Jansen 499.007 User manual

Operating instructions
Jansen welding table 499.007

Page 2 Edition 06/2015
Jansen AG
Industriestrasse 34
Postfach 220
CH-9463 Oberriet
Switzerland
Tel: [phone]
Fax: [phone]
Internet: www.jansen.com
E-Mail: [email protected]
Language of the original operating instructions: German
Document No: 02792
Edition: 06/2015
Read the operating instructions carefully before use!
These instructions are intended for the service and operating personnel.

Edition 06/2015 Page 3
Table of content
1Preface and introduction....................................................................................4
1.1 Preface...........................................................................................................4
1.2 Hazard symbols..............................................................................................5
1.3 Correct use.....................................................................................................6
1.4 Incorrect usage...............................................................................................6
2Safety regulations...............................................................................................7
3Placement, commissioning and disassembly..................................................8
3.1 Placement of the welding bench.....................................................................8
3.2 Adjust the height of the bench......................................................................10
3.3 Starting up....................................................................................................10
3.3.1 Switching on...........................................................................................10
3.3.2 Switching off...........................................................................................11
3.4 Disassembling the welding bench................................................................11
3.5 Permitted modes of transport.......................................................................12
4Description and operation................................................................................13
4.1 Configuration................................................................................................13
4.2 Description of function..................................................................................14
4.3 Operation......................................................................................................15
4.3.1 Control cabinet with footswitch...............................................................15
4.3.2 Support plates with clamping elements..................................................16
4.3.3 Working with lug support........................................................................17
4.3.4 Outside stop...........................................................................................18
4.3.5 Adjustment to required dimension..........................................................19
5Faults / Defects .................................................................................................20
5.1 Remedying faults..........................................................................................20
5.1.1 Electrical fault.........................................................................................20
5.1.2 Remedying a mechanical fault...............................................................21
5.2 Cleaning.......................................................................................................21
5.3 Determining defects......................................................................................22
6Repairs / Maintenance......................................................................................23
6.1 Repair on mechanical parts..........................................................................24
6.2 Repair of electrical parts...............................................................................24
7Additional instructions.....................................................................................25
7.1 Service and spare parts................................................................................25
7.2 Guarantee ....................................................................................................25
7.3 Disposal........................................................................................................25
8Technical data...................................................................................................26
8.1 General data.................................................................................................26
8.2 Dimensions of welding bench.......................................................................26
8.3 General layout drawing of welding bench.....................................................27
9Annex.................................................................................................................29
9.1 Spare parts list .............................................................................................30
9.2 Lubrication plan............................................................................................38
9.3 Setting the digital display..............................................................................39
9.4 Electrical schematics....................................................................................41
9.5 Manufacturer's declaration from Meag AG...................................................43

Page 4 Edition 06/2015
1 Preface and introduction
1.1 Preface
These operating instructions are intended to facilitate knowledge and use of the
welding bench. The operating instructions contain important notes on how to use the
welding bench safely, correctly and economically. Observance of the instructions
helps avoid dangers and increases the reliability and lifetime of the appliance.
The operating instructions must be available at the location of the welding bench at
all times. They are addressed to trained expert personnel (sheet metal workers, fit-
ters, welders) that have received initial instruction from Jansen or its representatives.
They must be read and applied by all persons working in any way on the welding
bench. Specifically, this work includes operation, adjusting the fixing plates, trouble-
shooting and maintenance.
In addition to these operating instructions and the country-specific accident-
prevention regulations, the acknowledged rules for safe and correct work must also
be observed.

Edition 06/2015 Page 5
1.2 Hazard symbols
Each hazard symbol in these operating instructions has a colour indicating the se-
verity of the hazard. The colour-coding of the hazard symbols and their assignments
to severity of hazard are listed as follows.
Danger
Red symbol:
Immediate hazards that always result in severe injuries
or death.
Warning
Orange symbol:
Hazards that might result in severe injuries or death.
Caution
Yellow symbol:
Hazards that might result in minor bodily injuries or se-
rious damage to property.
Note
Blue symbol:
Stands for technical requirements that must be adhered
to.

Page 6 Edition 06/2015
1.3 Correct use
The welding table is used to aid in welding Jansen steel profiles into fin-
ished window and door frames.
It is a clamping device to rivet and weld Jansen steel profiles into complete
frames.
Motor-drive for easy adjustment of the welding position.
Footswitch/control cabinet positioned outside of the hazard zone
All other uses are deemed incorrect.
1.4 Incorrect usage
It is not permitted to use the rotary motion and force for other
reasons that changing the position of the workpiece (element).
It is forbidden to rotate the welding bench when persons or
hindrances are within the hazard zone or even on the welding
bench itself!
The welding bench must not be used when it is not installed
compliant to the regulations and with the minimum clearances
to hindrances (see Chapter 2 Safety regulations)
Any manipulation to the footswitch by wedging or equipping
with an object is forbidden.
If the welding bench is not placed according to the regula-
tions then we cannot accept any liability for subsequent
damages resulting therefrom.
Do not clamp in any welding parts that protrude a long way
out from the welding bench, or only attach them with special
care (stop the rotary motion)
Use for any purpose other than that intended is forbidden.
The manufacturer or supplier does not accept liability for any
damages resulting from incorrect use of the welding bench.
The user accepts sole responsibility in such cases.

