OWNER S MANUAL MODEL: PT 450 / PT 450M WELDING POSITIONER

Transcription

1 OWNER S MANUAL RD-8450E Important Read these instructions before installing, operating or servicing this product. MODEL: PT 450 / PT 450M WELDING POSITIONER Serial number ~ and later Revised date May. 14th, 2015

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3 TABLE OF CONTENTS Introduction General Information Operation Instruction Service Parts list Circuit diagram Appendix Revision Instruction... i Safety precautions... ii Limited warranty... iii 1.1 Introduction Specifications Operation panel Maintenance Troubleshooting guide Parts list - machine Parts list - machine Parts list - control box (front) Parts list - control box (rear) control circuit diagram Diagram tilting control box Wiring diagram Revision

4 INSTRUCTION WARNING A procedure, which if not properly followed, may cause injury to the operator or others in the operating area. Equipment identification Receipt of equipment The identification number specification or part number, model, and serial number of this unit usually appear on a nameplate attached to the control panel; record these numbers for future reference. When you receive the equipment, check it against the shipping documents. Make sure it is complete and inspect the equipment for possible damage during shipping. If there is any damage, notify the carrier immediately to file a claim. Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc. to uncrate the unit. WARNING Falling machine due to lifting device failure may cause death or injury. * Lifting device may fail when overloaded. * Avoid sudden jerks, drops or swinging. * Check lifting device components visually for looseness and signs of metal fatigue. * Before changing any hardware, check grade and size of bolts, and replace with bolts of equal or higher size and grade. i

5 SAFETY PRECAUTIONS WARNING Operation and maintenance involves potential hazards. All operators and personnel should be alerted to possible hazards and precautions should be taken to prevent possible injury. Electrical safety Maintenance Individual safety Machine: * The counter, safety device against excess current and electrical installation, are compatible with its maximum power and its main voltage. * The connection, single-phase or three-phase, is possible on a stand compatible with the plug of its cable link. * If the cable is connected with the electrical network, the earth, must never be cut by the protection device against electrical shocks. Work Place: * Be very careful to avoid contact between metal part and phase conductor and the neutral of electric network. * Electrical messes of different electrical machine and apparatus are connected between themselves and with the terminal of earth neutral wire. Interventions: * Before control and repair, see the apparatus is switched off and insulated. * Connection with fixed installation cable is impossible. * It s on STOP and connection is impossible. * Some apparatus are provided with starting circuit HT HF (with a plate). Never enter into the corresponding switch cupboard. * Only qualified persons are authorized for intervention concerning electrical installation. * Often check the insulation and connection good state of apparatus and electrical accessories: taps, appliance cords, coatings, switch, extension cords, etc. * Maintenance and repair of insulating coatings operations are very important. * Do repair with a specialist or better replace defective accessories. * Check regularly the right adjustment and the non-heating of electrical connections. * The operator must be dressed and protected in relation with his work. * Avoid contacting metal parts connected or accidentally connected. * Wear leather gloves with gauntlet. * Safety clothes:gloves, apron, safety shoes protect the operator and his assistants against burns of hot parts, projections and slag. ii

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7 1.1 INTRODUCTION Instruction Main features * Welding positioned is normally used in the rotating and welding of the pipe or round work pieces. * It can be applied on all kinds of welding: SMAW, MIG, TIG, Plasma, etc. * It can adopt different fixture to get the welding effects you require. * The table can be tilted for 0~135º, which is convenient for all angles of the pipe welding or for adjusting welding angles. (It can adopt either manual or electrical operation.) * The table has a through hole of 25 mm, which is convenient for the long pipe welding or the purge shielding gas. * On the table, there are 4T- slots, suitable for all kinds of fixtures and grippers. * Ground current conduction:200amps (400Amps option). * All units are high frequency protected. 1

8 1.2 SPECIFICATIONS Model Unit PT- 450 / PT- 450M Power Input ~ 1 Phase, 110V/220V, 50/60Hz Capacity (Horizontal) kg 450/300 Rated centre of gravity mm 300 Rated eccentricity mm 100 Table diameter mm 450 Rotation speed rpm Spindle thru hole mm 25 Earthing Amp 200A (Max.400A) Tilt range deg Welding timer sec Overall length mm 630 Overall width mm 650 Overall height mm 625 Weight Kg 134 2

9 1.2 SPECIFICATIONS 3

10 2.1 OPERATION PANEL Front Panel: E-Stop:Emergency stop button PB1:Push button switch with signal S 1:Intern / Extern speed control selection switch S 2:Weld / Test mode selection switch S 3:Auto / Manual mode selection switch S 4:Clockwise / counter clockwise selection switch S 5:Weld / rapid speed selection switch VR1:Welding speed adjustment VR2:Welding timer adjustment Rear Panel: SW1:Power switch SW2:110 / 220VAC selection switch F1:Fuse (3A) CM1:Motor connector CM2:Variable speed foot switch connector CM3:Foot switch connector CM4:Welding source connector CM6:Tiling motor connector CM7:Tiling limit switches connector 4

