Miller Electric NSPR 8989 User Manual

Millerﬁ

November

1990

FORM:

OM-135

582B

MODEL:

Robot

(per

Interface

NSPR

8989)

OWNERS

iMPORTANT: and

the

safety

maintaining

by

persons

Do

ment.

Contact

power

material

trained

not

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source

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this

equipment.

untrained

allow

distributor

understand

and

manual

and

experienced

If

you

used

both

This

unit

persons

do

the

with

manuals,

and

In

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to

Install,

not

fully

entire

this

unit,

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safe

understand

MANUAL

both

contents

before

Instructions

operationofwelding

operate,

of

with

special

Installing,

maintain

or

these

are

Instructions.

this

manual

emphasis operating,

for

use

only

equip

this

unit.

on

or

MILLER

A

MIter

Group

P.O.

Box

Appleton,

Tel.

414-734-9821

ELECTRIC

Ltd..

Con~any

1079

WI

54912

Mfg.

USA

PRINTEDINU.S.A

Co.

Ui

ii

LIMITED

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MIl.LER

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Section

Connections

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OM-135

5828

Page

2

a

WARNING:

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OM-1355828Page3

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AMENDMENT

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OM-135

582B

Page

4

AMENDMENT

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Description

CAPACITOR,

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information

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Model

Description

No.

-

1

SAFETy

1-1. 1-2.

General

Safety

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check

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TABLE

AND

And

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any

al

OF

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Model

Senal

Date

CONTENTS

SIGNAL

Words

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Serial

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WORDS

or

No.

spaces

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on

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to

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Number

data

the

of

your

cardorthe

Page

Model

unit.

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nameplate.

No.

1

infor

SECTION

2-1.

3INSTALLATION

3-1. 3-2. 3-3. 3-4.

3-5.

3-6. 3-7. 3-8. 3-9.

4-

4-1.

4-2.

4-3.

4-4.

4-5.

4-6. 4-7.

Amps/lnductanc~

Description

Site

Selection

Equipment

Gas/Current

Voltage

Robot Robot

Arc

Welding

Burnback

OPERATOR

Power

Jog

Purge

Voltmeter

Wire

Indicator

Sensing

Interface

Failure

Wire

Switch

Push

Speed

Lights

Control

Buttons

Installation

Sensing

Control

Connections



Welding

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Robot

Terminal

Light

Installation

CONTROLS

Button

Meter

Interconnections

Power

Control

Strip

Source

Unit

Connections

1

2

2 3 3

4

5

6 6

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

Section

SECTION

No.

MAINTENANCE

6

&

TROUBLESHOOTING

Page

No.

SECTION

6-1.

6-2.

6-3.

6-4. 6-5.

6-6. 6-7.

7-

Diagram Diagram

Diagram

Diagram Diagram Diagram Diagram

-

8

Figure Figure Figure

Figure Figure

Figure

Routine

Overload Reinstallation

Display

Circuit

Maintenance

Protection

Of

Board

PC4

Handling

Troubleshooting

Use

Of

Indicator

ELECTRICAL

7-1.

PARTS

8-1.

8-2. 8-3. 8-4. 8-5.

8-6.

7-2.

7-3.

7-4.

7-5.

7-6.

7-7.

Circuit

Circuit Circuit

Circuit

Circuit Circuit Circuit Circuit Circuit Circuit

Circuit

Diagram Diagram

Diagram

Diagram Diagram

Diagram

LIST

Card,

Card, Card,

Card,

Hub

Meter

Lights

DIAGRAMS

Voltage

Motor Interface

Meter

Interface

Wire

Assembly

Check

Precautions

For

Troubleshooting

For

Robot

For

Voltage

Motor

Control

For

Interface

For

Display

For

Arc

Failure

For

Touch

Control

Speed

PC4

Touch

Digital

PC3

PC5

PC6

Interface

Board

PCi

Board

PC4

Board

Sense/Wire

PCi

PC2

PC3

PC5

Stick

Board

PC6

. . . .

8 9

9

10

11

13

14

15

16

17 17

18 18

22 24 26

27 28 29

Table

2-1.

Specifications

6-1.

