PEMA PBW 5000/2 User manual

Plate Butt Welding Station
PEMA PBW 5000/2
Instruction Manual

2
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.

3
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
TABLE OF CONTENTS
Table of Contents.......................................................................................................3
1Introduction..........................................................................................................5
1.1 Contact information................................................................................6
2Safety..................................................................................................................7
2.1 General Information...............................................................................7
2.2 Safety Instructions .................................................................................8
2.3 Safety related functions........................................................................12
3Technical Information ........................................................................................13
3.1 Machine structure ................................................................................13
3.2 Technical Data.....................................................................................14
3.2.1 Mechanical characteristics.................................................................14
3.2.2 Electrical characteristics ....................................................................14
3.2.3 Noise level.........................................................................................14
3.3 Machine plate.......................................................................................15
4Installation and Commissioning .........................................................................16
4.1 Handling and storing............................................................................16
4.2 Installation and start-up........................................................................16
5Operating Instructions........................................................................................17
5.1 Safety functions ...................................................................................18
5.1.1 Emergency stop function ...................................................................18
5.1.2 Emergency stop reset........................................................................18
5.1.3 Control panel in MC1.........................................................................18
5.1.4 Control panel RCA1...........................................................................20
5.1.5 Welding control..................................................................................22
5.1.6 Flux system control............................................................................23
5.2 Adjustments.........................................................................................24
5.2.1 Flux heating adjustment.....................................................................24
5.2.2 Adjusting contact jaw nozzle..............................................................25
5.2.3 Adjusting wire feeder.........................................................................25
5.2.4 Adjusting wire straightener.................................................................26
6Operation and programming functions...............................................................27
6.1 System overview WeldControl 500.......................................................27
6.1.1 Startup...............................................................................................27
6.1.2 Shutting down....................................................................................27
6.1.3 MAF...................................................................................................28
6.2 User interface pages and functions......................................................29
6.2.1 Sidebar and general UI functions.......................................................29
6.2.2 Start page..........................................................................................30
6.2.3 Operator page ...................................................................................32
6.2.3.1 Operator page; Joint tracking tab...........................................33
6.2.3.2 Operator page: META settings...............................................35
6.2.3.3 Operator page: multi-pass tab................................................37
6.2.3.4 Operator page: position tab ...................................................38
6.2.3.5 Operator page: settings tab ...................................................39
6.2.4 Work cycle page................................................................................41

4
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
6.2.5 WPS editor ........................................................................................43
6.2.5.1 WPS Editor: phase settings...................................................45
6.2.5.2 WPS Editor: movement settings ............................................46
6.2.5.3 WPS Editor: multipass editor.................................................47
6.2.5.4 WPS Editor: multipass dynamic fill and cap layers................50
6.2.5.5 WPS Editor: WPS info...........................................................51
6.2.5.6 WPS Editor: Parameters overview.........................................52
6.2.6 Start/Stop parameter editor................................................................53
6.2.7 Data collection...................................................................................55
6.2.8 System messages .............................................................................56
6.2.9 Settings .............................................................................................57
6.3 Welding................................................................................................58
6.3.1 WPS creation.....................................................................................59
6.3.1.1 Define welding parameter sets...............................................59
6.3.1.2 Setup multipass table ............................................................61
6.3.2 Seam tracking sensor calibration.......................................................62
6.3.3 Work cycle welding............................................................................65
6.4 Miscellaneous......................................................................................66
6.4.1 Reset.................................................................................................66
6.4.2 WeldControl 500 backup system .......................................................66
7Maintenance and Service Instructions ...............................................................68
7.1 Introduction..........................................................................................68
7.1.1 Lubrication instructions......................................................................69
7.2 Welding equipment maintenance.........................................................71
7.3 Lubricating the linear motion guides.....................................................73
7.3.1 Table for gear oil selection.................................................................75

