
RECEIVING-HANDLING
OM.135
583C
3/92
Before
age
claims
unpacking
that
may
for
loss
Assistance
from
ers
When
ways
distributor
the
Transportation
requesting
provide
Number.
Section
SECTION
have
for
the
or
filing
1-1.
1-2.
equipment,
occurred
or
settling
and/or
with
the
damage
Department.
information
Model
Description
No.
1
SAFETY
General
Safety
check
carton
during
shipment.
the
delivering
claims
equipment
about
this
and
PRECAUTIONS
Information
Alert
Symbol
for
any
be
may
manufactur-
equipment,
Serial
TABLE
And
And
dam-
File
any
carrier.
obtained
al
or
Style
OF
AND
Safety
Signal
Use
tion
mation
Model
Serial
Date
CONTENTS
SIGNAL
Words
the
following
Serial
and
located
is
________________________________
or
Style
of
Purchase
WORDS
or
No.
spaces
Style
the
on
____________________
______________________
to
record
Number
rating
of
label
Page
the
Model
unit.
your
or
nameplate.
No.
1
1
Designa
The
infor
SECTION
SECTION
SECTION
2
2-1.
3INSTALLATION
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
4OPERATOR
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
SPECIFICATIONS
Description
Site
Selection
Equipment
Gas/Current
Motor
Voltage
Robot
Robot
Failure
Arc
Preset
Peak
Preflow,
Welding
Setting
Power
Push
Jog
Purge
Voltmeter
Wire
Peak
Indicator
Installation
Connection
Sensing
Interface
InterfaceRobot
Light
Controls
Amps/Inductance
Postflow,
Wire
DIP
Switches
Switch
Buttons
Push
Speed
Amps/Inductance
Lights
Sensing
Connections
Welding
Terminal
And
Installation
CONTROLS
Button
Meter
Control
Power
Control
Strip
Control
Burnback
On
DVC
Meter
Interconnections
Source
Unit
Connections
Connections
Connections
Time
Presets
Board
PCI
1
2
2
3
3
3
4
4
5
6
6
6
7
7
8
8
8
8
8
8
8

REAR
VIEW
OF
DISPLAY
BOARD
Pc4
Input
Vo(ts
Command
Meter
...O.5V
=
For
50V
6-5.
a
a
Command
Input
Ammeter
CIRCUIT
-O.1V
=
BOARD
WARNING:
Do
Shut
robot,
not
touch
down
and
lockout/tagging
maintaining,
ing,
Lockoutltagging
ing
moving
fuses
disconnect
line
red-tagging
device.
ing
CAUTION:
can
(ESD)
Put
on
FORE
Transport
properly
handling
shielding
Perform
INCORRECT
can
plugs
Be
sure
aligned.
EXCESSIVE
board.
Use
only
ment
board
when
plugs
For
100A
HANDLING
ELECTRIC
live
electrical
unit,
welding
disconnect
procedures
or
procedures
switch
fuse
from
circuit
breaker
ELECTROSTATIC
damage
grounded
circuit
circuit
carriers
work
or
only
INSTALLATION
damage
that
plugs
PRESSURE
minimal
pressure
disconnecting
and
removingorinstalling
Figure
SHOCK
parts.
power
input
power
servicing.
Consist
in
open
or
box,
other
or
circuit
boards
boards.
boards.
in
packages.
static-safe
at
a
are
properly
board.
can
and
cIrcuit
6-2.
PRECAUTIONS
kill.
can
source,
employing
before
shutting
wrist
or
inspect
of
padlock
position,
off
disconnect
DISCHARGE
strap
proper
work
misaligned
installed
break
gentle
or
connecting
Display
and
re
and
BE
static-
area.
and
circuit
move
board.
Checks
6-6.
Meter
TROUBLESHOOTING
Board
WARNING:
a
Do
Shut
robot,
lockout/tagging
or
Lockout/tagging
locking
removing
red-tagging
device.
ing
MOVING
Keep
HOT
Allow
Troubleshooting
qualified
It
is
assumed
to
Section
ing
the
with
working
welding
The
remedies
this
circuit
dures.
function
properly,
process.
following
for
robot
interface.
diagram
If
the
theseprocedures,
ized
Service
tion,
strictly
instructions.
ELECTRIC
touch
not
down
unit,
and
disconnect
servicing.
line
disconnect
fuses
from
circuit
PARTS
from
away
SURFACES
cooling
persons.
the
of
3
and
while
this
of
is
of
Use
contact
the
unit
manual,
controls,
that
designed
the
performing
is
manufacturers
that
table
some
trouble
Station.Inall
follow
Power
Volts
live
electrical
welding
input
procedures
procedures
switch
fuse
breaker
can
cause
moving
can
cause
before
period
be
to
was
properly
the
the
the
trouble
to
troubles
table
this
troubleshooting
remedied
not
the
nearest
of
cases
Supply
And
Meter
0-
SHOCK
Ammeter
5VDC
can
parts.
power
box,
or
source,
power
before
consist
in
open
or
shutting
other
serious
parts.
severe
servicing.
performed
installed
operator
robot
interface
is
not
related
diagnose
that
may
in
conjunction
after
Factory
equipment
procedures
For
Ref.
