WELDING POSITIONER S OPERATION MANUAL CWP40

WELDING POSITIONER S OPERATION MANUAL CWP40 Revision May 19 2015 Note: The information contained in this manual is intended to be accurate. However the manufacturer retain the rights to make changes in design which may not be include herein Page # 1

Table of Content IRIZAR HEAVY INDUSTRIES INC 1.0 Welding Positioners Description 3 Welding Positioner CWP 40 3 2.0 Installation Instructions 5 Remote Control Box Operation 10 Main Control Box Operation 10 Tilt Brake 11 3.0 Lubrication and Preventive Maintenances 13 Gearboxes 13 Open Gears 14 Bearings 15 4.0 Warnings 16 5.0 Troubleshooting Procedures 17 Procedure to Re-Setting VFD (N2-200/400) 17 6.0 Technical Documentation 19 CWP 40 Foundation Drawing 19 CWP 40 Assembling Instructions 20 CWP 40 General Dimensions 21 CWP 40 Electrical Diagram 22 CWP 40 Capacity Chart 23 CWP 40 Data Plate 24 CWP 40 Table Drawings 25 CWP 40 Part List Drawing 28 CWP 40 Part List Description 29 CWP 40 Material Documentation 30 CWP 40 Electrical Part List 35 7.0 Limited Warranty 36 Page # 2

1.0 Welding Positioners Description Welding Positioner s are a state of art equipment designed and used to allow welding positioning of various shape work pieces. The positioners have variable table rotational speed through the use of a remote control box and tilt thought the main control box. Welding Positioner CWP 40 Standard package: Max Load Capacity @ 90 degrees 40 MT @ 1,200 mm GC 34 MT @ 1,400 mm GC 30 MT @ 1,600 mm GC 26 MT @ 1,800 mm GC 24 MT @ 2,000 mm GC 21 MT @ 2,200 mm GC Max Eccentricity: 300 mm Rotation Torque: 142,000 N-m Tilt Torque: 500,000 N-m Tilt Angle from 0-135 degrees Rotation Motor: 7.5 Kw @ 2 no. Tilt Motor: 7.5 Kw @ 2 no. Rotation Speed from 0.025 to 0.50 RPM Tilt Speed from 0.010 to 0.10 RPM Drop Off: 600 mm (from rotation center to top extension arms) Max work piece diameter: 3.90 m Octagonal table with inscribed circumference of 2.2 m Ø Extension arms: 4,600 mm Page # 3

Remote control box with variable speed on both table rotation and tilt forward/stop/reverse. Potentiometer and digital display in RPM. Cable length of 12 m Pedant control box with variable speed on both table rotation and tilt forward/stop/reverse. Potentiometer and digital display in RPM. Cable length of 12 m Foot control pedal for control table rotation forward/stop/reverse Protection class IP54 against dust and heavy rain on electric control box and motors Tilt Brake and Safety Devices Two self-lock worm gears are used in the tilt gearboxes so that when the motor is running the gears lock and do not allow the slewing bearing to tilt. Two electric brakes are used in the tilt motor so that when the motor are not in used the gearboxes do not rotate. The air cylinder tilt brakes (SG1 & SG2) supports the slewing bearing if there is a gear or gearbox failure. The tilt brake can be applied manually through the main control box or automatically through the PLC if there is a gear or gearbox failure. T shaped channels on table surface TECO VFD (Variable Frequency Driver) Cable clamp rated for 1,000 amps. Page # 4

