Bancroft TT-100 Installation manual

WELDING POSITIONER
OPERATION MANUAL
MODEL TT-100 V1.0
Carefully read and understand t ese operation instructions before operating,
inspecting, or servicing t is product.
T is manual for use wit Serial Numbers 001001 and following

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
2
TABLE OF CONTENTS
1. SAFETY INFORMATION……………………………………………………3
2. PACKING LIST………………………………………………………………….4
3. INSPECTION CHECKLIST…………………………………………………..4
4. MACHINE OVERVIEW………………………………………………………5
5. INSTALLATION…………………………………………………………………6
6. OPERATIONS…………………………………..……………….………………7
7. HANDLING MOUNTED OBJECTS……………………………………….8
8. TROUBLESHOOTING…………………………………………………………8
9. DAILY MAINTENANCE……………………………………………………….8
10. WARRANTY…….………………………………………………………………..9
11. ELECTRICAL SCHEMATICS…………………………………………………10
12. PARTS LIST….……………………………………………………………………12

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
3
SAFETY INFORMATION
ELECTRICAL SHOCK CAN CAUSE INJURY OR DEATH
Electrical equipment must be installed and maintained in accordance wit t e National Electrical Code, NFPA 70, and all local codes. Maintain Mig-
Guns, Electrode Holders, Tig Torc es, Plasma Torc es, Work Clamp, Welding Cable, and Welding Mac ines in good, safe operating condition.
Replace worn or damaged insulation. Do not try to repair or service equipment w ile t e power is still on. Do not service or repair equipment
unless you are trained and qualified to do so. T e Electrode and Work (or Ground) circuits are electrically “HOT” w en equipment power is on. At
no time s ould you touc t e Electrode and Electrical Ground at t e same time wit bare skin or wet clot ing w ile t e power is on. Insulate
yourself from work and ground using dry insulation. Keep gas cylinders, c ains, wire ropes, oists, cranes, and elevators away from any part of t e
electrical pat . Always be sure t e work cable makes a good electrical connection wit t e metal being welded. Occasionally c eck all ground
connections to determine if t ey are mec anically strong and electrically adequate for t e current required. T e ground connection s ould be as
close as possible to t e area being welded. W en not welding for any substantial period, make certain t at no part of t e electrode circuit will
accidentally make contact wit t e work or ground.
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Keep smoke, fumes, and gases from your breat ing zone and t e general area. Smoke, fumes, and gases from t e welding or cutting process are of
various types and strengt s. To ensure your safety, do not breat e t ese fumes or gases. Ventilation must be adequate to remove smoke, fumes,
and gases during t e welding procedure to protect operators and ot ers in t e immediate area. Never Ventil te with Oxygen, because oxygen
supports and vigorously accelerates fire.
HOT PARTS
Hot parts can cause serious burns. T e area at and near t e work being welded s ould be andled wit proper gloves. Proper clot ing s ould be
worn to prevent spatter or c ipped slag from causing burns. Never pick up welded material until it as properly cooled.
MOVING PARTS MAY CAUSE INJURY
Have only qualified people remove guards or covers for performing maintenance and troubles ooting. Moving parts suc as gears can maim
fingers or ands and catc loose clot ing. Keep tools, ands, air and clot ing away from moving parts. Be sure to reinstall all panels and guards
before operating equipment.
FALLING EQUIPMENT
Lift only t e unit to be moved wit out any running gear or accessories t at may be attac ed to it. Use equipment of a proper size to lift
and move t e unit. Falling equipment can cause personal injury and equipment damage.
IMPORTANT - Protect yourself and ot ers! Remember t at safety depends on you. T e operator, supervisor, and elper must
read and understand all warning and safety information provided in t ese instructions. Severe injury or de th could result if
equipment is not properly installed, used and maintained. Training and proper supervision are most important for a safe
work place. Installation, operation, repair work, and maintenance must be performed by qualified personnel. Retain t ese
instructions for future use.

