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Tecnar Rotoweld 3.0 Maintenance Manual

Automated welding work cell for pipe spool prefabrication
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MAINTENANCE
MANUAL
Automated welding
work cell for
pipe spool
prefabrication

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Summary of Contents for Tecnar Rotoweld 3.0

  • Page 1 • MAINTENANCE MANUAL Automated welding work cell for pipe spool prefabrication...

  • Page 2: Table Of Contents

    4 POSITIONERS MAINTENANCE ......39 4.1 Rotative ground maintenance ..............39 4.2 Gas cylinder pressure regulator maintenance ........40 4.3 Self centering chuck maintenance ............41 4.4 Gears assembly maintenance ..............41 4.4.1 Gear lubrification ......................42 ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 3 5.3 Wheels maintenance ................. 50 5.4 Flux pan maintenance ................50 6 MAINTENANCE SCHEDULE RECOMMENDED 51 6.1 Daily ......................51 6.2 Weekly ......................51 6.3 Monthly ....................... 52 6.4 Quarterly ..................... 52 6.5 Annually ...................... 53 ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 4 ¥ Rotoweld Technical Description Manual (40101-00037); hardware description. ¥ Rotoweld Prodatalog Manual (40101-00056); viewer for all the welding data history logged. ¥ Rotoweld Maintenance schedule (40101-00058). ¥ Rotoweld Suggested Welding Parameters (40103-00252 TO 40103-00257); baseline parameters for welding programs. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 5 To begin, components location will be showed with description explanations related with maintenance. Furthermore, detailed actions required to perform on each of the sub components. Should questions arise, feel free to contact us at service@tecnar.com ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 6: Flexible Cable Carrier Maintenance

    (see picture) and pull down at each extremity of the lid. 3. For removing a section raise at least 3 lids and remove two of them. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 7 6. Pull out the two sections from each other. 7. For the installation of the flange, raise 3 lids and remove 2 of them. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 8 2 flange spare lids. You have two different lids. The one without the little ears is the one for the flange Regular lids and the other one is for the regular chain. Flange lids ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 9: Track System Maintenance

    Validation of the chain tension, we put the carriage at a certain distance of the end of the track and we determine an amount play we suggest. Chain tension adjusting nut Chain tensioner localization ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 10: Welding Carriage Maintenance

    The pump head has a "built in" strainer on the inlet side of the pump. It is recommended to clean or replace the pump inlet strainer at least once a year. 1. Drain coolant from the reservoir and open the case of the water cooler. Located the pump. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 11 6. Hold pump head to apply counter-torque when loosening strainers 7/8 acorn nut. 7. Add 2 gallons of coolant constituted of 1 gallon (4 liters) of water and 1 gallon (4 liters) of glycol. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 12: Pump Motor

    1. Remove the plastic plugs located on the top of both the inboard and outboard bearing endcaps. 2. Re-oil each bearing with 30-35 drops of SAE 20 oil then reinstall both plugs. 3.1.5 Heat exchanger ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 13: Gas Flow Meter Maintenance

    3.2 Gas flow meter maintenance 1. Verify for leaks at the flow meter connections with soap & water. 2. Verify for leaks at the shielding gas cylinder input connections at the pressure regulators with soap & water. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 14: Wire Feeder Maintenance

    Maintenance 1. Clean and tighten wire feeder weld terminals. 2. Repair or replace cracked weld cable 3. Blow out or vacuum inside. 4. Repair or replace cracked weld cable 5. Clean drive roll ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 15: Pressurized Flux Feed Tank Maintenance

    3.4 Pressurized flux feed tank maintenance Shut down the air pressure valve before attempting any services ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 16 Do not unscrew completely. Allow the remaining air to escape completely from the reservoir. When the air is completely removed from the reservoir you can unscrew the cap completely. 2. Do services if needed ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 17 3. Install the tank cover and make sure it is properly tightened so that air does not escape. 4. Open the air valve ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 18: Stt Arc Sensor Maintenance