2.0 Installation Instructions IRIZAR HEAVY INDUSTRIES INC 1. The welding positioner must have a proper foundation and must be anchored to the ground adequately in accordance to its foundation drawing. CWP 40 Foundation Drawing 2. The welding positioner is assembled in accordance to its assembling instructions. CWP 40 Assembling Instructions 3. Ensure that bolts use to assemble the welding positioner and all bolts holding gearboxes to the positioner frame are tighten to the chart specs below. If the bolts are not tighten properly the bolts can shear producing an accident. Use bolts DIN 933 grade class 8.8, ANSI/ASME B18.231M, high strength. 8.8 HEX Bolt 8.8 HEX Bolt OD (mm) N-m ± 10% OD (mm) N-m ± 10% M12 60 M42 2,737 M14 97 M45 3,390 M16 150 M48 4,095 M18 201 M52 5,250 M20 282 M56 6,547 M22 390 M60 8,175 M24 499 M64 9,900 M27 746 M68 12,000 M30 982 M72 14,250 M33 1,331 M76 16,800 M36 1,717 M80 19,725 M39 2,220 M85 24,000 4. The positioner gearboxes, gears and bearings must be adequately lubricated prior to commissioning the positioner. There maintenance schedule must also be adequately follow to avoid long term damages. Lubrication and Preventive Maintenance Page # 5

5. All the cables coming from the positioner are directed to the main control box. Each cable directed to the main control box is marked with a designated number. Match and connect the marked cable in the main control panel circuit. The electrical wires are placed through the inside structure of the positioner. Note: L1, L2 and L3 are designated terminals for the main power. 6. The electric diagram is attached on the back of the main control box panel door. Ensure the system is properly wired and powered as per its electrical diagram and data plate. CWP 40 Electrical Diagram 7. The tilt limit switch comes pre-installed. Ensure that limit switch and limit switch stopper are making proper contact. Place the limit switch cover and fix it to the positioner frame using four bolts. 8. The tilt brake magnetic contactor located at the bottom of the hydraulic air actuator comes preinstalled. Ensure that the magnetic contactor is properly fixed to the hydraulic air actuator. Place the magnetic contactor cover and fix it to the positioner frame using four bolts. Page # 6

9. Connect compress air supply to the tilt brake air regulated. The air pressure should be set to 70-145 (psi). Ensure that there is air supply available at all times during the positioner operation. 10. Ensure the air tubes supplying air to both tilt breaks (SG1 & SG2) are properly connected in accordance to their labelled numbering system. 11. Ensure that the left and right tilt break sensors sw1 are properly fixed in their brackets. 12. Ensure that the welding positioner maximum eccentricity and gravity center are not exceed when placing the work piece. Use the capacity chart and data plate as reference. CWP 40 Capacity Chart CWP 40 Data Plate Page # 7

13. If the work piece used weights less than 2 MT and has a GC < 600 mm the supplied counter weights need to be placed on top of the left and right end beams. If the work piece has a GC > 600 mm the counter weights need to be removed. When there is no work piece on the positioner the counter weights are removed. Each counter weight is fixed by using two removable pins. 14. The ground clamp for the positioners is rated for 1000 amps. It can be access by removing four bolts located on the center of the octagonal table. The welding positioner must not be grounded directly since it can damage and reduce the bearings life. 15. Connect the remote control box or the pendant control box to the main control box. There is a single input for this controllers on the main control box located on the far bottom left. Note: only one controller can be use at a single time. Page # 8

16. Connect the foot control pedal to the main control box. There is a single input for this controller on the main control box located on the far top left. The foot control pedal controls table rotation forward/stop/reverse functions. Page # 9

Remote Control Box Operation Function SPEED r/min SPEED T / R FWD STOP REV Description Digital display screen that indicates current table rotation and tilting speed Potentiometers used to control the table rotation and tilting speed Toggle switch used to change between T: tilting or R: table rotation When T/R switch is on T or R activates tilt or table rotation forward function Stop FWD or REV function When T/R switch is on T or R activates tilt or table rotation reverse function WARNING! When switching from FWD and REV always press the STOP button first and let the table rotation or tilting come to full stop. Failure to do so will cause permanent motor or reducer damage. Main Control Box Operation Function LAMP TILT ROTATION LOCK ALARM POWER OFF POWER ON MANUAL TILT LOCK RESET Description When POWER ON the indicator lamp lights up When the remote control toggle switch T/R is set to T the indicator lamp lights up When the remote control toggle switch T/R is set to R the indicator lamp lights up This indicator lamp lights up if: a) MANUAL TILT LOCK toggle switch set to I b) The tilt lock automatically activates (see Tilt Brake section for more details) This indicator lamp lights up if there is an error or failure with the N2 VFD Off Power switch On Power switch Toggle switch used to manually lock and unlock tilt brake; I: activates tilt brake, O: retracts tilt brake Use to reset main control box in case of N2 VFD failure Note: The tilt brake must always be set to the lock position unless the tilting function is being used. Page # 10

