Savair - Weld Systems Integrators

Transcription

Savair
Savair
GM PPO Project
XMA – XPA – XWA – XZA
CMA – CWA – CZA
Manual Welding Guns
User’s
Manual
Savair Inc. - 48500 Structural Drive - Chesterfield Township - Michigan – 48051 - Tel. (586) 949-9353
Savair
DOCUMENT AMENDMENTS
Date
Document Reference
Amendment Description
3-24-2005
Manual Weldguns Training Manual
Creation
3-28-2005
Updated § 9.2 to include QC part #’s
3-28-2005
Updated §3.8 to include improved pics/callouts
3-29-2005
Included quick coupling detail and reference
4-01-2005
Removed emergency pushbutton from detail dwgs
4-07-2005
Corrected § 3.6.1 – circuit flow rates
4-07-2005
Clarified § 4.2 – pressure diff. measure location
4-08-2005
Corrected § 6.2.1.16 – control handle removal
4-08-2005
Corrected § 6.2.1.19 – elect. box removal
4-08-2005
Included 13A cylinder detail
4-08-2005
Corrected § 9.5.9 (CZA) voltage ref.
4-08-2005
Added 11C cyl. ref. to § 9.5.7 (CMA)
4-08-2005
Added 11A cyl. ref. to § 9.5.8 (CWA)
4-09-2005
Clarified § 3.6
4-18-2005
Added quick coupling part reference table to § 9.2
4-20-2005
Corrected cylinder kit part numbers in § 9.2
8-01-2005
Minor aesthetic updates per GM.
8-01-2005
Added warning to § 3.8
8-01-2005
Added quick coupling troubleshooting items to § 8.3
Savair
TABLE OF FIGURES................................................................................................ 6
1.
1.1
1.2
INTRODUCTION ............................................................................................ 7
GENERAL ................................................................................................................. 7
CODIFICATION AND CHARACTERISTICS ....................................................................... 9
1.2.1
XMA CODIFICATION ......................................................................................................................9
XMA DETAIL ................................................................................................................................10
1.2.2.1
1.2.2.2
XPA CODIFICATION .....................................................................................................................11
XPA DETAIL .................................................................................................................................12
1.2.3.1
1.2.3.2
XWA CODIFICATION ....................................................................................................................13
XWA DETAIL ................................................................................................................................14
1.2.4.1
1.2.4.2
XZA CODIFICATION ......................................................................................................................15
XZA DETAIL ..................................................................................................................................16
1.2.5.1
1.2.5.2
CMA CODIFICATION ...................................................................................................................17
CMA DETAIL ...............................................................................................................................18
1.2.6.1
1.2.6.2
CWA CODIFICATION ...................................................................................................................19
CWA DETAIL ...............................................................................................................................20
1.2.7.1
1.2.7.2
CZA CODIFICATION .....................................................................................................................21
CZA DETAIL .................................................................................................................................22
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
2.
2.1
XMA GUN ................................................................................................................... 9
1.2.1.1
1.2.1.2
XPA GUN .................................................................................................................. 11
XWA GUN ................................................................................................................. 13
XZA GUN................................................................................................................... 15
CMA GUN ................................................................................................................. 17
CWA GUN ................................................................................................................. 19
CZA GUN .................................................................................................................. 21
DESCRIPTION ............................................................................................. 23
CONSTRUCTION...................................................................................................... 23
2.1.1
2.1.2
2.1.3
SUSPENSION ................................................................................................................ 23
GUN HEIGHT ADJUSTMENT PROCEDURE ........................................................................... 23
ROTATION SYSTEMS ...................................................................................................... 23
2.1.3.1
2.1.3.2
2.1.3.3
2.1.3.4
GYROSCOPIC CIRCLE CURVED BAR ROTATION ...............................................................................23
ADJUSTING GUN BODY BALANCING ...............................................................................................24
GUN BODY CIRCLE ROTATION .......................................................................................................25
DISK SUPPORT ...............................................................................................................................25
2.1.4.1
2.1.4.2
NOSE, SLIDING BLOCK AND MOBILE ELECTRODE HOLDER .................................................................25
FIXED AND MOBILE ARMS ..............................................................................................................26
2.1.4
ARTICULATION SYSTEMS ................................................................................................ 25
2.1.4.2.1
2.1.4.2.2
2.1.4.3
ARTICULATION OF XWA GUNS AND FIXED ARMS OF CWA GUNS ....................................................27
2.1.4.3.1
2.1.4.3.2
2.1.4.3.3
2.1.4.4
2.1.4.5
2
Fixed arms ...........................................................................................................................................26
Electrode holder arm mounting ......................................................................................................27
Fixed and mobile arms......................................................................................................................27
Conducting current – fixed arm ......................................................................................................27
Conducting current – mobile arm (XWA) ......................................................................................28
DISASSEMBLY AND REASSEMBLY OF THE ARTICULATED SYSTEM.............................................................28
THE SECONDARY ELECTRICAL CIRCUIT .............................................................................................28
Savair
2.1.5
CYLINDER SYSTEMS ....................................................................................................... 28
2.1.5.1
2.1.5.2
CYLINDER AND SOLENOID VALVES ..................................................................................................28
CYLINDER OPERATING PRINCIPLE....................................................................................................30
2.1.5.2.1
2.1.5.2.2
2.1.5.3
PNEUMATIC SCHEMATIC.................................................................................................................32
2.1.6.1
2.1.6.2
2.1.6.3
2.1.6.4
2.1.6.5
2.1.6.6
ELECTRIC HANDLE .........................................................................................................................33
BRACKET AND HANDLE SUPPORT.....................................................................................................33
QUICK COUPLING.........................................................................................................................33
TRANSFORMER AND ELECTRICAL BOX ..............................................................................................34
ELECTRICAL DISTRIBUTOR ................................................................................................................35
ELECTRICAL SCHEMATIC.................................................................................................................36
2.1.7.1
2.1.7.2
2.1.7.3
CASING .......................................................................................................................................37
AIR AND WATER FEEDERS ...............................................................................................................37
COOLING ....................................................................................................................................37
2.1.6
2.1.7
ELECTRICAL SYSTEMS .................................................................................................... 33
CASE AND COOLING SYSTEMS ....................................................................................... 37
2.1.7.3.1
2.1.7.3.2
2.1.7.3.3
2.1.7.3.4
2.1.7.4
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
Single-stroke cylinder.........................................................................................................................30
Double-stroke cylinder ......................................................................................................................30
Connecting the water supply..........................................................................................................37
Cooling circuits and flow rates ........................................................................................................37
Electrode cooling ..............................................................................................................................37
Cooling schematic ............................................................................................................................38
CONNECTING THE AIR SUPPLY ........................................................................................................38
SETTING UP ................................................................................................. 40
GENERAL ............................................................................................................... 40
SUSPENSION BAR .................................................................................................... 40
3.2.1
3.2.2
SETTING THE LENGTH...................................................................................................... 40
ADJUSTING THE BALANCING AND STOPS .......................................................................... 40
GEOMETRICAL CHECKS ........................................................................................... 40
3.3.1 SECONDARY LOOP WINDOW ......................................................................................... 40
OPENING DIMENSIONS ............................................................................................................. 41
3.3.2.1 WORKING STROKE OPEN (PO) ......................................................................................................41
3.3.2.2 GUN FULLY OPEN (GO) ...............................................................................................................41
MECHANICAL CHECKS............................................................................................ 41
3.4.1
3.4.2
ELECTRODE FORCE ....................................................................................................... 41
RESPONSE TIME ............................................................................................................ 42
PNEUMATIC CHECKS ............................................................................................... 42
3.5.1
3.5.2
3.5.3
OUTLET BRAKING ......................................................................................................... 42
SOLENOID VALVE OPERATION ........................................................................................ 42
CHECKING THE UNIONS ................................................................................................ 43
COOLING CIRCUIT CHECKS ..................................................................................... 43
3.6.1
3.6.2
3.6.3
COOLING SYSTEM DESCRIPTION ...................................................................................... 43
WATER FLOW RATE ....................................................................................................... 43
CHECKING FOR LEAKS .................................................................................................. 43
ELECTRICAL CHECKS ............................................................................................... 44
3.7.1
3.7.2
INSULATION CHECK ...................................................................................................... 44
GROUND LOOP RESISTANCE .......................................................................................... 44
3
Savair
3.8
QUICK COUPLING .................................................................................................. 44
3.8.1
FIXED PLATE (GUN SIDE)................................................................................................................45
MOBILE PLATE (SUPPLY SIDE)..........................................................................................................45
3.8.2.1
3.8.2.2
FIXED PLATE ..................................................................................................................................45
MOBILE PLATE ...............................................................................................................................46
3.8.2
4
4.1
4.2
4.3
4.4
4.5
5
5.1
5.2
6
6.1
6.2
INSTALLATION .............................................................................................................. 44
3.8.1.1
3.8.1.2
MAINTENANCE ............................................................................................................ 45
START-UP .................................................................................................... 47
CONNECTION RECOMMENDATIONS.......................................................................... 47
4.1.1
4.1.2
4.1.3
ELECTRICAL CONNECTION ............................................................................................. 47
PNEUMATIC CONNECTION............................................................................................. 47
WATER SUPPLY ............................................................................................................. 47
NORMAL OPERATING AND STORAGE CONDITIONS ..................................................... 48
HANDLING ............................................................................................................. 49
4.3.1
ADAPTING THE WORK STATION ....................................................................................... 49
MAKING THE CONNECTIONS.................................................................................... 49
POSITIONING THE GUN BEFORE WELDING .................................................................. 49
STORAGE .................................................................................................... 50
PREPARING GUNS FOR STORAGE .............................................................................. 50
STORAGE CONDITIONS ........................................................................................... 50
REMOVAL AND INSTALLATION ................................................................. 51
NECESSARY PRECAUTIONS ....................................................................................... 51
6.1.1 FOR OPERATIONS NOT REQUIRING GUN REMOVAL .......................................................... 51
FOR OPERATIONS REQUIRING GUN REMOVAL .............................................................................. 51
REMOVAL AND INSTALLATION INSTRUCTIONS.............................................................. 52
6.2.1
MAIN COMPONENTS .................................................................................................... 52
6.2.1.1 REMOVAL OF THE CASINGS ............................................................................................................52
6.2.1.2 REPLACING THE LAMINATED CONDUCTOR .......................................................................................52
6.2.1.3 REPLACING AN ELECTRODE HOLDER ...............................................................................................52
6.2.1.4 REPLACING THE ELECTRODE HOLDER COOLING CIRCUIT...................................................................53
6.2.1.5 REPLACING THE WATER FEEDERS (C-TYPE) ......................................................................................53
6.2.1.6 REPLACING THE SLIDING BLOCK (C-TYPE) .......................................................................................54
6.2.1.7 REPLACING THE SLIDING BLOCK NOSE (C-TYPE) ..............................................................................54
6.2.1.8 REPLACING THE SEAL BUSHING AND SLIDE (C-TYPE) .........................................................................54
6.2.1.9 REPLACING THE MOBILE ARM (X-TYPE) ...........................................................................................54
6.2.1.10 REPLACING THE FIXED ARM ..............................................................................................................54
6.2.1.10.1 C-type guns ...........................................................................................................................................54
6.2.1.10.2 X-type guns............................................................................................................................................55
6.2.1.11 REPLACING THE COUPLING (X-TYPE) ................................................................................................55
6.2.1.12 ADJUSTING THE STROKE (X-TYPE) ......................................................................................................55
6.2.1.13 REPLACING THE CYLINDER ................................................................................................................56
6.2.1.14 REPLACING SEALS, CYLINDER BUSHINGS AND HOUSINGS.....................................................................56
6.2.1.15 REPLACING THE SOLENOID VALVES ...................................................................................................58
6.2.1.16 REPLACING THE CONTROL HANDLE ...................................................................................................58
6.2.1.17 REPLACING THE TERMINAL BOX .........................................................................................................58
6.2.1.18 REPLACING THE TRANSFORMER .........................................................................................................58
6.2.1.19 REPLACING THE ELECTRICAL BOX ......................................................................................................59
4
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7
7.1
7.2
8
8.1
8.2
8.3
8.4
9
9.1
9.2
9.3
9.4
9.5
PREVENTATIVE MAINTENANCE ................................................................. 60
MAINTENANCE TABLE 1 ........................................................................................... 60
MAINTENANCE TABLE 2 ........................................................................................... 61
TROUBLESHOOTING ................................................................................... 62
TROUBLESHOOTING TABLE 1 ..................................................................................... 62
APPENDICES .............................................................................................. 66
TIGHTENING TORQUE VALUES ................................................................................... 66
WEARING AND REPLACEMENT PARTS......................................................................... 67
9.2.1
9.2.2
9.2.3
WEARING AND REPLACEMENT PARTS TABLE 1 ................................................................... 67
RECOMMENDED PRODUCTS ..................................................................................... 70
9.3.1
9.3.2
LOCTITE® OR EQUIVALENT PRODUCTS ........................................................................... 70
OTHER PRODUCTS ........................................................................................................ 70
MAINTENANCE ACCESSORIES .................................................................................. 70
GUN DETAIL DRAWINGS .......................................................................................... 70
9.5.1
QUICK COUPLING ........................................................................................................ 71
9.5.1.1
9.5.1.2
9.5.2
9.5.3
9.5.4
9.5.5
9.5.6
9.5.7
9.5.8
9.5.9
9.5.10
QUICK COUPLING DETAIL ..............................................................................................................71
QUICK COUPLING REFERENCE .......................................................................................................72
CYLINDER ASSEMBLY DETAIL .......................................................................................... 73
SHANK & CAP COOLING DETAIL .................................................................................... 75
XMA GUN DETAIL ....................................................................................................... 76
XPA GUN DETAIL ........................................................................................................ 77
XWA GUN DETAIL ....................................................................................................... 77
XZA GUN DETAIL ........................................................................................................ 79
CMA GUN DETAI ........................................................................................................ 79
CWA GUN DETAIL ....................................................................................................... 80
CZA GUN DETAIL ........................................................................................................ 81
5
Savair
TABLE
OF
FIGURES
FIGURE 2.1-A – CURVED BAR HANGER ................................................................................................................24
FIGURE 2.1 B – FIXED ARM ..................................................................................................................................26
FIGURE 2.1-C – MOBILE ARM COUPLING .............................................................................................................28
FIGURE 2.1-D – CYLINDER ASSEMBLY (13A).........................................................................................................29
FIGURE 2.1-E – SINGLE STROKE PNEUMATIC DIAGRAM ...........................................................................................30
FIGURE 2.1-F – DOUBLE STROKE PNEUMATIC DIAGRAM..........................................................................................30
FIGURE 2.1-G – SERVO VALVE COMMAND BLOCK DIAGRAM ................................................................................31
FIGURE 2.1-H – PNEUMATIC SCHEMATIC ...............................................................................................................32
FIGURE 2.1-I – COMMAND HANDLE .....................................................................................................................33
FIGURE 2.1-J – QUICK COUPLING........................................................................................................................33
FIGURE 2.1-K – ELECTRICAL TRANSFORMER ...........................................................................................................34
FIGURE 2.1-L – QUICK COUPLING........................................................................................................................35
FIGURE 2.1-M – ELECTRICAL SCHEMATIC ..............................................................................................................36
FIGURE 2.1-N – ELECTRODE COOLING .................................................................................................................38
FIGURE 2.1-O – COOLING SYSTEM SCHEMATIC .....................................................................................................38
FIGURE 3.3-A – SECONDARY LOOP WINDOW .......................................................................................................40
FIGURE 3.3-B – WORKING STROKE OPEN ..............................................................................................................41
FIGURE 3.4-A - DYNAMOMETER ...........................................................................................................................41
FIGURE 3.4-B – RESPONSE TIMES ..........................................................................................................................42
FIGURE 3.5-A – OUTLET LIMITER............................................................................................................................42
TABLE 1 - INSULATION CHECK MEASURING POINTS .................................................................................................44
FIGURE 3.7-A – ELECTRICAL TRANSFORMER ...........................................................................................................44
FIGURE 3.8-A – QUICK COUPLING FIXED PLATE ....................................................................................................45
FIGURE 3.8-B – QUICK COUPLING MOBILE PLATE ..................................................................................................45
TABLE 2 - OPERATING & STORAGE CONDITIONS ....................................................................................................48
FIGURE 4.4-A – QUICK COUPLING LATCHING SYSTEM............................................................................................49
FIGURE 4.5-A – CLEARANCE STROKE OPEN POSITION ............................................................................................49
FIGURE 6.2-A – ELECTRODE HOLDER COOLING DIAGRAM .....................................................................................53
FIGURE 6.2 B – CYLINDER CROSS-SECTION ...........................................................................................................57
6
Savair
1.
