ProArc PT-502 User manual

OWNER’S MANUAL
Important
：
Read these instructions before installing, operating or servicing this product.
POSITIONING SYSTEM AND ACCESSORIES
MODEL
：
PT– 502 / PT– 502M
DIGITAL WELDING POSITIONER
Serial Number
：
202003 ~ and later
Revised Date
：
Feb. 24th , 2020
UNITED PROARC CORPORATION
No. 3 Gungye 10th Road, Pingjen Ind. Park Tel No：88634696600
Pingjen City, Taoyuan 324, Taiwan Fax No：88634696969
http://www.proarc.com.tw E-Mail：[e-mail]
RD-8465AE

TABLE OF CONTENTS
Introduction
General information
Operation instruction
Service
Parts list
Circuit diagram
Instruction............................................................................................................i
Safety precautions..............................................................................................ii
Limited warranty.................................................................................................iii
1.1 Introduction...................................................................................................1
1.2 Specifications ...............................................................................................2
2.1 Control panel................................................................................................3
2.2 Installation....................................................................................................4
2.3 Operation......................................................................................................5
2.4 Display operation..........................................................................................7
2.5 Timing diagram.............................................................................................8
3.1 Maintenance.................................................................................................9
3.2 Troubleshooting guide.................................................................................11
4.1 Parts list - machine......................................................................................13
4.2 Parts list – machine (Ground)......................................................................15
4.3 Parts list - control box..................................................................................16
5.1 Main control circuit diagram.........................................................................17
5.2 Tilting control circuit (PT-502)......................................................................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.
Furnish complete information concerning damage claims or mistake(s) in
shipment to United ProArc Corporation: No. 3 Gungye 10th Road, Pingjen Ind.
Park, Pingjen City, Taoyuan 324, Taiwan. Include the equipment identification
number along with a description of the parts in question.
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

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
LIMITED WARRANTY
UNITED PROARC CORPORATION warrants all new equipment to be free from defects in material and
workmanship, provided that the equipment is installed and operated according to instructions stated in this
manual.
UNITED PROARC’s obligation under this warranty policy is expressly limited to the replace or repair, at its
option, of the defected part only. ProArc’s option to repair or replacement of a defected part under this
warranty shall be based on FOB Taiwan basis.
The warranty period begins on the date of sale to the original-purchase user of the equipment.
UNITED PROARC CORPORATION shall not be liable for any loss or consequential damage or express
accruing directly or indirectly from the use of equipment covered by this warranty.
This warranty supersedes all previous ProArc warranties and is exclusive with no other guarantees or
warranties expressed or implied.
This warranty excludes the consumable parts that are used in normal operation.

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1
1.1 INTRODUCTION
Instruction
Main features
﹡Welding positioner is used in the rotating and welding of the pipe or
round work pieces.
﹡It can be applied with 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 φ25 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- 502 / PT- 502M
Power Input ~ 1 Phase 110V/220V 50/60Hz
Capacity (Horizontal) kg 500
Rated Centre of gravity mm 200
Rated eccentricity
mm
100
Table diameter
mm
450
Rotation speed rpm 0.12 ~ 2.0
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
135

3
2.1 OPERATION PANEL
1. LED Display
2. Stop button
3. Pulse knob with push button function.
4. Power switch (PSW)
5. CW/CCW selection switch (SW1)
6. Power On signal (LED)
7. Weld / Test mode selection switch (SW4)
8. Weld / Rapid speed selection switch (SW3)
9. Auto / OFF/Move mode selection switch (SW2)
10.Power source connector (P2)
11.Foot switch connector (P1)
12.Tilting control switch (SW5 / PT-502)

