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SteelBeast LIZARD Operator's Manual

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OPERATOR'S MANUAL
WELDING CARRIAGE
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Unit 21 Empire Business Park, Enterprise Way, Burnley, Lancashire,
BB12 6LT
Phone: +44 01706 229490, Fax: +44 01706 507347
www.steelbeast.co.uk
e-mail:
sales@jeisolutions.co.uk

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  • Page 1 OPERATOR’S MANUAL WELDING CARRIAGE Unit 21 Empire Business Park, Enterprise Way, Burnley, Lancashire, BB12 6LT Phone: +44 01706 229490, Fax: +44 01706 507347 www.steelbeast.co.uk e-mail: sales@jeisolutions.co.uk...

  • Page 2: Table Of Contents

    Contents 1. GENERAL INFORMATION ....................3 1.1. Application ......................... 3 1.2. Technical data......................3 1.3. Equipment included ....................4 1.4. Dimensions ........................ 5 1.5. Design ........................6 2. SAFETY PRECAUTIONS ....................7 3. STARTUP AND OPERATION ................... 9 3.1. Preparing ........................9 3.2.

  • Page 3: General Information

    LIZARD 1. GENERAL INFORMATION 1.1. Application The LIZARD is a welding carriage designed to make butt and fillet welds that are continuous or stitch. The carriage allows MIG/MAG torches and is clamped with permanent magnets. Accessories allow welding with oscillation, using torches with a larger diameter, and using two torches at the same time.

  • Page 4: Equipment Included

    JEI Drilling & Cutting Solutions Ltd LIZARD 1.3. Equipment included Carriage 1 unit Cardboard box 1 unit Cable anchor 1 unit Short rod torch holder with clamp 1 unit 3 m (10 ft) power cord 1 unit 6.5 m (21 ft) arc ignition cable...

  • Page 5: Dimensions

    JEI Drilling & Cutting Solutions Ltd LIZARD 1.4. Dimensions 447 mm (17.6″) This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 6: Design

    JEI Drilling & Cutting Solutions Ltd LIZARD 1.5. Design Cross slide Oscillation socket Control panel Guide arm Power switch Limit switch Magnet lever Lug for fall arrester Arc ignition socket Arc ignition switch LCD display Knob F2 Knob F1 (TEST / O / I)

  • Page 7: Safety Precautions

    JEI Drilling & Cutting Solutions Ltd LIZARD 2. SAFETY PRECAUTIONS 1. Before use, read this Operator’s Manual and complete a training in occupational safety and health. 2. Use only in applications specified in this Operator’s Manual. 3. Make sure that the carriage has all parts and they are genuine and not damaged.
  • Page 8 JEI Drilling & Cutting Solutions Ltd LIZARD 23. Keep the torch cables away from the surface. Hang the cables to decrease the load applied on the carriage. Use only cables whose weight is not more than 12 kg (27 lbs) for horizontal work and 8 kg (18 lbs) for vertical work.

  • Page 9: Startup And Operation

    JEI Drilling & Cutting Solutions Ltd LIZARD 3. STARTUP AND OPERATION 3.1. Preparing Use the carrying handle to transport the carriage to the worksite. Then, set to ‘O’ all switches (power, travel direction, and arc ignition switch) and the magnet lever.

  • Page 10: Connecting To The Welding Circuits

    JEI Drilling & Cutting Solutions Ltd LIZARD 3.2. Connecting to the welding circuits The carriage can control two torches by using the arc ignition cable plugged into the arc ignition socket. To do this, refer to the diagram from Fig. 2 and connect one blue- jacketed wire to one terminal of the welding circuit.

  • Page 11: Positioning At The Worksite

    JEI Drilling & Cutting Solutions Ltd LIZARD 3.3. Positioning at the worksite Put the guide arms so that the carriage is in constant contact with the workpiece. You can set them by a constant step (interval adjustment), or continuously after you swap them (continuous adjustment).
  • Page 12 JEI Drilling & Cutting Solutions Ltd LIZARD To put the carriage closer to the workpiece, use the 4 mm hex wrench to remove the roller assemblies. Next, install them at the other end of the guide arms, and then swap the guide arms (Fig. 3).

