Iso PT-450 User manual

OWNER’S MANUAL
Important：Read these instructions before installing, operating or servicing this product.
MODEL: PT‒450 / PT‒450M
WELDING POSITIONER
Serial number：1506003 ~ and later
Revised date：May. 14th , 2015
RD-8450E

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 ................................................................................................1
1.2 Specifications.............................................................................................2
2.1 Operation panel..........................................................................................4
3.1 Maintenance...............................................................................................6
3.2 Troubleshooting guide................................................................................7
4.1 Parts list - machine....................................................................................10
4.2 Parts list - machine....................................................................................12
4.3 Parts list - control box (front)......................................................................13
4.3 Parts list - control box (rear) ......................................................................14
5.1 control circuit diagram ...............................................................................15
5.2 Diagram –tilting control box…...................................................................16
Wiring diagram..............................................................................................17
Revision..........................................................................................................18

i
INSTRUCTION
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.
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.
WARNING
WARNING

ii
SAFETY PRECAUTIONS
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.
WARNING

iii
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1
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.

2
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
0.12-2.5
Spindle thru hole
mm
25
Earthing
Amp
200A (Max.400A)
Tilt range
deg.
0-135
Welding timer
sec.
0-60
Overall length
mm
630
Overall width
mm
650
Overall height
mm
625
Weight
Kg
134

3
1.2 SPECIFICATIONS

4
2.1 OPERATION PANEL
Front Panel：
E-Stop：Emergency stop button
PB1：Push button switch with signal
S1：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

5
2.1 OPERATION PANEL
1. Please set the 110 / 220VAC selection switch to the correct position according to the localAC 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.

6
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.

7
3.2 TROUBLESHOOTING GUIDE3.2 TROUBLESHOOTING GUIDE
SYMPTOM
POSSIBLE CAUSE / REMEDY
Power indicator light does not
illuminate
A. Blown fuse.
Check and replace the fuse when necessary.
B. Bad input power switch.
Check and replace the power switch when necessary.
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.
Motor has no motion
A. Motor coil damaged.
Measure CM1 female plug Pin 1 & 2 - if there is 2Ωreading, then
replace a new motor.
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.
Forward / Reverse revolutions not
functioning correctly
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.
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.

8
3.2 TROUBLESHOOTING GUIDE
SYMPTOM
POSSIBLE CAUSE / REMEDY
Can not adjust speed
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.
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
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.
The Welder does not start
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.

9
3.2 TROUBLESHOOTING GUIDE
SYMPTOM
POSSIBLE CAUSE / REMEDY
The arc cannot start for welding.
A. The ground cable is loose or breaks.
Check the ground cable connectors for adjustment.
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.
The tilt cannot move or over tilt.
A. The motor has no power.
Check the power.
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.

10
4.1 PARTS LIST ‒ MACHANISM
Fig. No.
Part No.
Description
Q’ty.
Remark
1
0127-0002
T-nut
4
M12
2
5014-1240000-10
Shaft
1
3
*
5014-1230000-20
Rotation-drive pinion
1
4-1
*
0353-0317
Worm reducer
1
4-2
*
0351-0701
Gear reducer
1
5GU 5KB
4-3
*
0361-1005-9
PMDC motor (with cable)
1
DC24,100W
5
*
0305-1001
Bearing
1
6
5014-2220000-31
Tilting-drive pinion
1
7-1
**
0353-0318
Worm reducer
1
PT-450
7-2
**
0351-0131
Gear reducer
1
PT-450
7-3
**
0361-1005-9
PMDC motor (with cable)
1
PT-450
8
**
0353-0316
Worm reducer
1
PT-450M
**
0130-0016
Handle
1
PT-450M
9
5014-2230100-31
Angle base plate
1
10
*
0305-0801
Bearing
1
11
0120-0004
Precision self-locking nut
1
12
5014-2230200-31
Angle base plate
1
13
*
0332-3001
Self lubricating bearing
2
*Recommended spare parts
**Option

11
4.1 PARTS LIST ‒MACHANISM

12
4.2 PARTS LIST ‒MACHANISM (GROUNDING)
Fig. No.
Part No
Description
Q’ty.
Remark
1
*
5010-2050102-10
Carbon brush
1
2
*
0144-0028
Spring
2
3
5010-2040100-20
PE plastic body
1
4
0106-0803
Hex cap screws (cupper)
1
5
0121-0804
Washer cupper
2
6
*
4000-039046
Terminal
1
7
0123-0802
Hex nut cupper
1
8
*
5015-3080010-21
Grounding
1st
* Recommended spare parts
**Option

13
4.3 PARTS LIST ‒CONTROL BOX ( FORNT )
Fig No.
Part No.
Description
Q’ty
Remark
1
**
3251-4206
Relay
2
PT-450
2
*
6651-0011
Motor speed control
1
Motor Control
3
*
6620-4133
Relay board
1
Relay board
4
6620-1240
Front panel board
1
Front panel board
5
3216-0003
Knob blue
2
Knob
6
*
3328-0003
Power supply
1
PS
7
3214-2009
E.S Push button
1
E-Stop
8
3747-1001
Potentiometer
1
VR1(10KΩ)
9
3747-1002
Potentiometer
1
VR2(1MΩ)
11
3271-3002-8
Push-Button switch
1
PB1
*Recommended spare parts
**Option

14
4.4 PARTS LIST ‒CONTROL BOX ( REAR )
Fig No.
Part No.
Description
Q’ty
Remark
1
**
3124-2005
Male connector socket 4pin
1
CM7(PT-450)
2
**
3124-2003
Male connector socket 2pin
1
CM6(PT-450)
3
*
6620-4311
PCB I/O board
1
I/O Board
4
**
3213-1001
Toggle switch
1
SW3(PT-450)
5
*
3226-2003
Fuse 3A 20mm
1
Fuse
6
3331-2001
Power entry module
1
SW1
7
*
0361-1005-9
Motor With cable & connector
1
8
3242-1003
Foot switch ass’y cable
1
Foot switch ass’y
9
3445-0001
Power cable
1
Power cable
*Recommended spare parts
**Option