RDA AHVP100-6 NA Manual - Red-D
Contents
1. suse 17 REPLACEMENT PARTS 17 S L MECHANICALPARTS 18 5 2 ELECTRICAL PARTS LIST 19 APPENDIX A OVERVIEW DRAWING eee nennen hehe nnne shore sees 20 APPENDIX B WIRING DIAGRAMI eee eee eene nennen nennt hes sese eee stereo sesso seo see sesso seus 21 APPENDIX C INVERTER DRIVE PARAMETER SETTINGS ccsscsccccsccccsceccscsccccsccccsceccscescsceseccncescscess 22 APPENDIX D GEARBOX MAINTENANCE eene eene nennen stesse 23 D 1 Measures before VR UT PES Quse AVEC sue aV a 23 DLE Eee emm 23 D 1 1 1 Checking the oil level in the gear unit housing eee eere eren nnn 23 D 1 1 2 Oil sight glass Special feature cccccscssceccscccceccscccceccsccscecceccsceccscesceccsceccescscescecens 24 D 1 1 3 Dipstick Special TeatulB TU 24 0 1 2 Startup without long term preservation cscsc2. 10 Figure 4 PANG TER UP REINO 11 Figure 5 Hand Control Pendant TET Dm 12 Figure 6 Roller Bearing sessionis neir 15 7 19 cia Reo el RT E 19 Control Panel CUO NR 19 Figure 10 Overview n 20 Red D Arc Welderentals Page 31 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com INDEX B O Back Frame Guard 18 OPEN GEARS 16 OPERATION 11 C CE CERTIFICATE 7 8 Centre of Gravity 12 Panel 11 12 13 CLEANLINESS ENVIRONMENT 17 Preface 3 Contents 2 CONTROL GEAR 17 Control Panel Frame 18 R Crosshead 18 Crosshead Spacer 18 Replacement Parts 17 Rotation Box Pad 18 Rotation Spur Pinion 18 E Rotation Spur Pinion Guard 18 ROTATION WORMBONX 16 earthing 10 Earthing 18 EARTHING 16 S Earthing Bracket 18 Earthing Brush Assembly 18 Slewing Ring 18 Eccentricity 12 Slot Cover 18 ELECTRICAL PARTS LIST 19 slots 12 SPECIFICATIONS 4 F T Forward 12 Front Frame Guar
3. 4 1 MAINTENANCE TAPER ROLLER BEARINGS LOCKNUTS 15 4 2 MAINTENANCE PHOSPER BRONZE BEARINGS csscsccsccsceccsccsceccsccececcnccscecceccscecceccscescncens 15 4 3 MAINTENANCE OPEN GEARS iissssi suse evi si veas baud ea eri 16 4 4 MAINTENANCE ROTATION eese stesse sese 16 4 5 MAINTENANCE suse 16 4 6 MAINTENANCE EARTHING BRUSHES eene eee eee eene nennen these eese stesse se sesso sense 16 4 7 MAINTENANCE ELECTRICAL MAINTENANCE eee eee eene nnne sense esee senses 16 4 8 MAINTENANCE CLEANLINESS 17 4 9 MAINTENANCE TIGHTNESS OF CONNECTIONS cssceccsccsccccsccsccccsccsceccsccscecceccscesceccscescncens 17 4 10 MAINTENANCE INSULATION eene eee eene nenne eese stesse sete 17 4 11 MAINTENANCE CONTROL
4. 1 70 9 HEIGHTS TO TABLE VERTICAL 222 1335mm 1655mm V 40 7 52 6 64 4 p amp 2o e TABLE DIMENSIONS Q1400mm 4 7 WITH 6 OFF 23mm 1 SLOTS T Ele BE EARTHING 300 Amps 5 TILT UP TILT DOWN FWD STOP REV c T ne lt 5 CONTROL PENDANT 6M CABLE SPEED CONTROL ESTOP 5 WE 2 INCOMING SUPPLY 16Amps 380 to 480 V 3Ph 50 60Hz mi COLOUR RAL3003 RED IS WEIGHT TBC kg TBC Ib NOTES p 1 IMPERIAL DIMENSIONS ARE APPROXIMATE AND PROVIDED FOR GUIDANCE PURPOSES ONLY 2 THIS DRAWING WAS ACCURATE AT TIME OF PREPARATION BUT IS SUBJECT TO FINAL DESIGN REVISIONS All drawings are the property of Key Plant Welding amp TITLE DRAWING NUMBER 2 positioning Equipment and contain confidential and ADJUSTABLE HEIGHT 5 0 1 1001 POSITIONER OVERVIEW NE propriety information that cannot be reproduced or divulged in whole or in part without prior permission c FOR VP 5 0 TON 1900mm THIRD DRAWN BY SCALE RED ARC A3 ANGLE Roe M 74 8 BASE LENGTH DO NOT SCALE PROJECTION DATE 14 06 2012 Figure 10 Overview Drawing Red D Arc Welderentals 667 South Service Rd Grimsby ON L3M 4G1 Page 20 Phone 905 643 4910 Efax 905 963 7810 Version v2 0 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 APPENDIX B WIRING DIAGRAM F1 hana
5. D 2 2 1 hours at the latest after 3 years Subsequent oil changes every 3 years or 10000 operating see D 2 2 1 hours contamination tightness Carry out complete inspection of at least once a tear see D 2 2 5 Red D Arc Welderentals Page 26 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com D 2 2 Description of maintenance and repairs D 2 2 1 Perform oil change or oil flushin A Meenemen Types of oil mineral oil CLP oil DIN 51517 3 synthetic oil with a specific base PGLP Ol Specifications like oil type oil viscosity and required oil quantity are shown on the name plate Thoroughly remove oil sludge abraded material and used oil residue from the housings by oil flushing A AN Shut down the gear unit by shutting off the drive unit 1 Place suitable collection receptacle under the oil drain plug of the gear unit housing 2 Unscrew vent plug on the upper side of the housing 3 Unscrew oil drain plug and drain oil off into the receptacle 4 Screw in oil drain plug 6 LL LLL 5 Filling with lubricant see D 1 4 6 Screw vent plug on the upper side of the housing Red D Arc Welderentals Page 27 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810
