Cladding HC2
HC2
Strip Cladding head
Instruction manual
2005--05
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
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2
ENGLISH
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the welding strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismounting the welding head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Strip cladding head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment of strip width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straightener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amount of flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
8
8
9
9
9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TOCe
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GB
SAFETY
SAFETY
Full responsibility for safety measures in respect of personnel working on, or in the
vicinity of, the system rests upon the user of the ESAB Welding Equipment.
All safety measures must fulfil all regulations and mandatory rules which apply to the
type of equipment concerned, in regard to the dangers and the level of hazard
involved with the operation of any Welding Plant.
The contents of these recommendations can be looked upon as a supplement to the
normal safety rules which apply to the working site.
1. All operations must be
S
carried out in accordance with the instructions
S
handled by specialized personnel
A wrong operation can result in an abnormal situation and injure the operator
and/or damage the equipment.
2. All personnel working with the Welding Plant must be fully aware of:
S
Handling of the equipment
S
Operation of the equipment
S
The location of emergency stop devices
S
All valid safety rules
To facilitate this, each selector switch, pushbutton or potentiometer is furnished
with a printed plate or symbol, which gives clear directions as to its proper use
and function.
3. The operator must make sure
S
that no--one is inside the work area before or during operation.
S
that no one is inside the danger zone when the carriage and the slides are
operated. Mind the area behind the carriage, which you cannot see from the
control panel!
4. The work area must be:
S
free of machine parts, tools and other piled--up material that can get in the
way of the operator.
S
so arranged that the requirements for unrestricted access to emergency stop
devices for the welding carriage are met.
5. Personal safety equipment
S
Always use the proper personal safety equipment, such as:
Welders’ goggles or face--shield, non--flammable clothing, protective gloves
S
Do not wear loose clothing such as belts, bracelets, etc., which may catch on
the equipment. In this respect, remember that even rings are dangerous:
fingers can be torn off.
6. Required fire--extinguishers should be available in specially marked areas.
S
Floor areas and machine parts are to be kept free of inflammable materials,
such as oily waste, cloths etc.
S
Remember that spatter may cause fires and skin burns.
SafeArcE
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GB
SAFETY
7. Live parts are normally semi--protected.
S
Control-- and connection boxes must not be opened while in operation, or if
power is connected to the equipment.
S
The above--mentioned boxes can be opened only with a key or a tool.
S
Check that recommended, earthed connectors are properly fitted.
S
Only authorised personnel may work on electrical equipment.
8. Maintenance
S
Lubrication and maintenance of the equipment must not be done during
operation.
S
Manual procedures involving hydraulic and pneumatic components may be
carried out only when the system is decompressed.
9. The function of all emergency and safety devices is to be checked daily, as
well as after any work has been carried out on the machine.
In the event of any abnormal function or signal, the underlying cause must be
found and remedied before the machine can be taken into normal use.
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
S
Install and earth the welding unit in accordance with applicable standards.
S
Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S
Insulate yourself from earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S
Keep your head out of the fumes.
S
Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS -- Can injure eyes and burn skin.
S
Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use earmuffs or other hearing protection.
S
Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
SafeArcE
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GB
TECHNICAL DESCRIPTION
TECHNICAL DESCRIPTION
General
The strip cladding head HC- 2 is intended for internal welding of circular containers.
HC- 2 is designed for automatic cladding with a single, corrosion resistant, strip within the strip width range of 30--100 mm.
Basic position setting is provided by a crosshead, on which the unit is mounted. An
automatic joint tracking unit follows the line of the joint by means of a tracking finger.
A one--litre flux hopper with flux recovery through an OPC flux recovery unit, a pneumatically operated flux valve and a flux nozzle, all mounted to the welding head and
connected to an FFRS flux handling system.
Main components
9
6
5
7
8
2
3
1
4
1.
Strip cladding head
4.
Flux recovery nozzle
7.
Wire guide
2.
Manually adjustable slide
5.
Strip guide
8.
Motor with gear
3.
Joint tracking unit
6.
Flux equipment
9.
