HGZ-40

Self aligning welding rotator

Manual Book

Wuxi Ronniewell Machinery Equipment Co., Ltd

ADD: Huayuan Cun, Yangshan Town, Huishan District, Wuxi, Jiangsu
Province, China 214156
TEL: +86-510-83050580 FAX: +86-510-83050580
WEB: www.ronniewell.com Email: sale@ronniewell.com
 Content
I. Overview:................................................................................................. 2

II. Main technical parameters:..................................................................2

III. Structure and elements：....................................................................3

IV. Installation and debugging:................................................................. 4

V. Maintenance and repair：.................................................................... 5

VI. Operation and Using：........................................................................8

VII. Troubles and trouble shooting...........................................................9

VIII. Notes on the safe operation：.......................................................... 9

IX. Safety warning:...................................................................................12

Appendix....................................................................................................13

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 The manual book and the warning label stick in the machine stated the

dangerous place and content.

When perform the maintenance and working, must read the manual book

carefully and abide by the content of warning scutcheon.

If ignore the content of warning scutcheon or not perform in order, it will

cause safety accident and may endanger life safety.

Self aligning welding rotator

(HGZ-40)

I. Overview:

This rotator is produced according to MMBEI Standard

ZBJ33003-90. Combining the advantages of oversea similar
products, self design and manufacture according to using condition
and requirements of customer. It is suitable for automatic welding of
metal circular seam cylinder. This rotator has following advantages:
practical, reliable, stable and easily operation etc. It is widely used
in cutting, grinding and assemble etc. Of workpiece, which is one of
ideal equipments of improve automatic and efficiency.

II. Main technical parameters:

1. Max. Loading capacity of one set：40000Kg

2. Applicable vessel dia.：φ600-φ4200mm

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 3. Roller center distance：1600mm

4. Roller linear speed：100-1000mm/min

5. Roller speed adjust way：VFD

6. Revolve motor power：3kW

III. Structure and elements：

The equipment mainly consists of drive rotator, idler rotator and electrical

control system etc. Drive rotator consists of base, plier rack, rollers and drive

device; Idler rotator without drive device.

（1）The base and plier rack are belonging to welding structure. All weld

seams are done according to the same grade intensity. The machine is

annealing treated to remove inner stress. It can prevent the distortion during

processing.

（2）Drive unit located on drive rotator, and mainly consists by reducer,

inverter speed adjustment motor and gear couple. Reducer adopts 2 stage

worm gear reducer which with a big output torque. Drive unit driven by

electric motor through reducer and gear couple, then drive 4 pieces of rollers

into rotation. The rotation speed is adjusted by VFD, stepless adjust the roller

linear speed with a range of 100-1000mm/min, meeting welding requirements

of different diameter workpiece.

（ 3 ） The plier racks situated on symmetric position of both sides of

drive/idler rotator, there are two pieces of rollers on each plier rack. The roller

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is adopt rubber roller and metallic roller combination structure, with stable

running. As per the different dia. Of workpiece, the plier rack can automatic

adjust to meet the different specification work piece.

（ 4 ） Electricity control system mainly consists of control cabinet and

pendant remote controller. The inverter, relay, terminal and etc in the control

cabinet, power switch install on door plank of control box. The panel of

control box has alarm indication, alarm clear and indication elements; the

remote panel has roller CW, CCW and stop switches.

IV. Installation and debugging:

Good installation and commissioning is the precondition of excellent

performance and high reliability. The thickness of concrete ground not less

than 200mm, strength is C30.

（1）Before installing, concrete foundation must be prepared, and give it

enough time to get strong. Ensure the installation position of machine at same

horizontal.

（2）Fix the machine by expansion bolt or clamp. Two sets of rotator

must be parallel when installing and center of two sets of rotator must be

aligned and ensure the integrity of each part of machine.

（3）After installing, check the installation of all parts of the equipment

according to the installation requirement and the wiring of all parts. Inspect

the area around the equipment and clear the area of the unwanted things and

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make sure the equipment normally work.

（4）For the trail run, there shouldn’t be abnormal noises and vibration.

If there is, you must find and clear troubles. Put work piece on the rotator, run

a trail cycle, observe whether the work piece is closely pressed against the

roller and scurry violently. Otherwise it is necessary to adjust the position of

rotator.

