Miller COMPUTER INTERFACE DUAL TORCH NSPR 9288 Owners manual

Millerfi

OWNERS

MANUAL

January

Effective

1994

With

Form:

Serial

No.

OM-141

KD509571

438A

cover

7/93

Dual Torch

Computer

persons

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understand

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SECTION

1-1.

1-2.

SECTION

2-1.

SECTION

3-1.

3-2.

3-3.
3-4.

3-5.

3-6.
3-7.

3-8.

SECTION

4-1.
4-2.

SECTION

5-1.

5-2.
5-3.
5-4.

SECTION

6-i.

6-2.

6-3.
6-4.
6-5.

SECTION

Diagram

Diagram

Diagram

Diagram
Diagram
Diagram
Diagram

Diagram

Diagram
Diagram

Diagram
Diagram

SECTION

Figure

Figure

Figure

Figure

Figure
Figure



1

SAFETY

General

Safety

2-

INTRODUCTION

PRECAUTIONS

Information

Alert

Symbol

Description

INSTALLATION

3

Location

Installation

Torch
Wire

Setting

Remote

Field
Connections
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4-OPERATOR

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Wire

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MAINTENANCE

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Circuit

Of

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for

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Module

Metal

Arc

Down

Of

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7-1.

7-2.

7-3.
7-4.
7-5.

7-6.

7-7.

7-8.
7-9.
7-10.
7-11.
7-12.

PARTS

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Wiring

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Module

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Panel

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Diagram

Diagram

System

TABLE

And

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PC2

OM-141

1
1

1

1

2
2
3

3

4
5

7

8

8

9

9

9

10

10

11
ii
11

13

14

15

16

18

20

21
22

22

23
23
24

24

26

31

32
33

34

36

438A-1/94

SECTION

1

-

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

A.

Information

bels,

design,

troubleshooting

followed

B.

The

shooting

and

safety

stalled,

sons

cautions
the

GENERAL

General

presented

and

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installation,

safe

for

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operation,

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which

Therefore,

INFORMATION

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on

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dual

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location

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Figure

3-4.

Remote

Jog

Switch

Connections

ST-139

887/S-0807

3-6.

a

a

A.

Installation

1.

2.

3.

OM-141

FIELD
DUAL

WARNING:





INSTALLATION

TORCH

ELECTRIC

Do

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and

out/tagging

touch

not

down

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line

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ing

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Page

disconnect

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circuit

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handlThg

circuit

carriers

work

Instructions

outlet

assembly,

robot.

on

original

Axis

5

output

customer-supplied

4

INSTRUCTIONS

WELDING

SHOCK

live

electrical

and

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input

power

procedures

switch

from

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breakerorother

DISCHARGE

boards.

grounded

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boards.

boards

or

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at

static-safe

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a

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remove

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hub.

dual

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and

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mounting

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semblies

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or

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assembly

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stabilizer

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nal

of

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tor/drive

Figure

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drive

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semblyhousing.

of

bracket

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sembly

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supplied

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cord

motor

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with

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motor/drive

washers

to

plug

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bracket.

Instructions

support

welding

end

on

plug

and

from

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brace

robot.

dual

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supplied

where

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motor/drive

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to

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assembly

insulating

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installs

strip

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bolts

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guns

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arm

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play

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one

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original

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of

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3-6.

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CONNECTIONS

FACES

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touch

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electrical

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OM-141

of

position,

open

shutting

off

disconnect

438

pad

and

Page

5

Voltage

Sensing

Leads

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Computer

~

RC1

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0

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RC8

RC2O

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9

To

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connecting

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ing

puter

3.

Connect

cord

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4.

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receptacle

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5.

receptacle

face.

6.

Connect

box

IMPORTANT:

tive

weld

routed

ing

to

7.

through

motor/drive

Connect

put

OM.141

438

matching

cord

Dual

on

plug

cord

to

receptacle

Interface.

matching

to

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plugonremaining

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on

on

plug

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on

plug

to

receptacle

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sure

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output

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weld

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on

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to

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end

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Figure

end

on

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panel.

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on

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on

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on

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one

supplied

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remaining

on

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weld

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power

boxes

from
power

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3-7.

of

supplied

9

on

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of

interconnect

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of

supplied

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of

motor

box.

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supplied

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cable

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sources

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motor

cord

box

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posi

connect

out

to

stud

are

to

to

At

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8.

9.

10.

IMPORTANT:

be

installed

semblies.

11.

12.

Interfaces

on

housing

drive

assembly

Connect

put

pieces

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to

each

terminals

fixtures.

or

one

receptacle

terface.

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leads

remaining

plug

face.

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on

top

with

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voltage

supplied

cables

nected.

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leadstothe

cable

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motor/drive

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supplied

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on

supplied

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power

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on

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(see

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to

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sensing

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motor/drive

each

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connected

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near

sources.

out

plug

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must

as

to

weld

con

weld

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receptacle

face.

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play

15.

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cord

16.

Connect

ing

17.

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hose

18.

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barbed

matching

Module

matching

to

receptacle

plug

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fitting

to

top

remaining

fitting

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on

module

on

remaining

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on

fitting

on

plug

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on

plug

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on

end

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on

end

rear

on

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on

remaining

on

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end

module

of

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supplied

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of

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stand.

supplied

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gas

cord

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supplied

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box.

