Irizar CWP40 Operation Manual - Home - Irizar Heavy

IRIZAR HEAVY INDUSTRIES INC 1512 Adamson View, Edmonton, Alberta, T6W 0V4, Canada P: 1 780 450 6695, F: 1 780 485 6677

E mail: [email protected], Website: www.jirizar.com

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WELDING POSITIONER’S

OPERATION MANUAL

CWP40

Revision May 19 2015

Note: The information contained in this manual is intended to be accurate. However the manufacturer retain the

rights to make changes in design which may not be include herein

mailto:[email protected]

http://www.jirizar.com/



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Table of Content 1.0 Welding Positioners Description 3

Welding Positioner CWP 40 3

2.0 Installation Instructions 5 Remote Control Box Operation 10 Main Control Box Operation 10 Tilt Brake 11

3.0 Lubrication and Preventive Maintenances 13 Gearboxes 13 Open Gears 14 Bearings 15

4.0 Warnings 16

5.0 Troubleshooting Procedures 17 Procedure to Re-Setting VFD (N2-200/400) 17

6.0 Technical Documentation 19 CWP 40 Foundation Drawing 19 CWP 40 Assembling Instructions 20 CWP 40 General Dimensions 21 CWP 40 Electrical Diagram 22 CWP 40 Capacity Chart 23 CWP 40 Data Plate 24 CWP 40 Table Drawings 25 CWP 40 Part List Drawing 28 CWP 40 Part List Description 29 CWP 40 Material Documentation 30 CWP 40 Electrical Part List 35

7.0 Limited Warranty 36





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1.0 Welding Positioners Description

Welding Positioner’s are a state of art equipment designed and used to allow welding positioning of various

shape work pieces. The positioners have variable table rotational speed through the use of a remote

control box and tilt thought the main control box.

Welding Positioner CWP 40

Standard package:

Max Load Capacity @ 90 degrees

40 MT @ 1,200 mm GC

34 MT @ 1,400 mm GC

30 MT @ 1,600 mm GC

26 MT @ 1,800 mm GC

24 MT @ 2,000 mm GC

21 MT @ 2,200 mm GC

Max Eccentricity: 300 mm

Rotation Torque: 142,000 N-m

Tilt Torque: 500,000 N-m

Tilt Angle from 0-135 degrees

Rotation Motor: 7.5 Kw @ 2 no.

Tilt Motor: 7.5 Kw @ 2 no.

Rotation Speed from 0.025 to 0.50 RPM

Tilt Speed from 0.010 to 0.10 RPM

Drop Off: 600 mm (from rotation center to top extension arms)

Max work piece diameter: 3.90 m

Octagonal table with inscribed circumference of 2.2 m Ø

Extension arms: 4,600 mm





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Remote control box with variable speed on both table rotation and tilt forward/stop/reverse.

Potentiometer and digital display in RPM. Cable length of 12 m

Pedant control box with variable speed on both table rotation and tilt forward/stop/reverse.

Potentiometer and digital display in RPM. Cable length of 12 m

Foot control pedal for control table rotation forward/stop/reverse

Protection class IP54 against dust and heavy rain on electric control box and motors

Tilt Brake and Safety Devices

Two self-lock worm gears are used in the tilt gearboxes so that when the motor is running

the gears lock and do not allow the slewing bearing to tilt.

Two electric brakes are used in the tilt motor so that when the motor are not in used the

gearboxes do not rotate.

The air cylinder tilt brakes (SG1 & SG2) supports the slewing bearing if there is a gear or

gearbox failure. The tilt brake can be applied manually through the main control box or

automatically through the PLC if there is a gear or gearbox failure.

“T” shaped channels on table surface

TECO VFD (Variable Frequency Driver)

Cable clamp rated for 1,000 amps.





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2.0 Installation Instructions

1. The welding positioner must have a proper foundation and must be anchored to the ground

adequately in accordance to its foundation drawing.

