Stanley Black & Decker RW30 User Manual
RW30
RW30
ROBOTIC
ROBOTIC
WELDER
WELDER
USER'S MANUAL
USER'S MANUAL
Safety, Operation and Maintenance
Safety, Operation and Maintenance
Copyright© The Stanley Works 2014
Copyright© The Stanley Works 2014
69893 8/2014 ver 7
69893 8/2014 ver 7
GENERAL INFORMATION
SERIOUS INJURY OR DEATH COULD RESULT FROM THE
IMPROPER REPAIR OR SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED
DEALER.
MAKE NO ALTERATIONS OR MODIFICATIONS TO THE TOOL.
SERIOUS INJURY COULD RESULT FROM IMPROPER CHANGES.
MODIFICATIONS OR ALTERATIONS COULD ALTER THE PERFORMANCE OR INTEGRITY OF THE TOOL.
IMPORTANT
To ll out a Product Warranty Recording form, and for information on your warranty, visit
Stanleyhydraulics.com and select the Company tab, Warranty.
(NOTE: The warranty recording form must be submitted to validate the warranty).
2 - RW30 USER MANUAL
TABLE OF CONTENTS
SAFETY SYMBOLS ................................................................................................................................................................................ 5
LOCAL SAFETY REGULATIONS ...........................................................................................................................................................5
SAFETY PRECAUTIONS ........................................................................................................................................................................ 6
OPERATION .......................................................................................................................................................................................... 11
OVERVIEW ........................................................................................................................................................................................ 11
PREPARING THE RW30 FOR OPERATION .................................................................................................................................... 11
CLAW VERSION ............................................................................................................................................................................... 11
CLAMP VERSION .............................................................................................................................................................................12
CONNECTING THE WIRE FEED/WELDING TIP TO THE RW30 ....................................................................................................13
SETTING THE STICK OUT ...............................................................................................................................................................13
OPERATING THE RW30 & THE CHARLIE CONTROL UNIT ........................................................................................................... 14
INFORMATION ON DATA TRACKING ..............................................................................................................................................16
MANUAL DATA ENTRY .....................................................................................................................................................................16
AUTOMATIC DATA ENTRY ............................................................................................................................................................... 16
OPERATOR DIALOGUE ................................................................................................................................................................... 17
STOP AND RESTART OF WELDING CYCLE ................................................................................................................................... 20
ERROR MESSAGES ......................................................................................................................................................................... 20
EQUIPMENT MAINTENANCE & CARE ................................................................................................................................................ 22
TROUBLESHOOTING ..........................................................................................................................................................................22
SPECIFICATIONS .................................................................................................................................................................................24
RW30 HEATER .....................................................................................................................................................................................25
ACCESSORIES..................................................................................................................................................................................... 26
SPARE PARTS ...................................................................................................................................................................................... 27
RW30110 / RW30112 PARTS LIST & ILLUSTRATION .........................................................................................................................29
RW30120 PARTS LIST & ILLUSTRATION ........................................................................................................................................... 30
RW30110 / RW30112 / RW30120 LEFT SIDE ILLUSTRATION ............................................................................................................31
RW30110 / RW30112 / RW30120 RIGHT SIDE ILLUSTRATION .........................................................................................................32
RW30110 / REW30112 / RW30120 MOTOR BOARD ILLUSTRATION ................................................................................................33
RW30110 / RW30112 / RW30120 SUPPORT PLATFORM ILLUSTRATION ........................................................................................34
RW30110 / RW30112 / RW30120 SUPPORT ASSEMBLY ...................................................................................................................35
CLAMP ASSEMBLIES ...........................................................................................................................................................................36
TORCH SUPPORT................................................................................................................................................................................37
TORCH SUPPORT (PULL GUN) ..........................................................................................................................................................38
WARRANTY ..........................................................................................................................................................................................39
SERVICING: This manual contains safety, operation, and routine maintenance instructions. Stanley Hydraulic
Tools recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an
authorized and certied dealer. Please read the following warning.