Support roller
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GB
TECHNICAL DESCRIPTION
Technical data
Strip Cladding head HC2
Weld joint, type:
Cladding
Strip dimension:
30 -- 100 mm, thickness. 0.4 ±0.1 mm, 0.5 ±0.1 mm
Wire feed motor:
type A6 VEC, 312:1, 8000 rpm
Welding current:
max 1500 A
Flux hopper volume:
1l
Flux handling system:
FFRS
Air consumtion:
0.35 Nm3./min at 6 kp/cm2
ffb6d1ea
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GB
INSTALLATION
INSTALLATION
General
S
Motor with gear A6 VEC, see manual 443 393.
S
Control box PEH, see manual 443 745.
S
Motorized slide A6 Slide, see manual 443 394.
S
Joint tracking equipment A6 GMD, see manual 443 403.
Loading the welding strip
1. Remove the drum (1) from the brake hub (2)
and take off the side plate (3).
2. Locate the strip reel on the drum (1).
3. Cut off the binding wires from around the
strip reel.
4. Replace the side plate (3).
5. Replace the drum (1) on the brake hub (2).
Check that the carrier (4) is in the correct position.
NOTE! The maximum angle for the wire bobbin is 25˚.
At extreme angles, wear will occur on the brake hub locking mechanism and the
wire bobbin will slide off the brake hub brake.
WARNING
To prevent the reel sliding off the hub:
S Lock the reel in place by turning the red knob as shown
on the warning label attached next to the hub.
6. Check that the feed roller are of the correct dimension.
WARNING
Rotating parts can cause injury, take great care.
ffb6i1ea
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GB
INSTALLATION
Dismounting the welding head
WARNING!
The anti--tipp devices must always be mounted on the rails during installation.
1. Place the boom in
S
bottom position -- vertical
2. Place the vertical slide in bottom position.
3. Disconnect from column and boom
S
electrical power
S
compressed air
4. Dismount all cables from the welding head
5. Dismount compressed air from the welding head.
Fitting the Strip cladding head
1. Fit the welding head to the end of the boom.
2. Connect the electrical cables supplied with the welding head.
S
See the electrical diagrams.
3. Connect compressed air to the welding head.
ffb6i1ea
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GB
INSTALLATION
Adjustment of strip width
Adjust the strip width by screw (2).
S
Max width 100 mm
S
Min width 30 mm
Straightener
S
Adjust the pressure on the strip against the drive roller (4) by hand wheel (1).
Amount of flux
S
Use the four wing nuts (3) to raise or lower the adjustment plates, thereby setting
the amount of flux.
1. Hand wheel
2. Screw
3. Wing nut
4. Feed roller
5. Pressure roller
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GB
OPERATION
OPERATION
General
Caution:
Have you read and understood the safety information ?
You must not operate the machine before then !
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
Before weld start
1. Check carrier functions.
2. Check Roller bed functions.
3. Check position and movements of vessel.
4. Check control and indicating functions:
S
Vessel revolution indicator
S
Edge tracking system
S
Anti--drift system
S
Joint tracking system
5. Check that all screws and nuts are tightened.
6. Check the welding power source.
7. Check that the current conductor is in good condition.
S
If not: Replace
S
The current conductor is a wear part and should be replaced after
approximately 300 hours of welding.
8. Check the flux system.
S
Empty the slag strainer in the flux suction unit.
S
Check air pressure for flux valve (max. 6 bar).
S
Check air pressure for flux suction unit (3--6 bar).
9. Check that the contact shoes are:
S
Correctly adjusted.
S
Clean and in good condition.
Strip cladding head -- HC
1. Check that the welding strip feeding is working correctly.
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GB
OPERATION
Welding
1. Position the welding head over the surface to be classed.
2. Lower the welding head until close to the surface.
3. Adjust the servo guide finger by means of the manually operated slide, to contact
with the surface of the welding object.
4. Select Process on the PLC unit, see PLC unit.
5. Open the flux valve and start the flux suction unit
6. Start welding compact.
Once in progress, the welding process should not be interrupted unless absolutely
necessary.
Keep a check on the flux supply.
