CAUTION
Your Honor customers：
We appreciate your selecting and using of products produced by WELD-FAB For your safety and interest, be sure to read carefully this operating manual and all other documents accompanied with the machine. This operating manual includes contents of main technical parameters、structure and features、matters concerned with operation、common trouble-shootings, which will help you a lot for practical application. WELD-FAB will not hold any responsibility on human or property injury、any other kind of loss caused from operation not on the basis of this manual.
For this manual
1 WELD-FABclaims rights on this manual；
2 If there exists any discrepancy between this manual and practical product, the latter has priority；
3 This manual is subject to modification and explanation by WELD-FAB. without written notice, we hereby hope your understanding.
We welcome your making telephone to us if ever you encountered any kind of technical problems.
1. Safety Requirement
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WARNING |
ARC WELDING MAY BE DANGEROUS |
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PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH,KEEP CHILDREN AWAY.PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights, BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. |
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1.ELECTRIC SHOCK can kill. n The electrode and work (or ground) circuit are electrically “hot” when the welder is on, Do not touch these “hot”parts with your bare skin or wet clothing. n Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. n In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are electrically “hot”. n Always be sure the work cable makes a good electrical connection with the metal being welded, The connection should be as close possible to the area being welded. n Ground the work or metal to be welded to a good electrical(earth) ground. n Maintain the electrode holder ,work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. n Never dip the electrode in water for cooling. n Never simultaneously touch electrically ”hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders. n When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. |
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2.ARC RAYS can burn n Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding .Head shield and filter lens should conform to nation standard . n Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. n Protect other nearby personnel with suitable, non-flame able screening and warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal. |
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3.FUMES AND GASES can be dangerous. n Welding may produce fumes and gases hazardous to health, Avoid breathing these fumes and gases. When welding , keep your head out of the fume. Use enough ventilation and exhaust at the arc to keep fumes and gases away from the breathing zone. n Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. n Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. n Read understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet and follow your employer’s safety practices. |
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4.WELDING SPARKS can cause fire or explosion. n Remove fire hazards from the welding area, if this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through samll cracks and openings to adjacent areas. Avoid welding near hydraulic lines. n Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. n When not welding , make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. n Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. n Vent hollow castings or containers before heating, cutting or welding. They may explode. n Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. n Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits .This can create fire hazards or overheat lifting chains or cables until they fail |
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5. CYLINDER may explode if damaged n Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings ,etc should be suitable for the application and maintained in good condition. n Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. n Cylinders should be located away from areas where they may be struck or subjected to physical damage and a safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. n Never allow the electrode, electrode holder or any other electrically ”hot” parts to touch a cylinder. n Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. n Valve protection caps should always be in place and hand tight except when the cylinder is use or connected for use. |
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6.FOR ELECTRICALLY powered equipment (apply in to welding and cutting equipment) n Turn off input power using the disconnect switch at the fuse box before working on the equipment. n Install equipment in accordance with the WELD-FAB’s recommendations(as: manual). n Ground the equipment in accordance with the WELD-FAB’s recommendations
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7. Other n Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands ,hair, clothing and tools away from V-belt, gears, fans and all other moving parts when starting, operating or repairing or repairing equipment. n In some cases it may be necessary to remove safety guards to perform required maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. n Do not put hands near the running fan, do not operate with panel open or guards off. |
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8.ELECTRIC AND MAGNETIC FIELDS may be dangerous. n Electric current flowing through any conductor causes localized Electric and Magnetic Fields(EMF).Welding current creates EMF fields around welding cables and welding machines. n EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. n Exposure to EMF fields in welding may have other health effects which are now not known. n All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: a. Rout the electrode and work cables together –Secure them with tape when possible. b. Never coil the electrode lead around your body. c. Do not place your body between the electrode and work cables.if the electrode cable is on your right side,the work cable should also be on your right side. d. Connect the work cable to the workpiece as close as possible to the area being welded. e. Do not work next to welding power source. |
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2. Summarize:
Welding rotator is a kind of our advanced welding equipment , which is be researched and manufactured absorbing domestic and international advanced equipment .it is mainly used for pipe, containers, boilers, pressure vessels, oil tank and other cylinder’s assembling, burnishing and welding, can use together with column and boom and SAW system to realize inside and outside girth and longitudinal welding. Its series includes self aligning rotators (HGZ), and conventional rotators (HGK). Accordingly this device has advantages of compact structure, small cubage, beautiful shape, lightweight, convenient operating and so on. The machine can assort all kinds of auto welding or manual welding, improving welding quality, lessening welding labor and improve productivity.