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fitting

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to

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by

fitting

to

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fitting

to

remaining

20.

21.

22.

23.

gas

Connect

barbed

housing

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hose

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gas

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flowmeter/regulator

24.

Install

inlet

supplied

motor/drive

dual

on

fitting

on

rear

end

sliding

end

on

fitting

end

on

on

fitting

guides

spindle

assemblies.

gas

end

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of

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of

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on

of

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ends

at

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ends

on

and

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valve

of

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one

robot.

on

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onto

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supplied

supplied

of

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of

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gas

gas

of

inlet

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gas

assembly

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column.

hoses

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cables

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3-8.

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SOURCES

(Figure

~

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ferent

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ing

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position.

multi-process

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3-7)

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disconnect

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COMPUTER

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live

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disconnect

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power

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dif

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14-

in

OM-141438Page7

SECTION

4-

OPERATOR

CONTROLS

Computer

Interface

Pilot

Circuit

(See

Ground

(See

(See

Wire

Light

Breaker

Section

Fuse

Section

Feed

Current

Section

Fl

6-2)

6-2)

Light

6-2)

CB1

Digitai

Dispiay

Dispiay

Seiect

Switch

inductance

Control

Purge

Switch

Display

Lights

Module

Computer

Ref.

ST-136

SA-136

interface

571-B

572-B

4-1.

The

pilot

the

Computer

4-2.

A.

Digital

The

speed

B.

DISPLAY

The
wire

INDUCTANCE

C.

This

when

puter

COMPUTER

light

DISPLAY

Display

digital

depending

Selector

feed

speed

control

the

welding

Interface

turns

on

Interface

MODULE

display

on

SELECT

switch

to

sets

inductance

power

uses

INTERFACE

when

from

shows

the

setting

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is

used

appear

Control

on

source

inductance.

115

vac

the

welding

CONTROLS

either

of

select

to

the

in

percentage

connected

PILOT

power

power

voltage

the

Selector

either

digital

display.

Figure

LIGHT

is

supplied

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wire

or

voltage

to

(0

the

to

4-1.

to

feed

switch.

or

100%)

Com

Front

Panel

Views

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PURGE

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the

Module.

The

to

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er

output

The
is

The

relay

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Indicator

are

indications

POWER

Computer

GAS

indicate

CONTACTOR

source

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RE

energized

CURRENT

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the

PURGE

Use

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five

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turns

energizes

switch

the

on

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process

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control

when

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the

on

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energized

when

on

wire

that

when

on

that

the

to

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interface.

functions.

115

vac

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gas

the

indicate

to

the

is

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an

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gas

the

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the

is

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that

wire

drive

current

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established.

valve

on

line

gas

are

Display

pow

weld

motor

detect

to

OM-141

438

Page

8

SECTION

5-

SEQUENCE

OF

OPERATION

a

5-1.

1.

2.

WARNING:

MOVING

IMPROPER
ENVIRONMENT



Do

not



Keep
operating.



Do

not

contact

The

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ated

with

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ARC

RAYS,

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MAGNETIC

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Arc

ing

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METAL

GAS

Install

and

Owners

Connect

3.

tion

ELECTRIC

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SPATTER,

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a

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and

work

WIRE

point

gun

FIELDS

pacemaker

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safety

ARC

connect

Manuals.

Computer

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AND

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of

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out

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robot

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Precautionsinthe

Owners

WELDING

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Interfaces

SHOCK

serious

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internal

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the

outer

SURFACES

HOT

NOISE

can

protection.

body
seriously

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use

AND

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nearby,

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to

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their

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CURRENTS

doctor

orspot

Manual

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injury;

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enclosure

damage

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know

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the

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TO

in

and

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its

to

Sec

3.

4.

5.

6.

7.

8.

5-2.

1.

2.

3.

3.

a

5-3.

The

Computer

power

valves,

Chart

Weld

Start

Wire

Feed

Weld

Voltage

Wire

inching

Feed Motor

Wire

Gas

Valve

Wire

Stick

Start

Wear

dry

insulating

clean,

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on

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to

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down

off

off

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all

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Prepare

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Energize

Wear

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Begin

SHUTTING

Stop

Shut

Turn

Turn

WARNING:

SHIELDING



Shut

off

OPERATION

(Chart

sources

weld

5-1.

Relay

Speed

5-1)

Interfaces

and

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Sequence

Open

n~p~

Command

Close

hH

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Check

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gas

HIGH

GAS

supply

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OF

use

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I

~

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ac

equipment.

the

at

source.

CONCENTRATION

harm

can

COMPUTER

Controltocontrol

feed

Of

initiation

health

when

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signals

from

speed.

Operation

Close

in

INTERFACES

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Timing

OF

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______

4Oto1OV~~~Crater

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Time

sec.

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OM-141

~

~i1s

438

Crater

Time

S-0384

Page

-

9

5-4.

WIRE

IMPORTANT:

1.

if

Section

A

applies

(see

Computer

source

IMPORTANT:

set

Section

A

2.

power

burnback
mand

wireisfreed.

The

3.

current

There

4.

The

5.

a

to

voltage

50to75

are

(see

relay

signal

current

The

6.
that

dicates

bot

If

7.

relay

ond

command

STICK

DIP

switches

3-2).

signal

contactor

enable

3-2).

source

signal

stick

relay

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11

Page

Table

6-1.

