welding and cutting equipment have ultimate responsibility for ensuring that anyone who works on or near the equipment observes all relevant safety precautions. Safety precautions must meet requirements that apply to this type of welding or cutting equipment. All work must be carried out by trained personnel well acquainted with operation of welding or cutting equipment. Incorrect operation of equipment may lead to hazardous situations which can result in injury to the operator and damage to equipment. The following recommendations should be observed in addition to standard regulations that apply to the workplace. 1. Anyone who uses welding or cutting equipment must be familiar with: Proper operation. Location of emergency stops. Designed function. Relevant safety precautions. Welding and/or cutting. 2. Operators must ensure that: No unauthorized person within the working area of equipment when it is started up. 3. The workplace must be: Suitable and Free from drafts. 4. Personal safety equipment: Always wear recommended personal safety equipment, such as safety glasses, flame proof clothing, and safety gloves. Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns. 5
5. General precautions: Make sure return cable is connected securely. Work performed on high voltage equipment may only be carried out by a qualified electrician. Appropriate fire extinguishing equipment must be clearly marked and close at hand. Lubrication and maintenance must not be carried out on equipment during operation. Maximum Tilt Allowed 15 Enclosure Class The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not intended to be used outside during precipitation unless sheltered. CAUTION If equipment is placed on a surface that slopes more than 15, toppling over may occur. Personal injury and/or significant damage to equipment is possible. WARNING WELDING AND CUTTING CAN CAUSE INJURY TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. 6
General Safety Recommendations FUMES AND GASES - Can be dangerous to health. Keep your head out of the fumes. Use ventilation, extraction at the cut, or both, to take fumes and gases away from your breathing zone and the general area. FIRE HAZARD - Sparks (spatter) can cause fire. Make sure that there are no flammable materials nearby. MALFUNCTION - Call for expert assistance in the event of malfunction. CAUTION READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! 7
CAUTION To avoid personal injury and/or equipment damage, lift using method and attachment points shown below. 8
Description Introduction The B4-350 lift assembly provides vertical motion for the torch, using a typical motor, screw, and slide configuration. The motor turns an enclosed spindle screw, which in turn raises/lowers the lifting plate along linear rails. Directional commands given from CNC determines direction of lift travel. Fixed limit switches are included to prevent upper and lower over travel. The lift assembly also contains components necessary to control height over work surfaces. 9
Major Components - B4 Lift 1 2 B4 Lift Electronics Enclosure B4 Lift Assembly 1 Technical Specifications Lift Speed: 315 IPM [8.0m per minute] Vertical Travel: 13.78 [350 mm] Approximate Weight of Lift Assembly: 120 lbs. [55 kg] 2 10
Installation Mounting B4 lift hole patterns are provided below to aid end users in mounting the station. (6) M8 x 1.25 x 40 Socket Head Cap Screws 4.13 [104.9mm] 3.64 [92.4mm] 0.49 [12.4mm] 0.53 [13.5mm] 2.50 [63.5mm] x6 M8x1.25-6H THRU HOLES 3.64 [92.4mm] 4.47 [113.5mm] 0.49 [12.4mm] 5.00 [127.0mm] 0.53 [13.5mm] 2.50 [63.5mm] x6 M8x1.25-6H THRU HOLES B4-350 Lift Assembly dimensions 4.47 [113.5mm] NOTICE Ensure lift assembly is mounted plumb; use a torpedo level and adjust mounting bolts as needed. Torpedo Level 11