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
4
PACKING LIST
Confirm t e supplied items
Before using t is product, confirm all items ordered are included in t e packaging. In t e event an item is
missing, please contact Bancroft Engineering or t e dealer w ere you purc ased t e product.
PRE-SHIP INSPECTION LIST
C ecklist of pre-s ip tests and inspections
Inspection OK Deficient
Comments
Low Speed Confirmation
Hig Speed Confirmation
CW-OFF-CCW Switc Confirmation
1 Hour test run completed
Spindle nut torque confirmed after run
-
in
(13.2 ft-lbs)
Optional Foot pedal test completed
Inspector Initials
ITEM NAME QUANTITY REMARKS
Positioner Main Unit 1
Power Cable 1
Operating Instructions 1 T is Manual
T-nuts & Studs 4 Optional
C uck 1 Optional
Foot Switc 1 Optional
Digital Display 1 Optional

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
5
MACHINE OVERVIEW
T e positioner is designed and intended to elp position a workpiece for steady welding. It rotates a table using a
motor and lets you adjust t e speed and rotational direction using a control dial and 3 position switc . An
optional foot switc can also be used to start/stop t e rotation.
T e table can be set to t e necessary tilt angle using tilt adjustment pull pin.
NEVER ADJUST THE TILT ANGLE WITH WORK RESTING ON THE TABLE! REMOVE ALL MATERIAL
INCUDING ANY WORK PIECE HOLDING BEFORE ADJUSTING TILT ANGLE.
SPECIFICATIONS
Positioner Dimensional Drawings
Horizontal
Vertical
Minimum
Max
Heig t
Eccentricity
Max Load (lbs)
Power Supply
External Dimensions
200
100
12
110V 60Hz AC
0
Table Heig t in Horizontal Position (in)
9.5
Heig t x Widt x Dept (in)
9.5 x 12 x 12
Table Diameter (in)
Table Rotation (RPM)
15.75
Tilt Angle (Degrees)
0 to 90
Center of Gravity
during Max Load (in)
4.0
2.0
44
Weig t of main unit (lbs)
Tilt Axis Heig t (in)
7.25
Allowable welding current (A)
250 @ max rpm

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
6
INSTALLATION
1.
Confirm t e packaged components (See Packing List, page 4)
2.
Installation Location
a.
Well-ventilated location. Fumes and gases must be ventilated during welding.
b.
Flat surface t at is strong enoug to support t e weig ts of t e mounted items and t e
positioner. If t e surface or floor is weak, unbalanced loads may cause t e positioner to fall over.
c.
DO NOT PLACE THE POSITIONER IN THE FOLLOWING LOCATIONS
i.
ANY LOCATION SUBJECT TO WATER
ii.
LOCATIONS SUBJECT TO HIGH TEMPERATURES
iii.
LOCATIONS NEAR DANGEROUS INFLAMMABLE OBJECTS
iv.
LOCATIONS WHERE WELDING SPARKS AND SPATTERS MAY CAUSE FIRE
3.
Equipment Installation
a.
Installing t e main unit
i.
Place t e main unit on a flat installation location.
ii.
Secure t e unit by inserting 5/16” or 10mm anc or bolts in t e four oles around t e
base of t e unit.
b.
Connecting t e foot switc (Optional)
i.
Remove protective cap.
ii.
Connect t e cable of t e foot switc to t e mating plug on t e main unit. Secure t e
connection wit t e locking nut.
4.
Eart ground conductor and work lead
a.
Properly connect t e eart ground
conductor on t e positioner main
unit (labeled wit a sticker)
b.
Directly attac t e welding ground
cable/work lead for t e power
supply to t e ground stud on
positioner, and secure it wit a nut.
WARNING: Be sure to connect t e eart ground
conductor to prevent an electric s ock.
5.
Connecting t e Power Supply
a.
Use specified power supply only.
i.
Route t e power supply cable so it will not be stepped on and in a location were not ing
will be placed on top of t e cable.
ii.
Connect t e power supply cable only after confirming t e safety of t e surrounding area.
iii.
Ground t e power supply cable properly, and fully plug into t e receptacle.
iv.
Do not connect t e eart conductor to a conduit, water pipe, or gas pipe.
v.
Supply power only after confirming t e toggle switc is in t e “off” position.