6. Glygoyle Optiflex TIVELA TRIBOL PGLP GS220 SG XP PGLP220 PGP220 D220EP 30 A220 OIL 800 220 ISOVG220 220 220 WB 4 4 Aralub Energrease Glissando BE Renolit CEN Mobilux Longti ALVA Wiolub TRIBOL EA HL3 LS3 30 FWA220 TRO 3 me NIA LFK2 4020 enean NEGI SIO HL2 LS2 20 3 PLEX 2 PD2 R3 220 2 9 FWA160 GLP402 u c We would be pleased to recommend further suitable lubricants of the makes ADDINOL CASTROL FUNCHS Lubritech OMV STATOIL TEXACO TUNAP and VALVOLINE Synthetic lubricants polyglycols in accordance with designation PGLP as per DN51 502 These oils are distinguished by their high aging resistance and favourable effect on the efficiency of the gear unit They are suitable for the following operating temperatures PGLP ISO VG 220 30 c 100 PGLP ISO VG 460 15 c 100 The maximum temperatures can be exceeded by 10K for a short time Red D Arc Welderentals Page 30 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com INDEX OF PICTURES Figure I Loading Calculation Diagram aa aaia 4 Figure 2 Loading 5 FIGURE RER duo
7. must include a copyright notice in the following format 2012 UL LLC Red D Arc Welderentals Page 9 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 2 0 INSTALLATION Remove transport protection if any from the machine Locate the machine on a level floor that is capable of withstanding approximately 5 tonnes over the contact area Connect the electrical mains to the machine 380 480 volts 3 phase 50 60Hz Connect the welding earth cable to the copper earthing strip that is located on the underside of the table fixed to the crosshead If this connection is NOT made the weld current will earth through the centre of the table assembly and damage the bearings and other transmission parts see photo below for earthing connection bracket Figure 3 Photo of Earthing Point Before making the machine fully operational remove any necessary covers and check that gearboxes have not lost any lubrication during transport Red D Arc Welderentals Page 10 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 3 0 OPERATION 3 1 Control Panel The control panel on the drive unit has the following 1 Power On Light Illuminates w
8. the protective devices Any damage of the coating should be repaired by an expert D 2 3 Lubricants Oil selection should always be determined by the oil viscosity ISO VG class specified on the rating plate of the gear unit The viscosity class is valid for the operating conditions agreed on by contract Under different operating conditions it will be necessary to consult us We have put together a list of suitable lubricants for the gear unit in the table below We are acquainted with the composition of these lubricants and know that in accordance with the latest technology they possess values in respect of loadability corrosion protection load carrying capacity with micro pitting as well as compatibility with seals and internal coating on which the design of the gear unit has been based Thus we recommend that our customer should select a lubricant from this table taking in account the viscosity class stated on the rating plate The lubricants listed have no approval according to USDA 1 2 United States Department of Agriculture and are as such not or only limited approved for use in the food or pharmaceutical industry The lubricants are not or only limited biologically decomposable They are usually according to the Classes 2 or 1 of hazard for water If lubricants are necessary according to these classifications please contact the factory If the gearboxes are filled with special lubricants from the factory for the cas
9. Checking all fixing screws for tightness eee eere eere eren nnne 28 D 2 2 5 Inspection of the drive 29 eigen 29 INDEX OF PICTUR 31 INDEX e 32 1 0 PREFACE This user s manual describes the everyday use and maintenance of our Welding Positioners Any actions that are required to be carried out by the manufacturer have not been included in this manual This manual is part of the machine Please keep this manual safe Information in this manual could be useful at a later time or when a repair or maintenance is carried out We suggest that a copy of the manual is made and kept with the machine the original should be kept in a safe place If necessary replacement copies can be supplied If the machine is sold at a later date then the manual should be also supplied with it to the new user Red D Arc Welderentals Page 3 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 1 1 MACHINE SPECIFICATIONS 1 2 LOADING DATA CONVENTIONAL POSITIONERS LOADING DATA Ns ROTATION TO
