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Stanley Black & Decker RW30 manual

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Table of contents for the manual

  • Page 1

    R W30 ROBOTIC WELDER Copyright © The Stanley W orks 2014 69893 2/2015 ver 8 USER'S MANUAL Safety , Operation and Maintenance R W30 ROBOTIC WELDER USER'S MANUAL Safety , Operation and Maintenance[...]

  • Page 2

    2 - RW30 USER MANUAL SERIOUS INJUR Y OR DEA TH COULD RESUL T FROM THE IMPROPER REP AIR OR SER VICE OF THIS TOOL. REP AIRS AND / OR SERVICE T O THIS TOOL MUST ONL Y BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER. MAKE NO AL TERA TIONS OR MODIFICA TIONS TO THE T OOL. SERIOUS INJUR Y COULD RESUL T FROM IMPROPER CHANGES. MODIFICA TIONS OR AL TERA TIONS [...]

  • Page 3

    RW30 USER MANUAL - 3 SERVICING: This manual contains safety , operation, and routine maintenance instructions. Stanley Hydraulic T ools recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized and certied dealer . Please read the following warning. SAFETY SYMBOLS ...........................[...]

  • Page 4

    4 - RW30 USER MANUAL DECLARATION OF CONF ORM ITY ÜBEREINSTIMM UNGS - ERKLARUNG DECLARATION DE CONFOR MITE CEE DECLARACION DE CONFO RMIDAD DICHIARAZIONE DI CONFORM ITA Hydraulic Tools _______ _________ ________ _________ ________ _________ ________ _________ ___ I, the undersigned: Ich, der Unterzeichnende: Je soussi gné: El abajo firmante: lo so [...]

  • Page 5

    RW30 USER MANUAL - 5 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 equip- ment. This safety alert and signal word indicate an imminently hazardous situa - tion which, if no[...]

  • Page 6

    6 - RW30 USER MANUAL T ool 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. Supe[...]

  • Page 7

    RW30 USER MANUAL - 7 • 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 RA YS OF THE ARC can burn the eyes and the skin, the NOISE can damage the ears, FL YING[...]

  • Page 8

    8 - RW30 USER MANUAL 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[...]

  • Page 9

    RW30 USER MANUAL - 9 • 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 th[...]

  • Page 10

    10 - RW30 USER MANUAL Moving engine parts can cause bodily injury . Before working on the generator , remove the spark plugs or fuel injectors to prevent the motor from ac- cidentally starting. Block the ywheel while working on the generator . Metal and dirt particles can cause injury to the eyes. Wear safety glasses that also of fer lateral pro[...]

  • Page 11

    RW30 USER MANUAL - 1 1 PREP ARING THE RW30 FOR OPERA TION CLA W VERSION 1. Position the claw on the rail. 2. Adjust the sliding jaw and tighten. 3. Check the jaw angle and reference supports. OPERA TION OVER VIEW The RW30 is an electric arc welding controller to be used for gas-free sheathed wires. It is unbeatable on railroad worksites for perform[...]

  • Page 12

    12 - RW30 USER MANUAL 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. 2. Slide in and engage the stop pin to the rack. 4. Set anti-slip bolt. 5. Assemble the mounting brackets by disengaging the stop pin, inserting the two brackets together and engaging [...]

  • Page 13

    RW30 USER MANUAL - 13 CONNECTING THE WIRE FEED/ WELDING TIP T O THE R W30 1. Place the welding tip into the support. 2. Support swivel blocking lever . 3. Support stick-out lever . SETTING THE STICK OUT The ideal setting is 30 mm. Use the template markers to check for proper distance. Adjusting the Clamp Summary of steps shown above. 30 mm Ideal Se[...]

  • Page 14

    14 - RW30 USER MANUAL OPERA TING THE RW30 & THE CHARLIE CONTROL UNIT 1. T urn ON the main switch on the RW30. 2. Unlock the ON/OFF switch on the Charlie Control Unit located on the right side of the unit. AUTOMA TIC TRACK MODE After preheating, this mode is used on carbon steel track for continuous surface work on three or four-sided octagonal [...]

  • Page 15

    RW30 USER MANUAL - 15 J.SAURON TRANSLAMATIC RW30 08 JS 063* du 17/12/2008 02/04/2009 PAGE : 6/68 3.1 Screen examples of scrolling thr ough the alphanumeric character list _ - - - - - - - - - - C - - - - - - - - - - A - - - - - - - - - - - _ - - - - - - - - - B - - - - - - - - - - B - - - - - - - - - - Examples: movin g the cursor from left to ri g [...]

  • Page 16

    16 - RW30 USER MANUAL LANGUAGE SETTING Different languages may be accessed and selected when the rst message “HELLO” appears by using the PLUS key . T ranslations of the message “HELLO” into different languages according to geographic areas are then displayed each time the PLUS key is pressed. SETTING THE DA TE AND TIME T o set the date [...]