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
7
OPERATIONS
1.
Control Functions
2.
Operational Procedure
This posi ioner is made o con rol TIG welding noise, bu o ensure safe y, use separa e power supplies
for he main uni and he welding power. During opera ion, do no allow he main uni cable and orch
cable o cross each o her.
1 Turn on buildings main power supply and t e power to t e positioner.
2 Adjust t e table angle to desired location.
3 Attac a workpiece to t e table.
4 Set t e rotational speed to 2.
5 Select t e direction of rotation using t e 3 position switc .
6 If optional foot pedal is connected, press pedal to start rotation.
7 Adjust t e rotation speed as needed.
8 Perform welding work.
9 Turn off t e unit.
10 Remove t e workpiece.
Main Unit

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
8
HANDLING MOUNTED OBJECTS
1.
W en attac ing work, always wear proper personal protective equipment including a elmet, protective
glasses, and safety s oes.
2.
Attac and align workpieces properly
3.
C eck t e surrounding area for impediments before starting table rotation.
4.
W en placing a workpiece on t e table be careful not to create a large impact.
5.
Do not place a load exceeding t e max allowable load, t is includes all work olding tooling.
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SOLUTION
Table does not rotate.
1
Power cord is not properly secured
Secure properly
2
Blown Fuse
Replace fuse
3
Power cord damaged
Replace t e power cord
4
Switc or
foot switc malfunction
Replace t e component
5
Faulty control board
Replace t e control board
6
Faulty motor
Replace t e motor
7
Bearing damage
Replace t e bearing assembly
Fuse Blown
1
Faulty control board
Replace t e control board
2
Faulty
motor
Replace t e motor
3
Bad power supply
Replace fuse and try different power supply
4
Power cord damaged
Replace t e power cord
Table does not rotate
smoot ly.
1
Bearing nut is loose
Torque bearing nut to 13.2 ft
-
lbs
2
Bearing damage
Replace t e
bearing assembly
3
Spatter from welding ad ered to
t e gears Clean and apply grease to t e gears
Table will not tilt 1
Tilt adjustment pull pin in engaged
Release t e pull pin by pulling out on t e pull
pin knob
DAILY MAINTENANCE
Inspect table ground for proper tension against table.
Test operation of 3 position power switc
Test operation of optional foot pedal if provided
C eck for any broken wires or loose connections
C eck for any damaged or worn parts

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
9
WARRANTY
LIMITED WARRANTY: Subject to t e terms and conditions ereof, B ncroft Engineering, Waukes a, WI warrants its products
to be free from defects in workmans ip and material at t e time of delivery. B ncroft Engineering will onor warranty claims
on products as a result of failure from a defect for a time period of 90 days from t e date of sale to t e original user. Upon
return of t e merc andise at t e user’s expense, B ncroft Engineering reserves t e rig t to eit er repair or replace as
necessary. T is is t e only warranty eit er expressed or implied covering t is product.

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
10
ELECTRICAL SCHEMATICS (1)
M in Control Bo rd Wiring Di gr m.
Service or repair of t is unit must be done by qualified personnel only.
Before performing any main enance on his con rol board disconnec he uni from any power supply.

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
11
ELECTRICAL SCHEMATICS (2)
Option l Foot Switch Wiring Di gr m.
Service or repair of t is unit must be done by qualified personnel only.
Before performing any main enance on his con rol board disconnec he uni from any power supply.

TT-100 Welding Positioner
Bancroft Engineering, LLC
21550 Doral Road Waukes a, WI 53186
P one: (262)786-1880
www.bancrofteng.com
V1.0
Page
12
PARTS LIST
Table of contents
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