ESAB B4-350 QuattroJet Assembly Instruction manual

B4-350 QuattroJet Assembly

®

Instruction Manual

Form Number 0558011891

Date: 010/2012

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

B4-350 QuattroJet Assembly

CAUTION

These INSTRUCTIONS are for experienced operators; if you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read booklet “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging” (Form 52-529). Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

2

B4-350 QuattroJet Assembly

Contents

Safety �� 5

Precautions �� 5

Enclosure Class �� 6

General Safety Recommendations �� 7

Description �� 9

Introduction �� 9

Major Components - B4 Lift �� 10

Technical Specications �� 10

Installation �� 11

Mounting ��11

Operation �� 13

Cut Data/Consumable part list �� 14

Maintenance �� 15

Preventative Maintenance Schedule �� 15

Daily ................................................................................................................................................................................................. 15

Weekly ............................................................................................................................................................................................ 16

Monthly .......................................................................................................................................................................................... 16

Semi-Annually .............................................................................................................................................................................. 16

3

B4-350 QuattroJet Assembly

Maintenance Procedures �� 17

B4-350 Lift �� 18

Introduction .................................................................................................................................................................................. 18

Lift Cleaning and Lubrication ................................................................................................................................................. 18

B4 Lift Part Removal and Replacement ...............................................................................................................................20

Basic B4 Lift Assembly Troubleshooting �� 27

Yaskawa Junma Servopack™ Alarm Indicators �� 28

Replacement Parts ��33

General �� 33

Ordering �� 33

Consumable and Spare Part Reference List �� 34

4

B4-350 QuattroJet Assembly

Safety

Precautions

Users of ESAB welding and cutting equipment have ultimate responsibility for ensuring that anyone who works on or near the equipment observes all relevant safety precautions. Safety precautions must meet requirements that apply to this type of welding or cutting equipment.

All work must be carried out by trained personnel well acquainted with operation of welding or cutting equipment. Incorrect operation of equipment may lead to hazardous situations which can result in injury to the operator and damage to equipment. The following recommendations should be observed in addition to standard regulations that apply to the workplace.

1. Anyone who uses welding or cutting

equipment must be familiar with:

…Proper operation. …Location of emergency stops. …Designed function. …Relevant safety precautions. …Welding and/or cutting.

2. Operators must ensure that:

…No unauthorized person within the working

area of equipment when it is started up.

3. The workplace must be:

…Suitable and …Free from drafts.

4. Personal safety equipment:

…Always wear recommended personal safety

equipment, such as safety glasses, ame proof clothing, and safety gloves.

…Do not wear loose tting items, such as

scarves, bracelets, rings, etc., which could become trapped or cause burns.

5

B4-350 QuattroJet Assembly

5. General precautions:

…Make sure return cable is connected securely. …Work performed on high voltage equipment

may only be carried out by a qualied electrician.

…Appropriate re extinguishing equipment

must be clearly marked and close at hand.

…Lubrication and maintenance must not be

carried out on equipment during operation.

Enclosure Class

Maximum

Tilt Allowed

15°

CAUTION

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not intended to be used outside during precipitation unless sheltered.

If equipment is placed on a surface that slopes more than 15°, toppling over may occur. Personal injury and/or signiﬁcant damage to equipment is possible.

WARNING

6

WELDING AND CUTTING CAN CAUSE INJURY TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ HAZARD DATA .

B4-350 QuattroJet Assembly

General Safety Recommendations

FUMES AND GASES - Can be dangerous to health.

• Keep your head out of the fumes.

• Use ventilation, extraction at the cut, or both, to

take fumes and gases away from your breathing zone and the general area.

FIRE HAZARD - Sparks (spatter) can cause re. Make sure that there are no ammable materials nearby.

MALFUNCTION - Call for expert assistance in the event of malfunction.

CAUTION

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

7

B4-350 QuattroJet Assembly

CAUTION

To avoid personal injury and/or equipment damage, lift using method and attachment points shown below.

8

B4-350 QuattroJet Assembly

Description

Introduction

The B4-350 lift assembly provides vertical motion for the torch, using a typical motor, screw, and slide conguration. The motor turns an enclosed spindle screw, which in turn raises/lowers the lifting plate along linear rails. Directional commands given from CNC determines direction of lift travel. Fixed limit switches are included to prevent upper and lower over travel.