  • Page 17

    RW30 USER MANUAL - 17 OPERA TOR DIALOGUE Power up: Then: Change language - press the arrows: Display software version and Charlie serial number . This mode allows to perform free polygons from 3 to 4 sides. • Setting the points without restriction (beads direction : Position O1 to Position O2). • When setting the 4 points, point 4 can be out of[...]

  • Page 18

    18 - RW30 USER MANUAL Set poin t Position O3. The torch cans only moves on the « Z » axis. Set point Position O4. This point should only be set vertically from point Position O1 with automatic tone of this position. Display the length and the width of the setting shape (1 mm equals to 0.04 inch). Surrounding selection: « YES », or « NO », (co[...]

  • Page 19

    RW30 USER MANUAL - 19 If V ALID key is pressed, torch will move to the starting point of the next bead. T orch return to starting point and start welding of the next bead. When resurfacing is over , the following message proposes to set a new resurfacing cycle: If V ALID key is pressed, you will have to set a new welding area. (As previously seen).[...]

  • Page 20

    20 - RW30 USER MANUAL Display of the step between each bead, (distance in mm, 1 mm equals to 0.04 inch) and estimate welding time in minutes. -Setting can be made up to 3 shapes: Option to repeat the same shape or change the size and shape as previously indicated. During welding: T orch moves to starting point of the rst bead. Shows the bead’s[...]

  • Page 21

    RW30 USER MANUAL - 21 Set Position O4: -In mode « ALIGNMENT OK » Position O4 must be vertical from Position O1. When the beads number has been modied: The step is bigger than the maximum allowed step. Raise the number of beads. The step is smaller than the minimal allowed step. Reduce the number of beads. These 2 values can be modied in the[...]

  • Page 22

    22 - RW30 USER MANUAL J.SAURON TRANSLAMATIC RW30 08 JS 063* du 17/12/2008 02/04/2009 PAGE : 8/68 6 TROUBLE SHOOTING The « ON » TRANSLAMATIC‘s green light does not work PROBABLE CAUSE CHECKS AND REMEDYS « ON/OFF » switch Check its good posi tion and its good working order Alimentation’s cable cutted Check the alimentation’s cable Alimentat[...]

  • Page 23

    RW30 USER MANUAL - 23 J.SAURON TRANSLAMATIC RW30 08 JS 063* du 17/12/2008 02/04/2009 PAGE : 9/68 Coder’s pulses defect Check the coder connexion on the right side and on the bottom of the interf ace card (J3 connector side). Replace the interface card. Axis engine’s cards Check if the card’s ligh ts are alight during a moving command. Switch [...]

  • Page 24

    24 - RW30 USER MANUAL • Check that the pin holder is not burnt or not holding the pin tightly . If not, remove the ring holder , clean all the parts and squeeze the ngers of the pin holder together . • Check the cables on the gun from time to time for damage. Replace as required. • Check that the lift level is correct with lift level tool.[...]

  • Page 25

    RW30 USER MANUAL - 25 Heater Element Thermostat Front Cover Back Cover RW30 COLD WEA THER UPDA TE KIT (70716) INCLUDES THE FOLLOWING Part No. Description 70719 Heater Element (1 10 V , 400 W) 70720 Thermostat (Red) 70718 Back Cover 70717 Front Cover 70721 Screw Kit 70722 Charlie Heater Kit 70723 Butt End Flask 71000 Thermostat (Blue) Charlie Heater[...]

  • Page 26

    26 - RW30 USER MANUAL Part No. Description 52736 Cable - Welder , Robotic 52737 Kit - T rack Wheel, Robotic 52738 Kit - T rack Wheel Welder , Robotic 52739 Wire - Coated Weld Std Rail 52740 Wire - Coated Weld Mn Rail 52741 Box - Transport 60872 15m Ground Cable 60875 Ground Clamp for Frog 60876 Ground Clamp for Rail 60822 Cable, Generator 15M Long [...]

  • Page 27

    RW30 USER MANUAL - 27 Charlie Box 65446 Charlie Main Board 69889 Interconnection Board 64969 No/Off Switch 69831 Motor X 64963 Power Supply 69830 Motor Y 64962 Motor Board 64961 T rigger Cord 70780 Power Cord Primary 70781 Rack 66551 (Includes Pinion Below) PGA Cable 70787 Charlie Cable 68208 Motor/Board Cable 70786 Power Supply Cord 70785 Y axis P[...]

  • Page 28

    28 - RW30 USER MANUAL Bearing Y Axis 66533 Bearing X Axis 64950 Nut 66529 Coupling, Y Axis 66535 Power Cable (1 15V) 68209 Pad Clamp 70775 Beam, Souriau 70779 T emplate guage for setting the stick height (see page 13). Removing wire feed tip using hex in template guage. Master Power Switch Off Master Power Switch On, this picture indicates the fan [...]