    3.5 STT arc sensor maintenance 1. Verify the wire, clamp and magnet for damages, repair or replace if required. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 19: Pyrometer Maintenance

    3.7 Foot pedal maintenance 3.7.1 Main & Secondary positioner: 1. Test the foot pedal functionality, forward reverse and the estop. 2. Visual inspection of the electrical cables for damages. 3. Repair or replace damaged wiring. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 20: Carriage

    2. Visual inspection of the electrical cables for damages. 3. Repair or replace damaged wiring. 3.8 Carriage wheels maintenance Lubrification of the wheel. 1. Use the zerk grease fitting to lubricate each wheel. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 21 Use Valvoline Crimson or equivalent multipurpose grease ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 22: Motorization Sprocket Maintenance

    3.9 Motorization sprocket maintenance 1. Validation the sprocket is tight on the transmission shaft axis and the height of the sprocket in the chain is properly set. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 23: Welding Manipulator Maintenance

    ¥ Specific tip and nozzle. ¥ Flux feeding hose (red in the right picture). ¥ Specific frame on top of the carriage to guide the MIG/SAW torch assembly, which is heavier than the MIG/MIG assembly. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 24: Y Position Torch Reference

    3.10.2 Servo Control timing belt Timing belt for J1, J2, and J3 motorization. 1. Verify if the belts are not slack. If the belt is loose, open the appropriated section and tight the belt. Motor drive localization ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 25 2. Unscrew the 4 screws of the motor without removing them. 3. Adjust the timing belt tension. When the desire tension is reached, tight the 4 screws previously mentioned in step 1. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 26 4. Unscrew the 4 screws of the motor without removing them. 5. Adjust the timing belt tension. When the desire tension is reached, tight the 4 screws previously mentioned in step 1. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 27 6. Unscrew the 4 screws of the motor without removing them. 7. Adjust the timing belt tension. When the desire tension is reached, tight the 4 screws previously mentioned in step 1. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 28: Root & Fill Torch Maintenance

    3.11 Root & Fill torch maintenance 3.11.1 Nozzle, contact tip, gas diffuser & liner replacement 1. Clean or replace nozzle if necessary. 2. Clean or replace tip if necessary. 3. Clean or replace gas diffuser if necessary. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 29: How To Replace Quick Loadª Liners Into Retainer Pin

    3. Remove the protective cap from the new QUICK LOAD Liner. 4. Insert the QUICK LOAD Liner through the neck using the wire as a guide. Push the QUICK LOAD Liner in using short strokes to prevent the wire from kinking. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 30: How To Replace Conventional Liners

    4. Feed the replacement liner through the gun using short strokes to avoid kinking. Twist the liner clockwise if necessary. 5. Using a 10mm wrench, turn thread-in liner collet in a clockwise direction and tighten in the power pin. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 31: Saw Fill Torch Maintenance

    Use the same method for liner change as mention above. In case of malfunction of the flux valve clean the inside filter and/or inspect the rubber pinch valve for hole or tear. Rubber Pinch Valve Filter ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 32: Control Station Maintenance

    3. Turn the Torch button to Up and hold to the right until the arm is completely calibrate. The Rotoweld will shut down. 4. Once the computer shut down process is completed, wait 1 minute. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 33 5. Turn off the main power switch. The monitor cabinet is located on the carriage where the main software is displayed. 6. Open the back panel of the monitor cabinet to access the monitor. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 34 9. pull down to release the top bracket from the bottom bracket. 10. Unplug all wires linked to the monitor. Voltage and video cable. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 35 Pull down the sleeve of the power connector before pulling down the cable of the outlet voltage. Locked position - DonÕt pull out Unlocked position - Pull out ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 36 13. Remove dust from the complete inside of the monitor cabinet with compress air (Make sure that there is no Oil or water expel from the compressed air hose) or vacum. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 37 1. Install the 4 screws that hold the monitor. Connect the 12vdc power cable and the video cable to the monitor. 2. Reinstall the computer to is initial location and tight all 4 screws. 3. Close the back panel of the cabinet. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 38: Fan Filters Maintenance

