ESAB 1500 ahma User manual

15OO AHIVIA
Positioner
Service manual
ESAB
C€
D07865-1 Valid for positioner PH103655 01

rönsÄxRAN ovr övnnnNssrÄMMELSE
OVERENS STEMMELSEERKLAERING
FORSIKRING OM OVERENSSTEMMELSE
VAATIMUSTENMUKAISUUSVAKUUTUS
DECLARATION OF CONF'ORMITY
KoNFoRnnrrÄr s nRrr,ÄnuN c
OVEREENSKOMSTIGHEID SVERKLARING
DICHIARAZIONE DI CONFORMITA ALLE NORME CE
GARANTIA DE CONCORDANCIA DA EC
DECLARACION COMUNITARIA DE CONCORDANCIA
cERTTFICAT DE coNronvrrrÉ
Tillverka re
P¡'od usent
Ploducent
Valmistaja
NIa n ufa ctuler
Hersteller
De Fabrikant
ll Produttore
Fa brica nte
Fablicanfe.
Le fabricant
PEMAMEK OY
FIN.322OO LOIMAA
FINLAND
Försäkrar att maskin
Garanterer ât maskin
tr'orsikrer at maskin.
Vakuuttaa, että laite
.A.ssure that the machine
Versichert, dass die lVlaschine
Velldaalt dat machine
Garan tisce
Garante que a maquina
Declara que la maquina
Declara que la machine
Typ
Type
Type
Tyyppi
T)'pe
Typ
Type
Tipo
Tipo
Tipo
Type
15OO AHMA
Positioner
Serienr
Serie n r.
Serienr.
Sarja nro
Serial No
Serienn ummer
Serienummer
Numero di serie
No. de serie.
No de serie
No. de serie
A 1213407
Ar tillverkad iöverensstämmelse med standard EN60204-f enligt direktiver 98137lF"C,20041I08/nC och 2006/95/EC
Er produsert i overensstemmelse med standard 8N60204-1 ifølge bettingelserne i direktiv 981371F,C,2004i108/EC og
2006t95tÐC
Er fremstillet ihenhold til standard 8N60204-1 ioverensstemmelse med bestemmesene idirektiv 9813718C,2006/108/EC og
2006t9stEC
On valmistettu standardia 60204-l noudattaen direktiivien 98137lF,C,2004ll08lüC ja2006l95lEC mukaisesti
Is manufactured in conformity with the standard 8N60204-1 and the directives 98137lF,C,200411081Ì,C and2006/95lr,;C
In Ubereinstimmung m¡t der norm EN60204-1 und den Bedingungen der Richtlinien98137lF;C,2004ll08ß,C und 2006/95/EC
Gefabriceerd is overeenkomstig met norm 8N60204-l volgens richtlijn g8l37lEC,2004ll08lüC en 2006l9SlEC
E costruita in conformita alle norme EN60204-1, e le direttive 98137lEC,2004ll08tÛC e2006l95lEC
Foi fabricada em conformidade com 8N60204-1, a directiva 98137IFJC,2004ll08lF;c e2006l95lEC
Ha sida fabricada conforme 8N60204-1, a la directiva 98131lEC,2004ll08lEC y 2006/958C
Est fabriquee conformement aux normes de Qualité 8N60204-l conformément aux directives 98/37lEC, 2004/108/EC et
2006t95t8C
Loimaa 19.02.2009
PEMAMEK OY
P.0. Box 50
Lomminkotu 47
FIN-32201 Loimoo
Valid since 17.12.2007
Phone:[phone]
Fox: [phone]D
www.pemomek.com
Pekka Heikonen
Managing Director

INDEX OF THE SERVICE MANUAL
I SERVICE AND MAINTENANCE
1.1 Senvlce-, oHEcKING-AND cLEANING PRocEDURES
1.2 LuenlcnloN tNSTRUcIoNS
1.2.1 Table for lubricant selection
2 RC-3I, INVERTER AND DRIVE PLC
2.1 Geruennl
2.2 ResernND ERRoRS
3 PEH- CONTROL
4 PART LISTS
4.1 ELEcTRIoAL DIAGRAMS
4.2 MecHnNIcAL DRAWINGS
4.3 Hyonnultc DIAcRAMS
FILE: D07865-'l AUTHOR: MSa 13.08.03 PRTNTED: LAr 13.8.2008

