1. Manuals
  2. Brands
  3. PEMA Manuals
  4. Welding System
  5. WS2
  6. Instruction manual

PEMA WS2 Instruction Manual

Welding station
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Welding Station PEMA WS2
Instruction Manual

Advertisement

Table of Contents
loading

Related Manuals for PEMA WS2

Summary of Contents for PEMA WS2

  • Page 1 Welding Station PEMA WS2 Instruction Manual...
  • Page 2 Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents ....................... 3 Introduction ......................5 Contact information ................6 Safety ........................7 General Information ................7 Safety Instructions ................. 8 Safety related functions ................ 13 Technical Information ..................14 Machine structure ................14 Functional Description ................17 Technical Data ..................
  • Page 4 6.2.1 Sidebar and general UI functions ............47 6.2.2 Start page ..................48 6.2.3 Operator page ................... 49 6.2.3.1 Joint tracking tab..............50 6.2.3.2 META settings ............... 51 6.2.3.3 Multi-pass tab ................ 53 6.2.3.4 Position and distance tab ............54 6.2.3.5 Settings tab................

  • Page 5: Introduction

    1 INTRODUCTION CAUTION Read and understand the INSTRUCTION MANUAL before installing or operating! · Observe the following safety precautions in addition to the standard regulations that apply to the work place. · Operator has the ultimate responsibility for ensuring that anyone who works with or near the equipment observes all the relevant safety precautions.

  • Page 6: Contact Information

    1.1 Contact information Manufacturer: Pemamek Oy Lamminkatu 47 FI-32200 Loimaa Finland Tel: +358 2 760 771 Fax: +358 2 762 8660 E-mail: pema@pemamek.com Service: Tel: +358 2 760 77 200 E-mail: service@pemamek.com Internet: www.pemamek.com Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 7: Safety

    2 SAFETY 2.1 General Information Pema WS2 welding station is designed for simultaneous welding of two circular outside seams. Station includes WS2 heavy duty welding manipulator with one-side welding platform. Platform is equipped with two Tandem SAW welding heads to weld simultaneously two seams with same rotation.

  • Page 8: Safety Instructions

    2.2 Safety Instructions DANGER MOVING PLATFORM – Crushing Hazard · Secure the working area before driving the platform! · Observe loading instructions before loading the platform. · DO NOT stay on the work piece! DANGER MOVING MACHINE – Crushing Hazard ·...
  • Page 9 WARNING CLIMBING AND WORKING ON PLATFORM – Falling Hazard! · DO NOT overload the platform. · Keep the platform clean. · Use fall protection equipment! WARNING FALLING OBJECT – Impact Hazard! · Keep the platform clean from idle objects. · Do not store idle tolls on platform. ·...
  • Page 10 WARNING ELECTRIC SHOCK - can kill · Install and earth the welding unit in accordance with applicable standards. · Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. · Insulate yourself from earth and the workpiece. ·...
  • Page 11 WARNING WELDING CUTTING can be injurious · Take precautions when welding. · Ask for your employer’s safety practices which should be based on manufacturer’s hazard data. · Make sure the welding ground cable is connected securely. · Read the safety instructions supplied with the welding equipment. ·...
  • Page 12 WARNING WELDING SPARKS – Fire hazard · Ensure there is no inflammable material nearby. · Ensure there is fire extinguishing equipment clearly marked and close at hand. WARNING HOT WORK PIECE – can burn · The work piece can be hot after welding or cutting. ·...

  • Page 13: Safety Related Functions

    WARNING BREAKDOWN PNEUMATIC EQUIPMENT – Loss of sight or hearing and impact hazard · Check the condition of the pneumatic system regularly and repair all failures immediately. · Repair all damaged components immediately. · Use appropriate personal protective equipment. WARNING IN CASE OF AN EMERGENCY –...

