roto-star benchtop welding positioner user`s manual - Trick
Contents
1. 12 of 14 This view added on 4 25 08 for part clarification and to show wiring connections for new ROS538 cord 13 of 14 PURGE PLUG When welding certain metals like stainless steel inconel titanium etc the back side of the weld will end up covered in black sugar as welders call it if not kept in an inert gas Such as argon atmosphere This is usually an issue when welding pipe or tubing made of these materials The purge plug attaches to the back end of the ROTO STAR spindle and allows purge gas to be flooded into the interior of the spindle and then into the interior of the pipe being welded When done this way the interior of the weld will look as good or better than the outside and the weld will infact be stronger this isn t just cosmetic Most high purity piping or aircraft work REQUIRES that purge gas be used JUNE 2009 14 of 142. ROTO STAR BENCHTOP WELDING POSITIONER USER S MANUAL JANCY ENGINEERING INC 2735 Hickory Grove Road Davenport Iowa 52804 Phone 563 391 1300 Fax 563 391 2323 Jancy Bench Top Welding Positioner Congratulations on your purchase of a Jancy welding positioner Please take a moment to complete and mail your product warranty registration card Doing so will validate your machine s warranty period and ensure prompt service if needed Thank you for selecting a welding positioner from Jancy Engineering Inc TABLE OF CONTENTS Table of contents and sss 2 Important safety and special 3 Installation and package 4 Maintenance and parts not 5 Optional equipment and 6 7 Breakdown and parts list ROTO STAR 1 8 Breakdown and parts list ROTO STAR 9 ParrtidenulcatioD escis eut ados teens inc 10 11 Variable speed pedal reference 12 Clarification VIEW tor ROSS8vigctidessuscacsencueaddciniwastacdarwabanddenss Piatuseenesupesaansanss 13 PUNO CY
3. Roto Star 3 Chuck Key Roto Star 1 Purge Plug Roto Star 3 Purge Plug Roto Star 1 Power Cord control box Cord var spd foot pedal 8 long Cord var spd foot pedal 15 long Cord var sod foot pedal 50 long Cord std foot pedal 7 6 long Female Plug Socket ext cord Power Cord control box extension 10 of 14 RO643 POTENTIOMETER Some of the older control boxes had 20 A fuses part number LEA ELE LE HL A dl Heference views of control box s with some part numbers and descriptions SLIDE SWITCHES ON ON PRINTED o enna noan ser nom sor yv SET BOTH Gn ae A a e Ec Top view of switch plate gt SA 9 E RO515 with T cover off 4 60649 Ceramic Capacitor 10000PF 2507 INote Some boxes may not have this capacitor KX il RO517 PC Board TEE speed foot pedal 715 m RO544 Motor cord ipa A 11 of 14 Variable Speed Foot Pedal View with top off for reference The ROTO STAR variable speed foot pedal system consists of a modified motor controller and a heavy duty continuously variable foot pedal assembly This system allows the speed of the ROTO STAR welding positioner to be controlled with your foot allowing you to more easily weld complex parts that require different speeds on different areas For those of you that purchased this option the safety and installation instructions came with the unit
4. SHCS M10 X 1 ss Washer flat 3 8 ss Scr CPSSS 5 16 18 x 1 2 ss 0010185 Scr CPSSS 3 8 24 x 5 16 Scr CPSSS 1 4 20 x 1 4 ss Scr CPSSS 5 16 18 x 3 8 ss Scr HHCS 1 2 13 x 1 1 4 ss Scr SHCS 5 16 18 x 3 8 ss Washer flat 5 16 ss Washer flat 1 2 ss Scr SHCS 1 4 20 x 1 ss Scr HHCS 10 32 x 1 2 ss Scr BHCS 10 32 x 1 2 ss Scr BHCS 10 32 x 3 8 ss Washer flat 10 ss Motor cord only with plug Base Frame Assy Roto Star 3 Upper Frame Roto Star 3 Chuck 3 jaw Roto Star 3 Drive Shaft Weldment Roto Star 3 Contact Plate Spacer Ring Roto Star 3 Thrust Washer Plate Roto Star 3 Thrust Washer Bearing Roto Star 3 Bronze Bushing Rear Locking Collar Roto Star 3 Chain Tension Rod Roto Star 3 Gear 45T Roto Star 3 Motor Mount Plate Roto Star 3 Motor 90 VDC Roto Star 3 Pinion Gear 10T Roto Star 3 Key 3 16 x 1 Chain Roto Star 3 Chain Guard Roto Star 3 Chain Guard bracket 1 Roto Star 3 Chain Guard bracket 2 Grounding Contact 13 long 2 gt A Handle with Knob Roto Star 3 Knob 9 of 14 Part identification Control Box complete std Control Box complete std 220v Foot Pedal var spd w cont box Foot Ped var spd w con box w15 crd Control Box var spd complete Foot Pedal variable speed Foot Pedal standard complete Surface Plate 16 for chuck ROTO3 Surface Plate 12 for chuck ROTO1 Chuck Key