Troubleshooting

TROUBLE

Unit

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OM-141

438

Page

12

6-5.

USE

OF

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LIGHTS

FOR

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flows:

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Circuit

7-7.

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BOARD

LCD

1-5ONRCI/PLG5

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7-8.

Diagram

H

A

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Diagram

For

For

Interface

PIJPGE

S

Display

Board

Module

PC4

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No.

SA-163

600

OM-141

438

Page

22

WIRESPEED

WIRE

UOLTAGE

SENSE

INPUT

SENSE-

Diagram

7-9.

Circuit

<CN

1

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For

Display

LED

1

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No.

No.

SB-i

SA-139

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051

648

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LED

Board

PC2

OM-141

438

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23

I>
3>
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No.

No.

SA-141

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554

140

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68

Circuit

For

7-11.

Circuit

PLC

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h/rnfl

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24

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For

NOTES

OM-141

438

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25

IT1

(I)

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366

ST-800

23

22

20

24

25

30

43

50

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51

52

53

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Illustrated)

37

Panel

38

Dual

(With

Interface

Computer

8-1.

Figure

7

2

56~~:~54

1

64

0

C.)

-u(U0)

62N~~~

-%

%

-%

61

Item

No.

Dia.

Mkgs.

Part

No.

Description

w/o

Panel

Quantity

Model

Dual

w/DuaI

Panel

2.

2.

3.

4...

PCi.

PLG1

PLG2O

5

6...RC5

.

.

PC2

2T

SRi

Ci

Ri

CR1

CR4,5

D4
D5

CR4
CR3

7...

8

9....FL1

10....

11

12

13...

14

15....

16....R3

17

18....

19

20....R2

21...

22.

22...

23...

24....5T

24...4T,5T

25

26....

27....T2

28

29...

Ti

PC7

PLG4,6

PLG7,9

PLG8

PLG12

PLG22

PLG3O

30

31...

PC3..

CN21,3i

134464

+133

+139

134201
152

165

079
131

113

031 251

165897

111

071

083

084

038
601
030

057
035

006
031

079
073

030651

010301

030

109

052

1469220009288
1469200009288

059

155

038

038

155

133
133
163

140

165

125

165
125
165
125

131

113

131

113

131

113

148490

152
165
125

862

465

371

896

747
054

746

030
642

147

171

832

219

170

357
704

426

692
497

914

941

006
964

266
602

855
855
604
876
877

597
777

885
748

884
748
886
748
052

746

056
746
054
746

145
884
748

8-1.

Figure

LABEL,

COVER

Computer

warning

general

COVER
STAND-OFF
CIRCUIT

CONNECTOR

CONNECTOR,

CONNECTOR

CONNECTOR,

BRACKET,

CONNECTOR

CONNECTOR,

CIRCUIT

GROMMET,

FILTER,

BLOCK,
LINK,

jumper

BUSHING,

BUSHING,
RECTIFIER,

CLAMP,

CAPACITOR,
RESISTOR,

WASHER,

RESISTOR,
BUSHING,

RESISTOR,

SUPPORT,

CARD,

mtg

voltage

&

SOCKETS,

rect

&

SOCKETS,

rect

connector

&

SOCKETS,

edge

scr

pwr

20A

term

motor

No

115/250V

CARD,

line

term

snap-in
snap-in

integ

capacitor

elctlt

WW

fxd

centering

WW

fxd

aI

.140

WW

fxd

8/iO

9P

blk

nyl

nyl

40A

2.000dia

750uf

ID

RELAY,encI24VACDPDT

RELAY,encI24VDCDPDT

DIODE,

DIODE,

RELAY,

SWITCH,
BLOCK,
BLOCK,
BRACKET,
TRANSFORMER,

TRANSFORMER,

PANEL,

CIRCUIT

CONNECTOR

CONNECTOR

CONNECTOR

CONNECTOR

CONNECTOR

CONNECTOR

BRACKET,

PCB,

CONNECTOR

w/leads
w/leads

end

reed

term
term

mtg

mtg

CARD,

CONNECTOR,

CONNECTOR,

CONNECTOR,

CONNECTOR,

CONNECTOR,

CONNECTOR,

mtg

II

Auto

CONNECTOR,

12OVAC

20A

2P

2P

20A

relays

control

control

components

dual

&

SOCKETS,

rect

&

SOCKETS,

rect

&

SOCKETS,

rect

&

SOCKETS,

rect

&

SOCKETS,

rect

&

SOCKETS,

rect

PC

card

&

SOCKETS,

rect

Interface

precautionary

PC

card

control

(consisting

skt

24-1

8ga

(consisting

skt

24-1

8ga

(consisting

skt

20-i8ga

control

speed

panel

hole

50-400Hz

20A

ID

.750
.937

800V

x

lDx

200VDC

25W

2K

ohm

.437dia

25W

x

100W

DPDT

torch

10

.250

ohm

OD

ohm

5

adapter

(consisting

skt

22-i8ga

(consisting

skt

22-1

8ga

(consisting

skt

22-i

8ga

(consisting

24-i

skt

Bga

(consisting

skt

24-i

Bga

(consisting

skt

24-1

8ga

(consisting

skt

22-i

Bga

.312/.375

of)

350980-i

Amp

of)

Molex

39-00-0038

of)

583362-2

Amp

.312sq

2A

at

1

.000mtg

i.i2Smtg

.312

x

of)

JST

SVH-21T-i.

of)

JST

SVH-2iT-i

of)

JST

SVH-21T-1

of)

Molex

39-00-0038

of)

Molex

39-00-0038

of)

Molex

39-00-0038

of)

JST-SVH-2iT-1

.500

hole
hole

high

1

.1

.1

.1

..8....