INTRODUCTION
1.1
GENERAL
All the welding gun models in the new ARO compact range are equipped with an integrated transformer
and a single or double-stroke multi-stage pneumatic cylinder.
This new range of X-type (scissor) and C-type (pinch) guns are available in four different sizes:
• Size M:
(XMA/CMA)
Medium-sized gun
• Size P:
(XPA/CPA)
Powerful guns
• Size W:
(XWA/CWA)
Aluminum arm/articulation
• Size Z:
(XZA/CZA)
Aluminum arm/articulation
They are designed to work in association with an electronics cabinet including:
• A fluids (air, water) control panel including a shutoff valve, filter and pressure selector
• A programmable welding sequence
• A power unit
• A differential circuit breaker
Each of the gun’s components has been specifically designed to work in the difficult conditions found on
light or heavy vehicle assembly lines.
Development has therefore essentially focused on:
• Ease of installation (small amount of space available in the factory)
• Ergonomics factors (to limit effort and tool handling)
• Easy maintenance (proven reliability of the products with easy access and quick
interchangeability of wear parts)
• Safety (conformity with electrical safety standards and reinforcement of each mechanical part
that contributes to safety)
The transformers, cylinders, articulations and balancing systems have been designed in such a way as
to facilitate general tool modularity and maneuverability.
Furthermore, in order to optimize grasping of the tool, it is fitted with one or more handles (4 max.),
whose angular and longitudinal positions are fully adjustable.
The gun’s balancing position on its curved bar, as well as its working height, can be easily adjusted, and
the guns are equipped with a new range of lightweight transformers adapted to each model’s specific
capacities. Their power rating is 57 kVA in medium frequency rectified technology (MFDC 1000/1200
Hz).
The articulations of the M and P size models are made of cast copper.
The secondary outputs from the transformer are connected directly to the articulation’s fixed arm without
any intermediate part, and a simple flexible laminated conductor is used to make the connection with the
mobile arm.
With the intention of limiting the tool’s weight, the W (large) and Z-size models have articulation and
electrode holder arms made of aluminum. The current is delivered from the transformer to the gun arms
by means of a flexible laminated conductor and two copper conductors cooled with water.
On all the models, the fixed arm is insulated from the rest of the gun, whereas the mobile arm and the
rest of the gun body are connected to ground.
The center distance between the arms increases with the size of the gun, going from 220mm (XMA) to
300mm (XWA) on scissor guns, and from 150mm (CMA) to 250mm (CZA) on C-type guns.
Each model is equipped with an Ø80mm single or double-stroke pneumatic cylinder, whose stroke (60 or
120mm) depends on the type of articulation (X or C) used, the number of stages, the model’s
mechanical capacity and on the network pressure available.
In order to make the gun more compact, the double-stroke cylinder has a locking system at the end of
the clearance stroke movement. This makes it possible to limit the total length of the cylinder whenever
an additional stage is added (up to 7 stages on the XWA guns). The cylinder-command solenoid valves
are installed directly on the flanks on each side of the cylinder.
7
Savair
In order to facilitate tool handling, the gun is mounted on a ball race inside a gyroscopic circle and its
power supply coupling is positioned in the prolongation of this circle’s axle. Thiis coupling is shielded by
the rear protection cover, and a sleeve installed on a bracket makes it possible to fasten the coupling’s
components.
On each gun model, the operator is protected against any risk of pinching by rigid covers installed in the
front on the fixed and mobile arms, and on the rear above welding cylinders. These easily removable
covers also provide easy access to all wear parts (hoses, flexible laminated conductors, etc.).
8
Savair
1.2
CODIFICATION AND CHARACTERISTICS
1.2.1
XMA Gun
1.2.1.1 XMA Codification
X
M
A
Scissors gun,
size M (Medium)
1
2
3
4
5
1 – Transformers MFDC : 1000 Hz
(2)
Code
U20=
[V]
57(1)
6,3
(2)
I2p=
[kA]
Rectifier
Sp 50%
[kVA]
6,2
4 diodes
57
(1) Preferential size
(2) U20 & I2p: Rectified (measured downstream of diode bridge)
2 – Cylinders ∅80mm, Max Force 1240daN
Type
4 – Project & Customer Code
Stroke
Code
# of
Stages
13A
3
Max
Pressure
[psi]
124.7
15A
4
94.3
15
55
5
17A
5
75.4
15
55
5
PO
[mm]
GO
[mm]
R
[mm]
15
55
5
PO: Working stroke open – GO: Gun fully open – R: Reserve
3 – Arm Center Distance (mounting)
(3)
Code
22
Center Distance
[mm]
220
(3) Fixed arm
10° tilt
This code consists of two digits. The first
digit contains a project-specific code; the
second identifies the customer.
5 – Voltage/Frequency Code
1
230V – 50Hz
2
400V – 50Hz
3
440V – 50Hz
4
415V – 50Hz
6
230V – 60Hz
7
400V – 60Hz
8
440V – 60Hz
M
500V – 1000Hz / 800V – 1200Hz
B
460V – 60Hz
C
480V – 60Hz
D
380V – 60Hz
9
Savair
1.2.1.2 XMA Detail
3
00 053 616
03 011 062
03 046 061
10 830 412
18
00 069 175
64 150 202
61 100 268
00 054 862
00 068 800
F2 175 412
Figure 1.2 A – XMA Gun Body
1
PART DESCRIPTION
PART NUMBER
Copper alloy fixed arm
F2 085 960
11
PART DESCRIPTION
PART NUMBER
Quick coupling fixed plate
n/a
2
Articulation joint
n/a
12
Fluids connection feeder
See fixed plate - § 3.8.1
3
Flexible laminated conductor*
00 056 217
13
Rear casing
n/a
4
Copper alloy mobile arm
F2 085 961
14
Transformer rear cover/dist
00 770 393
5
Mobile protective casing
00 083 448
15
Transformer
41 854 014
6
Front protective casing
00 083 187
16
Gyroscope disk
F2 083 134
7
Coupling
n/a
17
Gyroscope bridge clamp
62 040 121
8
Handle assembly
00 177 598
18
Hanging bar w/attach*
T2 083 695
9
Welding cylinder
50 083 935
19
Auxiliary handle & attach
00 640 411
10
Rear cover screw
10 920 352
10
*See diagram insets
Savair
1.2.2
XPA Gun
1.2.2.1 XPA Codification
X
P
A
Scissors gun,
size P (Large)
1
2
3
4
5
(2)
Code
U20=
[V]
57(1)
6,3
(2)
I2p=
[kA]
Rectifier
Sp 50%
[kVA]
6,3
4 diodes
57
Type
Stroke
Code
# of
Stages
13A
3
Max
Pressure
[psi]
145
15A
4
17A
5
19A
6
PO
[mm]
GO
[mm]
R
[mm]
15
55
5
109
15
55
5
87
15
55
5
73
15
55
5
(3)
Code
25
Center Distance
[mm]
(3) Fixed arm
10° tilt
1
230V – 50Hz
2
400V – 50Hz
3
440V – 50Hz
4
415V – 50Hz
6
230V – 60Hz
7
400V – 60Hz
8
440V – 60Hz
M
500V – 1000Hz / 800V – 1200Hz
B
460V – 60Hz
C
480V – 60Hz
D
380V – 60Hz
250
11
Savair
1.2.2.2 XPA Detail
3
00 053 616
03 011 062
03 046 061
10 830 412
18
00 069 175
64 150 202
61 100 268
00 054 862
00 068 800
F2 175 412
Figure 1.2 B – XPA Gun Body
1
PART DESCRIPTION
PART NUMBER
F2 085 962
11
PART DESCRIPTION
PART NUMBER
Quick coupling fixed plate
n/a
2
Articulation joint
n/a
12
3
Flexible laminated conductor*
00 054 855
13
Rear casing
n/a
4
Copper alloy mobile arm
F2 085 963
14
F2 086 766
5
00 083 699
15
Transformer
41 854 014
6
00 083 700
16
Gyroscope disk
F2 083 626
7
Coupling
n/a
17
62 040 121
8
Handle assembly
00 177 598
18
Hanging bar w/attach*
T2 083 695
9
Welding cylinder
50 083 955
19
00 640 411
10
Rear cover screw
10 920 352
12
*See diagram insets
Savair
1.2.3
XWA Gun
1.2.3.1 XWA Codification
X
M
A
Scissors gun,
size M (Medium)
1
2
3
4
5
(2)
Code
U20=
[V]
57(1)
6,3
(2)
I2p=
[kA]
Rectifier
Sp 50%
[kVA]
6,2
4 diodes
57
Type
Stroke
Code
# of
Stages
13A
3
Max
Pressure
[psi]
124.7
15
55
5
15A
4
94.3
15
55
5
17A
5
75.4
15
55
5
PO
[mm]
GO
[mm]
R
[mm]
(3)
Code
22
Center Distance
[mm]
220
(3) Fixed arm
10° tilt
1
230V – 50Hz
2
400V – 50Hz
3
440V – 50Hz
4
415V – 50Hz
6
230V – 60Hz
7
400V – 60Hz
8
440V – 60Hz
M
500V – 1000Hz / 800V – 1200Hz
B
460V – 60Hz
C
480V – 60Hz
D
380V – 60Hz
13
Savair
1.2.3.2 XWA Detail
Figure 1.2 C – XWA Gun Body
PART DESCRIPTION
PART NUMBER
PART DESCRIPTION
PART NUMBER
1
Aluminum alloy fixed arm
F2 084 540
13
2-part harness sleeve
n/a
2
Fixed arm copper rigid cond.
00 177 081
14
Rear casing
00 169 343
3
Articulation joint
n/a
15
n/a
4
Flexible laminated conductor
00 054 855
16
F2 086 766 / 88 741 124
5
Mobile arm rigid conductor
00 177 082
17
Transformer
41 854 014
6
Aluminum alloy mobile arm
F2 084 562
18
Gyroscope disk
F2 083 626
7
00 084 561
19
n/a
8
Coupling
n/a
20
Suspension rod w/attach
T2 083 695
21
00 640 411
00 084 560
10
9
Handle assembly
00 177 598
11
Welding cylinder
50 083 950
14
Savair
1.2.4
XZA Gun
1.2.4.1 XZA Codification
X
Z
A
Scissors gun,
size Z ()
1
2
3
4
5
(2)
Code
U20=
[V]
57(1)
6,3
(2)
I2p=
[kA]
Rectifier
Sp 50%
[kVA]
6,2
4 diodes
57
Type
Stroke
Code
# of
Stages
13A
3
Max
Pressure
[psi]
125
15
55
5
15A
4
94
15
55
5
17A
5
75
15
55
5
PO
[mm]
GO
[mm]
R
[mm]
(3)
Code
22
Center Distance
[mm]
220
(3) Fixed arm
10° tilt
1
230V – 50Hz
2
400V – 50Hz
3
440V – 50Hz
4
415V – 50Hz
6
230V – 60Hz
7
400V – 60Hz
8
440V – 60Hz
M
500V – 1000Hz / 800V – 1200Hz
B
460V – 60Hz
C
480V – 60Hz
D
380V – 60Hz
15
Savair
1.2.4.2 XZA Detail
8
7
9
10
6
5
4
3
11
12
2
13
1
14
15
Figure1.2 D – XWA Gun Body
PART DESCRIPTION
PART NUMBER
1
00 085 029
2
Fixed arm copper rigid cond.
00 177 365
3
Articulation joint
n/a
PART DESCRIPTION
PART NUMBER
Handle assembly
00 177 598
10
Welding cylinder
50 086 886
11
Transformer
41 854 014
9
4
00 164 410
12
Gyroscope disk
F2 086 581
5
Mobile arm rigid conductor
00 177 364
13
n/a
6
00 085 028
14
T2 083 695
7
Coupling
00 167 674
15
Auxilliary handle w/ attach
00 640 411
8
Coupling
n/a
16
Savair
1.2.5
CMA Gun
1.2.5.1 CMA Codification
C
M
A
C-type gun,
size M (Medium)
1
2
3
4
5
(2)
Code
U20=
[V]
57(1)
6,3
(2)
I2p=
[kA]
Rectifier
Sp 50%
[kVA]
6,2
4 diodes
57
Type
Stroke
Code
# of
Stages
08A
1
Max
Pressure
[psi]
145
11A
13A
2
87
30
PO
[mm]
GO
[mm]
R
[mm]
30
70
20
70
20
3
58
30
70
20
1
230V – 50Hz
(3)
1
145
/
40
20
2
400V – 50Hz
11Z(3)
2
87
/
40
20
3
440V – 50Hz
13Z(3)
3
58
/
40
20
4
415V – 50Hz
08Z
(3): Single-stroke cylinder without working stroke open.