I SERVICE AND MAINTENANCE
1.1 Service-, checking- and cleaning procedures
Check every day:
. General condition of machine
. Function of the motors
o Suitability of the working area
. Abnormalvibration and noise
. Excessive heating
' Cover and safety equipment must be in their places and in the proper condition
Check regularly:
. Table plate must be kept clean
. Electrical boxes must be kept clean
. Tightness of fastening bolts
. Amount of hydraulic oil
o Condition of rotation machinery
. Condition of cables
SERVICE OF ELECTRICAL DEVICES
GENERAL
Only a trained electrician is authorized to service electrical devices according to service instructions and
working safety instructions.
Turn off the supply at the main switch before starting the service work and before removal of machine's
protecting cover. Feeding fuses must also be relieved.
The manufacturer's instructions for servicing electric motors must be followed.
The released thermal relays and blown fuses are signals of disturbances, overloading or heavier moving
than normally.
Before restarting the machine or changing any parts must be cleared the reason for the fault. Unless this is
the case, repeated disturbances can cause more serious faults in covered structures e.g. in feed motor.
NOTE! Faults caused by non-pertinent use or service are not included in our guarantee termsl
FILE: D07865-1 AUTHOR: MSa 13 OB 03 PR|NTED: LAr i3 8 2008

SERVICE PROCEDURES
Checking
area Checking point Description Daily Every
month Every SIX
month
Functions
Working area Working area must
be suitable for work XVisualchecking
Abnormal vibration,
noise and heating XVisualchecking
(make immediately all
the needed repairs)
General
Whole machine
Generalcondition of
machine XVisualchecking
Fastening bolts Fastening bolts
have to be tiqht XTight all fastening bolts
Table plate Table plate must be
clean
Bolts have to be
tiqht
X
X
Cleaning
Check tightness
Cover and
safety
equipment
Must be in their
places and in proper
condition
XVisuaf checking
(make immediately all
the needed repairs /
chanqes)
Gearing has to be
greased and clean XTake off the table plate.
Clean, grease and
check the condition of
machinery
Mechanical
Rotation
machinery
Checking of the
gear oil XAdd oíl or change it
according to lubrication
instructions
FILE: D07865-1 AUTHOR: MSa 13.08.03 PRINTED: LAr 13.8.200B

SPARE PART LIST Page I
06.04.200s
www.pemamek.com
Item L00250,3
Creator Mikko Salonen
Created 01.07 .2004
Description POSITIONER
Partno Description IItem Rev Description 2Qtv
I LOV/ER FRAME L00231 4 PEMA I5OO
2 ARM L00249 1 PEMA I5OO
3 HYDRAULIC CYLINDER lf00642 1 HD 22O5PP A2
4 BOX 602864 0 AE 1045.600
5 HYDRAULICAGGREGATE 301079 0 llvl2.426.0l.CT.l4.SEI/NFOl/180-2xNO3-2xE0t I
6 ROTATIONMECHANISM r,00320 4 PEMA I5OO AHMA
7 TABLEPLATE L00720 I D:700
8 SHAFT LOO277 O PEMA I5OO AHMA
9 FASTENING PLATE L00281 2 PEMA I5OO AHMA
IO COVERING PLÂTE L00340 2
I I COVERING PLATE L0026s 3 PEMA I5OO AHMA
I2 COVERING PT,ATE L00264 I PEMA I5OO AHMA
13 EARTH TERMTNAI, 10166s 0 95 mm2. 160.360.882
14 SLIDING BEARING FLANGE) 102018 0 D5Ol55x25 4
15 TAP LOOs22 O PEMA I5OO A}IMA 2
16 TAP r.00269 r PEMA 15OO AHMA 2
17 AILENSCREW 102360 0 ISO 7380 10.9 Ml2 SINK. 4
ß I.OCKING DEVICE t01368 0 DIN 471 .50 x 22
19 LOCKING DEVICE 101366 0 DIN 47145x1.75 6
20 ALLEN SCREW 00054 0 DIN 912 8.8 Ml6 8
2I HYDRAT'LTC DIAGRAM M0064r O PEMA I5OO AHMA
22 S^|OP SCREW 00065 0 DIN9l3 MtOXl4 8.8 2
23 STOP SCREW 00064 0 DIN9l3 M8Xl4 8.8 2
24 T-SLOTTEDNUT 103076 0 M6 8x13 4
25 PROTECTIVEHOSE 600449 0 D:50 mm 150050
26 WELDTNG CURRENT CABLE 601001 0 H0IN2-D 70mm2 2

