Miller COMPUTER INTERFACE MR-5/PULSTAR Owners manual

November

1987

FORM:

OM-883

IMPORTANT

contents

manual

on

before

of

used

the

safety

installing,

equipment.

use

only

by

safe

operation

untrained

unit.

this

understand

Contact

both

with

material

This

persons

of

persons

these

this

and

manual

unit,

Riad

operating,

and

unit

trained

welding

to

install,

distributor

your

instructions.

understand

and

with

throughout

or

instructions

these

and

experienced

equipment.

operate,

the

power

special

both

emphasis

manuals,

maintaining

Do

not

maintain

or

do

if

you

not

entire

source

are

in

allow

fully

this

for

the

Effective

MR-5/PULSTAR COMPUTER GAS/CURRENT

CONTROL

With

Serial

MODEL

No.

JH274875

450ﬁ

INTERFACE

SENSING

OWN

MANUAL

MILLER

718

ADDITIONAL

ERS

ELECTRIC

S.

BOUNDS

APPLETON.

NWSA

COPY

PRINTED

ST.

WI

PRICE

CODE

IN

NO.

USA.

P.O.

54912

95

4579

MPG.

Box

USA

CENTS

1079

~lIIER

~

CO.



L

~

~

~)

~

This

warranty

LIMITED

tions

warrants

Equipment

ship

No

accessories

engines,

the

engines

date

have

Except

to

components

year,

MILLERMATIC

wire

not

Miller

ranted

within

ment

1.

2.

3.

4.

5.

6.

7.

provided

of

the

As

submitted

supersedes

WARRANTY

hereof,

to

furnishedbyMiller

materialasof

and

warranty

or

trade

warranties

warranted

are

of

original

two

a

year

as

specified

such

as

including

result

from

shall

Equipment

the

following

the

to

original

Arc

welders,

Load

banks

main

Original

-

1

Ilabor

All

welding

All

other

Replacement

Batteries

that

date

of

matter

a

by

all

Electric

by

their

-

the

Miller

items

respective

their

by

Miller

Distributor/Dealer

its

is

made

other

accessories

of

purchase,

warranty.

below,

normal

having

welder

spot

that

parts

nozzles

defect

be

required

in

the

nozzle

and

in

workmanship

event

periods

user:

sources,

power

rectifiers

power

only)

year

feeder/guns

guns,

Millermatic

Millerisnotified

such

of

the

or

repair

failure.

general

original

Feeders

policy

user

LIMITED

and

come

to

parts,

MILLER

Subject

Co.,

Mfg.

that

is

free

and

place

with

manufactured

other

manufacturers,

manufacturer

Tecumseh

except

Millers

useful

tips,

relay

in

contact

insulators

honor

of

failure

from

the

robots,

and

plasma

exclusive

in

writing

only,

within

the

to

Appleton,

all

from

defectinworkman

of

respect

items

are

warranty

lifeofless

and

where

material.

or

warranty

resulting

of

date

and

components

torches

of

within

Miller

the

foregoing

terms

delivery

contactor

delivery

EFFECTIVE:

warranties

and

Wisconsin

and

new

to

engines,

others.

by

sold

subject

if

for

one

engines

does

than

with

the

failure

claims

from

...

labor

.

thirty

honor

may

periods.

WARRANTY

OCTOBER

exclusive

is

and

condi

unused

Miller.

by

trade

Such

to

All

.

any

from

year

which

not

apply

one

points,

welding

on

defect

a

of

Equip

1

.

1

3

years

90

1

60

.

6

months

(30)

claims

.

does

war

year

daye

year

days

~.

Ii)

~

facility,

any

ANY

TION

CUSTOM

ANY

CLUDED

WRITING,

ULTIMATE

USERS

EXPERIENCED WELDING CONSUMER

TO,

MILLERS

1.

with

In

the

with

respect

therefore

where

or,

the

reasonable

Miller

service

(less

price

of

retum

of

option

Appleton,

therefore,

kind

defect

or

claim

procedures

ANY

EXPRESS

IMPLIED

AS BREACH MIGHT

IMPLIED

FITNESS

AND

EXCEPT

AND

1986

other

no

of

case

to

the

shall

be,

authorized

cost

station

reasonable

the

goods

repair

Wisconsin,

will

be

failure,

WARRANTY,

TO

OF

CONTRACT

ARISE

OF

TRADE

WARRANTY

FOR

PARTICULAR

ALL

AND

DISCLAIMED

AS

MILLER

PURCHASE

FOR

EQUIPMENT

USE.

NO

WARRANTIES

guarantees

Millers

broach

of

quality

at

Millers

in

writing

of

repair

or

(4)

payment

depreciation

Customers

at

or

replacement

or

F.O.B.,

no

compensation

allowed.

Miller

to

shall

be

followed.

Upon

instruct

WARRANTY

PERFORMANCE,

WHICH,

BY

IMPLICATION,

OR

COURSE

EQUIPMENT

EXPRESSLY

PRODUCTS

BY

OPERATION

IN

THE USE

AND NOT

MILLERS

RESELLER

TO.

or

warranties

of

warranty

the

goods,

any

(1)

option

Miller

by

or

replacement

of

based

risk

will

MILLER

at

a

for

receipt

the

PROVIDED

NOT

repair

in

appropriate

credit

or

upon

and

be

FOB.,

transportation

of

claimantonthe

GUARANTY

AND

ANY

BUT

FOR

OPERATION

OF

PURPOSE.

DEALING,

MERCHANTABILITY

WITH

FURNISHED

BY

MILLER.

PROVIDED BY

ARE

COMMERCIAL/INDUSTRIAL

BY

PERSONS

AND

MAINTENANCE

FOR

WARRANTIES

IS

AUTHORIZED

ANY

CONSUMER.

expressed

or

any

exclusive

12)

or

at

an

for

actual

expense.

authorized

notice

HEREIN

OR

REPRESENTA

REMEDY

THIS

RESPECT

BY

MILLER

INTENDED

TRAINED

CONSUMERS

DO

NOT

TO

or

implied.

other

duty

remedies

replacement

cases,

authorized

the

purchase

use)

upon

MILLERs

Factory,

service

costs

of

apparent

warranty

AND

FOR

PROVISION,

OF

LAW,

INCLUDING

OR

IS

EX

MILLER

FOR

AND

OR

EXTEND

I-

13)

at

of

OF

TO

IN

OF

*

this

After

appearing

manual

later

in

ERRATA

was

this

printed,

manual.

SHEET

refinements

in

equipment

design

occurred.

April

This

sheet

25,

1988

lists

exceptions

FORM:

to

OM-883

data

AMENDMENT

Add

the

Sensing

IMPORTANT

connected

terminal.

Amend

_~_

Robot

TO

following

Connections

the

to

-

2

Figure

Function

2

Strip

SECTION

Section

to

Ifdcelectrode

negative

4.

Arc

Control

Common

2

weld

Failure

Terminal

0

Weld

Alarm

Terminal

-

2

INSTALLATION

-

3A.

negative

output

Light

COMPUTER

welding

terminal

Connections

INTERFACE-WELDING

is

and

desired,

the

2TE

reverse

lead

with

connections

a

c/amp

POWER

is

connected

RETURN

Arc

Indicator

so

Failure

SOURCE

the

lead with

to

Computer

Light

CONNECTIONS:

the

FILE

Interface

a

ring

positive

COPY

TO

Arc

terminal

weld

is

output

FOLDER

**

4-2 4-15 4-19

083

111

110

Part

No.

Function

Strip

147

065 375

Control

2

Common

Weld

Replaced

With

147

083

121

313

110

375

To

(115VAC.

Terminal

Alarm

Terminal

Figure

GROMMET(qtychg)

PANEL,

STAND-OFF

24VAC,

2

Source

-

4.

24VDC)

Jig

Interface

Arc

Failure

Light

Connections

Voltage

Description

mtg-components(Effw/JJ377225)

(qty

chgl

2TE

+24VDC

*

Arc

Failure

indicator

TA-i

Light

16648-A

Quantity

2

1 7

**First BE

SURE

digit

TO

represents

PROVIDE

page

MODEL

-

no

AND

digits

SERIAL

following

NUMBER

dash

represent

WHEN

item

ORDERING

no.

REPLACEMENT

PARTS.

TABLE

OF

CONTENTS

SECTION

2-1.

SECTION

3-1.

3-2. 3

3

3-5. 3-6.

3

SECTION

Section

1

No.

-

1

-

1.

General

-

2.

Rec-eiving-Handling

-

3.

Description

2-INSTALLATION

Location

-

2.

2 2 2 2

-

3.

-

4.

-

5.

3

Gas/Current

Computer Computer Computer

-

PowerSwitch

Peak

-

3.

Overload

-

4.

Voltmeter

WireSpeed

Ammeter

-

7.

Indicator

-

4

INTRODUCTION

Information

Interface

FUNCTION

Amperage

Protection

Lights

SEQUENCE

Sensing

OF

Control

Meter

OF

And

Control

-

Welding

-

Welding

Terminal

CONTROLS

OPERATION

Safety

Connections

Power Power

Strip

Source

Connections

Interface

Connections

Page

No.