10. Mains Disconnect 20A ESC Black 2 5mm 10A Black 1 5mm L2 L3 Commander SK Drive 2 2kW 380 480V 3 Phase 1 25 2 62 1 4 1 5 51 2 4 9 60 Supply E 380 480 Volt TT T 50 60Hz 3 Phase amp Earth Y Wate 75mm Red 0 75mm s Power PR m o Seu we pe esc ESC pendant Reset PB ESC 11 ay 3 positon selector switch Direction selector als Lamp Variable speed F51 postion ganch R3 Fr i E LI O21 0 73 Variable z OHS 3 position selector switch Pendant 3 positon selector switch F51 relay Pendant position Pendant post an ew Stop endant n R2 1 1 2 6 i i FWD 3 position selector switch JE Variable speed F51 position Relay 2 REV S 6 24 Terminal Block Power Pendant FWD A 3 position selector switch 52 position Relay 4 Enable l m EU wn in grey extermal controls 14 Fwd FS2 p x 3 EDS NEUE Pendant Tilt Up C 51 Terminal Block Controls Terminal Block Tightening Torque 0 4 0 6 Nm adis TE 32 LS1 GS m 1 Pendant Tit Dawn Rod AC power 3 phase Black wire Ac power controls Red wire DC DrawnBy Kamil Jastrzebsio Created 234062013 Revised 23 06 2013 RED D ARC power carrots Bie wire 0 grounded White wire _ VE electrical diagram new vas wm p o se et
11. P Red D Arc Welderentals 667 South Service Rd Grimsby ON L3M 4G1 Page 21 Phone 905 643 4910 Efax 905 963 7810 Version v2 0 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com APPENDIX C INVERTER DRIVE PARAMETER SETTINGS The following settings have been programmed into the inverter at the factory Parameter Number Parameter Number All other values are as factory set by the inverter manufacturer and need not be altered Overloads are set at 4 Amps Note All other values are as factory set SS i Red D Arc Welderentals 667 South Service Rd Grimsby L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Page 22 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com APPENDIX D GEARBOX MAINTENANCE Startup D 1 Measures before startu D 1 1 Oil level check Before connecting up the drive system to the current supply check the oil level or Shut down the gear unit by shutting off the drive unit B D 1 1 1 Checking the oil level in the gear unit housin Screw out the plug screw at the point marked with this symbol Oil level For drives with only one plug screw checking the oil level is not possible Red D Arc Welderentals Page 23 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Web
12. RQUE R IS A STRAIGHT FORWARD CALCULATION OF LOAD W X ECCENTRICITY B BUT TO ENSURE AN ACCURATE FIGURE FOR TILT TORQUE T IT IS IMPORTANT TO USE THE FULL DISTANCE TO THE PIVOT POINT THIS IS OBTAINED BY ADDING TOGETHER THE CENTRE OF GRAVITY A AND TABLE PIVOT DISTANCE 6 THEREFORE ROTATION TORQUE R W X Kg METRES TILT TORQUE T 2 W X A G Kg METRES MULTIPLY BY 9 81 Figure 1 Loading Calculation Diagram Red D Arc Welderentals Page 4 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Version v2 0 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 1 3 LOADING CHART Figure 2 Loading Chart Red D Arc Weld Automation reddarc com VP5 is Loading Chart ammmrccentricity 4 entre of Gravity 3 5 2 5 Load tonnes 1 5 0 5 0 500 1000 1500 2000 2500 3000 Eccentricity amp Centre of Gravity mm Red D Arc Welderentals Page 5 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Version v2 0 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 1 4 SPECIFICATION Load capacity 5000kgs 150mm ecc amp 150mm c o g Table diameter 1400mm Degree of table tilting 135 Degree of table rotation i 360 Table rotation speed 0 07 1 RPM Table tilting speed i 60 seconds through 135 Height Settings when table h
13. Red D Arc Weld Automation feddarc com OPERATION MANUAL CONVENTIONAL POSITIONER Model RDA AHVP100 6 NA 10 000 Ib pe nee 5 P D 5 re For use with products having Serial Number 06911 and following Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com Contents MN 3 4 12 TOR DING 4 13 5 1 4 SPECIFICATION des veces 6 1 5 CE CERTIFICATE OF vide da Quee 7 1 6 UL CAS LISTING INFORMATION ccssccssccsssccesccesscnsscnsscnsscesecesecesscusscussccssececesesssesssusscuseeesceses 8 20 INSTALLATION M Hr 10 OPERATION Mec n 11 Emm 11 3 2 Control Pendant Operation cii ti sus eus ea ERE Fu E Cra Va SEE CAR VIE RES 12 3 3 Adjusting HeIPhEPOSIPIOD 13 AO MAINTENANCE 090 sec 87 040 050 Ue IS DUE a 15