  • Page 14: Technical Information

    3 TECHNICAL INFORMATION 3.1 Machine structure Pema WS2 welding station consists of the following main parts: 1. Rail car 2. Column 3. Operator platform 4. Ladder 5. Main control cabinet MC1 6. Hydraulic aggregate 7. Welding head 1 8. Welding head 2 9.
  • Page 15 Figure 1 Main parts a Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.
  • Page 16 Figure 2 Main parts b Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

  • Page 17: Functional Description

    3.2 Functional Description Pema WS2 welding station is designed to be operated according to the following steps. 1. Positioner to loading position 2. Load work piece Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.
  • Page 18 3. Check platform height to avoid collision! 4. Positioner / Work piece to welding position. 5. Check platform height and position 6. Welding heads to welding position Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.
  • Page 19 7. Adjust welding head position 8. Setup welding parameters 9. Enable welding sequence Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.
  • Page 20 10. Automatic welding 11. Seam tracking 12. Positioner / Work piece to loading position 13. Unloada work piece Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 21: Technical Data

    3.3 Technical Data 3.3.1 Mechanical characteristics Height (normal operation) 12 400 mm Width excluding carriages 6 360 mm Width including carriages 9 650 mm Depth 8 200 mm Weight excluding carriages 35 000 kg Weight including carriages 42 000 kg Rail movement speed 250-5000 mm/min Rail movement length...

  • Page 22: Machine Plate

    3.4 Machine plate Machine plate is attached to the side of the main control cabinet. The machine plate contains the following important information: Type: Type of the machine Ser. No: Serial number of the machine Art. No: Article number of the machine Man.

  • Page 23: Installation And Commissioning

    4.2 Installation and start-up Installation of Pema WS2 welding station is only allowed under the supervision of PEMA or its authorized representative. Installation must be carried out according to installation instructions in Pema lay-out and foundation drawings.

  • Page 24: Operating Instructions

    5 OPERATING INSTRUCTIONS CAUTION Read and understand the INSTRUCTION MANUAL before installing or operating! · Observe the following safety precautions in addition to the standard regulations that apply to the work place. · Operator has the ultimate responsibility for ensuring that anyone who works with or near the equipment observes all the relevant safety precautions.

  • Page 25: Safety Functions

    DANGER COLLISION – can break the equipment and cause injury! · Secure the working area before operating the machine! · In case of collision stop operation immediately and check possible damages. 5.1 Safety functions In case of an emergency the operation of the machine is stopped with emergency stop. The reason for emergency must be solved before continuing operation.
  • Page 26 Figure 3 Emergency stop buttons Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

  • Page 27: Emergency Stop Reset

    Figure 4 Emergency stop buttons on platform 5.1.2 Emergency stop reset Before resetting the emergency stop all actuated emergency stop buttons must be released. Emergency stop button is released by turning it clockwise. Emergency stop is reset with reset button in the door of the MC11. The location of the emergency stop reset button is indicated with letter R in Figure 3 and Figure 4.

  • Page 28: Control Functions

    Signal light is lit when pressure tank 2 is enabled. 4. Speed control potentiometer. a. Travelling speed of the WS2 is adjustable. 5. Key switch for selecting the control location. a. Control of the machine is in one place at a time.
  • Page 29 Figure 5 Control panel in MC1 Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

  • Page 30: Control Panel Op1

    When resetting the system the signal light is blinking frequently. 4. Drive rail car left / right. 5. Drive platform up / down. 6. Speed control potentiometer. a. Travelling speed of the WS2 is adjustable. DANGER COLLISION – can break the equipment and cause injury! ·...
  • Page 31 Figure 6 Control panel OP1 Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

  • Page 32: Op1 Touch Panel Structure

    5.2.2.1 OP1 Touch panel structure Figure 7 OP1 touch panel structure Touch panel in OP1 is indicated with number 1 in Figure 6. The structure of the OP1 touch panel is shown in the Figure 7. Touch panel pages three sections with the following function. The navigation bar, left side in the Figure 7, is used to navigate between pages.