  • Page 29

    RW30 USER MANUAL - 29 Item Part No. Qty Description 1 64983 1 Rear Beam 2 64984 1 Front Beam 3 71473 1 V entilation Box 4 66530 1 X-Axis Slide 5 66526 1 X-Axis Screw 6 --- -- --- 7 66529 1 Nut 8 66535 1 Coupling Y -Axis 9 66536 1 Chain Conduit 66537 1 Clamp for Chain Conduite (not show) 10 70718 1 Back Cover 11 70717 1 Front Cover Item Part No. Qty[...]

  • Page 30

    30 - RW30 USER MANUAL R W30120 P ARTS LIST & ILLUSTRA TION Item Part No. Qty Description 1 66515 1 Rear Beam 2 66519 1 Front Beam 3 66517 1 Protection Plate 4 66531 1 X-Axis Slide 5 66528 1 X-Axis Screw 6 --- -- --- 7 66529 1 Nut 8 66535 1 Coupling Y -Axis 9 66536 1 Chain Conduit 10 66537 1 Clamp for Chain Con- duite (not show) 11 66554 1 Hood [...]

  • Page 31

    RW30 USER MANUAL - 31 R W301 10 / R W301 12 / R W30120 LEFT SIDE ILLUSTRA TION Left Side Assembly Part No. 69818 Item Part No. Qty Description 1 66524 1 Left Side Plate (Motor) 2 69817 1 Motor Card Module 3 64945 1 Conical Stop 4 5 6 64959 1 Bearing Flange 7 64963 1 Motor X Axis 8 9 10 11 12 64957 1 Motor Support 13 14 15 Item Part No. Qty Descript[...]

  • Page 32

    32 - RW30 USER MANUAL Item Part No. Qty Description 1 66525 1 Right Side Plate 2 69830 1 Power Supply 3 4 64956 1 Bearing Support 5 64955 1 Bearing 6 7 72593 2 Carry Handle Assy (Fold Down) 8 9 10 11 12 13 14 15 16 17 18 64945 1 Conical Stop Right Side Assembly Part No. 69819 J.S AURON TRAN SLAMATI C RW30 08 JS 06 3 C du 03/12/ 2009 21/12/2 009 PAG[...]

  • Page 33

    RW30 USER MANUAL - 33 Item Designation Reference Material Qty D-1 Axis card ATC08660012 2 D-2 Interconnection card TAF00000001 1 D-3 Interconnection card bundle TAF00000023 1 D-4 Screw CHC M4-10 ( DI N 912 ) APG01120412 2 D-5 Nut H-M4 ( DIN 934 ) APG02140092 1 D-6 Star washer M4 ( DIN 6798 ) APT01120002 3 D-7 Column F/F M4-15 APG01120355 2 D-8 Colu[...]

  • Page 34

    34 - RW30 USER MANUAL Support Platform Assembly Part No. 69816 Item Part No. Qty Description 1 64986 1 Support Platform 2 --- -- ---- 3 64985 1 Y -Rail 4 66549 1 Jointed Wrist Bracket 5 66532 1 Bearing Support 6 64962 1 Y -Axis Motor 7 64959 1 Bearing Flange 8 66534 1 Y -Axis Screw 9 64958 1 Axis Bracket 10 66529 1 Nut 11 66538 1 Y -Bump Stop 12 66[...]

  • Page 35

    RW30 USER MANUAL - 35 Right Support Assembly Part No. 66542 Left Support Assembly Part No. 66543 Charlie Control Box Part No. 65446 Charlie Heater Part No. 70722 R W301 10 / R W301 12 / R W30120 SUPPORT ASSEMBL Y[...]

  • Page 36

    36 - RW30 USER MANUAL Frog Clamp Assembly Part No. 66546 Right Fixed Clamp Part No. 66547 Left Pivot Clamp Part No. 66548 Right Self Alignment Clamp Part No. 66544 Left Self Alignment Clamp Part No. 66545 CLAMP ASSEMBL Y[...]

  • Page 37

    RW30 USER MANUAL - 37 Item Designation Reference Material Qty J-1 25 mm dia. rack shaft ATC20460005 Aluminum 1 J-2 Rack ATC21910007 Delrin 1 J-3 Torch support hub ATC20460006 Aluminum 1 J-4 Rack pinion axis ATC2 1910006 Stainless steel 1 J-5 Rack pinion ATC20460008 Delrin 1 J-6 Torch retainer ATC08490024 Aluminum 1 J-7 Support clamping collar ATC2 [...]

  • Page 38

    38 - RW30 USER MANUAL T orch Support Pull Gun Part No. 69837 T ORCH SUPPORT (PULL GUN) ILLUSTRA TION[...]

  • Page 39

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  • Page 40

    Stanley Hydraulic T ools 3810 SE N aef Road Milwaukie OR 97267-5698 503-659-5660 F AX 503-652-1780 www .stanleyhydraulics.com[...]