2 2 2

2

3

4

5

6

7 7 7

7

SECTION

-

4

-

4

-

4

-

5

-

5

-

5

-

5

5-5.

5-6.

1.

Input

2.

3.

5

1.

2.

3.

4.

Signal

Output

Wire

-

Signals

Stick

MAINTENANCE

Inspection

Overload

Display

Board

Replacement

Troubleshooting

From

Check

And

Upkeep

Protection

PC4

Chart

Welding

Computer

TROUBLESHOOTING

&

Check

Meter

Procedures

Power

Source

Interface

UseOflndicatorLightsForTroubleshooting

7 7

7

8

10

13



SECTION

-

INTRODUCTION

1



MR-S

Gas/Current

Model

Pulstar

Sensing

Weight

lbs.

31

Control5lbs.

(14

(2.3

kg)

+16.5

in.

(419

4-1/2

(108

mm)

in.

case

only

(267

mm)

Diameter

in.

17.9

2

mm)

Holes

3-1/2

Ts-1

in.

mm)

10320

Figure

-

1.

1

Specifications

OM-883

Page

1

-

GENERAL

1.

1

General

A.

Information

labels,

ment

presented

tags,

design,

and

installation,

troubleshooting

followed

ment.

B.

The

installation,

for

Safety

the

troubleshooting

practices

and

be

persons

plicable

the Arc

Owners

Safety

pear

words

different

WARNING

_____________

and

carefully

or

t~.tUII.liI and

and

the

safety

installed,

in

accordance

codes

Section

of

end

Welding

Manual.

instructions

throughout

WARNING

____________

levels

maintenance

followed

loss

life.

of

maintenance

procedures

of

operated,

such

Power

of

statements

INFORMATION

in

on

plates

operation,

should

which

safe

and

operation,

of

arc

welding

which

others.

Therefore,

and

with

but

as,

-

1

Safety

Source

specifically

this

manual

and

hazard.

include

procedures

result

could

include

this

the

effective

maintained

not

in

the

CAUTION

___________

AND

manual

unit

pertainstoequip

maintenance,

be

read,

use

-

maintenance,

equipment

ensure

this

manual

limited

Rules

welding

pertaining

highlighted

installation,

or

practices

in

serious

installation,

proceduresorpractices

SAFETY

and

understood,

personal

equipment

only

to,

For

which

personal

SECTION

various

on

of

this

requires

by

qualified

and

listed

those

Operation

power

unit

this

to

the

by

identify

operation,

which

operation,

which

carefully

or

A tions

efficient

and

equip

1

this

the

have

damage

by

and

safety

is

to

all

ap

at

Of

source

ap

signal

if

not

injury

if

not

of

quest

When

ment, Number

1

trol

and

meter,

cuitry

for

can

The and

These when

cess.

2-INSTALLATION

followed

signal

which

to

word,

need

damage

third

operation

-

2.

RECEIVING-HANDLING

equipment,

unit

and

carefully

occurred

that

the

lading

may

purchaser

will

if

occasion

be

requesting

it

is

essential the

of

-

3.

DESCRIPTION

contains

weld

wire

peak

voltmeter,

interface

to

with

used

the

in

use

be

gas/current

current

sensing

components

the

using

could

this

equipment.

IMPORTANT

special

of

this

clean

inspect

during

have

with

furnished

file

to

information

that

equipment

feed

speed,

amperage

and

with

Pulstar

standard

sensing

reed

function

Gas

Metal

result

in

minor

,highlights

emphasis

to

equipment.

-

Before

all

packing

shipment.

occurredintransit

the

claim

for

carrier.

the

by

arises.

material

damage

any

Any

A

manufacturer

concerning

-

wire

the

450

or

control

Model

The

be

supplied.

computer

weld

control

feed

robot

welding

pulsed

Description

background

circuitry,

speed

control.

power

mode.

contains

relay.

with

the

Arc

Welding

personal

obtain

from

claim

must

copy

interface

meter,

The

the

robot

(GMAW)

injury

instruc

the

most

installing

around,.

that

may

for

loss

be

filed

of

the

bill

on

this

equip

and

Serial

con

voltage,

am

digital

and

cir

control

gas

system

and

valve

pro

source

or

re

is

2

The

covers

repair.

components.

Mounting

mounting

OM-883

-

1.

location

Page

LOCATION

and

wrappers

Lead

lengths

holes

purposes.

Arc

Receptacle

Welding

Interface

2

should

are

Sensing

Power

Receptacle

RC1

(Figure

allow

for

must

provided

Figure

RC12

Sou~ce

7

1-1)

to

room

installation,

be

considered

1

-1

Receptacle

in

each

gives

Peak

Output

open

maintenance,

Control

and

when

component

unit

dimensions.

Amperage

RC13

Figure

remove

and

locating

for

Strain

Relief

115

Volts

Control

-

2

1.

Normally

the should

source

of

robot

The

when

moisture,

Control

AC/Contactor

Receptacle

Panel

Rear

the

robot

control

be

mounted

and

manual

service

it

is

corrosive

Gas/Current

Receptacle

RC1

1

View

computer

unit.

wire

drive

for

life

and

subjected

Sensing

interface

The

in

gas/current

line

between

assembly.

specific

information.

efficiency

to

high

vapors,

RC9

and

of

is

mounted

the

See

installation

the

system

levels

extreme

on

sensing

welding

are

of

dust,

heat.

TB-i

top

control

power

section

reduced

dirt,

16632

of

-

GAS/CURRENT

2.

2

NECTIONS

WARNING

__________



Do



Shut

robot~.

(Figures

not

touch

down

and

ELECTRIC

lockout/tagging

terconnections.

Lockout/tagging

disconnect

from

breaker

A.

1.

2.

B.

Align

ching

rotate

C.

Route

output

trol,

weld

Owners

switch

fuse

box,

other

or

Computer

Control

keyways,

Align

ching

rotate

Align

keyways,

ching

and

rotate

Gas/Current

nections

keyways,

receptacle

threaded

Weld

cable

terminal,

the

to

wire

cable

Manual

or

Connections

receptacle

threaded

receptacle

insert

Cable

from

terminal

SENSING

2-1

And

SHOCK

live

electrical

unit,

disconnect

welding

procedures

open

ccrnsist

position,

off

procedures

in

shutting

disconnecting

Interface

insert

threaded

-

14-pin

on

computer

collar

fully

16-pin

on

gas/current

collar

Sensing

14-pin

clockwise.

fully

power

the

assembly

(see

plug

gas/current

on

gas/current

collar

Connections

welding

through

drive

for

location).

CONTROL

2-2)

kill.

can

parts.

power

input

source,

power

before

of

padlocking

removing

and

red-tagging

device.

Gas/Current

Amp

plug

interface,

clockwise.

Amp

plug

sensing

clockwise.

fully

Control-Motor

from

motor

sensing

source

control,

positive

sensing

and

connect

Motor/Drive

CON

and

employing

making

in

line

fuses

circuit

Sensing

into

mat

and

into

mat

control,

Con

into

mat

and

weld

con

cable

Assembly

D.

Gas

Connections

Connect

supplied) sing

assembly

gas regu

Connect

gas/current ing

hose

at

gas

control.

to

fitting

flow

must

lator/flowmeter

E.

Touch

cord

sensing

from

outlet

from

source

Connect

Sensor

with

cable.

gas

on

be

two

regulator/flowmeter

IN

to

gas

gas/current

accurately

the

at

source.

Connections

friction

controltotouch

Polarity

on

fitting

hose

sensing

connectors

is

not

from

controlled

sensor

important

(customer

gas/current

wire

control.

by

coming

leads

for

sen-.

drive

The

a

from

com

this

connection.

-

2

POWER

3.

COMPUTER

SOURCE

INTERFACE

CONNECTIONS

-

WELDING

(Figures

2-1

And

2-2)

WARNING

__________



Do



Shut

robot,

lockout/tagging

terconnections.

Lockout/tagging

disconnect

from

fuse

breaker

There

are

ween

source.

the

following

to

Volts

115

ELECTRIC

touch

not

down

and

switch

box,

other

or

several

computer

Examine

connections.

AC/Contactor

Cord

SHOCK

live

electrical

unit,

welding

disconnect

procedures

procedures

in

open

or

shutting

off

disconnecting

cords

used

interface

and

select

can

parts.

power

input

power

before

consist

of

position,

and

red-tagging

device.

for

interconnections

and

the

proper

kill.

source,

employing

making

padlocking

removing

circuit

welding

cord

power

for

and

in

line

fuses

bet

the

Welding

Source

Robot

Power

Interface

Control

Unit

Figure

Computer

Interface

-

2.

2

Control

Motor

Cord

Interconnection

Pulstar

Power

Diagram

Welding

Source

TB.109

Sensor

Connections

851-A

OM-883

Page

3

A.

Arc

1.

Align

into

and

2.

Connect

power

Connect

3.

source

B.

Output

1.

Align

ching

rotate

2.

Align

receptacle

threaded

C.

115

tions

1.

Align

matching

rotate

Sensing

keyway,

matching

threaded

rotate

lead

source

lead

negative

Control

keyway,

receptacle

threaded

keyway,

on

collar

Volts

keyways,

receptacle

threaded

Connections

insert

four-socket

receptacle

collar

with

ring

positive

with

clamp

output

Connections

10-socket

insert

on

computer

collar

fully

insert

10-pin

welding

clockwise.

fully

AC/Contactor

four-socket

insert

on

collar

fully

on

computer

fully

terminal

output

to

terminal.

clockwise.

plug

power

computer

clockwise.

