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COMPUTER INTERFACE NSPR 9112
Owners manual
34 pgs1.36 Mb0

Miller COMPUTER INTERFACE NSPR 9112 Owners manual

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Page 1
Millerfi
May
1990
FORM:
OM-136
224
MODEL:
Computer
NSPR
(per
Gas/Current
Control
And
Hub
Assembly
9112)
Sensing
Spindle
OWNERS
IMPORTANT:
the
and the
safety
maintaining
by
persons
Do
ment.
Contact
power
material
not
your
Read
source
throughout
this
equipment.
trained
allow
untrained
distributor
and
and
understand
manual
experienced
If
you
used
both
This
unit
persons
do
the
with
manuals,
and
In
the
to
install,
not
fully
entire
this
unit,
these
safe
understand
contents
with
before
installing,
instructions
operation
operate,
MANUAL
both
of
special
are
of
welding
maintain
or
Instructions.
these
manual
this
emphasis operating,
for
use
only
equip
this
unit.
on
or
MILLER
AMiDer
Group
P.O.
Box
Appleton,
Tel.
414-734-9821
ELECTRIC
Ltd..
Company
1079
WI 54912
Mfg.
USA
PRINTEDINU.S.A
Co.
Page 2
Page 3
RECEIVING-HANDLING
OM-136
224
5/90
Before
age
claims
unpacking
that
may
for
loss
Assistance
the
from
ers
When
ways
Number.
distributor
Transportation
requesting
provide
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
this
about
and
PRECAUTIONS
Information
Alert
Symbol
for
any
be
may
manutactur-
equipment,
Serial
TABLE
And
And
dam-
File
any
carrier.
obtained
al
or
Style
OF
AND
Safety
Signal
Use
tion
mation
the
following
Serial
and
located
is
or
spaces
Style
the
on
to
Number
data
record
of
card
the
your
or
Model
the
Designa
The
unit.
nameplate.
Model______________________________________
Serial
Date
CONTENTS
SIGNAL
Words
or
of
Purchase
WORDS
Style
No.
_____________________________
______________________________
No.
Page
1
I
infor
SECTiON
SECTION
SECTION
2
2-1.
3-1.
3-2.
3-3. 3-4.
3-5. 3-6. 3-7.
4-1. 4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
Description
3-INSTALLATION
Site
Equipment
Gas/Current
Robot Robot
Arc
Welding
4
Power Selector
Jog Purge
Voltmeter
Wire
Ammeter
Indicator
SPECIFICATIONS
Selection
Installation
Interface InterfaceRobot
Failure
Light
Wire
OPERATOR
Switch
Switch
Push
Button
Push
Button
Speed
Meter
Lights
Welding
Control
Sensing
Terminal
Installation
CONTROLS
Interconnections
Power
Control
Strip
Source
Unit
Connections
Connections
Connections
1
2
2 3
3 4
5
5
7 7 7 7
7
7 7 7
SECTION
5-1.
5-2.
5
SEQUENCE
Input
Signals
Output
OF
From
Signals
OPERATION
Robot
From
Robot
Control
Interface
Unit
8 8
Page 4
Section
No.
Page
No.
SECTION
SECTION
SECTION
6-
6-1. 6-2. 6-3. 6-4.
6-5. 6-6.
6-7.
7
Diagram
Diagram
Diagram
Diagram Diagram Diagram
8
Figure Figure Figure
Figure Figure
8-1. 8-2. 8-3.
8-4.
8-5.
MAINTENANCE
Routine
Oveiload
ReinstallationOfHub
Display
Circuit
Maintenance
Protection
Board
Board
&
P04
Handling
Troubleshooting
Of
Use
ELECTRICAL
PARTS
7-1. 7-2.
7-3.
7-4.
7-5. 7-6.
Circuit
Circuit
Circuit Circuit Circuit
Indicator
Circuit
Circuit
Circuit Circuit Circuit Circuit
LIST
Card, Card, Card,
Card,
Card,
Lights
DIAGRAMS
Diagram
Diagram Diagram Diagram
Diagram
Diagram
Voltage
Motor
Interface
Meter
Isolation/Amplifier
TROUBLESHOOTING
Assembly
Meter
Check
Precautions
For
Troubleshooting
For
Robot
Interface
For
Voltage
For
For
For
For
Control
Speed
PC4
Control
Motor
Interface
Display
Isolation
PCi
Digital
P03
Board
Board
Board
Board
PC5
PC2
PCi
Board
PC3
P04
PC5
P02
9
9
10 10
11 11
13
14
15
16 18 18 19
22
24 26
27 28
Table Table
2-1.
Specifications
6-i.
Troubleshooting
LIST
OF
CHARTS
AND
TABLES
1
12
Page 5
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
General
A.
Information
bels,
design, troubleshooting
followed
B.
Safety
The
installation,
shooting
and
procedures
safety
stalled,
Sons
codes
Section
of
Power
ing
Manual.
presented
and
tags,
installation,
the
for
of
arc
others.
of
operated,
in
accordance
such
as,
1
Source
plates
which
safe
operation,
welding
which
Therefore,
but
Safety
INFORMATION
in
this
the
on
operation,
should
effective
and
equipment
ensure
maintained
and
with
this
limited
not
Rules
in
the
welding
AND
manual
unit
and
pertains
maintenance,
be
read,
use
of
understood,
maintenance,
requires
personal
this
equipment
only
by
manual
to,
For
and
listed
those
Operation
source
power
SECTION
SAFETY
various
on
to
equipment
this
equipment.
and
practices
safety
to
is
qualified
all
applicable
at
Of
Arc
Owners
Ia-
and
and
trouble-
the
and
in-
be
per-
the
end
Weld-
2-
1-2.
SAFETY
WORDS
The
following
used
throughout
different
tify
This
/~.
~
words tiontothe
WARNING
practices
ous
CAUTION
personal
IMPORTANT necessary
ment.
SPECIFICATIONS
ALERT
safety
this
of
levels
safety
WARNING
safety
which
personal
which
injury
statements
for
the
most
SYMBOL
alert
symbol
manualtocall
hazard
alert
statements
injury
statements
and
symbol
and
statements.
be
must
loss
or
be
must
or
damage
identify
efficient
AND
and
signal
attentiontoand
with
used
procedures
of
life.
procedures
this
to
special
instructions.
to
equipment.
instructions
of
special
is
CAUTION
identify
followedtoavoid
identify
followedtoavoid
operation
SIGNAL
words
the
call
this
are
iden
signal
atten
or
seri
or
minor
equip
Robot
Sensing
Add
Add
2-1.
The
ABB
an
This
weld
Spool
robot
Component
Interface
Gas/Current
Control
Support
Assembly+
in.
2-1/4
in.
7/8
(22
DESCRIPTION
interface
robot
and
unit
provides
wire
volts,
mm)
for
control
Arc
an
for
(57
mm)
preselection
feed
speed,
front
Pak
Height
22-1/2
(572
4-1/2
(108
13-3/4
(349
brake
panel
is
designed
350
and
in.
mm)
in.
mm)
in.
mm)
resistor.
knob.
welding
and
digital
amperage.
to
interface
power
Table
2-1.
Dimensions
Width
16-1/2
(419
5-1/2
(140
8-3/4
(222
with
source.
display
SpecifIcations
in.,
mm)
in.
mm)
in.
mm)
Spool
The
and
of
These
using
Depth
in.*
6-1/4
(159
mm)
8-1/2
in.
mm)
in.
mm)
10-1/2
(267
(216
Support
gas/current
current
sensing
components
the
Gas
Metal
without
sensing
reed
function
Arc
Net
lbs.
38
(17
kg)
5
lbs.
(2.3
kg)
lbs.
6
(2.7
kg)
optional
control
relay.
with
Welding
Weight
wire
reel.
contains
the
(GMAW)
Total
robot
Ship
61
(27.7
the
system
process.
kg)
gas
lbs.
valve
when
OM-136
224
Page
1
Page 6
SECTION
3-INSTALLATION
3-1.
SITE
Select
2.
3.
4.
5.
6.
7.
8.
9.
1.
Correct
Shielding
Water
Adequate
No
A
clean
Proper
cold
Proper
Adequate
wrapper functions.
an
flammables
Mounting
the
cure
Table
2-1
3-2.
EQUIPMENT
A.
Supplied
The
following
installation
quires
1.
Weld
Cord
2.
Gas/Current
3.
Hub
4.
Spindle
5.
Two
Source
6.
10
ft.
B.
EquIpment
SELECTION
installation
input
gas
supply
ventilation
and
site
power
supply
(if
applicable)
area
dry
temperature
airflow
holes
system
gives
around
space
for
to
installation,
provide
components
overall
INSTALLATION
dimensions.