V. Maintenance and repair：

5-1Operation notice

For safety consideration, the operator should understand and abide by

the below content when checking and overhaul.

5-1-1Before maintenance

1. Understand the content in manual book and operate after training.

2. The maintenance and check should be performed by two persons, and

specify a charge person. It may happen an accident cause single person to

operate.

3. When perform maintenance and overhaul, please notify the

supervisor, operator and around person to avoid any accidents.

The label with " CHECKING" must be hang.

5-1-2 Enter into machine for maintenance and check

1.Cut off all power, hydraulic, gas before enter into machine for

checking to avoid any accidents.

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 2. Fixed the slide parts, turn off the valves of hydraulic and gas control

and release the rest pressure.

3.The operator or specified person should unplugging the key of

machine and keep it after finish checking.

4. Confirm all switches and valves off

5. Make sure no action of each part by operate of start button and valve.

6. All action parts should be locked to ensure no operation and hang out

the billboard.

5-1-3Perform machine action check

1. Ensure there is no person inside, the sudden action of machine may

lead to person involved.

2. Abide by indication of supervisor, operate after confirm safety.

3. Before machine start, notice operator or use buzz to inform all

persons for safety confirmation.

4. Do not enter into machine at will.

5. Do not touch, overhaul or adjustment the machine during running.

5-1-4 After maintenance and check

1. The discharged door and safety cover etc should recover as original.

2. Confirm no left with tools and parts inside machine. Recheck

everything is ok.

3. After check, the supervisor should confirm if all persons has already

left dangerous area.

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5-2When inspection or maintenance, please cut off power and take off the

plug

（1） Add Mobilgear SHC320 gear oil into reducer. Change the oil after

first month’s use. After that, change every 6 months.

（ 2 ） The gear rack couple, each rotate bearing of plier rack should add

Mobilgear SHC100 lubricating grease each month regular.

（3）Rubber roller can not contact with high temperature and oil to avoid fast

aging.

（4）The welding wire can’t directly contacted on the rotator, in case damage

bearings.

Daily Check:

（1）Environment should meet the requirements.（No water, No corrosive gas,

No high temperature environment）

（2）Let the equipment work without work piece, check if there is abnormal

noise, vibration and odour.

（3）Check the display part in normal condition.

5-3Periodic Check:

（1）Power voltage in allowed range.

（2）（2）Remove the dust on the control unit and board.

（3）Cable insulation, if damaged, stop using and repair immediately.

（4）Control cable and electrical elements, if damaged, repair or replace it.

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（5）Each joint parts, if loose, fasten it before use.

VI. Operation and Using：

6-1-1Preparation
1. Check health condition
2. Put on the applicable clothes, no things inside pocket and without any
decoration.
3. Keep the complete of tools
4.Confirm no person inside and around machine
5. Confirm no abnormal of safety unit and parts
6.Prepare the consumables
6-1-2 Running
1. No touch motion parts, avoid any accident cause stuck.
2. No add oil, adjustment, clean (enter into machine) when machine is
working.
3. Manage of abnormal stop or unstable running.
(1) If happens abnormal sound, unstable action of machine, stop it
immediately.
(2) When abnormal stop, press EMERGENCE STOP for safety.
(3) Press EMERGENCE STOP button when requires.
(4) Contact supervisor. Request the person to stop as per safety order.
Before shooting any dangerous source completely, the operator can not
enter into or touch machine.
6-1-3 After running
1. Stop machine as per order, cut off the main power.
2. Unplugging the key after stop, the key should be kept by supervisor.

6-1-4 When start the machine, there should be no abnormal noise or shaking.

Otherwise, it should be trouble shooting. When work piece hoise on the

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 rotator, first check if it at the appropriate position? If the work piece touch the

roller? If there is foreign on workpiece affect rotation (such as steel etc.) Trail

run can be only performed after everything is normal.

6-1-5 Before start motor, check the wiring carefully. After correct wiring,

switch on power button and start motor. Check if the rotation direction in

accord with require direction, then adjust speed knob of wireless remote to

require speed from low to fast (foreward).

Pendant remote box for long distance operate rotator, achieve foreward,

reversal and stop of roller.