  • Page 33: Welding Information

    5.2.2.2 Welding information Welding information page is shown in the Figure 8. Welding information page contains the following welding parameters for both of the welding heads: 1. The welding speed specified in the WPS. a. Please refer to WC500 instructions for detailed information. 2.

  • Page 34: Work Piece Diameters

    5.2.2.3 Work piece diameters Work piece diameters page is shown in the Figure 9. Work piece diameters page contains the parameters related to the work piece. These parameters should always be checked when the work piece is changed and the new welding operation is started. The page contains the following parameters: 1.

  • Page 35: Alarms

    5.2.2.4 Alarms Alarms page is shown in the Figure 10. Alarms page is used to show the active and acknowledged alarms, warnings and messages. Red color is used to identify the active alarms. Yellow color is used to identify active warnings. White color is used to identify messages.

  • Page 36: Service

    5.2.2.5 Service Service page is shown in Figure 11. Service page has the following functions: 1. Wheel diameter of the positioner in millimeters that is used in calculating the welding actual speed. 2. Revolution ratio between encoder and wheel 3. Invert encoder counting direction. (Preset encoder values required.) 4.

  • Page 37: Touch Panel Security Functions

    5.2.2.6 Touch panel security functions There are two different user levels in the touch panel: Administrator and Operator. Operators can change the values that are related to operate and for daily use of the machine. For configuring the machine the administrator level is required. Login dialog is shown in Figure 12 and is displayed whenever the higher user level is required.

  • Page 38: Control Panel In Mc11 And Mc21

    5.2.3 Control panel in MC11 and MC21 Both of the welding heads and the control systems to operate them have their own electric cabinet with a main switch and the main control panel up at the platform. In this control panel you can find an emergency push button as well as reset button to reset the machine after emergency stop.

  • Page 39: Control Panels Rc11 And Rc21

    5.2.4 Control panels RC11 and RC21 Functions of the welding heads and motorized cross slide are controlled with control panel RC11 and RC12 up at the platform. 1. Automatic welding Start / Stop Signal light is lit when the automatic working cycle is on Welding is stopped by pressing Stop button 3 seconds...

  • Page 40: Welding Control With Touch Screen Op11 And Op21

    5.2.5 Welding control with touch screen OP11 and OP21 Control of the welding process as well as movements of the boom is done with touch screen called operator’s panel OP1. Operator’s panel is seen in Figure 15. Operator’s panel OP1 is situated on the movable stand with camera monitor. In this section it is told the main principles of how the touch screen works, programming functions are described in the following sections.

  • Page 41: Flux System Control

    5.2.6 Flux system control Flux system has its own main switch. This makes it possible to keep the flux warm while other devices are switched off. There are signal lights serving information about the functioning of flux pressure tank within the control panels MC1, RC11 and RC21.

  • Page 42: Adjustments

    5.3 Adjustments 5.3.1 Flux heating adjustment Flux system has its own main switch. This makes it possible to keep the flux warm while other devices are switched off. Flux heating control panel is used to adjust heat of the flux tank. Heating keeps the moisture out from the flux pressure tank while it is in use.

  • Page 43: Adjusting Contact Jaw Nozzle

    5.3.3 Adjusting contact jaw nozzle When wire size is changed, contact jaw nozzle has to be adjusted. Adjustment screw is located on connector tube in welding head. 1. Adjust correct spring load to contact nozzle by fully tightening screw and then opening one round.

  • Page 44: Adjusting Wire Straightener

    5.3.5 Adjusting wire straightener Wire is kept straight with wire straightener. Wire straightener is located on welding head above wire feeder. 1. Move adjustment roll with adjusting wheel. Figure 21 Adjusting wheel of wire straightener Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 45: Operation And Programming Functions

    6 OPERATION AND PROGRAMMING FUNCTIONS 6.1 System overview WeldControl 500 WeldControl 500 is an advanced user interface for controlling Pema welding applications. It utilizes META laser seam tracking sensor to enable accurate multipass welding functions. WC500 enables users to store multiple different welding parameter sets and multipass tables for different applications and switch and modify them with ease.

