OPERATING INSTRUCTIONS
FOR
EP500 MK1
COLD PRESSURE WELDER
0
CONTENTS
1. SPECIFICATION EP500 2
1.1. CAPACITIES 2
1.2. DIMENSIONS 2
1.3. GENERAL DESCRIPTION 2
2. INSTALLATION 3
2.1. OFF-LOADING 3
2.2. AIR SUPPLY 3
2.3. ELECTRIC SUPPLY 4
2.4. FITTING THE DIES 4
3. PNEUMATIC SYSTEM 4
3.1. CYLINDERS 4
3.2. CYLINDERS LIMIT SWITCHES 5
3.3. SOLENOID VALVES. 5
4. ELECTRICAL EQUIPMENT 6
4.1. CONTROL PANEL 6
4.2. PROGRAMMABLE LOGIC CONTROLLER (PLC) 6
4.3. OPERATORS CONTROL PANEL 6
5. DE-FLASHING 7
6. SETTING THE NUMBER OF UPSETS AND DEFLASHES FOR
AUTOMATIC OPERATION 8
7. SETTING THE NUMBER OF UPSETS AND DEFLASHES FOR MANUAL
OPERATION 10
8. DIAGNOSTICS FOR EP500 12
8.1. PRE SET TIME DELAYS 14
9. ROUTINE MAINTENANCE 15
10. LIST OF PLC INPUTS AND OUTPUTS 15
11. EP500 PARTS LIST 16
12. SERVICE AND INFORMATION 21
1
1. SPECIFICATION EP500
1.1. CAPACITIES
COPPER: 5.00mm - 12.50mm DIAMETER
ALUMINIUM: 5.00mm - 15.00mm DIAMETER
Note:
These figures are given for materials of average hardness.
Non-ferrous Metals of other types and hardness can be welded within these
guidelines.
1. Details of other projected applications must be submitted to the manufacturers for
approval.
1.2. DIMENSIONS
Length: 1430mm
Width: 970mm
Height: 1240mm
Nett Weight: 960 Kg nett
Gross Weight: 1,160 Kg. (Packed)
1.3. GENERAL DESCRIPTION
1. The EP500 is designed to effect the end-to-end butt welding of NON-FERROUS,
circular and profile section rods and to take its place as an ancillary piece of
equipment in wire drawing and rod breakdown processing. The basic principle is
that of gripping the ends of opposing wires or rods in a pair of split dies and
bringing them together under intense axial pressure until the yield stress of the
material is exceeded. This pressure is repeated (typically 5 - 10 times) until a
uniform weld is formed. The union produced by these successive pressures (called
‘upsets’) is such that any previous oxidised areas on the ends of the rods, which
would inhibit a successful weld, are removed in the radial flow of metal which
extrudes from the weld zone. The bond thus formed prevents any further entry of
air which would re-oxidise the material, and is of equal strength to the basic
material.
The material extruded from the weld zone forms an irregular collar of metal around
the weld (termed a ‘flash’) and is removed by a ‘de-flashing’ operation in which
one of the die sets is run over the weld whilst the material is held clamped by the
other die set.
The basic process comprises the following cycle of operations:
i) Load
ii) Grip
iii)Upset (welding)
iv)De-flash
2
v) De-grip
vi)Unload
The operating sequence is controlled by an Allen Bradley programmable controller
(PLC) which takes the pneumatic operations through the required sequence and
monitors the system for problems.
The machine incorporates a pair of pneumatically operated gates, or clamps, for
each work piece. The purpose of these is to hold the work pieces as the grip arms
retract and thus prevent any tendency for them to move apart before the weld is
properly formed.
2. INSTALLATION
2.1. Off-Loading
1. The machine has a substantial under-frame and may be lifted by a fork lift.
Screwed holes for use with eyebolts, size M16, are also provided in the base
supports. The machine is mounted on swivel-wheels so that it can be easily moved
into position. When it is located in its working position, depress the foot operated
locking lever on the left hand wheel to prevent further movement.
