PEMA WS2 User manual

Welding Station PEMA WS2
Instruction Manual

2
Author: TLe Code-Revision: D23000-0 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: D23000-0 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........................................................................13
3Technical Information ........................................................................................14
3.1 Machine structure ................................................................................14
3.2 Functional Description..........................................................................17
3.3 Technical Data.....................................................................................21
3.3.1 Mechanical characteristics.................................................................21
3.3.2 Electrical characteristics ....................................................................21
3.3.3 Noise level.........................................................................................21
3.4 Machine plate.......................................................................................22
4Installation and Commissioning .........................................................................23
4.1 Handling and storing............................................................................23
4.2 Installation and start-up........................................................................23
5Operating Instructions........................................................................................24
5.1 Safety functions ...................................................................................25
5.1.1 Emergency stop function ...................................................................25
5.1.2 Emergency stop reset........................................................................27
5.2 Control functions..................................................................................28
5.2.1 Control panel in MC1.........................................................................28
5.2.2 Control panel OP1.............................................................................30
5.2.2.1 OP1 Touch panel structure....................................................32
5.2.2.2 Welding information...............................................................33
5.2.2.3 Work piece diameters............................................................34
5.2.2.4 Alarms...................................................................................35
5.2.2.5 Service ..................................................................................36
5.2.2.6 Touch panel security functions...............................................37
5.2.3 Control panel in MC11 and MC21......................................................38
5.2.4 Control panels RC11 and RC21.........................................................39
5.2.5 Welding control with touch screen OP11 and OP21...........................40
5.2.6 Flux system control............................................................................41
5.3 Adjustments.........................................................................................42
5.3.1 Flux heating adjustment.....................................................................42
5.3.2 Change of wire and adjustments of wire feeding system....................42
5.3.3 Adjusting contact jaw nozzle..............................................................43
5.3.4 Adjusting wire feeder.........................................................................43
5.3.5 Adjusting wire straightener.................................................................44
6Operation and programming functions...............................................................45
6.1 System overview WeldControl 500.......................................................45
6.1.1 Startup...............................................................................................45
6.1.2 Shutting down....................................................................................45
6.1.3 MAF...................................................................................................46
6.2 User interface pages and functions......................................................47

4
Author: TLe Code-Revision: D23000-0 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.
6.2.1 Sidebar and general UI functions.......................................................47
6.2.2 Start page..........................................................................................48
6.2.3 Operator page ...................................................................................49
6.2.3.1 Joint tracking tab....................................................................50
6.2.3.2 META settings.......................................................................51
6.2.3.3 Multi-pass tab........................................................................53
6.2.3.4 Position and distance tab.......................................................54
6.2.3.5 Settings tab............................................................................55
6.2.4 WPS editor ........................................................................................57
6.2.4.1 Torch phase and square-wave voltage settings.....................59
6.2.4.2 Movement settings.................................................................60
6.2.4.3 Multipass editor .....................................................................61
6.2.4.4 Multipass dynamic fill and cap layers.....................................63
6.2.4.5 WPS info ...............................................................................65
6.2.4.6 Parameters overview.............................................................66
6.2.5 Start/Stop parameter editor................................................................67
6.2.6 Data collection...................................................................................69
6.2.7 System messages .............................................................................70
6.2.8 Settings .............................................................................................71
6.3 Welding................................................................................................72
6.3.1 WPS creation.....................................................................................73
6.3.1.1 Define welding parameter sets...............................................73
6.3.1.2 Setup multipass table ............................................................75
6.3.2 Seam tracking sensor calibration.......................................................76
6.4 Miscellaneous......................................................................................78
6.4.1 Reset.................................................................................................78
6.4.2 WeldControl 500 backup system .......................................................78
7Maintenance and Service Instructions ...............................................................80
7.1 Introduction..........................................................................................80
7.2 Gear locations and maintenance instructions.......................................81
7.2.1 Gear locations....................................................................................81
7.2.2 Gear maintenance instructions ..........................................................82
7.3 Linear guides maintenance..................................................................84
7.4 Welding equipment maintenance.........................................................86
7.5 Hydraulic aggregate maintenance........................................................89
7.5.1 First hours of operation......................................................................90
7.5.2 Changing of oil...................................................................................91
7.6 Oil Specifications .................................................................................93
7.6.1 Lubricating the linear motion guides...................................................94
7.6.2 Tables for gear oil selection...............................................................96