Code
Center Distance(3)
[mm]
15
150
6
230V – 60Hz
7
400V – 60Hz
8
440V – 60Hz
M
500V – 1000Hz / 800V – 1200Hz
B
460V – 60Hz
C
480V – 60Hz
D
380V – 60Hz
(3) Fixed arm
10° tilt
17
Savair
1.2.5.2 CMA Detail
Figure 1.2 E – CMA Gun Body
PART DESCRIPTION
PART NUMBER
PART DESCRIPTION
PART NUMBER
1
F2 085 959
10
Rear casing
n/a
2
00 083 158
11
3
00 054 841
12
Trans rear cover
F2 085 025
4
Sliding block
00 175 436
13
Transformer
41 854 014
5
Gun nose
F2 082 998
14
Gyroscope disk
F2 083 134
6
Handle assembly
00 177 598
15
62 040 121
7
Welding cylinder
50 084 163
16
T2 083 695
9
Welding cylinder
50 084 163
17
Aux. handle & attachments
00 640 411
18
Savair
1.2.6 CWA Gun
1.2.6.1 CWA Codification
C
W
A
1
C-type gun,
size W (Large-
2
3
4
5
Aluminum arm)
(2)
Code
U20=
[V]
57(1)
6,3
(2)
I2p=
[kA]
Rectifier
Sp 50%
[kVA]
6,2
4 diodes
57
(2) U20 & I2p: Rectified (measured downstream of diode bridge.
Type
Stroke
Code
# of
Stages
11A
2
Max
Pressure
[psi]
128
13A
3
87
15A
4
65
PO
[mm]
GO
[mm]
R
[mm]
30
70
20
30
70
20
30
70
20
(3)
Code
26
Center Distance
[mm]
260
(3) Fixed arm
10° tilt
1
230V – 50Hz
2
400V – 50Hz
3
440V – 50Hz
4
415V – 50Hz
6
230V – 60Hz
7
400V – 60Hz
8
440V – 60Hz
M
500V – 1000Hz / 800V – 1200Hz
B
460V – 60Hz
C
480V – 60Hz
D
380V – 60Hz
Savair
1.2.6.2 CWA Detail
Figure 1.2 F – CWA Gun Body
PART DESCRIPTION
PART NUMBER
PART DESCRIPTION
PART NUMBER
1
F2 084 540
10
NOT APPLICABLE*
n/a
2
Fixed arm rigid conductor
00 176 295
11
NOT APPLICABLE*
n/a
3
00 083 837
12
n/a
4
00 164 411
13
Transformer rear cover
00 770 446
5
Sliding block
00 175 824
14
Transformer
41 854 014
6
Gun nose
F2 082 998
15
Gyroscope disk
F2 083 626
7
Handle assembly
00 177 598
16
62 040 121
8
Welding cylinder
50 084 919
17
T2 083 695
00 640 411
18
*Quick coupling mobile component replaces harness assembly
20
Savair
1.2.7
CZA Gun
1.2.7.1 CZA Codification
C
Z
A
C-type gun,
size Z ()
1
2
3
4
5
(2)
Code
U20=
[V]
57(1)
6,3
(2)
I2p=
[kA]
Rectifier
Sp 50%
[kVA]
6,3
4 diodes
57
Type
Stroke
Code
# of
Stages
13A
3
Max
Pressure
[psi]
10,0
15
55
5
15A
4
7,5
15
55
5
17A
5
6,0
15
55
5
1
230V – 50Hz
19A
6
5,0
15
55
5
2
400V – 50Hz
3
440V – 50Hz
4
415V – 50Hz
6
230V – 60Hz
7
400V – 60Hz
8
440V – 60Hz
M
500V – 1000Hz / 800V – 1200Hz
PO
[mm]
GO
[mm]
R
[mm]
Code
Center Distance(3)
[mm]
25
250
(3) Fixed arm
10° tilt
B
460V – 60Hz
C
480V – 60Hz
D
380V – 60Hz
21
Savair
1.2.7.2 CZA Detail
Figure 1.2 G – CZA Gun Body
PART DESCRIPTION
PART NUMBER
PART DESCRIPTION
PART NUMBER
1
Aluminum alloy fixed arm
F2 084 540
10
NOT APPLICABLE2
n/a
2
Fixed arm rigid conductor
00 177 365
11
NOT APPLICABLE2
n/a
3
00 083 837
12
n/a
4
00 164 411
13
Transformer rear cover
00 770 446
5
Sliding block
00 175 824
14
Transformer
41 854 014
6
Gun nose
F2 082 998
15
Gyroscope disk
F2 083 626
7
Handle assembly
00 177 598
16
62 040 121
8
Welding cylinder
50 084 919
17
T2 083 695
18
00 640 411
1 – Handle not shown in this detail
22
2 – Quick coupling mobile component replaces harness assembly
Savair
2.
DESCRIPTION
2.1
CONSTRUCTION
2.1.1
Suspension
The gun is suspended by hanging a bar from the cable of a spring balancer. This rod is mounted in a
self-tightening hub, and can slide vertically – making it possible to adjust the height (see § 2.1.2) of the
gun with respect to the floor.
A transverse cotter pin secures the rod-hub assembly.
2.1.2
Gun Height Adjustment Procedure
In order to adjust the height of the gun with respect to the floor, you must begin by unhooking the gun
from the spring balancer.
Once the gun is on the ground:
• Remove the splined cotter pin that passes through the rod and hub
• Loosen the two M8 screws that clamp the rod to the hub
• Use one of these screws in the intermediate tapping so as to separate the slot in the hub’s
self-tightening hole
• Slide the curved rod in the hub to the desired position
• Check the orientation of the rod so that it can be hung on the cable of the spring balancer
above the body of the gun
• Remove the M8 separating screw
• Tighten the two mounting hole closing screws to the proper torque value
• Counter bore the rod (∅6mm) in the hub
• Re-install the splined safety cotter pin
• Cut the rod to its new length (if necessary) by sawing underneath the hub
• Re-install the safety plug in the hole in the rod
NOTE – In order to limit the operations for customizing the hanging rod, ARO
has rods available in a range of sizes and configurations, making it possible to
adapt the gun to the requirements of any workstation.
2.1.3
Rotation Systems
2.1.3.1 Gyroscopic Circle Curved Bar Rotation
The circle-suspension rod link is made inside the hub by means of a self-lubricating bearing block and
two needle bearings mounted on an eccentric axle. A shoulder and a cover screwed on to the axle
ensure the stressing of the needle bearing/backplate pairs and the correct tightening of the cover is
secured by a lock screw.
The gun can then swing freely from the front to the back in a vertical plane around this axle. In order to
avoid any risk of pinching, the articulation is covered by a protective cover.
23
Savair
Figure 2.1-A – Curved Bar Hanger
PART DESCRIPTION
PART NUMBER
PART DESCRIPTION
PART NUMBER
Curved bar hooking hole
n/a
10
Protection cover
00 175 821
2
Disk w/transformer stops
3
Gyro stops
n/a
11
Cotter pin, ∅6mm
04 021 144
n/a
12
HC M6, cover/axle attachment
00 054 862
4
Ball bearing race
n/a
13
12mm Allen screw
12 220 248
5
Aluminum gyro bridge clamp
n/a
14
M10, hub/curved bar flange att.
n/a
6
Articulation axle boreholes
n/a
15
Articulation hub
n/a
1
7
Articulation axle support
n/a
16
Articulation bushing
61 100 268
8
Curved bar articulation stops
n/a
17
M24 lock nut
02 021 024
9
Stop bracket
64 150 202
18
Articulation axle w/6 19mm flats
n/a
19
Cotter pin, ∅6mm
04 021 144
2.1.3.2 Adjusting Gun Body Balancing
The bridge, connecting the circular part of the gyroscopic circle (ball race) to the tool’s suspension
assembly, is drilled with between three (M) and five (P and W) holes in which the eccentric axle can be
housed.
Gun body balancing is optimum when the suspension subassembly’s rotation axle is in alignment with
the gun body’s center of gravity. The rough adjustment of this balancing is carried out first by inserting
the eccentric axle into one of the holes in the bridge.
24
Savair
Fine adjustment is obtained by rotating the eccentric axle using a 19mm 6-flat wrench. Depending on
the position of the center of gravity, the optimum adjustment can be obtained by rotating the eccentric
axle either upward or downward.
Once you have obtained the optimum adjustment, a contact washer and an M24 nut ensure tightening of
the eccentric axle on the bridge. A retaining ring mounted on the axle retains the nut, should it come
loose.
By aligning the suspension’s rotation axle with the gun’s center of gravity, the gun will stabilize in the
horizontal position.
It is often preferable for process reasons that the tool be tilted downward or upward. To obtain this
positioning, simply rotate the eccentric axle to move the axle slightly forward or backward.
In the case of a gun that has to work vertically, this offset must be accentuated strongly by choosing the
hole in the bridge that is the most distant from the center of gravity.
An angular mark etched on the support disk makes it possible to recognize the selected balancing
position. In order to carry out certain extreme applications where the gun body’s center of gravity is very
far from the gyroscopic circle, a support plate fixed to the bridge makes it possible to create new
eccentric axle installation holes toward either the front or the back.
A set of removable and fixed bar stops on the edge of the support limit the amplitude of the swinging to
within a given range.
2.1.3.3 Gun Body Circle Rotation
A ball race between the circle and the gyroscope disk makes it possible to rotate the gun freely about its
main axis.
In order to assist in tool positioning, two removable and adjustable stops can be affixed to the edge of
the circle.
2.1.3.4 Disk Support
Besides its gyroscopic function, the disk also serves as the gun’s central support. The diameter of the
bearing races exist in different sizes, according to the gun model:
• Size M :
Ø220mm
• Size P/W:
∅240mm
The disk serves as the attaching part on its rear face for the:
• Transformer
• Welding cylinder
• Rear protection cover
In order to assure proper tool balancing, the articulation arms are positioned centered with respect to the
disk’s rotation axle.
For the same reason, the positions of the transformer and welding cylinders have been calculated in
such a way that the assembly’s center of gravity is situated as close as possible to the rotation axle of
the gyroscopic circle.
Furthermore, the disk is equipped with a flange that is used for:
• Attaching between 1 and 4 handle supports
• Positioning the gun body’s cylindrical protection cover through centering
2.1.4
Articulation Systems
2.1.4.1 Nose, Sliding Block and Mobile Electrode Holder
The nose, made of cast aluminum, is attached by four screws to the gyroscope disk. On its front part, a
bushing and anti-rotation slide ensure gliding of the slide block, whereas three tapped holes allow one or
more auxiliary grip handles to be installed.
The copper alloy-sliding block is chrome plated and ground, giving it high-performance mechanical and
electrical characteristics.
25
Savair
In addition, the sliding block does not require any particular greasing, and a wiper seal on the front part
of the nose removes any weld splatter from its surface.
The mobile electrode anti-rotation function is ensured by a flat surface along the complete length of the
sliding block.
ARO offers a complete range of sliding blocks which can be adapted to all the extension attachment
standards (M27x200, M24x150, M22x150 taps; MABEC ∅20mm clamp, Renault ∅20mm clamp, etc.).
On its rear part, the sliding block is tapped to M14x150 with a ∅16mm centering spot facing for ensuring
the proper attachment and positioning of the cylinder rod.
Mobile electrode cooling is ensured by two special union blocks attached to the sides of the sliding block,
and O-rings around the inlet and return holes ensure transfer sealing.
The circulation of water through the sliding block is ensured through a tube (water inlet) fitted inside a
drilled hole (water return around the tube).
NOTE – An IN or OUT marking located on the quick coupling fixed plate indicate
the cooling connection flow direction.
The sliding block transformer current is delivered via a flexible laminated conductor (shunt) and an
intermediate wedge plate. This silver-plated copper wedge plate is sandwiched between the laminated
conductor and the non-chromed rear part of the flat surface on the sliding block.
A removable flat conductor connected to the transformer’s upper secondary terminal connects the
secondary circuit to ground.
2.1.4.2 Fixed and Mobile Arms
2.1.4.2.1 Fixed arms
Figure 2.1 B – Fixed Arm
PART DESCRIPTION
PART NUMBER
PART DESCRIPTION
PART NUMBER
1
Seal
07 132 122
5
Insulating plate & bushing
00 054 230
2
Cant tightening washer
00 054 137
6
Arm-disk attachment screw
10 920 464
3
Insulating bushings
00 054 097
00 054 231
00 055 468
7
Mobile arm
n/a
Articulation axle & screw
10 810 408
03 011 060
4
Insulating washers
8
These cast copper arms are attached to the gyroscope disk by means of four screws that differ in size
depending on the gun model.
An insulating plate, bushings and washers achieve insulation between the fixed arm and the gyroscope
disk.
An M10 screw is used to attach the fixed arm directly to the transformer’s lower secondary terminal. The
fixed arm then delivers the current directly to the electrode holder arm.
The purpose of the 10° tilt of the scissor gun’s fixed arm mount is to keep the electrode holder arm away
from the tool’s articulation axle while keeping the excess weight to a minimum without affecting the good
balancing of the gun body inside the gyroscopic circle.
26
Savair
2.1.4.2.2 Electrode holder arm mounting
Fastening of the electrode holder arm to the fixed arm is obtained by mounting it in a split borehole. The
diameter of the borehole varies according to the gun model, as well as its power rating:
• CMA/CPA
∅44 or 45mm
• XMA
∅44 or 45mm
• XPA
∅49 or 50mm
Two M10 screws secure the bore to clamp the electrode holders in place.
Cooling of the electrodes and electrode holders is ensured via two ¼G taps on the back of each
mounting hole.
The circulation of the water through the arm is ensured by means of a nozzle (water inlet) which is
housed in the electrode holder’s tube. The water return is ensured around the circumference of this
tube.
NOTE – An IN or OUT marking located on the quick coupling fixed plate
indicates the water union flow direction.
2.1.4.3 Articulation of XWA Guns and Fixed Arms of CWA Guns
Refer to the detail drawings in § 9.5.3 and 9.5.6.
W-sized guns are reserved for harsh application situations requiring great welding forces and/or large
effective lengths.
The fixed and mobile arms of XW (scissor) guns are made of aluminum alloy in order to keep the overall
weight of the gun as low as possible.
The electrode holder arms are attached to these arms via six M14 screws.
Refer to Figure 2.1-B in § 2.1.4.2.1.
2.1.4.3.1 Fixed and mobile arms
The same fixed arm is used on the XWA and CWA gun bodies. The switch from one gun to another is
carried out on the front part of the disk by simply replacing the mobile arm and articulation part with the
guide nose and sliding block.