Equipment
or
assembly:
Control
and
Motor
with
Cord
Sensing
and
Spindle
Assembly
Support
10
ft.
(3
m)
Weld
Interconnecting
Gas
(3m)
Hose
Location
which
provides
supply
that
open
(see
(if
applicable)
and
fresh
avoids
unit
and
maintenance,
the
capability
in
a
is
supplied
Gas/Current
Control
Control
Cords
the
unit
nameplate)
air
supply
extremes
remove
install
to
permanent
standard
as
Sensing
Welding
following:
of
heat
or
and
cover
and
repair
and
se
location.
and
re
Control
Power
3.
The
interconnecting
are
they welding
4.
One
weld
Current
5.
Welding
the
tact
ment.
C.
Equipment
Obtain
as
ture
Gas/Current
onto
D.
The
Remove install
1.
2.
3.
4.
appropriate
necessary
for
equipment
structures
Installation
Hub
hub
assembly
the
it
as
Remove
Align
selected
support
brake
Reinstall
until
a
Install
Hub
Assembly
not
caught,
operations.
output
Sensing
wire
must
control
weld
InstallatIon
mounting
and
mounting
Sensing
in
the
is
hub
assembly
follows:
hex
nut
hole
and
in
keyway
depends
washers
slight
welding
Hub
hex
Support
Shaft
are
nut
drag
wire
cords
must
pinched,
cable
must
control.
be
routedsothat
or
any
brackets
hardware.
installation.
control,
welding
(FIgure
supplied
from
insert
hub
on
and
area.
3-1)
with
from
the
endofhub
hub
support.
wire
spool
properly
onto
support
is felt
while
according
Retaining
be
routed
strained
or
be
routedtothe
it
does
other
grounded
or
adapter
Prepare
Secure
all
the
weld
other
robot
shipping
support
selection
size.
Tighten
hub.
Section
Ring
shaft
Be
Washer
support
Hole
seatedinthe
shaft.
turning
to
that
so
during
Gas/
not
con
equip
plates
struc
control,
equipment
interface.
carton,
and
shaft.
through
in
hub
the
sure
hub.
hex
nut
3-7.
Hex
Nut
When
deciding
lowing:
1.
The
pable
2.
The
equipment
can
ing equipment
OM-136
224
on
equipment
of
supporting
lead
lengths
will
be
located.
optional
distributor).
2
Page
equipment
must
the
of
limit
the
Some
extension
location,
be
mounted
weight
the
area
cords
cords
cords
in
can
consider
to
of
the
supplied
which
be
extended
(check
the fol
structure
a
equipment.
with
the
equipment
by
with
welding
ca
the
us
FIgure
3-1.
Fiber
Hub
Washer
Assembly
Hub
Installation
Support
SA-128
870
Page 7
3-3.
There
ing
proper
To
Welding
REMOTE
GAS/CURRENT
CONNECTIONS
WARNING:
Do
not
Shut
robot,
lockout/tagging
connections.
Lockout/tagging
line
ing
moving red-tagging
device.
ing
several
are
control
Gas/Current
Control
To
Welding
REMOTE
interconnections.
for
cord
Receptacle
RC1
Power
14
Receptacle
Rd
5
Power
17
Receptacle
ELECTRIC
touch
down
and
unit,
disconnect
disconnect
fuses
from
circuit
cords
the
following
Sensing
RC9.
3
Source,
SENSING
(Figure
3-2)
SHOCK
live
electrical
welding
input
procedures
procedures
switch
fuse
box,
breaker
supplied
for
Examine
connections.
CONTROL
can
parts.
power
consist
open
or
shutting
other
source,
making
position,
power
before
in
or
gas/current
and
INTER
kill.
and
employing
inter
of
padlock
off
select
and
sens
the
disconnect
A.
Robot
Interface
Gas/Current
Sensing
Control
Connections
1.
Align
keyways,
receptacle
threaded
2.
Align
keyways,
receptacle
and
rotate
B.
re
Gas/Current
tions
Align
keyways,
matching
and
trol,
Align
keyways,
cord
into
and
rotate
C.
Weld
For
Electrode
from
welding
minal,
wire terminal
through
drive
receptacle
rotate
matching
threaded
Cable
assembly,
(see
insert
14-pin
RC9
on
fully
insert
on
clockwise.
16-pin
collar
collar
RC16
threaded
Sensing
insert
14-pin
RC7
threaded
insert14-socket
collar
tree-hanging
collar
ConnectIons
Positive/Reverse
power
Motor/Drive
source
the
gas/current
and
Assembly
Amp
robot
plug
interface,
plug
Amp
gas/current
clockwise.
fully
Control
plug
on
from
gas/current
clockwise.
fully
from
plug
receptacle
clockwise.
fully
Polarity,
POSITIVE
sensing
connect
cable
Owners
into
matching
and
into
matching
sensing
Motor
Connec
motor
sensing
motor
from
route
weld
output
control,
weld
to
Manual
rotate
control,
into
cord
con
control
motor,
cable
ter
the
to
cable
for
location).
D.
Gas
Connections
Connect
supplied)
ing
to
must at
3-4.
hose
from
at
gas
control.
fitting
the
Connect
on
gas/current
be
accurately
source.
ROBOT
SOURCE
WARNING:
Do
not
Shut
locko
ut/tagging
and
robot,
connections.
Lockout/tagging
line
ing moving
red-tagging
device.
ing
regulator/flowmeter
gas
gas
to
hose
source
sensing
controlled
INTERFACE
CONNECTIONS
ELECTRIC
touch
live
down
unit,
disconnect
procedures
disconnect fuses
procedures
from
circuit
IN
on
fitting
from
by
-
gas/current
wire
drive
controi.
a
regulator/flowmeter
WELDING
(Figure
SHOCK
electrical
welding
switch
fuse
breakerorother
power
input
before
in
box,
parts.
power
consist
open
or
shutting
(customer
assembly
The
gas
POWER
3-2)
kill.
can
source,
employing
making
of
padlock
position,
off
disconnect
sens
flow
and
inter
re
and
RCI
To
Robot
Figure
7
Control
3-2.
Right
Side
View
TB-hg
646
There
are
the
robot
and
select
A.
REMOTE
1.
Align
receptacle
threaded
2.
Align
ceptacle
threaded
two
cords
interface
the
proper
14
keyway,
RC13
collar
keyway,
on
collar
for
used
and
welding
for
cord
ConnectIons
insert
14-socket
robot
on
clockwise.
fully
insert
14-pin
welding
fully
power
clockwise.
interconnections
source.
power
the
following
interface,
plug
source,
plug
into
OM-136
connections.
into
and
matching
and
between
Examine
matching
rotate
re
rotate
224
Page
3
Page 8
B.
REMOTE
1.
Align
receptacle
threaded
2.
Align ceptacle
thread
Be
sure
that
and 440
(maximum)
ROBOT
3-5.
CONNECTIONS
a
Obtain
1.
supplied).
2.
Connect
ate
3.
Align
ceptacle
lar
4.
Route
cord
The
input
RC17
by
are
as
Socket
Socket
Socket
Socket
Socket
Socket
OM-136
17
ConnectIons
RC15
collar
on
Arc
insert
on
fully
insert
welding
clockwise.
fully
14/17
Pak
GTAW
keyway,
keyway,
collar
the
MAXIMUM
the
position.
INTERFACE
(Figures
touch
down
and
ELECTRIC
live
unit,
disconnect
procedures
WARNING:
Do
not
Shut
robot,
lockout/tagging
connections.
Lockout/tagging
line
ing
moving
red-tagging
ing
disconnect
fuses
device.
a
proper
conductors
from
circuit
cord
pinsinplug.
keyway,
clockwise.
fully
and
to
the
and
means
follows:
A:
B:
D:
E:
F:
insert
robot
on
connect
robot
output
of
the
Provides
use.
Current
with
respect
rated
tacts
Current
with
respect
rated
tacts
Contactor
robot
control
(Circuit
Jog
control
Common).
Forward;
unit
interface,
conductors
control
signals
connection
Detect
1
Detect
at1Aat
Control;
with
Common).
Gas
G:
Control;
control
unit
with
Common).
Page
4
224
17-socket
robot
clockwise.
17-pin
power
switch
-
electrical
welding
procedures
switch
fuse
breaker
and
24-pin
at
one
24-pin
unit.
at
robot
output
Socket
to
A
at
output
SocketB;isolated
to
unit
+24
respect
+24
respect
plug
interface,
plug
source,
is
OUTPUT
ROBOT
3-2
SHOCK
power
input
before
in
box,
or
Amphenol
endofcord
plug
and
rotate
at
the
sockets
interface
to
to
D;
VAC.