RW30 USER MANUAL - 3
Weisbeck, Andy
DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
DICHIARAZIONE DI CONFORMITA
______________________________________________________________________
I, the undersigned:
Ich, der Unterzeichnende:
Je soussigné:
El abajo firmante:
lo sottoscritto:
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
Surname and First names/Familiennname und Vor namen/Nom et prénom/ Nombre y apellido/ Cognome e nom e
Hydraulic Tools
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo: RW30
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
Has been manufactured in conformity with
Wurde hergestellt in Übereinstimmung mit
Est fabriqué conformément
Ha sido fabricado de acuerdo con
E’ stata costruita in conformitá con
Directive/Standards
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
CEE
CEE
CEE
CEE
CEE
CEE
EN
EN
EN
EN
Machinery Directive
Directive
No.
Nr
Numéro
No
n.
89/336/CEE:03/05/89
92/31/CEE:28/04/92
93/68/CEE:22/07/93
1999/5/CEE:09/03/99
73/23/CEE:19/02/73
93/68/CEE:22/07/93
60974/1:06/00
60974/1/1A:04/01
169:12/92
50199:01/97
2006/42/EC:2006
2004/108/EC:15/12/04
Robotic Welder
Stanley
All
Approved body
Prüfung durch
Organisme agréé
Aprobado
Collaudato
J. Sauron S.A.
CTF - France
19 rue Pierre JOSSE – Z.I. Les Bordes
C.E. 2413 – 91924 BONDOUFLE Cedex
Self
5. Special Provisions/Spezielle Bestimmungen/Dispositions particulières/Provisiones especiales/Disposizioni speciali: None
6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma
Position/Position/Fonction/Cargo/Posizione Engineering Manager
4 - RW30 USER MANUAL
Date/Datum/le/Fecha/Data 6-22-11
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
This safety alert and signal word indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage or damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
RW30 USER MANUAL - 5
SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the
stickers and tags attached to the tool and hose.
These safety precautions are given for your safety. Review them carefully before operating the tool and before performing
general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specic work area and local safety regulations.
If so, place the added precautions in the space provided on page 5.
The RW30 Robotic Welder will provide safe and dependable service if operated in accordance with the instructions given in
this manual. Read and understand this manual and any stickers and tags attached to the tool before operation. Failure to
do so could result in personal injury or equipment damage.
SHOCK HAZARD
Contact with live electrical parts can cause fatal accidents or serious burns. The electrode work piece circuit is live when
electricity is supplied to the outlet. The supply circuit and the internal circuits of the machine are also live when the current
is switched on. When welding the wire, the feeder, the feeder control panel and any metal parts in contact with the wire are
also live. Equipment that is incorrectly grounded constitutes a danger.
• Do not touch any live part.
• Wear insulated safety gloves that are both dry and without any holes, plus body protection.
• Insulate yourself from the work piece and from the ground with appropriate insulation materiel to prevent any
physical contact with either the work piece or the ground.
• Switch of the electricity supply or stop the machine before carrying out any maintenance on this machine.
• Install and ground this machine correctly and in compliance with the instruction manual and with local, governmental
or national legislation.
• Check the ground of the power supply regularly. Check that the ground wire of the mains cable is correctly connected
to the ground terminal in the connection box or that the connector is connected to an output that is correctly
grounded.
• When connecting the input, rst connect the ground. Double check the connections.
• Check the state of the mains lead and the insulation of the wires regularly – replace the lead immediately if it is
damaged as bare wires could cause fatal accidents.
• Switch off the machine when not in use.
• Do not use cables that are worn, damaged, under dimensioned or badly spliced.
• Do not wrap or carry cables around your body.
• If the work piece is to be grounded, ground it with a separate cable – do not use the clamp or the cable of the
work piece.
• Do not touch the electrode if you are in contact with the work piece, the ground or another electrode of another
machine.
• Only use properly maintained equipment. Repair or replace any damaged components immediately. Carry out
maintenance work on the machine according to the instructions manual.
6 - RW30 USER MANUAL
SAFETY PRECAUTIONS
• Wear a safety harness when working above ground.
• Anchor all panels and covers solidly.
• Fix the cable to the work piece or work bench with a good metal-on-metal contact as near as possible to the
construction.
WELDING HAZARDS
The RAYS OF THE ARC can burn the eyes and the skin, the NOISE can damage the ears, FLYING SLAG or SPARKS can
damage the eyes.
The welding arc produces intense visible and invisible rays (ultraviolet and infrared) which can burn the eyes and skin. The
noise generated can damage the ears. Metal particle or slag are projected into the air when chipping, grinding and when
joints are cooling.
