rw30110 rw30112 rw30120 robotic welder
Contents
1. 440 mm 17 3 in ETE Mm AE N RE EE N EE RE ER E EE RE M 25 kg 55 Ibs Charlie Control Box Weight with 5m of cable ER ER RE Ee RE Ee ee enne nennen 3 kg 6 6 Ibs Pull Gun Weight without wire reel 12 kg 26 4 Ibs RW30120 xu M 230V 60Hz 150W EN AEE qa RN omm 1250 mm 49 2 in T GOE IEP RE T E 350 mm 13 7 in EE EE EE EE EE EO N EE 1510 mm 59 4 in EE EE m E 830 mm 32 6 in ge dT 430 mm 16 9 in 34 kg 74 9 165 Charlie Control Box Weight with 5m of cable das kg 6 6 Ibs Pull Gun Weight without wire reel bc tiri amada ed add ioni 17 kg 37 4 lbs NOTICE In addition to the Safety Precautions in this manual observe the following for equipment protection and care Check that the pin holder is not burnt or not holding the pin tightly If not remove the ring holder clean all the parts and squeeze the fingers of the pin holder together e Check the cables on the gun from time to2. ie 22 eu eigege EURE 24 RPM NER d 25 MESEN T P eae ee 26 TN 27 RW30110 7 RW30112 PARTS HET amp ILLUSTRATION 29 RW30120 PARTSEISTSIELUSTRAF ION uuu er 30 RW30110 RW30112 RW30120 LEFT SIDE TIEEDSTISATIODJ a ei 21 RW30110 RW30112 RVV 30120 RIGHT SIDE ILLUSTRATION u u ea ee ee ee 32 RW30110 REW30112 RW30120 MOTOR BOARD ILLUSTRATION is eek seke ER N ee 33 RW30110 7 RW30112 RW30120 SUPPORT PLATFORM ILLUSTRATION a ea en 34 RW30110 RW30112 RW30120 SUPPORT ASSENBLY see ee pen 35 OLADPIEASSEMBLIRS 36 FR AA RP OR EE RE OE EE EE ON 37 TOR NMST PULEGEND unu 38 WARRANTY AR EE u 39 SERVICING THE STANLEY ROBOTIC WELDER This manual contains safety operation and routine mainte nance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Pl
3. Set point Position O2 The torch cans only moves on the X axis OPERATION Set point Position O3 The torch cans only moves on the Z axis PO4 ORCI Or PO4 TORCH Set point Position O4 This point should only be set vertically from point Position O1 with automatic tone of this position LENGTH xxmm WIDTH xxmm Display the length and the width of the setting shape 1 mm equals to 0 04 inch SURROUND YES VALID SURROUND NO VALID Surrounding selection YES or NO continuing bead from Position O1 to Position O2 then to Position O3 then to Position O4 and finally to Position O1 NUMBER BEADS XX Display the number of beads that will be made during the resurfacing the surrounding is not included in this number It is possible to modify this number if needed by pressing or V SPACING x xx mm WELD TIME xxmin 18 Display of the step between each bead distance in mm 1 mm equals to 0 04 inch and estimate welding time in minutes BEADS 1 BY 1 YES VALID BEADS 1 BY 1 NO VALID Welding mode choice bead by bead lt YES or continue NO If YES welding bead by bead Torch is moving at the be ginning of the next bead right after previous bead is done If NO beads are done in continue WELDING CYCLE VALID If VALID key is pressed Torch will move to starting p
4. Left Support Assembly Part No 66543 Charlie Heater Charlie Control Box Part No 70722 Part No 65446 35 CLAMP ASSEMBLIES Frog Clamp Assembly Part No 66546 Right Fixed Clamp Left Pivot Clamp Part No 66547 Part No 66548 Right Self Alignment Clamp Part No 66544 Left Self Alignment Clamp Part No 66545 36 TORCH SUPPORT PARTS LIST amp ILLUSTRATION Torch Support Assembly Part No 69815 Pinion Rack Torch Clamp Pinion Rack Includes 2 5 Torch Clamp Includes 6 10 15 18 Jointed Wrist Assy Includes 1 5 11 14 16 17 19 20 37 TORCH SUPPORT PULL GUN ILLUSTRATION Torch Support Pull Gun Part No 69837 38 WARRANTY IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty 39 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 503 659 5660 FAX 503 652 1780 www stanleyhydraulic com
5. 30 RW30110 RW30112 RW30120 LEFT SIDE ILLUSTRATION Left Side Assembly Part No 69818 ay 66524 refi Side Pie moon 3 4 T 10 ES _2_ _6_ 8 MON _10_ 2 69817 Motor Card Module 69826 Charlie box take off Conical Stop Bearing Flange Motor X Axis 1 Power On Off Switch Motor Support Carry Handle Assy Fold Down N WIWININI N INININININININJ A gt O cO CO N O cO Oo ad S 70720 Thermostat Red 71000 Thermostat Blue 31 RW30110 RW30112 RW30120 RIGHT SIDE ILLUSTRATION 13 15 14 2 I I Right Side Assembly Part No 69819 ay 1 66525 Right Side Plate 69830 Power Supply 64956 Bearing Support 64955 Carry Handle Assy z Fold Down Conical Stop 32 RW30110 REW30112 RW30120 MOTOR BOARD ILLUSTRATION Motor Board Assembly Part No 69817 1 64961 2 Motor Board 2 64969 1 Interconnection Board 33 RW30110 RW30112 RW30120 SUPPORT PLATFORM ILLUSTRATION Support Platform Support Platform Assembly Y Rail Part No 69816 Jointed Wrist Bracket Bearing Support Y Axis Motor Bearing Flange Y Axis Screw Axis Bracket Nut Y Bump Stop Coupling Y Axis Steel Roller Axle Ecentric Axle Bearing Conical Stop Screw FHC 1 1 1 1 1 1 1 1 1 1 4 2 2 1 2 2 34 RW30110 RW30112 RW30120 SUPPORT ASSEMBLY Right Support Assembly Part No 66542
