User manual ROTOWELD 2500

[. . . ] Rotoweld 2500 Pipe Welding Workstation Reference Manual By Tecnar Automation Ltée 1 TABLE OF CONTENTS INTRODUCTION GENERAL DESCRIPTION OPERATION OF THE WORKSTATION PREPARATION OF THE WELD START-UP. REMOTE PENDANT COLUMN OR BOOM PENDANT USER INTERFACE GENERAL PRINCIPLES DATE AND TIME CORRECTION ICONS DESCRIPTION EDITING THE WELDING PARAMETERS SELECTING CREATING DELETING A PROCEDURE SELECTING A PROCUDURE CREATING A PROCEDURE DELETING A PROCEDURE MAKING A BACKUP OF THE PROCEDURE GETTING THE LOG FILES RETRIEVING THE PRODATALOG FILES SELECTING CREATING DELETING WELDERS NAME SELECTING A WELDER NAME CREATING A WELDER NAME DELETING A WELDER NAME SET UP SCREEN LOADING A SPOOL. THE WELDING SEQUENCE OPERATION ROOT OPERATION FILL 28 30 30 31 32 33 34 4 4 6 6 7 11 13 14 14 17 19 21 22 23 24 24 24 25 26 26 27 27 2 SEQUENCING PERFORMING AN ADDITIONAL FILL PASS OR PASSES EDITING THE WELDING PARAMETERS. THE PARAMETER FUNCTION DEFINITION OF PARAMETERS SPECIFICATION OF THE SYSTEM ROTOWELD 2000 RTBP-2 PLATFORM ROTOWELD 2000 RGMAW SYSTEM ROTOWELD 2000 RSAW SYSTEM ELECTRICAL REQUIREMENTS ELECTRICAL REQUIREMENT INTERNATIONAL ELECTRICAL REQUIREMENT CANADA USA GLOSSARY OF TERMS 38 35 35 36 36 36 38 39 41 43 43 45 48 3 DESCRIPTION OF THE EQUIPMENT INTRODUCTION Rotoweld 2500 is a totally automated pipe-on-positioner welding system that performs full penetration root and filler passes in an open beveled butt joint. [. . . ] The welder can 6 The term "PROCEDURE" refers to a computer file containing a set of welding sequence parameters. 28 enter some information on the selected procedure on the idle screen. Modifying the SET Up for root or fill directly on the screen affects the procedures using this specific SET UP. Information for the welder The size of the welding wire The type of material this procedure is used on The shielding gas to use SET UP also contains the parameters used for the burnback, which are: travel, volts, wire, length. Note that the burnback function prevents the wire from getting stuck on the weld or melt the contact tip. The root pass SET UP, also contains the PEAK AMPS, a setting for the STT welding machine to perform the root pass. For stainless steel, it is typically set around 280 and for mild steel between 310 and 400. These numbers are used for the control of the root pass and dictate how the feedback reacts to the vision system data or to manual corrections made by the welder when welding the root pass. From the sub menu SET UP screen, you can create a new one by using COPY, or select, or DELETE a SET UP for root or fill by using the menu on the top right corner. With the arrow go beside CS CO2 for example, and press ENTER, this will let you access the sub menu (Figure 17). With the joystick, move right to select COPY, press ENTER to validate. You can now enter the new name using the joystick (POS. FOR/REV) to choose the proper letter or number, and move right with the joystick to the next character, once done press ENTER to validate or STOP to exit without any change. To DELETE a SET UP for root or fill, again use the menu on the top right corner. With the arrow, go beside CS CO2 for example, and press ENTER, this will let you access the sub menu (Figure 17). With the joystick, move right to select DEL, then press ENTER to validate. Please also note that this screen is rarely accessed by the operator since procedures created from the procedure sub menu include the complete SET UP. To go back to the idle screen, go beside the procedure name with the arrow and press ENTER, and TOP to exit the edit mode. 29 LOADING A SPOOL. The spool is locked in the rotator's chuck at one end and supported, if necessary by the track mounted idler rolls. Spacing and height of the rolls can be adjusted with the incorporated hydraulic jack. It is very important that the spool be leveled and centered on the rotation axis of the positioner. With the spool still held by the crane, engage into the chuck the end terminated by either a pipe, a flange, a concentric reducer or a tee. Slightly tighten the chuck and roughly level the spool with the crane. Lower the rolls on the idler so that it can freely slide underneath the spool, then close the lowering valve. Bring the idler as close as possible to the chuck and raise the rolls until they touch the surface of the pipe. Give the hydraulic jack an additional stroke, especially if it was loosely fitted in step 4. [. . . ] The results : 90% arc-on duty cycle, 400% productivity increase and a clean, high quality weld every single time. SPECIFICATIONS Welding Root Process: Surface Tension Transfer (STT) Fill Process: Spray Transfer Root Power source: Lincoln STT Fill & Cap Power source: Lincoln CV 400 Torches (2): Bernard Wire feeders (2): Miller type 64 (4 rolls, heavy duty) Water circulator: Lincoln, type 10-I Motion: Torch positioning: X-Y, computer controlled, servo driven slides. Torch oscillating: Computer controlled, servo driven oscillator (up to 3 cycle per seconds at an amplitude of 1") Carriage: Manually controlled motorization. Pipe rotation: Full interface with existing positioners, 0 to 3 RPM. Control: Operating software: Custom (developed in Delphi). Operating system: Windows 2000 Operator interface: Graphic, point&click type Computer: Asus P4B, 1. 6 GHz Pentium IV, 256MB RAM, 20GB HD Motion boards (2): Galil DM-630 4 axis servo controller Camera:: Panasonic Vision board: Mutech VGA-410 (8MB) Interface board: Metrabus MDB-64 Monitor: NEC LCD 1550V (15" flat screen) Pendant: Custom made with non-proportional joystick. Performance. Root pass: approx. [. . . ]