OPERATION MANUAL

RD-8480E

Important：Read these instructions before installing, operating or servicing this product.

MODEL：PT‒200s
WELDING POSITIONER

Serial Number：202103005 ~ Later

Revised Date：Apr. 07, 2021
UNITED PROARC CORPORATION
No. 3 Gungye 10th Road, Pingjen Ind. Park Tel No: 886 3 4696600
Pingjen City, Taoyuan 324, Taiwan Fax No: 886 3 4694499
http://www.proarc.com.tw E-Mail: [email protected]
 MENU

Safety Instruction Instruction................................................................................................................ i

Protection ................................................................................................................ ii
Specification 1.1 Specifications .................................................................................................... 1
1.2 Control Box Specification................................................................................... 2
1.3 Connector .......................................................................................................... 3
Operation 2.1 HMI....................................................................................................................6
2.2 Main Screen ...................................................................................................... 7
2.3 Manual Mode ..................................................................................................... 8
2.4 Auto Mode ......................................................................................................... 9
2.5 Setting ..............................................................................................................10
2.6 Program Save/Load.......................................................................................... 11
2.7 Program Note ................................................................................................... 12
2.8 Welding Sequence Setting ............................................................................... 13
2.9 Welding Current Setting.................................................................................... 14
2.10 Index Weld Setting ......................................................................................... 15
2.11 Autorun Function ............................................................................................ 16
2.12 Password Setting............................................................................................ 17
2.13 Program Backup ............................................................................................. 18
2.14 System Setting ............................................................................................... 19
2.15 System Information......................................................................................... 20
2.16 HMI Update .................................................................................................... 21
2.17 PLC Update .................................................................................................... 22
2.18 Alarm History .................................................................................................. 23
2.19 I/O Monitor...................................................................................................... 24
Troubleshooting 3.1 Error Message .................................................................................................. 25
3.2 Troubleshooting ................................................................................................ 26
Parameters 4.1 PT Servo Amplifier Parameters ........................................................................ 27

Part List 5.1 Part List - PT200s Mechanism .......................................................................... 28

5.2 Part List - HMI and Remote ............................................................................ 29
5.3 Part List - Control Box ..................................................................................... 30

Circuit 6 Circuit ..................................................................................................................31

INSTRUCTION

Read and understand the entire manual regarding the rules for users’
WARNING safety before installing, operating, or servicing the equipment.

A procedure, when not properly followed, may cause injury to the

WARNING operator or others in the operating area.

Equipment Identification 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.
Receipt of Equipment 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 loose spot 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.

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Protection

Operation and maintenance involve potential hazards. All operators and

WARNING personnel should be alerted to possible hazards and precautions should
be taken to prevent possible injury.

Electrical Machine：
﹡ The system’s non-fuse breaker is compatible with its maximum power and main
voltage.
﹡ The connection, single-phase or three-phase, is possible on a stand compatible with
the plug of its cable link.
﹡ To prevent accidental electrical shock, do not leave the ground cable disconnected
when the system’s power is connected to local power network.
Maintenance Work place：
﹡ Be very careful to avoid contact between metal part of 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.
Personal Interventions：
﹡ Before control and repair, see that the apparatus is switch off and electrically
insulated.
﹡ Connection with fixed installation cable is impossible.
﹡ Switch off by fixed connection is multi-polar (phase and neutral).
﹡ 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.

* Check regularly the equipment’s power cords, switch, extension cords’s electrical
insulation and connection and make sure they are in good state
* Maintenance and repairing of cable insulation are important to prevent injury.
* Do request trained personnel for system repair and replacement of defective
accessories.
* Check regularly all electrical connections for any sign of overheating.
﹡ Avoid touching metal area with bear hands..
﹡ Wear safety clothes, gloves, apron, safety shoes and glasses for protection against
welding burns, welding radiation and slag.

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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 SPECIFICATION

MODEL Unit PT- 200s

Power Input ~ 1 Phase 220V 50/60Hz
Capacity (Horizontal / Vertical )(W) kg 200 / 130
Rated center of gravity(S) mm 25
Rotation speed rpm 0.01 ~ 30
Tilt range deg. 0 ~ 120
Earthing amp 300
Overall length (A) mm 530
Overall width (B) mm 315
Overall height (C) mm 690
Center to floor (D) mm 600
Table diameter (E) mm 320
Spindle thru hole mm 22
Table slot bolt size M10
Weight Kg 45

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1.2 CONTROL BOX SPECIFICATION

Control Model Unit CB-500

Power Requirement 1 Phase 220V 50/60Hz 3A

Main power switch

2
1.3 CONNECTOR

Control box connector：

PG1 HMI Box (16Pin) PG3 Start output (7Pin)

PG2 Weld Machine (10Pin) PG4 Foot switch (5Pin)

3
 1.3 CONNECTOR

HMI & Food switch connection：

4
1.3 CONNECTOR

Welding equipment connection：

5
2.1 HMI OPERATION

Emergency stop.