120
to
120
+24
with
respect
dc
volts
volts
dc
And
parts.
power
Consist
open
or
other
2TA;
isolated
VAC.
volts
to
to
into
matching
and
into
matching
and
in
17
the
control
CONTROL
3-3)
kill.
can
source,
employing
making
of
padlock
position,
shutting
disconnect
plug
to
appropri
into
matching
threaded
remaining
of
receptacle
control
for
customer
robot
control
CR1
robot
control
CR1
dc
input
Socket
to
from
input
Socket
input
Socket
J
from
J
rotate
re
rotate
position
isinthe
UNIT
and
inter
re
off
and
(not
re
col
of
end
circuitry
unit
con
unit
con
from
J
robot
(Circuit
robot
(Circuit
not
H:
K:
L:
M:
N:
P:
0:
A:
S:
W:
X:
Y:
Z:
used.
Socket
SocketJ:
Socket
Socket
Socket
Socket
Socket
Socket
Socket
Socket
Socket
Socket
Socket
Socket
IMPORTANT:
are
FIgure
Receptacle
Stick
Wire
robot
(Circuit
Circuit all
circuit
Forward;
Jog
robot
(Digital Set-Up
control
Common).
Weave
with
respect
Stick
Wire
with
respect
indicates
contacts
Weld
with
respect
indicates
CR5
lated
Digital
P.
Inductance;
control
common)
Inductance;
Wire
Socket
Wire
+
robot
(analog
Arc
Volts;
Arc
Volts).
Arc
+
control
common)
The
_______________________
3-3.
Front
Check;
control
unit
Common).
Common
voltages
momentary
control
unit
Common).
Weave
and
with
unit
Set-Up
to
Signal
to
wire
is
rated
Standby
to
robot
contacts
Common
0-10
with
unit
equals
analog
Feed
Speed;
X(+Wire
Feed
Speed;
control
unit
common)
analog
0-10
Volts;
with
unit
equals
remaining
View
With
Socket
+24
with
Sockets
for
referenced
with
Set-Up
respect
output
Socket
output
Socket
stuck
1A
120
at
output
Socket
interface
rated
Sockets
for
volts
respect
0-maximum
common
Feed
0-10
with
equals
common
volts
respect
0-50
sockets
Of
24-Socket
DesIgnatIons
volts
respect
contact
respect
Socket
to
robot
to
0
(Digital
robot
to
0
(Digital
to
work;
VAC.
to
robot
Q
(Digital
in
is
3A
dc
input
Socket
to
analog
Speed).
volts
respect
0-1
for
dc
input
Socket?
to
volts
in
dc
input
Socket
to
E,
F,
G,
this
to
output
Socket
to
output
to
Q(Digital
control
Common).
control
Common);
isolated
control
Common);
standby;
120
at
K,
L,M,N,
from
S
inductance.
for
Socket
common
dc
input
to
Socket
1PM.
000
Socket
from
dc
output.
the
receptacle
Amphenol
from
J
and
H;
point.
to
Q
robot
unit
unit
CR2
unit
iso
VAC.
and
robot
(analog
R.
for
from
W
Z
(+
robot
(analog
S-0291
Page 9
3-6.
a
ARC
FAILURE
NECTIONS
WARNING:
Do
Shut
robot,
locko
(Figure
ELECTRIC
touch
not
down
and
disconnect
ut/tagging
connections.
Lockout/tagging
line
ing
moving
red-tagging
ing
disconnect
fuses
circuit
device.
LIGHT
TERMINAL
3-4)
live
electrical
unit,
welding
input
procedures
procedures
switch
from
fuse
breakerorother
SHOCK
in
box,
parts.
power
power
before
consist
open
or
shutting
STRIP
can
CON
kill.
source,
employing
of
padlock
inter
making
position,
off
disconnect
and
re
and
Common
If
So
Robot
Terminal
Equipped
+24VDC
Control
Robot
Unit
Control
Robot
Weld
Unit
If
Alarm
So
1TM
Interface
Terminal
Equipped
Arc
Failure
indicator
Ught
There
are
for
control
unit
on cess
door,
nections. and
close
cedure
The
ARC
el
is
turned
unit.
Obtain
for
this
1.
For
right
is
connection,
terminal
two
connections.
side
and
locate
Tighten
and
secure
finished.
FAILURE
and
on
proper
robot
control
panel
screws
light
off
length
and
3-4):
Route
a.
panel
nections
b.
Route
weld the
Connect
c.
minal.
2.
Forrobotcontrolunitswhen
is
used
Route
a.
panel
nections
b.
Obtain
CR1,
cord
of
robot
to
and
alarm
robot
control
+24
(Figure
cord
of
robot
to
115
a
and
install
1TL
connect
terminal
3-4):
1TL
inside
strips
Loosen
if
applicable,
appropriate
strain
on
front
panel
robot
the
on
a
by
signal
of
18
proceed
units
when
through
strain
interface,
1TM.
and
remaining
and
unit.
vdc
to
common
through
or
strain
interface,
1TM.
and
24
vac,
into
robot
the
robot
interface
strain
screws
open
terminal
relief
access
interface
from
on
front
strip
if
doorwhen
the
robot
relief
panel
for
necessary,
front
control
gauge/2-conductor
follows:
as
24
vdc
is
used
(Figure
relief
on
and
make
ground
relay
115
or24vac,or24vdc
relief
and
make
24
vdc
or
control.
right
proper
end
of
connection
contact
on
right
proper
isolation
cord
con
relay
ac
con
pro
pan
cord
side
con
ter
side
to
at
Common
If
So
To
Voitaqe
(115vAC,
+24VDC
FIgure
3-7.
A.
Installation
1.
Remove
2.
Slide
bottom
Terminal
Equipped
Source
24VAC,
lsoiatlon
(~o-o
~
WELDING
spool
of
24VDC)
Relay
Robot
3-4.
Arc
FaIlure
WIRE
Of
Spool-Type
retaining
of
wire
spool.
Weld
If
CR1
Control
Light
INSTALLATION
ring.
onto
hub
Alarm
Terminal
So
Equipped
Robot
Interface
ITM
Connections
Wire
that
so
Arc
Faliure
Indicator
(FIgure
wire
feeds
Ught
S-0292
3-5)
off
Route
c.
side
contact
d.
Connect
open
Connect
e.
coil
f.
Connect
vac,
remaining
of
to
or
and
connect
the
normally-open
and
ground.
+24
vdc
robot
control
lead
a
weld
alarm
proper
24
vdc)
side
remaining
to
remaining
relay
from
terminal.
voltage
between
of
robot
contact.
one
common
control
robot
side
source
end
side
of
relay
of
cord
control
of
normally-
robot
(115
vac,
terminal
coil.
to
one
relay
control
24
and
3.
Rotate
Slide
flange
4.
Reinstall
B.
Installation
Type
1.
Remove
assembly
2.
Lay
spool
spool
of
Wire
wire
until
hole
hub
onto
hub.
the
retaining
retaining
from
reel
ring
Of
Optional
ring
hub.
assembly
in
spool
until
onto
and,
flat
with
aligns
it
seats
hub.
Wire
Reel
if
applicable,
table
on
a
OM-136
in
pin
against
And
wire
floor.
or
224
hub.
back
Reel-
reel
Page
5
Page 10
Retaining
Spanner
Nut
Ring
Hub
3.
4.
5.
6.
7.
Remove
Remove
Be
sure
Reinstall
reel.
Slide
wire
sembly
Reinstall
spanner
wire
that
wire
wire
retainer
reel
assembly
until
hub
retaining
nut
feeds
guide
ring
from
and
off
and
pin
onto
wire
reel
install
wire
bottom
of
spanner
onto
hub,
is
seatedinreel.
hub.
assembly.
wire
onto
reel.
nut
onto
and
i~tate
reel.
wire
as
FIgure
3-5.
OptIonal
Hub
Wire
Reel
installation
Support
And
SC127
Reel-Type
WIre
308
C.
Adjustment
Check
or
shouldbesufticient lash
loosen
port
reel.
when
shaft
the
The
the
or
tighten
accordingly.
hub
wire
Of
tension
should
wire
the
Hub
to
feed
hex
Tension
by
slowly
unwind
keep
stops.
nut
rotating
freely,
wire
taut
if
adjustment
the
on
(Figure
the
but
and
prevent
end
of
3-1)
wire
hub
tension
is
required,
the
hub
spool
back
sup
OM-136
224
Page
6
Page 11
Gas
indicator
Light
SECTION
4-
OPERATOR
CONTROLS
Contactor
Light
POWER
4-1.