The lift assembly also contains components necessary to control height over work surfaces.

9

B4-350 QuattroJet Assembly

Major Components - B4 Lift

1

2

Technical Specications

• Lift Speed: 315 IPM [8.0m per minute]

1

• Vertical Travel: 13.78” [350 mm]

• Approximate Weight of Lift Assembly:

120 lbs. [55 kg]

B4 Lift Electronics Enclosure

B4 Lift Assembly

2

10

B4-350 QuattroJet Assembly

Installation

(6) M8 x 1.25 x 40 Socket Head Cap Screws

0.53” [13.5mm]

2.50” [63.5mm]

Mounting

B4 lift hole patterns are provided below to aid end users in mounting the station.

4.13” [104.9mm]

3.64” [92.4mm]

0.49” [12.4mm]

x6 M8x1.25 - 6H THRU HOLES

NOTICE

5.00”

[127.0mm]

4.47”

[113.5mm]

B4-350 Lift Assembly dimensions

Ensure lift assembly is mounted plumb; use a torpedo level and adjust mounting bolts as needed.

Torpedo Level

11

Lift Electrical Enclosure

Parts List

PART NUMBER

QTY

ITEM

IGNITION SUPPLY 24VAC / 1,5 V000464722811 Retaining Ring DIN472 32x1.2006.164.01112 Shim Ring 12x18x1 DIN 988006.261.041P13 MICRO SWITCH SR-3-E-SW05609352612

4

SUPPORT LIFTER B-350056093822215 SPINDLE SCREW B2-350056093822716 CLIP WIRE DOUBLE05609384052

7

BELT TIMING 5mm PITCH 16mm FACE056093843518 Fitting, Compression, M6-1 X 4mm OD056093845249 PULLEY TIMING

0560941403111

KEYLESS LOCKING ASSEMBLY 12MM X 18MM0560941404112 BELLOWS, B3-350 (Not Shown)0560941788113 Jumna Motor Mounting Bracket B40560943526114 PULLEY TIMING 5mm PITCH 16mm FACE 16T0560943527115 B4 Tensioning Plate0560943528116 Mount, Cable Tie Holder, M4

0560944119317

HOLDER FOR SWITCH0560944206118 Junma Motor 200W0560944262119 JUNMA MOTOR BUSHING

0560944265120

COVER, BOTTOM, B4 LIFT0560944360121 MANIFOLD, GREASE FITTING0560944390122 STATION BOX ADAPTER PLATE0560944392123 SHIELD, B4 LIFTER0560944476124 Linear Rail 25 x 510mm0560945346225 PLATE BACK B4-3500560945350126 SCREW NUT B4 LIFTER0560945353127 BRACKET LIMIT SWITCH B4-200 UPPER

0560945354128

Grease Line Right B4-2000560945355129 Grease Line Left B4-2000560945356130 ASSY, COVER B4-350 LIFT

0560945357131

Hole Plug Flush 7/8"0560945358132 Cam Limit Switch B4-3500560945359133 Spring Lower B4

0560945364134

BUSHING SCREW B4-2000560945418135 SPACER, B4-200 LIFT0560945419136

connection guide

2

4

12

B4-350 QuattroJet Assembly

1

3

1

2

3

4

SB2 - Input Power

SB1 - ACON

SB5 - Customer Interface

SB6 - Customer Interface

B4-350 QuattroJet Assembly

Operation

After the signal to start the process occurs inside the FANUC controller, do the following:

1. Turn on the fuel gas solenoid on the central manifold.

2. Turn on the heating oxygen and heating fuel gas valves on the stations in use.

3. Send the ignition gas values to the central manifold.

4. Turn on the ignition solenoids for oxygen and fuel gas.

5. Turn on the 230 VAC to the igniter in the lifter(s).

6. Wait for the ignition timer to time out.

7. Turn o the 230 VAC to the igniter in the lifter(s).

8. Turn o the ignition solenoid for fuel gas.

9. Wait for the purge timer, for the ignition oxygen, to time out before turning the ignition solenoid for oxygen o.

10. Send the high heating gas values to the central manifold.

11. Send the analog voltage height command to the lifter(s).

12. Turn on the AHC ON signal to the lifter(s).

13. Wait for TORCH IN POSITION to come back from all the lifters.

14. Wait for the heating timer to time out or when the customer presses an override button

15. Start ramping the cut oxygen gas value, from 0 to the nal cutting oxygen value, to the central manifold.

16. Turn on the cut oxygen valve on the stations in use

17. Wait for the pierce timer to time out.

18. Start moving the machine at a reduced speed.

19. Wait for the lead-in timer to time out.

20. Adjust the analog voltage height command to the lifter(s) as needed from this point until the end of the cut.

21. Turn on the AHC ON signal to the lifter(s).

22. Send the low heating gas values to the central manifold.

23. Accelerate the machine to full cutting speed.

After the signal to stop the process occurs inside the FANUC controller, do the following:

