HAS - Vorlage Report Customer: VR Track Ltd. ... SWEP 06 Work carried out: ok ... Check welding program X Program 919 – 925 / 19

Inspection Report

Customer: VR Track Ltd.

Customer Contact: Aki Loikala

Plant: AMS60 No.: 1.2624.2979

Service Engineer: Wayne Holzer

Inspection Date: 18.+ 19.07.2017

Schlatter Industries AG Brandstrasse 24 T +41 44 732 74 20 [email protected] 1/14 8952 Schlieren | Switzerland F +41 44 732 71 20 www.schlattergroup.com

Customer: VR Track Ltd. Material Administration P.O. Box 485 20101 Turku Finland Customer Contact: Aki Loikala Plant: Flash Butt Welding Machine AMS60 Inspection Date: 18.+ 19.07.2017 Order Number: 4006702 Schlatter Engineer: Wayne Holzer

mailto:[email protected]

http://www.schlattergroup.com/

Inspection Report



Plant: AMS60 No.: 1.2624.2979




1. Preface to the inspection protocol

- At the inspection the instruction manual should be considered. The instruction manual contains important information on how to operate the plant safely, properly and most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and life of the machine. - In addition to the operating instructions and to the mandatory rules and regulations for accident prevention and environmental protection in the country and place of use of the plant, the generally recognized technical rules for safe and proper working must be observed.

2. Mechanical installation

Work carried out:

n. o

k

ok

Recommended Repairs and Works:

Optical check mechanics X

Check if the way transducer is mounted firmly and is not dirty

X

Check electrodes fixed side X We change

Check electrodes mobile side X Well change

Check intermediate spaces and remove weld residue

X Machine is clean

Check electrical connections X

Check piston rod of upsetting cylinder X

Check mechanical safety device X

Check lubrication system X

Check guide cylinder X

Check clamping bar X



Inspection Report



Plant: AMS60 No.: 1.2624.2979




3. Electric installation and machine control

Work carried out: n

. o

k

ok


Lamps test X


Check electrical safety devices X

Check emergency switch off X

Check manual and automatic functions X

Shunt Control machine housing X 33.5 Ohm

Check connections SWEP06 X

4. Hydraulic installation

Work carried out:

n. o

k

ok


Optical check hydraulic X A little bit dirty

Check hydraulic circuit for leaks X

Check hydraulic oil with FLUID CHECKUP X Oil was changed in March 2017 incl. filters

Check hydraulic pressure (according to the hydraulic schema)

X

Check oil level X

Check motor cooling X

Check hydraulic filter X

Check Water / Oil cooler X

Check seals of servo valve X



Inspection Report



Plant: AMS60 No.: 1.2624.2979




5. Cooling water Installation

Work carried out:

n. o

k

ok


Check cooling water inflow pressure X

Check cooling water backflow X

Check cooling water quality/ frost protection Frosttemp. min -15°C Frost protection article No.: 24.01.213

X

Check cooling water level indicator X



Inspection Report



Plant: AMS60 No.: 1.2624.2979




6. SWEP 06

Work carried out: n

. o

k

ok


Correcting offset of servo valve (Bosch or Parker valve)

Check with AQ60: UE=UEQ=0V, max. Speed at nominal pressure 2mm/min

X

Check of system parameter 20, 21, 40 X 20) 0/0.01/0.02/0.03/789/850/49.6/172/0.75/999/850/0 21) 1.00/0.50/2.27/0.00/0.00/000 30) 05/20/05 40) 1.0/2/7/960/002/006/003/006/021

Diagnosis X E16-151/E18-109/E20-402/E23-318/E25-114/E29-1083

Check welding program X

Program 919 – 925 / 19 – 25 X

Weld counter X 12499 Welds

Type of rails X

Recording of SWEP diagnosis data with assessment (see DIAG page).

X


Work carried out:

n. o

k

ok


Perform self adjustment X

1 2 3 4 5 6 7 8

L L L L L L L H

(nach BAL 2B2653XX-GAAS80 6-23 par 6.9.1) After selection 597

Check is UEQH permanent high. Check SWEP06 Diagnose 04 (Kanal 3 = 000)

X

Compare WeldAnalyzer calibration with form A. Must be plausible.

X



Inspection Report



Plant: AMS60 No.: 1.2624.2979




7. Function examination

Work carried out: n

. o

k

ok


Function control with weld program without zero searches, (without deburring 37) clamping, program flow, retreat into instep position, pressure and return filter when undoing the instep cylinder

X

Carry out service program 922 function test Compare with previous records. Save new records.

X

8. Measurement

Work carried out:

n. o

k

ok


Instep 25%, 50%, 75% X 212kN, 391kN, 591kN

Check upsetting force 999% HP 140 bar X 223kN, 413kN, 595kN

Recording upsetting speed v (mm/s) X 0.29 mm/s

Check calibration current with UIC 60 (14000mm2 form 1.5m long)

X 52 kA

With program 20 being warm impulse 1.5 s with phase control 500 %o

X 30% 13 kA 50% 26.6 kA 70% 42.1 kA

Current measurement with WEA01/10kA/V, documenting with Picoscope.

X 30% 13.09 kA 50% 26.13 kA 70% 40.59 kA

Current measurement with REC01 1V/cm (max. 5V current)

X



Inspection Report



Plant: AMS60 No.: 1.2624.2979




9. WeldAnalyzer PC

Work carried out: n

. o

k

ok


WeldAnalyzer: Save all settings X

Clean up the PC data waste:

- Clean desktop - Delete ISO files of old backup - Drive C: und D: Clean up with the operating system and delete everything unnecessarily

X

Create PC Backup. X

PC-Type: WS 843

PC-No.: N / A

ISO file created and delivered with inspection report YES

Backup and calibration report created and saved under C/Welddata/Calibration+Check-Up YES

10. Summary

The machine is in a good and clean condition.

They did a good maintenance since last Schlatter visit.

Obsolete or no longer available components and parts

- Servovalve - Computer WeldAnalyzer-PC



Inspection Report



Plant: AMS60 No.: 1.2624.2979




11. Spare part recommendations

Parts have to be necessarily listed with item numbers. If in doubt take photos of nameplates and parts.

Description No. Article

No. urgent needed

on Stock

1 PC upgrade 1x

2 Servovalve upgrade 1x

3

5

6

7

8

10

11

12

13

Defects were noticed at the machine? Yes No X

Were Defects solved? Yes No X

Is the machine in a production capable condition? Yes X No

Control date : 19.07.17 Name : W.Holzer

Place: Lappeenranta



Inspection Report



Plant: AMS60 No.: 1.2624.2979






Inspection Report



Plant: AMS60 No.: 1.2624.2979






Inspection Report



Plant: AMS60 No.: 1.2624.2979






Inspection Report



Plant: AMS60 No.: 1.2624.2979






Inspection Report



Plant: AMS60 No.: 1.2624.2979






Inspection Report



Plant: AMS60 No.: 1.2624.2979






Documents

HAS - Vorlage Report Customer: VR Track Ltd. ... SWEP 06 Work carried out: ok ... Check welding program X Program 919 – 925 / 19