Tecnar Rotoweld 3.0 Manuale utente
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MAINTENANCE
MANUAL
Automated welding
work cell for
pipe spool
prefabrication
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
1 FLEXIBLE CABLE CARRIER MAINTENANCE .......6
1.1How to replace damaged covers and broken links ................................. 6
2. TRACK SYSTEM MAINTENANCE.........................9
2.1 Chain for motorization maintenance......................................................... 9
3. WELDING CARRIAGE MAINTENANCE............ 10
3.1 Water cooler maintenance ....................................................................... 10
3.1.1 Routine maintenance................................................................................................. 10
3.1.2 Reservoir coolant level............................................................................................... 10
3.1.3 Clean or replace the pump inlet strainer ................................................................ 10
3.1.4 Pump motor ................................................................................................................ 12
3.1.5 Heat exchanger .......................................................................................................... 12
3.2 Gas flow meter maintenance ................................................................... 13
3.3 Wire feeder maintenance......................................................................... 14
3.4 Pressurized flux feed tank maintenance ................................................. 15
3.5 STT arc sensor maintenance .................................................................... 18
3.6 Pyrometer maintenance............................................................................ 19
3.7 Foot pedal maintenance........................................................................... 19
3.7.1 Main & Secondary positioner: .................................................................................. 19
3.7.2 Carriage:...................................................................................................................... 20
3.8 Carriage wheels maintenance ................................................................. 20
3.9 Motorization sprocket maintenance ....................................................... 22
3.10 Welding manipulator maintenance ...................................................... 23
3.10.1 X Y position torch reference ................................................................................... 24
3.10.2 Servo Control timing belt........................................................................................ 24
3.11 Root & Fill torch maintenance................................................................ 28
3.11.1 Nozzle, contact tip, gas diffuser & liner replacement.......................................... 28
3.11.2 How to replace QUICK LOADª liners into retainer pin ..................................... 29
3.11.3 How to replace conventional liners ....................................................................... 30
3.12 SAW fill torch maintenance.................................................................... 31
3.13 Control station Maintenance.................................................................. 32
3.13.1 Monitor and computer enclosure maintenance .................................................. 32
3.13.2 Fan filters maintenance ........................................................................................... 38
4 POSITIONERS MAINTENANCE.......................... 39
4.1 Rotative ground maintenance.................................................................. 39
4.2 Gas cylinder pressure regulator maintenance....................................... 40
4.3 Self centering chuck maintenance .......................................................... 41
4.4 Gears assembly maintenance .................................................................. 41
4.4.1 Gear lubrification........................................................................................................ 42
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
4.4.2 Gear box maintenance .............................................................................................. 42
4.4.3 Gear backlash maintenance...................................................................................... 43
4.6 Pillow blocks maintenance ....................................................................... 43
4.7 Root power source maintenance............................................................. 45
4.7.1 STT II Preventive maintenance.................................................................................. 45
4.7.2 STT II input filter capacitor discharge procedure................................................... 46
4.7.3 STT module Power wave S500 Preventive maintenance ...................................... 47
4.8 Fill power source maintenance................................................................ 48
5 PIPE STANDS........................................................ 49
5.1 Hydraulic cylinder, hoses connection maintenance ............................. 50
5.2 Locking hydraulic valve maintenance..................................................... 50
5.3 Wheels maintenance................................................................................. 50
5.4 Flux pan maintenance............................................................................... 50
6 MAINTENANCE SCHEDULE RECOMMENDED51
6.1 Daily............................................................................................................. 51
6.2 Weekly ........................................................................................................ 51
6.3 Monthly ....................................................................................................... 52
6.4 Quarterly..................................................................................................... 52
6.5 Annually ...................................................................................................... 53
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
Other Rotoweld documentation:
¥ Rotoweld Startup Manual (40101-00059); requirements, step by step and
startup electrical installation.
¥ Rotoweld Cold Installation Manual (40101-00032); requirements and step by
step mechanical installation.
¥ Rotoweld User interface (40101-00033); detailed information of all the menus
and sub menus.
¥ Rotoweld Operation Manual (40101-00034); detailed information on how to
weld with the system.
¥ Rotoweld Troubleshooting Manual (40101-00035); in case of hardware issues.
¥ Rotoweld Welding Manual (40101-00036); welding program creation plus
welding tips using the Rotoweld.
¥ Rotoweld Technical Description Manual (40101-00037); hardware description.
¥ Rotoweld Prodatalog Manual (40101-00056); viewer for all the welding data
history logged.
¥ Rotoweld Maintenance schedule (40101-00058).
¥ Rotoweld Suggested Welding Parameters (40103-00252 TO 40103-00257);
baseline parameters for welding programs.
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
This system is easy to maintain and will deliver many years of operations.
We are proposing the actions required in time in a table at the end of the document.
To begin, components location will be showed with description explanations related
with maintenance.
Furthermore, detailed actions required to perform on each of the sub components.
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
1 FLEXIBLE CABLE CARRIER MAINTENANCE
This is important to keep the base clean where the cable carrier is moving to avoid early
abrasion of the plastic links, also visual inspection for broken covers or links to be
replaced.
The articulated cable carrier is a flexible conduit that contains the electrical cables, gas
lines and connectors required between the welding carriage and the main positioner.
1.1How to replace damaged covers and broken links
1. To raise the lids of the Cable track
management system, insert a flat
screwdriver in the appropriate hole
(see picture) and pull down at each
extremity of the lid.
2. Pull down at each extremity of the
lid
3. For removing a section raise at least 3 lids and remove two of them.
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
4. Insert flat screwdriver in the side
panel between the two sections and
push carefully to the outside and pull
out the two sections from each other.
5. Push carefully to the outside
6. Pull out the two sections from each
other.
7. For the installation of the flange, raise 3 lids and remove 2 of them.
1
2
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
8. To insert the flange in the chain, insert one side at the time. Make sure the
sections are correctly inserted.
Regular lids
Flange lids
Note:
We have included with the Nylatube 12
regular and 2 flange spare lids. You
have two different lids. The one without
the little ears is the one for the flange
and the other one is for the regular
chain.
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
2. TRACK SYSTEM MAINTENANCE
Keep the surface of the track system clean, use a broom, compress air or vacuum. This
assure the welding carriage and pipe stands can move along the tracks smoothly.
2.1 Chain for motorization maintenance
Validation of the chain tension, we put the carriage at a certain distance of the end of the
track and we determine an amount play we suggest.
Chain tensioner localization
Chain tension
adjusting nut
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ROTOWELD 3.0 Ð MAINTENANCE SCHEDULE MANUAL (40101-00058--00)
3. WELDING CARRIAGE MAINTENANCE
3.1 Water cooler maintenance
3.1.1 Routine maintenance
1. Remove accumulated dust and dirt from the internal components of the cooler by
blowing it out with a low-pressure air hose or removing the dust and dirt with a
vacuum hose.
Validate if the fans are operating
3.1.2 Reservoir coolant level
The reservoir volume should be checked monthly.
1. Remove the reservoir fill cap and check the coolant level. The reservoir is full
when the coolant level is just below the reservoir fill opening. Keep the reservoir
full, especially after disconnecting the water lines or changing the accessory
being cooled.
3.1.3 Clean or replace the pump inlet strainer
Warning
The pump head has a "built in" strainer on the inlet side of the pump. It is
recommended to clean or replace the pump inlet strainer at least once a year.
1. Drain coolant from the reservoir and open the case of the water cooler.
Located the pump.
Fan location
Altri manuali per Rotoweld 3.0
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Indice