22

:1

.2

.2
.1

.1

.1
.1

.1
.4

.1

.2

.1
.1

.2

.1

.1
.1

.1

OM-141

::::

438

12

18

.1

.2

.2

22

.1

.2

.1

1

2

2

1
1

1

1
1

4

1

2

1

1

1

1
1
1

2

5
2

16

14

1

2

3

Page

27

Item

No.

Dia.

Mkgs.

Part

No.

Description

w/o

Panel

Quantity

Model

Dual

w/Dual

Panel

32.

33.

34.

35.

36.

37.

38.

39.

40.

41

42.

43.

44.

45.

46.

47.

48.

48.

49.

49.

50.

51

52.

53.

53.

54

55...

56

57....

58...

58
59
60
61
62

63

64

OM-141

CN22,24

CN23

RC19

Psi

RC14,PC5

RC9

RC12

RC8,PC6

PLG19

PLG1O,19

PLG18

PLG

11,

..RC1O

RC11

CB1

P12

Fl

RC2O

CN37,

PL1

PC4

PLG2

PLG3

438

Page

18

1C402

28

...

885

165
125748

165
125

141

666
870

133

139

040

159

141

449

140

141

140
126

038

148

125

163
039
073

163

131

131

113

135

635

135

114

656

097

867
492

152
134

731

011

991
924

146

596

155

027645

432

046

*012655

073

130910

149923
039

146573

163562

137110

131056

113746

115094

113746

133868

133863

152370

079534
079739

110015

141

134731

079

886
748

682

839
667
872
368

782

596

966

577
718
515

569

054

054

746

635

973

885

162

739

Figure

CONNECTOR

CONNECTOR,

CONNECTOR

CONNECTOR,

PANEL,

..BASE

BUSHING,

PANEL,

PANEL,

CONNECTOR,

CASE

PLATE,

STAND-OFF

BLOCK,

CAPACITOR

POWER

CONNECTOR,
CONNECTOR,

CONNECTOR,

CONNECTOR,

CONNECTOR
CONNECTOR

CONNECTOR,

CONNECTOR
CONNECTOR

CONNECTOR,

CONNECTOR,

CONNECTOR

CONNECTOR,

CIRCUIT

PANEL,
PANEL,

NAMEPLATE,
LIGHT,

HOLDER,
FUSE,

CONNECTOR,

CABLE,

MOUNTING

CONNECTOR,

CONNECTOR,
LIGHT,

CIRCUIT
CONNECTOR

CONNECTOR,

CONNECTOR

CONNECTOR,
PANEL,
CABLE,

CONNECTOR

CONNECTOR,
CONNECTOR,

CABLE,

CONNECTOR

CONNECTOR,

CONNECTOR,

8-1.

Computer

&

SOCKETS,

skt

rect

&

SOCKETS,

skt

rect

rear

relief

strain

rear

side

circ

14

SECTION,

ident

front/bottom

control

SUPPORT,

term

20A

lop

SUPPLY,

switching

w/components

circ

i0skt

llskt

circ

w/components

&

SOCKETS,

&

SOCKETS,

skt

rect

&

PINS,

&

PINS,

rect

pin

circ

17

w/PINS,

circ

pin

lens

125VAC

mintr

1OA

i4skt

circ

assemble

circ

protective

circ

protective

125VAC

lens

interface

&

SOCKETS,

rect

&

SOCKETS,

rect

man

by

250V

insulator

skt

skt

BREAKER,

front
front

md

red

fuse

mintr

fiber

md

wht

CARD,

side

(order

cer

optic

BLOCK,

interconnecting

&

SOCKETS,

circ

circ

&

7/c

18

PINS,

circ

circ

port

No.

Interface

(Continued)

(consisting

22-l8ga

JST-SVH-21T-1.1

(consisting

22-1

.231/.394

pin

rcpt

PC

rcpt

rcpt

JST

8ga

ID

Amphenol

card

No.

85-i

32VAC/ii0-i

Amphenol

Amphenol

(consisting
(consisting

24-l8ga

Molex

(consisting
(consisting

24-l8ga

pin

rcpt

Molex

Amptienol

(consisting

push-in

model

rcpt

reset

and

Amphenol

fiber

cap

cap

14-l8ga

1P

Amphenol

Amphenol

(consisting

24-l8ga

Molex

(consisting

24-1

8ga

Molex

(consisting

(consisting

skt

push-in

rlf

str

clamp

(orderbyft)

(consisting

pin

push-in

rlf

str

clamp

of)

of)

SVH-21T-1

x

.733mtg

MS-3102A-22-19P

6

screw

MS-3102A-18-1S

MS-3102A-20-33S

of)

of)

39-00-0038

of)

of)

39-00-0040

MS-3102A-20-29P

of)

Amp

1.5A

250V

serial

number)

MS-3102A-22-19S

cable

optic

of)

39-00-0038

of)

39-00-0038

of)

of)

14-l8ga

17-20

sz

of)

14-l8ga

17-20

sz

hole

7OVDC

213603-1

9760-20
9760-14

Amp

Amp

Amp

Amp

.1

66358-6

206322-2

213603-1

206322-2

1 1
1

1

1
1 1
1
1 1
1 1
1 1

1 1

1

2

1

2 2

1

1 1

14

...

