Jansen 499.007 Operating Instructions Manual Download Page 16 | Manualshive

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Page 16

Edition 06/2015

4.3.2 S

upport plates with clamping elements

The welding bench is equipped with four support plates, allowing all four corners of
an element to be clamped precisely and stably.

Configuration:

View from above

Two support plates each are mounted on cross slides are can be moved at the cen-
tre by an adjustment spindle.
These two cross slides are mounted on a longitudinal slide which is also moved by
an adjustment spindle.

Digital dimension indicators are used to set dimensions. Refer to Chapter 4.3.5

Released corner
for welding the underside of the pro-
file

Horizontal
clamping
element

Outside stop block

Support plate

Vertical
clamping ele-
ment

Inside stop block

shiftable

Lug support

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Summary of Contents for 499.007

Page 1: ...Operating instructions Jansen welding table 499 007 ...

Page 2: ...l 41 71 763 91 11 Fax 41 71 761 22 70 Internet www jansen com E Mail info jansen com Language of the original operating instructions German Document No 02792 Edition 06 2015 Read the operating instructions carefully before use These instructions are intended for the service and operating personnel ...

Page 3: ... 2 Support plates with clamping elements 16 4 3 3 Working with lug support 17 4 3 4 Outside stop 18 4 3 5 Adjustment to required dimension 19 5 Faults Defects 20 5 1 Remedying faults 20 5 1 1 Electrical fault 20 5 1 2 Remedying a mechanical fault 21 5 2 Cleaning 21 5 3 Determining defects 22 6 Repairs Maintenance 23 6 1 Repair on mechanical parts 24 6 2 Repair of electrical parts 24 7 Additional i...

Page 4: ... instructions must be available at the location of the welding bench at all times They are addressed to trained expert personnel sheet metal workers fit ters welders that have received initial instruction from Jansen or its representatives They must be read and applied by all persons working in any way on the welding bench Specifically this work includes operation adjusting the fixing plates troub...

Page 5: ...r assignments to severity of hazard are listed as follows Danger Red symbol Immediate hazards that always result in severe injuries or death Warning Orange symbol Hazards that might result in severe injuries or death Caution Yellow symbol Hazards that might result in minor bodily injuries or se rious damage to property Note Blue symbol Stands for technical requirements that must be adhered to ...

Page 6: ...ard zone or even on the welding bench itself The welding bench must not be used when it is not installed compliant to the regulations and with the minimum clearances to hindrances see Chapter 2 Safety regulations Any manipulation to the footswitch by wedging or equipping with an object is forbidden If the welding bench is not placed according to the regula tions then we cannot accept any liability...

Page 7: ... of the welding bench It must not be operated if anyone is on the welding bench platform or within the slewing range of the welting bench Do not clamp in any welding parts that protrude a long way out from the welding bench or only attach them with special care stop the rotary motion If the location of the welding bench is changed even slightly then it must first be disconnected from the power sup...

Page 8: ...e hinged feet see Chapter 3 2 Check the connection and control cable footswitch for damage Lay the connection cable concealed to avoid the risk of tripping over it Place the footswitch control cabinet outside of the hazard zone Responsibility instructed personnel Initial instruction must be provided by personnel from JAN SEN or its representatives or by personnel from the com pany providing the ma...

Page 9: ...he pivot point is marked by a yellow black position point The clearance between the pivot point of the welding bench and any hindrance or object must be 2 5m The pivot point is marked by a yellow black position point If the welding bench is installed in a fixed position then the hazard zone should be marked in yellow boundary marking Place the footswitch control cabinet outside of the hazard zone ...

Page 10: ...corners of the baseplate using a square spanner 3 3 Starting up 3 3 1 Switching on For details of controls see Chapter 4 3 1 Connect the ground cable of the welding unit with the ground plate on the welding bench 2 Plug the mains connection plug into the 400 V socket Connection plate for ground cable Square spanner The socket must be fitted with a fuse ...

Page 11: ...ned in Chapter 4 3 3 3 2 Switching off The welding bench must always be switched off at the end of work Turn the main system switch at the control cabinet to the O position the green control lamp goes off 3 4 Disassembling the welding bench 1 Turn the longitudinal slides parallel to the foundation so that you can drive under the foundation with the forklift 2 Turn the main system switch at the con...

