Operating instructions
- Translation of the original operating instructions -
TITANARG®
L350TI
712 0001
Automatic welding system Important!
Do not dispose of these operating
instructions. The customer agrees to have
these operating instructions available and
understandable for all members of the
operating and service staff.
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TABLE OF CONTENTS
Page
1. Details concerning the manufacturer ................................................................................... 3
2. General ................................................................................................................................... 4
2.1. Intended use ......................................................................................................... 6
2.2. Liability and warranty ............................................................................................ 6
2.3. Note on environmental protection ......................................................................... 6
3. Safety regulations .................................................................................................................. 7
4. Technical data ...................................................................................................................... 10
4.1. Low-consumption transformer (option)................................................................ 11
5. Installation and designations .............................................................................................. 12
6. Inbetriebnahme .................................................................................................................... 13
7. Operation .............................................................................................................................. 15
8. Low-consumption transformer (option) ............................................................................. 16
9. Busschnittstellenkarte (optional) ........................................................................................ 17
9.1. Adressierung der Busschnittstellenkarte ............................................................. 18
9.2. Prozess- und Ansteuerdaten ............................................................................... 19
10. Maintenance and cleaning ................................................................................................... 20
10.1. Deadlines for tests acc. to BGV .......................................................................... 21
11. Search for faults - remedy ................................................................................................... 22
12. Spare parts list ..................................................................................................................... 23
13. Declaration of installation ................................................................................................... 24
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1. Details concerning the manufacturer
TITAN Umreifungstechnik GmbH & Co. KG
Berliner Straße 51 – 55
D - 58332 Schwelm
Germany
Phone: +49 (2336) 808-0
Fax: +49 (2336) 808-208
E-mail: [email protected]
Web: www.titan-schwelm.de
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2. General
Many thanks for your confidence in the technology of Titan Umreifungstechnik GmbH & Co. KG!
These operating instructions are meant to facilitate familiarity with and the intended use of the automatic welding system TITANARG®. These operating instructions comprise important information on how the automatic welding system is used safely, properly and economically. Meeting instructions helps reduce risks, repair works and downtimes and also increase the reliability and life of the automatic welding system. The operating instructions must always be available at the place of operation of the automatic welding system TITANARG®. They must be read and applied by all persons working with the automatic welding system. Such works especially include operation, troubleshooting and maintenance.
Setting and maintenance works may only be performed by trained technical staff. Apart from the operating instructions and the regulations for the prevention of accidents applicable in the operator's country and on the job site the acknowledged technical rules for safety-related and professional work have to be observed. The item numbers (...) and designations used in these operating instructions refer to the spare parts list or electrical documentation attached. Remarks concerning the warning and indication symbols:
Caution It is used in case of hazards threatening life and health. Attention! It is used in case of hazards that might cause damage to property. Note! It is used for general indications and indications whose disregard might cause disruptions in the operational sequences.
All rights of alterations to the scope of supply with the aim to improve the product reserved at any time.
Copyright © TITAN Umreifungstechnik GmbH & Co.KG 2017 All rights reserved.
The contents of this document must not be duplicated, handed to third parties or distributed in any form, neither entirely nor partly, without prior written consent by TITAN Umreifungstechnik GmbH & Co. KG.
is a registered trademark of TITAN Umreifungstechnik GmbH & Co. KG.
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The TITANARG® meets safety requirements of welding units being used in areas with
increased electrical risks. This is marked by the S-sign.
Ignition and stabilizing unit
By means of the ignition and stabilizing unit installed in the TITANARG® the electric arc for TIG welding can be ignited without contact. The ignition and stabilizing unit supplies voltage pulses in quick succession with peak values being so high that - at a distance of approx. 3 mm - sparks leap between the thorium-free tungsten electrode and the strap and initiate the electric arc. As an electrode is not in contact with the strap during such an ignition, the melting bath remains free from any impurities by the electrode material and the wear of electrodes remains low.
Optionally, the TITANARG® can be equipped with a low-consumption transformer that transforms network voltages from up to 525 V down to the 400-V network voltage of the TITANARG® (see item 7).
The automatic welding system TITANARG® meets the German and European safety requirements and conforms to the provisions of the following EU directives: (see Declaration of Installation)
Applied standards and technical specifications: (see Declaration of Installation)
The TIG automatic welding system has the following advantages:
Excellent good welding quality in case of automatic welding.
High economic efficiency by the saving of additional welding costs.
Interface: interface of the automatic system.
High degree of reproducibility of the welding data.
Customer-specific welding data are programmable via the freely programmable control (PLC).