2.2. Air supply
i) Connect a compressed air supply to the indicated point on the side of the
machine, it accepts fittings which are screwed 1/2in. B.S.P.
THE SUPPLY PIPE MUST HAVE A MINIMUM INTERNAL DIAMETER
OF 12mm. DO NOT USE QUICK SNAP ON PIPE CONNECTIONS AS
THESE DO NOT ALLOW SUFFICIENT AIR FLOW. Ensure that there are
no restrictions or tight bends in the pipe as reliable operation of the machine
depends on a volume of air with free flow.
ii) The supply pressure should be between 6-8 kg/cm2. DO NOT FIT ANY
FORM OF OIL MIST LUBRICATION IN THE AIR SUPPLY
iii)The filter unit located immediately inside the machine from the supply pipe will
remove particles above 50 micron in size, and also mixtures of water and oil in
the form of aerosols. It is nevertheless advisable to make sure that the supply is
free from water and oil. Any liquid contaminants remaining in the supply are
removed through the drain valve at the bottom of the filter unit. The drain valve
is of the automatic type controlled by a float in the bowl.
iv)The air pressure regulator is set at the factory at 5.62 kg/cm2. (5.52 Bar)(80
PSI.)
Check this setting on the pressure gauge during the initial running of the
machine, and see that the reading on the gauge does not fall below 4.6 kg/cm2.
(4.5 Bar)(65.4 PSI) for longer than a second or two during the operation of the
upset cylinder in the weld cycle.
v) The air regulator (DF1) for the de-flashing operation is given a factory setting of
3.9 kg/cm2.
Subsequent adjustment may be necessary after the first trial runs.
3
2.3. Electric Supply
i) The electrical control panel is mounted inside the machine behind the front covers.
The machine isolating switch is interlocked with the door. To open the door, put
the isolating switch to the ‘Off’ position and use the T-bar key supplied to open the
door (½ turn).
ii) A single-phase, 5 amp, electric supply of the specified voltage (usually 220-240
volts) is required and should be connected direct to the incoming terminals of the
isolating switch.
The supply cable should enter through the base or side of the control panel near to
the isolating switch. A 20mm diameter hole for a suitable cable gland should be
drilled in the control panel.
iii)HRC back-up fuses, say 15A rating, can be fitted in accordance with factory
requirements.
2.4. Fitting the Dies
1. The machine will normally be delivered with one of the specified die sets already in
place. If they are not, fit the required dies as follows:
2. Turn on electric and air supplies and close the control panel isolating switch,
3. If the top cover is not already closed, close it by operating the control switch on the
operators panel.
Remember, - NO MACHINE FUNCTION IS POSSIBLE WITH THE TOP
COVER OPEN.
4. Press the RESET button.
5. The grip arms will now move to their fully open position.
6. Raise the top cover by operating the control switch.
7. Switch off electric supply.
Locate the dies against the corresponding X and Y marks in the grip arms. Secure
them with the 10mm screws, ensuring that each segment is fully tightened.
The machine is now ready for use.
3. PNEUMATIC SYSTEM
1. The pneumatic circuit is shown on the circuit diagram accompanying this manual.
3.1. Cylinders
4
1. Grip cylinders. These are double-acting cylinders which operate the grip arms,
closing the die segments on to the work pieces. (Shown as No.254 on Fig.11)
2. Upset cylinder. A double acting cylinder providing the upset action. (Shown as
Nos.260/1 on Fig.10)
3. Stop cylinders. Two double-acting cylinders, each operating a stop-plate which is
ejected behind the piston rods of the grip cylinder so that they operate with a
reduced stroke. This provides a nearly-closed position of the die-holders for
loading purposes and also restricts the back stroke of the grips at each upset.
(Shown as No.255 on Fig.11)
4. Gate cylinders. Two double-acting cylinders operating the gate clamps. (Shown as
No.285 on Fig.10)
5. Top Cover cylinders. Two single acting cylinders for raising the top cover. The
cover closes by its own weight when the ‘close’ button is pressed, the cylinders
exhausting through controllable flow valves. The speed of closing can be adjusted
by the flow valves.
