MG WHM-2020 Manual

M MA AN NI IP PU UL LA AT TO OR R W WH HM M- -2 20 02 20 0
O OP PE ER RA AT TI IO ON N & & M MA AI IN NT TE EN NA AN NC CE E M MA AN NU UA AL L
W
WH HM M- -2 20 02 20 0

MG WELDING WHM-2020
CONTENTS
CONTENTS _______________________________________________ 1
IDENTIFICATION DATA _____________________________________ 2
SAFETY PRECAUTIONS ______________________________________ 3
1. General Safety Instruction…………………………………………………………………………………… 3
2. Installation Preparation………………………………………………………………………………………… 4
OPERATION AND MAINTENANCE ______________________________ 5
1. General Description………………………………………………………………………………………………..5
2. Main Specification……………………………………………………………………………………………………6
3. Basic Construction………………………………………………………………………………………………….7
4. Installation………………………………………………………………………………………………………………9
5. Pre-Operation Inspection………………………………………………………………………………………11
6. Operation………………………………………………………………………………………………………………12
7. Shutdown Operation ……………………………………………………………………………………………13
8. Maintenance………………………………………………………………………………………………………… 14
APPENDIX A GENERAL ARRANGEMEN__________________________ A
APPENDIX B ELECTRICAL DRAWINGS__________________________ B
APPENDIX C ASSEMBLY DRAWINGS___________________________ C
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MG WELDING WHM-2020
IDENTIFICATION DATA
Purchaser
：
MG WELDING
PO No.
：
MG7695
Seril No.
：
MG7695-01
Equipment Type
：
Manipulator
Model
：
WHM-2020
Vertical Speed
：
Max.925mm/min 0.37kw at 60Hz with brake
Brake Supply
：
220V
Boom Speed
：
290to2940mm/min 0.37kw at 6-60Hz with Farce Cooling
Power Supply
：
400V-3P-50HZ
Control Voltage
：
24V AC
Slewing Feature
：
Yes
Max. Under Boom Height
：
2000mm
Effective Boom Travel
：
2000mm
Color
：
RAL 3003Red
Quantity
：
1
Please quote the above serial no. and details when ordering spares or in any other
communications regarding this equipment.
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MG WELDING WHM-2020
SAFETY PRECAUTIONS
1. General Safety Instruction
1.1 This manual must be thoroughly understood prior to actual installation and
operation of the machine.
1.2 In additional to the manual, please refer to O & M Manual of Welding Equipment.
1.3 Please observe applicable legal and other mandatory regulations relevant to
accident prevention and environment protection. These compulsory regulations
may also deal with handling of hazardous substances, issuing and/or warning of
personal protective equipment, or traffic regulations.
1.4 Installation instruction contained herein must be supplemented by instructions
covering all duties involved in supervising and notifying other parties working
within the area of operation.
1.5 Observe all basic safety rules using the correct tools and lifting slings, wearing of
safety harass, etc.
1.6 Always use the lifting lugs provided on the equipment.
DO NOT COMPROMISE ON SAFETY.
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MG WELDING WHM-2020
2. Installation Preparation
2.1 During design and installation it is vital to take into account relevant standards and
regulations, the load bearing capacity of building or floor or other attachment
devices.
2.2 Before starting installation, prepare a sketch or drawing showing the extent of the
MG WELDING Manipulator System and its required area of operation with
respect to building.
2.3 Use only original MG WELDING components. When using supplementary bolt
or other fasteners, use only those according to the specified grade.
2.4 MG WELDING Manipulator is designed for ready-to-use and there is no further
mechanical installation requirement except to provide connection to the electrical
supply. However, we recommended that a thorough Visual inspection to be carried
out to ascertain that no visual damage has occurred during the course of shipment
and transit.
2.5 We recommend, after completion of installation but before taking the unit into
service, it is commissioned by recognized experts in the field. We remain naturally
at your service with hints and advise should you require them. It better to ask
once too much and nothing must be unclear. We trust that with proper installation
procedure, MG WELDING Manipulator will provide you years of trouble-free
service.
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MG WELDING WHM-2020
OPERATION AND MAINTENANCE
1. General Description
1.1 MG WELDING Welding Manipulators (Column & Boom) are categorised by the
horizontal outreach and the under boom height as measured from the underside
of boom to the floor.
1.2 MG WELDING Manipulators are modular in construction and robustly built to
withstand the rugged and harsh environment expected of such application. Detail
attentions such as grit blasting to SA 2.5 for all structural steel work and
polyurethane paintwork will ensure that our equipment provides you with many
years of uninterrupted use.
1.3 Various options are available such as Travel Car, Step over Control, Motorised X-Y
slide and many others. MG WELDING can customise the Manipulator to meet
the demand of the workpiece.
1.4 Main Component.
1.4.1 Table (1)
Item
Number
Description
Remarks
1
Hoisting Assembly
2
Mast Plate
3
Column or Mast
4
Boom
5
TravelCar
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MG WELDING WHM-2020