4
2.2 INSTALLATION
Power cord.
Connect the power cord to 1 phase 100V~240VAC
Grounding Stud.
To avoid potential electrical damage, please connect the grounding stud to actual ground.
Tilt Lock/Release Handle.
Clockwise rotation to lock, counter clockwise rotation to release.
Danger! Do not release the tilt handle when part is loaded on the faceplate.
(PSW) Power Switch.
I = On，O = Off
LED Indicator Color Identification.
Green：Standby.
Red：Stop button activated.
White：Auto-procedure in progress.
Flashing Green：Homing sequence in progress. (Options)
Flash Red：Overload.
Forward / Reverse Switch (SW1)
Faceplate rotation direction.
CW ( ) / CCW ( )
Forward
Reverse

5
2.3 OPERATION
WORK / OFF / MOVE Toggle Switch (SW2)
WORK：Enable the system in “WORK procedure” standby. Press/release the footswitch to start “WORK
procedure”. Faceplate rotates according to parameter setting (RPM and welding angle)
OFF：Reset error and stop work procedure.
MOVE：Enable the system in “MOVE” procedure standby. Press the footswitch to start the rotation, and
release footswitch to stop the rotation. Rotation speed varies according to parameter
NORMAL / RAPID Toggle Switch (SW3)
NORMAL：Faceplate rotation speed varies according RPM setting.
RAPID：Faceplate rotates with maximum speed.
WELD / TEST Toggle Switch (SW4)
WELD：Welder output (P2) will be enabled when faceplate start rotating in either WORK or MOVE (SW2)
procedure.
TEST：Welder output (P2) is disable in WORK/MOVE procedure.
Note：Welder output (P2) Type：Relay dry contact.
STOP Button
Press to stop the all control. Rotate CW/Pull to reset.
Homing Sequence (Option)
Homing sequence activates automatically when below condition are met.
A. Right after placing WORK / MOVE toggle switch (SW2) in WORK position.
B. 2 seconds after end of “WORK procedure”.
C. Flipping Forward/Reverse (SW1) switch in “WORK procedure” standby.
D. Reset the STOP button in “WORK procedure” standby.
Note：Homing sequence is divided into 2 stages. Faceplate first rotates in half of maximum speed until
home sensor is triggered and stops. Then faceplate rotates according to RPM rotation speed
setting to trigger the home sensor again. Problem may rise in second stage when RPM rotation
speed is adjusted too small.
Warning：Homing sequence is a semi-automatic process that activates when above conditions
are met. Operator caution is advised.

6
2.3 OPERATION
Variable Speed Foot Switch.
Variable foot switch change welding speed as a percentage of RPM rotation speed. Example1, Set weld
speed knob 100% and external variable foot switch 50%, the resulting rotation speed is 100% x 50% =
50%. Example2, Set weld speed knob 50% and external variable foot switch 50%, the resulting rotation
speed is 50% x 50% = 25%.
Tilting Control Switch. (SW5 / With PT-502)
Table Tilting Up/Down switch.

7
2.4 DISPLAY OPERATION
= Pulse knob on the operation panel. Press to switch and set parameters. Rotate to change and
modify display
After modifying the speed, the operator is required to step/press the footswitch to save the parameter.
The parameter is default to last value if the operator reboots the system without press/step on the
footswitch.

8
2.5 TIMING DIAGRAM (CB-104D With SENSOR)
CB-104D HOMING SEQUENCE

9
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.