3.2. Cylinders limit switches
Limit switches are fitted to the cylinders.
Upset cylinder A proximity switch detects the presence of the operating
rod clevis when the piston is at the ‘upset’ position.
Grips cylinder A proximity switch detects the piston of the master
cylinder at the ‘grip on’ position.
Both upset and grips proximity switches are fitted with a LED which lights up
when a switch is closed.
The position of the stops cylinders pistons is detected at
Stops cylinders both the retracted and engaged positions by roller operated
limit switches.
3.3. Solenoid Valves.
1) V3. L.H. Gate
V5. R.H. Gate
V4. Stops
V7. Top Cover
These are solenoid operated, spring return, mini-valves on appropriate sub-bases.
The diodes for 24v.d.c. operation are contained in the solenoid caps. The electrical
consumption is 2VA. All these valves are fitted with a manual override which can
operate the valve and latch it in the operated position. A ¼-turn of the screwdriver
adjuster is all that is required. Refer to diagram at the end of this section.
5
2) V1. Grips
V6. De-flash
These are solenoid operated, spring return, spool valves on sub-bases. They also are
fitted with diodes for 24v.d.c. operation and manual override.
3) V2. Upset
This is a solenoid-operated, air pilot, multi-function valve with spring return. 24v.
diodes in the solenoid cap and a manual override are fitted.
4. ELECTRICAL EQUIPMENT
4.1. Control Panel
This is mounted on the right hand side of the machine behind the front covers. Inside
it are mounted the isolator switch, 24 volt transformer (TX), rectifier RV1, Allen-
Bradley Micrologix PLC, fuses for the control circuit and solenoid valves and all
control circuit terminals.
The electrical circuit is shown on the Machine Circuit Diagram accompanying this
manual.
4.2. Programmable Logic Controller (PLC)
This is an Allen-Bradley Micrologix controller. Its function is to guide the machine
through its operating cycle and monitor the system for faults. It is programmed at
the factory to provide the required sequence of outputs to the solenoid valves in
response to the inputs and commands from the limit switches and push-buttons.
Each input and output terminal has a light diode which lights up when the
corresponding input or output is present. These are arranged in rows on the left
hand side of the unit.
The other lights indicate when power is on (POWER), when operation is in
progress (RUN) or when a fault is present (FAULT). The FORCE light is not used.
4.3. Operators Control Panel
This is on the sloping front of the machine facing the operator. It contains the
following push-buttons and switches for initiating and controlling the process.
i) START button This initiates the welding process .
ii) LOAD button
This brings the grip arms to the loading position.
iii)RESET (or unload)
button
6
This opens the grip arms fully and also resets all circuits.
These control the gates, holding the work-pieces in
i) L/H and R/H
position when loading.
GATES buttons
(OPEN/CLOSE)
For raising or lowering the top cover guard.
ii) TOP COVER switch
(Raising the guard stops all operations). During the
(OPEN/CLOSE)
weld process the switch is inoperative.
Operation of this button stops all operations
iii)EMERGENCY immediately. It is of latched type and stays down
STOP when operated. It is reset by twisting the button.
iv) READY
Indicating light
This illuminates with a steady light when the machine is ready for welding and
flashes when welding is in progress.
This is an intelligent, operator interface unit with a
v) E100 two-line alpha-numeric display and function keypad
which gives access to all the functions controlled by
the PLC.
The unit has a memory capacity for storage of the
operating system sequence and the display screen can
be called up to preset and display the number of weld
upsets and all the timed operations in the sequence.
Setting the number of welds and de-flashes is covered
in Section 6.
5. DE-FLASHING
i) This is the operation that removes the ‘flash’ from around the weld and is carried
out automatically at the end of the upsets.
ii) It is effected by supplying the right hand grip cylinders with air at reduced pressure
so that the dies slide forward over the weld, shearing off the flash collar. The left-
hand grip cylinder is supplied at full pressure during this operation, holding the
welded work-piece in position.