Placing
the bot
lion
4-2.
The
UP~
alorrobot
tions.
4-3.
The
Consult
JOG
4-4.
The switch.
purges
push
the
robot
interlace.
weld.
to
shuts
down
SELECTOR
SELECTOR
SET-UP
and
JOG
JOG
push
robot
button
push
PURGE
PURGE
This
the
button allows
energizing
VOLTMETER
4-5.
The
voltmeter
of
volt
while
a
Indicator
Wire
indicator
SWITCH
POWER
Placing
manufacturer
PUSH
switchinthe
The
the
the
interface.
SWITCH
switch
WEAVE.
BUTTON
button
Owners
function.
PUSH
push
switch
shielding
the
the
welding
(Figure
displays welding
Feed
Light
(Figure
interface
POWER
4-1)
ON
switchinthe
(Figure
has
three
positions:
Consult
SELECTOR
for
(Figure
is
a
momentary-contact
Manual
BUTTON
button
energizes
lineofthe
gas
flow
circuit.
is
meter
robot
or
(Figure
a
the
to
4-1)
weld
voltage
and
preset
Current
must
Indicator
Light
Figure
position
be
on
energizes
OFF
for
4-1.
the
posi
4-1)
SET
RUN,
Owners
robot
switch
Manu
func
4-1)
switch.
manufacturerfor
4-1)
momentary-contact
solenoid
gas
The
nearest
while
PURGE
without
tenth
idling.
gun.
be
adjusted
the
to
voltage
Front
ro
and
Failure
Arc
indicator
Panel
Light
Button
Controls
WIRE
4-6.
wire
The
the
nearest
tual
and
feed
wire
4-7.
The
ammeter
ampere
4-8.
There
visual
GAS
The
indicate
to
CONTACTOR
The
er
source
output
WIRE
The
is
energized
CURRENT
The
is
relay
ARC
The
connected there
SPEED
speed
inch
preset
speed
AMMETER
while
INDICATOR
five
are
indicationsofvarious
light
shielding
contactor
is
available.
FEED
energized
FAILURE
according
is
arc
an
Push
Jog
Switch
meter
per
wire
feedback
(Figure
displays
welding
LIGHTS
indicator
turns
light
light
indicate
to
light
to
outage
METER
displays
minute
feed
speed
4-1)
weld
and
preset
lights
when
on
flow.
gas
turns
is
energized
turns
that
turns
indicate
turns
light
instructions
to
while
(FIgure
preset
while
welding
are
circuit.
amperage
amperage
(Figure
the
on
process
the
gas
when
on
when
on
wire
when
on
that
on
welding.
4-1)
wire
the
same
4-1)
interface.
functions.
valve
the
indicate
to
wire
the
is
feeding.
the
an
arc
only
in
Section
OM-136
Th-119
Ret.
feed
speed
and
idling.
duetothe
to
the
nearest
while
These
is
energized
welding
that
drive
current
is
established.
when
properly
3-6,
224
645
to
Ac
idling.
are
pow
weld
motor
detect
and
7
Page
Page 12
Robot
Unit
interface
Computer
To
Robot
To
Unit
Control
Computer
interface
Control
Wire Feed
Output
Inductance
Gas
Control
Contactor
Fwd.
Jog
Check
Jog
Current
Wire
Stuck
Output
Shielding
Wire
Feed
Speed
Volta
0.iOV
Control
For
Wire
Detect
Voltage
Gas
SECTION
0-10V
0-1OV
0-100%
Stuck
0-SOy
0-1000
5-
1PM
SEQUENCE
OF
OPERATION
Normal
Abnormal
INPUT
5-1.
UNIT
The
robot
control,
current.
if
the
wire
(Figure
interface
control,
gas
It
also
is
stucktothe
SIGNALS
receives
receives
FROM
5-1)
jog,
welding
a
signal
workpiece
Figure
input
volts,
to
5-1.
ROBOT
signals
wire
initiate
at
the
endofthe
for
check
a
Input
CONTROL
contactor
speed,
to
And
and
see
weld.
Output
5-2.
The
control
standby.
Signal
OUTPUT
(FIgure
robot
unit
TIming
SIGNALS
5-1)
interface
for
Chart
sends
current
FROM
output
sense,
ROBOT
signals
wire
INTERFACE
to
stuck,
TA-094
the
and
382-A
robot
weld
OM-136
224
Page
8
Page 13
SECTION
MAINTENANCE
6-
&
TROUBLESHOOTING
ROUTINE
6-1.
IMPORTANT:
unit
this
maintained
when
necessary.
for
MAINTENANCE
six
Every
legibility.
in
a
All
clearly
See
precautionary/abe/s.
Usage
and
ment
~
and
of
type
every
WARNING:
Do
Shut
robot,
lockout/tagging
conditions
shop
maintenance.
months
three
ELECTRIC
touch
not
down
and
disconnect
live
unit,
procedures
maintaining,orservicing.
Lockout/tagging
line
disconnect
from
fuses
circuit
PARTS
from
away
SURFACES
cooling
period
be
to
replace,asrequired,
attention
where
areas
grease
and
electrical
parts
1.
2.
locking
removing
red-tagging
device,
ing
MOVING
Keep
HOT
Allow
Maintenance
persons.
Repair
give
lation
Remove
ture
or
particular
and
from
months
inspect
precautionary
readable
Parts
At
as
electrical
welding
procedures
fuse
breaker
can
moving
can
performed
to
it
grime
state
List
determine
minimum,
follows:
SHOCK
input
switch
box,
or
cause
parts.
cause
before
frayed
enters
from
and
cable.
for
parts.
power
power
before
consist
in
or
other
serious
severe
servicing.
only
all
hose
and
equipment.
components;
the
labels
labels
and
replaced
number
part
the
frequency
inspect
kill.
can
source,
employing
inspecting,
position,
open
shutting
disconnect-
Injury.
burns,
by
and
cracked
must
equip-
and
of
pad-
off
and
cable;
insu
mois-
on
be
of
A.
Wire
Drive
4-1)
WARNING:
tion
at
C~diflg.
Circuit
overload.IfCB1
Should
as
1.
2.
3.
4.
5.
B.
a
breaker
a
follows:
Check
correct
If
motor
drive
Check
rolls,
Reset
cooling
breaker
Resume
Main
WARNING:
tlon
motor
for
problem.
overload
motor.
for
and
circuit
period
can
operation.
Fuse
at
Ceedlng.
Motor
Read
beginning
CB1
protects
opens,
overload
jammed
If
wire
occurs
binding
correct
breaker
may
be
reset.
Fl
(Figure
problem.
Read
beginning
Circuit
and
of
the
wire
occur
wire
jams
often,
drive
by
be
necessary
4-1)
and
of
Breaker
follow
Section
the
and
or
clogged
wire
feed
CB1
often,
safety
6-2
drive
motorwould
replace
repairor
or
gear
misaligned
depressing
before
follow
Section
safety
6-2
CB1
before
motor
open,
gun
replace
the
before
(Figure
informa
pro
from
stop.
proceed
liner,
liner.
gun
wire
drive
button.
the
circuit
informa
pro-
and
A
6-2.
a
OVERLOAD
WARNING:
Do
Shut
robot,
lockout/tagging
not
down
and
PROTECTION
ELECTRIC
live
touch
unit,
disconnect
procedures
electrical
welding
maintaining,orservicing.
Lockout/tagging locking
removing
line
fuses
red-tagging
device.
ing
INCORRECT
Use
and
only
rating
(see
procedures
disconnect
from
fuse
breaker
circuit
FUSE
can
replacement
Parts
List).
SHOCK
input
switch
box,
or
damage
fuse
parts.
power
power
before
consist
in
or
other
of
same
kill,
can
source,
employing
inspecting,
of
position,
open
shutting
off
disconnect-
unit.
size,
and
pad-
and
type,
Fl
Fuse
short
or
interface lem
and
1.
Depress
wise.
2.
Pull
free.
3.
Insert
4.
Install
5.
Depress
cover
protects
excessive
shuts
down.ifthe
replace
and
fuse
out
fuse
new
with
fuse
and
is
secure.
the
robot
overload.
Fl
follows:
as
rotate
with
cover
into
fuse
rotate
fuse
fuse
fuse
holder
interface
if
fuse
fuse
opens,
holder
when
holder
holder
cover
Fl
cover
fuse
cover.
cover
from
an
opens,
correct
counterclock
holder
back
into
clockwise
OM-136
224
internal
the
robot
the
prob
cover
unit.
until
Page
is
9
Page 14
Retaining
Spanner
Ring
Nut
Wire
Retainer
Hub
Support
Shaft
Wire
Reel
Fiber
Keyed
Washer
Brake
Washer
Hub
Fiber
Washer
REINSTALLATION
6-3.
ure
If
it
becomes
assembly,
1.
