RDA AHVP30-6 NA Manual - Red-D
Contents
1. 24 D15 Driv With backsIpDu uuu y 25 D2 Maintenance and repair 26 D 2 2 Description of maintenance and repairs 27 his Qsdueiiiicc 31 INDEX 31 Red D Arc Welderentals Page 2 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 1 0 PREFACE This user s manual describes the everyday use and maintenance of our Welding Positioners Any actions that are required to be carried out by the manufacturer have not been included in this manual This manual is part of the machine Please keep this manual safe Information in this manual could be useful at a later time or when a repair or maintenance is carried out We suggest that a copy of the manual is made and kept with the machine the original should be kept in a safe place If necessary replacement copies can be supplied If the machine is sold at a later date then the manual2. 13 MAINTENANCE 15 4 1 MAINTENANCE TAPER ROLLER BEARINGS amp LOCKNUTS 15 4 2 MAINTENANCE PHOSPER BRONZE BEARINGS 15 4 3 MAINTENANCE OPEN GEARS 16 4 4 MAINTENANCE ROTATION WORMBOX 16 4 5 MAINTENANCE TILT WORM BOX 16 4 6 MAINTENANCE EARTHING BRUSHES 16 4 7 MAINTENANCE ELECTRICAL MAINTENANCI 16 4 8 MAINTENANCE CLEANLINESS ENVIRONMINT 17 4 9 MAINTENANCE TIGHTNESS OF CONNECTIONS 17 4 10 MAINTENANCE INSULATION 17 4 11 MAINTENANCE CONTROL GEAR 17
3. S OREPEACEMENT PARIS ssi tu FRU EUM ME 17 5 1 MECHANICAL PARTS LIST 18 S ZEEECTRICAL PARTS 19 APPENDIX A OVERVIEW DRAWING 20 APPENDIX B WIRING DIAGRAM 21 APPENDIX INVERTER DRIVE PARAMETER SETTINGS 22 APPENDIX D GEARBOX MAINTENANCE 23 D 1 Measures before startup 23 0 1 2 Startup without long term preservation 24 0 1 3 Startup in case of long term preservation 24 0 1 3 1 Long term preservation to 18 5 eene 24 D 1 3 2 Long term preservation up to 36 5 24 D 1 4 Filling with lubricant
4. reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 1 5 CE CERTIFICATE OF CONFORMITY Machine Type 1 5T Welding Positioner Model AHVP1 5 We hereby certify that the above machine has been manufactured by Key Plant Automation Limited and conforms with the essential requirements of the following E U Directives Supply of machinery Safety Regulations implementing the EC Machinery Directive 89 392 EEC amended 91 368 EEC and 93 44 EEC and 93 68 EEC codified to 98 37 EC 73 23 EEC Low Voltage Directive amended by the directive 93 68 EEC regarding safety of electrical equipment 89 336 EEC Electro Magnetic Compatibility amended by directives 92 31 EEC and 93 68 EEC As implemented by the UK Supply of Machinery Safety Regulations 1992 Authorised signatory Ma Steve Piercy Engineering Manager Red D Arc Welderentals Page 7 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation reddare com Conventional Positioner Model AH VP1 5 1 6 UL CAS LISTING INFORMATION GPNY E353668 Factory Automation Equipment Page Bottom Factory Automation Equipment r for i for F A mation ipmen KEY PLANT AUTOMATION LTD E353668 KENSINGTON HOUSE 7 ROE LANE SOUTHPORT MERSEYSIDE PR9 9DT UNITED KINGDOM Column and booms Model MD AMxBM Where A 2 3 or 4 and B 2 3 or 4 Model HD AMxB
5. for free and unobstructed operation This is very important for critical safety components Emergency Stop Pushbuttons and Relays 5 0 REPLACEMENT PARTS Use only parts as detailed by the supplier Failure to do so could impair safety of equipment personnel or impair machine operation or the design of the equipment Red D Arc Welderentals Page 17 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 5 1 MECHANICAL PARTS LIST Part Number Description Quantity KPVP010151 Positioner Mainframe Adjustable Height 1 KPVP010152 Baseframe Adjustable Height 1 I KPVP010102 Crosshead KPVP010103 Table KPVP010108 Trunnion Shaft KPVP010115 Rotation Box Pad 1 KPVP010118 Rotation Spur Pinion Guard 1 KPVP010204 0 75kW AC Tilt Motor with Brake 1 KPVP010207 Tilt Gearbox 1 KPVP010206 Tilt Sour Pinion 1 KPVP010205 Tilt Quadrant 1 I KPVP010220 Earthing Bracket KPVP010222 Earthing Strip 1 KPVP010225 Trunion Flanged Bush 1 KPVP010229 Crosshead Spacer 1 KPVP010240 Slot Cover KPVP010245 Back Frame Guard KPVP010246 Front Frame Guard KPVP010203 0 75kW AC Rotation Motor 1 KPVP010311 Earthing Brush Assembly 2 KPVP010320 Control Panel Frame 1 KPVP010350 Slewing Ring 1 KPVP010260 Tilt Angle Indicator amp Pointer 1 KPVP010262 Tilt Box Pad amp Gusset 1 KPVP01016