6. STANLEY RW 30110 RW30112 RW30120 ROBOTIC WELDER p _ a werf de EE SAFETY OPERATION AND MAINTENANCE USER S MANUAL Copyright The Stanley Works 2008 TABLE OF CONTENTS SAFETY YOL NE ERE eH MEMINI ee MEME 5 LOCALE AFET REGLLATIONS ne 5 PEN PRESAUTION SS aa en ee ea uD 6 PER TON unpas 11 11 PREPARING THE KAM FOR OPERATION uuu TT DE 11 CEANN ERS ION 11 CL IP YER 8 A 12 CONNECTING THE WIRE FEED WELDING TIP IO THE RWU vn 13 SETTING THE TIEK O UP u ee ee ee IDEE 13 OPERATING THE RW30 amp THE CHARLIE CONTROL UNIE ss sees sos ee ee ee een 14 INFORMATION ON DATA TRACKING 16 MI DIL DAE SENTE eee eee ee ee rer 16 AUTOMATIC DATA ENTRY ee 16 OPEL see DE ee N Ge N N Ge EE EE Ee Ge EE N OE EE E 17 STOP AND RESTART OF WELDING E OE een 20 ERROR NE OAOE ER OE 20 EQUIPMENT MAINIENANGE se J 22 IROVUBLE AN
7. Switch of the electricity supply or stop the machine before carrying out any maintenance on this machine Install and ground this machine correctly and in compliance with the instruction manual and with local governmental or national legislation Check the ground of the power supply regularly Check that the ground wire of the mains cable is correctly connected to the ground terminal in the connection box or that the connector is connected to an output that is correctly grounded When connecting the input first connect the ground Double check the connections Check the state of the mains lead and the insulation of the wires regularly replace the lead immediately if it is damaged as bare wires could cause fatal accidents Switch off the machine when not in use Do not use cables that are worn damaged under dimensioned or badly spliced Do not wrap or carry cables around your body If the work piece is to be grounded ground it with a separate cable do not use the clamp or the cable of the work piece Do not touch the electrode if you are in contact with the work piece the ground or another electrode of another machine Only use properly maintained equipment Repair or replace any damaged components immediately Carry out SAFETY PRECAUTIONS maintenance work on the machine according to the instructions manual Wear a safety harness when working above ground Anchor all panels and covers s
8. cause EQUIPMENT TO OVERHEAT 1 Allow time for equipment to cool 2 Reduce the current or operating cycle before restarting to weld 3 Respect the rated operating cycle 10 OPERATION OVERVIEW The RW30 is an electric arc welding controller to be used for gas free sheathed wires It is unbeatable on railroad worksites for performing maintenance and repairs on rails and track devices railways tramways metros shuttles etc RW30 after programming automatically executes the reloading of worn sections and accidental surface defects on treads rail butt joints lateral wears track devices or the deposits of safety stainless steel beads The RW30 controls the motorized movement of the welding head in the X axis length and Y axis width for work over a surface area of 400 mm by 350 mm The RW30 frame is made of composites aluminum and stainless steel This principle of construction was retained to combine lightweight and excellent behavior under bad weather conditions The RW30 is sold as standard with 1 RW30 Frame 1 Rail Gripping Set 1 Torch Support for the Pull Gun 1 Charlie Control Box with its Connecting Cable Torch Support 11 PREPARING THE RW30 FOR OPERATION CLAW VERSION 1 Position the claw on the rail Adjustment Tighten Reference Supports 1 OPERATION 4 Set anti slip bolt CLAMP VERSION 1 Disengage the stop pin on the mounting bracket insert the rac
9. from left to right lt lt Examples moving the cursor from right to left Examples moving back through the operator dialogue In welding mode WELDING CYCLE STOP CYCLE RESTART BEAD XX XX RESTART CYCLE WELDING CYCLE Example momentary stop in the welding cycle WELDING CYCLE STOP CYCLE END LAYER N X BEAD XX XX RESTART CYCLE LAYER N Y VALID Example definitive stop in the welding cycle 19 OPERATION LANGUAGE SETTING Different languages may be accessed and selected when the first message HELLO appears by using the PLUS key Translations of the message HELLO into different languages according to geographic areas are then displayed each time the PLUS key is pressed SETTING THE DATE AND TIME To set the date and time scroll until DATE AND TIME is displayed Set the date and time by pressing the PLUS or MINUS keys Confirm using the VALID key Depending on how the unit is configured the DATE TIME message may not be displayed if the most succinct level of operator dialogue is used PRINTING DATA To print the data stored in memory 1 Make sure that the unit is connected to a power source 2 Connect either a serial printer 9 pin connector or a parallel printer if the unit is equipped with a parallel interface 25 pin connector When using a serial printer make sure 1 that the serial printer communication parameters are set correctly 9600 bauds no parity 8 data bits
