PORTA-TRAC. Portable Flame Cutting Machine INSTALLATION AND OPERATION INSTRUCTIONS

Transcription

1 ADI 3046-B Certified ISO 9001 PORTA-TRAC Portable Flame Cutting Machine INSTALLATION AND OPERATION INSTRUCTIONS Before Installing or Operating, Read and Comply with These Instructions Controls Corporation of America 1501 Harpers Road Virginia Beach, VA To Order Call or Fax January 2003 Supersedes July 1992

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3 INTRODUCING We are very happy you have chosen the Porta-Trac. The machine which you have purchased is a model in whose ability we have much confidence. It can be used for various applications including cutting and welding and will surely contribute to efficiency and saving of labor in your shop. We would like to ask you to operate the machine properly so that you can use it for a long time. Please read through this manual carefully before start of operation, and always keep your machine in the best condition. PRE-OPERATION Flat space used for various purposes including welding, plasma cutting, heating and flaw detection. Speed control knob giving commands correctly and precisely. East-to-see scales indicate, in colors, values obtained from actual measurements. For easy observation of the wheel position, the upper portion of the body has been cut off. The tip support prevents damage of the nozzle and allows easy storage (cutting only). Pilot lamp tells you whether the power is on or off. Heat insulating plate and bottom plate made of ceramic fiber. Large clutch handle assuring quick response. Auxiliary wheel mount specially added for four-wheel drive. -3-

4 PRE-OPERATION: HANDLING PRECAUTIONS All the parts of the machine have passed strict testing and they are carefully assembled to prevent trouble or failure of the machine. However, an unexpected accident might happen. We would like you to take the following precautions: 1. The machine body is made of aluminum alloy for light weight. It is susceptible to violent impact. Take care not to drop anything onto the machine body, nor to drop the machine itself during transport. 2. Be sure to adjust the speed when the motor is running. 3. In changing the speed, first put the control to a point where the speed is a little lower than the setting at which you are going to set the speed. 4. Be careful because trouble will occur if the machine is operated on a voltage fluctuation over ±10%. 5. Always keep the surface of the rail clean. Especially, clean the portion of the rail along which the wheel moves (to prevent damage and knocking of the drive wheel and idle wheel). PREPARATIONS FOR OPERATION 1. Remove the machine body from the carton carefully, and put it on the rail. 2. Assemble parts on the machine body in the correct order referring to Parts List. 3. If you are going to use the machine for gas cutting, attach the tip support on the machine body, using the two hexagon bolts. 4. Be sure to put the machine switch to the neutral position before connecting to the power source. 5. Connect the power connector to the machine body, and connect the rubber plug to AC. Make sure that the power lamp is lit. (Put the clutch to the STOP position, and put the switch to the neutral position.) 6. Setting the cutting speed. (Put the motor switch to the ON position and put the clutch to the STOP position to prevent wear of the ring.) While observing the speed meter, slowly turn the speed control knob to the set speed. 7. Ascertain that the rail is properly aligned by putting the rail in parallel with a marking line and manually travelling the carrier or using a jig. Considering the thermal effect on the rail, the distance between the rail and cutting line should be more than 100mm (4"). 8. For easy work, bundle the hoses and cabtyre (power) cords with tape. FOR CUSTOMERS OF THE PORTA-TRAC 1. The machine is designed with emphasis on simplicity, heat resistance, and durability of the mechanism. 2. Always operate the machine according to correct procedures. 3. Be careful never to operate the 100/120V machine on 200V. 4. For prevention of an accident, connect the earth ground wire, attached to the cabtyre cord, to a ground using the clip. Cutting is done in the following directions: Reverse Forward -4-

5 FEATURES 1. Excellent handling. 2. Excellent heat-resistance and durability. 3. Strong drive force. 4. Stable travelling is assured because the center of gravity is properly balanced. 5. A compact highly efficient motor developed from many years of research and study is used as the drive motor. It has high resistance to heat and long durability. 6. The transmission mechanism consists of parts designed to met requirements in no-load operation for more than 5,000 hours. 7. The sides of the machine have heat shielding plate construction. The temperature of machine surface rises gradually as compared with other models. So, the Porta-Trac can be easily carried after long time use. 8. A heat shielding plate is used as the bottom plate. 9. The mechanism is simplified for easy maintenance. 10. The speed is not affected by temperature rise. SPECIFICATIONS Weight 11.0 kg (25 lbs.) Overall length 430 mm (17") Machine width 170 mm (7") Wheel Distance Motor Type Power source Current Speed Capacity Reduction gear Travelling speed Speed matter Maximum loading weights Attachments 160 mm (6 1 2") drive wheel-idle wheel Condenser type induction motor 100/120V AC and 200/240V AC 0.2 A at 100/120V AC. 0.1 A at 200/240V AC 1500 r.p.m./1800 r.p.m. without load applied 50/60 Hz, 9/10 W Double cone system Standard type: mm/min (for 50 Hz) (3" - 31") mm/min (for 60 Hz) (4" - 39") Conversion scale 50 kg (110 lbs.) One cabtyre cord (5M) (200") (3P for 100/120V and 4P for 200/240V) One tip support Two hexagon bolts CONSTRUCTION Composition The Porta-Trac consists of the case, motor, condenser, transmission mechanism, electricals, speed meter, handle, wheels, etc. -5-