6. reddarc com D 2 Maintenance and repair D 2 1 General Information on Maintenance A cM The periods listed in the table below are largely dependent on the conditions of use of use of the gear unit For this reason it is only possible to give average periods which refer to a Daily operating time of 24h Duty factor of ED 100 Input drive speed of 1500 min Oil temperature of 100 C NOTE Under different operating conditions the periods should be adjusted accordingly Measures Causes Remedy for changes during operation if possible a during operation if possible Oil level check Check gear unit for leakage monthly fe Initial oil change after startup after approx 10000 operating see D 2 2 1 hours at the latest after 3 years Subsequent oil changes every 3 years or 10000 operating see D 2 2 1 hours Clean vent plug see 0 2 2 2 contamination tightness gear unit Red D Arc Welderentals Page 26 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Version v1 0 Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com D 2 2 Description of maintenance and repairs D 2 2 1 Perform oil change or oil flushing A nom Types of oil mineral oil CLP oil DIN 51517 3 synthetic oil with a specific base PGLP Ol Specifications like oil
7. should be also supplied with it to the new user Red D Arc Welderentals Page 3 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 1 1 MACHINE SPECIFICATIONS 1 2 LOADING DATA CONVENTIONAL POSITIONERS LOADING DATA LOAD W ROTATION TORQUE R IS A STRAIGHT FORWARD CALCULATION OF LOAD W X ECCENTRICITY B BUT TO ENSURE AN ACCURATE FIGURE FOR TILT TORQUE T IT IS IMPORTANT TO USE THE FULL DISTANCE TO THE PIVOT POINT THIS IS OBTAINED BY ADDING TOGETHER THE CENTRE OF GRAVITY A AND TABLE PIVOT DISTANCE G THEREFORE ROTATION TORQUE R W X Kg METRES TILT TORQUE W X A G Kg METRES MULTIPLY BY 9 81 Figure 1 Loading Calculation Diagram Red D Arc Welderentals Page 4 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Version v2 0 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 1 3 LOADING CHART Red D Arc Weld Automation VP1 5 Loading Chart mmmmtccentricity Centre of Gravity 2500 3000 Eccentricity amp Centre of Gravity mm Figure 2 Loading Chart Red D Arc Welderentals Page 5 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conv
8. type oil viscosity and required oil quantity are shown on the name plate A mmm 000 Thoroughly remove oil sludge abraded material and used oil residue from the housings by oil flushing MESURE M Shut down the gear unit by shutting off the drive unit 1 Place a suitable collection receptacle under the oil drain plug of the gear unit housing 2 Unscrew vent plug on the upper side of the housing 3 Unscrew oil drain plug and drain oil off into the receptacle AN Bande FEMME 1 4 Screw in oil drain plug 6 gt a IS 5 Filling with lubricant see D 1 4 6 Screw vent plug on the upper side of the housing D 2 2 2 Clean vent plug Red D Arc Welderentals Page 27 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Version v1 0 Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com The vent plug must be cleaned after deposit of a dust layer at least every 3 months For this the filter must be unscrewed flushed out with cleaning benzene or a similar cleaning agent and dried or blown through with compressed air D 2 2 3 Clean the drive Shut down the gear unit by shutting off the drive unit eremo prevent accidentat startup notice atthe switch on pin Keep drives free of dirt and dust etc in order to ensure sufficient heat dissipation Cleaning the drive with a high pressure cleaning device is not permissib
9. 1 Height Adjustment Locking Pins 2 KPVP010162 Height Adjustment Stabilising Bolts 4 Red D Arc Welderentals Page 18 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc W tomati Conventional Positioner Model AH VP1 5 reddarc com 5 2 ELECTRICAL PARTS LIST N 2 k NA Ad N Se ann WB Wh fev rt TNNT ws 44 wu bu abel 1 12 13 14 2 bec IN P 4 Figure 9 Control Panel Interior m B Figure 8 Control Panel Exterior Figure 7 Control Pendant Photo Number Part Number Description Quantity 1 KP3007 Inverter Drive 3 Phase 0 75kW Rotation 1 KP1060 Relay and Base KP1020 2 Pole Circuit Breaker 0 5A KP1010 1 Pole Circuit Breaker 3A KP1030 Motor Circuit Breaker 1 6 2 5A KP1047 3 Pole Reversing Contactor 6A 24VA KP2028 Transformer 440V 24V 63VA KP1041 Contactor with Aux Block KP1008 3 Phase Fuse Holder and Fuses 6x10A 10 KP1028 Fused Door Isolator 17 KP4014 Footswitch Selector Red D Arc Welderentals Page 19 667 South Service Rd Grimsby ON L3M 4G1 Version v1 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com IN IN N P P IN Red D Arc Weld Automation reddare com Conventional Positioner Model AH VP1