14. SOUTHPORT MERSEYSIDE PR9 9DT UNITED KINGDOM Column and booms Model MD AMxBM Where A 2 3 or 4 and 2 3 or 4 Model HD AMxBM Where 3 4 5 6 7 or 8 and B 3 4 5 6 0r 7 Positioners Model VP X Where X 0 25 0 75 1 5 3 5 10 15 20 25 or 35 Rotators Model CR X Where X 10 20 30 60 100 125 200 300 400 or 500 Last Updated on 2012 06 25 Questions Print this page Terms of Use Page Top 2012 UL LLC When the UL Leaf Mark is on the product or when the word Environment is included in the UL Mark please search the UL Environment database for additional information regarding this product s certification The appearance of a company s name or product in this database does not in itself assure that products so identified have been manufactured under UL s Follow Up Service Only those products bearing the UL Mark should be considered to be Listed and covered under UL s Follow Up Service Always look for the Mark on the product UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions 1 The Guide Information Designs and or Listings files must be presented in their entirety and in a non misleading manner without any manipulation of the data or drawings 2 The statement Reprinted from the Online Certifications Directory with permission from UL must appear adjacent to the extracted material In addition the reprinted material
15. SS OF CONNECTIONS It will be necessary to periodically check the tightness of terminals and busbar connections including earth connections especially in areas where vibration is apparent Check for any hot spots developing during running Checks should be performed with the power supply isolated 4 10 MAINTENANCE INSULATION A visual check of cable control gear insulation should be performed at regular intervals If this inspection reveals any change in appearance an insulation resistance measurement is recommended For older equipment these measurements should be taken on a more regular basis where successive lower readings would indicate a problem NOTE It is important to use insulation testing equipment with care Electronic components should be securely isolated before employing meggers or similar test methods 4 11 MAINTENANCE CONTROL GEAR A visual inspection should be performed at regular intervals Movements should be checked for free and unobstructed operation This is very important for critical safety components Emergency Stop Pushbuttons and Relays 5 0 REPLACEMENT PARTS Use only parts as detailed by the supplier Failure to do so could impair safety of equipment personnel or impair machine operation or the design of the equipment Red D Arc Welderentals Page 17 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conv
16. Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com D 2 2 2 Clean vent plu The vent plug must be cleaned after deposit of a dust layer at least every 3 months For this the filter must be unscrewed flushed out with cleaning benzene or a similar cleaning agent and dried or blown through with compressed air D 2 2 3 Clean the drive Shut down the gear unit by shutting off the drive unit ene arive unito prevent Keep drives free of dirt and dust etc in order to ensure sufficient heat dissipation Cleaning the drive with a high pressure cleaning device is not permissible Do not use sharp edged tools D 2 2 4 Checking all fixing screws for tightness Shut down the gear unit by shutting off the drive unit E Check all fixing screws for tightness with a torque wrench M6 8 10 12 16 20 Note Unserviceable screws should be replaced by new ones of the same property class and type Red D Arc Welderentals Page 28 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com D 2 2 5 Inspection of the drive The drive should be checked annually In addition the drive should be checked according to the criteria described in section 2 Safety notes e g check tight fit of
17. achine will be ready to run If the emergency stop button has been depressed then release this by twisting the cap then press the emergency stop reset button on the control box Speed and movement of the positioner are controlled by the hand pendant see photo below The buttons on the pendant operate as follows Button A Hold to Run Push Button Tilt UP Button B Hold to Run Push Button Tilt Down Button C Table Rotation Reverse Direction Push Button D Table Rotation Stop Push Button Button E Table Rotation Forward Direction Push Dial F Rotation Speed Potentiometer Button G Emergency Stop Push Button Figure 5 Hand Control Pendant Red D Arc Welderentals Page 12 667 South Service Rd Grimsby L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com 3 3 Adjusting Height Position Arc MULUIIIQLI Conventional Positioner Model AHVP5 The positioner can be set at one of three height positions To alert the height of the machine please follow this simple procedure First loosen off bolts D 2 on either side of the machine this will release the table section so that it can be lifted Then connect a crane to the lifting eyes on either side of the machine A Take up the slack on the lifting eyes so the weight is taken by the crane then the lock pins B on either side of the positioner can be removed The table can then be raised or lowered by using the crane so that hole C lines