Amphenol

clockwise.

terminal.

welding

plug

interface,

into

source,

Control

Amp

interface,

plug

interface,

to

welding

power

into

mat

matching

and

rotate

Connec

plug

and

into

and

2.

Insert

two-pole

contactor

source,

3.

Place

TOR

4.

Insert

115

source,

-

4.

2

COMPUTER

POWER

(Figures

WARNING

________



Do



Shut

robot,

and

welding

CONTROL

three-pole

VAC

and

SOURCE

2-1,

2-2.

ELECTRIC

touch

not

down

and

lockout/tagging

terconnections.

Lockout/tagging

fuse

or

Align

ching

rotate

switch

box,

other

keyway,

receptacle

threaded

disconnect

from

breaker

1.

twistlock

control

rotate

power

receptacle

plug

source

switch

twistlock

receptacle

clockwise.

rotate

INTERFACE

And

2-3)

SHOCK

five

electrical

unit,

we/ding

disconnect

procedures

open

consist

position,

off

procedures

in

or

shutting

disconnecting

insert

24-socket

on

computer

collar

fully

plug

on

clockwise.

REMOTE

in

the

REMOTE

plug

the

on

can

parts.

power

input

power

before

of

and

red-tagging

device.

clockwise.

from

cord

welding

CONTAC

position.

from

cord

welding

-

WELDING

CONNECTIONS

kill.

source,

employing

making

padlocking

removing

into

plug

interface,

into

power

into

power

and

in

line

fuses

circuit

mat

and

Control

OM-883

Right

Robot

Side

Page

Unit

4

View

Chassis

Common

Figure

Wire

2

Red

-

3.

Lead

Stick

Blue

Wire

Welding

(-I

Stick

Lead

I

/

Green

~

1+)

Power

Lead

Welding

(WCR)

Source

Current

Detect

Lead~

Interface

Connections

TC-~

Source

14937

2.

Align

plugs receptacles

interface,

clockwise.

Remove

3.

panel.

Route

4.

through

source

Connect

5.

a.

b.

c.

keyways,

from

interconnecting

on

and

welding

remaining

strain

interface,

leadsasfollows:

Red

leadtoterminal

Blue

leadtoterminal

White

lead

insert

bottom

rotate

power

cord

in

relief

to

14-position

terminal

to

four-,

of

welding

threaded

source

from

bottom

52.

50.

six-,

cord

computer

of

terminal

35.

and

into

matching

power

collars

interface

welding

ten-pin

source

fully

side

power

strip.

Lockout/tagging

disconnect

from

breaker

There

terface

loosen necessary,

nection.

and

reinstall

The

ARC

panel

control

ductor

1.

switch

fuse

or

are

for

screws

box,

other

several

control

and

or

on

locate

Tighten

top

FAILURE

is

turned

unit.

cord

For

tionsatfunction

2-4):

Locate

for

robot

on

this

open

consist

position,

off

procedures

in

shutting

disconnecting

terminal

connections.

strain

strips

reliefonunit

appropriate

screws

cover

light

and

supplied

connection,

control

on

when

on

off

units

control

strain

procedure

the

computer

by

length

of

and

red-tagging

device.

inside Remove

terminal

relief

a

signal

of

and

proceed

with

no

terminal

padlocking

removing

the

computer

unit

top

rear

strip

if

necessary,

is

finished.

interface

the

from

18

gauge/2

as

other

2

strip

line

fuses

circuit

in

cover,

panel

for

con

front

robot

con

follows:

connec

(Figure

if

d.

e.

Reinstall

6.

-

2

5.

COMPUTER

CONNECTIONS

~



Do

not



Shut

and

lockout/tagging

terconnections.

Robot

Control

Unit

Robot

Unit

Green

Long

green

chassis

to

and

ELECTRIC

touch

down

unit,

disconnect

Function

Strip

Function

2

Strip

lead

ground.

secure

INTERFACE

live

welding

2

p

Weld

Terminal

Control

Common

terminal

to

with

lead

side

SHOCK

electrical

power

input

procedures

Control

Common

Alarm

Terminal

Terminal Terminal

36.

ring

panel.

TERMINAL

can

parts.

power

before

Terminal

To

(115

VAC.

Isolation

Relay

terminal

kill.

source,

Voltage

24VAC.

connects

STRIP

and

robot

employing

making

in

2TE

~-ii--

2TF

2TL

p

Source

24VDC)

i

+24VDC

a.

b.

c.

d.

e.

Open

function

Route

Make

common

robot

Close

through

interface.

puter

Connect

Computer

Arc

Failure

Indicator

Light

robot

control

cord

under

cord

and

control

strain

cordto2TE

-(3

control

unit

terminal

cross

connections

the

Weld

unit

relief

on

and

Interface

2TE

door,

strip

member

to

Alarm

door,

rear

2TF.

2.

below

terminal

terminal.

and

panel

24VDC

and

route

of

Arc

Indicator

locate

door.

strip

cord

com

Failure

Light

Terminal

Figure

2-4.

Jig

Interface

Arc

Failure

Light

Connections

2TL

TA-uS

648

OM-883

Page

5

2.

For

~4

2T

a.

b.

c.

vdc,

robot

is

(Figure

Obtain

and

relay

Open

function

Route conductor

door.

control

used

2-4):

115

a

install

robot

control

customer

units

at

or

control

cord

when

function

24

vac,

into

termina

supplied

under

control

or

interface.

jig

unit

cross

115

24

door,

strip

member

24

or

terminal

vdc,

and

2.

18

gauge/2-

or

vac,

strip

isolation

locate

below

f.

Connect

voltage

off

Cut

g.

18

gauge/2-conductor

minals

relay.

Connect

h.

normally-open

I.

Route

of

computer

cord

source.

terminals

to

connect

one

cord

through

isolation

to

from

to

end

of

contacts

strain

interface.

one

cord,

contacts

cord

isolation

on

relief

relay

end

and

to

of

on

install

a

rear

coil

and

supplied

ter

isolation

of

set

relay.

panel

d.

e.

Make

common

Close

to

jig

connections

cord

and

control

robot

interface.

Gas

Weld

the

Indicator

Light

Alarm

unit

door,

SECTION

Contactor

Indicator

Light

to

and

terminal

terminal.

route

-

3

Wire Feed

Indicator

Light

strip

cord

FUNCTION

Current

Indicator

Light

j.

OF

Indicator

Light

Connect

CONTROLS

Failure

cord

and

2TE

to

2TF.

TB-i

14436

-

1.

3

Placing

input

for

the

OFF

position

-

2.

3

The

Peak

a

ting

switchonthe

12OPPS

crease

IMPORTANT

welding.

OM-883

Page

POWER

the

power

robot

PEAK

Amperage

peak

position.

peak

6

SWITCH

POWER

the

to

weld.

to

shuts

AMPERAGE

amperage

welding

amperage.

This

switch

interface.

Placing

the

down

control

level

power

Rotate

control

(Figure

in

the

The the

interface.

CONTROL

provides

when

source

control

the

may

3-1)

ON

position

interface

POWER

a

means

the

Mode

in

is

clockwise

be

adjusted

Figure

must

switch

(Figure

of

Selector

the

6OPPS

-

3

1.

applies

be

on

in

the

2-1)

selec

or

in

to

while

Front

3

The

nal

opens,

replacement

The

overload

face

reset

Panel

-

3.

A.

interface

short

B.

wire

shuts

the

View

OVERLOAD

Protection

Fuse

excessive

or

interface

the

Drive

Wire

drive

circuit

by

down.

circuit

PROTECTION

is

protected

overload

shuts

procedures.

Motor

is

motor

protected

breaker

Manually

breaker.

from

down.

Circuit

CB1.

depress

damage

fuse

by

See

Breaker

from

If

CB1

the

(Figure

due

Fl.Iffuse

Section

damage

opens,

reset

3-1)

to

button

an

the

5-2

due

inter

Fl

for

to

inter

to

3

The

of

3

-

VOLTMETER

4.

voltmeter

volt

a

WIRE

5.

while

displays

welding

SPEED

(Figure

weld

voltage

and

preset

METER

3-1)

to

voltage

(Figure

the

nearest

3-1)

while

tenth

idling.

The

indicate

to

The

power

weld

GAS

light

CONTACTOR

source

output

turns

shielding

contactor

available.

is

when

on

gas

light

the

flow.

turns

is

energized

valve

is

to

energized

the

welding

indicate

that

gas

when

on

wire

The the

Actual

the

3

The

nearest

-

wire

6.

speed

nearest

and

feed

AMMETER

ammeter

amp

idling.

-

INDICATOR

7.

3

There

are

visual

are

4-1.

SOURCE

and

face.

parameters.

to to

INPUT

wire

These

preset

keep

drive

weld

meter

displays

per

wire

feedback

minute

feed

inch

preset

speed

(Figure

welding

LIGHTS

4-1)

send

are

welding

values

weld

and

lights

FROM

-

The

signals

and

at

displays

while

indicator

five

indicationsofvarious

SIGNAL

(Figure

motor

signals

During

welding

parameters

wire

preset

while

welding

the

are

speed

circuit.