6 Drive System The motor, transmission unit and reduction gear unit are made into one block, and are supported by ball bearings. The motor disk is attached to one end of the motor shaft, and a fan is fixed to the other end. Thus, the motor shaft is efficiently used. The ball bearings are sealed with special heat resistant grease, and this makes it unnecessary to lubricate the motor. The motor has heat insulating construction. Even if the machine temperature is raised by external heat, the motor r.p.m. is not affected at all. The transmission unit causes the drive wheel to rotate at a constant speed. The double cone stepless speed control system, which has never been mounted on other machines of this type, is employed. This speed control system assures great speed change despite its compact size. The standard variable speed range is mm/min. (3" 31") for 50 Hz and mm/min. (4" 39") for 60 Hz. If the speed adjusting handle is turned with fingers, the drive wheel continues to rotate at a constant speed whichever speed in the above range is selected. Reduction Gear Mechanism 1. Reduction greats are made of special heat resistant Bakelite, and the worm gear is employed at the last stage of the reduction hear unit. So, gear noise, vibration and knocking are eliminated. 2. The special pin type clutch can be smoothly engaged. 3. The drive wheel is knurled to prevent slippage and assure high traction force. Transmission Mechanism A conventional transmission (see figure) varies speed by the illustrated friction mechanism. This causes excessive wear and speed instability due to the large contact area of the rotating disks, where the area of contact is subjected to continual slippage except at an average radius distance. The Porta-Trac uses a cone-shaped disk to concentrate the frictional area to minimize slippage and speed instability. Thereby extending the performance life and efficiency of the transmission mechanism. Conventional Transmission Drive Wheel Drive Wheel Idle Wheel Idle Wheel -6-

7 MAINTENANCE To disassemble the machine, follow the steps below: 1. Remove the heat shielding plates on the sides of the machine. 2. Remove the bottom plate. 3. Remove the stand. 4. Remove the four counter-sunk head screws. Then, the case and the reduction gear and transmission mechanism can be removed. Perform the following periodic maintenance and inspection to keep the machine in the best condition. Daily Maintenance and Inspection 1. Wipe off stains on the machine with clean cloth. (Especially, clean the speed graduation plate and panel plate.) 2. Lubricate the wheel shaft for the idle wheel unit. 3. Wipe the circumference of the drive wheel and idle wheel with cloth containing oil. Monthly Maintenance and Inspection 1. Lubricate the speed adjusting handle shaft and clutch handle. 2. Check electrical resistance of AC connector insulation. Set switch to forward or reverse direction. Measure resistance between each AC pin to the metal case (plug removed). Electrical resistance should be greater than 5 MHz. 3. Remove the bottom plate. Remove dust and dirt on the electrical parts inside the machine. Maintenance and Inspection at Interval of Three Months (2,000 hours) 1. Disassemble the transmission from the motor. Wash old grease inside the gear box with kerosene and add new oil if necessary. 2. Replace parts inside the machine if they are excessively worn. 3. Wipe out oil substances on the motor disk and ring cone of transmission using thinner. Worm Wheel Worm Transmission Shaft Motor Fan Driving Wheel Driving Axle Friction Adjustment Mechanism Double Cone Stepless Speed Control System -7-

8 TROUBLESHOOTING 1. Machine will not move. (Motor will not run.) Power is off Possible Cause Procedure Remedy Check power source and wire connection Broken power cord Check the cord with tester Repair broken wire. Replace if necessary. Defective plug Check soldering of wires. Perform soldering. Defective power lamp Defective switch Remove connector. If tester indicates " " when it is applied to 2-1 and 5-4 with the switch put to the forward position, or when tester is applied to 2-3 and 5-6 with the switch put to the forward position, the switch is defective. Defective condenser Condenser is normal if tester applied to condenser separated from other units fluctuate a little and then immediately indicates " ". If not, condenser is defective. Replace Replace (refer to wiring diagram). Replace Defective soldering Check soldered parts. Perform soldering again. Broken lead wire Defective motor 2. Machine will not move. (Motor runs.) Check lead wire with tester. If tester indicates " ", lead wire is broken. If the above are normal, cause lies in motor. Replace Repair or replace. Possible Cause Procedure Remedy Clutch will not work Slippage on frictional surface 3. Machine moves but is abnormal. Remove stand and ascertain that connecting bar is connected to lever screw. See that pressure adjusting spring is working and that there is no oil sticking to frictional surface. Mount clutch properly. Replace if spring is defective. Remove oil, using thinner, if frictional surface is stained with oil. Trouble Possible Cause Remedy Speed cannot be controlled Pinion directly connected to handle is idle or gears or knock Repair or replace. pin is damaged. Too great noise and vibration 1. Gears are clogged with a foreign object. 2. Wear of gears 3. Defective motor 4. Wear or damage of cone Repair or replace. Replace. Repair or replace. Replace. -8-