Tilt Brake The welding positioner comes equipped with two tilt brakes SG1 and SG2 that can be activated manually or automatically. 1) Manually: through the use of the main control box MANUAL LOCK toggle switch O/I. The tilt brake must always be set to the lock position unless the tilting function is being used. 2) Automatically: in case of a tilt gear train failure or gearbox failure the tilt brake automatically activates Sensor sw1 measures the elapse time t1 between the teeth of gears M128 The sensor sw1 is control by PLC FX1N-24MT located in the main control box The logic is accordingly: if 0 < t < t1 normal working operation the tilt brake stays in unlock mode if t>t1 failure with tilting gear train or gearboxes; the tilt break will activate and hold gear M141 in place. The tilt brake will only activate if the elapse time failure occurs three times (meaning t>t1 occurs in three teeth) Page # 11

If there is a failure in the tilting gearbox M120 or/and M122 and the PLC activates as explained in PLC logic section. For safety reasons the tilt brake will only be removed by resetting the PLC. This can be done via connecting the jumper wire to the PLC reset terminals at the same time (COM,X11) while holding the terminals the tilt brake will begin to draw back. Once the tilt brake has been fully drawn back the indicator light in the PLC X13 and X14 will light up. At this point the PLC has been reset. Ensure that the reason for the failure is properly diagnose before operating the equipment again. The logic of the PLC can be tested to ensure the safety tilt brake is working properly as following: Remove both sw1 from their bracket. Ensure the tilt brake is set in the unlock position. Change the VFD function F10 = 0 see Procedure to Re-Setting VFD (N2-200/400) for more details. Place the remote control toggle switch on the tilt function. Quickly move one sw1 sensor against a piece of steel the led light should flash red. Do this three times. Both tilt brakes (SG1 & SG2) will automatically lock. In order to retract the tilt break the PLC must be reset manually as explained earlier. The same is process is done to the second sw1 sensor. Page # 12

3.0 Lubrication and Preventive Maintenances Gearboxes The gearboxes are factory shipped without lubrication they need to be lubricated prior to equipment commissioning. The below table and diagram show lubrication spec, location of gearboxes and maintenance schedule. Failure to properly lubricate and properly follow maintenance schedule will cause permanent gearbox damage. PART CODE QTY. DESCRIPTION CWP40-M120 1 CWP40-M122 1 left table rotation gearbox right table rotation gearbox CWP40-M124 1 left tilt gearbox CWP40-M126 1 right tilt gearbox GREASE OR OIL TYPE MOBIL EP023 or Equivalent MOBIL SHC-624 or SHC-625 or SHC-630 or Equivalent GREASE OR OIL REQUIRED -Approx. 37.5 kg -Oil level should be visible in the middle of the inspection glass. -Approx. 32.0 kg -Oil level should be visible in the middle of the inspection glass. MAINTENANCE SCHEDULE -Initial oil change after start up needs to be done after approx. 10,000 operation hours. -Sequence oil changes after every 3 years or 10,000 operations hours. -Check oil level monthly. -Check gearbox unit for leakage monthly. -Observe and check gearbox unit for unusual noises during operation. M124 and M126 tilt gearbox Open cap to fill gearbox with lubrication Open bottom plug screw to drain gearbox M120 and M122 table rotation gearbox Open plug screw to add and drain lubrication Note: The gearbox M124 and M126 use oil therefore it will flow out smoothly from the bottom drain plug screw hole in the reducer. The gearbox M120 and M122 use grease in order avoid possibility of leaks therefore in order to add the grease it must be heated for it to flow in the plug screw hole. When the gearbox needs to be drained the table rotation motor must be turned on for about 15 min in order to heat up the grease and allow it to flow out smoothly from the plug screw hole. Page # 13