1 1
1

1

1 1

1

1

2

1

1
1 1
1

14 14

1 1
4

2

1
1

14

..

1

5ft

1

14

.

1

2

5

1

7

1

1
1

1

1
1
1

6

1

1

2

2

2

1

14

....

1

1
1

1

1

1

2

1
1

1

4

1

1

1

14

1

5ft

1

14

....

1

133

073

039

Quantity

Model

Item

No.

Dia.

Mkgs.

Part

No.

Description

w/o

Dual

Panel Panel

w/Dual

133

864

097

868

116

964

604 910

097 866

866

686

828

133859

083184
070584

084286

146925

134308
039716
073332

134242
048 598
079 534
079739

127462

134471
073517

039 734

134240

134106

126493

126498
049 974
079974

131

356

004733

604738
604525

165971

126084

106299

131355

049972

112884
073476
084594
079975

099470

081

959

049310

146

912

073

982

116

964

Figure

CABLE,

..

CONNECTOR,

. . . .

CONNECTOR,

.

. . .

Amphenol
CABLE,

. . . .

CONNECTOR,

....

MS-3106A-20-29P

CABLE,

..

CONNECTOR,

. ...

CONNECTOR,

. . . .

Amphenol

CABLE,

TERMINAL,
TUBING,

TUBING,

CABLE,

CABLE,

CONNECTOR,
CONNECTOR,

Amphenol

CABLE,

CONNECTOR

CONNECTOR,

CONNECTOR,

CONNECTOR,

CABLE,

CONNECTOR,

MS-3i06A-20-33P

CONNECTOR,

Amphenol

CABLE,
CONNECTOR,

CABLE,

CABLE/CONDUIT,

CONNECTOR,

0-RING,
TUBING,

CLAMP,

TUBING,
CABLE,

CONNECTOR

CONNECTOR,

CABLE,

FITTING,

FITTING,

STRAIN

CLAMP,

LINER,

O-RING,.187IDx.lO3CSrbr
COLLAR,

SCREW,

GUIDE,

CABLE,

CONNECTOR,

CONNECTOR,

Amphenol

8-1.

Computer

Interface

interconnecting

circ

l7skt

circ

AN-3057-1012

port

volt

sense

AN-3057-6

shld

gI

acryl

htshnk

ring

clamp

No.

2Oga

17

circ

(consisting

circ

4skt

circ

clamp

No.i8ga

.500

tng

.129-.141

.270/.l5Odia

interconnecting

interconnecting

circ

10

circ

No.

&

circ

circ

clamp

i8ga

SOCKETS,

circ

skt

clamp

l0skt

AN-3057-i0

shld

interconnecting

circ

11

circ

No.

18

circ

clamp

12/c

iiskt

.030-.035

AN-3057-12

shld

combination

(consisting

cable

500

lDx.1O3CS

OD

.750

cop

cable

conduit

htshnk

port

black1.000/.SOOdia

No.182/c

&

PINS,

rect

composition

hose

hose

RELIEF,

strap

monocoil

locking

set

wire

outlet

barbed

cop

brs

nut

extension

rbr

5

holes

.030-.035

liner

6-32

.030-.035

interconnecting

14

circ

circ

MS-3057-10i2

clamp

(Continued)

(consisting

plug

str

5/c

(orderbyft)

pin

plug

of)

Amphenol

nt

20-22

sz

Amphenol

of)

Amphenol

plug

rlf

str

i/c

(orderbyft)

stud

ID

14-14S

sz

22-i6ga

(order

(orderbyft)

(consisting
(consisting

pin

plug

str

10/c

of)
of)

Amphenol

rlt

sz

(order

18

by

(consisting

push-in

str

plug

(consisting

pin

plug

str

14-l8ga

rlt

17-20

sz

JAE

of)

Amphenol

rlf

20-22S

sz

(orderbyft)

Amphenol

plug

wire

(consisting

of)

feeder

rbr

.065

x

(order

end

waIl

by

(consisting

pin

20-l4ga

bulk

core

.310

nipple

.625-18RH

wide

.375

wire

(consisting

(consisting

hol

plug

str

1k sIt

of)

Amphenol

rlf

20-22

sz

.094

x

(consisting

pin

MS-3106A-20-29S

MS-3106A-14S-2S

by

ft)

MS-3106A-18-1P

ft)

of)

Amp

206322-2

Amp

SRCN6A-21-iOS

MS-3108B-20-33S

of)

1.000

x

Ig

(order

by

ft)

of)

JST

SLM-61T-2.0

ID

(order

1/2tbg

4.625

x

Ig

of)

of)

stl

MS-3106A-22-i9P

66358-6

tt)

by

ft)

1

1

2

5ft

1

1
1

1

70ft 70ft

2

itt

itt

1

1

1

23ft 23ft

1

16

. .

1

..