NOISE
• Wear approved earplugs if the level of noise is high.
RAYS FROM THE ARC
• Wear a welding mask with an appropriate lter screen to protect your eyes and face while welding or watching
(see standards EN 169).
• Wear approved eye-protection goggles that give lateral protection.
• Use screens or barriers to protect observers and ask others not to look at arc.
Wear protective clothing made of appropriate re-proof materiel and protective shoes.
FUMES AND GASES
Welding produces fumes and gases. Inhaling these substances can be damaging to your health.
• Avoid fumes. Do not inhale fumes.
• When working indoors, ventilate the area and / or use fumes evacuation equipment to evacuate welding fumes
and gases.
• If ventilation is insufcient, use an approved air respirator.
• Read the safety recommendations concerning materials (MSDS) and the manufacturer’s instructions concerning
metals, consumables, coverings, cleansers and degreasing agents.
• Only work in conned places if is well ventilated or wearing an air respirator. Have a properly trained supervisor
stand by. Welding fumes and gases can accumulate and starve the atmosphere of oxygen which can lead to
fatal accidents. Check there is no danger in breathing the air.
• Do not weld in areas where others are degreasing, cleaning or spraying. Heat and arc rays can react with other
vapors and form gases which are highly toxic or an irritant.
• Do not weld coated metals such as galvanized steel, lead or cadmium plated metal until the coating has been
removed from the area to be welded. Make sure the area is well ventilated and, if necessary, wear an air respirator.
Coatings and the metals they contain can produce toxic fumes when welded.
RW30 USER MANUAL - 7
SAFETY PRECAUTIONS
GAS CYLINDERS
Cylinders of protective welding gas contain gas under pressure. If a cylinder is damaged, it can explode. As cylinders of gas
are part of the welding environment, they should be handled with caution.
• Protect gas cylinders from excessive heat, shock, slag, exposed ames, sparks from the welding arc.
• Store cylinders upright in a stationary rack or cylinder holder so that they cannot fall over.
• Keep cylinders away from welding circuits or any other electrical circuit.
• Never place a welding torch on a gas cylinder.
• A welding electrode should never make contact with a gas cylinder.
• Never weld a pressurised cylinder, there is a risk of explosion.
• Only use protective welding gas cylinders, regulators, hoses and ttings designed for this specic purpose, make
sure they and associated items are in good condition.
• Do not stand in front of the gas outlet when opening the gas valve on a cylinder.
• Keep the valve protection cap in place except when using or connecting the cylinder.
• Read and follow the instructions concerning the use of cylinders of compressed gas and associated equipment and
the other publications listed in the safety standards.
WELDING CAN CAUSE FIRE OR EXPLOSIONS
Welding container-like objects such as tanks, drums or pipelines can cause such objects to burst.
Sparks are projected from the welding arc. The projection of sparks, hot items and hot equipment can cause re and
burns.
Accidental contact of the electrode with metal objects can cause sparks, explosions, overheating or re. Before welding in
such cases, check that there is no danger.
• Protect yourself and others from the projection of sparks and hot metal.
• Do not weld in places where sparks can fall on ammable substances.
• Move ammable substances at least 10.7 metres/35 feet from the welding arc. If this is not possible, cover them
carefully with approved protective covering.
• Sparks and other hot welding matter can propagate from one area to another through small cracks and openings.
• Check for any re that may start and have a re extinguisher to hand.
• Do not weld container-like objects such as tanks, drums or pipelines unless they have been properly prepared.
• Connect the cable to the work piece as near as possible to the welding area to avoid having to feed the current
over long hazardous distances which could cause electrocution or re.
• Do not use welding equipment to defrost frozen pipes.
8 - RW30 USER MANUAL
SAFETY PRECAUTIONS
• When not in use, remove the rod from the electrode holder.
• Wear grease-free clothing such as leather gloves, a heavy shirt, hemless trousers, safety footwear and headgear.
• Before welding, remove all ammable substances from your pockets such as matches or any type of lighter.
EXHAUST FUMES
Exhaust fumes from the motor can cause fatal accidents. Motors emit toxic exhaust.
• Use the equipment outdoors in an open and well ventilated area.
• When using the equipment indoors, evacuate the exhaust fumes well away from any fresh air intake vents.