5
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
1 INTRODUCTION
CAUTION
Read and understand the
INSTRUCTION MANUAL
before installing or
operating!
·Observe the following safety precautions in addition to the standard regulations
that apply to the work place.
·Operator has the ultimate responsibility for ensuring that anyone who works with
or near the equipment observes all the relevant safety precautions.
·All work must be carried out by trained personnel who are familiar with the
operation of the equipment.
·Incorrect operation of the equipment may lead to a hazardous situation which can
result in injury to the operator and damage to the equipment.
·Anyone who uses the equipment must be familiar with
oits operation
othe location of the emergency stop
oits function
orelevant safety precautions
·Before starting the operation
omake sure that no unauthorized person is stationed within the working
area.
oappropriate fire extinguishing equipment is clearly marked and close at
hand
·The work place must
obe suitable for the purpose
obe free from draughts
·Protect yourself and others!
·In case of malfunction call immediately for expert assistance!
·Keep this manual for future reference.
!
!

6
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
1.1 Contact information
Manufacturer:
Pemamek Oy
Lamminkatu 47
FI-32200 Loimaa
Finland
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Service:
Tel: [phone]
E-mail: [e-mail]
Internet:
www.pemamek.com

7
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
2 SAFETY
2.1 General Information
The plate butt welding line works as a push through system. The welding stations are very
open and the operator can walk on panel, so no extra platform is needed. Welding station
has a magnet clamping system in welding table and side positioning devices for fixing the
plates to the right position. Welding table has hydraulic pre-bending function. Welding
carriage is mounted to PEMA PBW-5000 welding portal in top of welding table.
Conveyor system is integrated with welding tables to feed plates through the system.
Integration with milling machines including plate push and measurement carriage of MM1
has been considered in this offer and in case of milling machine supplier other than PEMA
specification of conveyor line has to be reviewed.
Pema plate butt welding portal has one fixed main beam mounted in top of welding table.
Beam is standing with own legs on the floor. Welding carriage is moving along the beam.
Tandem SAW welding head and flux handling equipment is mounted on the beam.
The machine is intended for industrial and for indoor use only.
In case you intend to use the equipment for any other purpose, please confirm the suitability
from the manufacturer or his representative.
Any modification made to the construction of the machine can yield to a hazard and will
terminate the warranty.

8
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
2.2 Safety Instructions
DANGER
MOVING MACHINE –
Crushing Hazard
·Secure the working area before driving the machine!
WARNING
CLIMBING AND WORKING
ON WELDING PORTAL
–Falling Hazard!
·Use fall protection equipment!
·Check the condition of the fall protection equipment before use according
to the manufacturer’s instructions.
·Remove noticed defects immediately!
·Keep the platform clean from idle objects!
WARNING
NOISE –Excessive noise can
damage hearing
·When noise level emissions reach 80 dB (A) or above it can damage
hearing.
·Protect your ears. Use earmuffs or other hearing protection.
·Warn bystanders of the risk.
!
!
!
!
!
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9
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
WARNING
ELECTRIC SHOCK - can kill
·Install and earth the welding unit in accordance with applicable standards.
·Do not touch live electrical parts or electrodes with bare skin, wet gloves
or wet clothing.
·Insulate yourself from earth and the work piece.
·Ensure your working stance is safe.
·Disconnect main power before service or maintenance.
WARNING
ARC WELDING AND
CUTTING can be injurious
·Take precautions when welding.
·Ask for your employer’s safety practices which should be based on
manufacturer’s hazard data.
·Make sure the welding ground cable is connected securely.
·Read the safety instructions supplied with the welding equipment.
·DO NOT lubricate or service the welding equipment during the use.
!
!
!
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10
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
WARNING
FUMES AND GASES –can be
dangerous to health
·Keep your head out of the fumes.
·Use ventilation, extraction at the arc, or both, to keep fumes and gases
from you breathing zone and the general area.
WARNING
ARC RAYS - Can injure eyes
and burn skin
·Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
·Protect bystanders with suitable screens or curtains.
WARNING
WELDING SPARKS –Fire
hazard
·Ensure there is no inflammable material nearby.
·Ensure there is fire extinguishing equipment clearly marked and close at
hand.
!
!
!
!
!
!