Lift Electrical Enclosure connection guide 2 1 1 2 3 4 SB2 - Input Power SB1 - ACON SB5 - Customer Interface SB6 - Customer Interface 6.53 [165.8] 4 3 12
Operation After the signal to start the process occurs inside the FANUC controller, do the following: 1. Turn on the fuel gas solenoid on the central manifold. 2. Turn on the heating oxygen and heating fuel gas valves on the stations in use. 3. Send the ignition gas values to the central manifold. 4. Turn on the ignition solenoids for oxygen and fuel gas. 5. Turn on the 230 VAC to the igniter in the lifter(s). 6. Wait for the ignition timer to time out. 7. Turn off the 230 VAC to the igniter in the lifter(s). 8. Turn off the ignition solenoid for fuel gas. 9. Wait for the purge timer, for the ignition oxygen, to time out before turning the ignition solenoid for oxygen off. 10. Send the high heating gas values to the central manifold. 11. Send the analog voltage height command to the lifter(s). 12. Turn on the AHC ON signal to the lifter(s). 13. Wait for TORCH IN POSITION to come back from all the lifters. 14. Wait for the heating timer to time out or when the customer presses an override button 15. Start ramping the cut oxygen gas value, from 0 to the final cutting oxygen value, to the central manifold. 16. Turn on the cut oxygen valve on the stations in use 17. Wait for the pierce timer to time out. 18. Start moving the machine at a reduced speed. 19. Wait for the lead-in timer to time out. 20. Adjust the analog voltage height command to the lifter(s) as needed from this point until the end of the cut. 21. Turn on the AHC ON signal to the lifter(s). 22. Send the low heating gas values to the central manifold. 23. Accelerate the machine to full cutting speed. After the signal to stop the process occurs inside the FANUC controller, do the following: 1. Turn off the AHC ON signal to the lifter(s). 2. Turn on the MANUAL UP signal to the lifter(s) until the raise on finish timer times out, then turn off the MANUAL UP signal to the lifter(s). 3. Send 0 volts to the central manifold for the cut oxygen value. 4. Turn off the cut oxygen valve on the stations in use. 5. If the customer does not want to keep the heating flame on: a. Turn off the heating fuel gas valve on the stations in use. b. Send 0 volts to the central manifold for the fuel gas value. c. Turn off the fuel gas valve on the central manifold. d. Wait for the post-flow timer to time out. e. Turn off the heating oxygen valve on the stations in use. f. Send 0 volts to the central manifold for the oxygen value. 13
Cut Data/Consumable part list Schneid- und Verbrauchstabelle für Schnellschneiddüsen Typ IPQ 300 S ( Propan, Erdgas ) *** Cutting and consumption table for High speed nozzles type IPQ 300 S ( propane, natural gas ) 0.300.064 Druck / Pressure Verbrauch / Consumption [ mm ] Schneidgeschwindigkeit Cutting speed DIN EN ISO 9013 *** [ mm/min.] [ bar ] [ bar ] [ bar ] [ m³ / h ] [ m³ / h ] [ m³ / h ] [ mm ] 3 600 2,0 0,5 4 600 4,0 0,7 4.450.611 5 630 4,0 0,7 6 630 4,0 0,7 6 630 5,0 1,6 8 600 5,0 1,6 4.450.612 10 560 6,5 1,9 15 520 7,5 2,1 15 520 7,0 3,4 1,9 20 4.450.613 460 7,5 2,0 0,2 3,6 0,83 0,22 2,0 4.400.136 25 420 8,0 3,8 2,1 QuattroJet 25 4.450.620 420 7,5 4,5 2,4 **** 30 QuattroJet 4.450.623 400 8,0 4,7 2,4 4.450.614 2,0 0,2 0,90 0,24 35 CoolJet Pro 380 8,0 4,7 2,5 40 360 8,5 5,0 2,5 40 360 7,5 5,7 2,6 50 4.450.615 310 8,0 2,0 0,2 6,0 1,00 0,26 2,7 60 290 8,5 6,2 2,8 60 340 6,0 7,6 3,9 80 4.450.616 300 7,5 2,0 0,2 9,6 1,30 0,30 4,0 100 270 8,5 10,2 4,0 100 270 7,5 13,3 4,0 150 4.450.617 230 8,5 4,5 0,6 14,9 2,40 0,60 4,2 200 180 9,5 16,5 4,4 4.400.136 QuattroJet **** 4.450.624 CoolJet Pro 200 180 6,5 22,0 5,2 4.450.618 4,5 0,6 2,40 0,60 250 130 8,5 22,0 5,5 4.450.621 QuattroJet 250 130 6,5 31,0 4.450.619 5,0 0,6 300 110 8,5 31,0 Die angegebenen Werte sind Richtwerte. The given values are appoximate values. 