1. Turn o the AHC ON signal to the lifter(s).

2. Turn on the MANUAL UP signal to the lifter(s) until the raise on nish timer times out, then turn o the MANUAL UP signal to the lifter(s).

3. Send 0 volts to the central manifold for the cut oxygen value.

4. Turn o the cut oxygen valve on the stations in use.

5. If the customer does not want to keep the heating ame on:

a. Turn o the heating fuel gas valve on the stations in use. b. Send 0 volts to the central manifold for the fuel gas value. c. Turn o the fuel gas valve on the central manifold. d. Wait for the post-ow timer to time out. e. Turn o the heating oxygen valve on the stations in use. f. Send 0 volts to the central manifold for the oxygen value.

13

B4-350 QuattroJet Assembly

Schneidgeschwindigkeit

Cutting speed

DIN EN ISO 9013

***

QuattroJet

****

QuattroJet

****

Schneid- und Verbrauchstabelle für Schnellschneiddüsen Typ IPQ 300 S ( Propan, Erdgas )

***

Cut Data/Consumable part list

0.300.064

Druck / Pressure Verbrauch / Consumption

1,0

0,55 0,14

0,2

1,5

1,6

0,75 0,20

0,2

2,0

0,83 0,22

0,2

2,0

0,90 0,24

0,2

2,0

1,30 0,30

1,00 0,26

0,2

2,0

2,40 0,60

0,2

0,6

2,0

4,5

8,0

TU 01.2010 V.2.2

0,60

0,62

2,40

2,50

0,64,5

0,6

5,0

14

Cutting and consumption table for High speed nozzles type IPQ 300 S ( propane, natural gas )

[ bar ] [ bar ] [ bar ] [ m³ / h ] [ m³ / h ] [ m³ / h ] [ mm ]

[ mm/min.]

4.400.136

4.450.623 CoolJet Pro

4.400.136

4.450.624 CoolJet Pro

ESAB CUTTING SYSTEMS GmbH - Robert-Bosch-Str. 20 - 61184 Karben Germany

4.450.620

QuattroJet

4.450.611

5 630 4,0 0,7

4 600 4,0 0,7

3 600 2,0 0,5

[ mm ]

4.450.612

8 600 5,0 1,6

6 630 5,0 1,6

6 630 4,0 0,7

4.450.613

20 460 7,5 3,6 2,0

15 520 7,0 3,4 1,9

15 520 7,5 2,1

10 560 6,5 1,9

4.450.614

30 400 8,0 4,7 2,4

25 420 7,5 4,5 2,4

25 420 8,0 3,8 2,1

4.450.615

60 340 6,0 7,6 3,9

60 290 8,5 6,2 2,8

50 310 8,0 6,0 2,7

40 360 7,5 5,7 2,6

40 360 8,5 5,0 2,5

35 380 8,0 4,7 2,5

4.450.616

80 300 7,5 9,6 4,0

4.450.617

100 270 8,5 10,2 4,0

100 270 7,5 13,3 4,0

150 230 8,5 14,9 4,2

4.450.621

QuattroJet

4.450.619

4.450.618

200 180 9,5 16,5 4,4

200 180 6,5 22,0 5,2

250 130 8,5 22,0 5,5

250 130 6,5 31,0

300 110 8,5 31,0

Tel. +49 (0) 60 39 / 40 0 - Fax +49 (0) 60 39 / 4 03 01 - www.esab-cutting.de - email info@esab-cutting.de

Die angegebenen Werte sind Richtwerte. The given values are appoximate values.

B4-350 QuattroJet Assembly

Maintenance

CAUTION

Preventative Maintenance Schedule

Time periods suggested below are based on average plasma station usage. If station is employed in a heavy usage cycle, used outdoors, or used on a multi-torch cutting machine, suggested time intervals should be shortened. Regularly scheduled maintenance will signicantly increase the life and performance of your equipment.