3-1)

peak

amperage

preset

amperage

the

process

3-1)

interface.

(Figure

on

SECTION

WELDING

welding

the

to

computer

used

these

determine

to

signals

compensations

levels.

preset

feed

speed

and

due

same

to

functions.

-

SEQUENCE

4

POWER

power

are

source

compared

are

to

idling.

to

the

while

These

inter

weld

made

The

motor

The

relay

The

outage

OF

Wire

Corn

WIRE

is

energized

CURRENT

is

energized

FAILURE

ARC

while

OPERATION

Start

Relay

Feed

Speed

mend

FEED

light

to

welding.

turns

light

indicate

to

turns

indicate that

turns

light

pen_

when

wire

an

when

the

arc

the

is

feeding.

current

is

there

_____________

on

that

when

on

Arc

Initiation

Close

drive

wire

detect

established.

is

an

arc

Welding

Welding Voltage

From

Weld

Detect

-

2.

4

TERFACE

input

motor,

the

of

source

Current

No-Load

Input

Motor

Abnormal

r

Start

Figure

OUTPUT

(Figure

signals

robot,

computer

wire

and

Arc

Initiation

Oto5OV

A



~p~w~ibnormaIity

-

1.

4

from

SIGNALS

the

wire

and

interface

feed

Input

-

4-2)

welding

stick

functions

Signal

FROM

interface

The

power

check

regulates

while

H

occurs.

Timing

COMPUTER

source,

circuit.

the

welding.

Crater

I

114379

TA-

Chart

interprets

wire

The

output

welding

power

Time

drive

Close

~lnching

~OutputToMotor~~



Start

-

4

STICK

if

the

puddle.

feedback

the

robot

2.

IN

the

Figure

-

4 weld determine the

weld.

weld,

WIRE

3.

is

completed,

weld

Feedbackisused

If

the

Output

CHECK

wire

the

welding

determineifthe

to

indicates

can

cycle

Signal

stick

wire

its

to

Open

Timing

(Figure

check

burned

has

wire

the

wire

I

TA-i

Chart

-

4-3)

is

performed

back

is

free

is

free

Time

14379

After

out

o~

of

the

to

of

the

OM-883

Page

7

Voltage

Command

Wire

Check

200

Contactor

Stick

ri

milliseconds

1.25VDC

I

Figure

feedback

the

If

to

feedback

its

to

feedback

the

voltage

wire

the

Abnormal

module,

the

source

minimum

should

determine

welding

wire

weld.

10vDc

5VDC

2.5VOC

I I

__________

__~~~i1_~__

_________

4-3.

Wire

Stick

__________

1i

11

Check

TA-i

I I I

IL

14379

power

provide

contactor

voltage

used

the cle

If

voltage

free

more

welding

If Weld

gram

from

is

pulsed

indicates

(see

remains

indicates

sent

is

welding

on.

be

enough

the

if

sequence.

indicates

is

given,

wire.

increases

Figure

stuck,

error

the

and

a

If

the

The

will

wire

the

.25

1

power

wire

the

free

to

wire

the

wire

and

check

used

are

4-3).

the

be

displayed

must

VDC

is

now

is

free,

the

robot

is

stuck,

command

source

was

stuck,

the

wire.

free

the

is

still

stuck,

contactor

is

performed

to

try

will

on

be

physically

the

output.

the

Feedback

the

of

robot

and

shut the

robot

welding

signal

The

pulsed

weld.

can

a

higher

pulsed

and

two

free

down,

pro

removed

to

is

If

cy

to

the

a

IMPORTANT

______________

this

maintained when

for

unit

necessary.

precautionary

WARNING:



Do



Shut and

INSPECTION

not

down

5-1.

lockout/tagging

inspecting

Lockout/tagging

disconnect

from

fuse

box,

and

type

Repair

and

or

other

shop

of

cracked

breaker

Usage

and

follows:

as

1.

equipment.

Remove

2.

moisture

-

2.

5

__________

WARNING



OVERLOAD

Do

not

Shut

and

dawn

lockout/tagging

inspectingorservicing.

Lockout/tagging

disconnect

from

fuse

box,

breakerorother

OM-883

Page

8

SECTION

six

Every

legibthty.

in

a

c/early

See

labels.

months

All

precautionary

readable

the

Parts

AND

ELECTRIC

live

touch

unit,

disconnect

SHOCK

electrical

welding

input

procedures

or

servicing.

procedures

switch

in

or

shutting

open

disconnecting

conditions

maintenance.

or

replace,asrequired,

cables;

give

insulation

grease

from

ELECTRIC

touch

live

unit,

disconnect

will

Inspect

particular

and

electrical

PROTECTION

SHOCK

electrical

welding

input

procedures

procedures

switch

in

or

shutting

open

disconnecting

5

inspect

state

List

UPKEEP

parts.

power

consist

position,

off

and device.

determine

and

areas

grime

parts

parts.

power

consist

position,

oft

and

device.

-

MAINTENANCE

the

labels

and

part

kill.

number

and

for

can

source,

employing

before

of

internally

padlocking

removing

red-tagging

the

frequency

equipment

all

hoses,

attention

to

where

from

components,

and

cables.

(Figure

can

source,

3-1)

kill.

and

employing

before

of

internally

padlocking

removing

red-tagging

on

be

must

rep/aced

of

robot

line

fuses

circuit

monthly

cords,

frayed

it

enters

robot

line

fuses

circuit

&

TROUBLESHOOTING

CAUTION

unit.



If

replacement

the

of

List).

To

1.

replace

the

Depress

counterclockwise.

2.

Pull

out

is

free.

Insert

3.

Install

4.

5.

Depress

until

-

DISPLAY

3.

5

Do Be

PC4

for

5-1)

for

the

not

sure

(Figure

board mand

WARNING

__________

 

cedures



Shut

or

down

test

practices.

ty

ELECTROSTATIC

electronic



Put

components.

on

handling



Transport

static-shielding

per



Perform

Remove

1.

IMPROPER

proper

fuse,

and

with

fuse

new

with

fuse

and

is

cover

BOARD

-

Check

checking

meters.

ELECTRIC

live

touch

that

personnel

familiar

are

unit

equipment

DISCHARGE

a

properly

circuit

static-sensitive

all

work

computer

becomes

size,

proceed

rotate

cover

into

fuse

rotate

secure.

points

power

electrical

with

before

lead

grounded

boards.

carriers

at

only

FUSES

necessary,

and

type,

follows:

as

fuse

when

holder

fuse

holder

fuse

PC4

are

provided

supply

SHOCK

parts.

performing

and

making

connections.

static-safe

a

interface

can

rating

holder

fuse

cover.

back

cover

METER

and

can

follow

or

changing

(ESD)

wrist

strap

components

and

packages.

work

cover.

top

damage

use

only

(see

holder

into

clockwise

the

on

input

kill.

testing

standard

can

damage

area.

this

fuses

Parts

cover

unit.

CHECK

display

com

pro

safe

meter

BEFORE

in

pro

Raar

Viaw

Of

Board

Display

PC4

Circuit

Input

Command

For

Wira

Input

Metar-.5V

Command

Volts

For

=

50V

Digital

Speed

Motor

Circuit

Input

Ammeter

Command

-

IV

For

=

100A.

Figure

-

1.

5

Display

Board

Meter

Checks

Mater

Display

Board

Receptacles

RC2O

Ref:TC-116

Circuit

PC4

And

633

RC24

interface

Board

Circuit

PC3

Receptacle

RC1

9

Figure

5-2.

Circuit

Board

Replacement

RF

Board

Receptacles

Filter

RC21

Terminal

Circuit

PC6

And

Ref:

TD-116634

RC22

OM-883

Page

9

2.

Locate

3.

Check

4.

If

a

correct

meter

5.Ifthe

rect, 5-4).

display

voltage

meter

and

(see

power

replace

power

the

Section

supply

board

PC4.

according

supply

is

meter

5-4).

or

command

display

board

to

and

command

not

working,

Figure

voltage

PC4

5-1.

voltage

replace

(see

the

is

incor

Section

is

b.

Gently

tain

Slide

c.

d.

Push

protruding

Reinstall

e.

meter

pull

spacers.

spacers

meter

lock board.

to

may

meter

straight

onto

into

socket

through

washers

Do

be

damaged.

new

meter

with

to

rear

and

not

overtighten

out

of

socket.

support.

meter

PC4.

nuts

supports

to

secure

nuts

Re

or

-

5

4.

BOARD

(Figure

I~I.1~hII~er

 

5-2)

Do

not

Shut

down

robot~,

and

~/ockout/

or

servicing.

ELECTRIC

touch

tagging

Lockout/tagging

disconnect from breaker

ELECTROSTATIC

circuit



INCORRECTLY

circuit



EXCESSIVE



~

with

Retain

reinstallation.

A.

1.

switchinthe

fuse

or

board

Put

handling

Transport

per

Perform

or

box,

other

components.

on

properly

circuit

all

static-shielding

work

boards.