Page 12: ...e scribed above Unscrew the ring screws after transport Be careful when located under suspended loads When transporting with a lorry or suchlike the welding bench must be secured on the load floor The cross slides must be closed for transport Longitudinal slides must be parallel to the foundation Forklift 2 tons bearing load Close the cross rails so that they are not able to touch the belts risk o...

Page 13: ... the following components Picture 1 a Fixed foundation height on all sides can be levelled b 1 longitudinal slide can be rotated horizontally in both directions c 2 cross slides d 4 supporting plates with bearing surfaces and clamping elements e Control cabinet with double footswitch for left and right rotary motion f Drive motor for rotary motion under a cover not visible Not shown tool cabinet d...

Page 14: ...ension may differ by 1 mm from the digital indicator due to the production tolerances of the spindle The profiles are horizontally clamped against an outside stop onto four plane sup porting plates of the welding bench With the inside stop version the inner profile lug can be additionally supported by a fixture After fixing the mitre perfectly the pro files are vertically fixed by a clamping devic...

Page 15: ...is any incorrect function If the footswitch is within the hazard zone then the mains connection plug must also be pulled in dangerous situations Additional details on the control cabinet are contained in the elec trical schematics in the annex Main system switch Control cabinet Control lamp green Ready for rotary drive Protective hood Attention The bench must only be rotated when no person is with...

Page 16: ...are mounted on cross slides are can be moved at the cen tre by an adjustment spindle These two cross slides are mounted on a longitudinal slide which is also moved by an adjustment spindle Digital dimension indicators are used to set dimensions Refer to Chapter 4 3 5 Released corner for welding the underside of the pro file Horizontal clamping element Outside stop block Support plate Vertical clam...

Page 17: ... the support plates and butted at the outer stops in case of pre cut tolerances the adjustment spindle must be readjusted to the dimen sion of the profile For lug profiles push the inside stop diagonally onto the inside pipe corner and fix it with the Allen head screw If required you can align the element corners carefully with the two horizontal clamping devices The height of the lug can be adjus...

Page 18: ...this nullifies the spindle play Place the cut profiles onto the support plates and butt against the outer stop in case of pre cut tolerances the adjustment spindle must be re adjusted to the dimension of the profile Swivel the vertical clamping devices onto the correct clamping position place a support on the mitre and clamp the profile tightly onto the support plate with the vertical clamping ele...

Page 19: ...tside The spindle play is thereby nullified To ensure during work that the dimension indicators are protected against weld spat ter soiling and the danger of crushing the mechanical protective covers are folded down Remove the crank after adjusting the dimension Risk of shifting on impact Protective cover folding Digital display with absolute dimension indicator Hand crank Dimension indicator The ...

Page 20: ...batteries has dropped to a low level this is signalised by a continuous battery symbol If the capacity of the batteries drops even further after this to below a certain level then the battery symbol flashes pulsating One month before complete discharge the display remains switched on or functional The electronic position indicator is supplied by 2 x AA standard 1 5 V DC batteries Depending on the ...

Page 21: ...ate the shaft because in this case the value can not be counted The device switches itself back on once the new batteries are inserted and displays the value that was valid before the batteries were replaced If the shaft has turned for any reason then the equipment must be recalibrated Additional details regarding parameter settings are in the annex 5 1 2 Remedying a mechanical fault Responsible i...

Page 22: ...cabinet must not be opened by the cleaning per sonnel Wipe off the complete surface of the welding bench with a hand cloth to remove coarse dirt and welding beads Only use fibre free cleaning cloths Do not use aggressive cleaning agent Use emulsion if need be Only wipe off supporting plates with dry cloths 5 3 Determining defects If damage is determined to the following when cleaning or during ope...

Page 23: ...em switch Check spindles weekly for contamination and clean Spindles must be greased weekly over their entire length with a brush A corresponding lubrication plan is in the an nex The instructed person is responsible for maintenance of the welding bench If questions arise during maintenance then the responsible per son must immediately contact JANSEN AG JANSEN AG accepts no liability for any damag...