2,0 0,2 0,2 0,55 0,14 0,75 0,20 ESAB CUTTING SYSTEMS GmbH - Robert-Bosch-Str. 20-61184 Karben Germany Tel. +49 (0) 60 39 / 40 0 - Fax +49 (0) 60 39 / 4 03 01 - www.esab-cutting.de - email info@esab-cutting.de 1,5 2,50 0,62 1,0 1,6 8,0 TU 01.2010 V.2.2 14
Maintenance Preventative Maintenance Schedule Time periods suggested below are based on average plasma station usage. If station is employed in a heavy usage cycle, used outdoors, or used on a multi-torch cutting machine, suggested time intervals should be shortened. Regularly scheduled maintenance will significantly increase the life and performance of your equipment. CAUTION Read all instruction manual s safety and maintenance procedures before beginning any preventative maintenance! Daily Wipe dust and fume buildup from lift assembly and components. Check for worn or damaged cables on all lift subassemblies. Ensure all mechanical fasteners and electrical connections are correct; no stripping of hardware, connections are tight, exposed wires, etc. Check that lift travel limit switches are functioning correctly. Use your CNC s station travel buttons to ensure lift assembly has proper, smooth movement. 15
Weekly Check alignment of lift assembly. Monthly Clean and lubricate slide assembly (see procedure on page 18). Semi-Annually Repeat all previous maintenance procedures. Consider calling your ESAB Service Representative to schedule an semi-annual station inspection. NOTICE Many replacement parts subject to wear or used in preventative maintenance schedules are available directly through ESAB Cutting Systems. See Consumables and Spare Parts section in Replacement Parts portion of this manual before ordering. 16
Maintenance Procedures The following section contains maintenance procedures for the lift assembly and components. This section will provide some basic troubleshooting methods to return your station to correct operation. Only qualified maintenance personnel should utilize these procedures. 17
B4-350 Lift Introduction The B4-350 heavy duty vertical lift employs an enclosed motor that turns a ball screw. This is made possible by using a pair linear bearing blocks and a drive belt, which lowers or raises the lifter assembly along linear rails. Direction depends on commands received form the CNC. The illustration at left is the B4 lift with some parts hidden for clarity. The three grease fittings can be accessed without removing lift covers. Lift Cleaning and Lubrication In order for B4 slide assemblies to perform at optimum levels, it will need to be inspected, cleaned and lubricated on a weekly basis. The following procedure will detail steps necessary to correctly clean and lubricate your slide assembly: 1. Remove (3) cap screws attaching front cover. 2. Run lift to lower limit and wipe ball screw with a clean, dry cloth. Apply lithium based NGLI 2 grease or softer grease directly to screw. 1 2 3 4 5 6 7 8 9 10 Spindle Ball screw Spindle Ball nut Upper Limit switch and cam Precision Linear rail (2) Linear Bearing blocks (2) Lower Limit switch Lift Electronics Enclosure Timing belt Motor / Encoder Lifter Assembly w/ bellows 18