11
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
WARNING
HOT WORK PIECE –can burn
·The work piece can be hot after welding or cutting.
·Use personal safety equipment.
WARNING
MOVING WORK PIECE –
entanglement and
crushing hazard
·Secure the working area before operating!
·Do not go near or under the moving work piece!
WARNING
LASER RADIATION –Can
injure eyes
·DO NOT have direct viewing of the beam.
·Ensure there are no reflections from mirror-like surfaces.
·Protect your eyes from laser radiation.
·Protect bystanders from laser radiation.
·Turn the laser off with key switch when the sensor head is not pointing at a
work piece.
·Class 3B device
!
!
!
!
!
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12
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
WARNING
BREAKDOWN OF THE
PNEUMATIC EQUIPMENT –
Loss of sight or hearing and
impact hazard
·Check the condition of the pneumatic system regularly and repair all
failures immediately.
·Repair all damaged components immediately.
·Use appropriate personal protective equipment.
WARNING
IN CASE OF AN EMERGENCY –
Stop machine with
emergency stop button!
·Emergency stop buttons are used in case of an emergency.
·Do not use emergency stop buttons for normal stopping of machine.
·Ensure safe working conditions before starting operation after emergency
stop!
2.3 Safety related functions
In case of an emergency the operation of the machine is stopped with emergency stop. The
reason for emergency must be solved before continuing operation.
All emergency stop buttons have similar function and stop the whole line.
After clearing the reason the emergency stop can be reset with a push button in the
main control panel.
!
!
!
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13
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
3 TECHNICAL INFORMATION
3.1 Machine structure
Pema PBW 5000/2 welding station consists of the following main parts:
1. Portal
2. Welding equipment
3. Coil stand
4. Ladder
5. Service platform
6. Flux tank
7. Electric cabinet
8. Control panel
Location of the main parts is shown in Figure 1
Figure 1 Main parts
6
1
4
3
2
2
7
5
8

14
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
3.2 Technical Data
3.2.1 Mechanical characteristics
Welding movement
5
000 mm
Height
5 365
mm
Width
8 625
mm
Weight
103
0
1
0 kg
Wire reels
3 x 100 kg
Cross slides
600 x 300 mm
3.2.2 Electrical characteristics
Main supply voltage
400 VAC / 50 Hz 3ph + N + PE
Power consumption
-
Main cabinet
45
kVA
-
Magnet cabinet
10 kVA
-
2 x PW1000 SD
90 kVA
-
Induction heater
127 kVA
-
Chiller
10 kVA
Required fuse size
-
Main cabinet
80 A (Slow)
-
Magnet cabinet
32 A (Slow)
-
2 x PW1000 SD
100 A (Slow)
-
Induction heater
100 A (Slow)
-
Chiller
32 A (Slow)
IP protection class
IP 54
3.2.3 Noise level
A
-
weighted sound power level
dB

15
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
3.3 Machine plate
Machine plate is attached to the side of the main control cabinet.
The machine plate contains the following important information:
Type:
Type of the machine
Ser. No:
Serial number of the machine
Art. No:
Article number of the machine
Man. Year:
Manufacturing year of the machine
Weight:
Weight of the machine
ph
Mains supply number of phases
Hz
Mains supply frequency
V
Mains supply voltage
A
Mains supply
fuse size
kVA
Power consumption of the Machine
NOTICE
Read and Understand the
INSTRUCTION MANUAL before
installing or operating
·The weight in the machine plate does not include accessories!
·Always mention the type, serial number and manufacturing year of the
machine when ordering spare parts.
!
!