10. stickers and tags attached to the tool and hose These safety precautions are given for your safety Review them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided on page 5 The RW30 Robotic Welder will provide safe and dependable service if operated in accordance with the instructions given this manual Read and understand this manual and any stickers and tags attached to the tool before operation Failure to do so could result in personal injury or equipment damage SHOCK HAZARD Contact with live electrical parts can cause fatal accidents or serious burns The electrode work piece circuit is live when electricity is supplied to the outlet The supply circuit and the internal circuits of the machine are also live when the current is switched on When welding the wire the feeder the feeder control panel and any metal parts in contact with the wire are also live Equipment that is incorrectly grounded constitutes a danger Do not touch any live part Wear insulated safety gloves that are both dry and without any holes plus body protection Insulate yourself from the work piece and from the ground with appropriate insulation materiel to prevent any physical contact with either the work piece or the ground
11. weld container like objects such as tanks drums or pipelines unless they have been properly prepared Connect the cable to the work piece as near as possible to the welding area to avoid having to feed the current over long hazardous distances which could cause electrocution or fire SAFETY PRECAUTIONS Do not use welding equipment to defrost frozen pipes When notin use remove the rod from the electrode holder Wear grease free clothing such as leather gloves a heavy shirt hemless trousers safety footwear and headgear Before welding remove all flammable substances from your pockets such as matches or any type of lighter EXHAUST FUMES Exhaust fumes from the motor can cause fatal accidents Motors emit toxic exhaust Use the equipment outdoors in an open and well ventilated area When using the equipment indoors evacuate the exhaust fumes well away from any fresh air intake vents MOTOR FUEL Do not top up with fuel while smoking or when near a source of sparks or a naked flame Do not fill the tank to the brim leave space for the fuel to expand Stop the motor and let it cool down before checking or topping up with fuel Do not spill fuel If fuel spills clean it up before starting the motor MOVING ENGINE PARTS Moving engine parts such as fans rotors and driving belts can cause serious hand injury Articles of loose clothing can also get caught up in them Keep all trap doors panels prop
12. 1 stop bit 2 that the correct serial cable is used 3 Make sure the printer is ONLINE and READY 4 Turn on the unit and scroll to the IMPRESSION step available by the automatic detection by the system of the presence of a printer 5 Select the output mode Welding number Operator ID Date All 6 Confirm choice using the VALID key 16 INFORMATION ON DATA TRACKING MANUAL DATA ENTRY Some areas may require manual data entry Operator stamp Location district code line mileage point track and rail line Type of metal deposition Type of power source Type of rail Type of resurfacing Two types of manual entries are possible 1 Character by character mode Pressing the PLUS or MINUS keys causes the allowable characters to be displayed each character is confirmed by the VALID key 2 Pre programmed values Pressing the PLUS or MINUS keys causes the various pre programmed values to be displayed Each value is then confirmed by pressing the VALID key When the characters appear this indicates characters available for manual character by character entry AUTOMATIC DATA ENTRY Data can also be acquired by reading bar codes Depending on the software installed in the unit and according to the user companies specifications data may be acquired automatically Depending on these specifications data may be required or optional The software includes a standard operator descript
13. BN Only 1 16 in 1 6 mm Rail Build Wire Charlie to Robot Cable All Models Welding Cable Negative 15 M UM Welding Cable Positive 15 M Wire Feed Cable Miller Lincoln Pre Heater Carbon Steel F RW30110BN Only HERR eee Wire Feed Cable 0X0 RW30110BN PGA Power Supply Cable Pull Gun Only Lincoln HD Wire Feed Cable RW30110 RW30112 RW30120 Models Only Screen for Charlie Wire Feed Cable Pull Gun Head Power Cable without End Plug Torch 4 M Charlie to Robot Cable Kit Stick Out Gauge Serial amp Parallel Option Stick Holder Rotary Head Kit Pre Heater Ramp Welding Current Kit Pull Gun Inverter Torch Tool Case with Tools Glasses Mask Automatic Darkening Mask Manual Charlie Main Board Cable 10 M Generator to Robot Pre Heater Carbon Steel Frogs 26 Trigger Cord 70780 Power Cord Primary 70781 Rack 66551 Includes Pinion Below Pinion 66551 Includes Rack above Motor Board Cable 70786 PGA Cable 70787 Charlie Cable 68208 Power Supply Cord 70785 Y axis Power Supply Cord 70784 X Axis Power Supply Cord 70783 Internal SPARE PARTS 2f Charlie Box 65446 Motor Board 64961 Power Supply 69830 No Off Switch 69831 Motor X 64963 Motor Y 64962 Power Cord LED 70782 Charlie Box Fuse 70774 SPARE PARTS Bearing Y Axis 66533 Pad Clamp 70775 Bearing X Axis 64950 Coupling Y Axis 66535 Nut 66529 Power Cable 115V 68209
