Introduction

Foot Pedal Interrupt Positioner Installation

Foot Pedal Connects to Controller Installation

Sensor Installation

Electrical Ratings

Sensor Information

When using the Rotary Adapter Kit with Dry Contacts there are a couple of ways that this can be connected to your existing rotary positioner. There are basically two types of control circuits used with the positioners. The first is the foot pedal itself acts as an interrupt in the main power going to the positioner. Typically what we see is that the positioner can be plugged into the wall directly or you can plug the positioner into the foot pedal and then the foot pedal plugs into the wall. The second system we have seen is where the foot pedal is used as an input into the controller for the positioner and the foot pedal is generally secured at a terminal strip inside the controller for the positioner.

To facilitate using the system where the foot pedal acts as an interrupt you will need to create an extension cord that the rotary can plug into and that is then plugged into the wall for power. This will replace the foot pedal that is currently in the system. On the extension cord, you will simply have a break in the hot wire and run that to the rotary adapter kit as shown in the image below

On systems where the foot pedal is connected to the rotary controller, we will simply add a pair of wires that will parallel the wires from the foot pedal where they are connected to the controller. For instance, on this Baileigh Industrial unit (wiring schematic below from Baileigh Industrial) the foot pedal is connected to the terminal strip inside the motor controller for the unit at wires 3 and 4 per the schematic.

Using the manufacturer’s user manual for the rotary positioner you want to use you should be able to determine where the wires for the foot pedal enter the controller and attach to the control board. If needed, you can contact the manufacturer for additional assistance.

The finished assembly should look similar to the image below.

Using the supplied 5-pin cable, connect the cable to the port on the adapter labeled Robot and then connect the other end to one of the (4) IO ports on the side of the robot cabinet. The Red port is the default port that is used in the Rotary Weld step in the Beacon Welding application but any of the 4 ports can be used and then just selected when setting up the weld. You can connect up to (4) rotary positioners to the robot.

Included in the KIT-1124 kit is a photoelectric sensor that has an adjustable sensing range using the small screw that is on the sensor you can adjust the range of detection. This sensor will be used to determine when the rotary has rotated the full 360 degrees. Most customers simply add something to the rotary table that the sensor can use to detect the rotation point. You can see in the image below that the customer added a long bolt in one of the table slots and then the sensor is picking up that bolt when it revolves. The red spot on the bolt is from the sensor.

To connect the sensor simply plug the supplied cable into the sensor and then to the adapter at the port labeled Sensor.

You can adjust the sensing range of the sensor using the screw as shown in the image below. The two LEDs will turn on when the sensor detects an object, the amber light turns on when the sensor initially detects and the green LED turns on when the sensor fully detects the object. The output from the sensor will turn on as soon as the amber LED is triggered.

You have now completed the installation of the KIT-1124 Rotary Adapter Kit for Dry Contact Positioners.

Any sensor can be used so long as it meets the following specifications