Read all instruction manual’s safety and maintenance procedures before beginning any preventative maintenance!

Daily

• Wipe dust and fume buildup from lift assembly

and components.

• Check for worn or damaged cables on all lift

subassemblies.

• Ensure all mechanical fasteners and electrical

connections are correct; no stripping of hardware, connections are tight, exposed wires, etc.

• Check that lift travel limit switches are

functioning correctly.

• Use your CNC’s station travel buttons to ensure

lift assembly has proper, smooth movement.

15

B4-350 QuattroJet Assembly

Weekly

• Check alignment of lift assembly.

Monthly

• Clean and lubricate slide assembly (see

procedure on page 18).

Semi-Annually

• Repeat all previous maintenance procedures.

• Consider calling your ESAB Service

Representative to schedule an semi-annual station inspection.

NOTICE

Many replacement parts subject to wear or used in preventative maintenance schedules are available directly through ESAB Cutting Systems.

See “Consumables and Spare Parts” section in Replacement Parts portion of this manual before ordering.

16

B4-350 QuattroJet Assembly

Maintenance Procedures

The following section contains maintenance procedures for the lift assembly and components. This section will provide some basic troubleshooting methods to return your station to correct operation. Only qualied maintenance personnel should utilize these procedures.

17

B4-350 QuattroJet Assembly

B4-350 Lift

Introduction

The B4-350 heavy duty vertical lift employs an enclosed motor that turns a ball screw. This is made possible by using a pair linear bearing blocks and a drive belt, which lowers or raises the lifter assembly along linear rails. Direction depends on commands received form the CNC. The illustration at left is the B4 lift with some parts hidden for clarity. The three grease ttings can be accessed without removing lift covers.

Lift Cleaning and Lubrication

In order for B4 slide assemblies to perform at optimum levels, it will need to be inspected, cleaned and lubricated on a weekly basis. The following procedure will detail steps necessary to correctly clean and lubricate your slide assembly:

1. Remove (3) cap screws attaching front cover.

2. Run lift to lower limit and wipe ball screw with

a clean, dry cloth. Apply lithium based NGLI 2 grease or softer grease directly to screw.

Spindle Ball screw

1

Spindle Ball nut

2

Upper Limit switch and cam

3

Precision Linear rail (2)

4

Linear Bearing blocks (2)

5

Lower Limit switch

6

Lift Electronics Enclosure

7

Timing belt

8 9

Motor / Encoder

10

Lifter Assembly w/ bellows

18

B4-350 QuattroJet Assembly

Parts List

DESCRIPTION

PART NUMBER

QTY

ITEM

IGNITION SUPPLY 24VAC / 1,5 V000464722811 Retaining Ring DIN472 32x1.2006.164.01112 Shim Ring 12x18x1 DIN 988006.261.041P13 MICRO SWITCH SR-3-E-SW05609352612

4

SUPPORT LIFTER B-350056093822215 SPINDLE SCREW B2-350056093822716 CLIP WIRE DOUBLE05609384052

7

BELT TIMING 5mm PITCH 16mm FACE056093843518 Fitting, Compression, M6-1 X 4mm OD056093845249 PULLEY TIMING

0560941403111

KEYLESS LOCKING ASSEMBLY 12MM X 18MM0560941404112 BELLOWS, B3-350 (Not Shown)0560941788113 Jumna Motor Mounting Bracket B40560943526114 PULLEY TIMING 5mm PITCH 16mm FACE 16T0560943527115 B4 Tensioning Plate0560943528116 Mount, Cable Tie Holder, M4

0560944119317

HOLDER FOR SWITCH0560944206118 Junma Motor 200W0560944262119 JUNMA MOTOR BUSHING

0560944265120

COVER, BOTTOM, B4 LIFT056 0944360121 MANIFOLD, GREASE FITT ING0560944390122 STATION BOX ADAPTER PLATE056 0944392123 SHIELD, B4 LIFTER0560944476124 Linear Rail 25 x 510mm0560945346225 PLATE BACK B4-3500560945350126 SCREW NUT B4 LIFTER0560945353127 BRACKET LIMIT SWITCH B4-200 UPPER