CWP 40 Foundation Drawing

2. The welding positioner is assembled in accordance to its assembling instructions.

CWP 40 Assembling Instructions

3. Ensure that bolts use to assemble the welding positioner and all bolts holding gearboxes to the

positioner frame are tighten to the chart specs below. If the bolts are not tighten properly the bolts

can shear producing an accident. Use bolts DIN 933 grade class 8.8, ANSI/ASME B18.231M, high

strength.

4. The positioner gearboxes, gears and bearings must be adequately lubricated prior to

commissioning the positioner. There maintenance schedule must also be adequately follow to avoid

long term damages.

Lubrication and Preventive Maintenance

8.8 HEX Bolt 8.8 HEX Bolt

OD (mm) N-m

± 10% OD (mm)

N-m

± 10%

M12 60 M42 2,737

M14 97 M45 3,390

M16 150 M48 4,095

M18 201 M52 5,250

M20 282 M56 6,547

M22 390 M60 8,175

M24 499 M64 9,900

M27 746 M68 12,000

M30 982 M72 14,250

M33 1,331 M76 16,800

M36 1,717 M80 19,725

M39 2,220 M85 24,000





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5. All the cables coming from the positioner are directed to the main control box. Each cable directed

to the main control box is marked with a designated number. Match and connect the marked cable

in the main control panel circuit. The electrical wires are placed through the inside structure of the

positioner. Note: L1, L2 and L3 are designated terminals for the main power.

6. The electric diagram is attached on the back of the main control box panel door. Ensure the system

is properly wired and powered as per its electrical diagram and data plate.

CWP 40 Electrical Diagram

7. The tilt limit switch comes pre-installed. Ensure that limit switch and limit switch stopper are making

proper contact. Place the limit switch cover and fix it to the positioner frame using four bolts.

8. The tilt brake magnetic contactor located at the bottom of the hydraulic air actuator comes pre-

installed. Ensure that the magnetic contactor is properly fixed to the hydraulic air actuator. Place

the magnetic contactor cover and fix it to the positioner frame using four bolts.





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9. Connect compress air supply to the tilt brake air regulated. The air pressure should be set to 70 -

145 (psi). Ensure that there is air supply available at all times during the positioner operation.

10. Ensure the air tubes supplying air to both tilt breaks (SG1 & SG2) are properly connected in

accordance to their labelled numbering system.

11. Ensure that the left and right tilt break sensors sw1 are properly fixed in their brackets.

12. Ensure that the welding positioner maximum eccentricity and gravity center are not exceed when

placing the work piece. Use the capacity chart and data plate as reference.

CWP 40 Capacity Chart

CWP 40 Data Plate





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13. If the work piece used weights less than 2 MT and has a GC < 600 mm the supplied counter

weights need to be placed on top of the left and right end beams. If the work piece has a GC >

600 mm the counter weights need to be removed. When there is no work piece on the positioner

the counter weights are removed. Each counter weight is fixed by using two removable pins.

14. The ground clamp for the positioners is rated for 1000 amps. It can be access by removing four

bolts located on the center of the octagonal table. The welding positioner must not be grounded

directly since it can damage and reduce the bearings life.

15. Connect the remote control box or the pendant control box to the main control box. There is a

single input for this controllers on the main control box located on the far bottom left. Note: only

one controller can be use at a single time.





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16. Connect the foot control pedal to the main control box. There is a single input for this controller

on the main control box located on the far top left. The foot control pedal controls table rotation

forward/stop/reverse functions.





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Remote Control Box Operation

Main Control Box Operation

Note: The tilt brake must always be set to the lock position unless the tilting function is being used.