18. cccccscsccccscscsccccccscsceccccscnceccccscscescececscesess 24 D 1 3 Startup in case of long term preservation eee eene eee eene hene 24 D 1 3 1 Long term preservation up to 18 24 D 1 3 2 Long term preservation up to 36 months e eee ee eene eene eher serenus 24 D 1 4 Filling with lubricant CH S 25 DIS Dfive with nu 25 D 2 Maintenance and SN 26 D 2 1 General Information on Maintenance eene sensere serere tese se sesso sen 26 D 2 2 Description of maintenance and 27 0 2 2 1 Perform oil change or oil flushing 27 0 2 2 2 28 D 2 2 3 tlie 28 m Red D Arc Welderentals Page 2 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com D 2 2 4
19. d 18 Table 18 TAPER ROLLER BEARINGS amp LOCKNUTS 15 TIGHTNESS OF CONNECTIONS 17 G Tilt Angle Indicator amp Pointer 18 Tilt Box Pad 18 gearbox 10 Tilt Pinion Guard 18 Gearbox 18 Tilt Quadrant 18 Gearbox Maintenance 22 23 Tilt Spur Pinion 18 Tilt Up 12 TILT WORM BOX 16 Trunion Flanged Bush 18 Trunnion Shaft 18 INSTALLATION 10 INSULATION 17 L UL CAS 8 LOADING CHART 5 LOADING DATA 4 V lubricants 24 29 30 Variable Speed Potentiometer 12 14 Mainframe 18 MAINTENANCE 15 wiring diagram 21 MECHANICAL PARTS LIST 18 Red D Arc Welderentals Page 32 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com
20. djustment is obtained by means of the two lock nuts BEARINGS SHAFT BEARING HOUSING LOCKNUTS Figure 6 Roller Bearing Replenish at 500 hour intervals with CASTROL SPHEEROL MP3 For high temperature conditions change grease to CASTROL SPHEEROL B3 4 2 MAINTENANCE PHOSPER BRONZE BEARINGS Replenish at 500 hour intervals be means of grease nipples using CASTROL SPHEEROL MP3 All of the phosphor bronze bushes used are retained with LOCTITE 601 bush retaining fluid Any bush which becomes displaced should be carefully removed thoroughly cleaned with the correct application of LOCTITE degreasing fluid and then coated with retaining fluid before being replaced Red D Arc Welderentals Page 15 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 4 3 MAINTENANCE OPEN GEARS All gears are liberally coated with grease CASTROL MS3 molybdenum disulphide At 500 hour intervals remove safety guards and check coating and if required replenish grease 4 4 MAINTENANCE ROTATION WORMBOX The worm box fitted on this machine is factory filled with a synthetic lubricant SHELL TIVELA SA and should not require any further maintenance during its lifetime It is important however to check at regular intervals that there are no leaks If any leaks are observed the unit must be drained new seal
21. entional Positioner Model AHVP5 reddarc com 5 1 MECHANICAL PARTS LIST Part Number Description Quantity KPVP050151 Positioner Mainframe Adjustable Height 1 KPVP050152 Baseframe Adjustable Height 1 I KPVP050102 Crosshead KPVP050103 Table I KPVP050115 Rotation Box Pad 1 KPVP050118 Rotation Spur Pinion Guard 1 KPVP050204 1 1kW AC Tilt Motor with Brake 1 KPVP050207 Tilt Gearbox 1 KPVP050206 Tilt Sour Pinion 1 KPVP050205 Tilt Quadrant 1 KPVP050222 Earthing Strip 1 KPVP050225 Trunion Flanged Bush 1 I KPVP050229 Crosshead Spacer KPVP050245 Back Frame Guard 1 KPVP050203 1 1kW AC Rotation Motor 1 KPVP050311 Earthing Brush Assembly 2 KPVP050320 Control Panel Frame 1 KPVP050350 Slewing Ring 1 KPVP050260 Tilt Angle Indicator amp Pointer 1 KPVP050262 Tilt Box Pad amp Gusset 1 KPVP050161 Height Adjustment Locking Pins 2 KPVP050162 Height Adjustment Stabilising Bolts 4 Red D Arc Welderentals Page 18 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 5 2 ELECTRICAL PARTS LIST RESET Wie 59255 5 S26 df i m VB ETERNI QE D i B i M e DIRECTION Figure 9 Control Panel Interior Figure 8 Control Panel Exterior Figure 7 Control Pendant Photo Number Part Number Description Quantity 1 KP3010 Inv