The number of deflash operations is preset on the E100 unit on the operators
control panel. The display count on the E100 counts upwards as deflashes are
made.
If deflashing is not required the deflash preset count should be set at zero (0).
iii)After completion of deflashing the machine returns to the Unload condition, the
dies open fully and the welded rod can be removed.
iv)The air pressure for deflashing is set by the pressure regulator DF1. Please note
that this operation will only remove the worst of the flash, final cleaning with a file
7
is still necessary. Adjust the pressure by the knob on the regulator (clockwise to
increase pressure).
6. SETTING THE NUMBER OF UPSETS AND DEFLASHES
FOR AUTOMATIC OPERATION
Switch on the electric and air supplies.
Check that the ‘POWER ON’ light on the PLC comes on and that the air pressure
gauge reading is between 5.5/6.0 kg/cm2.
At switch on the E100 display will show:
PWM.Ltd. EP500
F1=PREV F4=NEXT
Pressing F4 will always take you to the next screen. Pressing F1 will always take you
back one screen.
To set the number of upsets and deflashes.
Press F4.
The display will change to whatever values the UPSET & DEFL are set to.
During normal operation ensure that the E100 displays this screen as it will guide
the operator through the welding process.
UPSET ? DEFL ?
St # PRESS RESET
Press F4
This screen will display the current setup for upsets.
Upsets #
Press NUM to change
Enter the number of upsets required by pressing the NUM key simultaneously as
entering the number followed by the enter key.
If the current number is acceptable press F4.
This screen will display the current setup for deflashes.
Deflashes #
Press NUM to change
Enter the number of deflashes by simultaneously pressing NUM key and entering the
number, followed by the enter key
(If you do not require deflashing set the number to zero (0).)
If the current number is the same as you require press F4.
The display will now show:
WELD TIME #.#s
Press NUM to change
8
From this screen the operator is able to adjust the time delay for the upset cylinder to
pause after reaching the end of its stroke, normally one to three seconds, before de-
grip and de-upset starts. When the required time has been entered or if the time
displayed is acceptable press F4 and the following display is shown.
Manual mode off Or Manual mode on
Prev Help I/O Next Prev Help I/O Next
This screen allows the operator to choose between MANUAL or AUTOMATIC
operation by switching MANUAL operation ON or OFF. To turn manual operation on
or off use F3. Manual operation OFF will give automatic operation.
Press F4 and the display will change to:
TOTAL CYCLES
########
If you need to re-check or change the selection press F1 to move back through the
screens until the E100 displays
UPSET ? DEFL ?
St # PRESS RESET
To start AUTOMATIC operation, assuming that MANUAL operation has been turned
off, follow the instructions displayed on the E100
Press ‘RESET’ or ‘LOAD’ according to the display.
Enter the rod into the dies on each side of the machine
Press the ‘CLOSE GATES’ LH & RH BUTTONS on either side of the control panel.
Press ‘START’.
The machine will now go through the sequence automatically, counting up the preset
number of UPSETS and DEFLASHES. Following the deflash cycle the dies and gates
will open to the unload position.
Open the Top Cover by the control switch and remove the welded rod.
Inspect the weld and decide if any adjustment needs to be made to the number of
upsets or de-flashes. Reset the E100 to the new numbers if required.
Adjust the de-flash pressure if necessary by the air regulator DF1.
NOTE
If the emergency stop is pressed during welding, all motions are stopped and the E100
display reverts to:
Upsets # Defls#
St # EMERG STOP
To resume operations release the ‘EMERGENCY STOP’ and follow the instructions
on the E100 display.
9
Failure of air pressure or insufficient air during the cycle will stop the machine. The
E100 display will indicate:
Upsets # Defls #
St # LOW AIR PRESS
When the air supply has been re-established, press the RESET button and start again.
7. SETTING THE NUMBER OF UPSETS AND DEFLASHES
FOR MANUAL OPERATION
The following screen will be displayed if the electrical supply has just been switched
on or if menu is pressed.