0560945354128

Grease Line Right B4-2000560945355129 Grease Line Left B4-2000560945356130 ASSY, COVER B4-350 LIFT

0560945357131

Hole Plug Flush 7/8"0560945358132 Cam Limit Switch B4-3500560945359133 Spring Lower B4

0560945364134

BUSHING SCREW B4-2000560945418135 SPACER, B4-200 LIFT0560945419136 B4-350 BASIC SPARES

0560947287REF37

B4-350 EXTENDED SPARES0560947288REF38 Plug, Snap in, 1.5"0560947910139 ASSY STAT BOX B4 QUATTROJET

0560952873140

BLOCK RUNNER SLIMLINE SZ 25 LONG2238778241 Deep Groove Ball Bearing407 058242 FITTING GREASE M6 STR THD56997241143 NAMEPLATE 2.38 X 3.38954075144 Hexagon nut-ISO4032-M3-8-A1FLO-STD-00687

245

Hex Jam NutFLO-STD-00686146 Washer-ISO7092-6.4-140HV-FLO-STD-00684247 Spring Washer

DIN 128 - A4248

RING RETAINING EXTERNAL 12mmFLO-STD-00688149 Washer M6FLO-STD-00682150 Spr.L.Washer-DIN128-B8-FLO-STD-00056

451

Hex.S.H.C.Scr.-ISO4762-M6x20-8.8FLO-STD-000711452 Hex.S.H.C.Scr.-ISO4762-M6X16-8.8FLO-STD-00086453 Spr.L.Washer-DIN128-B6-FLO-STD-00100

654

Hex.S.H.C.Scr.-ISO4762-M5x16-8.8FLO -STD-00156455 HS Button Head Cap Screw M4 x 6FLO-STD-00161856

M4 x 10 COUNTERSUNK CROSS HEAD SCREWFLO-STD-001633

57

Hexagon socket set screw M5 x 20 Flat Point

FLO-STD-00164

158

Hexagon socket set screw M3 x 2 Flat PointFLO-STD-00165159 Hex.S.H.C.Scr.-ISO4762-M6x12-8.8FLO -STD-00166860 Hex.S.H.C.Scr.-ISO4762-M5x12-8.8FLO -STD-00167

661

HS Button Head Cap Screw M3 x 16 FLO-STD-00169462

HS Button Head Cap Screw M4 x 10 FLO-STD-001701063

HS Button Head Cap Screw M6 x 12 FLO-STD-00171464

Hex NutANSI B 18.2.4.1 M - M6 x 1465 Hex.S.H.C.Scr.-ISO4762-M4x30FLO-STD-00187266 Hex.S.H.C.Scr.-ISO4762-M8x20FLO-STD-00216

467

Spr.L.Washer-DIN128-B5FLO-STD-00218468 Washer galvanized B6FLO-STD-00219469 Hex.S.H.C.Scr.-ISO4762-M4x20-A2FLO-STD-00681

270

CAUTION

Do not use solvents or solvent-based lubricant to clean ball screw; this can remove lubricant from sealed linear bearing blocks.

3. Run lift to upper limit.

4. Apply same grease to three zerk ttings; apply

0.1 ounce (3cc) or half pump of a grease gun to each tting.

Screw Nut

zerk tting

NOTICE

Linear Bearing

zerk ttings

5. Reinstall front cover to lift assembly.

Lift covers do not need to be removed to access grease ﬁttings.

See illustration above for ﬁtting locations.

19

B4-350 QuattroJet Assembly

NOTICE

B4 Lift Part Removal and Replacement

Many replacement parts subject to wear or used in preventative maintenance schedules are available directly through ESAB Cutting Systems.

See “Consumables and Spare Parts” section in Replacement Parts portion of this manual before ordering.

The most common component on B4 lifts that will need replacement over its operational lifetime is the screw nut. Proper cleaning and lubrication of this assembly, along with 350 mm screw, will dramatically extended the years of service before part replacement is necessary (see page 18 above).

Limit Switch Cam

1

Bellow Retention screws (4)

2

Procedure - Screw Nut Replacement

1. Remove both B4 lift covers by extracting cap

screws with 2.5mm Allen wrench.

2. Remove limit switch cam by extracting (2)

socket head hex screws with 3mm Allen wrench.

3. Remove bellow retention screws by extracting

(4) socket head hex screws with 3mm Allen wrench.