The fixed arm is attached to the disk by six M12 screws, and the insulation between the fixed arm and
disk is ensured by an insulating plate, bushings and washers.
The mobile arm of XWA guns is insulated from the fixed arm at the articulation axle.
The gun’s articulation consists of:
• A rotation axle
• A guide ring (serves as a self-lubricating insulating bearing between the fixed and mobile
arms)
• Two self-lubricating insulating friction washers between the fixed and mobile arms
• Two contact washers (blocked in rotation) on the ends of the axle
• Two screws on either side of the rotation axle (for adjusting the articulation’s degree of
tightening)
2.1.4.3.2 Conducting current – fixed arm
The welding current is conducted between the transformer’s lower secondary terminal and the fixed
electrode holder arm via an arched copper conductor, which is cooled by circulating water and
connected to the fixed arm.
27
Savair
2.1.4.3.3 Conducting current – mobile arm (XWA)
The current is conducted on the mobile arm side of XWA guns by means of a flexible laminated
conductor with silver plated laminations and an arched copper conductor. This flexible laminated
conductor connects the transformer’s upper secondary terminal to the conductor.
The conductor attached to the gun’s mobile arm is cooled over its complete length by circulating water,
and delivers the welding current from the flexible laminated conductor to the electrode holder’s mobile
arm.
The secondary circuit is connected to ground by a removable flat conductor attached to the transformer’s
upper secondary terminal.
2.1.4.4 Disassembly and Reassembly of the Articulated System
The coupling consists of a fork screwed on to the cylinder rod and secured by a lock nut. It oscillates
around an axle, which transmits the movement to the mobile arm by means of two link rods. These rods
are held on each side of the axle by two rings. The link rod axles are able to oscillate in the anti-friction
rings located in the boreholes of the mobile arm.
Figure 2.1-C – Mobile Arm Coupling
PART DESCRIPTION
PART NUMBER
1
Mobile arm
varies
2
Stop rings
05 586 018
3
Friction bushings
61 100 153
4
Link rods
00 054 319
PART DESCRIPTION
PART NUMBER
5
End of welding cylinder rod
n/a
6
Lock nut
n/a
7
Coupling axle
00 054 434
8
Fork
00 054 320
2.1.4.5 The Secondary Electrical Circuit
From the transformer’s long output to its short output, the current goes through the flexible laminated
conductor, the arm and the mobile electrode holder and back through the fixed electrode holder and the
fixed arm.
The cooling water passes through the transformer and the electrode holders coming from a feeder
situated at the rear of the gun.
2.1.5
Cylinder Systems
2.1.5.1 Cylinder and Solenoid Valves
The welding cylinder may be of the single (work only) or double-stroke (approach + work) type. In both
cases, the action assembly consists of a working piston attached to the cylinder rod.
These rods are guided in the cylinder covers by seals and an anti-friction ring for the main rod. The antifriction ring is threaded to receive the coupling fork with a lock nut for X-type guns.
The stroke between the electrodes of X-type guns is adjusted after the lock nut has been loosened, by
screwing or unscrewing the rod within the limit of a 10mm withdrawal with respect to the completely
tightened position.
28
Savair
In the case of a single-stroke cylinder, the design of the front cylinder cover is conventional, with a guide
ring, seal, wiper ring and a single solenoid valve.
The double-stroke cylinder is equipped with a clearance stroke piston with a locking guide affixed to the
gyroscope disk by four M10 screws, and is commanded by a second solenoid valve. The whole cylinder
moves around the guide and the piston for the clearance stroke movement and bottoms out against one
of the piston’s faces. In this case, the rod is equipped with a locking sleeve and passes through the
guide and its ring.
The front part of the guide includes eight balls, which are pushed back by the rod’s sleeve to lock the
cylinder in the clearance position, before the cylinder’s front chamber and set of amplification pistons are
pushed back under pressure to close the electrodes completely.
A non-return valve is installed in the hole in the front cylinder cover supplying the working solenoid valve,
which prevents the gun from going to its fully open position when the clearance closing chamber (CH3,
see § 2.1.5.2.2) is purged.
The quality of the cylinder’s seals allows it to operate with non-lubricated air.
In order to ensure the cylinder’s anti-rotation function, the front cylinder cover is fitted with two pads,
which are pressed against and slide along the tie rods of the transformer, which is situated directly below
it. Since the cylinder’s front body serves as both a cylinder housing for the clearance piston and as the
first working stage (and as a partition between these two parts), it includes two flanges for attaching the
solenoid valves to the Namur installation plane. Proper sealing between the solenoid valves is ensured
by two O-rings around ∅6mm holes. There are drillings in the mass to ensure the supply to the
cylinder’s various chambers.
The coils of the solenoid valves are supplied with 24V-DC. The cables for this supply are equipped with
molded connectors, which are connected to the distributor in the electrical box.
Figure 2.1-D – Cylinder Assembly (13A)
Figure 2.1-D2 – Cylinder Assembly (17A)
1
2
PART DESCRIPTION
Threaded working rod
Locking sleeve
PART NUMBER
00 068 653
00 053 968
9
10
PART DESCRIPTION
Stages’ intermediate covers
Solenoid valve fastener
PART NUMBER
3
Locking guide & balls
n/a
11
Air port to cylinder chambers
n/a
4
Main body
varies
12
Front cover
F2 175 602
5
Amplification stage cylinders
varies
13
Guide skids
10 810 166
6
1/8” G and non-return valve
n/a
14
Fastening of the cylinder
n/a
7
Tie-rods & lock nuts
00 047 390
15
17mm flats (adjusting stroke)
n/a
8
Rear cover
F2 175 601
varies
n/a
As shown above, the larger (17A) cylinders are similar in design to the smaller (13A) ones, but have larger diameters and a greater number
of ports (CZA – 3 ports; XZA – 4 ports).
29
Savair
2.1.5.2 Cylinder Operating Principle
2.1.5.2.1 Single-stroke cylinder
When the solenoid valve’s Y1 coil is not powered, pressure P is admitted into chamber CH2, with
chambers CH1 being vented by E1. This causes piston P1 to be pushed back driving with it piston P11,
which puts the gun in the open position.
Figure 2.1-E – Single Stroke Pneumatic Diagram
When the solenoid valve’s Y1 coil is powered, pressure P is admitted into chamber(s) CH1, while
chamber CH2 is vented by E2. Pistons P1 and P11 are pushed forward, which forces the gun to the
closed position, squeezing the electrodes.
During the above action (Y1 powered), chamber CH22 is vented by E22.
NOTE – The power supply between the chambers (CH1, CH2, etc.) is ensured
inside the cylinder through a hole in the amplification piston rods.
2.1.5.2.2 Double-stroke cylinder
NOTE – Because of the clearance function locking system, this cylinder’s
working stroke can be commanded only when the approach stroke has been
completed. Similarly, the transition to gun fully open command can only be given
when the gun has returned to working stroke open.
Figure 2.1-F – Double Stroke Pneumatic Diagram
With Y1 not powered and Y3 excited, the pressure is admitted into chamber CH4, while CH3 is vented
by E3. The cylinder is then pushed back until its cover bottoms out against the clearance piston P2,
driving with it the mobile electrode holder. This places the gun in the fully open position.
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Savair
At this point, if Y2 is excited, CH4 is vented by E4 and the air is admitted into CH3. The cylinder
advances until the body of cylinder C bottoms against P2, putting the gun in the working stroke open
position.
From the working stroke open position, it is possible to power Y1, which vents CH2 via E2 and admits air
into CH1 (both CH1 chambers). CH22 is still being vented, as pistons P1 and P11 are pushed forward.
The rod’s sleeve pushes the guide’s eight balls back into the groove located in the front cylinder cover,
which locks the body of the cylinder on the gyroscope disk from the start of the closing movement,
before the squeezing of the electrodes becomes effective, putting the gun in squeeze mode..
NOTE – The power supply between the chambers (CH1, CH2, etc.) is ensured
inside the cylinder through a hole in the amplification piston rods.
When Y1 is no longer powered, air is admitted into CH2, while the CH1 chambers are vented by E1.
This causes P1 to be pushed back, driving with it P11 and the working rod until it bottoms out against the
partition separating CH4 and CH2. A ring installed on the working rod makes it possible to reposition the
locking sleeve, thus releasing the eight balls. At this point, the gun is in the working stroke open position
and the cylinder is unlocked.
Y1:
Weld closing servo valve
Y2:
Clearance stroke closing servo valve
Y3:
Gun fully open servo valve
Figure 2.1-G – Servo Valve Command Block Diagram
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Savair
2.1.5.3 Pneumatic Schematic
Figure 2.1-H – Pneumatic Schematic
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2.1.6
Electrical Systems
2.1.6.1 Electric Handle
The control handle (ARO ref. 00 177 598) is made of cast aluminum and includes an M8 insert to attach
it to the support’s notched bracket.
• A closing trigger for commanding welding closing (green-6)
• Three program selector buttons (one red-2, & two black-3,4)
Figure 2.1-I – Command Handle
PART DESCRIPTION
PART NUMBER
PART DESCRIPTION
PART NUMBER
1
Cable gland
88 741 102
2
Program selector 1 – RED
15 532 216
5
Machined handle
F2 085 060
6
Weld closing trigger - GREEN
15 532 224
3
Program selector 2 – BLACK
4
Program selector 3 – BLACK
15 532 217
7
Stopper
88 741 110
15 532 217
8
Cable w/M12 plug (not shown)
15 442 450
2.1.6.2 Bracket and Handle Support
The control cable passes through the pressure seal and is then connected to the various contacts. An
M12 eight-pin male plug connected to socket P1 or P2 on the distributor connects the other end of the
cable. Disconnecting the plug and loosening the M8 screw allows for quick changing of the handle.
The bracket is attached by a screw to one of the five locations on the support. The support is attached
by two screws to one of the four locations provided for that purpose on the gyroscope disk.
2.1.6.3 Quick Coupling
The quick coupling device integrates the connections for the electrical, pneumatic and cooling systems
into a single unit, easing the connect/disconnect procedures. The diagram below shows a detached
view of the quick coupling interface:
Figure 2.1-J – Quick Coupling
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Savair
As shown in Figure 2.1-J, there are two connections for water (one supply, one return) and a single
connection for the air supply. Located below these connections is the 25-pin electrical connector, which
is used for the controls components connections.
For proper installation of the quick coupling, assembly patterns are needed to place the plates according
to the electrical power connectors. There are patterns available for both the fixed plate (ARO ref. 87 580
001) as well as the mobile plate (ARO ref. 87 580 002). Also recommended are lubricants for the seals
(see § 3.8).
For further quick coupling assembly and maintenance instructions, see § 3.8.
2.1.6.4 Transformer and Electrical Box
The transformers have electrical characteristics and performance abilities identical to those defined by
the ISO 10656 standards.
All the guns can be equipped with AC (50/60Hz) and medium frequency rectified (MFDC) transformers.
The primary and secondary connections are specifically adapted to enable direct contact with the
electrode holder arms without any intermediate conductor.
The primary circuit is an enameled copper wire and the secondary is a large cross-section copper tube
cooled by circulating water. The magnetic circuit is made of silicon sheets, and the transformer
assembly is impregnated with vacuum-cast epoxy resin.
On the primary side, a casing serves as an electrical box and includes four drilled bosses, which are
used for sandwich fastening of the transformer against the gyroscope disk, by means of tie-rods and lock
nuts.
A 7mm groove inside the box makes it possible to connect the box to ground by means of a brass M6
screw, which is fastened directly to one of the ground connection terminals, located on the back of the
transformer.
The secondary connections are made on the two copper outputs on the front of the gyroscope disk. Two
M10 screws are used to connect the laminated conductor to both the long terminal as well as the fixed
arm. The secondary circuit’s ground connection is made by means of a removable conductor affixed to
that terminal.
The phase power and ground connections are made on the ∅6mm terminals screwed into the M6
tapped studs on the transformer’s primary. The center distance between the two studs of the primary
phases and the ground terminal is 25x13 and corresponds to the center distance defined in the ISO
10656 standard. It enables, in particular, the direct connection of a 135A multi-contact power plug.
Thermal protection is achieved using two thermostats, one of which is bonded to the primary circuit, and
the other to the secondary circuit. In the case of an MFDC transformer, a third thermostat is placed on
the rectifier. The wires of the thermostats and measuring coil are connected in the WAGO terminal bloc
of the distributor.
The welding current can be calculated by measuring the voltage on the terminals of a Rogowski coil
placed around the short terminal of the secondary circuit. The coil must be loaded with a 1000Ω
resistance.
Figure 2.1-K – Electrical Transformer
1
2
3
4
PART DESCRIPTION
Secondary long outlet
Fastener tie-rods
Transformer cooling ¼”G inlet/outlet
Harness support fastener
PART NUMBER
n/a*
n/a*
n/a*
n/a*
*Transformer replaced as unit.
34
5
6
7
8
PART DESCRIPTION
Power distributor & connector
Electrical box cover (rear)
Measuring coil embedded in resin
Control plug wire outlets
PART NUMBER
n/a**
00 770 393
n/a*
n/a*
**Actual connection distribution box will differ slightly from figure.
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2.1.6.5 Electrical Distributor
The quick coupling fixed plate acts as the electrical distributor for the various electrical components, as
well as for the controls, cooling and pneumatic connections that must be made to the gun. This
connection method simplifies the installation and removal processes.
Also see § 3.8.
Figure 2.1-L – Quick Coupling
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2.1.6.6 Electrical Schematic
Figure 2.1-M – Electrical Schematic
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2.1.7
Case and Cooling Systems
2.1.7.1 Casing
The rear part of the gun is protected on the inside by a monobloc cover.
The front section is inserted into the flange of the gyroscope disk and its rear part is attached to the
harness (quick coupling) support by two M8 screws. A tightening plate and two M8 screws hold the
casing in place.
In the case of scissor guns, two casings attached to the fixed and mobile arms protect the operator
against the articulation’s movements.
2.1.7.2 Air and Water Feeders
The air and water supplies are incorporated into the quick coupling assembly, which attaches at the rear
of the gun (see § 3.8.).
2.1.7.3 Cooling
The water connection is made on the feeder by connecting the fixed plate’s water inlet and return hose
unions to the union located on the left and right, respectively.
The six ¼G tapped outlets on the rear face of the feeder are used by the water cooling circuit, and are
connected to various gun components by means of flexible hoses. The three on the left are the inlets,
and the three on the right are the returns.
2.1.7.3.1 Connecting the water supply
The water connection is made on the feeder by connecting the fixed plate’s inlet and return hose unions
to the unions located on the left and right, respectively.
2.1.7.3.2 Cooling circuits and flow rates
The water flows from the inlet hole through parallel circuits at the following flow rates:
• Transformer
4 L/min
• Mobile arm
4 L/min
• Fixed arm
4 L/min
After flowing through the above cooling circuits, the water is drained through the feeder’s return hole.