  • Page 46: Maf

    6.1.3 MAF The system utilizes META DLS sensor for seam tracking. The sensor communicates with META MAF application which in turn communicates with the WeldControl 500 system. MAF is started automatically when the user interface starts. MAF is parameterized and operated through WC500 user interface and usually requires no attention from the user.

  • Page 47: User Interface Pages And Functions

    6.2 User interface pages and functions The user interface can be used with a keyboard and mouse and/or with touch screen and software keyboard. The following chapter introduces the different pages and their functions in the user interface. 6.2.1 Sidebar and general UI functions Sidebar is used to navigate between different main pages in the user interface.

  • Page 48: Start Page

    6.2.2 Start page Figure 25 Start page, manual welding selections 1. WPS selection Data collection on/off and work piece information Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 49: Operator Page

    6.2.3 Operator page Operator page displays information about the welding process, seam tracking and the progress of the multipass table. It also contains general equipment settings in the settings tab. Figure 26 Operator page 1. Actual welding data feedback: current (A), wire feed (m/min) and voltage (V) 2.

  • Page 50: Joint Tracking Tab

    6.2.3.1 Joint tracking tab Figure 27 Joint tracking tab 1. META OK indicator is green: META is ready and communication with META software is OK. 2. Seam lost indicator is red: Automatic tracking is ON and META cannot detect the joint anymore.

  • Page 51: Meta Settings

    6.2.3.2 META settings Figure 28 META settings 1. Laser ON/OFF. 2. Automatic tracking ON/OFF. When automatic tracking is turned ON, recording of a new track begins. When automatic tracking is turned OFF, the recorded track is saved. 3. Track top means that tracking point is moved from joint bottom to work piece surface level.
  • Page 52 a. Orange cross: calibration point. b. Green cross: tracking point. c. Green / purple circles: threshold points. They are green when tracking mode is ”Laser” and they are purple when tracking mode is ”Replay”. 7. Laser scan range determines how wide the laser scan area is. 8.

  • Page 53: Multi-Pass Tab

    6.2.3.3 Multi-pass tab Figure 29 Multipass tab 1. Multipass state 2. Times to do layer counter 3. Go to fixed fill. Sets active pass to first pass of the fixed fill layers. 4. Go to dynamic fill. Sets active pass to the first pass of the dynamic fill layers. 5.

  • Page 54: Position And Distance Tab

    6.2.3.4 Position and distance tab Figure 30 Position and distance tab 1. Fill in welding platform specific fields a) Welding start delay b) Work piece diameter c) Start position shift: Additional welding length per pass after full circle. 2. Currently configured external axis welding lap length (Full rotation + overlap distance) 3.

  • Page 55: Settings Tab

    6.2.3.5 Settings tab Figure 31 Settings tab 1. Equipment settings a. Flux start offset: Flux dropping starts this distance before welding start position b. Flux stop offset: Flux dropping stops this distance before welding stop position c. Flux cleaning offset: Length of flux cleaning movement after welding. d.
  • Page 56 2. Unit step settings: Set how much + and – buttons alter values Figure 32 Unit step settings 3. Manual Driving: Control movements from the touch screen. 4. Open Lincoln command center 5. Start screen cleaning mode: Disables touch screen for a short time Author: TLe Code-Revision: D23000-0 Date: 8.1.2015...

  • Page 57: Wps Editor

    6.2.4 WPS editor WPS editor is a tool for creating a complete welding parameter specification for a seam type. Each WPS contains: · Welding parameter sets o Welding parameters o Movement settings o Phase settings · Multipass table o Layer settings o Tracking mode settings for layers o Parameter set selections for layers Figure 33 WPS editor...
  • Page 58 6. Movement settings 7. Torch selection 8. Weld mode selection 9. Welding start and stop values selection 10. Use preset welding mode. Preloads welding mode to be used next in circumferential welding. Disables welding with this torch. 11. Fields for wire feed speed, current, voltage, DC-offset and limits 12.