22. erter 3 Phase 2 2kW Drive Rotation 1 2 KP1060 Relay and Base 3 KP1008 3 Phase Fuse Holder and Fuses 4 KP1010 Transformer 480V 24V 63VA 5 KP1042 Reversing Contactor 18A 24VAC 6 KP1032 Motor Circuit Breaker 4 0 6 3A 7 KP2009 Phase Detection Relay 8 KP1020 2 Pole Circuit Breaker 0 5A 9 KP1010 1 Pole Circuit Breaker 3A 10 KP1042 Contactor 5 5kW 12A 11 KP1028 Fused Door Isolator 15 KP1092 Mains Power On Lamp 18 KP1065 Pendant Housing 19 KP1068 Pendant Push Buttons Red Green Yellow Black White 20 KP2026 Speed Potentiometer 21 KP1075 Pendant Emergency Stop Button Not Shown KPPENCAB Pendant Cable eje ts I Red D Arc Welderentals Page 19 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation reddarc com Conventional Positioner Model AHVP5 APPENDIX A OVERVIEW DRAWING 2250mm 88 6 OVERALL LENGTH Qc ac gt D lt a 5 m lt e z C3 6 SPECIFICATIONS FOR POSITIONER MODEL RDA AHVP 5 0 5 0 METRIC TONNES 1102316 AFE WORKIN A TEM SARE 150mm 6 C OF G amp 150mm 6 ECCENTRICITY DEGREE OF TILTING 135 DEGREE OF ROTATION 360 TILTING SPEED 60 seconds FOR 135 ROTATION SPEED 0 07 1 RPM 2 HEIGHTS TO TABLE HORIZONTAL UEHUN lt 47 2 59
23. es given above this can be seen on the name plate e g CLP H1 VG220 or CLP E VG220 Note Asa precaution against misunderstandings we would like to point out that the recommendation does not imply any release in the sense of a warranty for the quality of the lubricant provided by your supplier Each lubricant manufacturer must warrant the quality of his product himself If you do not follow our recommendations you must take the responsibility for the technical suitability of the lubricant In the case of synthetic oils not listed in the table below the corrosiveness of the oil to our internal coating should be checked A check of this nature is carried out by us at cost cost on request Red D Arc Welderentals Page 29 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com Examples of lubricants Desig 2 T nation Lubricant according o fn M bil p NJ to FUCHS 1 Optimo srs Tribol DIN 81002 DEA w Saw Shell 4 oho eu Eien L Degol Enersyn Polydea GLYCO Renodiol Syntheso Glygoyle Optiflex TIVELA TRIBOL PGLP GS460 SG XP PGLP460 LUBE PGP460 D460EP HE460 A460 OIL 800 460 Synthetic ISOVG460 460 pay SD 1 Oils 2 OIL Enersyn Polydea Renodiol Syntheso
24. g techniques and be conversant with identifying the first signs of maloperation During maintenance fault finding etc the following points should be observed The equipment should be completely isolated whenever possible If an element of live diagnosis is required the use of barriers warning notices is a must Red D Arc Welderentals Page 16 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com The maintenance staff should be familiar with the appropriate factory and safety regulations that apply inthe province and country that they are employed in and work on the equipment is such a manner as to comply with them The period between specific maintenance tasks will vary dependant on such factors as type of equipment and environment of the equipment These factors should be assessed by the respective maintenance staff and maintenance periods adjusted accordingly Maintenance should include attention to the points listed below 4 8 MAINTENANCE CLEANLINESS ENVIRONMENT It is essential that the cubicle interior remains clean and dry Any ingress of moisture or dirt should be cleaned with a lint free cloth or suitable suction device Fans and filters should be checked regularly for blockages and dirty filter mats should be replaced with the correct grade of 4 9 MAINTENANCE TIGHTNE
25. hen the power is connected 2 Reset Button for resetting the machine after an emergency stop has occurred The button will be illuminated to show the rotator needs to be reset Footswitch Selector Direction L R Selector Emergency Stop Button Panel door opening key Door electrical isolator must be turned off before panel door can open EI Figure 4 Main Panel 3 Position Selector No 3 On Photo Position FS Control by footswitch with Speed Controller Position FS Il Control by footswitch without Speed Controller Speed control is performed via the hand pendant control PEND All controlled through the hand pendant 2 Position Selector No 4 On Photo lt gt Rotation direction selector clockwise anti clockwise for use with footswitch Red D Arc Welderentals Page 11 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 3 2 Control Pendant Operation It is imperative when loading the machine that the fabrication is held firmly on the table using the table slots provided It is also important that the machine is NOT OVERLOADED by placing on it fabrications which are heavy or are beyond the capacity of the machine in terms of Centre of Gravity or Eccentricity Once the machine has power connected and the power on light is illuminated The m