2.1.7.3.3 Electrode cooling
The water passes from the arm’s or the sliding block’s water inlet injector(4) into the copper tube(3) to
cool the electrode(1). The water is drained via the hollow area(6) in the electrode holder(2) surrounding
the inlet tube, which is connected to the water return orifice(5).
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Savair
Figure 2.1-N – Electrode Cooling
PART DESCRIPTION
PART DESCRIPTION
1
2
Electrode
Electrode holder
4
5
Water inlet injector
Water return
3
Copper tube
6
Recess (for water return)
Note – Arm/shank/electrode holder/electrode part #’s vary by gun model.
When there is an elbowed intermediate extension, the tube does not go as far as the electrode. It is cut
off before the arched section of the extension and is completed by a stainless steel flexible tube. These
two parts are placed end-to-end in a union and are welded together to obtain a watertight connection.
2.1.7.3.4 Cooling schematic
Figure 2.1-O – Cooling System Schematic
2.1.7.4 Connecting the Air Supply
The air supply is hooked up via the quick coupling assembly. For further information, see § 2.1.6.3 and
3.8.
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The outlet on the right-hand side supplies air to the clearance stroke-solenoid valve. The working
solenoid valve can be supplied via the cylinder’s clearance stroke chamber or via the feeder’s left-hand
lateral outlet.
The system air pressure is set outside of the gun.
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3
SETTING UP
3.1
GENERAL
Before being put into service, the gun must undergo a certain number of verifications and adjustments.
This work must also be performed when the gun is put into storage or is returned to service after storage
or repair. The main checks to be performed concern the geometry, mechanics, pneumatics, cooling and
electrical systems.
3.2
SUSPENSION BAR
3.2.1
Setting the length
With the gun removed, drive out the ∅6mm cotter pin using a ∅5.5mm steel pin. Loosen the two CHC
M10 screws attaching the curved bar to the suspension hub.
Determine a new curved bar penetration depth into the hub, and make a mark using a scribe through the
cotter pin hole to mark the spot to be drilled on the curved bar. Extract the curved bar and drill through it
with a ∅6 to ∅7mm drill at the marked spot.
Reinstall the curved bar and lock it into position using a new 6x45 cotter pin. Lock it by tightening the
two CHC M10 screws to a torque value of 35Nm.
3.2.2
Adjusting the Balancing and Stops
Using a screwdriver, remove the two M4x6 self-tapping screws attaching the protective cover to the hub.
Remove the cover; loosen the M24 nut using a 36mm box wrench until it bottoms out against its safety
cotter pin. Insert a 12mm Allen wrench in the recess in the eccentric axle. Rotate this axle to obtain
offsetting of the gun toward the front or rear of the curved bar axle, then firmly re-tighten the M24 nut.
In order to set the stops, loosen the CHC M6 screws, oscillate the gun downward to the desired limit
position and put one of the stops into contact against the hub, then firmly tighten its screw. Oscillate the
gun upward to the other desired limit position, and then tighten its screw.
Put the protective cover back in place.
3.3
GEOMETRICAL CHECKS
These are necessary to check the values of the openings and the secondary window dimensions to
ensure the proper operation of the gun.
3.3.1
Secondary Loop Window
The dimensional drawing gives the useful length and height of the secondary in which the workpieces
penetrate.
C-Type
The useful length (LU) is the distance from the electrode axis to the fixed arm, and the useful height
(HU) is the distance between the welding plane and electrode holder mount.
Figure 3.3-A – Secondary Loop Window
X-Type
The useful length (LU) is the distance from the electrode axis to the articulation. The useful height
(HU) is the distance between the electrode holders.
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Opening Dimensions
3.3.2.1 Working Stroke Open (PO)
The working stroke open dimension (PO) corresponds to the distance between new electrodes.
C-Type
This PO value is constant for C-type guns and is given on the gun detail drawing.
X-Type
The PO value for X-type guns depends on the length of the electrode holders, and is adjusted by
rotating the cylinder rod.
CAUTION: This adjustment also affects the GO dimension.
Figure 3.3-B – Working Stroke Open
3.3.2.2 Gun Fully Open (GO)
The gun fully open (GO) dimension corresponds to the distance between new electrodes.
C-Type
This value is constant for C-type guns and is given on the gun detail drawing.
X-Type
For X-type guns, the GO value depends on the length of the electrode holders, and is adjusted by
rotating the cylinder rod.
CAUTION: This adjustment also affects the PO dimension.
3.4
MECHANICAL CHECKS
3.4.1
Electrode Force
Consult the gun detail drawing for the maximum utilization pressure.
Place a dynamometer between the electrodes and close the gun with reduced pressure.
Note the force values for some pressures given in the inspection protocol or on the gun drawing and
compare them with the values given in those documents.
Figure 3.4-A - Dynamometer
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3.4.2
Response Time
In order to measure the working closing and opening times use a dynamometer associated with an
amplifier delivering an analog voltage corresponding to the measured forces range (for example: 0 to 10
Volts for 0 to 500 daN).
You will also need a two-channel oscillograph or curve recorder, one channel of which will be for the
closing coil (Y1) command voltage, and the other will be for the measured force signal (VD).
By convention, the response time (ta) between start of solenoid valve command (VE) and generation of
95% of the established electrode force is measured. See Figure 3.4-B.
Figure 3.4-B – Response Times
3.5
PNEUMATIC CHECKS
3.5.1
Outlet Braking
The outlet limiter setting makes it possible to brake and clamp clearance stroke opening when the mobile
arm has a large amount of inertia.
Figure 3.5-A – Outlet Limiter
PART DESCRIPTION
1
2
Exhaust valve silencer
Adjusting screw
PART DESCRIPTION
3
4
Clearance stroke opening command
Clearance stroke closing command
In order to adjust this setting, fully tighten the screw and then back it off by two turns. Check the
clearance stroke opening and adjust it if necessary by tightening or loosening it by ¼ or ½-turn at a time,
until you obtain the fastest opening without any rebound effect.
3.5.2
Solenoid Valve Operation
Check the correct operation of the solenoid valves by commanding the clearance stroke followed by the
working stroke, and only re-open the clearance stroke after the working stroke has re-opened. It is
recommended to conduct the test at maximum pressure (according to the limits given on the gun
drawing) and at a minimum pressure of 29psi.
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3.5.3
Checking the Unions
Check under maximum pressure that there are no air leaks at flexible hoses or unions. When the gun
moves, check that the flexible hoses do not rub against each other or on external components and that
they are not pinched, as this would significantly slow the movements of the gun.
3.6
COOLING CIRCUIT CHECKS
3.6.1
Cooling system description
The system consists of the manual welding gun with integrated transformer and tool changer, the MFDC
welding controller and 100 feet of hose connected to the gun. The water goes first through the controller
and on to the gun, where it is divided into three parallel circuits: one for the transformer, and one each
for both electrodes.
3.6.2
Water Flow Rate
The flow rate of the water must be measured with a minimum pressure differential of 65psi between the
water supply and return connections at the MFDC controller. To obtain accurate results, the pressure
must be measured and calibrated as near as possible to the water connections. The pressure
differential is distributed as follows:
• Approximately 30psi is required at the gun inlet for the adapters, caps and transformer.
• A 10psi pressure drop is created by the tool changer.
• Finally, a 25psi pressure drop is created by the 100-foot supply/return hoses.
To measure cooling water flow rate, use either a flow meter graduated in liters-per-minute or liters-perhour, or a 10-liter vessel and a stopwatch.
Total flow rate must be as close to the value specified on the gun control data sheet, and in all cases:
• 4 L/min for the transformer in MFDC mode
• 4 L/min for the mobile arm
• 4 L/min for the fixed arm
3.6.3
Checking for Leaks
Supply the gun with water under a pressure of 87psi to check the water tightness of the unions and other
various parts of the gun.
CAUTION: For this check, the gun must be closed to prevent the electrodes from being ejected under
high pressure. Also, check that the electrode arms are properly tightened.
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3.7
ELECTRICAL CHECKS
3.7.1
Insulation Check
This check must be performed with the gun in the open position and not electrically connected to power
or to auxiliary power.
Use a meghommeter measuring with 500V, for example.
The cooling circuit must be purged.
Insulation point to be checked:
Table 1 - Insulation Check Measuring Points
MEASURING POINTS
MINIMUM VALUE [MΩ]
Transformer primary – secondary
150
Transformer primary – ground
150
Transformer secondary – ground
Mobile arm – passive arm
0
150-0,01*
*This measurement depends largely on whether or not there is humidity in the cooling circuit.
(1)For this measurement, the conductors must be disconnected from the transformer and separated from it by a
thin insulator
3.7.2
Ground Loop Resistance
Connect the gun electrically but do not switch it on.
Use an ohmmeter on 10 ohms rating to check ground continuity for the following components:
• Transformer frame
• Transformer secondary (1)
• Electrical box (3)
• Electrical box cover (5)
Figure 3.7-A – Electrical Transformer
3.8
QUICK COUPLING
3.8.1
Installation
Refer to § 4.4.
The quick coupling mobile plate, once assembled, is plugged in to the fixed plate, at the rear of the weld
gun. The assembly is secured via two latching mechanisms located on the mobile section of the
coupling. Both handles must be locked simultaneously to ensure the coupling is properly secured.
CAUTION: DO NOT force the latching mechanisms into the closed position! This could cause bending
of the latching hooks!
For replacement contact pin and socket part numbers, see the following page and § 9.2.
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3.8.1.1 Fixed Plate (Gun Side)
For proper installation of the quick coupling fixed plate, use of the proper drill patterns (described in §
2.1.6.3) is necessary.
NOTE – During assembly, be cautious not to drill the seals or scratch the seats.
In addition, the connector should be used only with an electric cupboard
equipped with a shutdown of the two phases when the tong is disconnected.
Use the following instructions, referencing the pictures below:
• Loosen and remove the three screws (F19) and take off the back adapters (F17)
• Take off the REA male insert marked (F7)
• Make the connections to the male insert (F7)
• Proceed to the assembly of the insert and connection of the hoses.
• Make the connections to the power insert with the tool N 007 328 04
Figure 3.8-A – Quick Coupling Fixed Plate
3.8.1.2 Mobile Plate (Supply Side)
Use the following instructions, referencing the pictures below:
• Unscrew the reducing adaptor (M06) and remove the female insert (M03)
• Make the connections to the insert (M03)
• Proceed to the re-assembly of the insert and connection of the hoses.
• Make the connections to the power insert with the tool N 007 329 04.
Figure 3.8-B – Quick Coupling Mobile Plate
3.8.2
Maintenance
NOTE – Before any service intervention, all components must imperatively be
“dead” and depressurized.
3.8.2.1 Fixed Plate
Every 3 months or 1000 cycles:
• Lubrication:
o Functional parts of the plugs
o Guiding pins
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Savair
Periodically check for the correct tightness of the plugs. In case of a leak, replace as necessary and
tighten to 24Nm – without any spill.
Spare parts list:
• REA male insert (F7):
S 004 194 04
• SPC 08/OS plug:
N 004 325 02
• SPC 08 plug:
SPC 08.5418/IA/MD/JV
• Power outlet seal:
R 601 141 13
3.8.2.2 Mobile plate
Periodically check for the correct lubrication of the guiding seats. In the case of a leak, replace and
tighten to 24Nm.
Spare parts list:
• REA female insert (M03):
S 006 721 04
• SPC 08 coupling:
SPC08.2000/IA/JV
• Electric insert seal:
R 601 133 10 / R 601 132 1
Å MOBILE PLATE
Contact sockets (23ea)
CONTROL PLUG & SOCKET
Spring-loaded pressure contact pins (2ea)
FIXED PLATE Æ
Contact pins (23ea)
Pressure contact pin (2ea)
See § 9.2 for appropriate part numbers.
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Savair
4
START-UP
4.1
CONNECTION RECOMMENDATIONS
4.1.1
Electrical Connection
Verify the following:
• Check the voltage on the rating plate.
• The electrical power supply of the gun must be routed through a circuit breaker and be equipped
with a thermal or thermo-magnetic protective device.
• The operator is responsible for ensuring that these devices are suitably rated and properly set.
• The power supply cables must be adequately sized to prevent damage as a result of
overheating and to avoid voltage drops. Cables with inadequate cross-sections may lead to
extensive line losses and limit the performance of the gun. Use cables of H07 RNF quality or
equivalent.
• As soon as the installer of the gun makes any electrical connection to the gun, he becomes
responsible for proper electrical installation.
4.1.2
Pneumatic Connection
Use only the following components:
• Hoses in compliance with standard PN16
• 3-way valve allowing the gun to be depressurized
4.1.3
Water Supply
Confirm the following characteristics of the setup:
• The water supply and return must be equipped with a stopcock.
• It is strongly recommended that a purging system be installed to empty the cooling water from
the welding gun.
• Refer to § 4.2 (Table 2 – Operating & Storage Conditions) for suitable cooling water conditions
and requirements.
Savair
4.2
NORMAL OPERATING AND STORAGE CONDITIONS
Table 2 - Operating & Storage Conditions
CONDITIONS
VALUES
Cooling water:
maximum temperature
[°C/°F]
30 / 86
minimum temperature
[°C/°F]
10 / 50†
min. pressure differential between gun
supply and return*
filter
water hardness
[psi]*
40.0
[µm]
350
[meq/L]**
<2
pH value
-----
6.5 – 7.5
specific resistance
[Ω/cm]
> 2000
chlorides
[mg/L]
< 17
sulfates
[mg/L]
<8
These values are characteristic of “neutral water” recommended for our equipment by the Agence Fançaise pour l’Etude de l’Eau (A.F.E.E.)
Compressed air:
maximum pressure
[psi]
145‡
minimum pressure
[psi]
43.5‡
filter
[µm]
0,5
oil content
water content
[ppm]**
< 20
[g/Nm3]**
< 0,7
Ambient temperature:
operation
[°C/°F]
10–50 / 50–122
storage
[°C/°F]
5–70 / 41–158
Relative humidity: (max)
operation
[%]
80
storage
[%]
80
Electrical influences (on mains)
supply voltage U1
[Volt]
Extreme allowable values on French
for 230V
207 (-10%) – 244 (+6.08%)
for 400V
over-voltages can reach 2.5 x U1
358 (-10.5%) – 423 (+5.75%)
[Volt]
600 for 230V, 1100 for 400V
Mechanical influences:
-maximum acceleration
[m/s2]
*This required pressure differential value corresponds to measurements taken at the
supply side of the tool changer connections. For more information, see § 3.6.1.