Auto start / Auto stop.

Pulse adjustment knob：

1. Press the pulse adjustment knob to display red flashing cursor beside
Rpm and mm/min. Rotate the knob to modify speed.
2. Press the pulse adjustment knob again to display red flashing cursor
beside Amperage A2(H) & A3(L). Rotate the knob to modify both A2(H)
& A3(L).
3. Press the pulse adjustment knob again to cancel red flashing cursor and
disable online adjustment feature.

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2.2 MAIN SCREEN

Switch language Chinese / English.

Switch to "Manual Mode" screen.

Switch to "Auto Mode" screen

User level 1 clearance is required.
Default user level 1 clearance password：123
Default user level 2 clearance password：456
Refer to section 「2.11 Password」 to disable auto mode password protection.

Switch to "Setting" screen.

Switch to "System Info" screen.

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2.3 MANUAL MODE

Turn table current position:

Foot switch.
Blue field: current position.
direction selection.
Red field: set position.

Turn table rotation per round

Move to set position.
(RPM) setting.

Reset current position to 0. Return to beginning position.

Toggle between
welding/high turn table Manual activate welder.
speed.

Jog operation mode.

1. Hold/release the button
Force dry contact output
to rotate.
ON/OFF.
2. Press to toggle rotation
ON/OFF.

Switch to welding sequence

Turn table jog operation.
screen.

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2.4 AUTO MODE

Turn table current position

according to angle & Turn table current position:
diameter: Blue field: current position.
Blue field: current position. Red field: set position.
Red field: set position.

Turn table linear speed Turn table rotation per round

(mm/min) setting. (RPM) setting.

Welding diameter. Reset current position to 0

Welding current (A).

0~100% = 0~10VDC Simulation/Auto mode toggle.
If pulse mode is active, Welder ON is disable when
represents the peak (A2). Simulation mode is active.
(please refer to sec 2.8)

Second analog voltage Activate/stop auto welding

output. 0~100% = 0~10VDC sequence.

Switch to welding sequence

Turn table jog operation.
screen.

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2.5 SETTING

Switch to Program screen. Switch to Index Weld screen.

Switch to system setting screen.

User level 1 clearance is
required.
Switch to Program note screen. Default user level 1 clearance
password: 123
Default user level 2 clearance
password: 456

Switch to Weld Sequence screen. Switch to Password screen.

Switch to Program Backup

Switch to Weld Current screen.
screen.

Switch to Autorun function screen.

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2.6 PROGRAM SAVE/LOAD

Enter the program number in No. field and press

“Load” button to load the program’s welding
parameter.

Enter the program number and program name, the

press “Save” to save the parameters.

Press or  button to scroll to next/previous sets

of parameters.

Switch to Program note screen.

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 2.7 PROGRAM NOTE

Enter letter or number as program reminder. 10 letters for sh ort field, 24 letters for long field.

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2.8 WELDING SEQUENCE SETTING

T1 Welder ON delay after auto start is activated.

T2 Turn table rotation delay after arc on signal is received.

T3 Dry contact output-1 ON delay after arc on signal is received.

T4 Dry contact output-2 ON delay after arc on signal is received.

Dry contact output-3 ON delay after auto start is activated.

T5
Used for protective gas activation or pneumatic torch lifter.

T6 Welder OFF delay after turn table has reached target program position.

T7 Turn table stop delay after turn table has reached target program position.

Dry contact output-1 OFF delay after turn table has reached target program position.
T8
Also switches off when both T6 and T7 timer are finished.

Dry contact output-2 OFF delay after turn table has reached target program position.
T9
Also switches off when both T6 and T7 timer are finished.

Dry contact output-3 OFF delay after turn table has reached target program position.
T10 Output-3 is not limited by T6 and T7 timer, can be set for longer delay action like welding
protective gas or pneumatic torch lifter.

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 2.9 WELDING CURRENT SETTING

100% amperage value setting (analog output 1).