11 2.1 OPERATION PANEL 1. Please set the 110 / 220VAC selection switch to the correct position according to the local AC voltage first. Then, connect the power cord to the power socket located on the rear panel and turn on the power switch. Again press push-button switch, should light up immediately indicating power supply is ok. * Please make sure the E-Stop button is not pressed / activated before usage. All controls become invalid if E-Stop button is pressed. 2. S1(INTERN / EXTERN) switch select the speed control source. INTERN:Speed is controlled by the weld speed knob ( VR1 ) on the front panel. EXTERN:Speed is controlled by the variable speed foot switch. 3. S2 (WELD / TEST) switch enable/disable welding source activation output 4. S3 ( AUTO / MANU ) switch select the operation mode. Manual ( MANU ):Turn table rotation is controlled by the foot switch Automatic ( AUTO ):The start of the rotation is activated by the foot switch, the duration of the rotation and is controlled by the ( Timer ) knob on the front panel from for a duration of ( 0~60 second ). 5. S4 ( / ) direction switch select the direction of rotation ( clockwise or counterclockwise. ) 6. S5 ( WELD / RAPID )switch select the operating Welding speed ( WELD ):Turn table rotation speed can be adjusted from ( WELD SPEED ) knob on the front panel. Full speed ( RAPID ):Turn table rotation speed is set at full speed. 7. SW3 switch located on the rear panel controls the system s tilting motion * Press E-Stop button in case of any emergency situation. All motion and procedure would stop immediately. Reset the E-Stop button after clearing the emergency situation to return the system to operation mode. 5

12 3.1 MAINTENANCE Routine maintenance * After using the machine, make sure to turn off the input main power to prevent the leakage of the electricity. * To make sure the function of the machine could work well for a long time, please keep clean all around the machine and the switch from the oil pollution. * To make the machine run normally, the control box, the machine and the table should be kept clean all the time. * Check at any time the lubrication of the reducer to extend the lifetime of the machine. * Check if the cable is damaged or melted for overheat. * Check the contactor, relay and other connectors are loose or melted. * Check every limit switch is fixed or loses function. * Regularly give the machine cleaning and the anti-rust maintenance. * Regularly change and refill the lubrication of the worm reducer. 6

13 3.2 TROUBLESHOOTING GUIDE3.2 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE / REMEDY A. Blown fuse. Check and replace the fuse when necessary. B. Bad input power switch. Check and replace the power switch when necessary. Power indicator light does not illuminate C. Power supply has no output. Please make sure the input voltage to the power supply is correct AC110/220V. D. The Flat cable is damaged. (a) Check relay board CN1 Pin 7 & 8, it should read 24VDC (b) Measure front panel CN1 Pin 7 & 8, if there is no DC24V, replace a new flat cable. E. The LED is damaged. Measure front panel CN1 Pin 7 & 8, if there is DC24V, replace a new front panel board. A. Motor coil damaged. Measure CM1 female plug Pin 1 & 2 - if there is 2Ωreading, then replace a new motor. Motor has no motion B. Motor has power input, but no motion. Measure CM1 male socket Pin 1 & 2 - if there is 6.5VDC reading, then replace a new motor. C. The I/O board is damaged. (a) Check CN9 Pin 11 & 12, the reading should be about 6.5VDC. (b) Measure CM1 male socket Pin 1 & 2 - if there is no 6.5VDC, replace a new I/O board. A. Foot switch is damaged. (a) Measure footswitch connector Pin 1 & 2, step on the footswitch, check if it has good contact and conduct electricity, if not, replace a new footswitch. (b) Step on the footswitch and check if relay board D11 illuminates, if yes but has no action, replace a new relay board. Forward / Reverse revolutions not functioning correctly B. Forward / Reverse revolution switch is damaged. (a) Switch to "Forward" position and check if D3 illuminates, if not, please replace a new front panel board. (b) Switch to "Reverse" position and check if D4 illuminates, if not, please replace a new front panel board. C. K1-K4 relay is damaged. (a) Switch to "Forward" position and if D3 illuminates but the has no action, please replace a new relay board. (b) Switch to "Reverse" position and if D4 illuminates, but the has no action please replace a new relay board. 7