    3.13.2 Fan filters maintenance 1. Clean or change filter accordingly Fan monitor right Fan monitor left Fan carriage right ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 39: Positioners Maintenance

    It can only be used when the positioner is not controlled by the welding carriage pendant. Side left panel (Main positioner) Rotative Add grease ground accordingly grease (Tweco 8Z-L Shaft Lube) ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 40: Gas Cylinder Pressure Regulator Maintenance

    Co2 gas 1. The pressure pressure regulator regulator (gray) should always be set at 30psi Inert gas 2. The pressure pressure regulator regulator should always (black) be set at 30psi Gas cylinder pressure regulator ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 41: Self Centering Chuck Maintenance

    4.3 Self centering chuck maintenance 1. Clean or replace chuck gripper accordingly 4.4 Gears assembly maintenance To access the gear and pinion gear remove the front panel of the chuck Pinion gear access panel ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 42: Gear Lubrification

    4.4.1 Gear lubrification 1. Verify if grease is needed, add accordingly. Use Valvoline Crimson or equivalent multipurpose grease 4.4.2 Gear box maintenance 1. Visual inspection ¥ Oil leak ¥ Seal inspection ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 43: Gear Backlash Maintenance

    Gearbox Adjustment screws 4.6 Pillow blocks maintenance Use the side panel of the positioner to access the pillow block. 1. If needed, grease pillow block bearing with Valvoline Crimson or equivalent multipurpose grease. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 44 ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 45: Root Power Source Maintenance

    Meter reading should be 500,000 ohms or more. If meter reading is less than 500,000 ohms, check for electrical components that are not properly insulated from the case. Correct insulation if needed. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 46: Stt Ii Input Filter Capacitor Discharge Procedure

    4. Check voltage across terminals of all capacitors with a DC voltmeter. Polarity of capacitor terminals is marked on PC board above terminals. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 47: Stt Module Power Wave S500 Preventive Maintenance

    (not the STT¨ Module output). This is necessary because the default calibration mode senses voltage directly from the power source output studs. The STT¨ Module has no effect on the output current calibration. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 48: Fill Power Source Maintenance

    The calibration procedure itself requires the use of a grid, and certified actual meters for voltage and current. The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use. The Diagnostics Utility includes detailed instructions and is available at www.powerwavesoftware.com. ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 49: Pipe Stands

    Locks the height of the rolls by closing the hydraulic circuit. valve Manual pump Feed oil to the hydraulic cylinder for extension. Use the handles to tilt the flow basket to empty it ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 50: Hydraulic Cylinder, Hoses Connection Maintenance

    1. Grease wheels with Valvoline Crimson or equivalent multipurpose grease. 5.4 Flux pan maintenance 1. Transfer Flux from pans to pressure tank using proper screening for debris (if recycling of flux is permitted) ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 51: Maintenance Schedule Recommended

    Remaining pressure of the bottles of shielding gas Replacement: Fill Torch Contact Tip. *Submerged Arc Welding Model 6.2 Weekly Cleaning: Jaw inserts on the chuck Verification: Inspection of the cable carrier, replace broken cap or links if required Replacement: ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 52: Monthly

    Cleaning: Base of the welding carriage with a vacuum Verification: Visual inspection of the flow meters, flow meter for gas leak. Water cooler level Positioner Ground tightness and lubrication Replacement: Root torch liner ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

  • Page 53: Annually

    Grease Pillow block and flange bearing of the positioner Optical filter inside the optical tube of the camera Pipe stand, hose, leak & oil level Water cooler, re-oil the pump motor bearings Replacement: Coolant of the water cooler ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 54 ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
  • Page 55 ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)

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