  • Page 59: Torch Phase And Square-Wave Voltage Settings

    6.2.4.1 Torch phase and square-wave voltage settings To minimize the effects of magnetism in multiple arc systems maintaining phase relationship between the arcs (time offset between the arcs) is important. Every arc phase is set according to the leading arc. Figure 35 Phase settings 1.

  • Page 60: Movement Settings

    6.2.4.2 Movement settings Movement settings have a selection for end ramp and ‘movement waits for arc’. · End ramp: End ramp is a feature that can be used to reduce the crater in the end of the weld. It reduces the welding speed linearly from normal welding speed to the final speed in a given distance at the end of the weld.

  • Page 61: Multipass Editor

    6.2.4.3 Multipass editor Figure 37 Multipass editor 1. Layer display 2. Adds layer on top of the currently selected layer 3. Adds layer below the currently selected layer 4. Delete the currently selected layer 5. Increases the amount of passes in the currently selected layer 6.
  • Page 62 12. Start offset. Adjusts welding start position from the welding start position. Used to cascade weld starts during multipass welding. (Positive direction is the welding direction.) 13. Start offset. Adjusts welding stop position from the welding end position. Used to cascade weld ends during multipass welding.

  • Page 63: Multipass Dynamic Fill And Cap Layers

    In Figure 38: Example of laser tracking and replay mode settings is illustrated an example of laser tracking and replay mode settings. The first two layers utilize laser tracking and the last two are set to replay mode. · Laser tracking ·...
  • Page 64 Figure 39 Multipass editor with dynamic fill and cap enabled 1. Fixed fill: If the number of passes needed for filling the joint stays always the same, this is a good option (usually with small joints). Layers under ”fixed fill” are done number of times specified in the respective column.

  • Page 65: Wps Info

    6.2.4.5 WPS info Figure 40 WPS info Procedure and material information can be seen and edited by choosing WPS while being in WPS editor page and pressing Procedure and material information button. Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 66: Parameters Overview

    6.2.4.6 Parameters overview Figure 41 Parameters overview Parameters overview window displays all the welding parameter sets currently configured in the currently selected WPS in the editor. Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 67: Start/Stop Parameter Editor

    6.2.5 Start/Stop parameter editor It is possible to create different start/stop parameter sets to be assigned for welding parameter sets in the WPS editor. Figure 42 Start/Stop parameter editor Start/Stop parameters configure how the welding process starts and stops. Each parameter set contains parameters for CV(left) and CC(right) modes.
  • Page 68 Figure 43 Parameter set selection 1. Select welding start and stop parameters set 2. Add a new welding start and stop parameter set 3. Make a copy of currently selected set 4. Delete currently selected set 5. Change a name of currently selected set Author: TLe Code-Revision: D23000-0 Date: 8.1.2015...

  • Page 69: Data Collection

    6.2.6 Data collection Data collection records data from each weld under a file designated by workpiece name and serial number. Figure 44 Data collection page Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 70: System Messages

    6.2.7 System messages Figure 45 System messages 1. Active system messages from the machine control system 2. Messages from WeldControl 500 software 3. All messages are stored in a message history Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 71: Settings

    1. Change language 2. Change password 3. Reset communication between user interface and PLC 4. Shortcut to the to the joint tracking control window 5. Pema service settings Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 72: Welding

    6.3 Welding Here is a list of general steps to perform when starting a new welding. More detailed instructions on steps can be found in referenced chapters. 1. Generate WPS for welding (see chapter 6.3.1 WPS creation) 2. Select WPS and relevant selections (WPS selection etc. see chapter 6.2.2 Start page) 3.