**Remarks for information:
[meq/L] = milliequivalent gram of body considered per liter of solution. For
hardness °F (French degrees) are also used.
Relation between units: 1[meq/L]=5[°F]
19.6
†
Warning to users of our equipment: the relative humidity of the air in
the workshop and the temperature of the cooling water may lead to
condensation, which would be detrimental to our equipment (premature
oxidation of certain parts). ARO can in no case be held responsible for
this physical phenomenon and its consequences.
‡Provided
limits are complied with – see gun drawing.
[g/Nm3] = gram per normal cubic meter (cubic meter of air at atmospheric
pressure)
[ppm] = parts per million (in volume at atmospheric pressure)
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Savair
4.3
HANDLING
Handle with care in order to avoid damaging or upsetting the adjustment of certain components.
Use slings made of a flexible synthetic material and wear gloves to avoid cutting or pinching yourself on
articulated mechanical parts.
4.3.1
Adapting the Work Station
The height of the suspension device or workstation must be suited to the proper utilization range
authorized by the equipment being used.
If the superstructure receiving the gun’s suspension system is too high, use an intermediate sling to
lower the workstation. Alternatively, if the gun is too low, use the piece of enabling equipment to raise it.
4.4
MAKING THE CONNECTIONS
Once the appropriate fluid, power and controls connections to the mobile plate of the quick coupling
have been established, the quick coupling is ready for connection to the gun.
Properly securing the quick coupling connection requires that the two latches on the mobile plate be
secured to their appropriate latch-hooks on the gun.
Figure 4.4-A – Quick Coupling Latching System
To install the quick coupling, both latch handles must first be put in their open position (unlatched). With
the latch handles open, insert the quick coupling mobile assembly into the fixed plate on the gun. Once
the mobile plate is properly inserted, hook both latches to their appropriate hooks on either side of the
assembly, and simultaneously close (latch) the two latch handles to produce a secure connection.
For quick coupling removal, perform the above installation steps in reverse order.
Refer also to § 3.8.1.
CAUTION: Before disconnecting the quick coupling, the power supply must be switched off
4.5
POSITIONING THE GUN BEFORE WELDING
It is important the gun be placed in the clearance stroke open position before commanding the closing of
the gun to make a weld spot.
1 Mobile electrode in working stroke open position
2 Workpieces to be welded
Figure 4.5-A – Clearance Stroke Open Position
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5
STORAGE
5.1
PREPARING GUNS FOR STORAGE
Only store guns that are in perfect operating condition, repaired and inspected per the check procedures
described in § 3.
Before storage, purge the water and air pipes with compressed air at approximately 14.5psi and protect
the air and water holes with plugs or any other suitable blanking method.
Protect the electrical connections.
5.2
STORAGE CONDITIONS
Store in a clean and dry location away from dust, splashing water, flying sparks, chips and other similar
threats.
In addition, it is important that the guns be stored accordance with the conditions of stated in § 4.2.
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6
REMOVAL
6.1
NECESSARY PRECAUTIONS
AND
INSTALLATION
NOTE – For the pneumatic operating tests (before complete reinstallation of the
casings), it is important to ensure that you never place your hands or tools
between the cylinder’s front cover and the gyroscope disk. This is because of
the backwards disengagement of the cylinder assembly during the clearance
stroke movement.
6.1.1
For Operations NOT Requiring Gun Removal
CAUTION: If the operation is carried out after a collision, the gun or components may suddenly become
detached from the mount.
Precautions:
• Conform to the gun work station access rules
• Switch off the electrical power supplies (power and control units)
• Cut off the compressed air supply and depressurize the gun
• Cut off the water supply and return, and purge the gun water circuit
• Position the gun at a convenient working height and position
For Operations Requiring Gun Removal
CAUTION: If the operation is carried out after a collision, the gun or components may suddenly become
detached from the mount.
Precautions:
• Place an elevating platform under the gun before carrying out any work.
• Conform to the gun work station access rules
• Switch off the electrical power supplies (power and control units)
• Cut off the compressed air supply and depressurize the gun
• Cut off the water supply and return, and purge the gun water
circuit
• Position the gun at a convenient working height and position
• Disconnect the power, pneumatic and cooling system supplies
by disconnecting the quick coupling mobile plate (refer to § 4.4)
• Remove the gun from its mount, taking care to lift it until the
cable is completely wound up when it is suspended from a spring
balancer
• Maintenance work can be improved in many cases by using a
convenient rotating height-adjustable gun support table (ARO
ref. 00 585 214)
• Do not connect the electrical, air or water supplies during the
removal or installation phases
Figure 6.1-A – Adjustable Support Table
Savair
6.2
REMOVAL AND INSTALLATION INSTRUCTIONS
6.2.1
Main Components
6.2.1.1 Removal of the Casings
Refer to the detail drawings in § 9.5.
Prior to removing the casings, the quick coupling mobile plate must be removed (refer to § 4.4).
Rear Casing:
• Remove the two M8 screws attaching the casing at the rear
• Extract it by sliding the casing out (back) of its installed position.
Front Casing (C-Type):
• Remove the two M5 screws on each side of the sliding block’s nose and, for C-MA/WA/ZA,
the two M5 screws on the fixed arm.
• Extract the casing toward the front of the gun to disengage it from the electrodes.
Front Casing (X-Type):
• Large casing – Remove the handle and three M8 screws from the fixed arm and gyroscope
disk. Use both hands to separate it and pass it over the small casing.
• Small casing – Remove the M6 screw from the front of the mobile arm, and separate it and
pass it over the mobile arm.
6.2.1.2 Replacing the Laminated Conductor
Refer to the detail drawings in § 9.5.
Remove the front casing(s) per § 6.2.1.1.
C-Type
Pull the mobile electrode holder forward and remove the M10 screws holding the laminated conductor
to the transformer, and the M8 screws attaching it to the sliding block.
X-Type
Lift the mobile electrode holder, and then remove the CHC M10 screw attaching the laminated
conductor to the transformer, then the H M10 screw attaching it to the mobile arm using a 16mm halfmoon box wrench.
Clean the laminated conductor’s contact surfaces, then lightly coat them with contact grease. Check the
condition of the insulating plate, scrapping it if it is damaged and replacing it with a new one.
Install the new laminated conductor, aligning it properly and tightening the screws to 25Nm (M8) or
35Nm (M10).
6.2.1.3 Replacing an Electrode Holder
Prior to removing the electrode holder or electrodes, the water circuit must be purged.
Loosen the M10 screws, and insert a 1mm-thick steel plate in the slot in the clamp after having
completely unscrewed the screw located at the front.
Tighten the screw again to separate the clamp when the electrode holder is difficult to extract. Finally,
extract the electrode holder.
For C-type guns, unscrew the electrode holder at the arm attachment point.
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Savair
6.2.1.4 Replacing the Electrode Holder Cooling Circuit
With the electrode holder removed (§ 6.2.1.3), proceed as follows to remove the cooling circuit:
• Remove the electrode holder as described in § 6.2.1.3, then Remove the clamp holding the
extension
• Remove the extension with the electrode, and separate the electrode from the extension
• For ∅35mm electrode holders:
N
On the mount side of the electrode holder for ∅35mm, tap the brass square over a
length of 10-15mm with an M8 screw tap.
• For >∅35mm electrode holders:
N
Remove the clip that is retaining the plastic union
• Remove the copper tube by pulling on this union, and unscrew the union from the tube
• For ∅35mm:
N
Braze a new tube of the same length as the old one into a new brass square
• For >∅35mm:
N
Screw the union on to a new tube of the same length and the same thread as the old
one (also must be equipped with an identical flexible connection for elbowed
extensions)
• Cut the end of the tube or flexible connection at 45°
• Insert the tube into the electrode holder by pushing the union or brass square into position,
and reinstall the clip in its groove for the plastic union
• Before reinstalling the extension, the electrode and the electrode holder in their relevant
positions, lightly coat their electrical contact surfaces with contact grease (see § 9.3)
• Install the extension into the electrode holder, making sure the end of the tube or flexible
connection is exactly flush with the end of the extension
• Place a new electrode on the extension and lightly tap with a mallet
• Reposition the electrode holder in the articulation arm and tighten as described in § 9.1
Figure 6.2-A – Electrode Holder Cooling Diagram
6.2.1.5 Replacing the Water Feeders (C-Type)
Refer to the gun detail drawings in § 9.5.
With the gun purged of air and water, cut the hose from the block to be replaced. Pull the slide block
forward until the feeder attachment screws coincide with the holes, providing access to them on each
side of the nose. Using a 6mm Allen wrench, remove the M6 screw attaching the block.
Remove the sliding block and its seal, and clean the contact surface on the block.
Install the new block and seal, lightly coated with multi-service grease, and tighten it firmly. Remove the
hose by unscrewing the union at the other end using a 14mm box wrench. Cut a new push-lock hose to
the same length as the old one and install it first at the union on the distributor side, and lastly on the
sliding block’s feeder.
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Savair
6.2.1.6 Replacing the Sliding Block (C-Type)
Purge the air and water from the gun and separate the laminated conductor, electrode holder, cooling
circuit and water feeders per § 6.2.1.2 – 6.2.1.5.
Remove the rear casing per § 6.2.1.1 and remove the four M6 screws attaching the harness support to
the electrical box. Move the cylinder backward and remove the four M10 screws attaching the guide to
the gyroscope disk using an 8mm Allen wrench. Extract the cylinder with the sliding block.
Place the sliding block in a soft-jawed vice and heat the cylinder-sliding block attachment section with
60°C (140°F) (approx.) air to soften the thread lock. Using a 13mm open-ended wrench, unscrew the
end of the cylinder rod and clean the M14 thread to remove any traces of the thread lock material.
Apply some Loctite® 242 (normal lock, or equivalent) to the end of the thread, then install the new sliding
block until it comes into contact with the rod in the spot facing.
For installation, work backward through the above removal steps.
6.2.1.7 Replacing the Sliding Block Nose (C-Type)
Remove the M5 screws holding the front cover on either side of the nose (and the screws holding it to
the nose for larger guns). Separate the laminated conductor and water feeders from the sliding block
per § 6.2.1.2 and 6.2.1.5.
Move the sliding block back and remove the four M8 screws attaching the nose to the disk, then
disengage it from the front.
Prepare another nose with a guide bushing, wiper ring and anti-rotation slide, and then install it using the
reverse of the above removal instructions. Torque the M8 screws to 25Nm.
6.2.1.8 Replacing the Seal Bushing and Slide (C-Type)
Refer to the gun detail drawings in § 9.5.
Remove the nose per § 6.2.1.7, then, using an aluminum drift, drive out the bushing by striking lightly all
around it.
Clean and lightly grease the borehole, then install a new bushing by positioning it in such a way that the
split part is in the same plane as that of the slide. Press it in, taking care to ensure that it is still in the
axis of the borehole until it is pushed home. Install the wiper ring followed by the slide.
For installation, work backward through the above removal instructions.
6.2.1.9 Replacing the Mobile Arm (X-Type)
Refer to the detail drawings in § 9.5.1 – 9.5.4.
Disconnect the water hoses from the arm, and remove the attachment fastened by the M4 screw near
the mobile arm.
Remove the electrode holder, separate the laminated conductor and coupling per § 6.2.1.2, 6.2.1.3 and
6.2.1.11.
Remove one of the two H M10 screws from the articulation assembly, and drive the axle out using a
steel drift. Remove the mobile arm and retrieve the insulating washers and seals.
Clean the removed parts and the borehole in the fixed arm, discard any worn or damaged parts and
replace them with new ones.
For installation, work backward through the above removal steps. Moderately tighten the six M10
screws so that the two arms can be moved without requiring excessive force.
6.2.1.10 Replacing the Fixed Arm
6.2.1.10.1 C-type guns
MA Type Guns:
Remove the electrode holder per § 6.2.1.3, cut the water hoses and remove the four M12 screws
attaching the arm to the gyroscope disk and the M10 screw attaching the arm to the short output on the
transformer.
Remove the arm, retrieve the insulating components and clean them, replacing any damaged parts if
necessary.
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Savair
Clean the output from the transformer and lightly coat it with contact grease and install a new injector in
the bottom of the borehole in the new arm. Reinstall the arm with its plate, washers and insulating
bushings and torque the M10 screws to 35Nm and the M12 screws to 60Nm.
Clean the electrode holder, coat its mount with a thin coat of contact grease and reinstall it.
Other Guns:
Disconnect the hoses supplying the electrode holder and remove the six M10 screws holding the
electrode holder to the main arm. Clean the electrode holder arm.
Remove the six M12 screws attaching the arm to the gyroscope disk and the M10 screw attaching the
arm to the transformer.
Remove the arm, retrieve the insulating components and clean them, replacing any damaged parts if
necessary.
Clean the output from the transformer and lightly coat it with contact grease and install a new injector in
the bottom of the borehole in the new arm. Reinstall the arm with its plate, washers and insulating
bushings and torque the M10 screws to 35Nm and the M12 screws to 60Nm.
For installation, work backward through the above steps and torque the six M10 screws to 48Nm.
6.2.1.10.2 X-type guns
Remove the mobile arm per § 6.2.1.9, and disconnect the hoses supplying the electrode holder as per §
6.2.1.3. Cut the water hoses; remove the four M12 8-8 screws used to attach the arm to the gyroscope
disk. Remove the M10 screw attaching the arm to the short output from the transformer.
Remove the arm and retrieve the insulating parts. Clean them and, if necessary, replace them with new
ones. Clean the output from the transformer and lightly coat it with contact grease. Install a new injector
and new water unions into the bottom of the borehole in the new arm.
Reinstall the new arm with its plate, washers and insulating bushings, and lightly tighten the M12 or M14
(four or six – depending on gun type) screws. Lightly tighten the M10 screw and torque it to 35Nm.
Finally, torque the above M12/M14 screws to 60Nm (M12) or 32Nm (M14).
Clean the electrode holder and coat its mount with a thin coat of contact grease before reinstalling it.
For installation, work backward through the above removal steps. Torque the screws on the electrode
holder arm to 48Nm, and to 35Nm (M10) or 20Nm (M8) for the other guns.
6.2.1.11 Replacing the Coupling (X-Type)
With the air circuit purged, remove the front casings per § 6.2.1 and close the electrode holders. Using
an open-ended wrench, loosen the M14 nut on the fork and, using a 13mm open-ended wrench,
unscrew the cylinder rod to separate it from the fork. Push the rod back and clean the thread.
Remove the retaining ring immobilizing the fork axle and drive the axle out using an aluminum drift.
Disengage the fork, and drive the rods and SIC bushings out using the same drift. Clean the boreholes
in the arm.
Install new bushings, taking care to ensure they remain in the axis of the boreholes, and push them into
position.