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PEMA I5OO AHMA OEAl code

SPARE PART LIST
Item L00320,4
Creator Mikko Salonen
Created 30.06.2004
Description ROTATION MECHANISM
Page I
06.04.200s
www.pemamek.com
Partno Description 1Item Rev Description 2Qtv
1 TILTINGFRAME
2 BN,L BEARING TT]RNING RING 10s670 0 r.486.16.00.D2-S
3 DRIVING SHAFT L00s52 2 PEMA I5OO
4 WORMGEAR 107s45 0 RMI-85-F2-I
5 AC.MOTOR 100804 0 K2lR 80G6 0,55/t 4
6 SLOTBALLBEARING 101139 0 6207-2RS
7 LOCKINGDEVICE tot362 0 DIN 47135 x 1.5 2
8 FLAT WASHER LOt446 0 D:50/10.5x4
9 HEXSCREW 00029 0 DIN 933 8.8 Mlo
IO ISOLATION SLEEVE L01838 O PEMAPÖYDÄT 2
1I EARTH SPRING 102048 0 2,5x32x51,5 mm SS2387 3.5 N/mm 2
12 EARTH COPPF,R M00593 0 350A 2
13 HEX 00032 0 DrN 933 8.8 Ml2 4
14 HEXSCREW 00032 0 DIN 933 8.8 Ml2 l5
15 WEDGE STEEL I 00330 0 E335 l0x8

Mdrk Allerolion Dole Drown by
llem lif le of porl or ossembly drowing Drowing No/Code Moleriol, dimensions, quolily !Teighl Pcs
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www.pemomek.com
flbrnlroN MECHANtsM
PEMA ISOO AHMA OEM code

SPARE PART LIST Page I
06.04.2005
www.pemamek.com
Item M00641,0
Creator Markku Poso
Created 25.01.2000
Description HYDRAULICSCHEMA
Partno Description IItem Qty
Rev Description 2
OOI HOSE SET 301190 0 D12 - 3/8" 600 R2T - D12 90
OO2 HOSE SET 301191 0 Dl2 - 3/8" 500 R2T - D12
OO3 HOSE SET 301593 0 Dt2 90 - 3/8" 1000 R2T - Dl2 90 - 0
OO4 HOSESET 301108 0 Dl2 90" - 3/8" 800 R2T -Dt2 90" - 270
OO5 BANJO 300071 0 sEL-l2R(3/8) 3
oo6 ANGLE 300224 O SUEL-I2 2
OO7 BASECOUPLING 300168 0 BL-12R3/8
OO8 REACTOR M03893 0 D:1.2 4

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ESAB subsldlaries and representative offices
Europe
AUSTRIA
ESAB QBs,m.b,H
Vienne'¡¡E.¡no
T€l: +49 t aeOÞo tr
Fax: +€ I 888 2õ 11 Bs
BELGIUM
S.A. ESAB N,V
Brussele
Tel: +32274s11 oo
Fax: +32 Z l4E 11 Zg
IgFf'iiîgÅP,Y*,"
VamÞ€ft
Iå1,*-oo'lo'rlinlrttå
DENItIARK
Aldes€lokabst ESAB
HErlev
Tef: <-4596 sooi 11
r.Ð(: +4S 96 30 40 03
FINLAND
ESAB Oy
- , Flels¡nkl
, l€l: {-gSOg 542761
Fax: 4-g5O e 547 7Z 71
. FRA,I{CE
00
24
GERî,lAtfY
ESAB GrnbH
Sollngen
lel: +49 ZlZ 298 O
Fa)c {-49212 298 2tB
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FSAB Awmation rr¿
A.rxtover
T€l: +g f264 93 22 sg
rÐ(: {_44 l1e4ggZOT4
}IUNGARY
ESAB Kft
-Bt¡dapest
'Tel: +g6 1ZO 44 1Az
FÐC +96 I 20 ¡14 186
.'ALY
.4.
181
lHEIIETHERLANDS
esAIJ Nederland B.V
Tel: [phone]
Fax: +31 30 2¡185 260
I{ORWAY
AS ESAB
[arvlk
Tel: +47 OO l2 i0 OO
Faxi +42 gg 1l 52 03
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fratowlcà
TEI: +49 92 gS1 11 00
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PORTUqAL
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Usbon
Tel; +OSl € giO 960
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urallslava
Tel: +421 Z 44 BB 24 26
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sPAt¡t
A.
es (MADR|D)
3600
346 1
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B
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ESAB AG
Dietikon
Tel: [phone] Zs
t-ax: +4f 1 Z4O gO SS
Lrg*iffi south America
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Buenos Aires
Tel: +b4 fi 4 ZS3 4O3s
Frx +54 fi 4 ZS3 6913
BRAZIL
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Tel: +65 31 2f g1 ¿tsgg
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MÞ(co
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Tel: +86 2l SOOB ggp2
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Teli +gl gs 47g 4s 1Z
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PT, ESABindo pratama
.rakerla
Tel; +02 21 460 OÍBB
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Tokyo
T€l: +81 g 5296 TsZl
r-ax +gf g 5296 BOB0
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uqangof
Tel: +60 S eO2Z 9869
l-aJC. +60 g AO2Z 4754
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22
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¡rucnarest
T€l/Fax: +40 1 A2Ze674
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LLC ESAB
Moscow
Tel: +7 O9S S4A g28l
Fax: +7 0gS S43 92Bo