Be

ed

sure

onto

that

connectors

PRESSURE

Use

when boards.

respect

all

Display

Remove

minimal

only

disconnecting

the

to

hardware

Board

unit

REPLACEMENT

SHOCK

live

electrical

unit,

disconnect

welding

input

procedures

open

consist

position,

off

device.

procedures

shutting

disconnecting

DISCHARGE

grounded

boards.

static-sensitive

carriers

at

a

are

properly

before

can

pressure

or

PC4

cover.

static-safe

break

connecting

such

facing

during

And

only

INSTALLED

plugs

All

directions,

operator

removed

top

PROCEDURES

can

parts.

power

before

of

and

red-tagging

(ESD)

wrist

components

or

packages.

PLUGS

aligned

resuming

circuit

and

gentle

as

the

unit

this

Meter

kill.

source,

employing

inspecting

padlocking

removing

circuit

can

damage

BEFORE

strap

in

work

area.

can

damage

and

install

operation.

board.

movement

board

plugs

left

or

right,

front

panel.

procedure

Replacement

and

line

fuses

pro

or

are

for

6.

To

line

meters

7.

Reinstall

8.

Reconnect

receptacles

9.

Reinstall

B.

Motor

1.

Remove

2.

Remove

3.

Gently

4.

Insert

5.

Reinstall

6.

Reinstall

C.

Replacement

Boards

1.

Remove

2.

Disconnect

3.

Unlatch

ing

4.

Slide doffs.

install

board

and

Board

pull

new

standoffs

rail.

new

replacement

with

up

LEDs.

securing

PLG2O

new

on

unit

top

cover.

PC2

unit

top

cover.

securing

board

into

board

securing

unit

top

cover.

Procedure

cover

plug(s)

into

board

display

front

screws.

and

PLG24

PC4.

Replacement

and

screw

from

receptacle

RC5.

and

screw

and

from

board.

and

slide

retaining

board,

panel

unlatch

latch

For

locate

board

rail

openings

to

matching

standoff.

RC5.

standoff.

Remaining

board.

of

out

and

latch

carefully

for

retain

stan-

OM-883

2.

3.

4.

5.

Page

Remove

not

remove

Disconnect

ching

receptacles

Gently

and

To

a.

Do

replace

pull

not

LEDs

Remove

support.

10

screws

stand-offs.

plugs

board

pull

may

meter(s)

securing

or

up

be

nuts

board

PLG2O

PC4.

on

straight

down;

damaged.

proceed

and

lock

to

stand-offs.

and

PLG24

from

away

otherwise,

follows:

as

washers

from

front

the

from

Do

mat

panel.

meters

meter

5.

6.

-

5

WARNING

_________

 

Connect

new

Reinstall

5.

TROUBLESHOOTING

Do

not

Shut

and

plug(s)tomatching

board.

unit

ELECTRIC

touch

down

unit,

disconnect

lockout/tagging inspectingorservicing.

cover.

top

electrical

live

welding

procedures

SHOCK

power

input

CHART

parts.

power

receptacle(s)

kill.

can

source,

and

employing

before

internally

on

robot

Lockout/tagging

fuse

box,

other

or

PARTS

Keep

SURFACES

Allow

switch

or

clear

cooling

disconnect from breaker

MOVING



HOT



Troubleshooting

sons.

assumed

It

is

installed

that

according

open

consist

position,

off

procedures

in

shutting

disconnecting

cause

can

of

moving

can

to

the

period

be

to

parts.

cause

before

performed

computer

Section

of

and

red-tagging

device.

serious

severe

servicing. only

-

interface

of

this

2

padlocking

removing

injury.

burns.

qualified

by

was

properly

manual,

line

fuses

circuit

per

the

operator

unit

relatedtothe

designed

the

Use while trouble

cedures,

tion

is

was

working

to

troubles

this

chart

performing

is

not

the

should

malfunction,

should

be

strictly

familiar

with

properly,

welding

diagnose

that

may

in

conjunction

troubleshooting

remedied

nearest

be

contacted.

the

manufacturers

followed.

the

and

process.

and

provide

develop

after

Factory

In

function

that

the

The

following

remedies

in

this

unit.

with

the

procedures.

performing

Authorized

all

cases

recommendations

of

controls,

trouble

for

circuit

Service

of

the

is

not

chart

some

diagrams

If

the

these

pro

Sta

equipment

is

of

Unit

No

does

meter

wire

TROUBLE

not

display.

feed.

operate.

PROBABLE

Fuse

Fl

Circuit

Meter

breaker

not

Display

working.

Robot

signal.

CR1

Relay

Motor

board

ing.

open.

CB1

working.

board

not

PC2

CAUSE

tripped.

PC4

working.

work-

not

Check

5-2).

Fl,

Correct

operation.

Check

overload

Use mine

5-3).

Section

Use

(see

okay,

Check PC2.

and

Replace

CB1,

check

if

power

If

check

5-4).

check

Section

replace

input

Signal

B

(common)

CR1.

PC2

problem

and

overload

and

points

is

points

5-3).

PC4

signal

should

(see

REMEDY

replace

reset

before

on

display

available

are

determine

to

If

(see

from

be

RC5.

on

Section

if

necessary

problem

if

necessary.

continuing

board

to

meter

okay,

if

check

Section

robot

0-10

5-4).

points

vdc

(see

before

operation.

PC4

(see

replace

power

5-4).

to

motor

between

Section

continuing

Correct

deter

to

Section

meter

(see

is

available

do

not

test

board

pins

K

Wire

ly.

feeds

at

maximum

on-

Tach drive

board

motor

PC5

not

working.

wire

at

Replace

PC5.

OM-883

Page

11

TROUBLE

PROBABLE

CAUSE

REMEDY

No

arc

voltage

Robot

Touch

Robot

wireisstuck,

Wire goes

shuts

Sensor

moves

speed

to

zero.

control.

down

error.

when

(1PM)

due

to

welding

meter

Output

tions.

Arc

sensing

Voltage

working.

Incorrect

voltage.

Touch

Sensor

Control

ing.

Wire

stick

Arc

sensing

Incorrect

voltage.

control

connections.

board

robot

CR3

relay

connection.

connections.

robot

connec-

PCi

not

command

connections.

work-

not

command

Check

and

Check

and

Replace

Check

PCi.

ween

Check

PCi

robot

Command

K

pins

continuity

gas/current

Secure

Replace

Be

and

welding

minal

Check

PC2.

and

sure

blue

strip.

Signal

B

(common)

all

connections.

CR3.

that

lead

power

and

secure

robot

secure

(see

command

voltage

and

sensing

lead

red

is

source

command

should

connections

Section

voltage

should

A

(common)

of

leads

control.

is

connected

interface

connections

voltage

be

0-10

RC5.

at

5-4).

between

to

vdc

(see

at

voltage

be

0-10

RC14.

at

gun/torch

Repair

to

terminal

14

(see

Section

at

between

Section

vdc

or

replace.

terminal

50

position

motor

pins

2-3).

board

bet

and

52

on

ter

2-3).

board

K

No

Robot

wire

retract.

shuts

down.

Motor

board

PC2

ing.

Control

relay

CR2

ing.

Interface

board

working.

Incorrect

robot

voltage.

Loose

weld

tions.

output

Interconnecting

Interface

board

working.

not

PC3

command

connec-

cords.

PC3

work-

not

Replace

Check

PC2.

Signal

and

B

Clean

and

Check

or

replace.

Replace

PC2

(see

Section

CR2.

PC3

robot

(common)

tighten

all

interconnecting

PC3

(see

command

should

Check

(see

Section

be

RC5.

at

connections.

and

Section

5-4).

voltage

0-10

cords

secure

5-4).

at

vdc

between

for

all

connections.

motor

breaks;

board

pins

repair

K

OM-883

Page

12

-

5

6.

USE

OF

INDICATOR

LIGHTS

FOR

TROUBLESHOOTING

Gas

flows:

System

Contactor

System

On

normal

On

closed:

normal

On

(on).

Gas

does

Check

Contactor

Check cords.

Check

flow:

not

valve

gas

open:

interconnecting

interface

Wire

Indicator

Gas

operation.

Contactor

board

PC3.

Feed

Light

Gas

flows:

Check

and

Check

Indicator

~lr

Contactor

Check

Indicator

gas

line

gas

interface

Light

display

Light

valve

for

closed:

board

operation

leaks.

board

PC3.

PC4.

Gas

System

Contactor

System

dodes

normal

Off

Open:

Off

not

(off).

flow:

Wire

System

~1~

Arc

started:

System

No

arc:

Check

feeds:

normal

weld

(on).

On

-*

I

(on).

On.

parameters.

Wire

does

Check

No

arc:

Replace

~Ir

Arc

started:

Check

Signal

between

2TF.

not

circuit

CR1.

relay

interface

reed

relay.

from

signal

should

terminals

feed:

breaker

board

Current

Arc

be

24

CB1.

PC3.

Failure

robot.

vdc

2TE

Indicator

and

Wire

Check robot

Signal

between

(common)

Check

Light

Arc

started:

Replace

No

arc:

Normal

feeds:

input

to

motor

should

pins

wire

reed

Light

during

signal

be

K

RC5.

at

feed

relay.

idling.

board

0-10

and

board

from

B

PC2.

vdc

PC2.

