EWM TR-0102 User manual

Operating instructions
Turning Rolls (Rotators)
GB
TR-0102
099-010253-EW501 26.11.2010
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our
customer service department on [phone].
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other
form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the
user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are
observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.

Contents
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1Contents
1Contents..................................................................................................................................................3
2Safety instructions.................................................................................................................................4
2.1 Notes on the use of these operating instructions ..........................................................................4
2.2 Explanation of icons.......................................................................................................................5
2.3 General..........................................................................................................................................6
2.4 Transport and installation ..............................................................................................................6
2.5 Ambient conditions.........................................................................................................................7
2.5.1 In operation.....................................................................................................................7
2.5.2 Transport and storage....................................................................................................7
3Intended use...........................................................................................................................................8
3.1 Applications....................................................................................................................................8
3.2 Documents which also apply .........................................................................................................8
3.2.1 Warranty.........................................................................................................................8
3.2.2 Declaration of Conformity...............................................................................................8
3.2.3 Welding in environments with increased electrical hazards...........................................8
3.2.4 Service documents (spare parts and circuit diagrams)..................................................8
4Machine description – quick overview ................................................................................................9
4.1.1 Front view.......................................................................................................................9
4.1.2 Rear view........................................................................................................................9
4.2 Machine control – Operating elements........................................................................................10
4.3 CB-006.........................................................................................................................................10
4.3.1 Front view.....................................................................................................................10
4.3.2 Rear view......................................................................................................................11
5Design and function.............................................................................................................................12
5.1 General........................................................................................................................................12
5.2 Installation....................................................................................................................................13
5.3 Positioning the workpiece............................................................................................................14
5.4 Connection for workpiece lead ....................................................................................................14
5.5 Connecting the machine controls ................................................................................................15
5.6 Mains connection.........................................................................................................................16
5.6.1 TR-0102........................................................................................................................16
5.6.2 Setting the mains voltage (115V/230V)........................................................................16
5.6.3 Switching the machine on/off .......................................................................................17
5.6.4 Changing the mains fuse..............................................................................................17
5.7 Remote control.............................................................................................................................18
5.7.1 Foot-operated switch....................................................................................................18
5.8 Function sequence.......................................................................................................................18
5.8.1 Foot-operated switch....................................................................................................18
6Maintenance, care and disposal.........................................................................................................19
6.1 General........................................................................................................................................19
6.2 Servicing and lubrication instructions for geared motors.............................................................19
6.3 Mechanics....................................................................................................................................19
6.4 Electrical components..................................................................................................................19
7Technical data ......................................................................................................................................20
7.1 TR-0102.......................................................................................................................................20
8Appendix A ...........................................................................................................................................21
8.1 Overview of EWM branches ........................................................................................................21

Safety instructions
Notes on the use of these operating instructions
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2Safety instructions
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.

Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol Description
Press
Do not press
Turn
Switch
01
Switch off machine
01
Switch on machine
ENTER (enter the menu)
NAVIGATION (Navigating in the menu)
EXIT (Exit the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use

Safety instructions
General
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2.3 General
WARNING
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
Risk of injury in the hazard area!
Rotating movements carried out by the machine can injure people! The hazard area is
the immediate area around the machine and the workpiece, plus a safety area of 1 m.
• Before switching on the machine and during operation, ensure that nobody is standing in the
hazard area!
• Wear appropriate protective clothing (no loose clothing)!
• In the event of an emergency, press the emergency stop switch or disconnect from the
power supply (remove the plug from the mains)!
CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
• National implementation of the framework directive (89/391/EWG), as well as the associated
individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
2.4 Transport and installation
CAUTION
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!

Safety instructions
Ambient conditions
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2.5 Ambient conditions
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.5.1 In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.5.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C

Intended use
Applications
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3Intended use
This machine has been manufactured according to the latest developments in technology and current
regulations and standards. It must only be operated in line with the instructions on correct usage.
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not used
correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1 Applications
This machine is only suitable for the mechanised production of circumferential welds.
3.2 Documents which also apply
3.2.1 Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.2.2 Declaration of Conformity
The designated machine conforms to EC Directives and standards in terms of its design
and construction:
• EC Low Voltage Directive (2006/95/EC),
• EC EMC Directive (2004/108/EC),
This declaration shall become null and void in the event of unauthorised modifications, improperly
conducted repairs, non-observance of the deadlines for the repetition test and / or non-permitted
conversion work not specifically authorised by the manufacturer.
The original copy of the declaration of conformity is enclosed with the unit.
3.2.3 Welding in environments with increased electrical hazards
In compliance with IEC / DIN EN 60974, VDE 0544 the machines can be used in
environments with an increased electrical hazard.
3.2.4 Service documents (spare parts and circuit diagrams)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Original copies of the circuit diagrams are enclosed with the unit.
Spare parts can be obtained from the relevant authorised dealer.