6.53 [165.8] LINEAR RAILS GREASE POINTS CAUTIONITEM 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 QTY PART NUMBER 1 0004647228 1 006.164.011 1 006.261.041P 2 0560935261 1 0560938222 1 0560938227 2 0560938405 1 0560938435 4 0560938452 1 0560941403 1 0560941404 1 0560941788 1 0560943526 1 0560943527 1 0560943528 3 0560944119 1 0560944206 1 0560944262 1 0560944265 1 0560944360 1 0560944390 1 0560944392 1 0560944476 2 0560945346 1 0560945350 1 0560945353 1 0560945354 1 0560945355 1 0560945356 1 0560945357 1 0560945358 1 0560945359 1 0560945364 1 0560945418 1 0560945419 REF 0560947287 REF 0560947288 1 0560947910 1 0560952873 2 2238778 2 407058 1 56997241 1 954075 2 FLO-STD-00687 1 FLO-STD-00686 2 FLO-STD-00684 2 DIN 128 - A4 1 FLO-STD-00688 1 FLO-STD-00682 4 FLO-STD-00056 14 FLO-STD-00071 4 FLO-STD-00086 6 FLO-STD-00100 4 FLO-STD-00156 8 FLO-STD-00161 Do not use solvents or solvent-based lubricant to clean ball screw; this can remove lubricant from sealed linear Parts List DESCRIPTION bearing IGNITION blocks. SUPPLY 24VAC / 1,5 V Screw Nut zerk fitting CLIP WIRE DOUBLE 3. Run BELT lift TIMING to 5mm upper PITCH 16mm limit. FACE PULLEY TIMING KEYLESS LOCKING ASSEMBLY 12MM X 18MM 4. Apply same grease to three zerk fittings; apply BELLOWS, B3-350 (Not Shown) Jumna Motor Mounting Bracket B4 0.1 ounce PULLEY TIMING (3cc) 5mm PITCH or 16mm half FACE 16T pump of a grease gun to B4 Tensioning Plate each Mount, fitting. Cable Tie Holder, M4 Linear Bearing zerk fittings Retaining Ring DIN472 32x1.2 Shim Ring 12x18x1 DIN 988 MICRO SWITCH SR-3-E-SW SUPPORT LIFTER B-350 SPINDLE SCREW B2-350 Fitting, Compression, M6-1 X 4mm OD HOLDER FOR SWITCH Junma Motor 200W JUNMA MOTOR BUSHING COVER, BOTTOM, B4 LIFT MANIFOLD, GREASE FITTING STATION BOX ADAPTER PLATE SHIELD, B4 LIFTER Linear Rail 25 x 510mm PLATE BACK B4-350 SCREW NUT B4 LIFTER BRACKET LIMIT SWITCH B4-200 UPPER Grease Line Right B4-200 Grease Line Left B4-200 ASSY, COVER B4-350 LIFT Hole Plug Flush 7/8" Cam Limit Switch B4-350 Spring Lower B4 BUSHING SCREW B4-200 SPACER, B4-200 LIFT B4-350 BASIC SPARES B4-350 EXTENDED SPARES Plug, Snap in, 1.5" ASSY STAT BOX B4 QUATTROJET BLOCK RUNNER SLIMLINE SZ 25 LONG Deep Groove Ball Bearing FITTING GREASE M6 STR THD NAMEPLATE 2.38 X 3.38 Hexagon nut-iso4032-m3-8-a1 Hex Jam Nut Washer-ISO7092-6.4-140HV- Spring Washer RING RETAINING EXTERNAL 12mm Washer M6 Spr.L.Washer-DIN128-B8- Hex.S.H.C.Scr.-ISO4762-M6x20-8.8 Hex.S.H.C.Scr.-ISO4762-M6X16-8.8 Spr.L.Washer-DIN128-B6- Hex.S.H.C.Scr.-ISO4762-M5x16-8.8 HS Button Head Cap Screw M4 x 6 57 58 59 60 61 62 3 1 1 8 6 4 FLO-STD-00163 FLO-STD-00164 FLO-STD-00165 FLO-STD-00166 FLO-STD-00167 FLO-STD-00169 M4 x 10 COUNTERSUNK CROSS HEAD SCREW Hexagon socket set screw M5 x 20 Flat Point Hexagon socket set screw M3 x 2 Flat Point Hex.S.H.C.Scr.-ISO4762-M6x12-8.8 Hex.S.H.C.Scr.-ISO4762-M5x12-8.8 HS Button Head Cap Screw M3 x 16 63 10 FLO-STD-00170 HS Button Head Cap Screw M4 x 10 64 4 FLO-STD-00171 HS Button Head Cap Screw M6 x 12 56 65 66 67 68 69 70 71 72 80 81 4 2 4 4 4 2 1 2 2 2 ANSI B 18.2.4.1 M - M6 x 1 FLO-STD-00187 FLO-STD-00216 FLO-STD-00218 FLO-STD-00219 FLO-STD-00681 FLO-STD-00683 SocHeadCapScrew-MET 0560939898 FLO-STD-00685 Hex Nut Hex.S.H.C.Scr.-ISO4762-M4x30 Hex.S.H.C.Scr.-ISO4762-M8x20 Spr.L.Washer-DIN128-B5 Washer galvanized B6 5. Reinstall Hex.S.H.C.Scr.-ISO4762-M4x20-A2 front cover to lift assembly. Hex.S.H.C.Scr.-ISO4762-M6x16- M6-1.0 x 80 SHCS FITTING GREASE 45 DEGREE Spr.L.Washer-DIN128-B4 HING (ITEM 12) SCREWS HOWN ON SHEET 2. CLARITY. Recommended Bolt Torque Size Torque (Nm Torque (Ft- M3 1.3 1 M4 3 2.3 M5 7 5.2 M6 12 8.8 M8 30 22.1 M10 55 40.6 M12 100 73.8 NOTICE Lift covers do not need to be removed to access grease fittings. See illustration above for fitting locations. SHEET 1 OF 2 ASSY B4-350 LIFTER QUATTROJET OEM 0560952874_D 19