14. D cm mn 30 Welding speed displayed cm min 1 cm min equals to 0 4 inch min adjustable value in the parameter menu RETRACTING POINT Selection of Torch position after the welding of each bead evacuation point The setting is done as PO1 TORCH Set point position O1 PO2 TORCH Set point position O2 PO3 TORCH Set point position O3 TRIANGLE NO VALID Or TRIANGLE YES VALID Triangle can be weld if lt NO set point Position O4 If lt YES needed number of beads will be display PO4 TORCH Set point position O4 NUMBER BEADS XX Display the number of beads that will be made during the resurfacing the surrounding is not included in this number It is possible to modify this number if needed by pressing V OPERATION SPACING x xx mm WELD TIME xxmin Display of the step between each bead distance in mm 1 mm equals to 0 04 inch and estimate welding time in minutes Setting can be made up to 3 shapes SETTING SHAPE X NO VALID SETTING SHAPE X YES VALID Option to repeat the same shape or change the size and shape as previously indicated RETURN TORCH TO INITIAL POINT Torch moves to starting point of the first bead WELDING CYCLE BEAD xxx Shows the bead s number in welding xxx and the to tal number of beads of the whole resurfacing of the area yyy During welding MOVE TORCH Torch will moves t
15. ENT OK gt UNVALID POINT RETURN TO PO1 Position O4 must be vertical from Position O1 When the beads number has been modified The step is bigger than the maximum allowed step Raise the number of beads The step is smaller than the minimal allowed step Reduce the number of beads These 2 values can be modified in the parameters menu ERROR BEADS NUMBER gt 3 The number of beads must be superior at 3 DIV ERROR Show an inappropriate calculation not allow by the software 21 TROUBLESHOOTING The lt ON gt TRANSLAMATIC s green light does not work PROBABLE CAUSE CHECKS AND REMEDYS ON OFF switch Check its good position and its good working order Check the primary alimentation The ON TRANSLAMATIC s green light works but the Charlie box does not work Link cable between the TRANSLAMATIC and Check the connexions or and change the cable the Charlie box Charlie box s fuse Respect the ON process order Put ON the Translamatic before putting the Charlie box ON Interface card Check if the interface card alimentation s green light is alight during the cycle Call our After sales Dpt Stabilized alimentation out of service Check the alimentation s tension normally 27V in OG Call our After Sales Dpt The welding support head does not move on one or several axis PROBABLE CAUSE CHECKS AND REMEDYS Charlie box Try with another Charlie box Charlie box keyboard Check the go
16. Male Crosspin Knob M10 45 No Photo Beam Souriau 70779 73158 TEMPLATE GUAGE Template guage for setting the stick Template guage with 4 height set Removing wire feed tip using hex in height see page 13 tings indicated in milimeters and template guage inches i E STER POWER SWITCH 2009 OR EARLIER loff on Master Power Master Power Switch On this picture indicates the fan 1s on but the outside Master Power Switch Switch Off ambient temperature is below 10 C 14 F allow the unit to warm up until the and Fan On left power light comes on indicating the unit is safe to use Do not operate the unit when the left power light is off with the power switch turned on MASTER POWER SWITCH 2010 OR LATER 4 2 J 227 Master Switch OFF Power is On Heater Activated Unit On Heater Activated Unit On Heater Off 28 oO OO NOU W N Rear Beam Front Beam Ventilation Box X Axis Slide X Axis Screw Coupling Y Axis Chain Conduit Clamp for Chain Conduite not show Back Cover Front Cover 29 RW30110 RW30112 PARTS LIST amp ILLUSTRATION Cover Left Side Assembly Right Side Assembly Support Platform Assembly Left Support Right Support Torch Support Assembly Frog clamp Assy RW30120 PARTS LIST amp ILLUSTRATION Rear Beam Front Beam Protection Plate X Axis Slide X Axis Screw Coupling Y Axis Chain Conduit Clamp for Chain Con duite not show Hood 1252
17. are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equip ment IMPORTANT This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situa tion which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result in minor or moderate injury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage or damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the