Machine description – quick overview
Documents which also apply
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4Machine description – quick overview
The rotating units consist of two dollys, one of which is driven and the other passive. This construction
allows the rotating units to be adjusted to suit the workpiece.
4.1.1 Front view
Figure 4-1
Item Symbol Description 0
1 Drive rollers
2
Machine control
See Machine control – operating elements chapter
3
Drive motor
4 Dolly, driven
5 Dolly, passive
6 Foot-operated switch
4.1.2 Rear view
Figure 4-2
Item Symbol Description 0
1 Adjusting screw, drive rollers on main rollers clamping pressure
2 Guide holes, rollers clamping pressure
3 Rollers, passive

Machine description – quick overview
Machine control – Operating elements
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4.2 Machine control – Operating elements
4.3 CB-006
4.3.1 Front view Figure 4-3
Item Symbol Description 0
1
Display
2 Ready for operation signal light
Signal light on when the machine is switched on and ready for operation
Switch for changing the rotational direction of the rollers
• Workpiece rotates anti-clockwise, when viewed from the driven dolly
3
• Workpiece rotates clockwise, when viewed from the driven dolly
4
Changeover switch, “WELD/RAPID” rotation speed
• “WELD” position = welding mode with rotation speed set
• “RAPID” position = positioning, rotary plate with maximum speed regardless of the
set rotation speed. There is no start signal for the welding machine.
5 Rotary speed dial, "WELD SPEED"
Infinite adjustment of the rotation speed

Machine description – quick overview
CB-006
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4.3.2 Rear view
Figure 4-4
Item Symbol Description 0
1 Mounting holes
2
2-pole connection socket, motor connection
3 3-pole connection socket, foot-operated switch
4
Mains voltage 115V/230V changeover switch
5
Earth cable
6 Machine switch, on/off
7
Connection socket mains cable

Design and function
General
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5Design and function
5.1 General
CAUTION
Damage to the machine due to improper connection!
Incorrect connection assignments result in equipment damage!
• All connections must be made by a qualified electrician in compliance with the laws and
regulations
applying in that country.
CAUTION
Risk of injury in the hazard area!
Rotating movements carried out by the machine can injure people! The hazard area is
the immediate area around the machine and the workpiece, plus a safety area of 1 m.
• Before switching on the machine and during operation, ensure that nobody is standing in the
hazard area!
• Wear appropriate protective clothing (no loose clothing)!
• In the event of an emergency, press the emergency stop switch or disconnect from the
power supply (remove the plug from the mains)!
Risk of accidents due to tripping over and unsuitable installation site!
Persons can be injured due to the machine being installed on an incorrect site!
Improperly laid cables or tube packages are trip hazards and can cause accidents!
• Set up the machine so that there is sufficient space for setting the operating elements!
• Do not block any escape routes!
• Do not place cables or tube packages in the hazard area around the machine!
• Lay cables or tube packages straight and in bundles (where appropriate, use cable ducts or
other tools)!

Design and function
Installation
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5.2 Installation
WARNING
Risk of accidents if incorrectly secured!
A machine that is not properly secured can injure persons!
• The machine may only be secured by a suitably qualified person!
• Only the provided fixing points in the base plate are to be used for securing!
• Always mount driven and passive dollys parallel and at the same height (see graphic)!
• Only use suitable fixing materials with a minimum size of M8 x 25 mm to anchor the machine!
• The screws from the transport packaging are not suitable for anchoring the machine!
• Anchor the machine on a suitable, load bearing and even surface (observe the load of the
rotation unit and the weight of the workpiece)!
Figure 5-1
Figure 5-2

Design and function
Positioning the workpiece
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5.3 Positioning the workpiece
CAUTION
Damage to the machine due to incorrect position of the workpiece!
Workpieces that are not positioned properly damage the machine!
• Place the workpiece carefully on the rollers without touching other parts of the machine when
doing so!
5.4 Connection for workpiece lead
DANGER
Electric shock!
In order to avoid injuries, make sure that the cables and hoses are fitted correctly when
connecting and working with the machine.
• Connect all cables and hoses in such a way as to prevent them being crushed or getting
caught when using the turntable!
• After installation or conversion, all mechanical and electrical connections must be tested for
correct installation!
CAUTION
Risk of burns due to incorrect connection of the workpiece lead!
Paint, rust and dirt on the connection restrict the power flow and may lead to stray
welding currents.
Stray welding currents may cause fires and injuries!
• Clean the connections!
• Fix the workpiece lead securely!
• Do not use structural parts of the workpiece as a return lead for the welding current!
• Take care to ensure faultless power connections!
• Use a rotating earth clamp when connecting the workpiece lead.