  • Page 73: Wps Creation

    6.3.1 WPS creation 6.3.1.1 Define welding parameter sets Parameter sets are collections of welding settings. You can assign different parameter sets to welding layers in the multipass editor page. Figure 47 WPS Editor, WPS selection Click WPS selection and create a new WPS and name it. Select the created WPS and press ok. Author: TLe Code-Revision: D23000-0 Date: 8.1.2015...
  • Page 74 Figure 48 WPS Editor, Welding parameter set 1. New WPS has one parameter set named ‘Root pass’ by default. You can rename it or use it as it is. In this guide we decide to leave the name ‘Root pass’. 2.

  • Page 75: Setup Multipass Table

    6.3.1.2 Setup multipass table The multipass editor is used to configure layers and passes in multipass welding. You can assign welding parameter sets created in previous section to layers here. 1. Configure a fixed fill layer (see chapter 6.2.4.3 Multipass editor) a) Select layer b) Select a welding parameter set for the layer c) Define META seam tracking settings for layer...

  • Page 76: Seam Tracking Sensor Calibration

    6.3.2 Seam tracking sensor calibration Seam tracking sensor needs to be calibrated when lead torch position or sensor position has changed. Calibration defines torch position horizontally and vertically in relation to the sensor (sensor distance from the torches is defined separately in operator page settings tab). Recalibration is not needed if sensor and torches have not been moved.
  • Page 77 5. Go to META settings in operator page (see chapter 6.2.3.2 META settings) and press Calibrate. Calibration is successful if the yellow crosshair moves to the green cross and the green ‘calibration successful’ indicator lights up. Figure 51 Operator page, Meta settings Note: To achieve accurate tracking it is important to move the laser line to the position where correct torch position was determined...

  • Page 78: Miscellaneous

    If you want to preserve older backup files, please take them from panel with USB- stick. · Default folder for backup data is "C:\PEMA\WeldControl 500\Backups\". · "WpsManager.xml" contains WPS-data. "Sequencer.xaml" contains data for start and stop values. Other data files contain mainly user interface settings.
  • Page 79 Restoring WeldControl 500 backup file: 1. Shutdown WeldControl 500 software. 2. Go to folder "C:\PEMA\WeldControl 500\Data\". Take backups of the files inside this folder (if something goes wrong when restoring backups, you still have backups of the current data files).

  • Page 80: Maintenance And Service Instructions

    7 MAINTENANCE AND SERVICE INSTRUCTIONS 7.1 Introduction CAUTION Read and understand the INSTRUCTION MANUAL before maintaining or servicing the machine! · Observe the following safety precautions before servicing or maintaining the equipment. · Read manufacturer’s service instructions before servicing electric motors. ·...

  • Page 81: Gear Locations And Maintenance Instructions

    7.2 Gear locations and maintenance instructions 7.2.1 Gear locations 1. Planetary gear PLE80 2. Helical-bevel gear KA47BDRS71 3. Tooth gear RXP3 Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd.

  • Page 82: Gear Maintenance Instructions

    7.2.2 Gear maintenance instructions Planetary gear PLE80 (1) Gearboxes are filled at the factory with synthetic lubricant in a quantity suitable for operation in any mounting position. In the absence of contamination the original lubricant change can be considered “for life” and no periodical changes are required.
  • Page 83 Helical-bevel gear KA47BDRS71 (2) Lubricant / Lubricating period* Gear oil ISO VG 320-460 320- 460 cSt / 40 ºC First: 200 h Others: 4000 h Tooth gear RXP3 (3) Lubricant / Lubricating period* Gear oil ISO VG 320-460 320- 460 cSt / 40 ºC First: 200 h Others: 4000 h * The re-lubrication period will depend on the operating conditions of the machine: speed, load, number of working cycles per day etc.