1

1 1

2

26ft

1

OM-141

438

1
1

2

Sn

1

1

1

1

2

itt

itt

1
1

1

1
1

2

26ft

1

2

1
1

2

2

2
itt
2ft

1

2

7ft

1

1

1

2

1

1

1

1

1
1
1

2

Page

29

Item

No.

Dia.

Mkgs.

Part

No.

Description

w/o

Panel

Quantity

Model

Dual

w/Dual

Panel

096813

140840

604525

605156
071
079534
079739

1261600009288

165971
126084

049455

165970

155633

600322

134834

056108

010606

056851
056423
010603

010606

056112
051
603106

109293

026202

126083

010296

166075

126084

892

297

8-1.

Figure

CABLE,

Computer

shld

CONNECTOR,

CABLE,

CABLE,

CONNECTOR

port
port

No.182/c
No.

CONNECTOR,

CONNECTOR,
CABLE,

shock

CONNECTOR

CONNECTOR,

CABLE,



. . .

 . . .

CONNECTOR

port

CONNECTOR,

CABLE,

HOSE,

FITTING,

FITTING,

FITTING,

HOSE

VALVE,

weld

SAE

ASSEMBLY,
FITTING,
FITTING,

FITTING,

ADAPTER

HOSE,

24VDC

.187

hose
hose
hose

hose

hose
hose

nprn

DIODE,rectlA400VSP

FITTING,

FITTING,

CONNECTOR

pipe

hose

CONNECTOR,

No.

l8ga

circ

Interface

15/c

l4skt

(Continued)

(orderbyft)

plug

Amphenol

(orderbyft)

18

4/c

(order

w/SOCKETS,

circ

skt

circ

clamp

sensor

No.

split

&

PINS,

rect

18

2/c

&

SOCKETS,

pin

push-in

str

(consisting

(orderbyft)

ft)

by

(consisting

14-lBga

rif

17-20

sz

(consisting

of)

of)

20-l4ga

JST

(consisting

of)

Amp

SLM-61T-2.0

rectskt2o-14gaJSTSLF-61T-2.0

cop

brd

brs

&

strd

ID

brs

brs

brs

brs

brs
brs

2way

brs

PINS,

rect

ferrule

nut

barbed

No.

nipple

elbow

2/0

No.

OD

.410

x

.450

.625-18RH

nipple

(consisting

gas

barbed

.625-18RH

nut

ferrule

.250

1

x

IPS

1/4

hex

M

(consisting

pin

20-l4ga

(order

(order

ID

3/l6tbg

nipple

ID

.475

ID

port

1/4NPT

1/4NPT

by

by

.718

x

of)

1/4tbg

.718

x

(order

1/8

ort

x

.625-18RH

x

of)

JST

SLM-61T-2.0

ft)

ft)

Ig

by

1/4-19

MS-3106A-22-19S

66358-6

Amp

206322-2

of)

Ig

ft)

BSPT

8ft

1

2ft
2ft

1

14

1
1

1

2

2ft

2
2

120ff

6ff

2
2
2
2
2
2

2

1

33ff

1

1

1

1
1

4

+When

*Recommended

BE

OM-141

ordering

SURE TO

438

Page

a

component

Spare

PROVIDE

30

Parts.

MODEL

originally

AND

displaying

SERIAL

a

precautionary

NUMBER

WHEN

the

label,

ORDERING

should

label

REPLACEMENT

also

be

ordered.

PARTS.

Item

No.

2

5....

..6

.8

..i0....

ii

12

13

14

15

: : : :

Dia.

Mkgs.

.

PLG5....

R3....

Si

Ri,2....

Dl....

iT....

P02....

PLG4...

Part

No.

163

598

073

756..

164049..

lii

500..

121

771

113

333..

030

938..

013..

134

026

202..

038

042..

077175..
139

646..

134859..
125

748..

098691

163599..

115

360..

115359..

Description

Figure

STAND-OFF,

CIRCUIT

8-2.

CARD,

Display

6-32x.625

CONNECTOR,

POTENTIOMETER,

PB

SWITCH,

RESISTOR,
BRACKET,

DIODE,
STRIP,

MC

C

mtg

1A

rect

terminal

CONNECTOR,

CIRCUIT

CONNECTOR

CARD,

CONNECTOR,

STAND-OFF,

CASE

SECTION,
NAMEPLATE,
KNOB,
CAP,

peaked

6-32x.500

(order

arrow

Module

meter

rect

5skt

C

NO

.5W

1.2K

control

400V

4P

ii

circ

display

&

SOCKETS,

rect

front/sides

by

sltd

SPST

box

SP

pin

skt

model

Ig

plug

Amp

l/T

sft

115VAC

1A

ohm

Amphenol

rcpt

(consisting

22-i

8ga

Ig

and

640440-5

1W

10K

JST

SVH-21T-i

serial

ohm

MS-301

of)

number)

2A-20-33P

.1

Quantity

.2
.1

.1

1

1
2
1

1
1

1
1

1

6

2

1

1

1

1

1

1~

9

I

1

BE

SURE

14

TO

PROVIDE

MODEL

AND

13

SERIAL

Figure

NUMBER

8-2.

12

Display

WHEN

1~~

Module

ORDERING

11

10

REPLACEMENT

PARTS.

OM-141

438

ST-136

517-B

Page

31

Item

No.