2. Main Specification
1
Model
WHM-2020
2
Capacity
100Kg at 300mm from Boom End
3
Vertical Speed
Max.925mm/min 0.37kw at 60Hz with brake
4
Vertical Drive Motor
0.37KW with Brake
5
Boom Speed
390 to 3920mm/min
6
Boom Drive Motor
0.37KW with Farce Cooling
7
Travel Speed
N.A.
8
Max. Under Boom Height
2000mm
9
Effective Boom Travel
2000mm
10
Electrical Panel
Yes
11
Base Type
Fixed
12
Column Rotation
Manual
13
Power Supply
400V-3P-50HZ
14
Control Voltage
24V AC
15
Control Means
Via push button pendant on 10m cable
16
Surface Preparation
Gritblast to SA2.5
17
Color
RAL 3003Red
18
Qty
1 unit
19
Weight
1210KG
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MG WELDING WHM-2020
3. Basic Construction
3.1 Hoisting Assembly
This is a lifting system, which moves the entire Mast Plate Assembly, the
Boom, Welding Head and all ancillary fixtures that is mounted therein, up
and down the column.
The lifting force is effected via a geared motor c/w brake on a chain.
3.2 Mast Plate
The Mast Plate or commonly refer as the Saddle, is fitted with guide rollers
for the boom and guides the column.
The front face guide rollers engaged onto the Boom, thus allowing the Boom
to traverse left or right.
The rear face guides engaged onto the guide Rail of the Mast, thus allowing
the Mast Plate to move up or down.
3.3 Column or Mast
The Column is constructed in a box-up design and the rails are machined in a
single pass to ensure a tight tolerance.
The column is bolted down onto a Slew Ring, the latter being mounted on a
Fixed Base or a Travel Car.
a
locking screws.
3.4 Boom
This is tabular in construction and offer both rigidity and torsion, thereby
minimizing deflection during operation.
The guide rails are precision-machined in a single stroke.
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MG WELDING WHM-2020
A gear rack is bolted along the length of the Boom, where it is engaged by a
pinion, driven by a geared motor mounted on the rear face of the Mast Plate.
This effects the traversing of the Boom in left or right direction.
The traversing is limited via limit switches activated by striker block mounted
on Mast Plate and Boom respectively.
3.5 Travelcar
This is of manual push type, on V wheels.
3.6 Electrical Panel
This is mounted on the rear of column and houses all the electrical contacts,
termination and pc board, among others.
3.7 Pendant Controller
This is connected out of the Electrical Panel via a 6m long control cable.
The Pendant houses all movement controls of the Manipulator In addition to
the Emergency Stop.
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MG WELDING WHM-2020
4. Installation
4.1 MG WELDING Manipulators are designed for immediate put-to-use and
Therefore no mechanical connection is required. However, here is a list of
some guidelines that should be taken into consideration during installation.
Remove all Packing Material.
Check all quantity against the Detailed Packing List.
Check for damages from handling or leaking gearboxes.
Check for correct voltages.
4.2 Procedures
Select the area for installation. Preferably, this should be level and able to
take the load of work piece without subsequent soil settlement.
Study the area of operation to ensure that it will be large enough for the
work piece where extension will be required.
It is preferable to read this section together with Appendix A and B,C
For a Travel Car, simply place it on the rails. Check that the both wheels sit
snugly on the rails.
Lift up the Mast via the Lifting holes.
Place it over the Travel Car, lower the Mast slowly and insert and tighten all
screws.
Disengage the Boom drive motor. Lift the Boom and insert Boom into the
Roller’s opening.
Engage the Drive Pinion with the Boom’s gear rack,.
Terminate the Incoming Cable to the Electrical Panel.
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MG WELDING WHM-2020
Connect the 3-phase supply once the set up is completed.
Test up/down function to ensure the phases coincide with the equipment and
observe if there is any unusual noise or smell.
If the “up” function operate the down movement of Mast plate, change any 2
phases of the supply.
(Note: Do not continue to operate the machine as the limit switch will not
operate when phases are incorrect.)
Test the Stop Button on the Pendant Controller to ensure its functionality
Test the Emergency Stop Button on the Electrical Panel to ensure its
functionality.
Fine-tune the adjustment until the Boom is level to the ground.
Adjust all the Side Rollers so that the Boom is level in the Horizontal Plane.
Re-check that all Rollers are tightened.
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MG WELDING WHM-2020
5. Pre-Operation Inspection
5.1 General
To operate the manipulators properly, it is strongly recommended that the
person-in charged be knowledgeable enough of the theories behind the
operation of such equipment.
Check the work piece is free from encumbrances.
5.2 Power ON Procedure
Follow this Power ON Procedure whenever the equipment will be used:
No
Task
Results
1
Turn on the wall isolator.
Voltage is supplied to the main panel.
2
Turn on isolator main switch on
main electrical panel.
Power is turned on.
3
Turn the Potentiometer to “Low”
and test the function of all
buttons, especially the E-Stop.