Design and function
Connecting the machine controls
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5.5 Connecting the machine controls
Figure 5-3
Item Symbol Description 0
1 Mounting holes
2
Fixing pin
To fasten the machine control
• Position the machine control on the mounting bolts using the mounting holes.
NOTE
Mounting process using an example. Procedure is similar for other models as
appropriate.

Design and function
Mains connection
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5.6 Mains connection
5.6.1 TR-0102
CAUTION
Damage to machines caused by inconsistent voltages!
To avoid damage to machines, the mains voltage and the machine voltage must match!
• Check the setting on the machine operating voltage changeover switch!
• It may be necessary to adjust the machine to the available mains voltage (see technical
data).
• For mains fuse protection, please refer to the "Technical data" chapter.
5.6.2 Setting the mains voltage (115V/230V)
2
1
Figure 5-4
Item Symbol Description 0
1
Mains voltage 115V/230V changeover switch
2
“Set mains input voltage” sticker
• Set the mains input voltage on the mains voltage changeover switch to the mains voltage present.
• Remove the “Set mains input voltage” sticker.
• Insert mains plug of the switched-off machine into the appropriate socket.

Design and function
Mains connection
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5.6.3 Switching the machine on/off
CAUTION
Risk of injury in the hazard area!
Rotating movements carried out by the machine can injure people! The hazard area is
the immediate area around the machine and the workpiece, plus a safety area of 1 m.
• Before switching on the machine and during operation, ensure that nobody is standing in the
hazard area!
• Wear appropriate protective clothing (no loose clothing)!
• In the event of an emergency, press the emergency stop switch or disconnect from the
power supply (remove the plug from the mains)!
• Switch the machine on or off at the main switch.
5.6.4 Changing the mains fuse
DANGER
Electric shock due to live parts!
The machine carries voltage during operation! Working on the machine during operation
can result in fatal injuries!
• Before all work, switch off the main switch!
• Remove the mains connection cable!
5
4
3
2
11
Figure 5-5
Item Symbol Description 0
1
Main switch, machine on/off
2
Connection socket mains cable
3Fuse holder
4
Machine fuse (1A)
5
Replacement fuse (1A)
• Switch off machine at the main switch.
• Remove the mains connection cable.
• Fold down the fuse holder.
• Remove faulty machine fuse.
• Fit the replacement fuse.
• Fold the fuse holder back into position.
• Plug in the mains connection cable and switch on at the main switch.

Design and function
Remote control
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5.7 Remote control
5.7.1 Foot-operated switch
Functions
• Start/stop turntable/tilting table.
• It is connected to the 3-pole remote control connection socket.
5.8 Function sequence
5.8.1 Foot-operated switch
Item Symbol Description 0
Switch for changing the rotational direction of the rollers
• Workpiece rotates anti-clockwise, when viewed from the driven dolly
1
• Workpiece rotates clockwise, when viewed from the driven dolly
2
Changeover switch, “WELD/RAPID” rotation speed
• “WELD” position = welding mode with rotation speed set
• “RAPID” position = positioning, rotary plate with maximum speed regardless of the
set rotation speed. There is no start signal for the welding machine.
WELD SPEED
It
t
Figure 5-6
Symbol Meaning
I Welding current
t Welding process time
Rotating device turns right in a clockwise direction
Rotating device turns left in an anti-clockwise direction

Maintenance, care and disposal
General
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6Maintenance, care and disposal
6.1 General
WARNING
Risk of injury due to high temperatures!
The rotary table can heat up during operation! Injuries can be caused if touched!
• Allow the rotary table to cool down after use!
DANGER
Electric shock due to live parts!
The machine carries voltage during operation! Working on the machine during operation
can result in fatal injuries!
• Before all work, switch off the main switch!
• Remove the mains connection cable!
6.2 Servicing and lubrication instructions for geared motors
All moving components in the system must be kept clean at all times and greased when appropriate. The
system must be serviced at regular intervals and tested for faults depending on the operating conditions.
• Keep moving parts clean.
• Service at regular intervals and check for errors.
6.3 Mechanics
• Check that the machine is anchored.
• Check bearings for damage.
• Tighten the screw connections.
• Keep moving parts clean.
6.4 Electrical components
• Check the cables and operating elements for external damage.
• Thoroughly remove dust and foreign bodies at regular intervals.

Technical data
TR-0102
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7Technical data
7.1 TR-0102
Mains voltage 1 x 115/230 V
Frequency 50/60 Hz
Mains fuse (safety fuse, slow-blow) 10 A
Speed 80 to 1600 mm/min
Workpiece diameter 20 mm to 800 mm
Max. workpiece temperature 200 °C
Max. load 1000 kg
Roller diameter 200 mm
Roller width 50 mm
Roller material PU
Width (drive/running wheel) [A] 542 mm/450 mm
Length (drive/running wheel) [B] 320 mm/160 mm
Height (C) 335 mm
Weight (drive/running wheel) 37 kg/17 kg
C
BA
Figure 7-1