Dia.

Mkgs.

Part

No.

Descnption

Quantity

2
3

4

5

6
7
8

9

10

11

12

13....

RS1....

Ri....

iT....

PLG1

135

+135

131

140

010

057

135

028
038

135

123

134

039

047544..

920

938..

515..

786..

494..

358..

940..

285..
861

939..
531

241

828..

2

Figure

WRAPPER

LABEL,

SWITCH,
BUSHING,

BUSHING,

CASE

RESISTOR,
BLOCK,

..

BRACKET,

STRAIN

..

CABLE,

..

CONNECTOR,

CONNECTOR,

WCR

8-3.

warning

reed

snap-in

snap-in

SECTION,

C

term

20A

mtg

RELIEF,

shid

No.

Box

electric

nyl

nyl

bottom/sides

.5W

100

3P

box

cable

i8ga

circ

clamp

circ

4

pin

shock

1.375

1.000

ohm

flexible

2/c

(order

str

plug

1

ID

x

.75Omtg

ID

1

x

.375mtg

.231-.394

ft)

by

14-14S

rlf

sz

Amphenol

3

hole

hole

cable

Amphenol

AN-3057-6

MS-3106-14S-2SX

1
1

1

2
2

1

1

1

2

1

6ft

1
1

4

L

0

10 9

13

12

6

7

8

+When

BE

OM-141

SURE

438

ordering

TO

PROVIDE

32

Page

a

component

11

originally

MODEL

AND

Figure

displaying

SERIAL

NUMBER

WCR

8-3.

a

precautionary

WHEN

Box

label,

ORDERING

the

should

label

REPLACEMENT

also

be

PARTS.

ordered.

ST-136

518-A

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

1

2
3

4
5
6

7

8
9

10

11

...

12...

13..

14...

15...

.

RC7

Dl

.

5T

.

GS1

RC16

149

134

+079

109

115
010494
057
010 604

602

079
079 574
047
079

109938

038

109

090246

079

157

327

682

021

104

360

934
573

637
534

839

293

535

Figure

LABEL,

..

WRAPPER

..

CASE

..

CONNECTOR,

..

BUSHING,

..

BLANK,

..

FITTING,

..

FITTiNG,

..

FITTING,

..

BRACKET,

..

CONNECTOR

..

CONNECTOR,

. .

.

.

DIODE

..

BLOCK,

..

VALVE,

..

CONNECTOR

..

CONNECTOR,

. .

. .

8-4.

Control

warning

SECTION,

snap-in

snap-in

hose

pipe

pipe

mtg

term

24VDC

Box,

general

front/bottom/rear

clamp

nyl

brs

galv
galv

precautionary

cable

1.375

nyl

1

.375mtg

bushing

coupling

nipple

component

&

SOCKETS,

circ

skt

push-in

5P

20A

1/4

2way

w/PINS,

(consisting

circ

pin

6

push-in

Gas/Motor

.500

ID

1

x

hole

1/4NPT

.25ONPSC

L

.25ONPT

(consisting

14-l8ga

IPS

port

1/8

14-lBga

~H8

.75Omtg

.625-18RH

x

6.000

x

of)

orf

of)

hole

Amp

Amp

66358-6

66359-6

1

.

..

.

..

14

16

+Wheri
BE

SURE

2

ordering

TO

PROVIDE

a

component

originally

MODEL

14

8-4.

5

Control

15

Figure

displayingaprecautionary

AND

SERIAL

NUMBER

Box,

WHEN

6

Gas/Motor

label,

ORDERING

the

7

label

should

REPLACEMENT

also

be

ordered.

PARTS.

OM-141

Ref.

11

12

13

10

SC-109

438

680-A

Page

33

2

34

r

44.

43

42

41

includes

Items

25-27

27

Figure

8-5.

37

Motor

33

34

25

35

36

SD-070

798-F

Drive

&

Assembly

OM-141

438

Page

34

Item

No.

1

2

3

4

5

6

7

8
9

10

11
12
13

14

15
16
17

18

19
20
21

22

23
24

25

26

27

28
29
30
31

32

33
34
35
36
37

38

39

40

41

42

43

44

Dia.

Mkgs.

Part

No.

117

+046967

047636

079
079739
081630

+080802

080283
080 282

*080

114897

114898

049033

110738

049029
049031

110733

049032
049030
046779

602154
010224
046621

085242

010231
085243

085244
079669

079634

151828

046619

144172

604538
079772
075150
010910
602213
079624

092865
070396

070397
053842

079626

605518
072010
079625
000418

602241
093664
601872

602243

++146

++127

++123
+046

053

056192

056206

++010

124

535

281

911

815

314
781

700

021

Figure

MOTOR

8-5.