B4 Lift Part Removal and Replacement NOTICE Many replacement parts subject to wear or used in preventative maintenance schedules are available directly through ESAB Cutting Systems. See Consumables and Spare Parts section in Replacement Parts portion of this manual before ordering. The most common component on B4 lifts that will need replacement over its operational lifetime is the screw nut. Proper cleaning and lubrication of this assembly, along with 350 mm screw, will dramatically extended the years of service before part replacement is necessary (see page 18 above). Procedure - Screw Nut Replacement 1. Remove both B4 lift covers by extracting cap screws with 2.5mm Allen wrench. 2. Remove limit switch cam by extracting (2) socket head hex screws with 3mm Allen wrench. 3. Remove bellow retention screws by extracting (4) socket head hex screws with 3mm Allen wrench. 1 2 3 Limit Switch Cam Bellow Retention screws (4) 20
4. Extract (2) ball nut saddle bolts from lifter assembly with 5mm Allen wrench. Saddle Bolts (2) 5. Locate ball bearing retention blocks; these will be located inside B4 lift covers. As lifter assembly linear rails travel off bottom of bearing blocks, install (2) black plastic bearing retention blocks into linear bearing blocks. Ball Bearing Retention blocks (2) 21
1 1 2 Bearing retention blocks Spring retaining bolt 6. Continue sliding lifter assembly off linear bearing blocks; rest lifter assembly on a clean, moveable surface. 7. Using medium sized channel locks and 5mm Allen wrench, grasp ball screw so it does not move and loosen spring retaining bolt. 2 8. Continue removing 5mm bolt, washer and spring and set aside. 9. Thread screw nut off end of ball screw. Replace with new ball screw nut. 10. Thread new ball screw nut onto ball screw 2 [51mm] from top of screw. 11. To reassemble lift, perform steps #1-7 above in reverse order. 22
Procedure - Ball Screw Replacement 1. Following steps #1-9 of Screw Nut Replacement Procedure (from previous pages), remove motor angle bracket assembly by extracting (4) socket head hex screws with 6mm Allen wrench. Motor Angle Bracket and associated components 23
2. Using a standard press and illustration (at left), remove worn ball screw and replace with new screw. When pressing in new ball screw, apply force with press until step is reached. 24
B4 Timing Belt (top view) 2 1 Procedure - Timing Belt Replacement Loosen tensioning jam nut and adjust set screw so belt tensioning plate can slide towards larger of the two timing pulleys. Slip new timing belt over both pulleys. After a new timing belt has installed, tighten so that belt can only be displaced by ¹/₁₆ [1.587mm]. Use a small blunt object or your index finger to displace belt at its midpoint between timing pulleys. 3 4 1 2 3 4 Motor Angle Bracket Timing Belt Belt Tensioning Plate Tensioning Jam Nut & Set Screw Ensure belt cannot be displaced more/ less than 1/16 [1.587]. Area in dotted lines above represents correct displacement. 25
Procedure - Motor / Pulley Replacement Ensure correct operation of ball screw rotation motor. Illustration (at left) displays the correct parts breakdown for motor and associated components. 26
Basic B4 Lift Assembly Troubleshooting With proper preventative maintenance performed on the B4 lift assembly, it will provide many years of precision and reliable service. However, issues may arise over time, even with most proactive PM schedules. Information is provided below to correct some common assembly failure modes that may occur and return it to normal operation: Overload fault indicator on Yaskawa servopack will not clear: Seen after the station has been "slammed" into either lower or upper hard limit; first attempt to reset power to station by disconnecting input power cable and reconnect after 10 seconds. If fault persists, physically remove motor from slide assembly and shaft will release. 27