SD-117
838-B
kill.
and
employing
inspecting
of
pad
position,
and
off
disconnect
injury.
burns.
by
only
accord
familiar
is
was
the
to
and
provide
develop
with
the
proce
performing
Author
malfunc
and
in
OM~135
583
Page
12

SECTION
8
PARTS
LIST
Dia.
Mkgs.
Cl
C2-4
CB1
CR1
CR2,5
CR3
CR4
D1-3
Fl
PB1-3
PCi
PC2
PC3....
PC4
PC5
PC6....
PC7
PLG9
PLG16
PLG12
PLG1,19
PLG2
PLG3
PLG18,60
PLG2O
PLG24
OM-135
583
0499700008841
0943620007751
1065360008933
0821940009184
18
Page
.031692
006 426
028
.
011
109006
095
095
052
079
027811
048
026202
*012655
046
021
148320
073
110391
071
083147
149339
089 032
118550
110
139297
082194
047
079
079
073140
073140
048598
079534
049
073
039828
600
604109
601
601
600
079.748
079
115093
113746
131
113746
135559
079747
081
081
084198
081
Part
No.
991
964
844
029
432
756
642
375
636
535
739
989
686
848
226
228
750
747
204
379
378
378
291
521
033
105
Main
Assembly
CAPACITOR,
CLAMP,
capacitor
CAPACITOR,
CIRCUIT
RELAY,
RELAY,
RELAY,
RELAY,
BRACKET,
SPRING,
SOCKET,
CLIP,
BREAKER,
end
end
end
end
mtg
hold
relay
retaining
DIODE,rectlA400VSP
FUSE,
HOLDER,
SWITCH,
CIRCUIT
mintr
fuse
PB
CARD,
STAND-OFF,
GUIDE,
CIRCUIT
mtg
CARD,
GROMMET,
CIRCUIT
CIRCUIT
LENS,
CIRCUIT
STAND-OFF
..
CIRCUIT
CIRCUIT
CABLE,
CABLE,
....
HOUSING
CARD,
CARD,
LED
4341
CARD,
CARD,
CARD,
interconnecting
interconnecting
TERMINAL,
CLAMP,
CABLE,
CABLE,
HOUSING
cable
port
port
TERMINAL,
PLUG,
CLAMP,
WIRE,
WIRE,
volt
4skt
cable
lead
lead
CABLE,
INSULATOR,
CLAMP,
univ
TERMINAL,
HOUSING,
TERMINAL,
HOUSING
term
contact
PLUG
TERMINAL,
HOUSING
PLUG
TERMINAL,
HOUSING
PLUG
TERMINAL,
HOUSING,
TERMINAL,
HOUSING,
TERMINAL,
term
female
term
female
Description
200VDC
750uf
elctlt
2.000dia
.luf
man
DPDT
4PDT
4PDT
DPDT
500VDC
reset
cer
24VAC
24VDC
24VAC
24VDC
disc
relay
down
relay
14
pin
skt
relay
1
OA
cer
SPDT
No.
circuit
scr
250V
mintr
.250
voltage
6-32x.625
card
motor
No.
8/10
interface
meter
red
x
control
speed
1
.250
lg
isolation/amplifier
PC
SUPPORT,
card
isolation
preset
(consisting
(consisting
PLUG
&
PINS,
(consisting
1
male
No.
18
No.
18
PLUG
&
female
sense
(consisting
97-3106A-14S-2S
AN-3057-6
mot
l2ga
strd
l6ga
vinyl
clamp
25A
ring
tng
hdr
18
hdr
&
SOCKETS,
female
&
SOCKETS,
female
&
SOCKETS,
contact
hdr
lskt
hdr
6
lskt
18-14
pin
10/c
(order
10/c
(order
SOCKETS,
lskt
14-18
strd
(orderbyft)
(order
univ
stud
.500
pin
24-18
1skt24-~18wire
lskt
24-18
hdr
24-18
12
pin
22-18
pin
22-18
1P1
.5A
panel
mtg
digital
No.
6
screw
of)
(for
(for
of)
of)
wire
(for
ft)
by
ft)
(for
by
(consisting
wire
of)
ft)
by
25A
wire
16-14
wire
(consisting
(consisting
wire
(consisting
wire
wire
wire
250V
NSPR
NSPR
NSPR
NSPR
of)
of)
of)
of)
8933)
9184)
8933)
9184)
Quantity
13
.4
.4
1
1
14
lift
2Oft
1
16
1
1
1
35ft
l9ft
1
1
1
2
18
1
6
1
3
2
12
1
12
1
6

Dia.