5. Thrust Washer Plate Roto Star 1 Thrust Washer Bearing Roto Star 1 Bronze Bushing Rear Locking Collar Roto Star 1 Chain Tension Rod Roto Star 1 Gear 30T Roto Star 1 Motor Mount Plate Roto Star 1 Motor 90 VDC Roto Star 1 Pinion Gear 10T Roto Star 1 Chain Roto Star 1 Chain Guard Roto Star 1 Chain Guard bracket 1 Roto Star 1 Chain Guard bracket 2 Grounding Contact 12 long Grounding Post Handle with Knob Roto Star 1 Ser HHCS 1 2 13 x 5 1 2 h d ee gt gt 8 of 14 Description Knob Washer flat 1 2 SS Nut 1 2 13 nylock Washer flat 1 2 ss large od Scr FHSCS 3 8 16 x 3 4 ss Scr SHCS M8 1 25 x 20 ss Washer flat 5 16 ss Scr CPSSS 5 16 18 x 3 8 ss Scr HHCS 1 2 13 x 1 1 4 ss Scr SHCS 3 8 16 x 3 4 ss Washer flat 3 8 ss Scr SHCS 1 4 20 x 3 4 ss Scr SHCS 1 4 20 x 1 2 ss Washer flat 1 4 ss Scr CPSSS 1 4 20 x 1 4 ss Scr SHCS 5 16 18 x 5 8 ss Scr BHCS 10 32 x 3 8 ss Washer flat 10 ss Scr HHCS 10 32 x 1 2 55 Scr BHCS 10 32 x 1 2 55 Motor cord only with plug E e gt GO N 071 Breakdown ROTO STAR 3 Description em 26 Scr HHCS 1 2 13 x 7 Washer flat 1 2 ss Washer flat 1 2 ss large od Nut 1 2 13 nylock Scr FHSCS 3 8 16 x 3 4 ss Scr SHCS 1 4 20 x 1 2 ss Washer flat 1 4 ss Scr BHCS 1 4 20 x 1 ss Nut 1 4 20 ss Scr
6. 12 diameter for 1 P RO574 Wing Bolt adjustable clamp Roto Star adjustable arm rest ld ler i ler bly ROTO STAR 3 P shown ROTO STAR 1 P not shown Specifications Chuck 8 Swing at O maximum 16 20 16 20 Vertical weight capacity 200 Ibs 250 lbs 200 lbs 250 lbs Horizontal weight capacity 100 lbs 150 lbs 100 lbs 150 Ibs Thru spindle part capacity 1 1 2 diameter 2 1 2 diameter 1 1 2 diameter 2 1 2 diameter Spindle rotation 360 360 360 360 Spindle speed 0 to 15 RPM 8 RPM 0 to 15 RPM 0 to 8 RPM Angle adjustment 90 0 to 90 0 to 90 0 to 90 Grounding capacity 300A 300A 300A 300A Voltage 120v 120v 120v 120v Shipping weight 60 lbs 90 lbs 45 165 65 lbs Optional rotary table 12 diameter 16 diameter Fixed rotary table 12 diameter 16 diameter Adjusts in 15 increments Available in 220 voll single phase Roto Star welding positioners ROTO Roto Star ROTO3 Roto Star Ill Roto Star with plate Roto Star Ill with plate 6 of 14 DIMENSIONS ju N E fO 162 SS Ae Le ROTO STAR 3 Breakdown ROTO STAR 1 ON WY Frame Assy Roto Star 1 Upper Frame Roto Star 1 Chuck 3 jaw Roto Star 1 Drive Shaft Weldment Roto Star 1 Spacer Ring Roto Star 1
7. ED TROUBLE FREE OPERATION OF YOUR ROTO STAR Add a few drops of lubricating oil to the two oil fittings on the spindle housing Check that all connections to the welder ground system are secure and clean Check the drive chain for proper tension If the chain is too loose the spindle may reverse direction slightly when the motor is stopped especially if the load is not balanced Tighten the chain as follows A Loosen the two set screws securing the motor mount pins located on the back side of the spindle housing B Loosen the two 10 32 screws on the side of the chain guard where it attaches to the angle bracket to the motor mount Do not loosen the screws attaching the guard bracket to the motor mount C On the ROTO STAR 1 loosen the two 5 16 nuts attaching the chain guard to the front of the spindle housing The studs these nuts are on are actually long set screws that secure the motor mount pins on the front side of the spindle housing Loosen these two set screws with an Allen type wrench to allow the motor mount pins to move in the housing On the ROTO STAR 3 remove the two 5 16 bolts securing the chain guard to at the front of the spindle housing Then using an Allen type wrench loosen the two set screws securing the motor mount pins D You should now be able to slide the motor assembly back tightening the drive chain It will be necessary to apply pressure to the motor assembly holding the chain tight while you tighten a set scre