Low energy required by the inverter power unit.
Very high degree of efficiency.
Insensitive against network voltages.
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S
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2.1. Intended use The automatic welding system with inverter power unit and automatic interface was determined for the TIG welding of stainless steels as well as unalloyed, low- and high-alloyed steels in connection with a strapping head in a strapping machine.
Unintended use!
The automatic welding unit is NOT intended for manual welding.
The welding of materials apart from the ones mentioned above is NOT admissible.
The use of the automatic welding system for the defrosting of frozen pipes or the like is NOT admissible.
2.2. Liability and warranty TITAN Umreifungstechnik GmbH & Co. KG grants a six-month guarantee for all automatic welding units sold by them. That guarantee comprises all defects whose origin by deficient manufacture or defective material can be evidenced.
Wearing parts are excluded from guarantee!
Warranty and liability claims are excluded if they are caused by one of the following reasons:
Unintended use of the automatic welding system.
Unprofessional mounting, commissioning, operation and maintenance of the automatic welding system.
Operation of the automatic welding system when safety and protective devices are improper.
Disregard of indications in the operating instructions.
Unauthorized structural alteration to the automatic welding system.
Deficient monitoring of tool components being subject to wear.
Unprofessionally performed repair works.
2.3. Note on environmental protection
The units are manufactured without physical and chemical substances and such substances being detrimental to health. Waste disposal requires the meeting of the applicable legal regulations.
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3. Safety regulations
The disregard of the safety rules below as well as faulty handling of the automatic welding system can result in serious injuries.
Inform yourself!
Read the operating instructions of the automatic welding system carefully before working with it. Protect yourself!
Protect your eyes, face and hands (gloves resisting cuts) during works. Unauthorized persons are not allowed to use the automatic welding system or the strapping machine!
All safety and warning notes must be adhered to in any case; we especially refer to the EU Machine Directive. Before the first operation of the automatic welding system - in connection with a strapping head - the operating staff must be instructed most precisely and made familiar with its control system (PLC) on the strapping machine. Setting and maintenance works may only be performed by trained technical staff. The automatic welding unit must NOT be operated without protective devices (e.g. lid etc.). Protective devices must be inspected before any enable; they must neither be loose or removed! Before the beginning of cleaning works and / or troubleshooting the automatic welding system must be disabled: set main switch at position "OFF" and pull off the mains connector! The welding current source must NOT be used for the defrosting of frozen water pipes! Exclusively use original TITAN spare parts!
The use of spare parts not made by Titan excludes guarantee and liability. The use of strap not recommended can result in tearing strap during tensioning and poor seal qualities. Only use the relevant TITAN quality products!
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During TIG welding developing gases and vapours may be a threat to your health. Do not inhale gases or vapours; if they develop strongly, an exhaustion installation must be used or sufficient ventilation must be provided. NEVER use oxygen for ventilation! The shielding gas corona at the welding point must not be destroyed. Keep vapours originating in the radiation area of the arc away from the solvents; vapours originating from chlorinated hydrocarbon can be transformed to toxic phosgene by UV radiation. Caution!
Arc radiation may cause eye injuries and skin burns. Never look at arcs without eye protection! Protect your eyes against the arc. Even a short-time view of the arc with unprotected eyes (mainly of a highly intense protective gas arc) can cause permanent eye injuries. Should you, however, happen to have to look into an arc, use the relevant protective glasses of grade 13 (acc. to DIN 4647-1). Caution! Electricity!
An electric shock is critical and can even be lethal.
Never touch live parts in or on the TITANARG®.
Opening of the TITANARG® by authorized technical staff only.
Pull the mains connector; disabling it is not sufficient.
Wait 2 minutes until the condensers have been discharged!
In case of works (e.g. maintenance) on the open TITANARG® insulate the operator from the workpiece and the ground; wear insulating gloves, if required and use a rubber mat for the floor.
If possible, a residual current operated device (RCD) with power-up delay should be installed in the mains supply.
Do not touch the electrode when the TITANARG® has been enabled.
Safety devices (e.g. interlocks and circuit breakers) should never be disconnected.
Magnetic fields originating from HV current can affect cardiac pacemakers. Persons using a cardiac pacemaker should ask their doctors for consent when coming near the TITANARG®.
Caution! Fire and explosion!
All inflammable and ignitable substances in the welding area that could be ignited by welding sparks have to be removed.
Never perform welding when the air contains ignitable dust, gas or liquid containing vapours (like benzine).