Function Description

SPEED r/min Digital display screen that indicates current table rotation and tilting speed

SPEED Potentiometers used to control the table rotation and tilting speed

T / R Toggle switch used to change between T: tilting or R: table rotation

FWD When T/R switch is on T or R activates tilt or table rotation forward function

STOP Stop FWD or REV function

REV When T/R switch is on T or R activates tilt or table rotation reverse function

Function Description

LAMP When POWER ON the indicator lamp lights up

TILT When the remote control toggle switch T/R is set to T the indicator lamp lights up

ROTATION When the remote control toggle switch T/R is set to R the indicator lamp lights up

LOCK

This indicator lamp lights up if: a) MANUAL TILT LOCK toggle switch set to I b) The tilt lock automatically activates (see Tilt Brake

section for more details)

ALARM This indicator lamp lights up if there is an error or failure with the N2 VFD

POWER OFF Off Power switch

POWER ON On Power switch

MANUAL TILT LOCK Toggle switch used to manually lock and unlock tilt brake; I: activates tilt brake, O: retracts tilt brake

RESET Use to reset main control box in case of N2 VFD failure

WARNING!

When switching from FWD and REV always press the STOP button first

and let the table rotation or tilting come to full stop. Failure to do so will

cause permanent motor or reducer damage.





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Tilt Brake

The welding positioner comes equipped with two tilt brakes SG1 and SG2 that can be activated manually or automatically. 1) Manually: through the use of the main control box MANUAL LOCK toggle switch O/I. The tilt brake

must always be set to the lock position unless the tilting function is being used.

2) Automatically: in case of a tilt gear train failure or gearbox failure the tilt brake automatically activates

Sensor sw1 measures the elapse time t1 between the teeth of gears M128

The sensor sw1 is control by PLC FX1N-24MT located in the main control box

The logic is accordingly:

if 0 < t < t1 normal working operation the tilt brake stays in unlock mode

if t>t1 failure with tilting gear train or gearboxes; the tilt break will activate and hold gear

M141 in place. The tilt brake will only activate if the elapse time failure occurs three times

(meaning t>t1 occurs in three teeth)





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If there is a failure in the tilting gearbox M120 or/and M122 and the PLC activates as

explained in PLC logic section. For safety reasons the tilt brake will only be removed by

resetting the PLC. This can be done via connecting the jumper wire to the PLC reset

terminals at the same time (COM,X11) while holding the terminals the tilt brake will begin

to draw back. Once the tilt brake has been fully drawn back the indicator light in the PLC

X13 and X14 will light up. At this point the PLC has been reset. Ensure that the reason for

the failure is properly diagnose before operating the equipment again.

The logic of the PLC can be tested to ensure the safety tilt brake is working properly as following:

Remove both sw1 from their bracket.

Ensure the tilt brake is set in the unlock position.

Change the VFD function F10 = 0 see Procedure to Re-Setting VFD (N2-200/400) for more

details.

Place the remote control toggle switch on the tilt function.

Quickly move one sw1 sensor against a piece of steel the led light should flash red. Do this

three times.

Both tilt brakes (SG1 & SG2) will automatically lock.

In order to retract the tilt break the PLC must be reset manually as explained earlier.

The same is process is done to the second sw1 sensor.





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3.0 Lubrication and Preventive Maintenances

Gearboxes

The gearboxes are factory shipped without lubrication they need to be lubricated prior to equipment commissioning. The below table and diagram show lubrication spec, location of gearboxes and maintenance schedule. Failure to properly lubricate and properly follow maintenance schedule will cause permanent gearbox damage.

M124 and M126 tilt gearbox M120 and M122 table rotation gearbox

Note: The gearbox M124 and M126 use oil therefore it will flow out smoothly from the bottom drain plug screw hole in the

reducer. The gearbox M120 and M122 use grease in order avoid possibility of leaks therefore in order to add the grease it must

be heated for it to flow in the plug screw hole. When the gearbox needs to be drained the table rotation motor must be turned

on for about 15 min in order to heat up the grease and allow it to flow out smoothly from the plug screw hole.