Remove
semble
2.
Slide
in
order
a.
Spring
b.
Keyed
Fiber
c.
d.
Brake
Hub
e.
f.
Brake
Fiber
g.
3.
Align
selected
4~
Install
until
nut
5.
Install
OM-136
224
OPTIONAL
6-1)
necessary
reinstall
hub
assembly
discarding
the
following
given.
Washer
Washer
Washer
Washer
Washer
keyway,
hex
and
holeinhub
nut
a
slight
welding
10
Page
the
items
insert
onto
drag
wire
OF
HUB
to
replace
hub
new
from
hub
or
onto
broken
worn
hub
support.
hub
support
is
felt
while
according
Figure
ASSEMBLY
or
part
assembly
support,
parts.
hub
the
support
shaft.
turning
Section
to
6-1.
all
of
the
follows:
as
and
support
shaft
through
Tighten
hub.
3-7.
Hub
(Fig
hub
disas
shaft
hex
And
Reel
Assemblies
6-4.
DISPLAY
6-2)
Check
points
checking
ters.
4A
1.
Open
2.
Locate
3.
Check
Brake
Washer
BOARD
are
provided
supply
power
WARNING:
Do
Be
procedures
safety
Shut
meterortest
touch
not
sure
are
practices.
down
ELECTROSTATIC
damage
BEFORE
proper
electronic
Put
on
a
properly
handling
Transport
static-shielding
Perform
robot
display
voltage
work
interface
board
accordingtoFigure
METER
PC4
the
on
and
input
ELECTRIC
live
electrical
that
personnel
familiar
unit
before
equipment
DISCHARGE
components.
grounded
circuit
all
static-sensitive
at
only
access
PC4.
display
command
SHOCK
parts.
performing
with
and
making
lead
connections.
boards.
carriers
static-safe
a
door.
Hub
Support
Ref.
CHECK
board
for
kill.
can
follow
standard
or
changing
(ESD)
wrist
strap
components
and
packages.
work
6-2.
SC-127
328
(Figure
PC4
for
the
me
testing
can
in
area.
Page 15
REAR
VIEW
OF
DISPLAY
BOARD
PC4
Input
Volts
Command
Meter
For
O.5V=50V
Ref.
SD-117
838-B
4.
5.
6-5.
a
a
If
meter
a
correct
ter(see
thorized
If
the
replace
contact
and
Section
power
display
nearest
power
the
Service
supply
tion).
CIRCUIT
WARNING:
robot,
Do
Shut
not
and
BOARD
touch
down
lockout/tagging maintaining,
Lockout/tagging
line
ing
moving
disconnect fuses
red-tagging
device.
ing
CAUTION:
can
(ESD)
Put
BEFORE
shielding
on
handling
Transport
carriers
Perform
INCORRECT
can
plugs
Be
sure
aligned.
EXCESSIVE
board.
Use
ment
plugs
only
when
and
and
and
is
not
working, replace
contact
supply
meter
6-5
Station).
command
or
board
disconnect
PC4
Factory
HANDLING
ELECTRIC
live
unit,
welding
Authorized
electrical
procedures
or
servicing.
procedures
switch
from
circuit
fuse
breaker
ELECTROSTATIC
damage
properly
circuit
work
damage
that
minimal
circuit
grounded
circuit
boards
or
packages.
at
only
INSTALLATION
circuIt
are
plugs
PRESSURE
pressure
disconnecting
removing
or
installing
FIgure
command
nearest
voltage
Section
(see
PRECAUTIONS
SHOCK
parts.
power
input
power
before
consist
in
open
or
box,
other
or
boards.
boards.
in
a
static-safe
board.
properly
can
and
or
connecting
6-2.
voltage
the
Factory
is
incorrect,
6-5
Service
kIll.
can
source,
inspecting,
of
padlock
position,
shutting
disconnect
DISCHARGE
wrist
proper
work
or
misaligned
installed
break
gentle
board.
DIsplay
is
me
Au
and
Sta
and
re
off
and
strap
static
area.
and
circuit
move
board
Board
Meter
TROUBLESHOOTING
6-6.
4A
It
is
assumed
to
ing
with
the
working welding
The
following
remedies
this
robot circuit dures.
these
procedures,
ized
Service
tion,
strictly
instructions.
Checks
WARNING:
Do
not
Shut
robot,
lockout/tagging
touch
down
and
ELECTRIC
live
unit,
disconnect
welding
procedures
electrical
servicing.
Lockout/tagging
locking
line
procedures
disconnect
removingfusesfromfuse
circuit
red-tagging
device.
ing
MOVING
Keep
HOT
Allow
PARTS
away
SURFACES
cooling
Troubleshooting
Section
function
properly,
process.
for
interface.
diagram
If
the
persons.
that
the
of
3
and
table
some
while
trouble
Station.
follow
this
of
is
of
Use
contact
the
breaker
can
from
moving
can
period
to
unit
was
manual,
controls,
that
the
designed
the
troubles
this
table
performing
is
not
remedied
the
In
all
cases
manufacturers
SHOCK
can
parts.
power
input
before
switch
box,
or
cause
source,
power
inspecting
consist
in
open
or
shutting
other
serious
disconnect
parts.
cause
be
properly
the
trouble
to
severe
before
servicing.
performed
installed
the
operator
robot
is
not
diagnose
that
in
conjunction
interface
related
and
may
troubleshooting
after
nearest
Factory
of
equipment
procedures
kill.
and
employing
or
of
pad
position,
off
and
Injury.
burns.
only
by
accord
is
familiar
was
to
the
provide
with
proce
in
the
develop
performing
Author
malfunc
and
OM-136
224
Page
11
Page 16
Table
6-1.
Troubleshooting
TROUBLE
No
weld
output
Robot
moveswhenwelding
wireisstuck.
Wire
speed
to
does
meter
wire
zero.
not
display.
feed.
feeds
goes
Unit
No
No
Wire
only.
control.
(1PM)
operate.
~
at
maximum
~
meter
Output
Voltage
Incorrect
Wire
stick
Incorrect
Motor
Board
Fl
Fuse
Circuit
Meter
not
Display
Robot
signal.
CR1
Relay
Motor
Board
Tach
board
not
working.
PROBABLE
control
Board
robot
connection.
robot
PC2
Open.
breaker
working.
Board
not
PC2
PC7
CAUSE
connections.
PCi
not
working.
command
command
not
working.
CB1
tripped.
PC4
not
working.
working.
not
working.
wire
at
drive
voltage.
voltage.
motor
Check
and
3-4). Replace
est
Check PC5.
tween
Be
socketsHand
Check PC2.
and
Replace
est
Check
6-2).
ing
Check
6-2).
ing
Use
mine
6-4).
Section
rized
Use able
okay,
nearest
Check
PC2.
and
Replace
Replace
est
Replace
ers
PCi
Factory
robot
Command
sockets
that
sure
robot
Signal
B
(common)
PC2
Factory
and
Fl,
Correct
operation.
CB1,
Correct
operation.
check
points
if
power
If
check
6-5
Service
check
(see
points
Section
replace
Factory
input
Signal
B
(common)
CR1.
PC2
Factory
PC7
Manual).
REMEDY
secure
(see
Authorized
command
connections
Section
Service
voltage
voltage
Y
(common)
leads
from
N
RC17.
at
command
shouldbe0-10
RC5.
at
Section
(see
Authorized
replace
overload
and
overload
is
available
points
and
contact
reset
on
Display
are
Service
if
problem
if
problem
okay,
Station).
to
determine
If
6-4).
PC4
(see
Authorized
(see
(see
from
be
0-10
RC5.
on
Section
Service
motor/drive
signal
should
Authorized
(see
6-5
and
contact
Station).
Isolation
at
shouldbe0-10
Z
and
at
robot
voltage
6-5
vdc
are
at
between
and
connected
Motor
contact
Station).
necessary
necessary
to
Board
meter
before
(see
before
PC4to
(see
replace
nearest
check
Section
robot
Service
vdc
6-5
and
Factory
if
power
points
6-5
to
Motor
between
contact
Station).
assembly
Section
near
Board
vdc
be
7.
RC1
Board
pins
near
Section
(see
continu
Section
continu
deter
Section
meter
(see
Autho
is
avail
do
not
test
and
contact
Station).
