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PEMA PBW 5000/2 Instruction Manual

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Plate Butt Welding Station
PEMA PBW 5000/2
Instruction Manual

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  • Page 1 Plate Butt Welding Station PEMA PBW 5000/2 Instruction Manual...
  • Page 2 Author: TLe Code-Revision: D23399-0 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 ................ 12 Technical Information ..................13 Machine structure ................13 Technical Data ..................14 3.2.1 Mechanical characteristics ..............
  • Page 4 6.2.5 WPS editor ..................43 6.2.5.1 WPS Editor: phase settings ........... 45 6.2.5.2 WPS Editor: movement settings ..........46 6.2.5.3 WPS Editor: multipass editor ..........47 6.2.5.4 WPS Editor: multipass dynamic fill and cap layers ....50 6.2.5.5 WPS Editor: WPS info ............51 6.2.5.6 WPS Editor: Parameters overview .........

  • 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: D23399-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 7: Safety

    Conveyor system is integrated with welding tables to feed plates through the system. Integration with milling machines including plate push and measurement carriage of MM1 has been considered in this offer and in case of milling machine supplier other than PEMA specification of conveyor line has to be reviewed.

  • Page 8: Safety Instructions

    2.2 Safety Instructions DANGER MOVING MACHINE – Crushing Hazard · Secure the working area before driving the machine! WARNING CLIMBING AND WORKING ON WELDING PORTAL – Falling Hazard! · Use fall protection equipment! · Check the condition of the fall protection equipment before use according to the manufacturer’s instructions.
  • Page 9 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 work piece. ·...
  • Page 10 WARNING FUMES AND GASES – can be dangerous to health · Keep your head out of the fumes. · Use ventilation, extraction at the arc, or both, to keep fumes and gases from you breathing zone and the general area. WARNING ARC RAYS - Can injure eyes and burn skin...
  • Page 11 WARNING HOT WORK PIECE – can burn · The work piece can be hot after welding or cutting. · Use personal safety equipment. WARNING MOVING WORK PIECE – entanglement and crushing hazard · Secure the working area before operating! · Do not go near or under the moving work piece! WARNING LASER RADIATION –...

  • Page 12: Safety Related Functions

    WARNING BREAKDOWN OF THE 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 13: Technical Information

    3 TECHNICAL INFORMATION 3.1 Machine structure Pema PBW 5000/2 welding station consists of the following main parts: 1. Portal 2. Welding equipment 3. Coil stand 4. Ladder 5. Service platform 6. Flux tank 7. Electric cabinet 8. Control panel Location of the main parts is shown in Figure 1...

  • Page 14: Technical Data

    3.2 Technical Data 3.2.1 Mechanical characteristics Welding movement 5 000 mm Height 5 365 mm Width 8 625 mm Weight 103 010 kg Wire reels 3 x 100 kg Cross slides 600 x 300 mm 3.2.2 Electrical characteristics Main supply voltage 400 VAC / 50 Hz 3ph + N + PE Power consumption - Main cabinet...

  • Page 15: Machine Plate

    3.3 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 16: Installation And Commissioning

    4.2 Installation and start-up Installation of Pema PBW 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 17: 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 18: 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 19 Figure 2 Control panel in MC1 5. Main switch On; turn clockwise (green signal light is lit, reset light is lit in few minutes after start) Off; turn counterclockwise (green signal light turns off) Author: TLe Code-Revision: D23399-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 20: Control Panel Rca1

    5.1.4 Control panel RCA1 Functions of the welding heads and motorized cross slide are controlled with control panel RCA1. Figure 3 Control panel RCA1 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 WeldControl fault codes are reset by pressing Stop button for 3 seconds 2.
  • Page 21 c. Manual wire feeding torch d. Movement of welding carriage 5. Seam tracking sensor activation Light is flashing when seam is lost Light stays continuously on when laser is ready and tracking 6. Joystick for selected movement 7. Manual speed control potentiometer for selected movement Author: TLe Code-Revision: D23399-0 Date: 8.1.2015...

  • Page 22: Welding Control

    5.1.5 Welding control 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 4. 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 23: Flux System Control

    5.1.6 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 and RCA1.