PART CODE QTY. DESCRIPTION GREASE OR OIL

TYPE GREASE OR OIL

REQUIRED MAINTENANCE SCHEDULE

CWP40-M120 1 left table rotation gearbox

MOBIL EP023 or Equivalent

-Approx. 37.5 kg -Oil level should be visible in the middle of the inspection glass.

-Initial oil change after start up needs to be done after approx. 10,000 operation hours. -Sequence oil changes after every 3 years or 10,000 operations hours. -Check oil level monthly. -Check gearbox unit for leakage monthly. -Observe and check gearbox unit for unusual noises during operation.

CWP40-M122 1 right table rotation gearbox

CWP40-M124 1 left tilt gearbox MOBIL SHC-624 or

SHC-625 or SHC-630 or Equivalent

-Approx. 32.0 kg -Oil level should be visible in the middle of the inspection glass. CWP40-M126 1 right tilt gearbox

Open cap to fill gearbox with lubrication

Open bottom plug screw to drain gearbox

Open plug screw to add and drain lubrication





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Open Gears

The open gears are factory shipped without lubrication they need to be lubricated prior to equipment commissioning. The below table and diagram show lubrication spec, location of open gears and maintenance schedule. Failure to properly lubricate and properly follow maintenance schedule will cause permanent gear damage.

PART CODE QTY. DESCRIPTION GREASE TYPE MAINTENANCE SCHEDULE

CWP40-M128 2 gear 1 on tilt reducer shaft (M124 & M126)

-MOBIL DYNAGEAR 4000 or Equivalent

-The open gears must be coated with grease prior to equipment commissioning -At 500 hour operation interval remove safety guards and check the grease coating, if required replenish grease.

CWP40-M129 2 gear 2 on tilt shaft (M132)

CWP40-M130 2 gear 3 on tilt shaft (M132)

CWP40-M131 2 gear 4

CWP40-M140 1 table rotation slewing bearing gear

CWP40-M141 2 tilting slewing bearing gear





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Bearings

The bearings are factory shipped with lubrication. The bearing are lubricated through the use three grease pumps since the bearings are not easily accessible. The below table and diagram show lubrication spec, location bearings, location of grease pumps and maintenance schedule. Failure to properly lubricate and properly follow maintenance schedule will cause permanent bearing damage.

PART CODE QTY. DESCRIPTION OIL TYPE GREASE PUMP

MAINTENANCE SCHEDULE

CWP40-M140 1 table rotation slewing bearing

-MOBIL EP023 or Equivalent

#3 -The bearings are factory shipped with grease. -At 500 hour operation interval based on a daily operation time of 24 hours replenish grease.

CWP40-M141 2 table tilt slewing bearing #1 and #2

CWP40-M142 2 bearing 1 on tilt shaft n/a

CWP40-M143 2 Bearing 2 on tilt shaft n/a

Grease Pump #3 Grease Pump #1 and #2

M143 Bearings M142 Bearings

Insert grease gun to access bearing

Remove end cap to access bearing





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4.0 Warnings

WARNING

"Overload or misuse of a Welding Positioner can cause PROPERTY DAMAGE, BODY INJURIES OR DEATH”. Before operating read carefully and understand the information below. If you have any questions or concerns, please contact us @ 1 877 IRIZAR1 or [email protected]

1) Welding Positioner must not be operated by un-trained personal.

2) Welding Positioner must not be left ON without supervision.

3) Welding Positioner must not be operated without periodic preventive maintenance inspection.

4) Welding Positioner must not be overloaded. For your reference see max loading capacity on

positioner’s data plate.

5) Welding Positioner tilt brake must always be set to lock position unless tilting function is being

used.

6) Welding Positioner must not be operated without proper foundation.

7) Welding Positioner must not be operated unless all bolts in the equipment are properly tighten

in accordance to the bolt torque chart provided.