10. 3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation reddare com Conventional Positioner Model AH VP1 5 GPNY7 E353668 Factory Automation Equipment Certified for Canada Page Bottom Factory Automation Equipment Certified for Canada nf f mation i ifi KEY PLANT AUTOMATION LTD E353668 KENSINGTON HOUSE 7 ROE LANE SOUTHPORT MERSEYSIDE PR9 9DT UNITED KINGDOM Column and booms Model MD AMxBM Where A 2 3 or 4 and B 2 3 4 Model HD AMxBM Where 3 4 5 6 7 or 8 and B 3 4 5 6 or 7 Positioners Model VP X Where X 0 25 0 75 1 5 3 5 10 15 20 25 or 35 Rotators Model CR X Where X 10 20 30 60 100 125 200 300 400 or 500 Last Updated on 2012 06 25 Questions Print this page Terms of Use Page Top 2012 ULLLC When the UL Leaf Mark is on the product or when the word Environment is included in the UL Mark please search the UL Environment database for additional information regarding this product s certification The appearance of a company s name or product in this database does not in itself assure that products so identified have been manufactured under UL s Follow Up Service Only those products bearing the UL Mark should be considered to be Listed and covered under UL s Follow Up Service Always look for the Mark on the product UL permits the reproduction of the material contained in the Online Certification Directo
11. 5 APPENDIX A OVERVIEW DRAWING WIDTH DAMETE RALL LE b t 1 j 9 t z lt L w uy c mm 4 cU SAFE WORKING LOAD DEGREE OF TILTING DECREE OF ROTATION ROTATION SPEED HEIGHTS To TABLE HORIZONTAL LE OF TAE 2 HEIGHTS TO TABLE q VERTICAL TABLE DIMENSIONS F TABLE OF TABLE a 757 DOWN FWD ST I sl 2 i A NTR 7 L EN JANT D M LE cp n E ry NTR 2 L ESTO IWWERALL HEN d o ji mT c e rw i i m 7 a m i f J ww LO Lm t Ed 2 VEICHT THE x S lt iy lt p te rrr mm IMPERIAL DIMENSIONS ARE APPROXIMATE AND PROVIDED FOR GUIDANCE PURPOSES ONLY i 2 THIS DRAWING WAS ACCURATE AT TIME OF PREPARATION BUT m IS SUBJECT TO FINAL DESICN REVISIONS All drawings are the property of Key Plant Welding amp TITLE DRAWING NUMBER positioning Equipment and contain confidential and Mm STABLE EISHT RDA AHVP 1 5 1 1001 propriety information that cannot be reproduced or go E 2 AST Jt 1255 mm 409 4 BASE LENGTH divulged in whole or in part without prior permission A3 DO NOT SCALE Figure 10 Overview Drawing Page 20 Red D Arc Welderentals Version v1 0 667 South Service Rd Grims
12. M Where A 3 4 5 6 7 or 8 and 3 4 5 6 7 Positioners Model VP X Where X 0 25 0 75 1 5 3 5 10 15 20 25 or 35 Rotators Model CR X Where X 10 20 30 60 100 125 200 300 400 or 500 Last Updated on 2012 06 25 Questions Print this page Terms of Use Page Top 2012 UL LLC When the UL Leaf Mark is on the product or when the word Environment is included in the UL Mark please search the UL Environment database for additional information regarding this product s certification The appearance of a company s name or product in this database does not in itself assure that products so identified have been manufactured under UL s Follow Up Service Only those products bearing the UL Mark should be considered to be Listed and covered under UL s Follow Up Service Always look for the Mark on the product UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions 1 The Guide Information Designs and or Listings files must be presented in their entirety and in a non misleading manner without any manipulation of the data or drawings 2 The statement Reprinted from the Online Certifications Directory with permission from UL must appear adjacent to the extracted material In addition the reprinted material must include a copyright notice in the following format 2012 UL LLC Red D Arc Welderentals Page 8 667 South Service Rd Grimsby ON L