18. ease read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER MAKE NO ALTERATIONS OR MODIFICATIONS TO THE TOOL SERIOUS INJURY COULD RESULT FROM IMPROPER CHANGES MODIFICATIONS OR ALTERATIONS COULD ALTER THE PERFORMANCE OR INTEGRITY OF THE TOOL IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanleyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD Hydraulic Tools DICHIARAZIONE DI CONFORMITA I the undersigned Ich der Unterzeichnende Weisbeck Andy Je soussign El abajo firmante lo sottoscritto DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG Surname and First names Familiennname und Vornamen Nom et pr nom Nombre y apellido Cognome e nome hereby declare that the equipment specified hereunder best tige hiermit da erklaren Produkt genannten Werk oder Ger t d clare que l quipement vis ci dessous Por la presente declaro que el equipo se especifica a continuaci n Dichiaro che le apparecchiature specificate di seguito 1 Category Robotic Welder Kategorie Cat gorie Categoria Categoria 2 M Make Marke Marque Marca Marca Stanley 3 Type Typ Type T
19. erly in place or closed Only ask qualified personnel to remove the safety devices or other covers in order to carry out when necessary maintenance work or repairs To avoid the motor accidentally starting while carrying out maintenance work or repairs disconnect the cable from the negative terminal of the battery Keep hands hair loose clothing and tools away from engine parts After maintenance work or repairs replace all trap doors panels covers and other protective devices before starting the motor SPARKS Sparks can ignite BATTERY GASES and cause explosions BATTERY ACID can cause burns to the eyes and skin Batteries contain acid that give of explosive gases Always wear a protective screen over the face when working on the battery Stop the motor before connecting or disconnecting the cables from the battery terminals Avoid making sparks with tools while working on the batter Do not us welding equipment to other fast starting equipment SAFETY PRECAUTIONS Respect the correct positive and negative terminal polarity of the battery STEAM from HOT PRESSURISED COOLANTS cause burns to the eyes and skin Only check the level of the coolant when the motor is cold to avoid being scalded When the motor is hot and it is coolant follow the next two steps Wear protective eyeglasses and gloves and place a cloth over the cap Turn the cap slightly to release the pressure slowly Allow
20. ion card with a 30 digit ISO bar code 123456789012345678901234567890 L j 1 Operator Country Date Language Name Organisation Level Control OPERATION OPERATOR DIALOGUE Power up Memories Test Then HELLO Change language press the arrows A or V CTRL PROG x xxx CHARLIE Nxxxxxxx Display software version and Charlie serial number NO ALIGNMENT This mode allows to perform free polygons from 3 to 4 sides e Setting the points without restriction beads direction Position O1 to Position O2 When setting the 4 points point 4 can be out of the vertical alignment of point Position O1 without automatic control of any alignment Welding mode bead by bead ALIGNMENT OK Simple welding mode Shapes like rectangle triangle and butt welding Non stop welding our bead by bead Realization with or without surrounding Changing welding modes by pressing Validate by pressing Corrections can be made by pressing ALIGNMENT OK Note This is also effective during all welding cycle To go to the next step press To step back to the previous step press SPEED 30 cm mn Welding speed displayed cm min 1 cm min equals to 0 4 inch min adjustable value in the parameter menu Allow to move the torch according into 2 axis X et Z LAYER 1 TORCH PO1 Set point Position O1 Define the resurfacing area PO2 TORCH
21. ipo Tipo RW30 4 Serial number of equipment Seriennummer des Ger ts Num ro de s rie de l quipement All Numero de serie del equipo Matricola dell attrezzatura Has been manufactured in conformity with Wurde hergestellt in Ubereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in conformit con Directive Standards No Approved body Richtlinie Standards Nr Pr fung durch Directives Normes Num ro Organisme agr Directriz Los Normas No Aprobado Direttiva Norme n Collaudato 98 37 CEE 22 06 98 J Sauron S A 89 336 CEE 03 05 89 92 31 CEE 28 04 92 93 68 CEE 22 07 93 1999 5 CEE 09 03 99 73 23 CEE 19 02 73 93 68 CEE 22 07 93 60974 1 06 00 60974 1 1A 04 01 169 12 92 50199 01 97 Machinery Directive 2006 42 EC 2006 5 Special Provisions Spezielle Bestimmungen Dispositions particuli res Provisiones especiales Disposizioni speciali None 6 Representative in the Union Patrick Vervier Stanley Dubuis 17 19 rue Jules Berthonneau BP 3406 41034 Blois Cedex France Vertreter in der Union Repr sentant dans l union Representante en la Union Rappresentante presso l Unione Done at Ort Fait Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 6 22 11 Signature Unterschrift Signature Firma Firma NE bh Position Position Fonction Cargo Posizione Engigeering Manager SAFETY SYMBOLS Safety symbols and signal words as shown below
