EWM CB-007-1 Operating Instructions Manual

EWM
Brand
EWM
Model
CB-007-1
Category
Welding System
Type
Operating Instructions Manual
Operating instructions
Functional characteristics of control unit
GB
CB-007-1
Observe additional system documents!
099-010268-EW501 28.03.2011
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General instructions
CAUTION
Read the operating instructions!
The operating instructions provide an introduction to the safe use of the products.
• Read the operating instructions for all system components!
• Observe accident prevention regulations!
• Observe all local regulations!
• Confirm with a signature where appropriate.
NOTE
In the event of queries on installation, commissioning, operation or special conditions at the
installation site, or on usage, please contact your sales partner or our
customer service department on +49 2680 181-0.
A list of authorised sales partners can be found at www.ewm-group.com.
Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other
form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the
user on commissioning the equipment.
The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are
observed during installation, operation, usage and maintenance of the equipment.
An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,
we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,
improper operation or incorrect usage and maintenance or any actions connected to this in any way.
© EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany
The copyright to this document remains the property of the manufacturer.
Reprinting, including extracts, only permitted with written approval.
Subject to technical amendments.
Contents
Notes on the use of these operating instructions
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3
1 Contents
1
Contents..................................................................................................................................................3
2 Safety instructions.................................................................................................................................4
2.1 Notes on the use of these operating instructions ..........................................................................4
2.2 Explanation of icons.......................................................................................................................5
2.3 General..........................................................................................................................................6
2.4 Transport and installation ..............................................................................................................7
2.5 Ambient conditions.........................................................................................................................7
2.5.1 In operation.....................................................................................................................7
2.5.2 Transport and storage....................................................................................................7
3 Intended use...........................................................................................................................................8
3.1 Applications....................................................................................................................................8
3.2 Use and operation solely with the following machines..................................................................8
3.3 Documents which also apply .........................................................................................................9
3.3.1 Warranty.........................................................................................................................9
3.3.2 Declaration of Conformity...............................................................................................9
3.3.3 Service documents (spare parts) ...................................................................................9
4 Machine description – quick overview ..............................................................................................10
4.1 CB-007-1......................................................................................................................................10
4.1.1 Front view.....................................................................................................................10
5 Design and function.............................................................................................................................11
5.1 Mains connection.........................................................................................................................11
5.2 Machine control connection.........................................................................................................12
5.3 Software architecture...................................................................................................................13
5.4 Main menu...................................................................................................................................14
5.4.1 Settings.........................................................................................................................15
5.4.1.1 Set functional sequence................................................................................16
5.4.1.2 Index welding................................................................................................18
5.4.1.3 System settings.............................................................................................19
5.4.1.4 Automatic functions.......................................................................................20
5.4.1.5 Program ........................................................................................................21
5.4.1.6 Notes.............................................................................................................22
5.4.1.7 Setting the operating mode...........................................................................23
5.4.2 Manual control..............................................................................................................24
5.4.3 Automatic control..........................................................................................................26
5.4.3.1 Mini Oszilloskop............................................................................................28
5.5 I/O list...........................................................................................................................................29
5.5.1 Monitor input signals ....................................................................................................29
5.5.2 Monitor output signals..................................................................................................30
5.6 Alarm............................................................................................................................................31
6 Maintenance, care and disposal.........................................................................................................32
6.1 General........................................................................................................................................32
6.2 Cleaning.......................................................................................................................................32
6.3 Maintenance ................................................................................................................................32
6.4 Disposing of equipment...............................................................................................................32
6.4.1 Manufacturer's declaration to the end user..................................................................32
7 Technical data ......................................................................................................................................33
8 Appendix A ...........................................................................................................................................34
9 Appendix B ...........................................................................................................................................36
9.1 Overview of EWM branches ........................................................................................................36
Safety instructions
Notes on the use of these operating instructions
4
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2 Safety instructions
2.1 Notes on the use of these operating instructions
DANGER
Working or operating procedures which must be closely observed to prevent imminent
serious and even fatal injuries.
• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.
• The hazard is also highlighted using a symbol on the edge of the page.
WARNING
Working or operating procedures which must be closely observed to prevent serious
and even fatal injuries.
• Safety notes include the "WARNING" keyword in the heading with a general warning
symbol.
• The hazard is also highlighted using a symbol in the page margin.
CAUTION
Working or operating procedures which must be closely observed to prevent possible
minor personal injury.
• The safety information includes the "CAUTION" keyword in its heading with a general
warning symbol.
• The risk is explained using a symbol on the edge of the page.
CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.
NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.
Safety instructions
Explanation of icons
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2.2 Explanation of icons
Symbol Description
Press
Do not press
Turn
Switch
0
1
Switch off machine
0
1
Switch on machine
ENTER (enter the menu)
NAVIGATION (Navigating in the menu)
EXIT (Exit the menu)
Time display (example: wait 4s/press)
Interruption in the menu display (other setting options possible)
Tool not required/do not use
Tool required/use
Safety instructions
General
6
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2.3 General
WARNING
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
CAUTION
Noise exposure!