A1 Initial current (A) Initial current level after arc ON signal is received.
Main welding current. If pulse wave function is enabled, this
A2 Peak current (A)
value is the peak current value.
If pulse wave function is enabled, this value is the low current
A3 Valley(low) current(A)
value. Can’t set more than A2.

A4 Welding crater current(%) Welding ending current.

T1 Initial current time(sec) 0~10 sec, initial arc stabilize time after arc ON signal is received.

T2 Rise current time(sec) 0~10 sec, rise time from initial current A1 to peak current A2

0.01~10 sec, peak current duration before change to valley

T3 Peak current time(sec)
current.
0.01~10 sec, valley current duration before change to peak
T4 Valley current time(sec)
current.
0~10 sec, amount of time current drop from A2 to A4. The count
T5 Current fall time(sec)
starts after welder output is switched off. \

T6 Welding crater time(sec) 0~10 sec, amount of time for crater current.

CH2 Analog voltage(%) Channel 2 analog voltage 0~100% = 0~10VDC.

Note 1: If both T3 & T4 are set to 0, the wave pulse function is disabled.
Caution: Even though pulse wave function’s output voltage can reach a frequency of 50Hz, the
welder may not be able to change current at this rate.

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2.10 INDEX WELD SETTING

Set number of index welding.

a ~ b：Set index welding angle and speed.

b ~ c：Set positioning angle and speed.

Turn table jog operation.

Move to position “b”.

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2.11 AUTORUN FUNCTION

X：Disable feature.
O：Enable feature.

X：Turn table doesn’t wait Arc on feedback signal.

Turn table start rotation T2 sec after welder on signal is active.
1 O：Turn table waits for Arc on feedback signal.
Turn table start rotation T2 sec after receiving arc on feedback.

2 Reset current position to 0 when auto start is activated.

3 Automatically return turn table to original position.

4 Foot switch function: Rotate CW, rotate CCW, Auto Start.

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2.12 PASSWORD SETTING

User level 2 clearance is required.

Default user level 1 clearance password：123
Default user level 2 clearance password：456

User level 1 clearance is required.

Disable auto mode password protection.

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2.13 PROGRAM BACKUP

Export all 100 welding setting and store into USB (does not include
program note).

Import all 100 welding setting and store into system. USB (does not
include program note).

Stop USB function. Activate this function before extract USB.

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2.14 SYSTEM SETTING

Time adjustment. Position setting.

Backlight calibration function. Speed setting.

Touch screen calibration. Maximum rotation speed limitation.

Metric / inch unit setting. Minimum rotation speed limitation.

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2.15 SYSTEM INFORMATION

1. Motor type
2. HMI software version
3. HMI file name
4. PLC software version
5. PLC file name

HMI update function.

PLC update function.

Switch to I/O monitor screen,

Switch to Error History screen.

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 2.16 HMI UPDATE

1. Copy HMI update program (HMI_AutoUP) into USB disk (FAT32 format).
2. Insert the USB disk into USB port behind HMI display
3. Wait for a few second and system would automatically search for HMI AutoUP files
4. Upon Start automatic updata prompt appeared? Select “Yes” to start update
5. Do not unplug USB during update. HMI would restart upon update completion.
6. After HMI reboot, the same update prompt would appear again. Select “NO” this time and unplug the
USB to complete update procedure.

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 2.17 PLC UPDATE

1. Copy PLC update program(CB500PT01.dvp) into a USB disk (FAT32 format).

2. Insert the USB disk into USB port behind HMI display.
3. Press ”PLC download” button, and a keypad is shown
4. Enter the password
5. Press ”YES” in the following prompt to download the PLC program
6. Success or failure message is displayed afterward.

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 2.18 ALARM HISTORY

1. Alarm history record up to 1000 system error. The history can’t be deleted.
2. Left most column「O」indicates the moment error appears,「X」indicates the moment error is reset.
3. Second/third column is the time and date of occurred error.
4. Forth column is the error content.

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2.19 I/O MONITOR

System I/O status, For troubleshooting/installation purpose.

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3.1 ERROR MESSAGE

1. Alarm window appears whenever a system error/problem has occurred.

2. Reset button：
Clear the system problem first before pressing reset button. Reset button only attempts to reset system
error. If problem is still present while pressing the reset button, the window could reappear immediately
after.
Servo error can only be reset by power off/on.
3. Closing the Alarm window without reset：
Pressing alarm window’s “close” icon without reset disables the alarm window. A red square would
appear in lower left corner indicating the error is still present. Pressing the red square would activate the
alarm window again.