All buttons should function according
to its purpose specified in Appendix B
Note that Function Test is only possible if there is no work piece mounted on
the rotators. In case there is a work piece, common sense must prevail.
All controls of the pendant must be tested to ensure that they operate as it is
intended.
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MG WELDING WHM-2020
6. Operation
Observe the following guidelines whenever operating the equipment:
Only authorized and trained personnel are allowed.
Before welding any work piece, bring the speed down to minimum by turning
the potentiometer to 5.
Always ensure that the work piece is in good contact.
The operation of the manipulator is limited to the functions of the pendant.
General safety requirement needs to be observed as with all moving
equipment.
Always warn fellow workers before movement.
Always shut down when unattended.
In case of doubts of the machine functionalities, always report to the supervisor
and discontinue the use of the equipment until it has been rectified and certified
by an authorized maintenance personnel.
IGNORANCE IS NOT AN EXCUSE!!
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MG WELDING WHM-2020
7. Shutdown Operation
7.1 Power OFF Procedure
Follow this Power OFF Procedure after operating the equipment:
No
....
Task
Results
1
Depress STOP button
Equipment stops operation.
2
Depress Emergency STOP button on
electrical panel
No Power to Main Contactor.
3
Turn off main switch on the electrical
panel
Power is turned off the Breaker.
4
Turn off wall isolator
Power OFF to the main panel.
7.2 Clear the operation area and keep all tools in their proper location.
PRACTICE GOOD HOUSEKEEPIN!!
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MG WELDING WHM-2020
8. Maintenance
8.1 Only authorized and trained personnel are allowed.
8.2 Preventive maintenance consists of inspecting, adjusting and cleaning of the static
and dynamic parts of the whole mechanical unit. Regular inspection at intervals
dependent upon the service conditions are the best insurance against costly
breakdown.
Component
Inspection/Action
Interval
Electrical Panel
Clean with light Compressed Air
3 months
Filter at Panel
Replace
6 months
Pedant
Open and clean
3 months
Bolt & Fastener
Visual on corrosion, missing
Weekly
Warning Labels
Visual, replace where torn
Weekly
8.3 All moving parts, for example, bearings and couplings, are to be lubricated at
regular interval. Nipples are to be greased by means of a grease-gun, so that all
the internal moving parts can be lubricated, hence, prolong the life-span of the
whole mechanical unit.
Component
Inspection &
Action
Lubricant &
Detergent Code
Interval of Hours
Travel Car :
Slewing Ring
Grease
B
1000 Hours
Mast –Plate :
Mast Way
Boom Way
Clean
Clean
F
F
As Necessary
As Necessary
Hoisting Assembly :
Leadscrew
Gearbox
Clean & Lubricate
Oil Top-Up
F
A
As Necessary after
cleaning
As Necessary
2000Hours or 18Months
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MG WELDING WHM-2020
Before running the machine for any length of time, the user must ensure
that all the reducers and the transmission have oil up to the proper level in
their respective cases.
Oil of proper grade for local use must be regularly checks and top-up to
commensurate with either time or usage, whichever is earlier.
Attempt must be made to eliminate all sources of contamination, moisture
and for maximum insulation life for electrical motor.
8.4 Daily Check
Rails are clear from obstruction.
Familiarize with the obstruction along the path of the Boom.
Unusual noise or smell during operations.
8.5 Troubleshooting of Mechanical Parts
No
Malfunction
1
No move or lights
No Incoming Power
Faulty Motor Starter
Faulty Panel Isolator
Turn on Wall Isolator
Turn on Panel Isolator
Release Panel E-Stop
Release Pendant E-Stop
Replace
Replace
2
Incorrect Direction
Incorrect Phases
Change any 2 phase at Wall
Isolator
3
Alarm Light Up
Inverter Problem
Overload relay trip
Motor burnt
Replace inverter
Reset inverter
Reset relay
Replace motor
4
Speed cannot be
regulated
Parameter setting
Faulty Potentiometer
Wire loose or broken
Reset inverter
Replace potentiometer
Tighten or replace
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MG WELDING WHM-2020
APPENDIX A
GENERAL ARRANGEMENT
The General Arrangement is a CAD module illustrating the general set-up of the
equipment. The main specifications of the equipment are also listed in the GA. The
General Arrangement for the WHT-3 ROTATOR is presented in the succeeding pages.

A
MG WELDING WHM-2020
APPENDIX B
Electrical Drawings
Electrical Drawings are compiled in this section to give the user a detailed graphical
illustration of the electrical components and circuit diagrams associated with the
equipment. For more information regarding the electrical and electronic system of this
Manipulator model, please visit the respective manufacturer’s website.

B
MG WELDING WHM-2020
APPENDIX C
ASSEMBLY DRAWINGS
Detailed Parts List Drawings are not included in this manual. However, you may contact
our sales department through the contact numbers listed at the back page of this
manual to request for the detailed parts list drawings to assist you when ordering spare
parts.

C
C