Noise exceeding 70 dBA can cause permanent hearing damage!
• Wear suitable ear protection!
• Persons located within the working area must wear suitable ear protection!
Risk of injury in the hazard area!
Rotating movements carried out by the machine can injure people! The hazard area is
the immediate area around the machine and the workpiece, plus a safety area of 1 m.
• Before switching on the machine and during operation, ensure that nobody is standing in the
hazard area!
• Wear appropriate protective clothing (no loose clothing)!
• In the event of an emergency, press the emergency stop switch or disconnect from the
power supply (remove the plug from the mains)!
CAUTION
Obligations of the operator!
The respective national directives and laws must be observed for operation of the
machine!
• National implementation of the framework directive (89/391/EWG), as well as the
associated individual directives.
• In particular, directive (89/655/EWG), on the minimum regulations for safety and health
protection when staff members use equipment during work.
• The regulations regarding work safety and accident prevention for the respective country.
• Setting up and operating the machine according to IEC 60974-9.
• Check at regular intervals that users are working in a safety-conscious way.
• Regular checks of the machine according to IEC 60974-4.
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, remote controls, spare parts and replacement parts, etc.) from our range of
products!
• Only insert and lock accessory components into the relevant connection socket when the
machine is switched off.
Safety instructions
Transport and installation
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2.4 Transport and installation
CAUTION
Damage due to supply lines not being disconnected!
During transport, supply lines which have not been disconnected (mains supply leads,
control leads, etc.) may cause hazards such as connected equipment tipping over and
injuring persons!
• Disconnect supply lines!
2.5 Ambient conditions
CAUTION
Equipment damage due to dirt accumulation!
Unusually high quantities of dust, acid, corrosive gases or substances may damage the
equipment.
• Avoid high volumes of smoke, vapour, oil vapour and grinding dust!
• Avoid ambient air containing salt (sea air)!
Non-permissible ambient conditions!
Insufficient ventilation results in a reduction in performance and equipment damage.
• Observe the ambient conditions!
• Keep the cooling air inlet and outlet clear!
• Observe the minimum distance of 0.5 m from obstacles!
2.5.1 In operation
Temperature range of the ambient air:
• -20 °C to +40 °C
Relative air humidity:
• Up to 50% at 40 °C
• Up to 90% at 20 °C
2.5.2 Transport and storage
Storage in an enclosed space, temperature range of the ambient air:
• -25 °C to +55 °C
Relative air humidity
• Up to 90% at 20 °C
Intended use
Applications
8
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3 Intended use
This machine has been manufactured according to the latest developments in technology and current
regulations and standards. It must only be operated in line with the instructions on correct usage.
WARNING
Hazards due to improper usage!
Hazards may arise for persons, animals and material objects if the equipment is not
used correctly. No liability is accepted for any damages arising from improper usage!
• The equipment must only be used in line with proper usage and by trained or expert staff!
• Do not modify or convert the equipment improperly!
3.1 Applications
The CB-007 control is used as a touch screen control for the PT-102 and PT-202 locators.
NOTE
Only the combinations of turn table and machine control specified may be used
together. Older machines are not permitted!
3.2 Use and operation solely with the following machines
CB-001D CB-001DV CB-002D CB-007
PT-102
; ; ; ;
PT-202
; ; ; ;
FR-001
î‚… ; î‚… î‚…
; possible
 not possible
Intended use
Documents which also apply
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3.3 Documents which also apply
3.3.1 Warranty
NOTE
For further information, please see the accompanying supplementary sheets "Machine
and Company Data, Maintenance and Testing, Warranty"!
3.3.2 Declaration of Conformity
NOTE
see Annex.
3.3.3 Service documents (spare parts)
DANGER
Do not carry out any unauthorised repairs or modifications!
To avoid injury and equipment damage, the unit must only be repaired or modified by
specialist, skilled persons!
The warranty becomes null and void in the event of unauthorised interference.
• Appoint only skilled persons for repair work (trained service personnel)!
Spare parts can be obtained from the relevant authorised dealer.