Page 24: ...ll repair work on the electrical component a visible disconnection point between the mains and the welding bench must be ensured by pulling the mains plug The welding bench must be marked by a warning sign on the main system switch Only original spare parts should be used The circuit diagram of the welding bench in the annex of the operating in structions is binding and must be studied No changes ...

Page 25: ...riestr 34 CH 9463 Oberriet Switzerland Tel 41 71 763 91 11 Fax 41 71 761 22 70 E Mail info jansen com Spare parts must comply with the technical requirements stipu lated by the manufacturer Only original spare parts should be used 7 2 Guarantee The guarantee time is two years from the date of purchase 7 3 Disposal This welding bench must be disposed of at the end of its lifetime according to the l...

Page 26: ...rk compliant with Machinery Directive 2006 42 EC Manufacturer s address MEAG AG Bodenackerstrasse 11 CH 5014 Gretzenbach Switzerland Certified compliant with ISO 9001 8 2 Dimensions of welding bench Length 2850 mm Width 1900 mm Working height adjustable 980 1050 mm Weight 1320 kg Bearing capacity max weight of ele ment 300 kg Installation data Electrical connection 400 V Frequency 50 Hz Power 0 12...

Page 27: ...Edition 06 2015 Page 27 8 3 General layout drawing of welding bench ...

Page 28: ...Page 28 Edition 06 2015 ...

Page 29: ...dition 06 2015 Page 29 9 Annex General layout drawings Circuit diagrams Spare parts list Electronic positioning indicator EC Declaration of Conformity Welding table accessories Welding table spare parts ...

Page 30: ...Page 30 Edition 06 2015 9 1 Spare parts list ...

Page 31: ...Edition 06 2015 Page 31 ...

Page 32: ...Page 32 Edition 06 2015 ...

Page 33: ...Edition 06 2015 Page 33 ...

Page 34: ...Page 34 Edition 06 2015 ...

Page 35: ...Edition 06 2015 Page 35 ...

Page 36: ...Page 36 Edition 06 2015 ...

Page 37: ...Edition 06 2015 Page 37 ...

Page 38: ...Page 38 Edition 06 2015 9 2 Lubrication plan ...

Page 39: ...Edition 06 2015 Page 39 9 3 Setting the digital display ...

Page 40: ...Page 40 Edition 06 2015 ...

Page 41: ...Edition 06 2015 Page 41 9 4 Electrical schematics ...

Page 42: ...Page 42 Edition 06 2015 ...

Page 43: ...Edition 06 2015 Page 43 9 5 Manufacturer s declaration from Meag AG ...

Page 44: ...Page 44 Edition 06 2015 ...

Page 45: ...s Article number PU Designation 499 354 4 try squares left 4 try squares right Stop plate Arte for welding table 499 423 4 try squares left 4 try squares right Stop plate HI for welding table Stop plate Janisol Arte 499 354 Stop plate Janisol HI 499 423 ...

Page 46: ...02 Wst 245_74 Adjustable foot Art Nr 17338 SRU1216150 499 603 Wst 258_58d Screw ciamp 499 604 Wst 258_59 Screw ciamp 499 605 Wst 245_73 Digitale position display type EP20 A G G032092621A00001 499 607 Wst 259_60 Cover 499 608 Wst 258_41 Spindle nut large 499 609 Wst 256_42 Spindle nut large 499 610 Wst 256_43 Spindle nut small 499 611 Wst 257_44 Spindle nut small 499 613 Wst 254_24 Welding support...

Page 47: ...ermediate part retrofitting 499 008 499 619 Wst 261_120 Akku Adapter 499 620 Wst 276_125 Support 499 621 Wst 254_30 Shaping jaw Only fort he old welding tables with num ber 499 007 001 to 499 007 120 499 622 Wst 249_06 Clamping plate 499 623 Wst 250 05 Clamping plate 499 624 Socked wrench Type AFM 10 mm 623200 499 625 Wst 261_123 Welding plate 499 626 2007 0001 Lifting roller typ SLP 01 75 for 499...

Page 48: ...Jansen AG Steel Systems Industriestrasse 34 9463 Oberriet Schweiz jansen com Steel Systems I 06 2015 I Subject to change ...

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