  • Page 24: Adjustments

    5.2 Adjustments 5.2.1 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 25: Adjusting Contact Jaw Nozzle

    5.2.2 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 26: Adjusting Wire Straightener

    5.2.4 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 9 Adjusting wheel of wire straightener Author: TLe Code-Revision: D23399-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 27: 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 28: 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 29: 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 30: Start Page

    8. Machine parameter editor 9. Go to service page 10. Shut down WC500 11. Load selected settings and enable automatic mode. Play mode is active when yellow square is displayed instead of green triangle. Press again to disengage play mode. 12.
  • Page 31 Figure 14 Start page WPS selection / Welding length selection If selected from work cycle page 1. Work cycle selection 2. WPS selection 3. Welding length selection 4. Data collection on / off and work piece information Author: TLe Code-Revision: D23399-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 32: 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 15 Operator page 1. Actual welding data feedback: current (A), wire feed (m/min) and voltage (V) 2.

  • Page 33: Operator Page; Joint Tracking Tab

    8. Flux tank pressure on/off 9. Flux heating on/off 10. Work light on/off 11. Machine lights on/off 6.2.3.1 Operator page; Joint tracking tab Figure 16: Operator page, joint tracking tab 1. META OK indicator is green: META is ready and communication with META software is 2.
  • Page 34 Search: Tracking is turned ON and sensor is searching correct position for wires. Tracking: Tracking is turned ON, correct wire positions have been found and META sensor is ready for welding. FAULT. There is an error with the communication between META software and META sensor.

  • Page 35: Operator Page: Meta Settings

    6.2.3.2 Operator page: META settings Figure 17: Operator page, 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.
  • Page 36 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 37: Operator Page: Multi-Pass Tab

    6.2.3.3 Operator page: multi-pass tab Figure 18: Operator page, 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 38: Operator Page: Position Tab

    6.2.3.4 Operator page: position tab Figure 19: Operator page, positions tab 1. Current axis positions 2. External axis position preset and preset positon selection 3. Currently configured external axis welding lap length (Full rotation + overlap distance) Author: TLe Code-Revision: D23399-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 39: Operator Page: Settings Tab

    6.2.3.5 Operator page: settings tab Figure 20: Operator page, 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.
  • Page 40 Figure 21: 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: D23399-0 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 41: Work Cycle Page

    6.2.4 Work cycle page Work cycle editor is a tool for creating flexible custom work cycles without the need to hard code the functionality into program. Right clicking the task list brings up action menu and left clicking a task in the task list opens the task parameters on the right side of the screen. Figure 22: Work cycle page, editor view Author: TLe Code-Revision: D23399-0...
  • Page 42 In play mode the work cycle page shows the current state of the work cycle. Figure 23: Work cycle page, status view Author: TLe Code-Revision: D23399-0 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 43: Author: Tle Code-Revision: D23399-0

    6.2.5 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 ·...
  • Page 44 1. WPS selection 2. Parameter set selection 3. Add, copy, delete and change name of parameter sets 4. Welding speed and limits 5. Torch phase and balance settings 6. Movement settings 7. Torch selection 8. Weld mode selection 9. Welding start and stop values selection 10.

  • Page 45: Wps Editor: Phase Settings

    6.2.5.1 WPS Editor: phase settings Figure 26: WPS editor, phase settings 1. Frequency 2. Balance. The positive part of square-wave voltage in percentage of the whole period 3. Delta. The phase shift of the other torches in degrees in relation to the first torch. To minimize the effects of electromagnetism in multiple arc systems, maintaining phase relationship between the arcs (time offset between the arcs) is important.

  • Page 46: Wps Editor: Movement Settings

    6.2.5.2 WPS Editor: 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 47: Wps Editor: Multipass Editor

    6.2.5.3 WPS Editor: multipass editor Figure 28: WPS editor, 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 48 10. Layer can be set to repeat multiple times to reduce the visual size of the multipass table. Note: Adaptive welding with seam area reference will not work correctly if same layer is repeated. 11. The torch position in reference to the seam bottom width. [0—100%] 100% is to the right bottom edge when looking from the tracking sensor towards the welding torches.
  • Page 49 Figure 29: Example of laser tracking and replay mode settings Author: TLe Code-Revision: D23399-0 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 50: Wps Editor: Multipass Dynamic Fill And Cap Layers

    6.2.5.4 WPS Editor: multipass dynamic fill and cap layers Adaptive filling is a multipass welding feature that repeats layers until defined seam bottom width is reached. It can change to different adaptive filling layers on defined seam bottom width thresholds. Adaptive filling is meant to be used with large seams to simplify multipass table creation in cases where fixed multipass table would not be feasible.