Yaskawa JUNMA Servopack Yaskawa Junma Servopack Alarm Indicators 1 2 The Yaskawa Junma Servopack unit is responsible for motor speed, direction, and acceleration as well as encoder count and pulse monitoring. Tables on following pages will describe the servopack s alarm displays, their cause and meaning, and generalized information for corrective action: 3 1 2 3 Alarm Indicator 1 Alarm Indicator 2 Alarm Indicator 3 28
Table 1 - Speed Errors Alarm Display Alarm Name Condition Trigger Cause Corrective Action Speed Error Power was turned ON. A servopack fault occurred. Replace the servopack. AL1 = On AL2 = Off AL3 = Off Servo was turned ON. Phases U, V, and W in servomotor are wired to wrong terminals. Correct wiring. Encoder wiring is incorrect. Malfunction occurred due to noise in encoder wiring. Take measures against noise for encoder wiring. Servomotor operation was started or was switched to high speed operation. A servopack fault occurred. Replace the servopack. Phases U, V, and W in servomotor are wired to wrong terminals. Correct wiring. Encoder wiring is incorrect. Malfunction occurred due to noise in encoder wiring. Position pulse reference input has exceeded 10,000 pulses per revolution. Take measures against noise for encoder wiring. Correct reference value input. A servopack fault occurred. Replace the servopack. 29
Table 2 - Overload Errors Alarm Display Alarm Name Condition Trigger Cause Corrective Action AL1 = Off AL2 = On AL3 = Off Overload Power was turned on. A servopack fault occurred. Replace the servopack. Servo was turned ON or servomotor did not operate for a reference input from the controller. Servomotor main circuit cable wiring is incorrect or its contact wiring is faulty. Check and correct servomotor wiring. Encoder cable wiring is incorrect or its contact wiring is faulty. Normal operation A servopack fault occurred. Replace the servopack. Drop in power supply voltage. Servomotor coil burned out. Servomotor was operated with holding brake engaged. Ambient temperature around servomotor exceeded 131 F (55 C ). Ensure power supply voltage is within permissible range. Measure coil resistance. If open, replace servomotor. Measure voltage of brake terminals and release brake. Take measures to ensure working area is less than 131 F (55 C ). A servopack fault occurred. Replace the servopack. 30
Table 3 - Encoder Errors Alarm Display Alarm Name Condition Trigger Cause Corrective Action AL1 = On AL2 = On AL3 = Off Encoder Error Power was turned on or during servomotor operation. Encoder wiring and contact wiring are incorrect. Correct wiring. Noise intererence occurred because encoder cable distance is too long Disconnected encoder cable. Ensure encoder is no more than 20 meters. Replace encoder cable through ESAB Customer Service. A zero point error occurred. Replace the servopack. An encoder fault occurred. Table 4 - Voltage Errors Alarm Display Alarm Name Condition Trigger Cause Corrective Action AL1 = Off AL2 = Off AL3 = On Voltage Error Power was turned on or normal operation. Main power was turned ON again before the power supply to servopack was completely OFF. Wait until servopack's REF indicator is OFF, and turn on main power again. AC power supply voltage exceeded permissible range. Ensure AC power voltage is within specified range. A servopack fault occurred. Replace the servopack. 31