Grease the boreholes in the new fork and rods, and assemble them with a new axle. Finally, lock the
axle with the retaining ring. Screw the cylinder rod back in and torque the lock nut to 64Nm, then
reinstall the casings.
6.2.1.12 Adjusting the Stroke (X-Type)
With the air circuit purged, remove the front casings per § 6.2.1.1 and close the electrode holders.
Using an open-ended wrench, loosen the M14 nut on the fork. With the lock nut loosened, fully tighten
the cylinder rod, and then adjust the stroke by loosening the rod within the limit of a maximum 10mm
withdrawal.
Apply a minimum pressure to determine the opening value obtained until the desired setting is reached,
then remove and purge the air and secure the lock nut. Return the gun to operating condition.
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Savair
6.2.1.13 Replacing the Cylinder
Remove the solenoid valves per § 6.2.1.15.
Follow the instructions in § 6.2.1.6, making sure that the replacement cylinder corresponds to the model
to be installed.
Install the solenoid valves with new seals on the new cylinder. Test the sealing and measure the forces
on the electrodes.
For installation, work backward through the above removal steps.
6.2.1.14 Replacing Seals, Cylinder Bushings and Housings
Remove the cylinder per § 6.2.1.6 and 6.2.1.13.
Remove the return ring, and remove and discard the four M8 lock nuts attaching the tie-rods to the rear
cylinder cover. If the tie rods show signs of impact or scratches, discard and replace them, too. Also, if
the guide pads are worn, replace them as well.
Gradually separate the various cylinder covers, housings and pistons associated with them. Remove the
front cover associated with the guide, piston and sheath, and place the guide’s flats in a soft-jawed vice,
with the piston on top. Using a ∅5mm pin wrench, remove the piston by turning it counter-clockwise.
Separate the guide from the cover, followed by separating the sheath from the guide.
Remove the spring, push bushing and the balls and clean their housing in the guide. If the guide or the
front covers are loose, discard and replace them with new ones.
Using an aluminum drift, drive the guide bushing out through the inside of the guide, and replace it if it is
loose. Remove and discard the spring and all of the seals and rings.
Clean all parts, paying special attention to the seal grooves.
If the rods show signs of impact, wear or scratches they must be replaced.
Examine the inside of the housings for any scratches. If any scratches exist, the housings must be
replaced.
Install the new seals corresponding to their cylinder using the following steps:
• Lightly grease the seal grooves
• Soften the gasket in a bath of water at 50°C (122°F)
• Install the O-rings in the corresponding grooves:
o For external grooves: pull O-ring around object, making sure it is properly seated
o For internal grooves: compress O-ring into heart shape and insert into groove, making
sure it is properly seated
Lightly coat the boreholes, rods and housings with multi-service grease.
For installation, work backward through the above removal instructions.
NOTE – If the tie-rods have been discarded, use only tie-rods that conform to the
specifications indicated on the detail drawing. Do NOT use threaded rods.
Apply Loctite® N°242 to the threads on the front of the tie-rods, and screw them completely into the front
cover.
Use new lock nuts, makings sure to balance the tightening to avoid warping the rear cover.
Check the sealing and cylinder operation, as well as gun forces and response times.
NOTE – Semi-rigid friction seals do not provide absolute tightness when they are
new. If the cylinder is immersed in water, air bubbles are liable to escape
through the seals. This is normal and will stop after several hundred operations.
Excessive leakage, however, may be due to seals being damaged during
installation or to scratched rods or housings.
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Savair
Figure 6.2 B – Cylinder Cross-Section
1
PART DESCRIPTION
Rear cover/cylinder head
PART NUMBER
F2 175 601
17
PART DESCRIPTION
Piston-cover seal
PART NUMBER
07 091 080*
2
Amplifier stage cyl. housing
n/a
18
Wiper ring
05 226 080*
3
Stages’ intermediate cover
n/a
19
Rod-cover wiper ring
05 226 022*
4
Cyl-stage intermediate cover
n/a
20
Working stroke piston
00 053 971
5
Cover – main housing
n/a
21
Rod-cover seal
07 101 020**
6
Front cover
n/a
22
Stages’ working stroke rod
00 054 179
7
Locking guide
n/a
23
Housing-cover seals
07 132 124**
8
Sleeve return ring
05 018 016*
24
Main rod
00 068 653
9
Locking sleeve
00 053 968
25
M10 screw holes (for cyl. attach.)
n/a
10
Push bushing
n/a
26
Guide pads & M4 attachments
10 810 166
11
Sleeve guide bushing
00 053 967***
27
Flange-cover O-rings
07 052 008*
12
Compensation spring
62 040 106***
28
∅6mm air passage – CS
n/a
13
Locking balls
21 122 579
29
M5, solenoid attachment
n/a
14
Guide-cover seal
07 101 040*
30
M8 tie-rods & lock nuts
00 047 390
15
Clearance stroke piston
00 053 971
31
∅8mm air passage – WS
n/a
16
Piston-rod seal
07 091 022*
32
¼G and anti-return
00 054 721
*Maintenance spare parts in kit HPM 50000
**Maintenance spare parts in kit HPM 50001
***Maintenance spare parts in kit HPM 50013
NOTE: Also see 17A cylinder assembly detail in § 9.5.2.
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Savair
6.2.1.15 Replacing the Solenoid Valves
Remove the rear casing per § 6.2.1.
Disconnect the connectors and hoses from the solenoid valve and remove the M5 screws affixing the
solenoid valves to the cylinder.
Remove the seals and clean the flanges around the air passage holes. Fit the new solenoid valves with
a new air union and with clean outlets (or replacements if the old ones are damaged).
Install new seals lightly coated with multi-service grease, and then install the solenoid valves, firmly
tightening the screws. Reconnect the hoses and connectors.
Test the solenoid valve sealing and operation manually, then electronically. Check the gun’s opening
and closing speeds per § 3.4.2 and make adjustments to the outlet limiter as necessary per § 3.5.
6.2.1.16 Replacing the Control Handle
Refer also to the drawings in § 2.1.6.1.
Unscrew the M12 male plug from the female socket to detach the cable, and remove the attachment
screw from the handle. Once the screw is removed, oscillate the handle slightly to remove it from the
handle base.
Clean the base and install the new handle, tightening the attachment screw to a torque value of 4.5Nm.
Replace the M12 plug, and test the various commands for proper operation.
6.2.1.17 Replacing the Terminal Box
Refer to § 2.1.6.4 and 2.1.6.5.
Remove the rear casing per § 6.2.1.1, then disconnect the quick coupling per § 3.8.
Disconnect the connections from the fixed plate, and remove the M6 screws attaching the fixed plate to
the electrical box, as described in § 6.2.1.19.
Disconnect the thermostat and measuring coil wires connected to the terminal block, and remove the M5
screws attaching the manifold to the electrical box.
Remove the M6 nuts attaching the transformer tie-rods to the electrical box using an Allen wrench for the
nuts on top, and a 10mm open-ended wrench for the nuts on the underside.
Extract the electrical box, clean the transformer’s primary, and examine the power pins. Replace the
pins if they show signs of wear due to excessive heating or electrical arcing.
For terminal box installation, work backward through the above steps.
6.2.1.18 Replacing the Transformer
Remove the electrical box per § 6.2.1.19.
Disconnect the hoses at the front of the transformer and those on the fixed electrode holder. Cut the
cable-ties attaching the various cables to the side of the transformer.
Remove the M10 screws attaching the transformer’s secondary to the laminated conductor and to the
electrode holder.
Extract the transformer and clean its location on the disk and the underside of the cylinder. Also clean
the laminated part of the laminated conductor that is in contact with the transformer, and likewise for the
fixed arm, and then lightly coat them with contact grease. Install the new transformer (equipped with
new pins), making sure that the tie-rods are completely screwed into the gyroscope disk, and bond them
in the disk with Loctite® 270 strong thread lock.
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Savair
Re-install the assembly in the reverse order of the above removal instructions, tightening the M10
screws to a torque value of 35Nm.
It is important at re-installation to achieve a good electrical contact between the lower secondary terminal
and the gun’s fixed arm. To ensure this, slightly loosen the four (M12) or six (M14) screws that attach
the fixed arm, and reposition the transformer with its electrical box, then lightly tighten the transformer
attachment nuts on the M6 tie-rods.
Lightly tighten the M10 screws attaching the transformer’s lower terminal to the fixed arm, and then
torque to 35Nm.
Finish re-installation by tightening to the specified torque the M6 nuts attaching the transformer to the tierods.
NOTE – Do NOT forget to tighten to the specified torque value the four (M12) or
six (M14) screws attaching the fixed arm to the gyroscope disk.
Test the gun first with water, then pneumatically and electrically.
6.2.1.19 Replacing the Electrical Box
Disconnect the quick coupling assembly per § 4.4.
Remove the rear casing per § 6.2.1.1.
Disconnect the hoses from the rear of the air and water manifold, affixed to the bottom of the quick
coupling fixed plate. Remove the seven M6 screws attaching the fixed plate to the gun. Unless
necessary, do not remove the screws joining the air and water manifold to the fixed plate.
Detach the electrical connections from the electrical box, and set the quick coupling fixed plate aside.
Remove the four M6 nuts attaching the transformer tie-rods to the electrical box using an Allen wrench
for the nuts on the top, and a10mm open-ended wrench for the ones underneath. Extract the box.
Clean the transformer’s primary, examine the power pins and replace them if they show signs of wear
due to heat or electrical arcing.
Reinstall the electrical box by performing the above steps in reverse order.
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Savair
7
PREVENTATIVE MAINTENANCE
7.1
MAINTENANCE TABLE 1
COMPONENT
Gun assembly
ACTION
TOLERANCE
5
Removal of welding splatter
As necessary
A few drops
10 Cycles
Check of air tightness
Noise audible at 1m
10 Cycles
Daily
6
10 Cycles
Removal of welding splatter between arms
Check of lateral play between arms
10 Cycles
Check the tightness of cylinder-coupling
M14 nut
Check the pressure of the retaining ring
holding the axle
Check the SIC bushings
Cylinder
6
Overhaul – testing on bench
Check of freedom of movement of the
arms with respect to each other
Gun coupling
5
Check of water tightness
Check of gun attachment
Gun articulation
FREQUENCY
10 Cycles
General cleaning
5
±1mm on the electrodes
for effective length of
400mm
Torque to 64Nm
Slightly defective
appearance
6
10 Cycles
Monthly
New retaining ring
after each
maintenance
operation
6
4x10 cycles
6
Check play in the fork (X-type)
<0,5mm
10 Cycles
Check leaks at the rod level
Slightly audible noise
10 Cycles
Slightly audible leak
4x10 Cycles
5
Replace the seals & wear parts
Examine the cylinder housings (replace if
scratched)
6
4x10 Cycles
Replace the guide pads
Replace the cylinder tie-rods (do not use
threaded rod)
Check for presence of sleeve return ring
Electrical box &
distributor
Laminated conductors
1mm of wear
6
4x10 Cycles
Install a new ring at each
intervention
Check tightness of lugs/pins on primary
and condition of insulating parts
Check coating of the power pins
It must not be possible to
see the support through its
coating
Monthly
Ensure you have
a spare harness in
case excessively
worn pins cause
socket explosion
Daily
Check laminations (remove any broken)
5
10 Cycles
Tighten the screws
Replace laminated conductors
>10 laminations broken
Check insulating plate
Slight wear
Replace insulating plate
6
Daily
Plate blunted
Savair
7.2
MAINTENANCE TABLE 2
COMPONENT
Electrode holder
ACTION
TOLERANCE
6
Detect any water leaks which indicate
gradual cracking
10 Cycles
Check the tightening torque of the arm
mount (§ 6.2.1.3)
Monthly
Extensions
Check there is no deformation/wear of the
assembly cone or hammering (re-machine
or replace)
Must conform to
specifications on drawing
Electrodes
Check there is no deformation/wear
Check for suitable force
Check that the dressing is suitable
(replace)
Must conform to
specifications on drawing
Electrical Handle
Check the cable feed-through, its correct
attachment and the presence of the cable
gland on the gyroscope disk
Cables & hoses
Check the condition of the cables & hoses
(replace if abnormally worn)
Cuts & slight wear
Check for correct installation in all gun
openings
Each cable & hose has a
corresponding recess
Curved bar &
suspension
FREQUENCY
At each
maintenance
operation
Daily
At each
maintenance
operation
5
10 Cycles
At each
maintenance
operation
Daily
Check the tightening of the articulation
and the curved bar suspension
attachment
Monthly
Check the presence and tightening of the
cotter pins & stop screw (see drawing)
Check the out-of-roundness of the
suspension hole caused by the snap-hook
<2mm out-of-round
Monthly
Rotation system
Check that the assemblies pivot easily
(replace bearings if necessary)
Resistance to movement
without any hard points
(handling should be
smooth)
Monthly
Secondary electrical
junctions
Tighten all the transformer-electrode
attachments
Monthly
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Savair
8
TROUBLESHOOTING
8.1
TROUBLESHOOTING TABLE 1
FAULT OBSERVED
Approach stroke not
performed
POSSIBLE CAUSES
CORRECTIVE ACTIONS
Approach solenoid valve defective
Replace
Solenoid valve coil defective
Replace
Solenoid valve connector defective
Repair/replace
Coil power supply defective
Check the electrical box
Handle command defective
Replace
Handle wiring defective
Redo
Solenoid valve in manual command
Reset
Cylinder defective
Repair/replace
Electronic command defective
Repair/replace
Working stroke not
performed
Like above with working solenoid valve
Loss of force on the
electrodes
Wear of cylinder and/or cover seals
Replace seals or housings per § 6.2.11
Excessive wear on the
cylinder guide pads
Poor condition of the tie-rods or threaded tierods (not smooth)
Replace with compliant parts (do NOT
use threaded rods)
Strokes too slow
Insufficient pressure
Adjust
Hoses crushed
Reposition
Solenoid valve outlets and/or slide valves
clogged
Clean
Air poorly/not filtered
Use filtered air in accordance with § 5.2
Outlet limiters excessively closed
Adjust
Cylinder rod broken at the
level of the X-type gun
coupling
Insufficient tightening of the M14 nut
Replace per § 6.2.8, 6.2.10, 6.2.11 and
torque to 64Nm
Loss of coupling axle on Xtype gun
Loss of the retaining ring
Install new retaining ring at each
intervention
Loss of initial stroke, loose
coupling of X-type guns
Wear of the coupling’s SIC bushings
Replace the bushings per § 6.2.8
Absence of cylinder sleeve
return ring
Install a new ring after each intervention
Deformation of the
workpieces at clamping
Mating too abrupt
Tighten the outlet limiter
Rapid destruction of the
laminated conductor
Insufficient gun cooling
Overhaul the cooling circuit
Poor tightening or vibrations
Tighten to torque value per § 6.2.2
Absence/wear of insulating plate
Replace
Defective laminated conductor alignment
Ensure correct alignment when replacing
Savair
8.2
FAULT OBSERVED
POSSIBLE CAUSES
CORRECTIVE ACTIONS
Rapid deterioration or
bursting of the coupling
cables/hoses
Cables poorly anchored, cables & hoses not
housed in correct recesses
Reposition the cables
Explosion of the power
connector’s connection
socket
Wear of the pin coating
You should have a spare harness to limit
the intervention times
Sticking of the electrodes
Insufficient cooling of the electrodes due to
insufficient pressure/flow rate
Check the harness/hoses/cooling
insulation
Poor balancing of gun’s balancing circuits
Measure flow rates of circuits
Cooling tube inside electrode holder
blocked/broken
Replace the electrode cooling circuit as
per § 6.2.4
Excessive clogging of the electrodes on zincplated workpieces
Dress more frequently as in accordance
with § 7.2
Insufficient welding current
See below
Inappropriate cable gland on the gyroscope
disk or cable poorly attached
Install a cable in compliance with gun
specifications
Electric handle command
cable cut
Check the condition of the pins monthly
Correctly attach the cable
Curved bar articulation cover
separated
A screw is being blocked
Screw the cover correctly and attach it
with HC M6 screw with a stop pad
Curved bar articulation
separated
M24 nut loose
Tighten per § 3.2.2
Insufficient welding current
Serious primary voltage drop
Check the presence of 5x30 cotter pin
Check the network voltage
Correct the section/length of cables
Current measuring coil inoperative in
utilization with current regulation
Measure the resistance of the coil and its
connection
Connection loose in secondary circuit
Remove, clean, grease, install & tighten
Connection loose in primary circuit
Remove, clean, grease, install & tighten
63
Savair
8.3
FAULT OBSERVED
Weld spots deformed/offset
or electrodes worn
asymmetrically or
extensions deformed
POSSIBLE CAUSES
CORRECTIVE ACTIONS
Loosening/cracking of the arms/extensions
Tighten or replace
Play between arms (defective bushings)
Check and replace defective parts
Electrodes poorly aligned
Realign
Electrode axis not perpendicular to
workpiece
Reconsider the accessibility of the spot
to be made
Dressing poorly suited to electrodes
Dressing to be compliant to specs
Wear on the extension cone
Re-machine or replace
Force too great
Check the pressure and force on the
electrode
Insufficient welding force
Check the welding pressure & force
Excessive deformation of the arms or
electrode holders (loose or cracked)
Tighten to correct torque value per § 9.1
or replace
Excessive wear of the electrodes
Replace
Inappropriate extensions or electrodes
Consult gun drawing
Cylinder defective
Repair or replace
Welding time or current too high
Check the parameters
Working solenoid valve defective
Replace
Frequent triggering of the
transformer’s thermostats
Poor transformer cooling
Check water flow rate & temperature
Excessive welding rate
Check welding thermal current
Difficulty adjusting curved
arm articulation balancing
Difficult to access the M24 nut
Conform to specified cotter pin length of
5x30 and use a 36mm box wrench to
loosen
Very serious sparking during
welding
64
Savair
8.4
FAULT OBSERVED
Ground fault will not clear
Difficulty coupling gun with
controller cable
POSSIBLE CAUSES
CORRECTIVE ACTIONS
Ground pins pushed back into quick coupling
Replace latching hooks
Bent latching hooks will not bring coupling
flush to connection face.