PWM.Ltd. EP500
F1=PREV F4=NEXT
To set the number of upsets and deflashes
Press F4.
The display will change to:
UPSET 0 DEFL 0
PRESS RESET
Press F4
The display will change to:
Upsets #
Press NUM to change
If the number displayed is acceptable press F4
If not enter the number of upsets required by simultaneously pressing the NUM key
and the required number and press enter.
The display will change to:
Deflashes #
Press NUM to change
If the number displayed is acceptable press F4
If not enter the number of deflashes required and press enter.
The display will change to:
WELD TIME #.#s
Press NUM to change
From this screen the operator is able to adjust the time delay for the upset cylinder to
pause after reaching the end of its stroke, normally one to three seconds, before de-
grip and de-upset starts. When the required time has been entered or if the time
displayed is acceptable press F4 repeatedly until the display shows:
10
Manual mode off
Prev Help I/O Next
This screen allows the operator to choose between MANUAL or AUTOMATIC
operation by switching MANUAL operation on or off. Press F3 to change between
manual mode on or off.
MANUAL OPERATION ON (Gives manual operation)
MANUAL OPERATION OFF (Gives automatic operation)
Press F4 and the display will change to:
TOTAL CYCLES
00000000000
If you need to re-check or change the selection press F1 to go back through the
screens.
If the electrical supply has just been switched on the display will show:
UPSET 0 DEFL 0
PRESS RESET
Or if the machine has been in operation the displayed message will be.
UPSET 0 DEFL 0
PRESS LOAD
To start MANUAL operation, assuming that MANUAL operation has been turned on,
follow the instructions displayed on the E100.
Ensure the top cover is in the closed position.
Press ‘RESET’ or ‘LOAD’ according to the display.
Enter the rod into the dies on each side of the machine, it is not necessary to prepare
the rod ends in any way.
Press the ‘CLOSE GATES’ LH & RH BUTTONS on either side of the control panel.
Press ‘START’.
The machine will make one complete cycle each time the ‘START’ button is pressed
until the programmed number of UPSETS and DEFLASHES have been reached.
Following the deflash cycle the dies and gates will open to the unload position.
Open the Top Cover by the control switch and remove the welded rod.
Inspect the weld and decide if any adjustment needs to be made to the number of
upsets or de-flashes. Reset the E100 to the new numbers if required.
Adjust the de-flash pressure if necessary by the air regulator DF1.
Remember:
The machine cannot start or function in any way unless the TOP COVER is closed.
If in difficulty, pressing the ‘EMERGENCY STOP’ button stops all motions.
Pressing the ‘RESET’ button stops the process and resets all circuits ready for a re-
start.
11
8. DIAGNOSTICS FOR EP500
Some diagnostic aids:
1. The solenoid valve plugs have LED lights on them to show that they are energised
2. The proximity switches have LED lights on them to shown when they have
operated.
3. The PLC has indicating lights showing which ‘inputs’are present and which outputs
are on.
4. The E100 indicates which stage in the cycle the machine has reached.
5. Generally, pressing the RESET button will bring the machine back to the start
position. If this fails try switching off and on again. This can clear PLC faults.
6. The diagnostics can be run at any time pressing F4 until any of the following
screens are displayed.
The screens displayed are as follows:
Upsets # Defls #
Step 0 Press reset
Upsets # Defls #
Step2 Grip closed
Upsets # Defls #
Step 3 Load stops out
Upsets # Defls #
Step 9 Press load
Upsets # Defls #
Step 10 Grips closed
Upsets # Defls #
Step 11Load stops in
Upsets # Defls #
Step 13 Close gates
Upsets # Defls #
Step 15 Gates open
Upsets # Defls #
Step 16 Upset advance
Upset # Defls #
Step 17 Weld time
Upset # Defls #
Step 18 closing gates
Upset # Defls #
12
Step 19 opening
Upset # Defls #
Step 32 opening
If the machine stops for any reason read the message and this will indicate that the
control is waiting for a specific command and until this has been given the machine
will remain in the stopped position.