22. ised cylinder there is a risk of explosion Only use protective welding gas cylinders regulators hoses and fittings designed for this specific purpose make sure they and associated items are in good condition Do not stand in front of the gas outlet when opening the gas valve on a cylinder Keep the valve protection cap in place except when using or connecting the cylinder Read and follow the instructions concerning the use of cylinders of compressed gas and associated equipment and the other publications listed in the safety standards WELDING CAN CAUSE FIRE OR EXPLOSIONS Welding container like objects such as tanks drums or pipelines can cause such objects to burst Sparks are projected from the welding arc The projection of sparks hot items and hot equipment can cause fire and burns Accidental contact of the electrode with metal objects can cause sparks explosions overheating or fire Before welding in such cases check that there is no danger Protect yourself and others from the projection of sparks and hot metal Do not weld in places where sparks can fall on flammable substances Move flammable substances at least 10 7 metres 35 feet from the welding arc If this is not possible cover them carefully with approved protective covering Sparks and other hot welding matter can propagate from one area to another through small cracks and openings Check for any fire that may start and have a fire extinguisher to hand Do not
23. k adjust to one of the three positions and engage the stop pin Disengage Stop Pin 5 Assemble the mounting brackets by disengaging the stop pin inserting the two brackets together and engaging the stop pin to secure Disengage Stop Pin Engage Stop Pin Heel Jaw in the Fixed Position Heel Jaw in the Mobile Position 12 OPERATION Adjusting the Clamp CONNECTING THE WIRE FEED WELDING TIP TO THE RW30 1 Place the welding tip into the support SETTING THE STICK OUT The ideal setting is 30 mm Use the template markers to check for proper distance 30 mm Ideal Setting OPERATION OPERATING THE RW30 amp THE CHARLIE CONTROL UNIT 1 Turn ON the main switch on the RW30 2 Unlock the ON OFF switch on the Charlie Control Unit located on the right side of the unit AUTOMATIC TRACK MODE After preheating this mode is used on carbon steel track for continuous surface work on three or four sided octagonal polygons MATIC Rail Automatic Mode AUTOMATIC POINTS FROG MODE With no preheating this mode is used on manganese steel points and frogs For strip by strip work alternately of 1 to 3 three or four sided polygonal surfaces After preheating this mode is used on carbon steel points or frogs for continuous surface work on three or four sided polygons TRANS MATIC Crossing Automatic Mode 14 Display Screen Valid Button Direction A
24. o retracting point after bead VALID TO START FOLLOWING BEAD Press VALID key to start the next bead END LAYER N 1 LAYER 2 VAL If VALID key is pressed you will have to set anew welding area As previously seen 20 If RESET key is pressed NEUTRAL POINT TRANSPORT VALID Allow to place the torch in Parking position If VALID key is pressed torch will move to Parking posi tion If RESET key is pressed back to message HELLO STOP AND RESTART OF WELDING CYCLE During the welding in whatever mode you have selected stopping the welding cycle is always possible Pressing the RESET key will stop the weld cycle STOP CYCLE RESTART CYCLE To restart the welding cycle press VALID key According to what mode you are using a correction of the exact positioning of the torch during the stopping can be done Maximum correction 1 cm following the 2 axis lt X gt and lt 2 stop the welding cycle press the RESET key ERROR MESSAGES During the setting of the points some errors message can appear Set Position O2 MIN LEN 30mm LENGTH xx mm The distance between points Position O1 and Position O2 must be minimum or equal to 30mm on X axis This mes sage will be displayed only if the distance between Position O1 and Position O2 30mm Note this distance 30mm equals to 1 18 inch is set in the parameters menu OPERATION Set Position O4 In mode lt ALIGNM
25. od working order of the keyboard s contacts Check the good working order of the keyboard using it in the test mode for example Call our After Sales Dpt Interface card Check the connexions Check if the card s lights are alight during a moving command Call our After Sales Dpt Axis engine s cards Check if the card s lights are alight during a moving command Switch the connexions between the 2 engines and the recheck the moving of the torch the movements are reversed Call our After Sales Dpt Translation s screw mechanically blocked Check if the screw 1s not top blocked on the stop bumpers or on the ball bearing or on the cardan Unscrew manually the screw if it is possible Call our After Sales Dpt Uncontrolled speed of the torch and or no high speed and or speed not as usual PROBABLE CAUSE CHECKS AND REMEDYS Charlie box Try with another Charlie box Change the Charlie box card 22 TROUBLESHOOTING Coder s pulses defect Check the coder connexion on the right side and on the bottom of the interface card J3 connector side Replace the interface card Axis engine s cards Check if the card s lights are alight during a moving command Switch the connexions between the 2 engines and the recheck the moving of the torch the movements are reversed Call our After Sales Dpt Interface card Check all the connexions Check if the card s lights are alight during a moving command Replace the interface card Call our Afte