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2 Safety regulations
Appropriate safety equipment must be worn when working
with the welding bench (protective gloves, welder's head
protection, safety shoes and clothes)
This welding bench must be placed so that the clearance to
an object, all or any other hindrance is at least 2.5 m to the
pivotal point of the device (pivotal point is marked with yel-
low-black position point!).
This safety clearance must always be observed to ensure
that there can be no collision between the supporting table,
which is rotated horizontally, and any object, wall or other
hindrance.
The footswitch must be located outside of the slewing range
of the welding bench. It must not be operated if anyone is on
the welding bench platform or within the slewing range of the
welting bench!
Do not clamp in any welding parts that protrude a long way
out from the welding bench) or only attach them with special
care (stop the rotary motion)
If the location of the welding bench is changed, even slightly,
then it must first be disconnected from the power supply!
Safety clearances to possible hindrances must be checked
once more before recommissioning the welding bench. Only
then is it permitted to correctly reconnect the power supply.
The operating instructions must be observed during recom-
missioning!
The welding bench must be placed on an even, antislip, vi-
bration-free surface.
The hinged feet must then be used to level the bench. The
ring screws must be disassembled after transport with the
crane.

Page 8 Edition 06/2015
3 Placement, commissioning and disassembly
3.1 Placement of the welding bench
The welding bench is delivered completely preassembled (unpacked) and can be
erected at the workplace, which must comply with the following safety guidelines.
Only startup the welding table on an even, antislip, vibration-free
surface.
Level the foundation using the hinged feet (see Chapter 3.2)
Check the connection and control cable (footswitch) for damage.
Lay the connection cable concealed to avoid the risk of tripping
over it.
Place the footswitch/control cabinet outside of the hazard zone.
Responsibility: instructed personnel
Initial instruction must be provided by personnel from JAN-
SEN or its representatives or by personnel from the com-
pany providing the machine.
These instructed persons are then responsible for instruct-
ing and training other persons.
Operation of the welding bench is forbidden for untrained
staff!

Edition 06/2015 Page 9
The welding bench must be placed compliant with the following specifications:
When placing the welding table in front of a
wall, the clearance to the pivot point must be
2.5m!
(The pivot point is marked by a yellow-black
position point)
The clearance between the pivot point of the
welding bench and any hindrance or object
must be 2.5m!
(The pivot point is marked by a yellow-black
position point)
If the welding bench is installed in a fixed
position then the hazard zone should be
marked in yellow (boundary marking).
Place the footswitch/control cabinet outside
of the hazard zone.

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3.2 Adjust the height of the bench
The height of the bench can be adjusted to the required working height of 980 –
1050 mm at the corners of the baseplate using a square spanner.
3.3 Starting up
3.3.1 Switching on
(For details of controls, see Chapter 4.3)
1. Connect the ground cable of the welding unit with the ground plate on the
welding bench.
2. Plug the mains connection plug into the 400 V socket
Connection plate
for ground cable
Square spanner
The socket must be fitted with a fuse!

Edition 06/2015 Page 11
3. Turn the main system switch at the control cabinet to the I position
The green control lamp lights up ready for operation
The green control lamp does not light up not ready for operation
Reason: The motor protection switch has triggered
Feed to the footswitch is not OK , e.g. defective cable,
footswitch not connected to plug connection
The rotary drive of the welding bench is ready for operation as soon as the green
control lamp lights up. The clamping plane of the welding bench can be horizontally
rotated clockwise or anticlockwise by a motor. It is operated by the double footswitch.
Pressing the footswitch moves the horizontal clamping plane; releasing the
footswitch interrupts the power supply and the bench stops rotating. The bench re-
verberates slightly when stopping!
Additional operating instructions are contained in Chapter 4.3.
3.3.2 Switching off
The welding bench must always be switched off at the end of work!
Turn the main system switch at the control cabinet to the O position
the green control lamp goes off
3.4 Disassembling the welding bench
1. Turn the longitudinal slides parallel to the foundation so that you can drive under
the foundation with the forklift.
2. Turn the main system switch at the control cabinet to the O position.
3. Disconnect the mains plug from the power supply and place the cable rolled onto
the platform.
4. Disconnect the control cable of the control cabinet from the welding bench.
5. For transport, fully close the cross slides with the adjustment spindle.
The welding bench can be moved using a forklift (2T bearing capacity).
The welding bench can also be moved with a crane; there are two M12 threaded
boreholes in the foundation for this. The supplied M12 ring screws are screwed in;
the bench may only be hooked on at the ring screws.
Use four-strand hook rope or transportation belts to hook on.
(min. bearing load of crane 2 tons)