  • Page 84: Linear Guides Maintenance

    7.3 Linear guides maintenance Platform lifting Linear guides Lubricant: HIWIN G05 Lithium type soap base Vaseline NLGI2 Period: 3-4 months Welding head movement Linear guides Lubricant: HIWIN G05 Lithium type soap base Vaseline NLGI2 Period: 3-4 months Rack bar Clean rack bar with pressured air once a month.
  • Page 85 Cross slide hand adjustment Linear guides Lubricant: HIWIN G05 Lithium type soap base Vaseline NLGI2 Period: 3-4 months Cross slide horizontal Linear guides Lubricant: HIWIN G05 Lithium type soap base Vaseline NLGI2 Period: 3-4 months Cross slide vertical Linear guides Lubricant: HIWIN G05 Lithium type soap base Vaseline NLGI2 Period: 3-4 months...

  • Page 86: Welding Equipment Maintenance

    7.4 Welding equipment maintenance Pema flux system Check regularly condition and wearness of flux hoses. Repair leakages or replace hoses instantly. Between the flux pressure tank and the cut- off valves control pressure (meaning the systems main pressure) the difference needs to be at least 2,5bars.
  • Page 87 Wire drums brake Wire drums should not rotate freely. By turning the bolt the brakes friction is increased. Check regularly wearness of the brake pads. Replace if needed. Period: 3-4 months Welding equipment Power Wave AC/DC 1000 SD In extremely dusty locations, dirt may clog the air channels causing the welder to run hot.
  • Page 88 Cooling unit R1100 V/G The coolant mixture is 65 % water and 35 % glycol. Period for coolant replacement is approx. once a year. 1 week period: Remove dust from heat exchanger with compressed air. 12 month period: Clean the pump filters. Put about 10 to 15 drops of oil in each end- bearing of the motor.

  • Page 89: Hydraulic Aggregate Maintenance

    7.5 Hydraulic aggregate maintenance CAUTION Read and understand the INSTRUCTION MANUAL before maintaining or servicing the machine! · Observe the following safety precautions before servicing or maintaining the equipment. · Read manufacturer’s service instructions before servicing hydraulic aggregate. · Check amount, temperature and quality of oil. ·...

  • Page 90: First Hours Of Operation

    CAUTION Read and understand the INSTRUCTION MANUAL before maintaining or servicing the machine! · Observe the following safety precautions when starting up the equipment. · Read manufacturer’s service instructions before operating hydraulic aggregate. · During the first hours of operation the system has to be run carefully. Avoid maximum loading the equipment.

  • Page 91: Changing Of Oil

    7.5.2 Changing of oil The condition of oil is followed visually from time to time. If the oil gets unclear, it is mixed with water condensed into the tank. Water can be separated from oil with special equipment. In small volume systems it is usually easier to change the oils. If the oil gets very black, it is obviously getting quickly oxidized.
  • Page 92 Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

  • Page 93: Oil Specifications

    7.6 Oil Specifications ÖLJYSUOSITUKSET - OIL RECOMMENDATIONS ÖLEPFEHLUNGEN - OLJEREKOMMENDATIONER Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd.

  • Page 94: Lubricating The Linear Motion Guides

    7.6.1 Lubricating the linear motion guides Lubricate linear motion guides with a grease gun. Lubrication must be done carefully, avoid pressing too much grease at time. Too much grease damages bearing protections. Service and lubrication for linear bearings and tracks Linear tracks and bearings have a critical part in machine functioning.
  • Page 95 CRC Quickleen. If this doesn’t help, contact Pema service for assistance. Don’t try to remove rust mechanically by grinding or sand paper. Lubricate the linear bearings by crease gun. Use only high quality grease. Cheapest one is not usually the best.

  • Page 96: Tables For Gear Oil Selection

    7.6.2 Tables for gear oil selection Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.
  • Page 97 Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.
  • Page 98 Author: TLe Code-Revision: D23000-0 Date: 8.1.2015 Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third person without written consent of Pemamek Ltd. Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek Ltd.

Table of Contents