13. Rd Grimsby ON L3M 4G1 Version v1 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com APPENDIX D GEARBOX MAINTENANCE Startup D 1 Measures before startu D 1 1 Oillevel check Before connecting up the drive system to the current supply check the oil level or Shut down the gear unit by shutting off the drive unit A E 5 Checking the oil level in the gear unit housing Screw out the plug screw at the point marked with this symbol Oil level For drives with only one plug screw checking the oil level is not possible D 1 1 2 Cil sight glass Special feature Red D Arc Welderentals Page 23 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Version v1 0 Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com If an oil inspection glass is provided the oil level must be visible in the middle of the inspection glass Oil level D 1 1 3 Dipstick Special feature Check oil level with dipstick The oil level must be between the lower and upper mark of the dipstick D 1 2 Startup without long term preservation MOTOX drives are delivered with the appropriate lubricants ready for operation depending on the specified conditions of use A EC It must be used at the position indicated by this
14. Red D Arc Weld Automation feddarc com OPERATION MANUAL CONVENTIONAL POSITIONER Model RDA AHVP30 6 NA 3 000 Ib For use with products having Serial Number 06980 and following Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com Contents ill c uu 3 LUMACHINE SPECIFICATIONS aen Sess dece oda 4 1 2 LOADING DATA 4 ESLOADING CHART i c 5 LA SPECIFICTON 6 1 5 CE CERTIFICATE OF CONFORMITY 7 1 6 UL CAS LISTING INFORMATION 8 OINSIALLATIDN S 10 uuu cea HH 11 JL OU enr T u sus 11 3 2 Control Pendant Operation 12 3 3 Adjusting Height Position
15. by ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com APPENDIX B WIRING DIAGRAM BIE TOE SIGHED DATE A ORIGINAL NB 8 REVISED UL 56 15612 C REVISED UL W C NOTE EMERGENCY ERP YR LOWE X VARIABLE SPEED POOH RELAY TERMINAL LAYOUT TERMINAL BLOCK TIGHTNING TORQUE 0 4 0 6 Nm A BRAKE FORWARDAREV ER yel m we mi ma mo n 0 MOTOR SUPPLY MOTOR CONTAC TOR TL UP Me DO NOT CONTRACT REF SCALE 0114055508116 VPI SUL M E PLAN DECIMAL DIMENSIONS MACHINING FABRICATIONS f ORAN NSnih SCALE BALAS npa 0 200 4 05 iz HEIGHT amp WIDTH SUE 200 19004 1 5 NEAREST DATE 140509 CENTRE CENTRE TO SEM dd OVER 15009 30 EQUIV Figure 11 Wiring Diagram Red D Arc Welderentals 667 South Service Rd Grimsby ON L3M 4G1 Page 21 Phone 905 643 4910 Efax 905 963 7810 Version v1 0 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com APPENDIX C INVERTER DRIVE PARAMETER SETTINGS The following settings have been programmed into the inverter at the factory Parameter Number Parameter Number All other values are as factory set by the inverter manufacturer and need not be altered Red D Arc Welderentals Page 22 667 South Service
16. capacity with micro pitting as well as compatibility with seals and internal coating on which the design of the gear unit has been based Thus we recommend that our customer should select a lubricant from this table taking in account the viscosity class stated on the rating plate The lubricants listed have no approval according to USDA H1 H2 United States Department of Agriculture and are as such not or only limited approved for use in the food or pharmaceutical industry The lubricants are not or only limited biologically decomposable They are usually according to the Classes 2 or 1 of hazard for water If lubricants are necessary according to these classifications please contact the factory If the gearboxes are filled with special lubricants from the factory for the cases given above this can be seen on the name plate e g CLP H1 VG220 or CLP E VG220 Note Asa precaution against misunderstandings we would like to point out that the recommendation does not imply any release in the sense of a warranty for the quality of the lubricant provided by your supplier Each lubricant manufacturer must warrant the quality of his product himself If you do not follow our recommendations you must take the responsibility for the technical suitability of the lubricant In the case of synthetic oils not listed in the table below the corrosiveness of the oil to our internal coating should be checked A check of this nature is carried out by