VII. Troubles and trouble shooting

Problem Reason Trouble shooting

1. Abnormal input voltage 1. Input normal voltage
No action of

2. No output of transformer 2. Check transformer

motor

3. Remote panel fail 3. Repair

4. Wrong wiring of motor or 4. Right wiring or replace
motor damaged motor
1. Inverter alarm 1. Refer to manual book
Motor is not
adjustment
No speed
start

VIII. Notes on the safe operation：

1. The clothes worn should be neat, may be left in danger may be

involved, and should wear suitable clothing of the job.

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 2. Must wear the prescribed protective equipment for operations.

3. Around the equipment to keep the finishing, to rectify the state, and

cleaned up.

4. Before using the device should be recognized that the safety devices

are safe, effective and correct.

5. Education, training, and enable operating personnel to understand the

equipment, and supervisory personnel responsible for directing.

6. Not free to change the location and structure of the safety devices, to

changes in advance to discuss with the supervisory staff and contact with the

company.

7. Management and supervision of personnel, operations to confirm the

operator's health, physical discomfort, it may not operate job.

8. Pre-operational check to confirm the safety, inspection, interlinked

sound echoes.

9. Unrecognized operating equipment near or inside the device other

personnel shall not be undertaken.

10. Known equipment failure without repair could no longer use, the

need for timely contact with the person in charge and take action.

11. Equipment in use, not refueling, adjust the machine cleaning.

12. Equipment in operation, such as abnormal mechanical action, or

judgment that is necessary to take measures to prevent, not then any part of

the body to probe into the machine. Is timely to press "stop" button to stop the

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equipment in accordance with safe operating procedures, to discuss with the

person in charge of handling measures.

13. Equipment in operation, not to touch the moving parts.

14. To probe into the device, you should cut off the power supply and

remove the key to bring their own, and maintain a short electrical protection,

suggesting.

15. Due to gravity, the components are possible activities and the

whereabouts of the place, not be fixed, not allowed to enter the machine.

16. Not up and down ladders, hand tools, parts, or their pocket.

17. Inspection, maintenance work, shall be in pairs, and set a team leader.

To achieve job security measures, and oversight of key carried by the person

in charge.

18. Shall not be switched on before the full security inspection,

maintenance, unrecognized.

19. Used tools, materials may not be forgotten in the machine, confirm

the number is no different, and then drive to run.

20. The coating layer has broken wires may not be used.

21. Mechanical equipment shall not be placed in the vicinity of the

fireworks (no smoking), and maintenance required the use of fire should

flammable material is removed, and ready to fire extinguishers, then the job.

22. A job mistakes, immediately contact with the person in charge.

23. The job site to keep bright.

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 24. Fire explosion, harmful gases, dust and ventilation devices.

IX. Safety warning:

Warning: protect yourself and others from serious injury or death.

1）Electrical shockproof

Earth the equipment by qualified electrician, avoid to touch uncovered with

electricity point. At wet environment and sweaty place, make sure the earth

wire is connected perfectly with work piece.

2）Burning protection

Protect eyes and skin not to be hurt by high-bright ultra-violet, light, spark

and burning metals. Never look at welding arc directly. Use protection glasses

or welding mask. And tell others do it like this.

3）Protection against poisonous soot

To avoid being hurt by poisonous gas (created during welding), keep your

head away from the smoke created by welding, and install exhaust smoke

equipment according to relative standard. When welding Pb, Zn, Cd, Hg and

Be, workers should be more careful. No welding close to such operation

zones as degreasing, cleaning and painting which would generate chloride

carbohydrate. Solution steam would react again and generate high toxic

gas-phosgene as well as other irrigative things by arc light and thermal power.

4）Gas cylinder

Use the special cylinder and appropriate manometer. All the pipes and

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 connects should be in good condition. Keep the gas cylinder stand, and be

fasted on chassis or bracket. Keep it away from welding and cutting area and

other places which creating heat, spark and fire. When open the gas valve,

face at the opposite side of it. Close the valve when you do not use the gas.

Appendix

Electric diagram

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HGZ40-00-D2-00
HGZ40-00-D2-00
Electric diagram
1:1.2
2017-08-03
WUxi Ronniewell Machinery Equipment CO.,Ltd