Keep the TITANARG® clean and fully functional, free from oil, grease and metal parts that might cause short-circuits in the electrical components.
Caution! Burns!
After welding the strapping material is still hot at the seal; do not touch the seal immediately after welding.
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Attention:
Exceeding the nominal operation-on time has the consequence that the heat overload protection circuit is activated and the outgoing current is disabled, until the TITANARG® has been cooled down to operating temperature. The continuous exceeding of the nominal operation-on time can damage the power source. Do not exceed the operation-on time (ED) specified! The air intake openings providing an air throughput for the cooling of the TITANARG® must have a clearance of min. 160 mm. Do not cover the air intake openings. Any guarantee expires, should any filter materials be attached to the air intake openings! Use the carry handles provided for the transport of the TITANARG®. Before the transport the TITANARG® must be disabled and the mains connector must be pulled off. Always use both carry handles for transport. Workplace!
Keep your workplace orderly. A disorderly workplace results in risk of accident. Never operate the tool when the working position is unfavourable! Maintenance of the tool!
Just a tool in a faultless condition is a safe tool. Regularly check the state of your tool for defective or worn parts. Never work with a tool that has defective or worn parts. Alterations to tools are strictly forbidden. The disregard of that instruction can result in very serious injuries.
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4. Technical data
Welding capacity:
Setting range: 5 A / 10.2 V... 350 A / 24 V (continuous)
DB 100 % ED: 210 A / 18.4 V
DB 60 % ED: 260 A / 20.4 V
DB 25 % ED: 350 A / 24.0 V
(DB = continuous operation / ED = operation-on time)
Mains connection:
Mains voltage: 3 x 400 V 50/60 Hz
Permanent / maximum load: 5.3 / 10.6 kVA
Permanent / maximum current: 2.2 / 7.2 A
Fuse (slow-blow): 16 A
Connection line: 4 x 2.5 mm² H07RN-F
Power factor cos. phi.: 0.99
No-load voltage: 63 V
Protection: IP 23
Cooling: AF
Insulation class: H
Dimensions: 555 x 290 x 350 mm (L x W x H) h = without carry handles
Weight: approx. 22.5 kg
Noise emission: the noise pressure level acc. to DIN 45635 is ≤ 68 dB (A)
Ambient conditions:
Temperature: - 25 to + 40° C
Relative humidity: up to 50 % at + 40° C up to 90 % at + 20° C
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4.1. Low-consumption transformer (option)
Designation: Three-phase low-consumption transformer
Standard: EN 61558-2-13 / UL / CSA
Type: I-953502-01
Installation: in housing
Function display: LED
Primary: 3 x 420 / 440 / 460 / 480 / 500 / 525 ± 10V
Secondary: 3 x 400V – 16A
Frequency: 50/60 Hz
Mains input connection: Terminal, touch-proof according to BGV A3
Mains output connection: CEE socket 3P+N+PE 16A
Protection: IP 23
Cooling: A0
Insulation class: T40/E
Kind of operation: DB (continuous operation)
Dimensions: 390 x 290 x 320 mm (L x W x H)
Weight: 24 kg
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5. Installation and designations
A Interface automatic machine
B1 Bus connection
C Main switch
D Workpiece connection (+) / burner connection (-)
E Mains port
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A
B
C
D
E
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1 2 + 24V: 5 ignited: 6 Analogue -:11 Analogue +:12 PE
1 2 3 4 5 6
PE
6. Commissioning
As long as the TITANARG has been purchased with a TITAN strapping machine, none of the following measures described have to be carried out for commissioning.
Only trained specialised personnel may carry out the commissioning of the TITANARG!
Connecting the control unit and the strapping machine with the automatic interface of the TITANARG- Plug assignment of the 16-pin interface as follows:
Control unit (PLC) machine TITANARG
Socket no. Assignment
1 + 2 Signal torch button: Start / stop
5 + 24V from external supply
6 Feedback to PLC if ignition has been carried out
11 Analogue voltage: Minus
12 Analogue voltage: Plus
PE Earthed conductor
recommended supply line: 7 x 1.5 mm² (Ölflex CY)
Start/Stop:
0-10V
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If the plus / minus connections are not connected yet, this must be carried out now.
The workpiece connection (+) must be connected to a good electrical conductive point of the strapping unit with its other end. The other end of the welding torch connection (-) must also be connected to the welding and electric console (SEK) of the strapping head.
Then the CEE connector of the mains cable must be inserted into a respective 400 V mains socket.
Now the TITANARG is ready for operation!