17. cation during transport Red D Arc Welderentals Page 10 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Conventional Positioner Model AH VP1 5 Red D Arc Weld Automation 3 0 OPERATION 3 1 Control Panel The control panel at the rear of the positioner has the following controls 1 Power On Lamp 2 Emergency Stop Reset Button After an Emergency Stop or when first powering up this button must be pressed before the machine will operate Once pressed and the machine is ready the button will illuminate Footswitch Selector Direction L R Selector Panel Door Opening Key Emergency Stop Button Door electrical isolator must be turned off before panel door can open 208 1E oral Figure 4 Main Panel 3 Position Selector No 3 On Photo Position FS Control by footswitch with Speed Controller Position FS Il Control by footswitch without Speed Controller Speed control is performed via the hand pendant control PEND All controlled through the hand pendant 2 Position Selector No 4 On Photo lt gt Rotation direction selector clockwise anti clockwise for use with footswitch Red D Arc Welderentals Page 11 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 3 2 C
18. ears are liberally coated with grease CASTROL MS3 molybdenum disulphide At 500 hour intervals remove safety guards and check coating and if required replenish grease 4 4 MAINTENANCE ROTATION WORMBOX The worm box fitted on this machine is factory filled with a synthetic lubricant SHELL TIVELA SA and should not require any further maintenance during its lifetime It is important however to check at regular intervals that there are no leaks If any leaks are observed the unit must be drained new seals fitted and re filled with the correct amount of lubricant 4 5 MAINTENANCE TILT WORM BOX The worm box fitted on this machine is factory filled with a synthetic lubricant SHELL TIVELA SA and should not require any further maintenance during its lifetime It is important however to check at regular intervals that there are no leaks If any leaks are observed the unit must be drained new seals fitted and re filled with the correct amount of lubricant 4 6 MAINTENANCE EARTHING BRUSHES All rotary tables that are used for manipulating components to be welded are fitted with Earthing Brush s to carry welding current away from the machines rotating axis to a suitable pickup point IT 15 MOST IMPORTANT TO CONNECT AN EARTHING CABLE TO THE MACHINES PICKUP POINT AND NOT TO EXCEED THE MAXIMUM RATING STATED OTHERWISE SERIOUS DAMAGE CAN OCCUR TO MACHINES ROTATING AND ELECTRICAL PARTS 4 7 MAINTENANCE ELECTRICAL MAINTENANCE It is the re
19. entional Positioner Model AH VP1 5 reddarc com 1 4 SPECIFICTION Load capacity 1500kgs 150mm ecc amp 150mm c o g Table diameter 920mm Degree of table tilting 135 Degree of table rotation 360 Table rotation speed 0 07 1 40 RPM Table tilting speed 30 seconds through 135 Height Settings when table horizontal Position 1 850 Position 2 1000 Position 3 I 1150mm Table machined with concentric circular markings and 6 off 19mm wide slots Table equipped with efficient built in earthing 300 amps and mounted on pre loaded crossroll bearing Table rotation fitted with AC motor and controlled by an Inverter unit suitable for 380 to 480V 3 Phase supply Tilting through AC electric motor equipped with limit switches to prevent over run Table can be manually elevated from the base and locked into position using one of the three pin locations The main control panel mounted on the machine containing the following mains isolator mains on lamp emergency stop button and reset button The positioner is also supplied with a low voltage remote pendant control containing forward stop reverse tilt up tilt down pushbuttons and a variable speed potentiometer connected with 6 meters of cable to the control panel Mains electrical supply suitable for 380 480 Volts 3 phase 50 60 Hz Red D Arc Welderentals Page 6 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website
20. er the heights of the machine please follow this simple procedure First loosen off bolts D 2 on either side of the machine this will release the table section so that it can be lifted Then connect a crane to the lifting eyes on either side of the machine A Take up the slack on the lifting eyes so the weight is taken by the crane then the lock pins B on either side of the positioner can be removed The table can then be raised or lowered by using the crane so that hole C lines up with the lock pin B holes Pin B on both sides of the machine can then be replaced Once pins B are fully in place on both sides then the weight of the table can be taken by the pins and the crane removed Tighten the 4 bolts D 2 on either side of the machine this will prevent any movement of the positioner inside the height adjustment sleeve Red D Arc Welderentals Page 13 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Front Top Conventional Positioner Model AH VP1 5 Rear Top Note the vertical leg with holes C through is designed to sit flush metal on metal at the top rear and bottom front of the sleeve see pictures above These areas are designed to take the weight of the machine The bolts D are there to close the gap at the top front and bottom rear of the sleeve so that there is movement of the position in the s