9 Trouble Possible Cause Remedy Clutch will not disengage 1. Snap ring for clutch pin is dislocated. Replace. Knocking is caused Connection of Wires After Repair 1. Wear of gears 2. Faulty clutch pin 3. Wear of clutch key groove 4. Improper contact between shaft and drive wheel 5. Wear and damage of cone 6. Heat shield is in contract with rail or steel plate. 7. Foreign object or damage on rail groove 8. Hose and cabtyre cord interferes travelling 9. Defective idle wheel unit 10. Damage or foreign object on drive wheel or idle wheel Replace. Replace. Replace. Repair or replace. Replace. Adjust. Adjust and repair. Use care. Repair or replace. Repair or replace. 1. If the motor will not run, check the wires. 2. If the motor rotates in the opposite direction (reverse direction), exchange connection of the motor lead wires. -9-

10 WIRING DIAGRAM Green 25ø3P Metal Connector (100/120V AC) Motor (100V/120V) Black Black Pilot Lamp Red Red Brown Forward/Reverse Switch Black Black Condenser (100V, 18µFX2) Condenser (120V, 1.5µFX2) 3P Poly-Block Green 25ø4P Metal Connector (200V AC) Motor (200V) E (Earth) Pilot Lamp Red Forward/Reverse Switch Red Red Brown Yellow Gray Black Black 4P Poly-Block 2µF Condenser -10-

11 Warranty Information This equipment is sold by CONTROLS CORPORATION OF AMERICA under the warranties set forth in the following paragraphs. Such warranties are extended only with respect to the purchase of this equipment directly from CONTROLS CORPORATION OF AMERICA or its Authorized Distributors as new merchandise and are extended to the first Buyer thereof other than for the purpose of resale. For a period of one (1) year from the date of original delivery (90 days in corrosive service) to Buyer or to Buyer s order, this equipment is warrantied to be free from functional defects in materials and workmanship and to conform to the description of this equipment contained in this manual and any accompanying labels and/or inserts, provided that the same is properly operated under conditions of normal use and that regular periodic maintenance and service is performed or replacements made in accordance with the instructions provided. The foregoing warranties shall not apply if the equipment has been repaired: other than by CONTROLS CORPORATION OF AMERICA or a designated service facility or in accordance with written instructions provided by CONTROLS CORPORATION OF AMERICA, or altered by anyone other than CONTROLS CORPORATION OF AMERICA, or if the equipment has been subject to abuse, misuse, negligence or accident. CONTROLS CORPORATION OF AMERICA s sole and exclusive obligation and Buyer s sole and exclusive remedy under the above warranties is limited to repairing or replacing, free of charge, at CONTROLS CORPORATION OF AMERICA s option, the equipment or part, which is reported to its Authorized Distributor from whom purchased, and which if so advised, is returned with a statement of the observed deficiency, and proof of purchase of equipment or part not later than seven (7) days after the expiration date of the applicable warranty, to the nearest designated service facility during normal business hours, transportation charges prepaid, and which upon examination, is found not to comply with the above warranties. Return trip transportation charges for the equipment or part shall be paid by Buyer. CONTROLS CORPORATION OF AMERICA SHALL NOT BE OTHERWISE LIABLE FOR ANY DAMAGES INCLUDING BUT NOT LIMITED TO: INCIDENTAL DAMAGES, CONSEQUENTIAL DAMAGES, OR SPECIAL DAMAGES, WHETHER SUCH DAMAGES RESULT FROM NEGLIGENCE, BREACH OF WARRANTY OR OTHERWISE. THERE ARE NO EXPRESS OR IMPLIED WARRANTIES WHICH EXTEND BEYOND THE WARRANTIES HEREINABOVE SET FORTH. CONTROLS CORPORATION OF AMERICA MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE EQUIPMENT OR PARTS THEREOF. -11-

12 ADI 3046-B Certified ISO 9001 Controls Corporation of America 1501 Harpers Road Virginia Beach, VA To Order Call or Fax