14 3.2 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE / REMEDY A. Motor control PCB is damaged. (a) Check the motor control PCB. It should have an input voltage of 30VDC between DC+ & DC-. (b) Adjust weld speed measure the voltage between A1 & A2, it should read approx. 6.5VDC, if not, replace a new motor control PCB. Can not adjust speed B. Weld / Speed switch is damaged (Weld / Full speed). (a) Switch to manual mode and adjust the weld speed dial to about 50%, then step on the footswitch. (b) Switch to both weld and speed positions, the motor should respond with slow and fast speeds respectively, if not then replace a new front panel board. C. The Potentiometer is damaged. (a) Detach the CN2 connector, measure Pin 1 & 2. (b) Rotate the weld speed variable resistor's and check if the resistance is changing. If not, please replace VR1. D. Foot switch is damaged. While measuring the female plug between Pin 1 & 2, step on the footswitch, make sure the resistance of the potentiometer having a 0~10KΩ variation, if no proper variation, replace a new potentiometer. Weld Timer not functioning The Welder does not start A. T1 timer is damaged. (a) Switch to "Auto" position and step on the footswitch. (b) Check T1 the motion window of the timer, the "UP" signal should lit, if not, please replace a new relay board. B. T1 the timer is unable to halt the operation properly. (a) Detach the J1 connector, measure Pin 1 & 2. (b) Rotate the timer variable resistor's and check if the resistance is changing. If not, please replace VR2. A. Weld/Test switch is damaged. Switch to "Test" position and check if D10 illuminates, if not, please replace a new front panel board. B. Relay board is damaged. Switch to "Test" position and check if D10 illuminates, if yes but has no action, please replace a new relay board. 8

15 3.2 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE / REMEDY A. The ground cable is loose or breaks. Check the ground cable connectors for adjustment. The arc cannot start for welding. B. Current collection carbon has loose contact. Check the current collection carbon. C. The circuit of welding torch switch works abnormally. Check the cable of the CM4 plug. A. The motor has no power. Check the power. The tilt cannot move or over tilt. B. The reducer is damaged. Change the reducer. C. The location of the limit switch is incorrect or breaks down. Adjust to the correct location or change the switch. 9

16 4.1 PARTS LIST MACHANISM Fig. No. Part No. Description Q ty. Remark T-nut 4 M Shaft 1 3 * Rotation-drive pinion * Worm reducer * Gear reducer 1 5GU 5KB 4-3 * PMDC motor (with cable) 1 DC24,100W 5 * Bearing Tilting-drive pinion ** Worm reducer 1 PT ** Gear reducer 1 PT ** PMDC motor (with cable) 1 PT ** Worm reducer 1 PT-450M ** Handle 1 PT-450M Angle base plate 1 10 * Bearing Precision self-locking nut Angle base plate 1 13 * Self lubricating bearing 2 *Recommended spare parts **Option 10

17 4.1 PARTS LIST MACHANISM 11

18 4.2 PARTS LIST MACHANISM (GROUNDING) Fig. No. Part No Description Q ty. Remark 1 * Carbon brush 1 2 * Spring PE plastic body Hex cap screws (cupper) Washer cupper 2 6 * Terminal Hex nut cupper 1 8 * Grounding 1st * Recommended spare parts **Option 12

19 4.3 PARTS LIST CONTROL BOX ( FORNT ) Fig No. Part No. Description Q ty Remark 1 ** Relay 2 PT * Motor speed control 1 Motor Control 3 * Relay board 1 Relay board Front panel board 1 Front panel board Knob blue 2 Knob 6 * Power supply 1 PS E.S Push button 1 E-Stop Potentiometer 1 VR1(10KΩ) Potentiometer 1 VR2(1MΩ) Push-Button switch 1 PB1 *Recommended spare parts **Option 13

20 4.4 PARTS LIST CONTROL BOX ( REAR ) Fig No. Part No. Description Q ty Remark 1 ** Male connector socket 4pin 1 CM7(PT-450) 2 ** Male connector socket 2pin 1 CM6(PT-450) 3 * PCB I/O board 1 I/O Board 4 ** Toggle switch 1 SW3(PT-450) 5 * Fuse 3A 20mm 1 Fuse Power entry module 1 SW1 7 * Motor With cable & connector Foot switch ass y cable 1 Foot switch ass y Power cable 1 Power cable *Recommended spare parts **Option 14

21 5.1 CONTROL SYSTEM DIAGRAM 15

22 5.2 DIAGRAM - TILTING CONTROL BOX ( PT 450 ) 16

23 APPENDIX:WIRING DIAGRAM 17

24 REVISIONS Manual number Print data RD-8450 RD-8450E May. 14, 2016 Aug. 05, 2016 RD-8450E RD-8450E Nov. 30, 2016 Mar. 14, 2017 Changed page Revisions RD-974FE RD-8450 For PB1 4.3 (P13) Revised No Revised No Adding No (P14) Revised No Appendix (P17) Revised circuit 4.2 (P12) Adding No (P10) Revised No