Machine description – quick overview
CB-007-1
10
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4 Machine description – quick overview
4.1 CB-007-1
4.1.1 Front view
Figure 4-1
Item Symbol Description 0
1
7-pole connection socket, motor
Geared motor/encoder connection
2
3-pole connection socket
Foot-operated switch connection (start/stop)
3
4-pole connection socket, wire feed unit
Start signal, wire feed unit
4
5-pole connection socket, welding machine start/stop
5
6-pole connection socket, solenoid valve
6
4-pole connection socket
Option
7
Main switch, machine on/off
8
Ready for operation signal light
9
Touchpanel
10
Key button, welding start
11
Emergency stop switch
Design and function
Mains connection
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5 Design and function
5.1 Mains connection
4
3
2
2
1
5
Figure 5-1
Item Symbol Description 0
1
Main switch, machine on/off
2
Fuse holder
3
Connection socket mains cable
4
Replacement fuse (2 A)
5
Machine fuse (2 A)
Design and function
Machine control connection
12
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5.2 Machine control connection
Figure 5-2
Item Symbol Description 0
1
7-pole connection socket, motor
Geared motor/encoder connection
2
3-pole connection socket
Foot-operated switch connection (start/stop)
3
4-pole connection socket, wire feed unit
Start signal, wire feed unit
4
5-pole connection socket, welding machine start/stop
5
6-pole connection socket, solenoid valve
6
4-pole connection socket
Option
Design and function
Software architecture
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5.3 Software architecture
Figure 5-3
Design and function
Main menu
14
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5.4 Main menu
4321 5
Figure 5-4
Item Symbol Description 0
1
Button, Language settings
2
Button, Manual screen
3
Button, Automatic screen
4
Button, Settings screen
5
Button, History
Design and function
Main menu
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5.4.1 Settings
Figure 5-5
Item Symbol Description 0
1
Button, Program screen
2
Button, Functional sequence screen
3
Button, Function screen
4
Button, System screen
5
Button, Notes screen
6
Button, Index welding screen
7
Button, Operating mode screen
8
Button, I/O list screen
To monitor input and output signals
9
Button, Main menu
10
Button, Manual screen
11
Button, Automatic screen
12
Button, Accessories screen
Design and function
Main menu
16
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5.4.1.1 Set functional sequence
6
7
4
3
2
1
10
5
9
14
11
121516
8
13
Figure 5-6
Item Symbol Description 0
1
T1
T1
Tailstock delay
Changes to T1 affect T2
2
T2
T2
Torch delay from
Starting T2 switches the welding machine on.
3
T3
T3
Turn table rotation delay after the welding machine has been switched on.
4
T4
T4
Wire feed unit delay after the welding machine has been switched on.
5
T5
T5
Oscillator delay after the welding machine has been switched on.
6
Input field, program number
7
T10
T10
Torch lift delay
8
T6
T6
Turn table rotation stop delay after the welding machine has been switched off.
9
T7
T7
Wire feed unit switch-off delay after the welding machine has been switched off.
10
T8
T8
Oscillator switch-off delay after the welding machine has been switched off.
11
T9
T9
Mini oscilloscope switch-off delay
12
Button, Index welding screen
13
Button, Settings screen
14
Button, Automatic screen
Design and function
Main menu
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Item Symbol Description 0
15
Button, Manual screen
16
Button, Main menu
Design and function
Main menu
18
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5.4.1.2 Index welding
Figure 5-7
Item Symbol Description 0
1
Input field, welding angle
To enter the required welding angle for the sequence
2
Input field, rotational angle
To enter the required rotational angle for the sequence
3
Display field, Actual position
4
Button, Direction of rotation
5
Button, Functional sequence screen
6
Button, Settings screen
7
Button, Continue mode
8
Button, Automatic screen
9
Button, Manual screen
10
Button, Main menu
11
Button, Go to
The turn table moves to the position set in the "Degree" input field.
12
Input field, RPM
To enter the rotational speed
13
Input field, Repetitions
To enter the repetitions for the specified welding sequence
Design and function
Main menu
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5.4.1.3 System settings
Figure 5-8
Item Symbol Description 0
1
Button, Time setting
Opens the Time setting screen
2
Button, Background setting
Opens the Background setting screen
3
Buttons, Foot-operated remote control settings
To set the foot-operated remote control for manual operation.
The turn table moves to the position set in the "Degree" input field. (Set on
the "Manual control" screen.)
Turn table direction
4
Buttons, Gear selection
Use the A to D buttons to select the desired gear.
Selecting the wrong gear may cause damage to the machine.
The "Reduction ratio" input field is protected by a password.
5
Button, Main menu
6
Button, Manual screen
7
Button, Automatic screen
8
Button, Settings screen
Design and function
Main menu
20
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5.4.1.4 Automatic functions
Figure 5-9
Item Symbol Description 0
1
Display, automatic function disabled
2
Display, automatic function enabled
Figure 5-10
Item Symbol Description 0
1
I>0 feedback
2
Stop after welding, tailstock return
3
Torch and tailstock keep their position when an emergency stop is activated
4
In the Automatic control mode you can start the sequence using the foot-
operated remote control.
5
Button, Main menu
6
Button, Manual screen
7
Button, Automatic screen
8
Button, Settings screen
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EWM CB-007-1 Operating Instructions Manual

EWM
Brand
EWM
Model
CB-007-1
Category
Welding System
Type
Operating Instructions Manual
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