  • Page 13: Starting

    JEI Drilling & Cutting Solutions Ltd LIZARD 3.4. Starting Plug the power cord into the power source and set the power switch to ‘I’ to turn on the carriage. Then, an initial screen with the current firmware number shows. If an oscillator is connected to the oscillation socket, shows.
  • Page 14 JEI Drilling & Cutting Solutions Ltd LIZARD Parameter Value Description 0–130 cm/min Speed of the carriage. 0–52 in/min [step: 1 or 0.1] 1–250 cm Length of a single weld. 1–100 in [step: 1 or 0.1] 0–100 cm Space between welds. If set to zero, ‘crater fill’...

  • Page 15: Welding Procedure

    JEI Drilling & Cutting Solutions Ltd LIZARD To change the language of the menu, go to setting by rotating the knob F1 to the right, and then rotate the knob F2 to choose among the available languages. After the rest of the parameters from Tab. 1 is set, go to choose a program number by rotating the knob F2, and press the knob to save the current values to this number.

  • Page 16: Operating

    JEI Drilling & Cutting Solutions Ltd LIZARD 3.7. Operating To control the torch through the carriage, set the arc ignition switch to ‘I’. If the arc ignition switch is set to ‘I’, the torch starts welding promptly after you select a travel direction.

  • Page 17: Using Oscillator (Option)

    JEI Drilling & Cutting Solutions Ltd LIZARD 3.8. Using oscillator (option) 3.8.1. Installing Install the oscillator in the shown sequence. • Remove the torch holder (1). • Use the 4 mm hex wrench to remove the screws (2) and the torch holder plate (3).
  • Page 18 JEI Drilling & Cutting Solutions Ltd LIZARD 3.8.2. Welding with oscillation After you connect the oscillator to the welding carriage, several new settings will show in the menu (Tab. 2). Welding with oscillation is done in the standard manner, but the weld form a shape similar to the shape shown in Fig. 7 instead of the straight line from Fig.
  • Page 19 JEI Drilling & Cutting Solutions Ltd LIZARD 3.8.3. Operating The carriage with connected oscillator is operated similarly to operating without the oscillator. During welding with the oscillator, the menu from Fig. 8 shows on the display. Rotate the knob F1 to change the oscillation amplitude by 1%.

  • Page 20: Troubleshooting

    JEI Drilling & Cutting Solutions Ltd LIZARD 3.9. Troubleshooting Problem Cause Solution Dark LCD display after power- Malfunction of the power Contact service center for ing. cord, power switch, power check and repair. supply, or controller. Errors on the LCD display.

  • Page 21: Maintenance

    JEI Drilling & Cutting Solutions Ltd LIZARD 4. MAINTENANCE Each day: 1. Clean the chassis and wheels. 2. Clean the rollers of the guide arms. Make sure that the rollers rotate freely. 3. Clean the torch nozzle and replace if damaged.

  • Page 22: Accessories

    JEI Drilling & Cutting Solutions Ltd LIZARD 5. ACCESSORIES 5.1. Oscillator Allows welding with oscillation. Can be installed vertically or horizontally. Part number: ZSP-0477-10-00-00-0 Oscillation type Pendulum (maximum 11°) Oscillation amplitude at r=150 mm (5.9″) 1–30 mm (1–100%) Oscillation speed at oscillation amplitude of 10 mm (0.4″) 7–164 cycles/min (1–100%)
  • Page 23 JEI Drilling & Cutting Solutions Ltd LIZARD This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 24: Torch Clamps

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.2. Torch clamps 5.2.1. 16–22 mm torch clamp Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Part number: ZRZ-0466-04-01-00-0 5.2.2. 16–22 mm torch clip Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex wrench to tighten the torch in the clip.

  • Page 25: Rods

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.3. Rods 5.3.1. Short rod Provides a 120 mm (4.72″) reach. Part number: WLK-0476-20-01-00-0 5.3.2. Long rod Provides a 240 mm (9.45″) reach. Part number: WLK-0466-04-10-00-0 This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 26: Torch Holders

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.4. Torch holders 5.4.1. Short rod torch holder with clamp Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Part number: UCW-0476-20-00-00-0 5.4.2. Short rod torch holder with clip Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex wrench to tighten the torch in the clip.
  • Page 27 JEI Drilling & Cutting Solutions Ltd LIZARD 5.4.4. Long rod torch holder with clamp Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Part number: UCW-0466-04-00-00-0 5.4.5. Long rod torch holder with clip Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex wrench to tighten the torch in the clip.

  • Page 28: Torch Extension Arm

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.5. Torch extension arm Increases the reach of the torch. Use the 4 mm hex wrench to remove the M5x10 screws that attach the cross slide. Next, use the same screws to attach the cross slide at the end of the arm as shown in the figure.