Open Gears The open gears are factory shipped without lubrication they need to be lubricated prior to equipment commissioning. The below table and diagram show lubrication spec, location of open gears and maintenance schedule. Failure to properly lubricate and properly follow maintenance schedule will cause permanent gear damage. PART CODE QTY. DESCRIPTION GREASE TYPE MAINTENANCE SCHEDULE CWP40-M128 2 gear 1 on tilt reducer shaft (M124 & M126) CWP40-M129 2 gear 2 on tilt shaft (M132) CWP40-M130 2 gear 3 on tilt shaft (M132) CWP40-M131 2 gear 4 CWP40-M140 1 table rotation slewing bearing gear CWP40-M141 2 tilting slewing bearing gear -MOBIL DYNAGEAR 4000 or Equivalent -The open gears must be coated with grease prior to equipment commissioning -At 500 hour operation interval remove safety guards and check the grease coating, if required replenish grease. Page # 14

Bearings The bearings are factory shipped with lubrication. The bearing are lubricated through the use three grease pumps since the bearings are not easily accessible. The below table and diagram show lubrication spec, location bearings, location of grease pumps and maintenance schedule. Failure to properly lubricate and properly follow maintenance schedule will cause permanent bearing damage. PART CODE QTY. DESCRIPTION OIL TYPE GREASE PUMP MAINTENANCE SCHEDULE CWP40-M140 1 table rotation slewing bearing #3 -The bearings are factory shipped with grease. CWP40-M141 2 table tilt slewing bearing -MOBIL EP023 #1 and #2 or Equivalent CWP40-M142 2 bearing 1 on tilt shaft n/a -At 500 hour operation interval based on a daily operation time of 24 hours replenish grease. CWP40-M143 2 Bearing 2 on tilt shaft n/a Grease Pump #3 Grease Pump #1 and #2 M143 Bearings M142 Bearings Insert grease gun to access bearing Remove end cap to access bearing Page # 15

4.0 Warnings WARNING "Overload or misuse of a Welding Positioner can cause PROPERTY DAMAGE, BODY INJURIES OR DEATH. Before operating read carefully and understand the information below. If you have any questions or concerns, please contact us @ 1 877 IRIZAR1 or jirizar@jirizar.com 1) Welding Positioner must not be operated by un-trained personal. 2) Welding Positioner must not be left ON without supervision. 3) Welding Positioner must not be operated without periodic preventive maintenance inspection. 4) Welding Positioner must not be overloaded. For your reference see max loading capacity on positioner s data plate. 5) Welding Positioner tilt brake must always be set to lock position unless tilting function is being used. 6) Welding Positioner must not be operated without proper foundation. 7) Welding Positioner must not be operated unless all bolts in the equipment are properly tighten in accordance to the bolt torque chart provided. 8) Welding Positioner must not be operated unless all gearboxes are properly lubricated 9) Welding Positioner must not be grounded directly since it can damage and reduce the bearings life. It must be grounded to the ground clamp 10) Limited Warranty: Any repair or modifications made by unauthorized third parties without written consent shall void this warranty Page # 16