20

Saddle Bolts (2)

B4-350 QuattroJet Assembly

4. Extract (2) ball nut saddle bolts from lifter

assembly with 5mm Allen wrench.

Ball Bearing Retention blocks (2)

5. Locate ball bearing retention blocks; these

will be located inside B4 lift covers. As lifter assembly linear rails travel o bottom of bearing blocks, install (2) black plastic bearing retention blocks into linear bearing blocks.

21

B4-350 QuattroJet Assembly

1

Bearing retention blocks

1

Spring retaining bolt

2

6. Continue sliding lifter assembly o linear

bearing blocks; rest lifter assembly on a clean, moveable surface.

7. Using medium sized channel locks and 5mm

Allen wrench, grasp ball screw so it does not move and loosen spring retaining bolt.

2

22

8. Continue removing 5mm bolt, washer and

spring and set aside.

9. Thread screw nut o end of ball screw. Replace

with new ball screw nut.

10. Thread new ball screw nut onto ball screw 2”

[51mm] from top of screw.

11. To reassemble lift, perform steps #1-7 above in

reverse order.

B4-350 QuattroJet Assembly

Procedure - Ball Screw Replacement

1. Following steps #1-9 of Screw Nut Replacement

Procedure (from previous pages), remove

motor angle bracket assembly by extracting (4) socket head hex screws with 6mm Allen wrench.

Motor Angle Bracket and

associated components

23

B4-350 QuattroJet Assembly

2. Using a standard press and illustration (at left),

remove worn ball screw and replace with new screw. When pressing in new ball screw, apply force with press until step is reached.

24

B4 Timing Belt (top view)

2

B4-350 QuattroJet Assembly

Procedure - Timing Belt Replacement

Loosen tensioning jam nut and adjust set screw so

1

3

belt tensioning plate can slide towards larger of the two timing pulleys. Slip new timing belt over both pulleys. After a new timing belt has installed, tighten so that belt can only be displaced by ¹/₁₆” [1.587mm]. Use a small blunt object or your index nger to displace belt at its midpoint between timing pulleys.

Motor Angle Bracket

1

Timing Belt

2

Belt Tensioning Plate

3

Tensioning Jam Nut & Set Screw

4

Ensure belt cannot be displaced more/ less than 1/16” [1.587]. Area in dotted lines above represents correct displacement.

25

B4-350 QuattroJet Assembly

Procedure - Motor / Pulley Replacement

Ensure correct operation of ball screw rotation motor. Illustration (at left) displays the correct parts breakdown for motor and associated components.

26

B4-350 QuattroJet Assembly

Basic B4 Lift Assembly Troubleshooting

With proper preventative maintenance performed on the B4 lift assembly, it will provide many years of precision and reliable service. However, issues may arise over time, even with most proactive PM schedules. Information is provided below to correct some common assembly failure modes that may occur and return it to normal operation:

Overload fault indicator on Yaskawa

servopack™ will not clear:

Seen after the station has been "slammed" into either lower or upper hard limit; rst attempt to reset power to station by disconnecting input power cable and reconnect after 10 seconds. If fault persists, physically remove motor from slide assembly and shaft will release.

27

B4-350 QuattroJet Assembly

Yaskawa JUNMA Servopack™

Yaskawa Junma Servopack™ Alarm Indicators

The Yaskawa Junma Servopack unit is responsible for motor speed, direction, and acceleration as well as encoder count and pulse monitoring. Tables on

1

2

3

following pages will describe the servopack’s alarm displays, their cause and meaning, and generalized information for corrective action:

28

Alarm Indicator 1

1

Alarm Indicator 2

2 3

Alarm Indicator 3

Alarm

Condition

Corrective

AL1 = On

Phases U, V, and W in

Servomotor operation

Table 1 - Speed Errors

B4-350 QuattroJet Assembly

Display

AL2 = O AL3 = O Servo was turned ON.

Name

Speed Error

Trigger Cause

Power was turned ON. A servopack fault occurred. Replace the servopack.

was started or was switched to high speed operation. Encoder wiring is incorrect.

Action

servomotor are wired to wrong terminals. Correct wiring.

Encoder wiring is incorrect.

Malfunction occurred due to noise in encoder wiring.

A servopack fault occurred. Replace the servopack.

servomotor are wired to wrong terminals. Correct wiring.

Malfunction occurred due to noise in encoder wiring.