8) Welding Positioner must not be operated unless all gearboxes are properly lubricated

9) Welding Positioner must not be grounded directly since it can damage and reduce the bearings

life. It must be grounded to the ground clamp

10) Limited Warranty: “Any repair or modifications made by unauthorized third parties without

written consent shall void this warranty






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5.0 Troubleshooting Procedures

Procedure to Re-Setting VFD (N2-200/400)

If a function or functions have been randomly changed in the VFD. Follow the below steps in order to

get the VFD working in accordance with the welding positioner. The keypad command locations can be

seen in the diagram below.

1. Press “DSP FUN” until “000Fn” appears on display.

2. Press the scroll arrows “up and down” to navigate to the desire function code. To change digit place

press “RESET”.

3. Input Function Fn-123 and press “READ ENTER” to get into the function code.

4. Press the scroll arrows “up and down” to change the value of the function code. To change digit

place press “RESET”. Input (1111) if 60 Hz is used and press “READ ENTER” to save values.

5. This will reset the VFD to its factory settings.

6. Repeat steps 2-4 but enter the following function codes:

7. The VFD has now been re-set press the RESET button on the main control box; check to see that all

functions in the remote control box and main control box work adequately.

Function Code

Set Value

Function Code

Set Value

Fn01 10 Fn10 1

Fn02 10 Fn11 2

Fn03 0 Fn46 1

Fn05 10-15 Fn47 111

Fn06 60 Fn72 0

Fn07 3 Fn76 0

Fn98 1011





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6.0 Load Test Procedure

1) Ensure the positioner is properly anchored to the ground in accordance to its foundation drawing.

2) Ensure that all bolts are properly torqued in accordance to the torque chart provided by Irizar.

3) Ensure the positioner gearboxes M120, M122, M124 and M126 are properly lubricated.

4) Ensure the overall system is properly wired and connected to the main control panel.

5) Ensure the tilt brake air regulator is properly connected to a steady compress air supply line. The

air pressure in the tilt brake air regulator should be set to 70-145 psi.

6) The following functions of the CWP 40 must be tested prior to setting work piece on the

positioner.

a. Table rotation variable speed.

b. Tilt variable speed.

c. The tilt limit switch needs to be tested at 0 degrees and 135 degrees.

d. Manually test the tilt brake.

7) Ensure the welding positioner maximum eccentricity and gravity center are not exceeded when

placing the work piece on positioner.

8) Ensure there is a clear path behind and in front of the positioner for when the work piece is

being tilted.

9) Ensure the work piece is properly fixed to the positioners table.

10) When rotation or tilting a work piece always start at low speeds. If it’s not required do not rotate

or tilt at high speeds.

11) Once required tilt has been reached the tilt brake should be set to LOCK.





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7.0 Technical Documentation CWP 40 Foundation Drawing





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CWP 40 Assembling Instructions

Part Code Part Name Weight (MT)

A100 left bottom base 2.94

A101 left end beam 7.10

A102 left counter weight 2.30

A103 cradle beam 11.40

A104 rotating table 4.50

A105 right counter weight 2.30

A106 right end beam 7.10

A107 right bottom base 2.94

A108 main control box 0.30

A109 foundation n/a

A110 extended arm 0.20

STAGE SEQUENCE DESCRIPTION

1 A100 - A101 anchor A100 into A109 using its pre drill holes

2 A101 - A100 attach A101 into A100 using a total of 12 bolts M24x85 include adequate washers, lock washers and nuts

3 A103 - A101

attach A103 into A101 secure this attachment by first setting the two lower pins in place in order to properly align the rest of the holes then use a total of 7 bolts M24x120 include adequate washers, lock washers and nuts

4 A107 - A106 attach A107 into A106 using a total of 12 bolts M24x85 include adequate washers, lock washers and nuts.

5 A103-A106

bring A106 close to A103 and secure this attachment by first setting the lower pins in place in order to properly align the holes then use a total of 7 bolts M24x120 include adequate washers, lock washers and nuts.