5.0 Troubleshooting Procedures Procedure to Re-Setting VFD (N2-200/400) If a function or functions have been randomly changed in the VFD. Follow the below steps in order to get the VFD working in accordance with the welding positioner. The keypad command locations can be seen in the diagram below. 1. Press DSP FUN until 000Fn appears on display. 2. Press the scroll arrows up and down to navigate to the desire function code. To change digit place press RESET. 3. Input Function Fn-123 and press READ ENTER to get into the function code. 4. Press the scroll arrows up and down to change the value of the function code. To change digit place press RESET. Input (1111) if 60 Hz is used and press READ ENTER to save values. 5. This will reset the VFD to its factory settings. 6. Repeat steps 2-4 but enter the following function codes: Function Code Set Value Function Code Set Value Fn01 10 Fn10 1 Fn02 10 Fn11 2 Fn03 0 Fn46 1 Fn05 10-15 Fn47 111 Fn06 60 Fn72 0 Fn07 3 Fn76 0 Fn98 1011 7. The VFD has now been re-set press the RESET button on the main control box; check to see that all functions in the remote control box and main control box work adequately. Page # 17

6.0 Load Test Procedure IRIZAR HEAVY INDUSTRIES INC 1) Ensure the positioner is properly anchored to the ground in accordance to its foundation drawing. 2) Ensure that all bolts are properly torqued in accordance to the torque chart provided by Irizar. 3) Ensure the positioner gearboxes M120, M122, M124 and M126 are properly lubricated. 4) Ensure the overall system is properly wired and connected to the main control panel. 5) Ensure the tilt brake air regulator is properly connected to a steady compress air supply line. The air pressure in the tilt brake air regulator should be set to 70-145 psi. 6) The following functions of the CWP 40 must be tested prior to setting work piece on the positioner. a. Table rotation variable speed. b. Tilt variable speed. c. The tilt limit switch needs to be tested at 0 degrees and 135 degrees. d. Manually test the tilt brake. 7) Ensure the welding positioner maximum eccentricity and gravity center are not exceeded when placing the work piece on positioner. 8) Ensure there is a clear path behind and in front of the positioner for when the work piece is being tilted. 9) Ensure the work piece is properly fixed to the positioners table. 10) When rotation or tilting a work piece always start at low speeds. If it s not required do not rotate or tilt at high speeds. 11) Once required tilt has been reached the tilt brake should be set to LOCK. Page # 18

7.0 Technical Documentation CWP 40 Foundation Drawing IRIZAR HEAVY INDUSTRIES INC Page # 19

CWP 40 Assembling Instructions IRIZAR HEAVY INDUSTRIES INC STAGE SEQUENCE DESCRIPTION 1 A100 - A101 anchor A100 into A109 using its pre drill holes 2 A101 - A100 3 A103 - A101 4 A107 - A106 5 A103-A106 attach A101 into A100 using a total of 12 bolts M24x85 include adequate washers, lock washers and nuts attach A103 into A101 secure this attachment by first setting the two lower pins in place in order to properly align the rest of the holes then use a total of 7 bolts M24x120 include adequate washers, lock washers and nuts attach A107 into A106 using a total of 12 bolts M24x85 include adequate washers, lock washers and nuts. bring A106 close to A103 and secure this attachment by first setting the lower pins in place in order to properly align the holes then use a total of 7 bolts M24x120 include adequate washers, lock washers and nuts. 6 A107 - A109 anchor A107 into A109 using its pre drill holes 7 A110 - A104 8 A104 A103 attach A100 into A104 to the top of the octagonal table using a total of 6 bolts M24x80 per arm then using a total of 6 bolts M24x80 secure the arm to the side octagonal table. This process is done to the 8 arms in the CWP. Include adequate washers. attach A104 to A103 using a total of 32 bolts M27x85. 9 A108 A107 attach A108 to its designated bracket Part Code Part Name Weight (MT) A100 left bottom base 2.94 A101 left end beam 7.10 A102 left counter weight 2.30 A103 cradle beam 11.40 A104 rotating table 4.50 A105 right counter weight 2.30 A106 right end beam 7.10 A107 right bottom base 2.94 A108 main control box 0.30 A109 foundation n/a A110 extended arm 0.20 Page # 20