Take measures against noise for encoder wiring.

Position pulse reference input has exceeded 10,000 pulses per revolution. Correct reference value input.

A servopack fault occurred. Replace the servopack.

29

B4-350 QuattroJet Assembly

Alarm

Condition

Corrective

Table 2 - Overload Errors

Display

AL1 = O AL2 = On AL3 = O

Name

Overload

Trigger Cause

Power was turned on. A servopack fault occurred. Replace the servopack.

Servo was turned ON or servomotor did not operate for a reference input from the controller.

Normal operation

Servomotor main circuit cable wiring is incorrect or its contact wiring is faulty. Check and correct servomotor wiring.

Encoder cable wiring is incorrect or its contact wiring is faulty.

A servopack fault

Drop in power supply voltage.

Servomotor coil burned out.

Servomotor was operated with holding brake engaged.

Ambient temperature around servomotor exceeded 131°F

occurred. Replace the servopack.

Ensure power supply voltage is within permissible range.

Measure coil resistance. If open, replace servomotor.

Measure voltage of brake terminals and release brake.

Take measures to ensu

(55 °C ).

less than 131°F (55 °C ).

Action

re working area is

30

A servopack fault occurred. Replace the servopack.

B4-350 QuattroJet Assembly

Alarm

Condition

Corrective

Table 3 - Encoder Errors

Display

AL1 = On AL2 = On AL3 = O

Alarm

Display

Name

Power was turned on or

Encoder

Error

Table 4 - Voltage Errors

Alarm

Name

during servomotor operation.

Condition

Trigger Cause

Encoder wiring and contact wiring are incorrect. Correct wiring.

Noise intererence occurred because encoder cable distance is too long

Disconnected encoder cable.

A zero point error occurred. Replace the servopack.

An

encoder fault occurred.

Trigger Cause

Action

Ensure encoder is no more than 20 meters.

Replace encoder cable through ESAB Customer Service.

Corrective

Action

AL1 = O AL2 = O AL3 = On

Voltage

Error

Power was turned on or normal operation.

Main power was turned ON again before the power supply to servopack was completely OFF.

AC power supply voltage exceeded permissible range.

ervopack fault occurred. Replace the servopack.

A s

Wait until servopack's REF indicator is OFF, and turn on main power again.

Ensure AC power voltage is within specied range.

31

B4-350 QuattroJet Assembly

Alarm

Display

AL1 = O AL2 = On AL3 = On

Alarm

Display

Alarm Name

Built-in

Fan

Stopped

Alarm Name

Condition

Trigger Cause

Power was turned on or during motor operation. Fan motor stopped. Replace cooling fan in Servopack.

Air intake is blocked. Inspect and clear obstruction.

Condition

Trigger Cause

Corrective

Action

Corrective

Action

ALL On

Alarm

Display

All ash

on to o

at regular

intervals

System

Error Power was turned on. A servopack fault occurred.

Alarm Name

Reference

changed

Power was turned on or during servomotor operation. N/A

Condition

Trigger Cause

Replace the servopack and c customer support.

Corrective

Action

Turn on main power again (operation of the servomotorcan continue during display of this alarm).