Mkgs.
Part
No.
Description
Quantity
PLG28-30
PLG31
.
PLG6I
.
Ri
R2
R3
R4
RC5
RC7,9
.
.
RC12
RC13
RC15
RC16
.
.
RC17
.
.
Si
..
SRi
.
.
T1,3
.
.
T2
..
.
IT,2T
.
.
3T
..
.
135
081
131
113
135
079747
030651
605
030
030
010199
079 683
056
010193
057
079
603 856
1065380007751
117
009 335
047
079
048
076
094
089646
097
094593
011
035
035
036
038
601219..
038
010
107
1324810008933
010
1124730008933
+1169690008933
045
134
150
010855
010 853
073
121
1215940009184
094
116
110
110
094482
045
0453480009148
047
079
079
787
378
054
746
788
741
941
949
170
084
497
374
637
534
144
624
480
867
609
704
759
135
856
772
916
983
311
852
327
866
487
594
481
964
015
015
348
636
535
739
Main
Assembly
HOUSING
..
TERMINAL,
. . .
.
HOUSING
..
TERMINAL,
. ...
HOUSING
..
TERMINAL,contacthdr24-l8wire
.
.
.
.
RESISTOR,WWfxd25WiOohm
..
CLIP,
. .
RESISTOR,
..
HEAT
. .
TUBING,
..
HEAT
.
.
SHIELD,
. .
TUBING,
..
BUSHING,
. .
RESISTOR,
..
POTENTIOMETER,
..
BRACKET,
. .
HOUSING,
..
STAND-OFF,
.
.
HOUSING
..
TERMINAL,
.
.
. .
TERMINAL,
.
.
RECEPTACLE,
..
RECEPTACLE,
..
RECEPTACLE,
..
RECEPTACLE,
..
RECEPTACLE,37sktMS-3102A-28-21S
..
SWITCH,
..
RECTIFIER,
..
TRANSFORMER,
..
TRANSFORMER,
..
BLOCK,
..
mtg
SINK,
SINK,
term
resistor
sti
resistor
sti
tgl
(Continued)
PLUG
&
SOCKETS,
female
RECEPTACLE
female
PLUG
&
PINS,
.312
WW
fxd
rect
.275
lDxl.000
resistor
.375
ODx.250
snap-in
WW
mtg
term
RECEPTACLE
male
nyl
fxct
potentiometer
conn
No.
4-40
female
1
pin
4
pin
14
pin
10
pin
17
pin
SPDT
15A
30A
integ
control
control
12P
20A
lskt
lskt
ID
100W5ohm
.250
25W
WW
sltd
22posn
.625
x
lskt
plug
MS-3102A-14S-2P
MS-3102A-20-27P
MS-3102A-18-1P
MS-3102A-20-29P
125VAC
600V
LINK,jumpertermblk2oA
20A
BLOCK,
..
CONNECTOR,
. .
BLANK,
. .
CABINE1~
. .
CLAMP,
.
.
PANEL,
. .
DOOR,
.
.
CLIP,
.
.
LABEL,
. .
LABEL,
.
.
RETAINER,
..
FASTENER,
.
.
NUT,
.
.
NAMEPLATE,
CABLE,
.
CABLE,
.
.
PLUG,
. . .
.
CLAMP~
.
..
CABLE,
.
. . .
CABLE,
...
.
PLUG,
.
.
..
CABLE,
. .
CABLE,
. .
HOUSING
.
.
..
CLAMP~
.
.
. .
term
snap-in
control
nyl
mtg
access
component
warning
caution
speed
interconnecting
interconnecting
14
cable
port
port
14skt97-3106A-20-27S
motor
motor
TERMINAL,
cable
6P
clamp
nyl
.500mtg
.750c1p
dia
components
cabinet
.68Tdia
general
incorrect
scrNo.2
sltd
scr
No.
pin
hd
2
(order
by
MS-3106A-20-27P
97-3057-1012
No.
18
No.
18
(consisting
(consisting
&
PLUG
male
strain
PINS,
1
cable
.500
x
precautionary
DVC
No.
model)
(consisting
(consisting
7/c
7/c
pin
relief
(consisting
wire
22-18
&
SOCKETS,
wire
24-18
(consisting
ID
x
.375mtg
2K
ohm
sft
lOfT
Ig
&
SOCKETS,
wire
14-18
keying
mintr
115/36VCT
115/24VAC
.750
hole
wide
DIP
board
2
of)
of)
by
by
(for
(for
ft)
ft)
NSPR
NSPR
(order
(order
of)
of)
(consisting
18-14
16
sz
17
sz
of)
(consisting
of)
hole
2W
10K
ohm
(consisting
switch
NSPR
(for
NSPR
(for
NSPR
(for
NSPR
(for
8933)
9184)
of)
wire
of)
of)
8933)
9184)
8933)
9184)
OM-135
583
14
1
20ft
14
Page
1
7
1
2
1
4
1
4
1
1
2
1
1
4
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
2
1
2
4
1
1
4
1
1
1
1
1
1
1
2
2
2
I
1
1
1
2
Oft
1
1
1
2
19

Dia.