Page 12 Edition 06/2015
3.5 Permitted modes of transport
Within the premises, the welding bench can be transported or moved in one of two
ways:
With a forklift (bearing load 2 tons)
Risk of cable jamming!
With a crane (bearing load 2 tons)
Never transport the welding bench in any other way than those de-
scribed above. Unscrew the ring screws after transport. Be careful
when located under suspended loads.
When transporting with a lorry or suchlike, the welding bench must
be secured on the load floor.
The cross slides must be closed for
transport.
Longitudinal slides must be
parallel to the foundation.
Forklift
2 tons bearing load
Close the cross rails so that
they are not able to touch the
belts (risk of damage!)
Four-strand hook rope
2 tons bearing load
or
4 harnesses
Bearing load per harness
500 kg

Edition 06/2015 Page 13
4 Description and operation
The welding bench provides rational and cost-effective production of door and win-
dow elements from Jansen steel profiles.
4.1 Configuration
The welding bench is comprised of the following components
Picture 1:
a. Fixed foundation (height on all sides can be levelled)
b. 1 longitudinal slide (can be rotated horizontally in both directions)
c. 2 cross slides
d. 4 supporting plates with bearing surfaces and clamping elements
e. Control cabinet with double footswitch (for left and right rotary motion)
f. Drive motor for rotary motion (under a cover, not visible)
Not shown: tool cabinet (delivered loose)
a.
b.
c.
d.
e.
f.

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4.2 Description of function
Using the welding bench, door and window elements of perfect quality can be pro-
duced in a time-saving manner. In principle, the bench is a quickly adjustable gauge
that guarantees that even single elements can be rationally processed.
The JANSEN welding bench has four supporting plates (planar) with clamping devic-
es mounted on adjustable slides. The supporting plates are parallel to each other, the
stops are arranged at exact angles of 90°. These plates have been given special sur-
face treatment that repels weld spatter. The previously mentioned slides can be ad-
justed in their width and longitudinal directions by spindles. The digital mass indicator
is thereby used for initial setup of the size of the bench. The effective dimension may
differ by +/- 1 mm from the digital indicator due to the production tolerances of the
spindle.
The profiles are horizontally clamped against an outside stop onto four plane sup-
porting plates of the welding bench. With the "inside stop" version, the inner profile
lug can be additionally supported by a fixture. After fixing the mitre perfectly, the pro-
files are vertically fixed by a clamping device. The arrangement of the supports also
allows the frame to be riveted at the underside of the profile.
The stable stops and clamping devices prevent the construction from slipping during
the welding process; subsequent alignment of the elements is therefore usually not
required.
The welding bench can be rotated clockwise and counterclockwise by a motor (hori-
zontally). It is operated by a footswitch.
Footswitch for
direction of rota-
tion
Control cabinet
with
main system switch
Pivot point
Spindle
adjustment
of length
Main beam
Cross beam
Spindle
adjustment
of width
Support plates

Edition 06/2015 Page 15
4.3 Operation
4.3.1 Control cabinet with footswitch
Main system switch at control cabinet to switch off the control volt-
age!
Emergency stop (red/yellow) Emergency-stop device to prevent
injury to persons and damage to property.
The mains connection plug must be pulled immediately if there is
any incorrect function! If the footswitch is within the hazard zone
then the mains connection plug must also be pulled in dangerous
situations!
Additional details on the control cabinet are contained in the elec-
trical schematics in the annex.
Main system
switch
Control cabinet
Control lamp, green
Ready for rotary
drive
Protective hood
Attention!!
The bench must only be rotated
when no person is within its slewing
range
Emergency stop
Rotation footswitch
Welding bench
control connec-
tion
Mains connection
cable

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4.3.2 Support plates with clamping elements
The welding bench is equipped with four support plates, allowing all four corners of
an element to be clamped precisely and stably.
Configuration:
View from above
Two support plates each are mounted on cross slides are can be moved at the cen-
tre by an adjustment spindle.
These two cross slides are mounted on a longitudinal slide which is also moved by
an adjustment spindle.
Digital dimension indicators are used to set dimensions. Refer to Chapter 4.3.5
Released corner
for welding the underside of the pro-
file
Horizontal
clamping
element
Outside stop block
Support plate
Vertical
clamping ele-
ment
Inside stop block
shiftable
Lug support