Replace latching hooks
Dirt or debris (weld splatter) on coupling
interface
Clean interface and re-couple
Savair
9
APPENDICES
9.1
TIGHTENING TORQUE VALUES
QUANTITY
TORQUE [mN]
Laminated conductor/transformer or
mobile arm
COMPONENT
CHC M10
DESIGNATION
1
35
Laminated conductor/sliding block
CHC M8
2
20
Electrode holder
CHC M8
2
20
Electrode holder & XMA-XPA-CMA
gun arms
CHC M10
2
35
Transformer tie-rods
CHC M6
4
20
Cylinder tie-rods
Lock nuts H M8
4
12
Cylinder/mobile arm coupling on xtype guns
Nut M14
1
64
Cylinder-disk guide
CHC M10
4
48
Sliding box nose
CHC M8
4
25
Articulation axle
H M10
2
N/A
Fixed arms-disk
H M12-8-8
4 or 6
60
Fixed arms-transformer
CHC M10
1
35
Command handle
CHC M5
4
4.5
Power connector
CHC M5
2
4.5
COMMENTS
Install new lock nuts
after each removal
Tighten moderately
for smooth motion
Savair
9.2
WEARING AND REPLACEMENT PARTS
9.2.1
Wearing and Replacement Parts Table 1
00 054 605
F2 069 025
00 054 097
00 054 231
DESIGNATION
Cylinder anti-rotation pad
Manifold
Fixed arm/gyroscope disk insulating bushing
Fixed arm/gyroscope disk insulating washer
T2 083 695
00 068 800
00 175 821
02 021 024
64 150 202
61 100 268
00 054 706
Hanging bar
Eccentric axle
Cover
M24 lock nut
Needle stop & counter-plates
Bushings
Gyroscopic circle stop
00 177 598
F2 085 060
00 294 127
15 532 224
15 523 216
15 532 217
15 532 217
88 741 110
88 741 102
15 442 450
Handle assembly
Machined handle
Handle mounting plate
Closing trigger – green
Program selector 1 – red
Program selector 2 – black
Program selector 2 – black
Stopper
Cable gland
Cable
REFERENCE
Suspension
Command handle
Parts common to C60 & C120 cylinders
F2 175 601
F2 175 602
F2 175 603
00 053 967
00 053 971
00 053 971
05 018 016
62 040 106
05 226 022
05 226 080
07 091 022
07 101 040
07 091 080
00 054 721
Rear cover
Front cover
Working stage intermediate cover
Brass guide bushing
Clearance stroke piston
Working stroke piston
Return ring retaining clip
Compensation spring
Ring D22 rod cover wiper ring
Ring D80 wiper ring
Piston rod seal – BECA D22mm
Guide cover seal – BECA D40mm
Piston cover seal – B+S D80mm
1/4-G & anti-return spring
Amplification stage kit
00 053 971
F2 175 601
07 091 080
07 101 020
Working piston
Rear cover/cylinder head
Piston cover seal
Rod cover seal
67
Savair
9.2.2
REFERENCE
DESIGNATION
Quick Coupling†
Alternate Part Numbers
MS-02098
MS-02356
MS-0321
MS-0322
CUUAT-04284
CUUMS-02370
N00432502
R60114113
S00419404
CUUMS-02369
S00672104
R60113213
R60113310
Contact sockets (control plug)
Contact pins (control plug)
Spring loaded pressure contact
Pressure contact pin
Contact sockets (power plug)
Water fitting (male) – fixed side
Air coupling
Seal – AS568A141
RMP90REA adaptor
Water fitting (female) – mobile side
REA13 female insert
Seal – AS568A132
Seal – AS568A 133
Multi-Contact BP1.5/0.5-1.5
Multi-Contact SP1.5/0.5-1.5
Multi-Contact DBP2/0.5-1.5
Multi-Contact DSP2/0.5-1.5
Multi-Contact BP6/25
SPC08.5418/IA/MD/JV
SPC08.5418/MD/OS/JV
SPC08.2000/IA/JV
Electrical Cords
299 904
299 523
1544208D
888030P02M020
888030P02M030
Main cordset – EV
Main cordset – EV-Y1/Y2
Main cordset – 2 handles
Extension cord – 2 meters
Extension cord – 3 meters
Insulating components
00 054 097
00 054 870
00 054 230
00 054 766
00 054 810
00 053 615
Insulating sleeve – D20-25, L=63mm
Insulating sleeve – D35-30, L=69mm
CMA/XMA insulation
XMA insulation
CWA/XWA insulation
Bushing – D56-45, L=30mm
† See also § 9.5.1 for full Quick Coupling detail drawing and part description.
68
Savair
9.2.3
REFERENCE
DESIGNATION
Protective components
00 083 699
00 084 561
00 083 448
00 083 837
00 083 158
00 084 560
00 083 187
00 083 700
00 086 560
00 177 320
00 164 861
00 085 721
XPA mobile cover
XWA mobile cover
XMA mobile cover
CWA fixed cover
CMA fixed cover
XWA fixed cover
XMA fixed cover
XPA fixed cover
CWA/XPA/XWA rear cover
CMA/XMA rear cover
XZA rear cover
CZA rear cover
Electrical system components
MASDAT-008
00 176 295
00 164 868
00 177 365
00 176 296
00 177 364
00 177 365
70 080 890
70 080 891
00 054 841
00 054 855
00 056 217
00 054 855
00 054 841
00 164 411
00 175 640
00 054 604
02 081 006
03 062 041
00 056 705
00 054 704
41 854 014
Masdat tag with M12 connector
CWA/XWA conductor
CZA conductor – mobile arm
CZA conductor – fixed arm
XWA conductor
XZA conductor – upper arm
XZA conductor – lower arm
24VDC distributor – P01515EM4008D6A
24VDC distributor – P01515EM400AB6A
CMA/CPA flexible shunt
XPA flexible shunt
XMA flexible shunt – 5400A
XWA flexible shunt
CMA flexible shunt
CWA flexible shunt
Electrical distributor
M6 Allen nut – transformer tie-rods
M6 lock nut
D6 safety washer
M6 tie-rod
Transformer cooling extension
57KVA transformer
Pneumatic system components
50 083 929
50 083 935
50 083 950
50 083 955
50 083 956
HPR01007
HPR01016
62 040 121
15 440 063
00 068 676
00 068 677
00 202 113
JL4-UWV0060102
3-stage cylinder – D80 C40/20
Cylinder kit
Cylinder kit
Ball – 25/64
Valve – MAC-VALVES KD24
Valve – CMA/CWA/CZA
Valve – CMA/CWA/CZA
Valve – D8.1-5/16”
Valve – CZA ONLY
Articulation components
F2 083 324
F2 083 325
F2 083 580
F2 083 581
XMA mobile arm – D45
XMA fixed arm – D45-10°
XPA fixed arm – D50-10°
XPA mobile arm – D50-10°
69
Savair
9.3
RECOMMENDED PRODUCTS
9.3.1
LOCTITE® or Equivalent Products
9.3.2
REFERENCE
COLOR
APPLICATION
242/247
BLUE
Threadlock – normal removal
270
GREEN
Threadlock – difficult removal
542
BROWN
Sealing of taper threads (pneumatic & hydraulic)
549
RED
572
WHITE
Sealing of taper threads
601
GREEN
Blocpress – disassembly impossible
932
BROWN
Sealing & threadlock – easy removal
Sealing of machined flat surfaces, torque transmission
Other Products
Other products for installation and/or maintenance:
• Multi-service grease for mechanical installation: DS 2000, UNIL.
• Contact grease ref. 93 790 for all weldgun secondary connections
• Grease KONTASYNTH BA MC 73 1050 for primary circuit electrical contacts
9.4
MAINTENANCE ACCESSORIES
Rotating height-adjustable gun support table (see § 6.1.2), ARO ref. 00 585 214.
9.5
GUN DETAIL DRAWINGS
See following pages (65-71) for gun detail drawings.
Savair
9.5.1
Quick Coupling
9.5.1.1 Quick Coupling Detail
EView
F10 F15
F16 F02
F05
F06
F18 F11
F03
F
F04
F14
F04
E
F17
F09
F07
F08
F01
F19
FView
M06
M08 M03
M04
M01
M11
M05
M02
M09
M07
M13
F13
71
Savair
9.5.1.2 Quick Coupling Reference
QTY
F1
PART DESCRIPTION
PART NUMBER - STAUBLI
1
RMP90 plate
S00120403
1
RMP90 distributor NPTF
S00623504
1
RMP90 distributor NPTF
S00623604
F3
2
RMP90 Column
S00340603
F4
2
RMP90 Roll
S00341003
F5
2
Water fitting – fixed side
SPC08.5418/IA/MD/JV
F6
1
SPC08.5418/MD/OS/JV
N00432502
F7
1
REA13 male insert
S00672004
F8
1
REA03 dowel pin
R15718300
F9
1
seal AS568A141
R60114113
F10
2
Screw M 6X 30 H
H52063000
F11
4
SCHNORR Washer Ø6
R69750600
F13
1
Distance part
S00341103
F14
2
RMP90 Roll axis
S00411603
F15
2
M6 Washer
S00522303
F16
2
Dowell pin 6 X 16
S00522503
F17
1
RMP90REA adaptor
S00419404
F18
4
Screw CHC M6X12
S00522703
F19
3
GPV08 Screw CHC M3 X 8
S00813898
M01
1
Mobile plate
S00120503
M02
3
Water fitting – mobile side
SPC08.2000/IA/JV
M03
1
REA13 female insert
S00672104
M04
3
Water fitting – mobile side
S00551704
M05
2
RMP90 handle bottom
S00735304
M06
1
M48 / PG16 reduction
S00415903
M07
8
Screw M5 X 12 CHC
H54451202
M08
1
REA03 dowel pin
R15718300
M09
1
Seal AS568A132
R60113213
M10
1
Seal AS568A 133
R60113310
M11
1
Harness holder
S00121103
M13
4
Screw CHC M5 X 10
S00522103
F2
REA13 male insert (ref. S00672004, marker F7) is made of a 4 FL7-3183-00 Multi Contact insert with 23 contact pins and (ref.
18.9004) and 2 pressure contact pins (ref. 18.9061).
REA13 female insert (ref. S00672104, marker, M03) is made of a 4 FL7-3184-00 Multi Contact insert with 23 contact sockets (ref.
18.8004) and 2 spring loaded pressure contacts (ref. 18.8061).
See also § 9.2 for additional part numbers.
72
Savair
9.5.2
Cylinder Assembly Detail
Savair
9.5.2
Cylinder Assembly Detail
Savair
9.5.3 Shank & Cap Cooling
Detail
Savair
9.5.4
XMA Gun Detail
XMA
Gun Body
Detail
Savair
9.5.5
XPA Gun Detail
XPA
Gun Body
Detail
Savair
9.5.6
XWA Gun Detail
XWA
Gun Body
Detail
78
Savair
9.5.7
XZA Gun Detail
XZA
Gun Body
Detail
79
Savair
9.5.8
CMA Gun Detai
CMA
Gun Body
Detail
80
Savair
9.5.9
CWA Gun Detail
CWA
Gun Body
Detail
81
Savair
9.5.10 CZA Gun Detail
CZA
Gun Body
Detail
82

Savair - Weld Systems Integrators

Transcription

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