5
Author: TLe Code-Revision: D23000-0 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: D23000-0 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

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Author: TLe Code-Revision: D23000-0 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
Pema WS2 welding station is designed for simultaneous welding of two circular outside
seams. Station includes WS2 heavy duty welding manipulator with one-side welding
platform. Platform is equipped with two Tandem SAW welding heads to weld simultaneously
two seams with same rotation. Welding platform can be moved along rails and operate with
integrated roller beds equipped with anti-creep function.
The machine is equipped with a control system which combines welding parameter control,
welding data storage, remote control and other advanced welding functions into the
machines control interface.
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: D23000-0 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 PLATFORM –
Crushing Hazard
·Secure the working area before driving the platform!
·Observe loading instructions before loading the platform.
·DO NOT stay on the work piece!
DANGER
MOVING MACHINE –
Crushing Hazard
·Secure the working area before driving the machine!
·DO NOT enable the extended vertical movement if it not necessary.
DANGER
FALLING MACHINE –
Crushing and impact Hazard
·Obey local regulations for passenger hoists!
·Observe loading instructions before loading the platform.
·DO NOT overload the platform.
·Ensure daily the proper fastening of the safety hooks in the rail car.
·Obey the preventive maintenance instructions!
!
!
!
!
!
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9
Author: TLe Code-Revision: D23000-0 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
CLIMBING AND WORKING
ON PLATFORM
–Falling Hazard!
·DO NOT overload the platform.
·Keep the platform clean.
·Use fall protection equipment!
WARNING
FALLING OBJECT –Impact
Hazard!
·Keep the platform clean from idle objects.
·Do not store idle tolls on platform.
·Ensure the proper fastening of wire reels before starting welding.
·Use helmet when working under the platform!
WARNING
NOISE –Excessive noise can
damage hearing
·When noise level emissions reach 85 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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!
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10
Author: TLe Code-Revision: D23000-0 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 workpiece.
·Ensure your working stance is safe.
·Disconnect main power before service or maintenance.
WARNING
HYDRAULIC LEAK –Skin
injection hazard
·Protect hands and body from high pressure fluids.
·Repair all possible leaks immediately.
·Relieve pressure before disconnecting hydraulic or other lines and tighten
all connections before applying pressure.
·In case of accidental skin injection, seek immediate surgical treatment.
·Failure to follow this warning can result in amputation or serious injury.
!
!
!
!

11
Author: TLe Code-Revision: D23000-0 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
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.
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.
!
!
!
!
!
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12
Author: TLe Code-Revision: D23000-0 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
WELDING SPARKS –Fire
hazard
·Ensure there is no inflammable material nearby.
·Ensure there is fire extinguishing equipment clearly marked and close at
hand.
WARNING
HOT WORK PIECE –can burn
·The work piece can be hot after welding or cutting.
·Use personal safety equipment.
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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13
Author: TLe Code-Revision: D23000-0 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.
Please see further instructions in chapter Safety functions.
!
!
!
!

14
Author: TLe Code-Revision: D23000-0 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 WS2 welding station consists of the following main parts:
1. Rail car
2. Column
3. Operator platform
4. Ladder
5. Main control cabinet MC1
6. Hydraulic aggregate
7. Welding head 1
8. Welding head 2
9. Control cabinets MC11 and MC21
10. Control panels OP1, RC11, RC21 and WeldControl 500 panels
Location of the main parts is shown in Figure 1 and Figure 2.

15
Author: TLe Code-Revision: D23000-0 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 1 Main parts a

16
Author: TLe Code-Revision: D23000-0 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 Main parts b

17
Author: TLe Code-Revision: D23000-0 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 Functional Description
Pema WS2 welding station is designed to be operated according to the following steps.
1.
1. Positioner
to loading position
2.
2. Load work piece

18
Author: TLe Code-Revision: D23000-0 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. Check platform height to avoid collision!
4. Positioner / Work piece to welding position.
4.
5. Check platform height and position
6. Welding heads to welding position

19
Author: TLe Code-Revision: D23000-0 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.
7. Adjust weldi
ng head position
6.
8. Setup welding parameters
9. Enable welding sequence

20
Author: TLe Code-Revision: D23000-0 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.
7.
10. Automatic welding
11. Seam tracking
8.
12. Positioner / Work piece to loading position
13. Unloada work piece