ontact ESAB

32

Replacement Parts

ITEM QTY PN DESCRIPTION

46 4 M8 x 1.25 Hex Nut

47 4 M3 x 0.5 x 16 Broached Hexagon Socket Button Head Cap Screw - Metric

48 10 M4 x 0.7 x 10 Broached Hexagon Socket Button Head Cap Screw - Metric

49 8 M4 x 0.7 x 6 Broached Hexagon Socket Button Head Cap Screw - Metric

50 4 M6 x 1 x 12 Broached Hexagon Socket Button Head Cap Screw - Metric

51 1 M3x0.5 x 2 Broached Hexagon Socket Set Screw - Flat Point

52 1 M5 x 20 Hexagon socket screws

53 1 D0560946668 B4 M3 Station Wiring Build

54 1 D0560946668 B4 M3 STATION WIRING BUILD

55 4 DIN 126 - 6.6 Washers for hexagon bolts

56 4 DIN 128 - A5 Spring Washer

57 1 DIN 9021 - 6.4 Washer

58 2 M4 x 16 Cylinder Head Cap Screw

59 9 M6 x 12 Cylinder Head Cap Screw

60 4 M6 x 16 Cylinder Head Cap Screw

61 2 DIN 934 - M3 Hex Nut

62 2 IS 3063 - 4 LOCK WASHER

63 4 IS 3063 - 6 LOCK WASHER

64 4 IS 3063 - 8 LOCK WASHER

65 1 ISO 4035 - M5 Hex Jam Nut

66 2 M4 x 30 Hexagon Socket Head Cap Screw

67 10 M5 x 12 Hexagon Socket Head Cap Screw

68 12 M6 x 20 Hexagon Socket Head Cap Screw

69 4 M8 x 20 Hexagon Socket Head Cap Screw

70 2 M4 x 10 - 4.8 - H Countersunk at head screws

71 2 STD-000149 Spring Washer DIN 128 - A3

72 2 SocHeadCapScrew-MET M6-1.0 x 80 SHCS

73 4 M4 x 16 Hexagon Socket Head Cap Screw

PARTS LIST

BOLT SIZE TORQUE (N-m) TORQUE (Ft-lb)

M3 0.9 0.7

M4 2.6 1.9

M6 8.7 6.4

M8 21.1 15.6

M12 73.2 54

RECOMMENDED BOLT TORQUE VALUES

Replacement Parts

General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit serial number plate.

Ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers.

Note

Items listed in the following Bill of Materials that do not have a part number shown are not available from ESAB as a replaceable item and cannot be ordered. Descriptions are shown for refer-

ence only. Please use local retail hardware outlets as a source for these items.

Note

Replacement Parts, Schematics and Wiring Diagrams are printed on 279.4mm x 431.8mm

(11” x 17”) paper and are included inside the back cover of this manual.

M5 5.0 3.7

M10 42.0 31.0

Replacement Parts

Consumable and Spare Part Reference List

NOTICE

1-800-ESAB-123

BASIC SPARE PARTS, B4-350 LIFT, ESAB P/N 0560947287

The following section was designed to assist operators in identifying and ordering maintenance/ consumable parts. Items listed below are parts that will need replacement at least on a yearly basis, many with smaller maintenance intervals. Quantities suggested are estimated, based on normal machine usage, product lead times and availability; end users will need to best decide what quantities to purchase based on their production schedule.

The parts represented here, at some point, will be necessary to maintain the process tool. Please dial our toll free number for pricing and availability or contact your nearest distributor.

ITEM QTY PN DESCRIPTION

1 1 0560935261 MICROSWITCH SR-3-E-SW

2 1 0560938435 TIMING BELT

3 1 0560938227 SPINDLE SCREW, B2-350

4 1 05609414 03 TIMING PULLEY

5 1 0560943527 TIMING PULLEY

6 1 0560945353 ACME SCREW NUT

7 2 2238778 RUNNER BLOCK

8 2 407058 BALL BEARING

Replacement Parts

EXTENDED SPARE PARTS, B4-350 LIFT, ESAB P/N 0560947288

ITEM QTY PN DESCRIPTION

1 2 0560945346 LINEAR RAIL

2 1 0560935261 MICROSWITCH SR-3-E-SW

3 1 0560938435 TIMING BELT

4 1 0560938227 SPINDLE SCREW, B2-350

5 1 0560941403 TIMING PULLEY

6 1 0560943527 TIMING PULLEY

7 1 0560944262 JUNMA MOTOR

8 1 0560945353 ACME SCREW NUT

9 1 0560945364 SPRING

10 2 2238778 RUNNER BLOCK

11 2 407058 BALL BEARING

12 1 0006164011 RETAINGING RING

13 1 056 0941404 KEYLESS BUSHING

14 1 0560943507 MCU JUNMA

15 1 0560944331 JUNMA SERVOPACK

NOTES

REVISION HISTORY

Original release - this manual created from 0560946015 format, 10/2012.

Customer // Technical Support

(843) 664-4405

(800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products

PO BOX 100545 Ebenezer Road

Florence, SC 29501-0545

http://www.esab.com

ESAB Cutting Systems – Canada

6010 Tomken Road

Mississauga, Ontario Canada L5T 1X9

Phone: (905) 670-0220

Fax: (905) 670-4879

ESAB Cutting Systems GMBH

Robert-Bosch-Strasse 20

Postfach 1128

D-61184 Karben 1

Phone 011-49-6039-400

Fax 011-49-6039-403-02

http://www.esab.de

®