When the EMERGENCY STOP (E/STOP) has been pressed the machine stops
welding and returns to the unloaded position, the E100 will display the following
message.
Upset # Defls #
St # EMERG STOP
At this time you should release the E/STOP and follow the instructions on the E100
display.
If during the operation, or when the top cover is closing, the safety switch is not made
or becomes unlatched, the machine will stop and the E100 will display the following
message.
Upset # Defls #
St # GUARD NOT SHUT
When the top cover has been closed the E100 will display the following message.
Upset # Defls #
St # PRESS RESET
If there is no Air supply, or insufficient Air, the E100 will display the following
message.
Upset # Defls #
St # LOW AIR PRESS
When the Air supply has been corrected the E100 will display the following message.
Upset # Defls #
St # PRESS RESET
The E100 will also display a message:
TOTAL CYCLES
00000000000
The bottom line indicates the total cycles that the machine has performed since new
and is not adjustable.
The E100 will also display a message:
13
Diagnostics?
PREV HELP YES NEXT
This requires a special access code and should be used by specially trained
maintenance personnel only.
Likewise the following screen requires a password and is for specially trained
maintenance personnel only.
System timers?
PREV HELP YES NEXT
8.1. Pre set time delays
Time delay Factory setting Part of Cycle Timed movement
No. (Secs.)
1. .01 Loading Grips Pressure switch signals grips at
weld position.
2. 2.0 Loading Grips opening to load position.
3. .01 Upset Grips pressure switch signals grips at
De-flash weld position.
Unloading
4. 1.0 Loading Stops limit switch signals stops
De-flash retracted.
Unloading
5. 3.0 Upset Upset pressure switch signals upset
De-flash position.
6. 1.5 Upset Upset cylinder retracted.
De-flash
7. 1.0 Upset Gates open to gates closed and gates
Unloading closed to gates open
De-flash Each 1.0 second.
8. 0.25 Upset Grips off prior to retraction.
De-flash
In addition there is an inbuilt 5 second delay before the machine is stopped due to low
air pressure or loss of air supply. This accommodates transient pressure drops due to
large air movements.
All the solenoid valves are fitted with a manual override facility. This allows the
forcing of valves operation and can be of assistance in fault finding. The position of
the manual override on each type of valve is shown in the diagram in section 3.
9. ROUTINE MAINTENANCE
i. The welder requires minimum maintenance and lubrication, if parts are dismantled
or replaced should they be lubricated with molybdenum disulphide grease on
assembly. Once a week the thrust columns and pins (#112-113-134) should be
lubricated with a grease gun by removing the covers over the top of the upset arms
14
at each end of the machine. (Fig.10)
ii. The worktop area should be kept clean and the die-holders clear of swarf and dust.
iii.Empty the swarf tray as required.
iv. Clean the air filter periodically; attention is required when the air bowl becomes
discoloured.
a) Unscrew the bowl guard (turn anti-clockwise) and remove the bowl with its ‘O’
ring and float assembly.
The filter element now exposed can be removed by unscrewing the central cross-
head screw.
b) Clean the bowl and filter in soapy water. The float assembly can be left in place.
Do not use solvents; the use of these will eventually cause minute cracks to appear,
thus reducing the ability of the bowl to withstand the working pressure.
c) Replace the filter, bowl with its ‘O’ ring, and guard.
d) During normal use of the welder, ensure that the air pressure is switched off at the
end of the working shift, so that the accumulated water in the bowl can drain out
through the valve in the bottom of the bowl.
e) Check the operation of the emergency stop and the top cover switch monthly. All
lights on the PLC should go out when the emergency stop is pressed. The top cover
switch can be checked by opening the guard at any point in the welding cycle. All
motions should stop.