26. il quantity required will be found on the rating plate Finally check the oil level see 7 1 1 A eer D 1 5 Drive with backstop J N secre drive unit to prevent accidental startup Affix notice at the swich on pint airestion of rotation before putting into seee E g by manually turning the input shaft or the motor Check the motor direction of rotation according to the phase sequence swap two supply leads if necessary Red D Arc Welderentals Page 25 667 South Service Rd Grimsby ON L3M 4G1 Phone 905 643 4910 Efax 905 963 7810 Version v2 0 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com D 2 Maintenance and repair D 2 1 General Information on Maintenance The periods listed in the table below are largely dependent on the conditions of use of use of the gear unit For this reason it is only possible to give average periods which refer to a Daily operating time of 24h Duty factor of ED 100 Input drive speed of 1500 min Max Oil temperature of 100 C NOTE Under different operating conditions the periods should be adjusted accordingly Measures Causes Remedy for changes during operation if possible etenim during operation if possible moth seDi11 J Oil level check monthly see D 1 1 Check gear unit for leakage monthly Initial oil change after startup after approx 10000 operating see
27. lations implementing the EC Machinery Directive 89 392 EEC amended 91 368 EEC and 93 44 EEC and 93 68 EEC codified to 98 37 EC 73 23 EEC Low Voltage Directive amended by the directive 93 68 EEC regarding safety of electrical equipment 89 336 EEC Electro Magnetic Compatibility amended by directives 92 31 EEC and 93 68 EEC As implemented by the UK Supply of Machinery Safety Regulations 1992 Authorised signatory Mea Steve Piercy Engineering Manager Red D Arc Welderentals Page 7 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model 5 reddarc com 1 6 UL CAS LISTING INFORMATION GPNY E353668 Factory Automation Equipment Page Bottom Factory Automation Equipment r f for mation ipmen KEY PLANT AUTOMA TION LTD E353668 KENSINGTON HOUSE 7 ROE LANE SOUTHPORT MERSEYSIDE PR9 9DT UNITED KINGDOM Column and booms Model MD AMxBM Where A 2 3 or 4 and B 2 3 or 4 Model HD AMxBM Where 3 4 5 6 7 or 8 and 3 4 5 6 7 Positioners Model VP X Where X 0 25 0 75 1 5 3 5 10 15 20 25 or 35 Rotators Model CR X Where X 10 20 30 60 100 125 200 300 400 or 500 Last Updated on 2012 06 25 Questions Print this page Terms of Use Page Top 2012 UL LLC When the UL Leaf Mark is on the product or when the word Environment is included i
28. n the UL Mark please search the UL Environment database for additional information regarding this product s certification The appearance of a company s name or product in this database does not in itself assure that products so identified have been manufactured under UL s Follow Up Service Only those products bearing the UL Mark should be considered to be Listed and covered under UL s Follow Up Service Always look for the Mark on the product UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions 1 The Guide Information Designs and or Listings files must be presented in their entirety and in a non misleading manner without any manipulation of the data or drawings 2 The statement Reprinted from the Online Certifications Directory with permission from UL must appear adjacent to the extracted material In addition the reprinted material must include a copyright notice in the following format 2012 UL LLC Red D Arc Welderentals Page 8 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model 5 reddarc com GPNY7 E353668 Factory Automation Equipment Certified for Canada Page Bottom Factory Automation Equipment Certified for Canada n nf f mation ipmen fied for Can KEY PLANT AUTOMA TION LTD E353668 KENSINGTON HOUSE 7 ROE LANE
29. orizontal Position 1 i 1200mm Position 2 i 1500mm Position 3 1800 Table equipped with efficient built in earthing 300 amps and mounted on pre loaded crossroll bearing Table rotation fitted with AC motor and controlled by an Inverter unit suitable for 380 to 480V 3 Phase supply Tilting through AC electric motor equipped with limit switches to prevent over run Table can be manually elevated from the base and locked into position using one of the three pin locations The main control panel mounted on the machine containing the following mains isolator mains on lamp emergency stop button and reset button The positioner is also supplied with a low voltage remote pendant control containing forward stop reverse tilt up tilt down pushbuttons and a variable speed potentiometer connected with 6 meters of cable to the control panel Mains electrical supply suitable for 380 480 Volts 3 phase 50 60 Hz Red D Arc Welderentals Page 6 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 1 5 CE CERTIFICATE OF CONFORMITY Machine Type 5T Welding Positioner Model AHVP5 We hereby certify that the above machine has been manufactured by Key Plant Automation Limited and conforms to the essential requirements of the following E U Directives Supply of machinery Safety Regu