+ -
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7. Operation Enable the TITANARG® by turning the main switch to the right to position I. Then, the TITANARG® is ready for welding operations! All further settings like e.g. welding current - welding time - etc. must be implemented via the relevant machine control system (PLC). The welding operation is initiated by the "Start/stop signal" which is sent by the machine control system (PLC) via the automatic interface of the machine to the TITANARG®. For further information on the potential welding settings see the attached operating instructions for the strapping machine.
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8. Low-consumption transformer (option) Optionally, TITAN offers a low-consumption transformer in addition to your TITANARG®. You will need that unit if the in-house mains voltage at your company exceeds 400 V. The TITAN economy-consumption transformer transforms that extra voltage to the value of 400 V needed by the TITANARG®.
Only have the economy-consumption transformer connected by authorized technical staff!
The economy-consumption transformer is supplied ready for connection; to connect the economy-consumption transformer to the TITANARG® proceed as follows:
It is most reasonable to install the economy-consumption transformer into the machine control system. If there is no design space available there, it is also possible to install the autotransformer near to the TITANARG®.
Connecting the autotransformer according to the existing mains voltage (see example for 525 V).
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9. Bus interface card (optional) For the connection of the TITANARG® to an existing bus system, TITAN offers bus interface cards for Profibus and Profinet. This allows, amongst others, the implementation of a realtime transmission of all relevant welding parameters to a higher level control unit for flawless quality assurance. Allocation of the bus interface card: A TITANARG® connection B External 24V voltage supply C Selector switch for network addressing (only Profibus) D Profibus / Profinet connection
D
A
B
C
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9.1. Addressing the bus interface card
The Profibus bus interface card must be assigned to a clear unique address in the network before commissioning. This is carried out via two selector switches in a range of 1 to 99. The right switch selects the 1 series digit, the left switch the 10 series digit for setting the address. The setting is carried out in decimal format:
Example: Address 42 = left switch position 4 (x10) + right switch position 2 (x1)
The settings for the network address must be set before commissioning the module. Subsequent changes to the settings will only be taken over after activating the voltage and switching on the module again.
Addressing of the Profinet bus interface card is carried out using the software "Anybus IPconfig“, that can be obtained at www.anybus.com.
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9.2. Process and control data
Control data
Byte no.
Bit no.
Function Bit
assignment Description
1 4 Error reset Acknowledge signal for system errors
1 5 User-defined output Switches the user-defined relay output on the bus module
0 Relay not switched
1 Relay switched
1 7 Weld simulation Activates the weld simulation function
0 Simulation active
1 Simulation deactivated
4 0-7 Assignment of main current, low-byte
Assignment of the weld current, the scaling is always 100% based on the respective system current: Range: 0 to 0x7FFF 0 equivalent to RANGE-MIN 0x7FFF equivalent to max. system current
Process data
Byte no.
Bit no.
Function Bit
assignment Description
0 0 I > 0 Current flows signal from the process
0 No current flow
1 Current flow, light arc present
0 1 Ready for welding Ready signal from the process
0 System not ready
1 System is ready
0 3 Error General error message from the process
0 No error
1 Error occurred and is not rectified
0 6 Process active Indicates the completion of the welding process
0 Process ended
1 Process running
1 0-7 Error Error number of an error occurring
4 0-7 Actual welding voltage value, low-byte
Current actual value of the welding voltage Range: 0 to 0x7FFF equivalent to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, high-byte
Current actual value of the welding voltage
6 0-7 Actual welding voltage value, low-byte
Current actual value of the welding current Range: 0 to 0x7FFF equivalent to 0 A to 1,000 A
7 0-7 Actual welding voltage value, high-byte
Current actual value of the welding current
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10. Maintenance and cleaning
Before the beginning of maintenance and cleaning works the automatic welding system must be disabled. Main switch at position OFF; disconnect the mains connector.
The TITANARG® does not require special care and maintenance. Apart from the fans with special bearings hardly requiring any maintenance no rotating components have been installed. If the TITANARG® is operated in extremely dusty surroundings, it is recommended that the parts installed are cleaned every six months.
Maintenance works on the TITANARG® may only be performed by authorized technical staff.
Check cables for wear, cracks and other damages. Replace cables with excessively worn-out or damaged insulation to avoid potentially lethal electrical shock by bare cables.