  • Page 29: Guide Arms

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.6. Guide arms 5.6.1. Edge following guide arms Allow guiding the carriage along outside edges. Use the 4 mm hex wrench to remove the standard guide arms and install the new guide arms.
  • Page 30 JEI Drilling & Cutting Solutions Ltd LIZARD 5.6.2. Adjustable guide arms Allow guiding the carriage along lap joints and templates. Use the 4 mm hex wrench to remove the standard guide arms and install the new guide arms. Part number (2 units): PRW-0476-22-00-00-1 This document is protected by copyrights.
  • Page 31 JEI Drilling & Cutting Solutions Ltd LIZARD 5.6.3. Magnet guide arms Allow guiding the carriage on ceilings. Use the 4 mm hex wrench to remove the standard guide arms and install the new guide arms. Part number (2 units): PRW-0476-52-00-00-1 This document is protected by copyrights.
  • Page 32 JEI Drilling & Cutting Solutions Ltd LIZARD 5.6.4. Low guide arms Allow guiding the carriage along low walls. Use the 4 mm hex wrench to remove the standard guide arms and install the new guide arms. Part number (2 units):...
  • Page 33 JEI Drilling & Cutting Solutions Ltd LIZARD 5.6.5. High guide arms Allow guiding the carriage along walls that have holes. Use the 4 mm hex wrench to remove the standard guide arms and install the new guide arms. Part number (2 units): PRW-0476-55-00-00-1 This document is protected by copyrights.

  • Page 34: Dual Torch Mount

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.7. Dual torch mount Allows using a second torch. Use the 5 mm hex wrench to remove the M6x20 screws and washers that attach the carrying handle. Next, use the same screws and wash- ers to attach the mount to the carriage.

  • Page 35: Flexible Guide Set

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.8. Flexible guide set Allows guiding the carriage on planes along a straight line, and on pipes and tanks. A single flexible guide is 1.85 m (6 ft) long. Its minimum curve radius is 1 m (3.3 ft).
  • Page 36 JEI Drilling & Cutting Solutions Ltd LIZARD This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 37: Guide Adjustment Tool

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.9. Guide adjustment tool Allows the guide to be put parallel to an outside edge or a groove. Part number: UST-0466-53-00-00-0 Attach the magnets to the guide, and put the guide on the workpiece along the direc- tion of welding.

  • Page 38: Mm Cross Slide

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.10. 76 mm cross slide Increases the up-down or left-right adjustment range from 0–35 mm (0–1.38″) to 0– 76 mm (0–3″). Part number: ZSP-0466-46-00-00-1 Use the 4 mm hex wrench to remove eight side screws and the standard cross slide, and then install the new cross slide.

  • Page 39: Display Protection Shield

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.11. Display protection shield Protects the display from dirt. Use the 2.5 mm hex wrench to remove the top screws of the panel, and use them to attach the shield. Part number: OSL-0476-23-00-00-0 5.12.

  • Page 40: Stainless Steel Wheels

    JEI Drilling & Cutting Solutions Ltd LIZARD 5.13. Stainless steel wheels Allow working in horizontal position on a preheated plate. Part number (1 unit): KOL-0476-57-00-00-0 As shown in the figure, use the 2.5 mm hex wrench to remove the cover and use the 3 mm hex wrench to remove four wheels.

  • Page 41: 5-230 V Wiring Diagram

    JEI Drilling & Cutting Solutions Ltd LIZARD 6. 115–230 V WIRING DIAGRAM This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 42: Wiring Diagram

    JEI Drilling & Cutting Solutions Ltd LIZARD 7. 42 V WIRING DIAGRAM This document is protected by copyrights. Copying, using, or distributing without permission of JEI Group Ltd is prohibited.

  • Page 43: Declaration Of Conformity

    JEI Group Ltd Unit 21 Empire Business Park Enterprise Way, Burnley Lancs, BB12 6LT, UK We declare with full responsibility that: LIZARD WELDING CARRIAGE is manufactured in accordance with the following standards: • EN 12100 • EN 60745-1 • EN 60974-10 and satisfies regulations of the guidelines: 2004/108/EC, 2006/95/EC, 2006/42/EC.

  • Page 44: Warranty Card

    WARRANTY CARD No..................in the name of Manufacturer warrants the LIZARD Welding Carriage to be free of defects in material and workmanship under normal use for a period of 12 months from the date of sale. This warranty does not cover wheels as well as damage or wear that arise from misuse, accident, tempering, or any other causes not related to defects in workman- ship or material.

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