21. hanical Parts List 18 Wiring Diagram 21 Red D Arc Welderentals Page 32 667 South Service Rd Grimsby ON L3M 4G1 Version v1 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com
22. he respective maintenance staff and maintenance periods adjusted accordingly Maintenance should include attention to the points listed below 4 8 MAINTENANCE CLEANLINESS ENVIRONMENT It is essential that the cubicle interior remains clean and dry Any ingress of moisture or dirt should be cleaned with a lint free cloth or suitable suction device Fans and filters should be checked regularly for blockages and dirty filter mats should be replaced with the correct grade of mat 4 9 MAINTENANCE TIGHTNESS OF CONNECTIONS It will be necessary to periodically check the tightness of terminals and busbar connections including earth connections especially in areas where vibration is apparent Check for any hot spots developing during running Checks should be performed with the power supply isolated 4 10 MAINTENANCE INSULATION A visual check of cable control gear insulation should be performed at regular intervals If this inspection reveals any change in appearance an insulation resistance measurement is recommended For older equipment these measurements should be taken on a more regular basis where successive lower readings would indicate a problem NOTE It is important to use insulation testing equipment with care Electronic components should be securely isolated before employing meggers or similar test methods 4 11 MAINTENANCE CONTROL GEAR A visual inspection should be performed at regular intervals Movements should be checked
23. le Do not use sharp edged tools D 2 2 4 Checking all fixing screws for tightness Shut down the gear unit by shutting off the drive unit A eee ICM Check all fixing screws for tightness with a torque wrench M6 M8 M 10 M 12 M 16 M 20 Note Unserviceable screws should be replaced by new ones of the same property class and type Red D Arc Welderentals Page 28 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com D 2 2 5 Inspection of the drive The drive should be checked annually In addition the drive should be checked according to the criteria described in section 2 Safety notes e g check tight fit of the protective devices Any damage of the coating should be repaired by an expert D 2 3 Lubricants Oil selection should always be determined by the oil viscosity ISO VG class specified on the rating plate of the gear unit The viscosity class is valid for the operating conditions agreed on by contract Under different operating conditions it will be necessary to consult us We have put together a list of suitable lubricants for the gear unit in the table below We are acquainted with the composition of these lubricants and know that in accordance with the latest technology they possess values in respect of loadability corrosion protection load carrying
24. leeve Version v2 0 Red D Arc Welderentals 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Page 14 Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 4 0 MAINTENANCE 4 1 MAINTENANCE TAPER ROLLER BEARINGS amp LOCKNUTS Self aligning roller bearings are present to give zero end float In time due to wear and vibration they may slacken off They should then re tightened to regain zero end float Adjustment is obtained by means of the two lock nuts BEARINGS SHAFT BEARING HOUSING LOCKNUTS Figure 6 Roller Bearing Replenish at 500 hour intervals with CASTROL SPHEEROL MP3 For high temperature conditions change grease to CASTROL SPHEEROL B3 4 2 MAINTENANCE PHOSPER BRONZE BEARINGS Replenish at 500 hour intervals be means of grease nipples using CASTROL SPHEEROL MP3 All of the phosphor bronze bushes used are retained with LOCTITE 601 bush retaining fluid Any bush which becomes displaced should be carefully removed thoroughly cleaned with the correct application of LOCTITE degreasing fluid and then coated with retaining fluid before being replaced Red D Arc Welderentals Page 15 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 4 3 MAINTENANCE OPEN GEARS All g