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10.1. Deadlines for tests acc. to BGV The administrative employer's liability insurance VBG demands in its accident prevention regulation BGV A3 (edition January 2010) in §5 (Tests) that the operator of electrical systems must take care that the electrical systems are tested for their proper state. Such tests must be performed by a specialized electrotechnical worker! The following deadlines acc. to BGV A3 §5 apply: (excerpt)
Stationary electrical systems and devices
Plant / devices Deadline for test
Kind of test Inspector
Electrical plants and stationary devices
4 years for proper state Electrotechnical expert
Setup of low-voltage plants; requirements concerning locations, rooms and plants of a special kind (DIN VDE 0100-701)
1 year for proper state Electrotechnical expert
Protective measures with residual current operated device in non-stationary installations
1 month for efficiency
Electrotechnical expert or electrotechnically trained person in case of use of appropriate measuring instruments and test units
Residual current, differential current and faulty voltage protective switch
in stationary plants in non-stationary plants
6 months every workday
for faultless function by actuation of the test installation
User
Table 1 A: Repeated tests of stationary electrical systems and devices
Non-stationary electrical devices
Plant / devices Deadline reference and
maximum values Kind of test Inspector
Non-stationary electrical devices (if used)
Reference value 6 months, on sites 3 months *). If a fault rate of < 2 % is reached, the deadline can be extended accordingly.
for proper state
Electrotechnical expert in case of use of appropriate measuring instruments and test units, or electrotechnically trained person
Extension and unit connection lines incl. connectors
Connection lines incl. connectors
Mobile lines incl. connectors and stationary connection
Maximum values: on sites, at production locations and workshops or under similar conditions one year, in offices or under similar conditions two years.
*) For ascertainment see BG information "Selection and operation of electrical installations and devices on sites and at mounting locations" (BG 608)
Table 1 B: Repeated tests of stationary electrical systems and devices
If the location of the TITANARG® is not in Germany, the regulations for the prevention of accidents applicable in the operator's country and the acknowledged technical rules for safety-related and professional work have to be observed.
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11. Search for faults - remedy
Fault Cause Remedy
TITANARG® does not weld TITANARG
® is not activated
Enable TITANARG®, turn main
switch to position 1
Gas supply interrupted, gas valve defective
Open gas valve or replace gas valve in the SEK, see operating instructions for strapping machine
Gas supply hose kinked Repair kinky points
Tungsten electrode defective or blunt
Whet or replace electrode; see operating instructions for strapping machine.
Unknown. Contact Titan customer service
For fast support (emergency service) TITAN CARE We are ready to support you 24 hours 7 days a week! Belonging to the TITAN family guarantees each customer:
Personal contact 24 hours a day
Competent advice in a multi-stage concept
Permanent readiness for repairs by our technician
Phone: +49 (2336) 808 247
Fax: +49 (2336) 808 322
TITAN CARE – we are ready to help!
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12. Spare parts list
Order No. Description Pcs.
76712000000 Automatic welding system L350TI R
8700000066 Autotransformer O 76712000040 Stand foot adapter O
76712000100 Bus interface card
Profibus O
76712000110 Bus interface card
Profinet O
76712000120 Connection cable 0.5 m
for bus interface O
76712000130 Connection cable 1 m
for bus interface O
76712000140 Connection cable 5 m
for bus interface O
76712000150 Connection cable 10 m
for bus interface O
76712000160 Connection cable 15 m
for bus interface O
V = Wearing parts B = if necessary R = Replacement parts O = Option
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13. Declaration of installation
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Das TITAN Gesamtprogramm
Umreifungsgeräte für Stahl- und Kunststoffband Umreifungsmaschinen und Aggregate für Stahl- und Kunststoffband Ballenumreifungssysteme für Stahl- und Kunststoffband Crimpsysteme Stanzverbinder Verpackungsband aus Stahl- und Kunststoffband Verschlusshülsen Zubehör
The TITAN range of products
Strapping tools for steel and plastic strap Strapping machines and heads for steel and plastic strap Baling systems for steel and plastic strap Crimp systems Strip joining devices Strapping Steel and plastic strap Seals Accessories
La gamme de produits TITAN
Appareils de cerclage pour feuillard d’acier et plastique Machines et têtes de cerclage pour feuillard d’acier et plastique Systèmes de cerclage de balles pour feuillard d’acier et plastique Systèmes crimp Système d’agrafage de bobines Feuillard d’emballage Acier et plastique Chapes Accessoires
TITAN Umreifungstechnik GmbH & Co. KG P.O. Box 440, D-58317 Schwelm Berliner Straße 51-55, D-58332 Schwelm Phone: +49 2336 8080 Telefax: +49 2336 808 208 E-Mail: [email protected] www.titan-schwelm.de Technische Änderungen vorbehalten Subject to technical alterations Sous réserve de modifications techniques