Board
pins
near
Own
to
K
K
OM-136
224
Page
12
Page 17
6-7.
Gas
System
USE
flows:
normal
OF
On
INDICATOR
-a
(on.)
LIGHTS
Gas
Check
does
gas
TROUBLESHOOTING
FOR
Gas
flow
not
valve
operation.
Indicator
Light
Gas
Check
and Check
flows:
gas
line
gas
interface
valve
for
operation
leaks.
board
PC3.
~
Gas
does
System
Off
normal
not
flow
(off).
l~r
Contactor
System
~,
Wire
feeds:
System
On
I
closed:
normal
On
normal
~
(on).
a
(on).
Contacotor Check
cords.
Check
interconnecting
interface
¶1!
Wire
does
Check Check Check
circuit
relay
interface
open:
not
CR1.
Contactor
board
Wire
feed:
breaker
board
PC3.
Feed
CB1
PC3.
Indicator
Contactor
Check
Indicator
Wire
Check
robot
Signal
between
(common)
Check
Light
display
Light
1~
feeds:
input
to
should
motor
closed:
motor
pins
at
board
signal
board
be
0-10
K
and
RC5. board
from
B
PC2
PC4.
PC2.
vdc
~
Oft
Contactor
System
~
Off
Wire
does
System
I
open:
normal
normal
not
(off).
feed:
(off).
I!
Arc
started:
System
No
arc:
Check
On
normal
On
I
weld
(on).
~
parameters.
No
arc:
Replace
Arc
started:
Check
Signal
between
1TM.
and
Check
reed
from
signal
should
terminals
display
Current
relay.
Arc
robot.
be
24
board
vdc
1TL
Indicator
Failure
PC4.
Light
Arc
started:
Replace
Indicator
No
arc:
Normal
reed
Light
during
relay.
idling.
No
arc:
System
Arc
started:
Normal
OM-136
~Off
~
normal
Off
I
~1~
while
(oft).
welding.
224
Page
13
Page 18
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36
SC-i
No.
Diagram
Circuit
Interface
Robot
For
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N
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0
69
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0
Page 19
262
C-131
No.
Diagram
Circuit
PCi
Board
Voltage
For
Diagram
Circuit
7-2.
Diagram
Page 20
ALL
ALL Ct1I~4
H
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VQTAOES
WITH
POINT
RE~ECT
AT
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OM-136
224
Page
R
Circuit
Diagram
16
7-3.
Diagram
For
Motor
Control
Board
PC2
Page 21
cri
Circuit
Diagram
No.
OM-136
SD-083
224
388-A
Page
17
Page 22
AR
AU
ARANMAJflHG
t44
A;
AD
AC
A
B
AZ
A
AA
AP
AL
AD
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E
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7-4.
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Diagram
P020
A-P
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AA-AF
1~J~
11
A
A
A
RC23
g
Irt2
2
P024
ON
Circuit
C,
Diagram
U
For
LED3
U
Interface
A A
A
RC2I
A
Board
Circuit
PC3
9
9
A
A
A
PC22
Diagram
A A
~ri
No.
i-i
SB-115
Z
925
9Z
9
OM-136
224
Page
Circuit
Circuit
Diagram
18
7-5.
Diagram
For
Display
Board
PC4
Diagram
No.
B-ill
341
Page 23
0
F
E
D
B
AA
AS
BA
85
C
AG
AF
AE
AD
AC
SD
SF
SE
SD
BC
Diagram
7-6.
Circuit
Diagram
For
Circuit
Isolation
Board
Diagram
PC5
No.
SB-114
732
OM-136
224
Page
19
Page 24
SECTION
8-
PARTS
LIST
Dia.
Mkgs.
Ci
C4,5
R4
C6-i
CB1
CR1
Fl
FL1
PB1,2
PCi
PC2
PC3
PC4
PC5
PLG9
PLG16
PLG
PLG15
PLG18
PLG2O,26
PLG24
PLG25
PLG28-30
Ri
R2
OM-136
0
1185500008259
14,19
224
Page
20
Part
No.
031 006
117
000 601
028
011 109006
*012
046
084
021
131
110 110391
071
083
118
117836 089 073 756
109 047 079 535 079 096813
048
079534 079 079
108
863
097868
039 734 090
097866
079
747
079
081
379
081
378
084
081
378
081
380
081
378
135 081
378
030651 605741
030
941
030
949 010 079
683
056
010
193
692 426
726 859
394
291 991
655
432
171
105
247 375
642
147
547
032
041
636
739
598
748
747
263
760
198
787
199
170
Descnption
Main
Assembly
elctlt
750uf
CAPACITOR,
CLAMP,
capacitor
2.000dia
CAPACITOR/RESISTOR,
CAPACITOR,
RESISTOR,
CAPACITOR,
CIRCUIT
elctlt
C
2W
cer
BREAKER,
disc.1uf
200VDC
(consisting
220uf
10K
ohm
500VDC
reset
man
RELAY,encI24VACDPDT
FUSE,
HOLDER,
FILTER, SWITCH,
CIRCUIT
STAND-OFF
GUIDE,
CIRCUIT
GROMMET,
CIRCUIT
CIRCUIT
LENS,
STAND-OFF,
CIRCUIT
CABLE,
HOUSING,
HOUSING,
HOUSING,
HOUSING,
TERMINAL,
HOUSING,
TERMINAL,
HOUSING
minatceriOA25OV
line
CARD,
mtg-circuit
CARD,
CARD, CARD,
LED
CARD,
interconnecting
HOUSING
TERMINAL,
CLAMP, CABLE,
HOUSING
cable
pwrshld
interconnecting
PLUG, CLAMP, CABLE,
PLUG,
TERMINAL,
i7sktMS-3106A-20-29S
cable
pwr
17
fuse
minat
115/250V
pwr
PB
SPDT
voltage
SUPPORT,
motor
No.
scr
interface
meter
red
4341
No.
6-32
isolation/amplifier
PLUG
&
male
i8ga
PLUG
&
female
term
header
contact
AN-3057-12
No.
1
MS-3106A-20-29P
pin
term
header
contact
term
header
female
term
header
female
term
header
female
PLUG
&
female
.250x1.250
control
PC
card
speed
8/10
(Fig
(Fig
.625
x
(consisting
PINS,
1
sz
pin
15/c
SOCKETS,
iskt
18
header
(consisting
18/c
8ga
12
header
12
lskt22-l8wire
6
pin
iskt
22-18
14
iskt22-l8wire
SOCKETS,
iskt
22-18
RESISTOR,WWfxd25Wl0ohm
CLIP,mtgresistor.312ID
WW
fxd
ID
OD
100W
x
x
1.000
.250
RESISTOR,
HEAT
SINK,
TUBING,
HEAT
SINK,
SHIELD,
TUBING,
rect
stl
.275
resistor
resistor
stl
.375
35VDC
1P
1.5A250V
panel
of)
(Fig
card
No.
digital
Hz
8-i)
(Fig
50-400
8-3)
8-4)
Ig
(Fig
of)
(consisting
1618-14
(order
by
(consisting
wire
14-18
pin
wire
24-18
of)
(order
by
pin
24-18
wire
pin
wire
pin
(consisting
wire
5
ohm
6
scr
8-5)
of)
wire
ft)
ft)
mtg
8-2)
of)
of)
Quantity
1 1
1
2
1
5
1
1
1
1
1
2
1
6
3
1
2
1
1
5 7
1
1 1
14
2
18ft
1
16
2
18
1 1
2
1
5ft
1 1
12
2
12
1
6
1
14
3
7
1
4
1
1
2
1
1
4
Page 25
Dia.
Mkgs.
Part
No.
Descnption
Quantity
R3
RC5
RC9
RC13 RC15 RC17
Si S5
SR1,2
Ti
T2
T3
iT,2T
Dl
GS1 RC7
RC1
REED
4T
1324810008989
6
057084
079
117374
009
047 079 109
097867
094592 011
086895
097922
035 035 036
116849
038
601
010 916 070 047
112
+116
123
010 010 853 073
121
111
109
116964
110015
iii
109
045
047
079535
079
073
071
079534 048
056
604
010 606 056
056
118
026
109
047
079 090 079535 079
038
497
335 637 534 768
609
704
759
135
783
219
371
838
473
969
154
855
487
594
122
770
123
771
348 636
739
139
892
144
462 550
108
851
953
202
293
637
534
246
687 081
Main
Assembly
BUSHING, RESISTOR,
TERMINAL,
STAND-OFF,
HOUSING
TERMINAL,
RECEPTACLE, RECEPTACLE, RECEPTACLE,
SWITCH,
tgl
SWITCH,
KNOB,
pointer
RECTIFIER,
TRANSFORMER,
TRANSFORMER, TRANSFORMER,
BLOCK,
LINK,
term
jumper
CONNECTOR,
BLANK, BLANK,
snap-in snap-in
CABINET,
PANEL,
DOOR,
LABEL,
mtg
access
warning
RETAINER,
speed
NAMEPLATE
CABLE,
.