8. G ELECTRIC TOOLS BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE RISK OF FIRE ELECTRIC SHOCK AND PERSONAL INJURY READ AND SAVE ALL INSTRUCTIONS FOR FUTURE REFERENCE Keep work area clean Cluttered areas and benches invite injuries Consider work area environment Do not expose power tools to rain Do not use power tools in damp or wet locations Keep work area well lit Do not use tool in presence of flammable liquids or gases Guard against electric shock Prevent body contact with grounded surfaces For example pipes radiators ranges and refrigerator enclosures Keep children away Do not let visitors contact tool or extension cord All visitors should be kept away from work area Store idle tools When not in use tools should be stored in a dry high and locked up place out of reach of children Do not force tool It will do the job better and safer at the rate for which it was intended Use the right tool Do not force a small tool or attachment to do the job of a heavy duty tool Dress properly Do not wear loose clothing or jewelry They can be caught up in moving parts Non skid foot wear is recommended when working outdoors Wear protective hair covering to contain long hair Check for damaged parts Before further use of the tool a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function Check for alignment of moving
9. OU UN REL T E UU 14 LIMITED WARRANTY Jancy Engineering Inc will within 12 months from the original date of purchase repair or replace any goods found to be defective in materials or workmanship provided the product warranty registration card has been returned to Jancy Engineering Inc within 30 days of purchase date This warranty is void if the item has been damaged by accident neglect improper service or other causes not arising out of defects in materials or workmanship This warranty does not apply to machines and or components that have been altered changed or modified in any way or subject to use beyond recommended capacities and specifica tions Electrical components are subject to respective manufactures warranties All goods returned defective shall be returned prepaid freight to Jancy which shall be the buyer s sole and exclusive remedy for defective goods In no event shall Jancy Engineering be liable for loss or damage resulting directly or indirectly from the use of merchandise or from any other cause Jancy Engineering is not liable for any costs incurred on such goods or consequential damages No officer employee or agent of Jancy is authorized to make oral representations of fitness or to waive any of the foregoing terms of sale and none shall be binding on Jancy JANCY ENGINEERING RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE 2 of 14 IMPORTANT SAFETY INSTRUCTIONS WHEN USIN
10. al cord Then plug the foot pedal connector into the AC line socket The foot pedal acts as a switch in the AC line applying power to the motor controller only when depressed Test ROTO STAR motion Test the installation as follows Turn the speed control knob on the motor controller fully CCW zero RPM Turn the AC power switch on the motor controller ON may be marked 0 1 1 is on If so equipped switch the Break Run switch on the controller to Run Depress the foot pedal Slowly turn the speed control knob CW to start rotation You should be able to go from Zero RPM at fully CCW on the speed control to maximum speed approx 15 RPM on the ROTO 1 and 8 on the ROTO 3 at fill CW Lifting off the foot pedal should stop all rotation With the motor stopped change the direction of rotation by switching the FWD REV switch on the controller and again press the foot pedal and check rotation in the opposite direction NEVER CHANGE ROTATION DIRECTION WITH THE MOTOR RUNNING Doing so will cause excessive motor current possibly resulting in damage to the motor and or controller A B C D uu Package contents ROTO STAR 1 and 3 ROTO STAR 1 P and 3P Main unit with chuck Main unit with face plate T handle Warranty card 5 16 Allen type wrench DVD Warranty card Manual DVD Manual Foot pedal Control box Foot pedal Control box 4 of 14 MAINTENANCE PERIODICALLY CHECK THE FOLLOWING MAINTENANCE ITEMS TO ENSURE CONTINU