M
kgs.
Part
No.
Description
Quantity
GS1
PC6
PLG1
Ri
RC16
REED
Shunt
T4
iT
*Recommended
+When
BE
SURE
ordering
TO
073139
073139
071
079
048144
089
039716
073
073140
089 647
1338640008933
1338640009184
097
116964
604910
604910
097 866
056 462
134834
010606
056108
056851
0831530008933
003538
135517
073
079798
079
074051
090246
079
140786
030084
0830840007751
1214090007751
035759
038861
021
010604
602934
010190
083
083085
0830870008933
+083
121
072 094
058
058
010191
135205
057971
010233
072
058427
092
134464
Parts.
Spare
a
component
PROVIDE
MODEL
892
534
870
332
868
756
747
535
795
083
086
316
428
628
292
989
originally
WHEN
Main
Assembly
CABLE,
CABLE,
RECEPTACLE
port
port
TERMINAL,female
TERMINAL,
CABLE,
CABLE,
CABLE,
HOSE,
interconnecting
PLUG,
CLAMP,
CABLE,
PLUG,
10
cable
port
lOsktMS-3106A-18-1S
interconnecting
interconnecting
PLUG,
CLAMP,
CABLE,
CABLE,
PLUG,
HOSE,
l7skt
cable
pwr
pwr
17
gas
SAE
FITTING,
FITTING,
FITTING,
CONTROL
VALVE,
CIRCUIT
BOX,
115VAC
CARD,
STAND-OFF,
HOUSING,
TERMINAL,
RESISTOR,
RECEPTACLE
TERMINAL,
SWITCH,
SHUNT~
SHIELD,
meter
heat
BRACKET,
TRANSFORMER,
BLOCK,
TUBING,
term
stl
FITTING,
FITTING,
FITTING,
BRACKET,
BRACKET~
CONTROL
WRAPPER
LABEL,
HUB
HUB,
warning
&
SPINDLE,
spool
WASHER,
WASHER,
stl
NUT,
slflkg
WASHER,
SPRING,
SHAFT,
RING,
SUPPORT,
LABEL,
cprsn
spool
retaining
spindle
warning
displaying
ORDERING
(Continued)
No.16
6/c
No.16
6/c
w/SOCKETS,
lskt
1
male
pin
No.
pin
MS-3106A-18-1P
AN-3057-10
18
10/c
MS-3106A-20-29S
97-3057-1012
shld
2Oga
shld
2Oga
MS-3106A-20-29P
pin
(consisting
.187
hose
hose
hose
No.
term
contact
C
of)
ID
x
brs
nut
brs
ferrule
brs
barbed
feedback
gas
2
way
feedback
6-32x.375
hdr
13
hdr
.5W
100
w/PINS,
1
reed
mtg
.375
hose
pipe
pipe
mtg
mtg
BOX,
male
5OMV
20A
galv
galv
pin
600A
shunt
control
3P
OD
x
brs
bushing
coupling
nipple
control
components
shunt
general
(consisting
brake
stl
fbr
.656
ID
x
hex
stl
.970
reg
keyed
00
flat
support
spool
(consisting
general
a
precautionary
REPLACEMENT
(orderbyft)
by
ft)
(order
(consisting
wire
14-18
plug
keying
by
(order
(order
00
(order
ID
of)
ft)
of)
of)
by
by
x
3/l6tbg
(consisting
(order
(consisting
(consisting
5/c
5/c
.410
.625-18RH
.425
nipple
(consisting
IPS
1/4
port
Ig
pin
wire
24-18
ohm
(consisting
18-14
wire
mintr
115/36VCT
.750
i/4NPT
.25ONPSC
L
.25ONPT
precautionary
of)
OD
1.500
.625-11
1
.500dia
1250
x
x
w/nyl
x
of)
precautionary
label,
PARTS.
NSPR
(for
NSPR
(for
(for
(for
ft)
(for
ft)
(for
by
.718
orf
1/8
of)
.625-18RH
x
10.000
x
.1
25thk
insert
.1
25thk
the
label
of)
NSPR
NSPR
ft)
Ig
of)
NSPR
NSPR
should
8933)
9184)
8933)
9184)
8933)
9184)
:
also
be
28ft
20ff
14
.2
.2
lOft
2
lOft
20ft
1
lift
.4
13
16
ordered.
OM-135583Page20