HGK and HGZ Series roller is used for the rotation of the work piece through the friction between the power frame roller and the work piece, which can adjust the angle between the rollers group to fit the different diameter of the work piece, There are bolt adjust equipment by moving on pedestal; The roller rotation adopts AC motor driving, inverter speed adjusting with wide range of speed adjustment, smooth rotation and low speed advantage.
3.Technical Parameters:
Loading Capacity: 100 Ton
Motor Power: 2x3KW
Rotation Speed: 100-1000mm/min
Suitable Vessel Diameter: 800-5000mm
4.Structure:
4.1 The machine consists of 1 set of driving roller, 1 set of idler roller and electric control system.
4.2 Driving roller frame is consists of 2 drive rollers and 1 pedestal. The Idler roller frame is consists of 2 idler roller and 1 pedestal.
4.3 The rollers are equipped on the support bracket, through moving the support bracket by screw realize adjust of rollers center distance to suitable the difference diameter of work-piece between 45º ~ 110º
4.4 Each roller on driving frame is driven by separate one motor and reducer achieves rotating. Working principle of the roller: Direct-type motor reducer- make roller rotating, the wheels linear speed 6 to 60 m/min
4.5 The gear reducer is made by our company, which have low noise, big torque and stabilized speed and so on.
4.6 The rollers are assembled by metal roller and rubber roller, with heavy loading and strong driving.
4.7 Control system consists of control board and remote box. With the control speed characteristic of large range and lasting torque, control speed smoothly, no torque puissant; corresponding power adopts transducer made by TAIWAN N2, which has low noise, high capacity and various function. Signals adopt simulator control; speed display adopts high precision digital display and high stability. In addition, control board’s height is light and volume is small, which is installed at the end of pedestal according to using requirements or put it on the ground separately.
5. Operation Commissioning
5.1 The drive roller and idle roll must be put the foundation in same horizon. Two sets roller must be parallel to put, the ground horizontal plane must even. If the long-term usage base needs to be fix. (The operation can not make the work piece have the big drift on the axes direction)
5.2 The worm wheel decelerator of the machine adopts lubricating oil, other gears and bearings adopt grease lubrication, periodic change. Note: the lubricating oil isn’t oiled into the machine at shipping, the users must oil assigned lubricating oil, and then begin to use.
5.3 The work piece put at roller, after; observe first a position of work whether seemly? Does the work piece stick to rolleer tightly?. On the work piece whether have the dynamic foreign body which will hinder to revolve.( such as; need not of steel bar ) ,when normal of everything, can to run the machine.
5.4 Wiring: see the electric principle diagram, see clearly the AC motor’s wire, and its wire is star circuit (Y), every phase voltage is 240V.
5.5 Turn on the power switch ,Before start to rotation ,select (FWD)forward or (REV) reverse, the AC motor run ,make speed setting potentiometer clockwise turning, the roller revolve clockwise accelerating , counterclockwise ,speed decelerates, push STOP button, motor stop.
5.6 Make the sports such as forward or reverse. In spite of, while needing to change the direction, must turn to the stop position first, waiting motor stop, and then push the contrary direction button to change the direction.
5.7 That machine can not appear to tremble to move while make the sport of various function, the deadlock or excrescent voices ring, if have and should stop immediately, the check and trouble shooting.
5.8 Various the welding experiment, when put the work piece on the rotation, must consult relevant the manual carry on.
5.9 Equipment is after using to complete, keep the center of load gravity stability, then cut off the power supply.
6. Attention items and checking
6.1 Operator must be training of the operation technical ability knowledge, and carry on to the following important point to study in earnest, strictly forbid someone carry on various operation under blindness.
6.2 In the normal circumstance ,the installation of rotator had better adopt the bolt to fix originally.
6.3 When finished installation, check whether tight firmware of each port loosens to move the phenomenon or not, if have, please tighten them immediately.
6.4 Before the usage check the machine and clear some bar the on board ,the rubber roller can not get in touch with oil, and keep off the heat possibly.These will prevent gum the gum roller to aging.