25. on the efficiency of the gear unit They are suitable for the following operating temperatures PGLP ISO VG 220 30 c 100 c PGLP ISO VG 460 15 c 100 c The maximum temperatures can be exceeded by 10K for a short time Red D Arc Welderentals Page 30 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com INDEX OF PICTURES Figure 1 Loading Calculation Dias 4 Force lla Ch RR 5 PICULES Photo of Earthing POIBU uu CSS 10 Feure 4d Man s Rz NRI OR T T mm 11 Fo S COMO CGN E o EETA 12 Figure 5055501 15 Figure 7 Control PABSLEXEBELTIO leas 19 Figure 8 Control Panel u toe erroe OE Urna erae x PUE ee ab REP rix 19 Heure 9 Control Peng used aa lem DUM MEN 19 Heure 10 Overview uuu u u pua top 20 WirinB ae SET uuu eH S 21 Red D Arc Welderentals Page 31 Version v1 0 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld A
26. ontrol Pendant Operation It is imperative when loading the machine that the fabrication is held firmly on the table using the table slots provided It is also important that the machine is NOT OVERLOADED by placing on it fabrications which are heavy or are beyond the capacity of the machine in terms of Centre of Gravity or Eccentricity Once the machine has power connected and the power on light is illuminated The machine will be ready to run If the emergency stop button has been depressed then release this by twisting the cap then press the emergency stop reset button on the control box Speed and movement of the positioner are controlled by the hand pendant see photo below The buttons on the pendant operate as follows Button A Hold to Run Push Button Tilt UP Button B Hold to Run Push Button Tilt Down Button C Table Rotation Reverse Direction Push Button Button D Table Rotation Stop Push Button Button E Table Rotation Forward Direction Push Button Dial F Rotation Speed Potentiometer Button G Emergency Stop Push Button Figure 5 Hand Control Pendant Red D Arc Welderentals Page 12 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Bum sa bi ed D Arc Weld Automati ae wee E GW ELil il Conventional Positioner Model AH VP1 5 3 3 Adjusting Height Position The positioner can be set at one of three height positions To alt
27. ry subject to the following conditions 1 The Guide Information Designs and or Listings files must be presented in their entirety and in a non misleading manner without any manipulation of the data or drawings 2 The statement Reprinted from the Online Certifications Directory with permission from UL must appear adjacent to the extracted material In addition the reprinted material must include a copyright notice in the following format 2012 UL LLC Red D Arc Welderentals Page 9 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com 2 0 INSTALLATION Remove transport protection if any from the machine Locate the machine on a level floor that is capable of withstanding approximately 2 5 tonnes over the contact area Connect the electrical mains to the machine 380 480 volts 3 phase 50 60Hz Connect the welding earth cable to the copper earthing strip that is located on the underside of the table fixed to the crosshead If this connection is NOT made the weld current will earth through the centre of the table assembly and damage the bearings and other transmission parts see photo below for earthing connection bracket Figure 3 Photo of Earthing Point Before making the machine fully operational remove any necessary covers and check that gearboxes have not lost any lubri