Alarm Display Alarm Name Condition Trigger Cause Corrective Action AL1 = Off AL2 = On AL3 = On Built-in Fan Stopped Power was turned on or during motor operation. Fan motor stopped. Replace cooling fan in Servopack. Air intake is blocked. Inspect and clear obstruction. Alarm Display Alarm Name Condition Trigger Cause Corrective Action ALL On Alarm Display System Error Power was turned on. A servopack fault occurred. Alarm Name Condition Trigger Cause Replace the servopack and contact ESAB customer support. Corrective Action All flash on to off at regular intervals Reference changed Power was turned on or during servomotor operation. N/A Turn on main power again (operation of the servomotorcan continue during display of this alarm). 32
Replacement Parts Replacement Parts General Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit serial number plate. Ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-esab parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor. Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers. Note Items listed in the following Bill of Materials that do not have a part number shown are not available from ESAB as a replaceable item and cannot be ordered. Descriptions are shown for reference only. Please use local retail hardware outlets as a source for these items. Note Replacement Parts, Schematics and Wiring Diagrams are printed on 279.4mm x 431.8mm (11 x 17 ) paper and are included inside the back cover of this manual. RECOMMENDED BOLT TORQUE VALUES BOLT SIZE TORQUE (N-m) TORQUE (Ft-lb) M3 0.9 0.7 M4 2.6 1.9 M5 5.0 3.7 M6 8.7 6.4 M8 21.1 15.6 M10 42.0 31.0 M12 73.2 54
Replacement Parts Consumable and Spare Part Reference List NOTICE 1-800-ESAB-123 The following section was designed to assist operators in identifying and ordering maintenance/ consumable parts. Items listed below are parts that will need replacement at least on a yearly basis, many with smaller maintenance intervals. Quantities suggested are estimated, based on normal machine usage, product lead times and availability; end users will need to best decide what quantities to purchase based on their production schedule. The parts represented here, at some point, will be necessary to maintain the process tool. Please dial our toll free number for pricing and availability or contact your nearest distributor. BASIC SPARE PARTS, B4-350 LIFT, ESAB P/N 0560947287 ITEM QTY PN DESCRIPTION 1 1 0560935261 MICROSWITCH SR-3-E-SW 2 1 0560938435 TIMING BELT 3 1 0560938227 SPINDLE SCREW, B2-350 4 1 0560941403 TIMING PULLEY 5 1 0560943527 TIMING PULLEY 6 1 0560945353 ACME SCREW NUT 7 2 2238778 RUNNER BLOCK 8 2 407058 BALL BEARING
Replacement Parts EXTENDED SPARE PARTS, B4-350 LIFT, ESAB P/N 0560947288 ITEM QTY PN DESCRIPTION 1 2 0560945346 LINEAR RAIL 2 1 0560935261 MICROSWITCH SR-3-E-SW 3 1 0560938435 TIMING BELT 4 1 0560938227 SPINDLE SCREW, B2-350 5 1 0560941403 TIMING PULLEY 6 1 0560943527 TIMING PULLEY 7 1 0560944262 JUNMA MOTOR 8 1 0560945353 ACME SCREW NUT 9 1 0560945364 SPRING 10 2 2238778 RUNNER BLOCK 11 2 407058 BALL BEARING 12 1 0006164011 RETAINGING RING 13 1 0560941404 KEYLESS BUSHING 14 1 0560943507 MCU JUNMA 15 1 0560944331 JUNMA SERVOPACK
NOTES
REVISION HISTORY Original release - this manual created from 0560946015 format, 10/2012.
Customer // Technical Support (843) 664-4405 (800) ESAB-123 (372-2123) ESAB Welding and Cutting Products PO BOX 100545 Ebenezer Road Florence, SC 29501-0545 http://www.esab.com ESAB Cutting Systems Canada 6010 Tomken Road Mississauga, Ontario Canada L5T 1X9 Phone: (905) 670-0220 Fax: (905) 670-4879 ESAB Cutting Systems GMBH Robert-Bosch-Strasse 20 Postfach 1128 D-61184 Karben 1 Phone 011-49-6039-400 Fax 011-49-6039-403-02 http://www.esab.de