Stop welding
1. Stop welding.
2. Close the flux valve.
3. Stop the flux suction unit.
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GB
MAINTENANCE
MAINTENANCE
General
Note:
All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
NB! Before doing any kind of maintenance work, make sure the mains is
disconnected.
For the maintenance of the A2--A6 Process Controller (PEH), see the instruction
manual 0443 745 xxx.
For the maintenance of the motor with gear (A6 VEC), see the instruction manual
0443 393 xxx.
Daily
S
Clean any flux and dust off moving parts of the automatic welding machine.
S
Make sure that all electrical cables and hoses are undamaged and properly
connected.
S
Make sure that all bolted joints are tight.
S
Check the braking torque of the brake hub. The resistance should not be so
small that the wire reel continues to rotate when wire feed is stopped and it
should not be so high that the feed rollers slip. The recommended torque for a
30 kg reel of wire is 1.5 Nm.
S
Adjusting the braking torque:
S
Set the locking button (006)
to the locked position.
S
Insert a screwdriver into the
hub springs.
Turning the springs (002) clockwise reduces the braking torque.
Turning them anticlockwise increases the torque.
NOTE! Turn each spring the same amount.
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Regularly
S
Every three months check the condition of the motor brushes and replace them
when they are worn down to 6 mm.
S
Inspect the slides and lubricate them if necessary.
S
Check the electrode guides, drive rollers and contact tip of the wire feed unit.
Replace any components that are worn or damaged.
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Spare parts list
Item
no.
Qty
Ordering no.
Denomination
Notes
30--100mm
0155972880
Strip Cladding Head
1
2
0218810181
Insulated hand wheel
6
1
0156008001
Guiding device
7
4
0148326001
Journal
8
4
0221301812
Ball bearing
10
4
0332413001
Wall
11
480
0148342001
Coupling plate
13
1
0156000001
Bar
14
1
0156001880
Lever--right
15
16
0212109160
Screw msg
16
4
0156018001
Side plate
17
12
0148325001
Contact jaw
18
2
0156010001
Guard plate
19
2
0156011001
Adjusting plate
21
4
0212102331
Screw brass
22
2
0156006001
Spacer
24
1
0156001881
Lever--left
25
12
0148324001
Contact finger
26
12
0192190035
Pressure spring
27
1
0156003001
Bar
29
1
0155999002
Rail left
30
1
0212204502
Stop screw
31
1
0155999001
Rail right
32
4
0156013001
Spacer
34
2
0156016001
Shaft
36
1
0191558002
Screw msg
38
1
0215503601
Insulating collar
39
1
0148335881
Feed roller
40
1
0148332001
Journal
43
1
0156012001
Shaft
44
1
0415498001
Cap
46
2
0144953001
Ball bearing
47
2
0146253001
Stub shaft
48
1
0156015001
Spacer
49
1
0415499001
Cap
50
2
0156014002
Shim
51
1
0156009001
Guiding device
54
1
0156022880
Holder
56
1
0153491001
Branching tube
57
1
0443383001
Flux hose
64
1
0449075001
Angle plate
f155972s
19/6x6
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m6x16
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m6x8
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ajl 17
d32/25
-- 13 --
polyuretan
f155972s
-- 14 --
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 745 11 28
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Herlev
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 218
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.zo.o.
Katowice
Tel: +48 32 351 11 00
Fax: +48 32 351 11 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 8 310 960
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: +34 91 878 3600
Fax: +34 91 802 3461
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB international AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 5308 9922
Fax: +86 21 6566 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. ESABindo Pratama
Jakarta
Tel: +62 21 460 0188
Fax: +62 21 461 2929
JAPAN
ESAB Japan
Tokyo
Tel: +81 3 5296 7371
Fax: +81 3 5296 8080
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 8027 9869
Fax: +60 3 8027 4754
SINGAPORE
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 6861 43 22
Fax: +65 6861 31 95
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
SOUTH KOREA
ESAB SeAH Corporation
Kyungnam
Tel: +82 55 269 8170
Fax: +82 55 289 8864
UNITED ARAB EMIRATES
ESAB Middle East FZE
Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
070514
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