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3.2 TROUBLESHOOTING

Error Code Error Message Description

PLC battery voltage is too low, malfunctioned, or absent

1. Check if PLC’s battery LED indicator on front cover is flashing.
2. Check if PLC’s battery is absent.
Solution: Replace/Add battery A.S.A.P.
M480 PLC Low Battery
Note: The error message can’t be disabled before the battery
problem is fixed, but the system is still functional.
Do not shut off power before the battery is replaced to prevent
data loss.

Insufficient DC24V supply voltage.

1. Measure and check the DC24V supply voltage. If insufficient,
M481 PLC 24VDC Low
check circuitry/sensor for any short circuit.
Note: This message only appears as warning.

PLC Program has error

1. Reset the error. If the system can’t be reset, shut the power
down for 5 seconds and restart.
M482 PLC Program Error
2. If error still persists, please contact the manufacturer.
3. Note: Usually caused by some calculation division by 0. Please
check any parameter that’s set as 0.

E. Stop activated.
M484 Emergency Stop 1. Reset Emergency Stop button.
2. Check PLC _ Input _ X07 circuitry.

Turn table servo motor alarm

1. Reset the error.
2. If error can’t be reset, open the control box cover and check
the servo error code on the amplifier LED display. Refer to the
M487 Servo motor alarm
servo motor manual for any information. Usually caused by
loosen connector or system collision.
If error can’t be reset, power off for 10 second and power ON
again. If error still persists, contact the manufacturer.

Arc ON signal time out.

1. After torch ON signal is activated, the system would wait 5
second for Arc ON signal. If this signal is not received, the
error is shown.
M492 Arc on failure 2. If the welder doesn’t have Arc ON signal, go to system setup
to disable this function. (Refer to section 2.15)
3. Inspect welder’s Arc ON signal cable, or check
PLCInputX10 circuitry
4. Check the torch, tungsten, and welding accessories.

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4.1 PT SERVO AMPLIFIER PARAMETERS

No. Parameter Setting

1 P1-00 0002
2 P1-01 0100
3 P1-44 192000
4 P1-45 360
5 P2-10 0101
6 P2-11 0100
7 P2-14 0100
8 P2-15 0100
9 P2-16 0100
10 P2-17 0100
11 P2-18 0101
12 P2-19 0105
13 P2-20 0109
14 P2-21 0007
15 P2-22 0103

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5.1 PART LIST ― PT-200s (MECHANISM)

Item. Part No. Description Q’ty. Remark

1 0312-0501 Shaft 2
2 0331-2003 Self-lubricating bushing 2
3 * 0353-0356 Worm reducer 1
4 * 0364-0206 Servo Motor 1
5 3053-1002 Tilting hand wheel 1
6 5010-1010100-10 Faceplate 1
7 5010-2040010-20 Grounding brush w/ conducting seat 1
8 5012-2350000-20 Tilting worm shaft 1
9 5012-2360000-22 Tilting worm reducer 1
10 5114-12305104000-10 Reducer flange 1
* Recommended spare parts

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5.2 PAT LIST ― HMI BOX

Item. Part No. Description Q’ty. Remark

1 2505-0022-01 HMI & Software 1

2 3214-2009 E.S Push button 1
3 3271-2005 Push button 1
4 3216-0004 Knob 1
3169-1223 Rotational with switch encoder 1
＊ Recommended spare parts

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5.3 PART LIST ‒ CONTROL BOX (INTERNAL)

Item. Part No. Description Q’ty. Remark

1 3013-0006 Analog output module 1

2 2505-0021-01 PLC & Software 1
3 3017-0007 Power supply 1
4 3031-2212 Servo amplifier 1
5 3251-4207 Relay with terminal 1
6 3331-2002 IEC Inlet filter 1
7 3121-6002 Plug male (10Pin) 1
3122-4004 Socket female (10Pin) 1
8 3121-4003 Plug male (7Pin) 1 PG3
3122-4003 Socket female (7Pin) 1 PG3
9 3123-2006 Plug female (5Pin) 1 PG4
3124-2006 Socket male (5Pin) 1 PG4
10 3121-7001 Plug male (16Pin) 1 PG1
3122-7001 Socket female (16Pin) 1 PG1
＊ Recommended spare parts.

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6. CIRCUIT

31
6. CIRCUIT

32
6. CIRCUIT

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