15
10. LIST OF PLC INPUTS AND OUTPUTS
INPUTS
I/0 LEFT HAND GATE OPEN
I/1 LEFT HAND GATE CLOSED
I/2 RIGHT HAND GATE OPEN
I/3 RIGHT HAND GATE CLOSED
I/4 LOAD PUSHBUTTON OPERATED
I/5 START PUSHBUTTON OPERATED
I/6 RESET (UNLOAD) PUSHBUTTON OPERATED
I/7 EMERGENCY STOP OPERATED
I/8 TOP COVER (GUARD) CLOSED
I/9 GRIPS ON (PROXIMITY SWITCH OPERATED)
I/10 STOPS RETRACTED
I/11 STOPS ENGAGED
I/12 UPSET ON (PROXIMITY SWITCH OPERATED)
I/13 AIR PRESSURE OPERATED
OUTPUTS
0/0 LEFT HAND GATE CLOSE SOLENOID VALVE (V1)
0/1 RIGHT HAND GATE CLOSE SOLENOID VALVE (V2)
0/2 CLOSE GRIPS SOL. VALVE (V3)
0/3 ENGAGE STOPS SOL. VALVE (V4)
0/4 UPSET SOL. VALVE (V5)
0/5 DE-FLASH SOL. VALVE (V6)
0/6 READY LAMP
0/11 TOP COVER (GUARD) SOL. VALVE (V7)
FIRST LINE ELECTRICAL SPARES
Note: Always quote the Machine Serial No. when ordering electrical spares.
Fuses (Control Circuit) 1 set
F1. F2. F3.=3 amp.
FUSES (Solenoid Valves) 1 set
F10 - F16.=1 amp
PUSHBUTTONS.
LOAD (Black) 1
RESET (Yellow) 1
START (Green) 1
GATES (L.&R.H.) 2
EMERGENCY STOP 1
RECTIFIER 1
PRESSURE SWITCH 1
PROXIMITY SWITCHES 2
SOLENOID VALVE COILS (of each type) 1 set
SOLENOID VALVE CAPS (c/w diodes) 1 set
GUARD SWITCH 1
16
PRE-PROGRAMMED PLC AND) Information from
E100 UNIT ) Pressure Welding Machines Ltd.
11. EP500 PARTS LIST
PART No. QTY ITEM
8-03-105 2 CAST BRACKET
8-03-106 4 GRIP ARM
8-03-108 2 UPSET ARM
8-03-109 1 LONG PIVOT SHAFT
8-03-110 1 SHORT PIVOT SHAFT
8-03-111 2 THRUST PAD
8-03-112 2 THRUST COLUMN
8-03-113 2 THRUST PIN
8-03-114 2 FULCRUM PIN
8-03-117 2 GRIP CYLINDER BRACKET
8-03-118 2 GRIP CYLINDER YOKE
8-03-119 4 GRIP ARM LINK
8-03-120 4 YOKE PIN
8-03-121 4 LINK PIN
8-03-122 2 REMOVABLE STOP BASE
8-03-123 2 REMOVABLE STOP
8-03-124 2 CYLINDER SUPPORT
8-03-125 4 GUIDE STRIP
8-03-131 8 GRIP ARM BUSH
8-03-132 2 HANGING BRACKET BUSH
8-03-133 1 CENTRALIZING BAR
8-03-134 2 LONG THRUST PIN
8-03-135 1 HANDLE
8-03-137 2 UPSET ARM COVER
8-03-138 1 UPSET CYLINDER GUARD
8-03-142 1 ALIGNMENT BUSH
8-03-143 2 SHORT SPRING HOLDERS
8-03-148 1 ECCENTRIC SHAFT
8-03-151 2 PNEUMATIC GATE CLAMPS
8-03-154 2 CYLINDER LINK PIN
8-03-155 2 CENTRALIZING LINK
8-03-156 2 LINK ARM PIN
8-03-157 1 CENTRALIZING ARM
8-03-158 1 CENTRALIZING SUPPORT
8-03-159 6 WASHERS
8-03-161A 2 GATE CYLINDER SUPPORT
8-03-161B 2 GATE CLAMP FIXED
8-03-161C 2 GATE CLAMP MOVING
8-03-162 2 UPSET LENGTH STOP
8-03-235 1 AIR GAUGE 160 PM
8-03-236 1 FILTER REGULATOR 342-03-131 1/2
8-03-254 2 CYLINDER PES125TA100
8-03-259 2 FEMALE ROD CLEVIS 200 434-00-021
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8-03-261 1 CYLINDER PES200TA200
8-03-262 1 CYLINDER PES200TA280 (EXT.)