16
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
4 INSTALLATION AND COMMISSIONING
CAUTION
Read and understand the
INSTRUCTION MANUAL
before installing or
operating!
·Observe the following safety precautions in addition to the standard regulations
that apply to the work place.
·Read all relevant manuals and safety precautions carefully before starting to
unpack and install the equipment.
·Ensure installation is carried out by suitable trained personnel.
·Check the machine weight from the technical data before lifting the machine.
·Observe and obey the lifting instructions that apply to the work place.
·Protect yourself and others!
4.1 Handling and storing
The machine parts are packed on a basis, suitable for lifting by crane and/or forklift. Use only
the designated lifting loops to lift up the machine.
Unload the machine from the packing and check the outer condition. Do not store the
machine outside or in damp places.
4.2 Installation and start-up
Installation of Pema PBW welding station is only allowed under the supervision of PEMA or
its authorized representative. Installation must be carried out according to installation
instructions in Pema lay-out and foundation drawings.
!
!

17
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
5 OPERATING INSTRUCTIONS
CAUTION
Read and understand the
INSTRUCTION MANUAL
before installing or
operating!
·Observe the following safety precautions in addition to the standard regulations
that apply to the work place.
·Operator has the ultimate responsibility for ensuring that anyone who works with
or near the equipment observes all the relevant safety precautions.
·Only a trained person is allowed to operate the machine.
·In case of an emergency stop the operation with emergency stop button!
·Ensure safe working conditions before starting operation after emergency stop!
·Before operation:
oSecure working area
oEnsure proper fastening of work piece
oEnsure the connection of welding ground cables.
oCheck the program parameters.
oCheck the condition and location of welding torch.
·Never leave machine unattended when operating!
·Protect yourself and others!
!
!

18
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
DANGER
COLLISION –can break the
equipment and cause injury!
·Secure the working area before operating the machine!
·In case of collision stop operation immediately and check possible
damages.
5.1 Safety functions
In case of an emergency the operation of the machine is stopped with emergency stop. The
reason for emergency must be solved before continuing operation.
5.1.1 Emergency stop function
Emergency stop switches off all machine functions.
Emergency stop also switches off the welding equipment.
Note1: The control voltage (24VDC) is remains after emergency stop!
Note2: The power of the flux heating system remains after emergency stop!
5.1.2 Emergency stop reset
Before resetting the emergency stop all actuated emergency stop buttons must be released.
Emergency stop button is released by turning it clockwise.
5.1.3 Control panel in MC1
In the door of the main control cabinet there is a control panel for controlling the main
movements of the machine.
Control panel in MC1 is shown in Figure 2 and it has the following functions:
1. Emergency stop button
2. Flux pressure tank on/off
a. Signal light is lit when pressure tank is enabled.
3. Emergency stop reset / PBW
4. Emergency stop reset / Conveyor
!
!

19
Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
Figure 2 Control panel in MC1
5. Main switch
- On; turn clockwise (green signal light is lit,
reset light is lit in few minutes after start)
- Off; turn counterclockwise (green signal
light turns off)
12
3 4
5

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Author: TLe Code-Revision: D23399-0 Date: 8.1.2015
Copyright 2013 © Pemamek Oy Ltd This document is confidential and can neither be copied nor communicated to any third
person without written consent of Pemamek Ltd.
Any use of this document is subject to prior written permission of Pemamek Ltd. Title to this document belongs to Pemamek
Ltd.
5.1.4 Control panel RCA1
Functions of the welding heads and motorized cross slide are controlled with control panel
RCA1.
1. Automatic welding Start / Stop
- Signal light is lit when the automatic working cycle is on
- Welding is stopped by pressing Stop button 3 seconds
- WeldControl fault codes are reset by pressing Stop button for 3 seconds
2. Emergency stop button
3. Flux suction and Flux drop
4. Selection switch for manual movement
a. Torch longitudinal manual movements forward/ backward
b. Manual up/down/left/right for torches
Figure 3 Control panel RCA1
2
1
3
4
6
7
5