  • Page 51: Wps Editor: Wps Info

    6.2.5.5 WPS Editor: WPS info Figure 31: WPS editor, 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: D23399-0 Date: 8.1.2015 Copyright 2013 ©...

  • Page 52: Wps Editor: Parameters Overview

    6.2.5.6 WPS Editor: Parameters overview Figure 32: WPS editor, 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: D23399-0 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 53: Start/Stop Parameter Editor

    6.2.6 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 (see page: 43 WPS editor). Figure 33: 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 54 6. Burnback defines the time the power source holds a voltage in the torch after it stops the wirefeeding to prevent wire from sticking to the work piece. 7. Restrike attempts to reignite welding arc if it drops in the middle of welding before giving an arc error.

  • Page 55: Data Collection

    6.2.7 Data collection Data collection records data from each weld under a file designated by workpiece name and serial number. Figure 35: Data collection page Author: TLe Code-Revision: D23399-0 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 56: System Messages

    6.2.8 System messages Figure 36: 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: D23399-0 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 57: 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: D23399-0 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 58: Welding

    6.3 Welding The following list is a general list of steps to perform before welding. See page: 65, Work cycle welding. 1. Generate WPS for welding (see page: 59, WPS creation) 2. Check the general equipment settings (see page 39: Operator page: settings tab). 3.

  • Page 59: 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 38: 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: D23399-0 Date: 8.1.2015...
  • Page 60 Figure 39: 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 61: 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. Figure 40: WPS editor, multipass editor 1. Configure a fixed fill layer (see page 47: WPS Editor: multipass editor). e.

  • Page 62: Seam Tracking Sensor Calibration

    2. Create more layers as needed and configure their parameters as in step 1. 3. Enable dynamic fill and cap layers if needed. Create and configure dynamic fill and cap layers. Set the width thresholds for each dynamic fill layer and set the depth threshold for the cap layers. (see page 50: WPS Editor: multipass dynamic fill and cap layers) 6.3.2 Seam tracking sensor calibration Seam tracking sensor needs to be calibrated when lead torch position or sensor position has...
  • Page 63 4. Move the laser line backwards to where the lead torch was, using the welding axis movement. Remember not to move the cross slide. Figure 42 Move the laser starting position without moving the cross-slide 5. Go to MAF settings in operator page (see page 32: Operator page) and press Calibrate. Calibration is successful if the yellow crosshair moves to the green cross and the green ‘calibration successful’...
  • Page 64 Note: To achieve accurate tracking it is important to move the laser line to the position where correct torch position was determined before calibration. If calibration is done without moving the laser line, the possible misalignment of welding direction and seam or seam shape variation (seam is different in the laser position than in the torch position) might cause an offset error to tracking.

  • Page 65: Work Cycle Welding

    In work cycle mode the WPS selection and welding length is defined in the work cycle definition or in Pema main page depending on work cycle selection. Work cycle also operates the seam tracking sensor and advances multipass table automatically.

  • Page 66: Miscellaneous

    (if something goes wrong when restoring backups, you still have backups of the current data files). 3. Go to folder "C:\PEMA\WeldControl 500\Backups\". This is a folder to store backup data. Each backup file inside this folder has a date and time prefix.
  • Page 67 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 68: 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 69: Lubrication Instructions

    7.1.1 Lubrication instructions Gear assembly A302 Gearboxes from A102 to A303 are life lubricated with synthetic oil and do not require periodical oil change. Gear MP060 Lubricated for life Lubricant specs can be found on the nameplate. Linear guides Lubricant: HIWIN G05 Lithium type soap base Vaseline NLGI2 Period: 3-4 months Rack bar...
  • Page 70 Ball screw Lubricant: HIWIN G05 Lithium type soap base Vaseline NLGI2 500 h / 6 month, whichever comes first * The re-lubrication period will depend on the operating conditions of the machine: speed, load, number of working cycles per day etc. The adjacent table gives recommended values (operating temperatures not exceeding +70º...

  • Page 71: Welding Equipment Maintenance

    7.2 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 72 EFD Induction heater Check induction heater units maintenance instruction. See machines own manual for special maintenance instructions. Author: TLe Code-Revision: D23399-0 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 73: Lubricating The Linear Motion Guides

    7.3 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 74 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 75 7.3.1 Table for gear oil selection Author: TLe Code-Revision: D23399-0 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.

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