3:i-8 / -1 L+
3:l-8 / -GND
-K1 1-K12
3:F-7
Y1
YLOS-KALLISTUS-ALAS
UPP.TILTING-DOWN
AUF-KIPP-AB
UPP-KIPP-NED
-K13
3:F-7
-WY2
-K14
3:c-7
YLOS-NOSTO.ALAS
UPP-HEIGHT-DOWN
AUF.HOHE-AB
UPP.HÖJD-NED
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PEMA 15OO AHMA/ FA
VALVE CONTROL
Pemgl M pemâmek com
04.12.2007
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5
7
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This dæument is conf¡dential and cân
ne¡lher be copìed nor communicated to
âny third persoo wjthout our Mitten consent

PART LIST, ELECTRICS
Item 305097,0
Description ELECTRICÄLASSEMBLY
PEMARC3TH
REMOTE CONTROL UNIT
Created 01.12-2005
www.pemamek-com
Page I 15.08.2006
Description 2
Code - Rev
Description IPcs
ParEro Dimensions Length Widrh Qty
-RC31 REMOTE CONTROL 603247 -0 RC-31H
-v/1
-xl.2
-xl.2
-xl 2
-xi.3
-x1.3
-x1.3
CABLE
MILITAR-CONNECTOR
MILITAR.CONNECTOR
MILITAR-CONNECTOR
MILITAR-CONNECTOR
MILITAR-CONNECTOR
MILMAR-CONNECTOR
602452 -0
600763 -0
600775 -0
602875 -0
600764 -0
600775 -0
602875 -0
SEMOFLEX 8 x
MS-18-1P
MS3l06A-18
MS-3057-10A
MS-18-1S
MS3I 06A-1E
MS-3057-10A

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-RC3l-H
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REMOTE CONTROL UNIT
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s05097-0 s05097-0

PART LIST, ELECTRICS
Paltno Description I
EARTH PLUG
TERMINAL BLOCK
TERMINAL BLOCK
Item 504081,3
Code - Rev
600617 -0
600647 -0
600646 -0
Page 2
Dimensions Length Widrh
mm mm
Descliption 2
wPE-2,5
WDU 2,5 BL
wDU 2.5
Qty Pcs
1
6
X3
X3
X4
3

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400
400
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2'.G-4
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-1 F1
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PYORITYS
ROTATION
DREHEN
ROTATION
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HYDRAULIC PUIVP
HYDRAULISCHE PUMPE
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MAIN CIRCUIT
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3
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21
122
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13--142:F-3
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14 2..8-4
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3--a 1:D-0
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+S04081-93

F
OPTION FOR
EXTERNAL START
F
s05093
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4--34'.C-3 4--34:D-3
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1
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PEMA 15OO AHMA/ FA
CONTROL CIRCUIT
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7
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Electric cabin Electric cabin has to
be clean XVacuum the cabin
Connections Screw and plug
contacts have to be
tight and in good
condition
XTight and check all
connections
Cable must be
unbroken XVisual checking
(change when needed )
Emergency stop
button has to be
unbroken
XCheck the function
Remote control
Function XCheck allthe functions
and repair when
needed
Cables and
SENSOTS
Cables and sensors
must be unbroken XVisual checking
(broken cables and
sensors must be
changed immediatelv)
Components Check relays,
contactors and
fuses
XVisual checking
(check tips and change
when needed)
Electrical
Welding earth Check earth
contactors and
sliding surfaces
XTake off table plate and
check the condítion of
earth contactors and
slidinq surfaces
Leaks XOil leaks must be
repaired immediatelv
General
Function XTest allfunctions
Oiltank Amount and quality
of oil Add oilwhen needed or
change it according to
lubrication instructions
Components Machine must be
clean for secure the
confidence function
XVisual checking
(cleaning when
needed)
Hydraulics
Hoses Hoses must be in
good condition X Visual checking
(change immediately
cracked and broken
hoses)
FILE: D07865-1 AUTHOR: MSa'13.08.03 pR|NTED: LAr.13 8.2008