Wire

System

No

arc:

System

Arc

started:

Normal

does

while

not

normal

~

Off

I.

normal

Off

feed:

(off).

welding.

Check

display

board

PC4.

OM-883

Page

13

0

A

C

B

41

0

DOIVE

RCI.LS DRIVE

PLGB

r<*7

P016

~

i~T



CR2~~

2/

I

CR

RC9

~

CR2

~~~1

~~WFS

5016

7

AtE--,

PLGI6

PLG9

~

POWER

\sI

2

RCII

I

SELl

PEIER

I(

~Eiii_

~TER

I

1

185.

150.

By

TI

1

~T

REAPI

~1

.1

~T

U

PC4(C)

~:1

G

L_~_~~_.~yyJ

1000

I

~CRI

38

Dl

8

C

AC At)

0

J

AlA AJ

AAAA

L

PC

RCI5

RCI4

RCI6

DO

A-P

AAPJ<

BA-RB

PCI

BA)~D

<AG

I

i

OF

ABAC

N

AA

A

U

_L~~~

~4TREL

POWER

~

(

C

BELLS

DRIVE

4

I

RETER

~LLL

08]

P04(B)

r

<<00

x

RC9

97

32

~3~PLG

240.

C4~

C3r

/

4>

_v

P06(B)

Lv

0

97

34

35

32

0

E

F

OC

00

OB

31

/70

490

/0/0

E

OA

21

A

IT

6/0

ff2

~

F

OB

729C726D/50

290

5

E

C

B

3/0

729

726

620

62

L7

A

F

2/

P

23

C

22

0

24

~

IA

100

CONNECT

SENSOR

550CR

3

U

13

RC

B

SENSE

ARC

C

RCI2

REED

2

~

U

40014

ASOL

4408

500

36005/0

J

G

U

0

720L

/208

3805

350

34

42

46J

4011

1

41

~5

~

PLG9

RC9

5)6

6

>><

4/

B>

J

8

K

BOARD

RCS

DO

1101DB

AZ

PC2

-

1

/

~Dls

2Ypu

~F1,

,PLG9

IY

P00(6

4RCI6

~

17

WIRE

4PLGZ

,RC7

19

CLRRErOT

FEED

GAS

,_/

//

~I

41

~I

~I

I

RC2O

RC24

ON

A-Il

AA-AF

BOARD

II

L

DISPLAY

PCAIA)

0

A

E

Vv

_________J_ii

)L-~-O

I

lA)>0

~

F

C

N

U

AC

U

LAA

AD

K



AA

S

15

__

A____

AL

I

rAA

~

72)~

I

J

_v_v_vl

AR

BOARD

P019

8dB

DO

INTERFACE

AN

A-B

AA-RN

PC3

RIO

_v_v

~

B

6

FAILURE

IB~

ARC

~lB

CDOTACTOW

*

0

S

~1

RC22

POOl

LG

DO

AP

U-AS

~

BOARD

~

PC6)A)

NE

~

T~I

AA

A



~ ~:

AS AD AC

26

49

34

A

RB

60

~i

3IRC9O~

1RC161

308

C116

No.

Diagram

Circuit

Interface

Computer

For

Diagram

Circuit

3.

-

5

Figure

PS

UV

-v

CA,

0

BA(

I

BB(

AC(

AF(

P

AA

AB

N

AK

AH

AG

AJ

A-PONRCI4

ON

AA-AK

BA-BB

I

CR

2

RCI5

RCI6

ON

AD(

AE

J

F

C

0

E

IH

CR2

<

Circuit

Diagram

No.

B-116

188

Figure

5-4.

Circuit

Diagram

For

Voltage

Control

Board

PCi

OM-883

Page

15

Fl

OM-883

Page

16

Figure

5-5.

Wiring

Diagram

a

-I

to

20a

-I

3

-I -a

0)

0

p.)

0

-v

to

4

0,

S

388

C-083

No.

Diagram

Circuit

PC2

Board

Speed

Motor

Digital

For

Diagram

Circuit

6.

-

5

Figure

-v

a

C

0

WELD

JOG

CL~RENT

~

C~4O~

WELD

RELAY

START

>FWD(

(REV>

V.

15

V.

.24

G

A8

AE

~j

AL AJ

H

AK

24

0

F

C

GAS

I

~

)L

~

I~6

CR2

GAS

E

A14

R~OT

Cl.PRENT

~TECT

AN

REV.

RELAY

K

AA-AF

A-P

Figure

PC2O

ON

RC24

Circuit

-

Circuit

7.

5

Diagram

For

I

Interface

Board

Diagram

PC3

No.

)AA

CR4

)

B-113

C~4TACTOR

AC

431

U

A

A A

A

Rc23

U

Figure

-

Circuit

8.

5

Diagram

U

For

A A

SCSI

Display

Board

A AAA

pCn

Circuit

PC4

Diagram

U

A

No.

z

B-ill

OM-883

341

Page

19

RC22

AA

AE

PP

AR

AG

IF

AD AC

AN

AL AK

All

AN

AR

AS

RC2I

4

-~

___

~

C32

H-

4

-~

G

Figure

C30

I

H

_

5

~

HL

-

9.

Circuit

~

i

I

~

C28

F

Diagram

MDC~

I

~

-3

~..

C24

H-

I

.

~

~.

C22

H

~r

C23

Circuit

RF

For

Filter

Board

PC6

~

CAR

-~

~r

C49

Diagram

I

H-

~

i~IL4

3

~

C20

H

~

C21

No.

B-ill

117

OM-883

Page

20

November

1987

FORM:

OM-883

Effective

With

Serial

No.

JH274875

PARTS

LIST

2

OM-883

Page

52

-

A

Figure

1

Control

Box

TC-116633

Item

No.

Dia.

.

Mkgs.



Part No.

Description

Quantity

Figure

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

A

R2

PLG9

PLG16

RC1

PLG12

PLG17

ICN4

ICN2

ICN3

Control

116774 010 010 853 070

+109

079683 030

010

010199 030949

056

109 047

079

079 096813

048 079 010 000

097922

115

039 716 073 073 089647 057

1

048 283

079 049 073

039 328 604 600

600 750

601

111199

109 091

604 910

604

090

109 159

109 157

604

109

CONTROL

855

RETAINER,

FASTENER,

634

-LABEL,

026

COVER,top

HEATSINK

941

RESISTOR,

193

TUBING, TUBING,.275IDx.O48wallxl

HEATSINK

170

SHIELD,

041

CABLE,

636.HOUSING

535

. .

739

CLAMP,

.

.CABLE,18ga15/c(orderbyft)

598

HOUSING

.

534

.

916

CONNECTOR,

527

BLANK,

KNOB

959

CABLE,

PLUG,

.

332

CLAMP,

.

140

CABLE,

.

.PLUG,l0socketMS-3106A-18-1S

360

BLANK,

RECEPTACLE

535

TERMINAL,

.

989

CABLE,

686

PLUG,

.

CLAMP,

.

109

WIRE,

.

848

WIRE,

.

TERMINAL,

.

226

INSULATOR

.

228

CLAMP,

.

CABLE,

330

PLUG,

.

100

CLAMP,

.

CABLE,

.

571

CABLE,

.

890

CABLE,

.

CONNECTOR

.

CONNECTOR

.

825

CABLE,

.

158

CONNECTOR

.

Box

PANEL

screw

screw-hd

warning

WWfixed

3/8

ODxl8gawaIlxl/4

(Fig

No.2

No.

electric

B

shock

100

Pg4)

resistor

interconnecting-motor/gas

&PINS

PLUG

TERMINAL,

male

cable

SOCKETS

&

PLUG

TERMINAL,

female

3/4

clamp

snap-in

7/8

mtg

interconnecting

MS-3106A-18-1

10

97-3057-10-639

cable

No.18

snap-in

10/c

3/8

W/PINS

(order

mtg

(consisting

inch

hole

(consisting

hole

male

volt-sensing

4

socket

cable

stranded

universal

interconnecting

24

socket

cable

20

ga

(consisting

MS-3106A-14S-25

AN-3057-6

16

(order

ga

12

(orderbyft)

ga

ring

tongue

25

amp

MS-3106A-24-28S

AN-3057-16

5/c

(order

1/2

(consisting

18ga4/c(orderbyft)

No.

208/c

183/c

(order

byft)

2

kill

can

watt

etc

5

ohm

(consisting

(consistingof)

(consisting

of)

P

byft)

of)

ft)

by

stud

of)

ft)

by

ft)

by

of)

1

4

1

4

2

1 1

1

14

2

l8ft

1

16

1

1 1 1

1 1

2Oft

1

1 1

4

1

1 1

1

9ft

35ft

1

1 1 1

6ft

6ft 6ft

1

6ft

1

OM-883

Page

2

Item

No.

.

Mkgs.

Dia.

Part

No.

Description

Quantity

Figure

45 46

47

48

49

50 51

52

53

54

55

56 57 58 59

60

61

A

RC12

RC17

RC13

C2-4

PC4

PLG2O,21

Fl

Si

CB1

R4

RC9

Di

PLG14,15

PLG16

PLG18

PLG19

PLG2O PLG22 PLG24

113736 076624 094591 089646 028

057

117836

073

081

112254

089

046

*012

073 487 011

011

603 856

115821 047

079534 109558

090

082798

079 760 079

081

092

084

Control

CABINET,

RECEPTACLE, RECEPTACLE,

-RECEPTACLE,

291

CAPACITOR,

084

BUSHING,

CIRCUIT

756