28. sponsibility of the user to ensure only competent personnel deal with the operation and maintenance of the equipment Operators should be conversant with the equipment and be able to recognise the symptoms maloperation and or degraded performance They should also be aware of what action to take in the event of a fault emergency It is recommended that maintenance personnel have adequate training on the system and also the component parts They should have a thorough knowledge of diagnosis and fault finding techniques and be conversant with identifying the first signs of maloperation During maintenance fault finding etc the following points should be observed The equipment should be completely isolated whenever possible If an element of live diagnosis is required the use of barriers warning notices is a must Red D Arc Welderentals Page 16 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com The maintenance staff should be familiar with the appropriate factory and safety regulations that apply in the province and country that they are employed in and work on the equipment is such a manner as to comply with them The period between specific maintenance tasks will vary dependant on such factors as type of equipment and environment of the equipment These factors should be assessed by t
29. symbol D 1 3 Startup in case of long term preservation D 1 3 1 Long term preservation up to 18 months JAN ee ring up te gear unt shouldbe le with labret 60 4 D 1 3 2 Long term preservation up to 36 months i 7 The oil level should be reduced to the level marked with this symbol see D 1 1 9 D 1 4 Filling with lubricant e Screw out venting screw or venting filter or plug screw at the highest point see 3 2 or point of ventilation Red D Arc Welderentals Page 24 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Version v1 0 Red D Arc Weld Automation Conventional Positioner Model AH VP1 5 reddarc com renee VET NN Data such as oil grade oil viscosity and oil quantity required will be found on the rating plate Finally check the oil level see 7 1 1 A meme sl D 1 5 Drive with backstop AA secure drive unit o prevent accidental startup Affic notice at the swih on point sreckthesirecionofotation nefore putting ino serice E g by manually turning the input shaft or the motor Check the motor direction of rotation according to the phase sequence swap two supply leads if necessary Red D Arc Welderentals Page 25 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AH VP1 5
30. us at cost cost on request Red D Arc Welderentals Page 29 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Version v1 0 Red D Arc Weld Automation reddarc com Desig Conventional Positioner Model AH VP1 5 Examples of lubricants nation s I Lubricant according m T il p N to F CHS Tribol Sk Tribo DIN 51502 p stoner REM Shell e 4 EEE Se tat ee ite ce 4 OIL Enersyn Polydea Renodiol Syntheso Glygoyle Optiflex TIVELA TRIBOL PGLP SG XP PGLP460 PGP460 D460EP HE460 A460 OIL 800 460 Synthetic ISOVG460 460 3 iab Ee _50 i Oils 2 OIL Enersyn Polydea Renodiol Syntheso Glygoyle Optiflex TIVELA TRIBOL PGLP SG XP PGLP220 PGP220 D220EP 30 A220 OIL 800 220 ISOVG220 220 WB Energrease Glissando Renolit CEN Mobilux Longti ALVA Wiolub TRIBOL eod dian glos LS3 30 FWA220 TRO 3 me NIA LFK2 4020 earing greases NLGI 3 2 LS2 20 PLEX 2 PD2 R3 220 2 FWA160 GLP402 COMPE We would be pleased to recommend further suitable lubricants of the makes ADDINOL CASTROL FUNCHS Lubritech OMV STATOIL TEXACO TUNAP and VALVOLINE Synthetic lubricants polyglycols in accordance with designation PGLP as per DN51 502 These oils are distinguished by their high aging resistance and favourable effect
31. utomation Conventional Positioner Model AH VP1 5 reddarc com Back Frame Guard 18 Open Gears 16 Operation 11 Overview Drawing 20 Ce Certificate 7 8 Centre Of Gravity 12 Cleanliness Environment 17 Panel 11 12 13 Contents 2 Preface 3 Control Gear 17 Control Panel Frame 18 Crosshead 18 R Crosshead Spacer 18 Replacement Parts 17 Rotation Box Pad 18 E Rotation Spur Pinion 18 Rotation Spur Pinion Guard 18 Earthing 10 Rotation Wormbox 16 Earthing 18 Earthing 16 Earthing Bracket 18 S Earthing Brush Assembly 18 Eccentricity 12 Slewing Ring 18 Electrical Parts List 19 Slot Cover 18 Slots 12 F Specifications 4 Forward 12 T Front Frame Guard 18 Table 18 Taper Roller Bearings amp Locknuts 15 G Tightness Of Connections 17 Tilt Angle Indicator amp Pointer 18 Gearbox 10 Tilt Box Pad 18 Gearbox 18 Tilt Pinion Guard 18 Gearbox Maintenance 22 23 Tilt Quadrant 18 Tilt Spur Pinion 18 Tilt Up 12 Tilt Worm Box 16 Trunion Flanged Bush 18 Installation 10 Trunnion Shaft 18 Insulation 17 U L Ul Cas 8 Loading Chart 5 Loading Data 4 Lubricants 24 29 30 V Variable Speed Potentiometer 12 14 Mainframe 18 W Maintenance 15 Mec
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