26. oint of Position O1 Welding will start While welding RETURN TORCH TO INITIAL POINT Torch moves to starting point of the welding or at the beginning of the new bead if bead by bead mode has been selected WELDING CYCLE SURROUND Surrounding welding if that option has been selected WELDING CYCLE BEAD xxx Shows the bead s number in welding xxx and the to tal number of beads of the whole resurfacing of the area yyy If bead by bead option is selected the following screen appears at the end of the previous bead and after the torch is set VALID TO START FOLLOWING BEAD OPERATION If VALID key is pressed torch will move to the starting point of the next bead RETURN TORCH TO INITIAL POINT Torch return to starting point and start welding of the next bead END LAYER N 1 AN n When resurfacing is over the following message proposes to set a new resurfacing cycle If VALID key is pressed you will have to set a new welding area As previously seen If RESET key is pressed NEUTRAL POINT TRANSPORT VALID Allow to place the torch in Parking position If VALID key is pressed torch will move to Parking posi tion If RESET key is pressed back to message HELLO NO ALIGNMENT Note This is also effective during all welding cycle To go to the next step press the VALID key To step back to the previous press the RESET key SPEE
27. olidly Fix the cable to the work piece or work bench with a good metal on metal contact as near as possible to the construction WELDING HAZARDS The RAYS OF THE ARC can burn the eyes and the skin the NOISE can damage the ears FLYING SLAG or SPARKS can damage the eyes The welding arc produces intense visible and invisible rays ultraviolet and infrared which can burn the eyes and skin The noise generated can damage the ears Metal particle or slag are projected into the air when chipping grinding and when joints are cooling NOISE Wear approved earplugs if the level of noise is high RAYS FROM THE ARC Wear a welding mask with an appropriate filter screen to protect your eyes and face while welding or watching see standards EN 169 Wear approved eye protection goggles that give lateral protection Use screens or barriers to protect observers and ask others not to look at arc Wear protective clothing made of appropriate fire proof materiel and protective shoes FUMES AND GASES Welding produces fumes and gases Inhaling these substances can be damaging to your health Avoid fumes Do not inhale fumes When working indoors ventilate the area and or use fumes evacuation equipment to evacuate welding fumes and gases If ventilation is insufficient use an approved air respirator Read the safety recommendations concerning materials MSDS and the manufacturer s instructions concerning metals c
28. onsumables coverings cleansers and degreasing agents Only work in confined places if is well ventilated or wearing an air respirator Have a properly trained supervisor stand by Welding fumes and gases can accumulate and starve the atmosphere of oxygen which can lead to fatal accidents Check there is no danger in breathing the air Do not weld in areas where others are degreasing cleaning or spraying Heat and arc rays can react with other vapors and form gases which are highly toxic or an irritant Do not weld coated metals such as galvanized steel lead or cadmium plated metal until the coating has been removed from the area to be welded Make sure the area is well ventilated and if necessary wear an air respirator 7 SAFETY PRECAUTIONS Coatings and the metals they contain can produce toxic fumes when welded GAS CYLINDERS Cylinders of protective welding gas contain gas under pressure If a cylinder is damaged it can explode As cylinders of gas are part of the welding environment they should be handled with caution Protect gas cylinders from excessive heat shock slag exposed flames sparks from the welding arc Store cylinders upright in a stationary rack or cylinder holder so that they cannot fall over Keep cylinders away from welding circuits or any other electrical circuit Never place a welding torch on a gas cylinder A welding electrode should never make contact with a gas cylinder Never weld a pressur