HOUSING
interconnecting
TERMINAL,
CLAMP,
CABLE,
HOUSING
cable
port
CABLE,
HOUSING
motor
~TERMINAL, CLAMP,
CABLE,
RECEPTACLE
cable
port
(Continued)
snap-in
WW
fxd
term
No.
RECEPTACLE
female
14 17
24skt
SPDT
rotary
integ
20A12P
term
clamp
nyl
nyl1.000mtg
control
components
cabinet
general
No.
scr
sltdhdNo.
scr
2
No.
PLUG
male
97-3057-1012
No.
PLUG
female
(consisting
PLUG
male
strain
No.
w/SOCKETS,
ID
.250
nyl
25W
conn
22posn
4-40
x
lskt
97-4102A-20-27P
pin
MS-3102A-20-29P
pin
MS-31
15A
30A
600V
control
control control
20A
blk
cable
1.093/1.1
2K
ohm
.625
Ig
&
SOCKETS,
14-18
02A-24-28S
125VAC
mintr
115/24VAC
.750
25mtg
hole
x
precautionary
2
2
(consisting
&
PINS,
(consisting
45
sz
1pm
187/c(orderbyft)
&
SOCKETS,
lskt
16-22
of)
&
PINS,
1
16
(consisting
pmnsz
relief
sz
6/c
(order
1618-14
17
(consisting
~TERMINAL,femaIe1skt14-18wire
.
HOSE,
gas
HOSE, FITTING,
FITTING,
FITTING,
CONTROL
DIODE,
VALVE,
.
HOUSING
RECEPTACLE
~TERMINAL,
.
RELAY,
BLOCK,
(consisting
nprn
hose
hose
hose
BOX,
rect
24VDC
RECEPTACLE
current
term
1
male
brd
No.
brs
brs
brs
pin
nut
ferrule
barbed
gas/current
1A
400V
2
way
female
w/PINS,
1
male
4P
20A
plug
keying
of)
1
x
ID
.187
.625-18RH
.425
nipple
sensor
SP
1/4
IPS
&
SOCKETS,
lskt
14-18
(consisting
pinsz
1618-14
.375
mtg
hole
(consisting
wire
115/36VCT
hole
of)
of)
16-22
wire
(consisting
wire
45
sz
of)
wire
by
ft)
(orderbyft)
ID
.718
x
Ig
3/l6tbg
(consisting
ort
1/8
port
(consisting
wire
of)
wire
of)
of)
of)
of)
of)
OM-136
224
1 1 1
2
1
14
1 1 1 1
1
1
2
1
1
1
2
4 1
1 1
1
1
I
2
2 2
I
14
2
lOft
1
14
1
1
14
2
28ff
1
14
2
1
lift
14
16
Page
21
Page 26
Dia.
Mkgs.
Part
No.
115
010
057
010 602 079
079
109
-i-079 047 072 058428
058
010
601
057971
010
072 058 092
121
104 494 358 604
934
573
574 021
682 497
094
628
191
844
233
292 427 989
316
Main
Assembly
CONNECTOR,
BUSHING,
BUSHING, FITTING, FITTING, FITTING,
BRACKET,
CASE
SECTION,
WRAPPER
LABEL,
HUB
&
SPINDLE,
HUB,spool
WASHER,
WASHER,
sti
NUT, WASHER,
SPRING,
SHAFT, RING,
retaining
SUPPORT,
LABEL,
snap-in snap-in
hose
pipe
galv
galv
pipe
mtg
warning
brake
fbr
.656
hex
slflkg
stl
flat
cprsn
spool
support
spindle
warning
Description
(Continued)
cable
clamp
nyl nyl
brs
bushing
coupling
nipple
control
bottom/front/sides
general
(consisting
stl
ID
mscr
keyed
OD
.970
.500
ID
1.375
ID
1.000
1/4NPTx
.25ONPSC
.25ONPT
L
precautionary
of)
1.500
x
4-40
1.500diax
1.250
x
spool
(consisting
general
precautionary
OD
of)
1
x
.75Omtg
1
x
.375mtg
.l25thk
x
.l25thk
hole
hole
.625-18RH
6.000
x
Quantity
1 2 2 2
1
1
2
1
1
1
1
1
2
2
1
1
1
1
1 1 1
Recommended
+When BE
ordering
SURE
TO
Spare
a
component
PROVIDE
Parts.
MODEL
originally
displayingaprecautionary
SERIAL
AND
NUMBER
WHEN
(SOLDERED
label,
ORDERING
TO
c12
R48
I
the
&
L3)
label
should
REPLACEMENT
alsobeordered.
PARTS.
OM-136
224
Page
SC-131
248
8-1.
FIgure
22
CIrcuit
Card,
Voltage
Control
PCi
Page 27
Dia.
MkQs.
Part
No.
Description
Quantity
PCi
A1-3
C1,2
C3,4
C5-15,17-30
C16
D1-4,6
L1-4
Qi
Ri
R2,34,35,41
R3
R4,20,26,27,
30,38,40
1
Note
R6,7,12-15,36
R8
Ru
6
,i
R17
R19,21,43
R22,42
R23 R24 R31 R32 R33
R45
R48,49
RC25
RC26
Ui
U2,4
U3
VR1 VR2
247
131
096275
039482 000
073739
488
097
028
351
095 037
035
824
009
039
333
039
000
044 052 000 039 053 572
052138 052
039 052
035
091
035823
049015
092
089
089
112058 095268 008 970 095
046932
348
258 200
173
332 885
789
136
038
331
139
325 137 826 799
648 347
346
269
8-1.
FIgure
linear
IC,
CIrcuit
324
CAPACITOR,
CAPACITOR, CAPACITOR,
CAPACITOR, DIODE,
CHOKE,
.020A
sig
l000uh
TRANSISTOR,
RESISTOR,
CF
POTENTIOMETER, RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
CF
CF
MF
MF
CF
POTENTIOMETER, RESISTOR,
RESISTOR,
CF
MF
100uI35VDC
elctlt
tantlm
cer
mono
cer
mono
75V
28MA
NPN
.25W
.25W
.25W
.25W
.25W lOOK
.25W
.25W
.25W
Card,
.47u1
.1uf5OVDC
.l5uf
SP
200MA
270
cermet
18K
15K
10K
150K
cermet
4.7K
12.1K
Voltage
35V
ohm
ohm
ohm
ohm
RESISTOR,MF.25W2OKohm RESISTOR, RESISTOR,
MF MF
MF
CF
MF
39.2K
.25W
.25W
82.5K
.25W5.11K
.25W
6.8K
.25W
8.25K
RESISTOR,CF.25WlOOohm
RESISTOR,CF.25Wlomegohm
WW
RESISTOR,
interlace
IC,
interlace
IC,
IC,
digital
linear
IC,
linear
IC,
fxd
header
header
212 211
4011
3i7T
7915
14
12
zero
ohm
pin pin
40V
trmr
ohm
ohm
trmr
ohm
ohm
5OVDC
ohm
ohm
ohm
ohm
ohm
20/T
2511
.5W
.5W
5K
2K
ohm
ohm
3
2 2
25
1
5
4
1 1
4
1
7
11
7
1 2
1
3
2 1 1 1 1
1
1 2
26
1 1 1
2
1 1 1
Note
BE
1:
SURE
R5,9,1
0,18,25,28,29,37,39,46,47
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-136
224
Page
23
Page 28
380-E
SO-093
PC2
Digital
Speed
Motor
Card,
Circuit
8-2.
Figure
0
a) N)
N)
N)
(Q
Page 29
Dia.
Mkgs.
Part
No.
Description
Quantity
PC2
A50-53
C50 C51
C52,61 C53,62
C54
C55,66-75,77
C56
C57 C60
C63,64
C65
CR50
D50-54,56-60
D55
1C50
050,53
051 Q52
R50
Notel
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
VR1
VR5O
.
642
071
009159
039
482
699
031 073
739
833
035 005
023
031
073 549
007
035
044 031 095033
091 861
079 026202
080910
081 037 037
355
039 030
839
035827 052
039
332
035
884
030
335
039 039 039
331
049015
039
328
052 039
886
035
035825
030937 030
090
092
648
085
399
047272
081
799
643
742
561
602
721
844
800 200
824
138
007
106
142 108
Figure
8-2.