STAND-OFF,

380

HOUSING,

LABEL,

032

LENS,

432

HOLDER,

655

FUSE, NUT,

609

SWITCH,

CIRCUIT

991

POTENTIOMETER,

PLATE,

637

HOUSING

TERMINAL,

DIODE,

469

HOUSING, HOUSING, HOUSING,

798

HOUSING,

379

HOUSING,

159

HOUSING,

198

HOUSING,

Box

(Contd)

control

4

MS-3102A-14S-2P

24

10

ceramic

ID

1/4

snap

No.

terminal

robot

4341

fuse

No.

toggle

meter

6-32x5/8

header

computer

glass

2

SPOT

1

CARD,

Miller

led

miniature

speed

BREAKER,

WW

mtg-potentiometer

RECEPTACLE

female

1

400

amp

terminal terminal terminal

terminal

terminal terminal terminal

volts

header

header header header header

MS-3102A-14S-2P MS-3102A-18-i

0.1uf500 3/8

x

(Fig

10

amp

15

pole

10

&

SP

mtg

C

Pg

1/4

x

14

interface

250

125

amp

1

.5

amp

turn2watt

SOCKETS

18

2

12

13

12

16

6

volts

hole

ii)

hex

volts

P

dc

250

volts

10K

ohm

(consisting

of)

1 1

3

1

7

2

1

5

1 1

4

1

1 1

14

2

1 1 1 1

1

*Recommended

When

+

BE

ordering

SURE

TO

Spare

a

PROVIDE

Parts

component

MODEL

originally

AND

displaying

SERIAL

a

precautionary

NUMBER

WHEN

label,

ORDERING

the

label

REPLACEMENT

should

alsobeordered.

PARTS.

OM-883

Page

3

Item

No.

Dia.

Mkgs.

-

Part

No.

Description

Quantity

Figure

2 3

4

5

6

7

8 9

10

11

12

13

14

15 16 17 18

19

20

21 22

23

B

PC2

CR2

Ti

SRi

T2

R3

Ri

Cl

CR1

iT

2T,3T

PC6

CR3

PCi

PC3

116

071 083 052

109

035

109

605 079 030 006 031

034

038

038 783

111 110 110 110

110

116

113

009

073

774

642

147

964

099

914

017

741 497

651 426 692 841 832

065 565

391

386

375

528 221 335

730

Control

CIRCUIT

Panel

CARD,

GROMMET,

RELAY,

enclosed

TRANSFORMER,

RECTIFIER, TRANSFORMER,

CLIP,

mtg-resistor

RESISTOR,

RESISTOR, CLAMP,

capacitor

CAPACITOR,

24

RELAY,

BLOCK,

BLOCK, PANEL,

CIRCUIT

GUIDE,

RELAY,

voltsacDPDT

terminal

mtg-components

CARD,

mtg-circuit

enclosed

STAND-OFF,

CIRCUIT CIRCUIT

CARD, CARD,

STAND-OFF,

TERMINAL,

A

(Fig

digital

8-10

screw

24

volts

control

integrated

control

WW

fixed

WW

2

inch

electrolyte

20

amp9

20

amp

filter

(Fig

card

24

voltsacDPDT

support

voltage

interface

4-40

No.

header

22

2

Pg

motor

push

dc

30

amp

25

watt

25

watt

750

pole

12

B4

control

(Fig

5/8x1/4

x

Item

speed

in

DPDT

400

2K

10

uf

pole

Pg

B3

1)

(FigB2Pg8)

volts

ohm

200

volts

10)

Bi

(Fig

9)

Pg

dc

6)

1 1 1 1

1 1

4

1 1

1 1 1

2

1

3

8

1

2

1

BE

SURE TO

PROVIDE

MODEL

AND

SERIAL

Figure

NUMBER

B

-

Control

WHEN

Pan&

ORDERING

REPLACEMENT

PARTS.

OM-883

4

4

Page

+

_________

__

&IoI

>

o~

DI~

02

L1

04

.:i

ASSEMBLY

6528

+

o

I

___________

<~UOUJL2I)~_J~ZQ

Q~

~

~

CI

A2

iE~i

c~

~

RCI4

___

~~R2

E~I~R3

P4

1

R14

____Al

~6L_E~_i~~

_

I

~Rl2

P131

I

<~OOW1~C~I)~ <<<<<<<<<<

~

P17

R

I

6

R15CR2

~

CR1

2

+

o

2

L

RI

I

RCI5

+QC9

___

H

RCI6

Ref.

+

C-i

16526

OM-883

Page

COMPONENTS

QUALIFIED

-

Figure

5

Bi

BE

TO

PERSONNEL

Circuit

Card,

REPLACED

ONLY

Voltage

BY

Dia..

Mkgs.

Part

No.

Description

Quantity

Figure

Al A2

Cl

,2

C3,4

C5-8,11

C9

ClO

CR1

CR2

01-4

Ri

R2,15,16

R3

R4,14

R5 R6

R7

R8,9

Rl0,11

R12,13

R17

R18

RC14 RC15 RC16

VR1

VR2

Bi

116

528

096275

159

009

482

039

348

000

073

739 861

000

340

093

558 033

095

091

861 079 844 026

202 035

888

331

039

330

000 038 035

887 009

173

039 329 035

827

095 828

206

084

035

826 035 823

092

648

347

089 089 345

082

799 083772

046 392

Circuit

Card,

Voltage

Control

(Fig

IC,linear324

IC,linear358

100

0.47

uf50voltsdc

0.1 33uf35

0.01

uf50volts

ac

SP

0.25

20

0.25

uf35volts

volts

uf

35

volts

4PDT

2.2K

watt

4.7K

watt

0.5

turn

0.5

turn

10K

watt

CAPACITOR, CAPACITOR,

CAPACITOR,

CAPACITOR, CAPACITOR, RELAY,

RELAY,

SOCKET, SPRING, DIODE, RESISTOR, RESISTOR,

RESISTOR,

electrolyte

tantalum

ceramic

electrolyte

ceramic enclosed enclosed

relay

holddown-relay

lamp

carbon

carbonfilm0.25watt3.9Kohm

POTENTIOMETER,

RESISTOR,

carbonfilm0.25watt3.3Kohm

POTENTIOMETER,

RESISTOR,

carbonfilm0.25watt2.7Kohm

carbon

400

120

24

volts

film

cermet25

cermet

film

voltsac4PDT

RESISTOR,metalfilm0.25watt26.7Kohm RESISTOR,

RESISTOR,

metalfilm0.25watt3.32Kohm

film

0.25

watt6.8K

100

watt

carbon

film

RESISTOR,WWfixedzeroohm

TERMINAL,

header header header

14 10 2

pin pin

IC,linear78l5

linear

IC,

7915

B

Pg

dc

ohm

watt2K

watt

ohm

5K

Item

4

ohm

20)

1

2 2

5

1 1 1

2 2

4

1

3

2

1

2

2 2

1

1 1

1

1 1

1

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-883

Page

6

Ref.

D-093

449-G

OM-883

Page

REPLACED

COMPONENTS

QUALIFIED

-

Circuit

Figure

7

B2

BE

TO

PERSONNEL

Card,

Motor

ONLY

Speed

BY

Dia.

Mkgs.

Figure

B2

A50-53

C50 C5

1

C52,61

C53,62

C54

C55,66-75,77

C56 C57 C60

C63,64

C65

CR50

050-54,56-60

055

1C50

Q50

.53

1

Q5

Q52

R50

R51

,54,55,57,67,

68,74,75,82,89

R52,56,61

R53

R58,62,65,66,71,

72,76,90

R59

R60,87,88

R63,79

R64 R70

R73,83

R77

R78 R80

R81,84

R85

R86

T50

VR5O

VR51

Part

No.

071

642

009

159

039

482

031

699 739

073 035 833

023

005

643

031 073

549

677

031 035

561

602

044 031

721

033

095

091

861

079

844 202

026

910

080 081

800 200

037

037 824 039 335 030

839

035

827

052

138

039 332

035 884

030

007

039

335

106

039

331

039

049

015

328

039

142

052 039

108

886

035 035 825 030 937

090

030

092 648

085

399

081

799 272

047

261

037

Circuit

IC,

CAPACITOR,

CAPACITOR, CAPACITOR,

CAPACITOR, CAPACITOR, CAPACITOR,

CAPACITOR,

CAPACITOR, CAPACITOR,

RELAY,

SOCKET,

SPRING,

DIODE, DIODE, IC,

Card,

linear

358

enclosed24volts

relay

holddown-relay

1

amp

zener

interface

2907

electrolyte mylar

ceramic

mylar

tantalum ceramic

mylar

tantalum

mylar poly-film

mylar

15

TRANSISOTR,

THYRISTOR,

SCR

TRANSISTOR, RESISTOR,

RESISTOR, RESISTOR, RESISTOR,

RESISTOR,

WW

carbon

POTENTIOMETER,

RESISTOR, RESISTOR,

RESISTOR,

RESISTOR, RESISTOR, RESISTOR,

RESISTOR,