6 A107 - A109 anchor A107 into A109 using its pre drill holes

7 A110 - A104

attach A100 into A104 to the top of the octagonal table using a total of 6 bolts M24x80 per arm then using a total of 6 bolts M24x80 secure the arm to the side octagonal table. This process is done to the 8 arms in the CWP. Include adequate washers.

8 A104 – A103 attach A104 to A103 using a total of 32 bolts M27x85.

9 A108 – A107 attach A108 to its designated bracket





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CWP 40 General Dimensions





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CWP 40 Electrical Diagram





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CWP 40 Capacity Chart





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CWP 40 Data Plate





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CWP 40 Table Drawings





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CWP 40 Part List Drawing





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CWP 40 Part List Description

PART CODE QTY. DESCRIPTION MFG CODE TPQ ht MTR ht

CWP40-M120 1 left table rotation gearbox - - -

CWP40-M121 1 left table rotation motor - - -

CWP40-M122 1 right table rotation gearbox - - -

CWP40-M123 1 right table rotation motor - - -

CWP40-M124 1 left tilt gearbox - - -

CWP40-M125 1 left tilt motor - - -

CWP40-M126 1 right tilt gearbox - - -

CWP40-M127 1 right tilt motor - - -

CWP40-M128 2 gear 1 on tilt reducer shaft (M124 & M126) 150201C;150201D 0001553;0001554 L4956

CWP40-M129 2 gear 2 on tilt shaft (M132) 150122A;150122B CD7/8 CD7/8

CWP40-M130 2 gear 3 on tilt shaft (M132) 150201E;150201F 0001555;0001556 L4956

CWP40-M131 2 gear 4 150201A;150201B 0001551;0001552 L4956

CWP40-M132 2 tilt shaft 150122C;150122D 2145 131130511

CWP40-M140 1 table rotation slewing bearing - - -

CWP40-M141 2 tilting slewing bearing - - -

CWP40-M142 2 bearing 1 on tilt shaft - - -

CWP40-M143 2 bearing 2 on tilt shaft - - -

CWP40 FRAME STRUCTURE

MTR CERTIFICATE NO. JBC 1401901; JBC1401350; JBC1401719

TPQ tempering and quenching

MFG manufacture SN

ht heat number





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CWP 40 Material Documentation





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CWP 40 Electrical Part List

PART CODE DESCRIPTION

CWP40-E100 N2 inverter

CWP40-E101 control relay

CWP40-E102 contactor

CWP40-E103 control transformer

CWP40-E104 resistance

CWP40-E105 dc power

CWP40-E106 fuse

CWP40-E107 power lamp

CWP40-E108 alarm lamp

CWP40-E109 reset button

CWP40-E110 e-stop button

CWP40-E111 power contactor

CWP40-E112 speed display

CWP40-E113 control button

CWP40-E114 resistance

CWP40-E115 control transformer

CWP40-E116 motor breaker

CWP40-E117 PLC

CWP40-E118 tilt limit switch

CWP40-E119 Sw1 sensor

CWP40-E120 magnetic contactor





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8.0 Limited Warranty

IRIZAR HEAVY INDUSTRIES INC warrants all new equipment to be free from defects in material and

workmanship for the period of one year, provided that the equipment is installed and operated according

to instructions. Any repairs or modification made by unauthorized third parties without written consent

shall void this warranty. IRIZAR HEAVY INDUSTRIES INC's obligation under this warranty is expressly

limited to replacing or repairing any defective part or correcting any manufacturing defect without charge

during the warranty period, if IRIZAR’s factory inspection confirms the existence of such defects. Exercise

of IRIZAR’s option of replacement or repair will be at IRIZAR’s factory and/or warehouse; therefore no

reimbursement for transportation cost of any kind will be allowed. IRIZAR HEAVY INDUSTRIES INC

will not be liable for any loss or consequential damage or expense accruing directly or indirectly from the

use of equipment covered by this limited warranty.



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