6.5 Check whether the electricity each operation button is failure or not, indicator whether by rule designation.
6.6 The rotation of roller whether normal, and the control of Y series motor is failure or not.
6.7 When welding , equipments must have the credibility to connect ground wire, to insure the safety, can’t connect directly to roller , the in order to prevent damage bearings.
6.8 When the equipments occurrence break down, should cut off the power supply immediately, then carry on check or maintain, and can continue to use.
6.9 The external connects of control box must accord with the electricity system diagram conjunction, careful check, can not connect wrong.
6.10 Check usually
ü Switch on electricity and not open to control the box, check the movement of the equipments from the exterior, confirm to have no excrescent circumstance.
ü Running performance according to standard norm of the function sign.
ü Surroundings environment meets to request.( have no rain water, have no causticity air and the heat environment)
ü Indicator parts are normal.
ü Have no excrescent voice, vibration and smell.
ü Has no over hot or change color etc circumstance.
6.11 Periodical check
ü When periodically checking, stop the movement first, cut off the power supply and open the control device cover.
ü Power supply electric voltage is within the scope of allow.
ü Clear the dust of controller.
ü The electric cable of insulates the circumstance, if there is damage should stop usage immediately to check to fix.
ü Various connector parts, if have already loosen to move, the tight solid rear can use.
ü Control each electric appliances of circuit component, if have damage piece and can affect to act or become to break down hidden trouble, must take into the repair.
7. The equipments lubricates and maintains
7.1 The reducer of this equipments all adopts the lubricant lubrication, the open type wheel gear and bearingses adopt the grease lubrication.
7.2 Before using, reducer box need to add the oil to the mark centerline, while running should usually watch the oil height, add the lubricant of the same oil in time.
7.3 Lubricant and grease should periodically replace, the general first time replace in order to circulate 300 hours, should do away with the survive and dirty oil while replace, hereafter separate to replace a times 6 month each time.
7.4 While already had no usage with long hours, while restarting should replace the lubricant and lubricate grease .
7.5 The lubricant chooses to use lubricant of the industry wheel gear oil or functions very much, lubricate grease recommendation usage the special kind lubricates grease according to your country.
The worm gear reducer use Mobil DTE 24 or equivalent lubrication oil, other gears and shafts use lubricating grease. When first time use, change oil after one month, and then change oil every half year.
Note: See measuring scale for oil level
| SPECIFICATIONS | MobilDTE 24 |
| ISO Grade | 32 |
| cSt @ 40º C | 31.5 |
| cSt @ 100º C | 5.29 |
| Viscosity Index, ASTM D 2270 | 98 |
| Specific Gravity @ 15.6º C/15.6º C, ASTM D 1298 | 0.871 |
| Copper Strip Corrosion, ASTM D 130, 3 hrs @ 100º C | 1B |
| Rust Characteristics Proc B, ASTM D 665 | Pass |
| Pour Point, ºC, ASTM D | -27 |
| Flash Point, ºC, ASTM D 92 | 220 |
| FZG 4-Square Load Support, DIN 51354, Fail Stage | 12 |
| Foam Sequence I, II, III, ASTM D 892 , ml | 200 |
7.6 The periodical check control each electric appliances of circuit component, if have damage piece and can affect to act or become to break down hidden trouble, must take into the repair.
8. The parameter of inverter and adjustment
8.1 The digital indicator shows the rotation speed, if show the speed out of accordance with actual speed, adjust the potentiometer on the electricity control panel in the box, make indicator value and actual values to agree with.
8.2 When over load or short circuit phenomenon, inverter will alarm on automatically, and stop output.
8.3 Reset or change the parameter of inverter, detailed read to the machine manual. 8.4 The electricity principle diagram sees attach the page
9. Trouble shooting
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Trouble |
Causation |
Method |
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Rotation act malfunction
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1. input power wrong 2. motor over load 3. inverter run wrong 4. motor malfunction 5. contactor,relay malfunction |
1. adjust it 2. examine gear box 3. examine it 4. examine it 5. replacing |
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Speed and display differ |
RP2 malfunction |
Adjust or replacing |
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Inverter or transducer act malfunction |
Read its manual |
Read its manual |
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Rotation motor run but speed can not change |
1. potentiometer malfunction 2. Inverter malfunction |
1. examine it 2. read its manual |
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Speed display is not accurately |
1. No DC+5V input 2. potentiometer normal 3. indicator malfunction |
1. examine it 2. replacing 3. examine it |