8-03-275 1 GREEN BUTTON
8-03-276 1 YELLOW BUTTON
8-03-278 1 BLACK BUTTON
8-03-279 1 RED BUTTON
8-03-280 2 BUTTON
8-03-285 2 STOP CYLINDER PES32TA50S
8-03-301 8 SOCKET CAP SCREW M16x40
8-03-302 8 SOCKET GRUB SCREW M10x20
8-03-312 4 DE-UPSET COMPRESSION SPRING
8-03-314 1 BUSH PM 556050 DX
8-03-315 2 BUSH PM 353030 DX 2.63
8-03-316 4 BUSH GLY PG859080A DX
8-03-317 8 BUSH GLY PG859080A DX
8-03-318 4 BUSH GLY PG252825A DX
8-03-323 4 BUSH GLY PG455030A DX
8-03-343 2 NON RETURN VALVE 346-00-125
8-03-396 10 SOCKET GRUB SCREW M10x12
8-03-404 1 SHUTTLE VALVE 346-00-119
8-03-405 1 FLOW REGULATOR
8-03-406 1 MOUNTING 343-00-016 4/6
8-03-424 2 CYLINDER PES50TA25S
8-03-431 2 CYLINDER C25AS80 435-00-289
8-03-433 1 TROJAN SWITCH F178-181
8-03-434 1 COVER SAFETY GLASS 530X200
8-03-495 2 189-90-001 VALVE STEM
8-03-496 4 430-04-158 24VD/C COIL
8-03-501 2 JUMPER BARS 426-288
8-03-502 1 VALVE 542-00-017 24V D/C(V2)
8-03-503 1 SUB BASE 355-00-042 (V2)
8-03-505 3 END STOP 424-917
8-03-506 4 VALVE 520-00-002 D/C(3,4,5,7,)
8-03-507 2 VALVE 551-00-052 24V D/C(1.6)
8-03-509 4 MECHANICAL SWITCH XCM-A11
8-03-510 4 SOLENOID HEADS WITH 2M LEAD
8-03-516 1 VALVE 1/2 BSP 469-13-21 SELF
8-03-517 2 CASTOR 5-99-CI
8-03-518 2 CASTOR 5-91-CI-BR
8-03-519 1 MICROLOGIX PLC
8-03-520 1 BEIJER E100 (from machine serial no.266 on)
8-03-521 1 PRESSURE SWITCH 7032-3 4 BAR
8-03-522 1 COMMUNICATION CABLE 1761
8-03-523 3 SOLENOID HEAD 881-22-405 2M
8-03-527 2 PROXIMITY SWITCH XS4P12P
8-03-531 1 PILOT LAMP ZB2-BV6
8-03-532 1 PILOT LAMP BODY ZB2-BV03
8-03-533 1 BULB DL1-CE024
8-03-536 1 RECTIFIER 264-888
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8-03-537 1 SWITCH 191-7533
8-03-538 8 FUSES 157-9737
8-03-539 1 TRI-RATED CABLE 364-405
8-03-541 1 TRANSFORMER 207-295
8-03-542 2 MOUNTING BRACKET 256-001
8-03-543 3 FUSE 157-9787
12. SERVICE AND INFORMATION
Pressure Welding Machines Ltd.
Unit 1, Belmont Farm Business Centre
Snoad Hill
Bethersden
Kent. TN26 3DY Telephone: +44 (1233) 820847
England. Fax: +44 (1233) 820591
E-Mail: PWM@btinternet.com
Website: pwmltd.co.uk
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