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3.2 TROUBLESHOOTING GUIDE
SYMPTOMS POSSIBLE CAUSES / REMEDIES
Power indicator LED does not
illuminate.
A. Blown fuse：Check the fuse, replace fuse when necessary.
B. Input power switch malfunction
：
Check and replace the power
switch.
C. Check for any loose cable connection between Control Board
and Switch Board.
D. LED malfunction, replace Switch Board.
E. Power supply malfunction, use a voltmeter and check power
supply’s 24VDC output.
Motor has no motion.
A. Damaged motor：Use ohmmeter to measure CM1 female plug
pin1 & Pin2 and It should read around 2ohm. Replace motor
when reading is either 0 (short circuit between wires) or infinite
(broken wires)
B. Check motor power cable for loose or disconnect cable
C. Damaged foot switch：Step on the footswitch and use an
ohmmeter to measure footswitch connector pin4 and pin5. The
reading should be 0 (short circuit). Replace the footswitch when
necessary.
D. Inspect Control Board JP2 for loose connection.
E. Inspect Control Board fuse F1.
Welder start output no response.
A. Damaged Weld / Test toggle switch (SW4), replace Switch
Board.
B. Inspect Control Board JP3 for loose connector.
Forward / Reverse rotation function
no response.
A. Switch Board：Step on the footswitch and flip the CW/CCW
toggle switch (SW1). Observe the TR and TL LED on the
Control Board. If both LEDs have no response, replace the
Switch Board.
Display Problem
A. Display malfunction.
B. Inspect cable between Switch Board and Display JP1 connector
for any loose connection.
Overload (Blinking Red LED) Inspect the work and make sure it isn’t over-spec ( weight / eccentricity..etc ). Place the Work / Move switch (SW2) in “OFF”
position to reset the system.

12
3.2 TROUBLESHOOTING GUIDE
SYMPTOMS POSSIBLE CAUSES / REMEDIES
Home sequence problem
A. Work / Move switch (SW2) malfunction, replace Switch Board.
B. If the green LED is flashing and there is no rotation, place the Work /
Move switch (SW2) in “Move” position and adjust the rotation speed
setting to desired speed. Restart the homing sequence.
C. Proximity switch too far：Adjust the proximity switch so it can sense
the homing block correctly.
D. Proximity switch malfunction：use a screwdriver to test trigger the
proximity switch. Replace when necessary.

13
4.1 PARTS LIST ―MACHANISM
Item.
Part No.
Description
Q’ty.
Remark
1 0127-0002 T-nut 4 M12
2
5014-1210000-11
Faceplate
1
3 5014-1220000-11 Rotation drive pinion 1
4
5014-1240000-10
Shaft
1
5 5014-3230000-40 Pinion Cover 1
6
＊
5014-1230000-20 Rotation-drive pinion 1
7
0305-1001
Bearing
1
8 5014-3210000-40 Gear box 1
9
0305-0801
Bearing
1
10 0120-0004 Precision self-locking nut 1
11
＊
0353-0317 Worm reducer 1 PT-502/PT-502M
＊
0351-0706
Gear reducer
1
PT-502/PT-502M
＊
0361-1107-9 PMDC Motor w/Cable terminals 1 PT-5020/PT-502M
3169-1224-8
Encoder w/Connector & Cover
1
12 5015-3080010-21 Ground kit 1 Please see 4.2
13 5115-08002104000-21 Front cover 1
14
＊
5014-2220000-31
Tilting-drive pinion
1
15 5014-2210001-30 Drive pinion 1
16
＊
0353-0318
Worm reducer
1
PT-502
＊
0351-0131 Gear reducer 1 PT-502
＊
0361-1005-9 PMDC motor (with cable) 1 PT-502
17
5015-2100000-10
Angle scale
1
18 5014-2250000-21 Indicator 1
19
5014-2230600-10
Angle base plate
2
20 0332-3001 Self-lubricating bearing 2
21 5014-2230200-31 Angle base plate 1
22
5014-2230100-31
Angle base plate
1
23 5014-4200000-32 Column 1
24
6511-0420
Control box
1
Please see 4.3
6511-0440 Control box (w/Sensor)1 Please see 4.3 (Option)
25
＊
0353-0316 Worm reducer 1 PT-502M
5014-2240200-10
Shaft
1
PT-502M
0130-0016 Handle 1 PT-502M
26-1
5014-1120000-20
Proximity sensor plate
1
w/Sensor (Option)
26-2
＊
3231-2007-8 Proximity sensor w/ connector 1 w/Sensor (Option)
26-3
5010-4040002-20
Home sensor assembly kit
1
w/Sensor (Option)
＊Recommended spare parts