MOTOR FUEL
• Do not top up with fuel while smoking or when near a source of sparks or a naked ame.
• Do not ll the tank to the brim – leave space for the fuel to expand.
• Stop the motor and let it cool down before checking or topping up with fuel.
• Do not spill fuel. If fuel spills, clean it up before starting the motor.
MOVING ENGINE PARTS
Moving engine parts such as fans, rotors and driving belts can cause serious hand injury. Articles of loose clothing can also
get caught up in them.
• Keep all trap doors, panels, properly in place or closed.
• Only ask qualied personnel to remove the safety devices or other covers in order to carry out when necessary
maintenance work or repairs.
• To avoid the motor accidentally starting while carrying out maintenance work or repairs, disconnect the cable from
the negative (-) terminal of the battery.
• Keep hands, hair, loose clothing and tools away from engine parts.
• After maintenance work or repairs, replace all trap doors, panels, covers and other protective devices before
starting the motor.
RW30 USER MANUAL - 9
SAFETY PRECAUTIONS
Moving engine parts can cause bodily injury.
Before working on the generator, remove the spark plugs or fuel injectors to prevent the motor from accidentally starting.
Block the ywheel while working on the generator.
Metal and dirt particles can cause injury to the eyes.
Wear safety glasses that also offer lateral protection.
Static Electricity can damage the components on the electric board.
Before manipulating cards or other components, connect an earth wire to the earth terminal.
Use antistatic packing material for storing, moving or transporting PC cards.
Magnetic elds created by high voltage can interfere with the workings of pacemakers.
Pacemaker wearers should keep their distance.
Pacemaker wearers should rst consult their doctor before going near any place where welding
operations are being carried out.
Read the instructions.
Only use original spare parts.
Replace the fuel injectors and the fuel system air bleeder as indicated in the motor instruction manual.
MAKE SURE SPARKS FROM THE ENGINE EXHAUST DO NOT START A FIRE
1. Use an approved spark arrester on the motor exhaust wherever or whenever required – check the
legislation in vigour.
LOW VOLTAGE AND FREQUENCIES can damage electrical equipment such as motors.
1. Switch off or disconnect the equipment before starting or stopping the motor.
EXCESSIVE WEAR can cause EQUIPMENT TO OVERHEAT.
1. Allow time for equipment to cool.
2. Reduce the current or operating cycle before restarting to weld.
3. Respect the rated operating cycle.
10 - RW30 USER MANUAL
OPERATION
OVERVIEW
The RW30 is an electric arc welding controller to be used for
gas-free sheathed wires. It is unbeatable on railroad worksites
for performing maintenance and repairs on rails and track
devices, railways, tramways, metros, shuttles, etc.
The RW30 after programming automatically executes the
reloading of worn sections and accidental surface defects
(on treads, rail butt joints, lateral wears, track devices), or the
deposits of “safety stainless steel beads”.
The RW30 controls the motorized movement of the welding
head in the X-axis (length) and Y-axis (width) for work over a
surface area of 400 mm by 350 mm.
The RW30 frame is made of composites, aluminum and
stainless steel. This principle of construction was retained
to combine lightweight and excellent behavior under bad
weather conditions.
The RW30 is sold as standard with :
-1 RW30 Frame
-1 Rail Gripping Set
-1 Torch Support for the Pull Gun
-1 Charlie Control Box with its Connecting Cable
PREPARING THE RW30 FOR
OPERATION
CLAW VERSION
1. Position the claw on the rail.
2. Adjust the sliding jaw and tighten.
Adjustment
Tighten
Frame
3. Check the jaw angle and reference supports.
Torch Support
Jaw Angle
Rack
Reference
Supports
RW30 USER MANUAL - 11
OPERATION
4. Set anti-slip bolt.
5. Assemble the mounting brackets by disengaging the stop
pin, inserting the two brackets together and engaging the
stop pin to secure.
Disengage
Stop Pin
CLAMP VERSION
1. Disengage the stop pin on the mounting bracket, insert
the rack, adjust to one of the three positions and engage the
stop pin.
Disengage
Stop Pin
2. Slide in and engage the stop pin to the rack.
Summary of Steps shown above.
1.
3. & 4.
Engage
Stop Pin
Heel Jaw in
the Fixed
Position
2.
Heel Jaw in
the Mobile
Position
5.
12 - RW30 USER MANUAL
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