Circuit
Card,
Motor
iC,iinear358
CAPACITOR,
CAPACITOR,
CAPACITOR, CAPACITOR, CAPACITOR,
CAPACITOR,
CAPACITOR, CAPACITOR, CAPACITOR, CAPACITOR,
CAPACITOR,
RELAY,
SOCKET,
SPRING,
DIODE,
elctlt
.0022uf
mylar
.luf
cer
mylar
tantlm
.Oluf
cer
mylar
lOut
elcttt
4uf
mylar
film
poly
mylar
encI24VAC4PDT
relay
hold
down-relay
1A400VSP
5OVDC
.033uf
2.2uf
500
.Ol5uf
35V
200V
.47uf
.22uf
100VDC
20V
VDC
200V
200VDC
35VDC
lOOuf
DIODE,zenerl5V5W
interlace
IC,
TRANSISTOR, THYRISTOR,
TRANSISTOR,
RESISTOR,
2907
SCR
WW
NPN
UJT
fxd
200MA
7.4A
15MA
5W
200V
40V
220
RESISTOR,CF.25WlOKohm
.25W
20K
15K
100K
cermet
47K 470
4.7K
ohm ohm
ohm
1511
ohm
ohm
ohm
RESISTOR, RESISTOR,
CF
CF
CF
POTENTIOMETER, RESISTOR, RESISTOR, RESISTOR,
CF CF
CF
.25W
.25W
.25W .25W
.25W
RESISTOR,CF.25Wlomegohm
CF
.25W
1.5K
120K
22K
lKohm
ohm
ohm
ohm ohm
RESISTOR,
RESISTOR, RESISTOR,
CF
CF CF CF
.25W .25W82K .25W .25W
RESISTOR,CF.5WlOohm
.5W
fxd
47
zero
pulse
ohm
ohm
RESISTOR,
RESISTOR,
CF
WW
TRANSFORMER,
linear
linear
78L12
78L08
IC, IC,
Speed
200VDC
400VDC
40V
ohm
.75W
Digital
50K
ohm
PC2
4
1
1
2 2
1
12
1 1
1
2
1 1 1
1
10
1
1
2
1 1 1
10
3
1
8
1
3
2
1
1 2 1
1 1
2
1 1
15
1
1
1
Note:
BE
SURE
R51
,54,55,57,67,68,74,75,82,89
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-136
224
Page
25
Page 30
Dia.
Mkqs.
Part
No.
Description
Quantity
PC3
Al
C2-7,15
C8
C9
Cll,12
C13 C14
CR1
,2
CR3-6
D1,13-17
D2-8
02-8
Al
,4,8,9
R2
R3,5,6,23
R7
R10-14,17-29
R15
R16
R24-27
R28
R30
RC18 RC19
UI
VR1
118
547
009
159
073
739
083 973
031
677 000348 072
130
000
859 095
521 099
018 079
844
091
861
028351
026202
037
200
035
826 039332 035
827
035825
039331
039
329
039336
053 572
035
884
035823
092
648
079
759
079
749
094
594
081832
CircuIt
FIgure
IC,
8-3.
linear
358
CAPACITOR, CAPACITOR,
CAPACITOR, CAPACITOR,
CAPACITOR,
CAPACITOR,
RELAY,
RELAY,
SPRING, SOCKET,
end end
hold
relay
24VDC
24VDC
.luf
cer
elctlt
tantlm tantim
tantlm
elctlt
down
Card,
5OVDC
l000uf
5.6uf .47uf35V luf
220uf
4PDT
SPDT
relay
DIODE,sig.O2OA75VSP
DIODE,
TRANSISTOR,
RESISTOR,CF.25W22OKohm RESISTOR,
RESISTOR,CF.25WlOOohm
TERMINAL,
IC, IC,Iinear78Ml5
1A400VSP
4098
digital
NPN
CF
.25W
.25W
CF
.25W4.7Kohm
CF
.25W
CF
MF
.25W
.25W
CF
WW
fxd
header
header
200MA
6.8K
10K
2.7K
lOOK
zero
12
18
12.1K
pin pin
Interface
35VDC
35VDC
35VDC
35VDC
40V
ohm
ohm
ohm
ohm
ohm
ohm
1
7
1 1
2
1
1 2 4
2 2
6 7 7
4
1
4 1
12
1
1 4
1
1
10
1
1
1
1
L~~EJ~
Uurn
~
Figure
13
8-3.
C,
~
CIrcuit
E~
Card,
Interface
PC3
A-
118
549
OM-136
224
Page
26
Page 31
Dia.
Mkgs.
PC4
117
Part
No.
836
FIgure
8-4.
CircuIt
Description
Meter
Card,
Quantity
Cl
,2
C3,4
Dl
,2
LCD1,2
LED1
,2,4-7
LED3
R1-5,11,12
R6,8 R7,9
RC2O
RC21,22
RC24 RC27
VR1
,2
ASSEMBLY
e
I
'
LED4
RC21i
__
348
000
073739
351
028
108453
028
089
763
097
030028
030140 003272
648
092
381
081
161
109
084
194
084
193
071
248
070
026
L~I
~rij
v~i
LEDI
'
CAPACITOR,
tantlm
.47uf
35V
CAPACITOR,cer.1uf5OVDC DIODE,
sig
.020A
SP
75V
METER,digital
5330A1040MCD
LED,
5330A19200MCD
LED,
.5W1.5K
ohm
POTENTIOMETER,cerl5/T.75W200Kohm
RESISTOR,CF.25Wlmegohm
TERMINAL, TERMINAL, TERMINAL,
TERMINAL,
linear
IC,
STAND-OFF,
I
RO
WW
fxd
header header
header
header
78M05
No.
6-32
LCD2
+
Rc221
c~J
L
LED2
zero
12
l3skt
6
pin
4
pin
x
ohm
pin
.437
v~
E~J
R3'
DI
D2
~
=1
£$
2
2 2
2 6
1
7
2
2
2
1
2
1
1
2
6
LDD3
I
RC23
*
I
I
BE
SURE
TO
PROVIDE
MODEL
AND
Figure
SERIAL
II1I1IIIIIIIIIIHIIII
8-4.
NUMBER
Circuit
Card,
WHEN
Meter
ORDERING
PC4
Hllllll~
REPLACEMENT
PARTS.
OM-136
Ref.
224
SD-117
Page
838-B
27
Page 32
Dia.
Mkgs.
Part
No.
Description
Quantity
PC5
A1,3
A4-6
C1,5,9
C2,4,6,8,10,12
C3,7,11
Ri
,14,27
R2,15,31
R3,16,28
R4,17,29 R5,18,30 R6,19,32 R7,20,33 R8,21
,34
R9-1
2,22-25
35-38
1185500008259
112339
159
009
697
093
739
073 053992 052
138
035825
225
053
179
082
039
331 327
039
335
039
151
052
827
035
823
035
892
099
RI
R2
FIgure
IC
Jinear202
linear
IC, CAPACITOR, CAPACITOR,
CAPACITOR,
RESISTOR, RESISTOR, RESISTOR,
POTENTIOMETER, RESISTOR,
RESISTOR, RESISTOR,
POTENTIOMETER,
RESISTOR, RESISTOR,
E3R5
R3
Cl
-
8-5.
356
CIrcuit
mica
.luf
cer
.OOlut
cer
MF
.25W
CF
.25WiKohm
CF
.25W
CF
.25W
CF
.25W
CF
.25W
CF
.25W
CF
.25W
header
RI4RIS
Card,
lOOpt
5OVDC
20K
39K
cermet
4.7K
220
47K
cermet
10K
100
7
pin
IsolatIon/Amp
300VDC
1000V
ohm
ohm
25/T
trmr
ohm
ohm
ohm
25/T
trmr
ohm
ohm
RIO
R16
7
UR19UU
.5W 25K
.5W
lOOK
R27
R31
ohm
ohm
E
..
R3~
R28
C9
R29
~I1
~
R34
3
3 3
6 3
3
3 3
3
3 3 3 3
12
3 3
BE
SURE
TO
PROVIDE
RI
C2E
C31
Figure
MODEL
R9
RIO
U~1~c4
R12
Ru
~jR4
Circuit
NUMBER
AA
Card,
~
AND
L~J
8-5.
SERIAL
R20
C5
R24
___~jA5
BA~.
P
Isolation/Amplifier
WHEN
ORDERING
PC5
REPLACEMENT
0
~
R35 R36
A3
U
LlULHe
R38
R37
~32~
~A6
PARTS.
A-118
552-A
Cli
OM-136
224
Page
28
Page 33
Page 34
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