carbon

carbon carbon carbon carbon carbon carbon

carbon

carbon carbon

TRANSFORMER,

IC,Iinear78LO8

IC,Iinear78Ll2

HEAT

SINK

Digital

Motor

100

0.0022uf200

0.1

0.033uf100

2.2uf20

0.01

0.015

5.6uf35

4

uf

200

0.47uf400 uf

0.22

ac

400

volts

SP

5

watt

NPN200MA4OvoIts

7.4

fixed

film

amp

5

watt

0.25

UJT15MA

filmO.25

film

0.25

cermet

film

0.25

film

0.25

film

0.25

film

0.25

film

0.25

film

0.25

film

0.25

film

0.25

film

0.25

0.5

watt

0.5

watt

film

0.25

pulse

Description

Speed

uf35voltsdc

voltsdc

uf50voltsdc

voltsdc

volts

500

uf

volts

200

uf

volts

200

voltsdc

4PDT

200

volts

40

220

ohm

10K

watt

watt20K

15K

watt

lOOK

watt

watt watt

watt

watt watt

watt

watt watt

10

47

watt

turn

ohm ohm

0.75

47K

1K

4.7K 10 1 120K

82K 22K

1Kohm

zero

15

(Fig

dc

volts

SP

ohm

meg

.5K

ohm ohm ohm

ohm

dc

ohm

watt

ohm

Quantity

B

4

Item

Pg

50K

ohm

1)

4

1 1

-

2 2

1

12

1 1 1

2

1

1 1

10

1 1

2

1 1

10

3

1

8

3 2

1

2

1

2

1

15

1 1 1

1

BE

SURE TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-883

Page

8

Dia.

Mkgs.

Figure

B3

Al

Cl

C2 C3 C4 C5

CR2

CR4-6

03-8

D9,l0,15

Ql-3

Rl,2,8,1l

R3,6,7,12,13

R4

10

R5,

R9

RC18

RC19

VR1

Part

No.

221

113

159

009

482

039

348

000 072

130

005

023

739

073

521

095

018

099

091

861

079

844

026

202

028

351 037 200 035

826 039

331

072

561 039

106

052

145

079

759

079

795 081

832

Circuit

IC,

linear

Card.

358

CAPACITOR,

CAPACITOR, CAPACITOR,

CAPACITOR, CAPACITOR, RELAY,

RELAY, SOCKET, SPRING,

DIODE, DIODE,

enclosed enclosed24volts

relay

holddown-relay

1

amp

signal

TRANSISTOR,

RESISTOR,

RESISTOR, RESISTOR, RESISTOR,

TERMINAL,

78M15

linear

IC,

Interface

electrolyte

tantalum

tantalum tantalum

ceramic

volts

24

400

volts

0.020

amp

200MA

NPN

header

film

12 13

carbon

carbon carbon

(Fig

100

0.47 1

uf

35

2.2

uf20volts

0.1

uf50voltsdc

dc

SP

75

0.25

Description

4

B

Pg

uf35volts

dc

volts

4PDT

SPOT

SP

volts

40

6.8K

watt

4.7K

watt

270K

watt

470

watt

470K

watt

Item

ohm

Quantity

21)

dc

1

4

2

3

1 1

6

3 3

4

5

2

C2

~

Qc

08

El

07

~0d~

L_____

RCl8<a~UoujwoI~~_J~

$

p~

U,~

~

~r-~

~LJ!

ND

~41LK

~

t_-.~_

Cl

CP6~

00

COMPONENTS

c~J

P11

I

5

-o~

Al

1~U~J

P7

2)JU

~3

R2

CR5~

~

u

H

Jo.,0

0

~

TO

QUALIFIED

PERSONNEL

~

OLt

PCI9<~~)D~~

<<<~~~~<<<<

REPLACED

BE

ONLY

>-

Ret:

B-fl3

(1)

222-A

(01

Z

BY

BE

OM-883

SURE

Page

-

B3

NUMBER

Circuirt

WHEN

Figure

TO

PROVIDE

9

MODEL

AND

SERIAL

Card,

Interface

ORDERING

REPLACEMENT

PARTS.

Dia.



Mkgs.

Part

No.

Description

Quantity

Figure

B4

Cl

-6,9-14,46,47

C20-25,28-33,48,49

Li

-3,5-7,9

AC21 R

C22

__

__________

(

C

_____

___________

C

0

110

028 028

110 089 092

565

292 291

190

347~

160

__

__________

Circuit

Card,

CAPACITOR,

CAPACITOR, CHOKE,

1000UH

TERMINAL,

C48DC



r



~i1

J~____

C24

DC

C21



J~

C25

ABCDEFGHJKLMNP

~

DL

c~o

DC

C49

DE~c~



i

_____

___________

031

DL

header header

__

__________

Interface

ceramic ceramic

14

16

c22

C28

029

(FigBPg

0.005uf

0.1

uf500voltsdc

pin pin

)

)~

~

0

1000

ASSEMBLY

032

4

volt

Item

sdc

I

0565

16)

e

___

____id

~d2

___C46

C47

~F~C4

_____iC3

0

14 14

7

1

BE

SURE

TO

PROVIDE

MODEL

COMPONENTS

QUALIFIED

Figure

AND

SERIAL

B4

NUMBER

TO

PERSONNEL

-

Circuit

BE

WHEN

REPLACED

Card,

ONLY

Interface

ORDERING

BY

REPLACEMENT

Ref.

C-i

10567

PARTS.

OM-883

Page

10

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

C1,2

C3-5

Di,2

LCD1-3

LED1

LED3

Ri

R6,8,i

R7,9,10

R

C20

RC21

R

C24

VR1,2

C

,2,4,5

-5

1

-23

3

117

000 348 073 028

108 089 028 097

030

003

081

109

084 071

070 026

ASSEMBLY

7836

r

5C211

0

LED4

Circuit

836

CAPACITOR,

739

CAPAcITOR,

351

DIODE,

453

METER,

LED,

763

LED,

028

RESISTOR,

140

POTENTIOMETER,

272

RESISTOR,

381

TERMINAL,

161

TERMINAL,

194

TERMINAL,

248

IC,linear78M05

STAND-OFF,

LCD

fl~

L..~J

vs

i

+Q

__

LEDI

0

Meter

Card,

tantalum ceramic

0.020

signal

DCO-200MV

5330A10

5330A19200MCD

4OMCD

carbon

header

No.

I

RB

LEO5

~0

DI

02

6-32

3

(FigAPg

0.47

0.1uf50

amp

0.5

watt

cermet

film

0.25

12

13

socket

6

7/16

x

+

RC22~

R2

~0

75

uf

volts

1.5K

15

watt

L002

LED2

35

turn

x

3

volts

SP

ohm

0.75

1

1/4

fl~

Item

49)

dc

watt

ohm

meg

hex

1

I



__

~~0LED3

j

220K

5020

2

3 2 3

4

1

5

ohm

3

R024

3

2 6

3

BE

SURE TO

OM-883Pagell

PROVIDE

MODEL

COMPONENTS

QUALIFIED

Figure

SERIAL

AND

TO

PERSONNEL

C-Circuit

NUMBER

BE

WHEN

REPLACED

Card,

ORDERING

Meter

ONLY

BY

REPLACEMENT

PARTS.

Ref:

0.117837

Item

No.

.Dia.

Mkgs.

Part No.

Description

Quantity

Figure

2 3

4

5 6

7

8 9

10

11

12

13

14

15 16

17

D

REED

A

D2 4T

GS1

AC16

C7

109

047

+079

079

109

049

115 010 057 010 604 602 079 079

047

079

109

038

109 090

079

936

497

682

687 021

455 104

494

358

934

573 574 637 534 938 081 561

246

535

Control

LABEL,

Box.

general

WRAPPER

RELAY,

CASE

CABLE,

current

SECTION,

No.

CONNECTOR, BUSHING,

BUSHING, FITTING,

FITTING,

BRACKET,

HOUSING

TERMINAL,

DIODE, BLOCK,

VALVE,

1

terminal

24

RECEPTACLE

TERMINAL,

Gas/Current

precautionary

bottom/front/sides

182/c

(order

clamp-cable

1-3/8IDxl-3/4

snap snap

hose-brass

pipe-coupling

pipe-nipple

mtg-component

RECEPTACLE

female

amp

volts

male

400

W/

ID

20

dc

PINS

1

.37

x

bushing

1/4

L

1/4

volts

SP

amp

2

way

(consisting

byft)

1/2

mtg

NPT

SOCKETS

&

4

pole

1/4

Sensor

inch

hole

1/4

x

IPS

hole

mtg

NPTx

6

(consisting

1/8

port

of)

5/8-18

orifice

of)

1 1

1

2ft

1

2

2 2

1 1

2

1

14

9

+When

BE

SURE

ordering

TO

PROVIDE

a

component

MODEL

Figure

originally

AND

D

displaying

SERIAL

-

Control

Box,

a

precautionary

NUMBER

Gas/Current

WHEN

label,

ORDERING

Sensor

the

label

REPLACEMENT

should

also

be

ordered.

PARTS.

TC.~O9

680

OM-883

Page

12