30. s fitted and re filled with the correct amount of lubricant 4 5 MAINTENANCE TILT WORM BOX The worm box fitted on this machine is factory filled with a synthetic lubricant SHELL TIVELA SA and should not require any further maintenance during it s lifetime It is important however to check at regular intervals that there are no leaks If any leaks are observed the unit must be drained new seals fitted and re filled with the correct amount of lubricant 4 6 MAINTENANCE EARTHING BRUSHES All rotary tables that are used for manipulating components to be welded are fitted with Earthing Brush s to carry welding current away from the machines rotating axis to a suitable pickup point IT IS MOST IMPORTANT TO CONNECT AN EARTHING CABLE TO THE MACHINES PICKUP POINT AND NOT TO EXCEED THE MAXIMUM RATING STATED OTHERWISE SERIOUS DAMAGE CAN OCCUR TO MACHINES ROTATING AND ELECTRICAL PARTS 4 7 MAINTENANCE ELECTRICAL MAINTENANCE It is the responsibility of the user to ensure only competent personnel deal with the operation and maintenance of the equipment Operators should be conversant with the equipment and be able to recognise the symptoms maloperation and or degraded performance They should also be aware of what action to take in the event of a fault emergency It is recommended that maintenance personnel have adequate training on the system and also the component parts They should have a thorough knowledge of diagnosis and fault findin
31. site reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com D 1 1 2 Oil sight glass Special feature If an oil inspection glass is provided the oil level must be visible in the middle of the inspection glass Oil level D 1 1 3 Dipstick Special feature Check oil level with dipstick The oil level must be between the lower and upper mark of the dipstick D 1 2 Startup without long term preservation MOTOX drives are delivered with the appropriate lubricants ready for operation depending on the specified conditions of use o q It must be used at the position indicated by this symbol D 1 3 Startup in case of long term preservation D 1 3 1Long term preservation up to 18 months gear unit should be fea wih brane D 1 3 2Long term preservation up to 36 months i The oil level should be reduced to the level marked with this symbol see D 1 1 A NN Red D Arc Welderentals Page 24 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com D 1 4 Filling with lubricant e Screw out venting screw or venting filter or plug screw at the highest point see 3 2 or point of ventilation Cy Data such as oil grade oil viscosity and o
32. up with the lock pin B holes Pin B on both sides of the machine can then be replaced Once pins B are fully in place on both sides then the weight of the table can be taken by the pins and the crane removed Tighten the 4 bolts D 2 on either side of the machine this will prevent any movement of the positioner inside the height adjustment sleeve Red D Arc Welderentals Page 13 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 Front Top Rear Top Note the vertical leg with holes C through is designed to sit flush metal on metal at the top rear of the and bottom front of the sleeve see pictures above These areas are designed to take the weight of the machine The bolts D are there to close the gap at the top front and bottom rear of the sleeve so that there is movement of the position in the sleeve Red D Arc Welderentals Page 14 667 South Service Rd Grimsby ON L3M 4G1 Version v2 0 Phone 905 643 4910 Efax 905 963 7810 Website reddarc com Red D Arc Weld Automation Conventional Positioner Model AHVP5 reddarc com 4 0 MAINTENANCE 4 1 MAINTENANCE TAPER ROLLER BEARINGS amp LOCKNUTS Self aligning roller bearings are present to give zero end float In time due to wear and vibration they may slacken off They should then re tighten to regain zero end float A
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