ASSEMBLY,

CONNECTOR

CONNECTOR,
CLAMP,
CORD,

motor

MOTOR,

COVER,

SPRING,

-BRUSH

COVER,

RIVET

SPACER,

CIRCUITCARD,tach
HOUSING,
SHAFT,

OPTICAL

CLAMP,

COVER,

WIRE

DRIVE,

SCREW,

PIN,

spring

HOUSING,
FASTENER,

SPRING,

KNOB,

ad]

WASHER,

LEVER,

PIN,

hinge

cotter

PIN,
LEVER,
FITTING,

WASHER,

...KNOB

WASHER,

WASHER,

WASHER,

SCREW,
KEY,

STRIP,

cap

.122x.122x.750

mtg

INSULATION,

GEAR,

SCREW,
SCREW,

spur

mach

cap

WASHER,
WASHER,
SCREW,

cap

WASHER,
GEAR,

NUT,

stl

spur

hex

WASHER,

BRACKET,

INSULATOR

WASHER,

drive

KIT,

ROLL,

drive

GUIDE,

GUIDE,

CLAMP,

stl

Description

Motor&Drive

&

PINS,

circ

cable

gear

housing

extension

ENCODER

strain

housing

17

brush

brush

front

tach

in

1/Bhp

shield

tach

feedback

armature

relief

tach

(consisting

stl

CS

.187x1.000

hexhd

cap

adapter

pinned

.770

cprsn

tension

cupped

mtg

pressure

hair

.042x.750

mtg

pressure

brs

barbed

flat

SAE

stl

shldr

.406

flat

SAE

stl

lock

stl

split

stl

hexhd

motor

motor

insul

w/bearing

filh

stl

stl

hexhd

shldr

.316

stl

hexhd

SAE

stl

insulated

full

fnsh

std

dual

mtg

shldr

.266

&

guide

V

groove

inlet
intermediate

cush

.562dia

stl

spring

flat

flatstl

roll

wire

wire

Assembly

(consisting

(consisting

pin

push-in

115V

200RPM

DISC

feedback

of)

.250-20x.500

gun/feeder

OD

.105

x

.328

ID

x

stl

gear

gear

M

3/l6tbg

.312

ID

1.000

x

.375

.375

.375-16x2.250

slflkg

10-32x.875

.250-20x1.250

IDx.812

.500

slflkg

.250

drive

.375-16

.375

OD

shakeproof

.250-20x.500

feeder

IDx.687

OD

(consisting

wire

.035

x

.343mtg

of)

of)

14-lBga

(consisting

wire

x

OD

.812

.250-20

x

.l85thk

OD

x

.lB7thkx.437

x

.O62thk

x

of)

hole

Amp

1

.225p1d

.125

x

x

x

.359

.619

66359-6

of)

lip

OD

OD

OD

x

x

x

.578

.125

.190

Quantity

:::::

lip

..

...

lip

lip

...

1

1

14

1

1

2

2
2

1

2

2

1
1

1
1

1
1
1
2
2

1

2

2
2
2

1

1

1

1
1
1

1
2
2

4

2

1

1

1
4

15

4
2

2

1

1

1
2

2

1

1

5

1

4

1
1

1

+When
*Recommended

++ltems
BE

ordering

not

SURE

included

PROVIDE

TO

a

component

Parts.

Spare

with

originally

Motor/Drive

MODEL

displayingaprecautionary

Assembly

AND

SERIAL

NUMBER

WHEN

label,

ORDERING

the

label

should

REPLACEMENT

also

be

PARTS.

OM-141

ordered.

438

Page

35

Item

No.

Part

No.

Figure

8-6.

Inlet

Cable

Description

System

Quantity

10

11

1

.058427

108

124904
124905
124900

085

.605941
.010233



.057971

.010

058

.058428



.072475

044



.

072

.080651

.093269

076069

.602177

.602

071

118718

.046720

.046713



.046719

.046714

008

980

191

628

937
298

178
126

RING,

REEL,

retaining

wire

NUT,

(consisting

spanner

RETAINER,

NUT,

.



WASHER,

SUPPORT,

stl

hex

reel

full

flat

SPRING,cprsn

WASHER,
WASHER,



.

flat
fbr

.WASHER,brakestl

HUB,

spool

SUPPORT,

 .

BASE,

PLATE,
ADAPTER,
FITTING,

feeder

mtg

pipe

spindle

support

inlet

CONNECTOR,

.250-20

SCREW,
SCREW,

HOSE,
LINER,

WASHER,
BRACKET,

WASHER,

FITTING,

set

.250-20x.375

set

brd

nprn

monocoil

shldr

mtg

fIat

wire

spool

of)

spool

support

spool

support

spool

fnsh

.625-11

stl

sti
.656

.640

.9700Dx

keyed

ID

ID

x

1.500

1.500

1.000

x

.l20wirex

spindle

cable/feeder

nipple

close

galv

cable/adapter

.250

x

1

No.

.030-1/8

.562

inlet

.750

guide

ID

cable

ID

inlet

x

x

x

1.125

.375

wirex300.000

1.125

cable

OD

dia

OD

.25ONPT

knrlpt
knrlpt

ID

(order

OD

OD

x

l4ga

1.250p1d.

.l25thk

x

.l25thk

x

sch

stl

sch

stl

by

.l2Sthk

x

.l2Sthk

x

.375

ft)

in

thk

x

nyl

ID

.740

ODx.234

lip

.2

.1
.1

.1

.1

.2

.2

2

2
4
4
2

1

1
1
1
1

2

4

4

25ft

1
1

1
1
1

OPTIONAL

SURE

BE

OM-141

438

TO

Page

PROVIDE

36

MODEL

AND

3

Figure

SERIAL

8-6.

NUMBER

Inlet

Cable

WHEN

9

System

ORDERING

11

REPLACEMENT

10

.13

Ret

SC-ill

561-A

PARTS.