Edition 06/2015 Page 17
4.3.3 Working with lug support
The lug support is mainly used for the lug profiles, with which the inside lug can be
supported or easily aligned.
First the required dimensions are set using the adjustment spindle. When setting the
dimension, the spindle play must be nullified, i.e. always move with the support
plates from the inside to the outside to the exact dimension! This thereby nullifies the
spindle play.
The cut profiles are placed onto the support plates and butted at the outer stops (in
case of pre-cut tolerances, the adjustment spindle must be readjusted to the dimen-
sion of the profile). For lug profiles, push the inside stop diagonally onto the inside
pipe corner and fix it with the Allen head screw.
If required, you can align the element corners (carefully) with the two horizontal
clamping devices.
The height of the lug can be adjusted with the lug support by adjusting the height us-
ing the threaded stud bolt.
Then tighten the vertical clamping element.
You can now start riveting and welding.
Lug support version:
Vertical spanner
Lug support
Inside stop
Support
Support plate
Janisol
Wing profile

Page 18 Edition 06/2015
4.3.4 Outside stop
The horizontal clamping elements must be removed when working with the outside
stops.
First, the adjustment spindles are set to the required dimension. The digital dimen-
sion indicators are adjusted to the outer stops, i.e. the dimension indicators match
the outer dimensions of the element. The outer dimension of the element can be
used. If the lug protrudes over the outer stop then when adjusting the dimension you
must take into consideration that 2x the width of the lug must be removed from the
adjusting dimension.
Always nullify the spindle play when adjusting the dimension, i.e. always move from
the inside to the outside with the support plates to the exact dimension; this nullifies
the spindle play.
Place the cut profiles onto the support plates and butt against the outer
stop (in case of pre-cut tolerances, the adjustment spindle must be re-
adjusted to the dimension of the profile). Swivel the vertical clamping
devices onto the correct clamping position, place a support on the mitre
and clamp the profile tightly onto the support plate with the vertical
clamping element. Make sure that the element is correctly aligned.
If necessary, you can clamp the profile onto the outside stop with a bar clamp. To do
this, place the bar clamp on the inside of the profile and the outside of the outside
stop and then clamp.
You can now start riveting and welding.
Outside stop version:
Vertical clamp
Support
Outside stop
Element
Support plate
For Jansiol Arte (499.354) and Janisol HI (499.423) sys-
temes are special stop plates available. Look at the welding
table accessoires at the end of the dossier.

Edition 06/2015 Page 19
4.3.5 Adjustment to required dimension
All three adjustment spindles on the welding bench are equipped with absolute digital
dimension indicators. The indicators are adjusted on the outside stops.
When adjusting the dimensions with the hand
crank, always nullify the spindle play, i.e. always
adjust to the required dimension from the inside to
the outside! The spindle play is thereby nullified.
To ensure during work that the dimension indicators are protected against weld spat-
ter, soiling and the danger of crushing, the mechanical protective covers are folded
down.
Remove the crank after adjusting the dimension 
Risk of shifting on impact.
Protective cover
(folding)
Digital display
with absolute dimension
indicator
Hand crank
Dimension indicator
The indicated dimension may differ by +/- 1 mm from the effective
dimension due to the production tolerances of the spindle!
(dimension indication is not used to control the saw cut)

Page 20 Edition 06/2015
5 Faults / Defects
5.1 Remedying faults
5.1.1 Electrical fault
a) Rotary drive not working:
Check:
Is the power cable connected and the external power supply live?
Is the main system switch set to the I setting and is the green control lamp
lit?
Is the control cable with plug connector correctly connected to the control
cabinet?
Are the cables OK?
Has the emergency-stop switch been enabled?
If the welding bench is still not turning, additional troubleshooting must be carried out
by a trained electrician or a service technician!
b) Display of battery discharge
Blights up:
replace battery
If no symbol appears in the display then the battery is in perfect condition. If the ca-
pacity of the batteries has dropped to a low level this is signalised by a continuous
battery symbol. If the capacity of the batteries drops even further after this to below a
certain level then the battery symbol flashes (pulsating). One month before complete
discharge, the display remains switched on or functional.
The electronic position indicator is supplied by 2 x AA standard 1.5 V DC batteries.
Depending on the quality of the batteries, this is sufficient for 1 year of operation (al-
kali type). Discharge of the battery is indicated by a "flashing" in the display. One
month before complete discharge, the display remains switched on or functional.
Responsible: instructed personnel or trained electrician
Before remedying faults, switch off the welding bench
and disconnect from power supply. Make sure that the
welding bench is not accidentally switched back on
when remedying the fault. Appropriate safety measures
must be taken.