29. r Sales Dpt No wire feeding The PGA Close or set up the wire s pressure with the PGA s rollers The Roll n Roll Check the wire s drum and or set the Roll n Roll brake Check the connexions and the PGA s alimentation cable Charlie box Try with another Charlie box Check if the welding command light is alight on the interface card Link cable between the TRANSLAMATIC and Check the connexions or and change the cable the Charlie box Welding trigger opened Welding control Check the closing of the welding trigger with an connector ohmeter value to 20 ohms between the pins 3 and 4 of the 7 points connector or C an D of the Amphenol connector 19 points Stabilized alimentation out of service Check the alimentation s tension normally 27V in CC Call our After Sales Dpt Wire feeding OK but no welding PROBABLE CAUSE CHECKS AND REMEDYS Ground cable Make sure that the ground cable is well connected Interface card Check if the card s lights are alight during a moving command Call our After Sales Dpt Arc welder generator Check the parameters and the good operating of the arc welder Call our After Sales Dpt 23 SPECIFICATIONS RW30110 RW30112 u EE OR EE 115V 60Hz 175W AAKS ENE ER EE EE 400 mm 15 7 in RE EO EE NE EE IE 350 mm 13 7 in EEE ue 925 mm 36 4 in VV e a c 650 mm 25 5 in gon AEE
30. rrows Stop Reset Button Charlie Control Unit A computerised control unit to command the welding cycle Charlie is presented in a polycarbonate housing unit equipped with a liquid crystal display and a six keypad keyboard under lexan for man machine dialog Its 5 metre shielded mains cord can be wrapped around its tubular shaped chassis The Charlie control unit is adapted for on site work Its protec tion rating classifies it for uses under all weather conditions THE CHARLIE CONTROL UNIT CONTROLS The SCREEN displays messages as well as tracing informa tion for the user The VALID is used to validate the current step During a cycle it is used to display the welding U and I The STOP button is used to return to the previous step Dur ing a cycle it is used to momentarily or definitively stop the welding cycle The UP and DOWN arrows are used to scroll through the alphanumeric character list during the tracing data acquisi tion stage In the setting stage it is used to move the head along the Y axis The LEFT and RIGHT arrows are used to scroll through the alphanumeric character list during the tracing data acquisi tion stage In the setting stage it is used to move the head along the X axis OPERATION Below are screen examples of scrolling through the alphanumeric character list In tracing mode Examples scrolling up the list Examples scrolling down the list gt gt Examples moving the cursor
31. the pressure to decrease completely before removing the cap Avoid making sparks with tools while working Moving engine parts can cause bodily injury Before working on the generator remove the spark plugs or fuel injectors to prevent the motor from ac cidentally starting Block the flywheel while working on the generator Metal and dirt particles can cause injury to the eyes Wear safety glasses that also offer lateral protection Static Electricity can damage the components on the electric board Before manipulating cards or other components connect an earth wire to the earth terminal Use antistatic packing material for storing moving or transporting PC cards Magnetic fields created by high voltage can interfere with the workings of pacemakers Pacemaker wearers should keep their distance Pacemaker wearers should first consult their doctor before going near any place where welding operations are being carried out Read the instructions Only use original spare parts Replace the fuel injectors and the fuel system air bleeder as indicated in the motor instruction manual MAKE SURE SPARKS FROM THE ENGINE EXHAUST DO NOT START A FIRE 1 Use an approved spark arrester on the motor exhaust wherever or whenever required check the legislation in vigour LOW VOLTAGE AND FREQUENCIES can damage electrical equipment such as motors 1 Switch off or disconnect the equipment before starting or stopping the motor EXCESSIVE WEAR can
32. time for damage Replace as required Check that the lift level is correct with lift level tool Always store the tool in a clean dry space safe from damage or pilferage Always keep critical equipment markings such as warning stickers and tags legible Equipment repair should be performed by experienced personnel only Do not use the equipment for applications for which it was not intended 24 RW30 HEATER INSTALLED 2009 OR EARLIER Thermostat Heater Element Front Cover Back Cover Charlie Heater 70722 RW30 COLD WEATHER UPDATE KIT 70716 INCLUDES THE FOLLOWING Heater Element 110 V 400 W Thermostat Red Back Cover Front Cover Screw Kit Charlie Heater Kit Butt End Flask Thermostat Blue Heater Element me a Thermostats Red amp Blue 25 ACCESSORIES Cable Welder Robotic Roll Un Roll Drum Holder Kit Track Wheel Robotic Blue bag for Charlie Kit Track Wheel Welder Robotic Male base 6 P gnd wire feeder electri Wire Coated Weld Std Rail cal conn Wire Coated Weld Mn Rail Plug for Male Base Protective Box Transport Male base 3 P gnd power cord 15m Ground Cable Adaption Box Ground Clamp for Frog Ground Clamp for Rail Cable Generator 15M Long Europe Cable Generator 15M Long Miller Transport Box RW20110 USA Transport Box RW20120 USA Tracability Kit Carbon Frog Insert Angle Attachment 1 16 in 1 6 mm Frog Build Wire Cables RW30110
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