11. parts binding of moving parts breakage of parts mounting and any other condition that may effect its operation A guard or other part that is damaged should be properly repaired or replaced by an authorized service center Do not use this tool if switches do not turn it on and off Have defective switches replaced by an authorized service center SPECIAL INSTRUCTIONS Always securely fasten the ROTO STAR to the work surface using 2 bolts through the holes in the base plate The ROTO STAR is not stable unless fastened down especially with a load in the chuck or on the face plate Use caution when changing the tilt position of the ROTO STAR Never remove the tilt bolt unless the tilting portion of the ROTO STAR is securely held Never attempt to change the tilt position with a load in the chuck or on the face plate Ensure that the ROTO STAR is securely attached to the welder s ground lead either through the underside of the base plate to a grounded metallic work surface or by clamping the welder s ground lead to the ground stud on the base plate Never reverse the direction of rotation with the motor running Allow the motor to come to a complete stop before reversing Failure to do so will result in excessively high motor current possibly resulting in damage to the motor and or controller 3 of 14 INSTALLATION Read and follow all instructions Securely bolt or clamp the ROTO STAR to the work surface It is imperative that
12. the base plate of the ROTO STAR be securely fastened to a stable work surface Failure to do so may result in the ROTO STAR and its load tipping over possibly resulting in equipment damage and or operator injury Use 1 2 bolts through the mounting holes provided in the base plate If so desired the grounding of the ROTO STAR may be accomplished by securing the unit to a metallic work surface that is connected to the welding machine ground the under side of the ROTO STAR is bare metal Attach ROTO STAR to welding machine ground If you have bolted the ROTO STAR to a metallic work surface in step 1 above then ensure that the welding machine ground is securely attached to the work surface If it is not possible to ground the ROTO STAR through the work surface then attach the welding machine ground clamp to the aluminum ground stud located on the base plate below the chuck Failure to securely ground the ROTO STAR to the welding machine will result in motor and or controller damage The ROTO STAR warranty does not cover damage due to failure to properly ground the unit Attach ROTO STAR motor to controller Plug the ROTO STAR motor into the controller Rotate the cable connector against the socket on the controller until it drops into place and then rotate the outer ring on the cable connector to lock it in place Attach motor controller to foot pedal and AC line Plug the motor controller AC line into the connector on the end of the foot ped
13. w on each motor mount pin The slotted attachment for the chain guard should allow sufficient movement of the motor assembly to allow the chain guard to be tightened If not the chain may need replacement E Reverse the steps above to tighten the four set screws securing the motor mount pins the guard screws to the angle bracket and the guard attachment at the front of the spindle housing Parts not shown Part Description RO631 DGR130 Kit low gearing for Roto Star 3 RO633 2 Motor Roto Star 3 220 V RO635 Motor brush Roto Star 1 RO637 Motor brush Roto Star 3 RO639 Brush cover Roto Star 1 RO641 Brush cover Roto Star 3 RO647 Kit low gearing for Roto Star 1 RO721 Hex key 5 16 inch short 5 of 14 Optional equipment Surface plates Roto Star machines equipped with surface plates add versatility when welding irregular shapes and materials Machined from 0510 Roto Star adjustable arm rest solid aluminum Roto Star plates provide a quality work surface DESCRIPTION ROS 0 idler roller assembly suitable for most welding applications All surface plates have eee speed pedal with control box reference rings for quick part positioning and tapped holes for EE secure clamping 12 and 16 diameters are available for ROTO 555 Roto Star purge plug and ROTO reseecfivel RO501 12 surface plate for with chuck TS ane RO507 16 diameter for 3 P He eI ed ace bol RO503
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