CWP 40 General Dimensions IRIZAR HEAVY INDUSTRIES INC Page # 21

CWP 40 Electrical Diagram IRIZAR HEAVY INDUSTRIES INC Page # 22

CWP 40 Capacity Chart IRIZAR HEAVY INDUSTRIES INC Page # 23

CWP 40 Data Plate Page # 24

CWP 40 Table Drawings IRIZAR HEAVY INDUSTRIES INC Page # 25

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CWP 40 Part List Drawing IRIZAR HEAVY INDUSTRIES INC Page # 28

CWP 40 Part List Description IRIZAR HEAVY INDUSTRIES INC PART CODE QTY. DESCRIPTION MFG CODE TPQ ht MTR ht CWP40-M120 1 left table rotation gearbox - - - CWP40-M121 1 left table rotation motor - - - CWP40-M122 1 right table rotation gearbox - - - CWP40-M123 1 right table rotation motor - - - CWP40-M124 1 left tilt gearbox - - - CWP40-M125 1 left tilt motor - - - CWP40-M126 1 right tilt gearbox - - - CWP40-M127 1 right tilt motor - - - CWP40-M128 2 gear 1 on tilt reducer shaft (M124 & M126) 150201C;150201D 0001553;0001554 L4956 CWP40-M129 2 gear 2 on tilt shaft (M132) 150122A;150122B CD7/8 CD7/8 CWP40-M130 2 gear 3 on tilt shaft (M132) 150201E;150201F 0001555;0001556 L4956 CWP40-M131 2 gear 4 150201A;150201B 0001551;0001552 L4956 CWP40-M132 2 tilt shaft 150122C;150122D 2145 131130511 CWP40-M140 1 table rotation slewing bearing - - - CWP40-M141 2 tilting slewing bearing - - - CWP40-M142 2 bearing 1 on tilt shaft - - - CWP40-M143 2 bearing 2 on tilt shaft - - - CWP40 FRAME STRUCTURE MTR CERTIFICATE NO. JBC 1401901; JBC1401350; JBC1401719 TPQ MFG ht tempering and quenching manufacture SN heat number Page # 29

CWP 40 Material Documentation IRIZAR HEAVY INDUSTRIES INC Page # 30

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CWP 40 Electrical Part List IRIZAR HEAVY INDUSTRIES INC PART CODE CWP40-E100 CWP40-E101 CWP40-E102 CWP40-E103 CWP40-E104 CWP40-E105 CWP40-E106 CWP40-E107 CWP40-E108 CWP40-E109 CWP40-E110 CWP40-E111 CWP40-E112 CWP40-E113 CWP40-E114 CWP40-E115 CWP40-E116 CWP40-E117 CWP40-E118 CWP40-E119 CWP40-E120 DESCRIPTION N2 inverter control relay contactor control transformer resistance dc power fuse power lamp alarm lamp reset button e-stop button power contactor speed display control button resistance control transformer motor breaker PLC tilt limit switch Sw1 sensor magnetic contactor Page # 35

8.0 Limited Warranty IRIZAR HEAVY INDUSTRIES INC IRIZAR HEAVY INDUSTRIES INC warrants all new equipment to be free from defects in material and workmanship for the period of one year, provided that the equipment is installed and operated according to instructions. Any repairs or modification made by unauthorized third parties without written consent shall void this warranty. IRIZAR HEAVY INDUSTRIES INC's obligation under this warranty is expressly limited to replacing or repairing any defective part or correcting any manufacturing defect without charge during the warranty period, if IRIZAR s factory inspection confirms the existence of such defects. Exercise of IRIZAR s option of replacement or repair will be at IRIZAR s factory and/or warehouse; therefore no reimbursement for transportation cost of any kind will be allowed. IRIZAR HEAVY INDUSTRIES INC will not be liable for any loss or consequential damage or expense accruing directly or indirectly from the use of equipment covered by this limited warranty. Page # 36