Troubleshooting

LIST

OF

CHARTS

AND

TABLES

1

12

SECTION

1

-

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

GENERAL

1-1.

AG

Information

bels,

design, troubleshooting

followed

B.

Safety

The

installation,

shooting

and

procedures

safety

stalled,

Sons

codes

Section

of

Power

ing

Manual.

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enera

presented

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Source

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which

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INFORMATION

in

this

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on

operation,

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effective

and

equipment

ensure

maintained

and

with

this

limited

not

Rules

in

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welding

AND

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unit

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pertains

maintenance,

be

read,

of

use

maintenance,

requires

personal

this

equipment

only

manual

to,

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and

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Operation

power

SECTION

SAFETY

to

equipment

understood,

this

equipment.

and

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practices

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qualified

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all

applicable

listedatthe

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source

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ous

personal

CAUTION

practices

personal

for

ALERT

safety

this

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WARNING

safety

which

injury

statements

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most

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alert

symbol

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hazard

of

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statements

injury

statements

and

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and

statements.

must

or

be

must

or

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efficient

AND

and

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attention

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of

to

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this

instructions.

with

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to

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equipment.

special

is

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identify

be

followed

loss

identify

followedtoavoid

special

operation

SIGNAL

words

iden

to

and

the

signal

call

to

atten

seri

avoid

minor

instructions

of

this

equip

are

or

Component

Robot

Gas/Current

Sensing

Spool

Assembly+

Add

2-1/4

*Add

7/8

2-1.

DESCRIPTION

The

robot

Panasonic

a

Maxtron,

provides

Interface

Control

Support

in.

(57

in.

(22

mm)

interface

robot

Pulstar

or

digital

display

mm)

for

control

and

450

Height

22-1/2

(572

4-1/2

(108

13-3/4

(349

for

brake

front

panel

is

designed

Arc

an

welding

of

weld

in.

mm)

in.

mm)

in.

mm)

resistor.

knob.

to

Pak

350,

source.

power

volts,wire

Table

Dimensions

Width

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5-1/2

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8-3/4

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interface

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feed

speed,

2-1.

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mm)

in.

mm)

in.

mm)

+Spool

and

with

unit

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and

These

using

Depth

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mm)

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10-1/2

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(216

peak

gas/current

current

the

in.

mm)

in.

8-1/2

mm)

Support

amperage

sensing

components

Metal

Gas

without

or

sensing

reed

function

Arc

Net

lbs.

38

kg)

(17

5

lbs.

(2.3

kg)

lbs.

6

(2.7

kg)

optional

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wire

control

relay.

with

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Weight

Total

reel.

contains

the

robot

(GMAW)

Ship

61

(27.7

the

gas

system

process.

lbs.

kg)

valve

when

OM-135

582

Page

1

SITE

3-1.

Select

2.

3.

4.

5.

6.

7.

8.

9.

1.

Correct

Shielding

Water

Adequate

No

A

Proper

cold

Proper

Adequate

wrapper functions.

an

flammables

clean

Mounting

the

cure

2-1

Table

EQUIPMENT

3-2.

A.

Supplied

The

following

1.

installation

Weld

Cord

quires

SELECTION

installation

input

power

gas

supply

ventilation

and

dry

temperature

airflow

space

for

installation,

holes

provide

system

gives

components

overall

Equipment

equipment

Control

and

Motor

which

site

supply

(if

around

or

(if

applicable)

and

area

that

unit

to

open

the

dimensions.

INSTALLATION

is

supplied

assembly:

with

Gas/Current

Cord

SECTION

provides

unit

(see

applicable)

fresh

air

supply

avoids

and

extremes

remove

maintenance,

capability

in

to

a

permanent

standard

as

Sensing

the

following:

nameplate)

of

heat

cover

and

repair

install

and

location.

and

Control

3INSTALLATION

3.

4.

5.

C.

Obtain

as

or

and

se

re

necessary

ture

Gas/Current

onto

D.

The

Remove install

1.

2.

3.

4.

The

interconnecting

not

are

they

welding

One Current

Welding

tact

ment.

operations.

weld

output

Sensing

wire

the

weld

Equipment

appropriate

and

for

equipment

Sensing

structures

Installation

Hub

hub

assembly

the

hub

follows:

it

as

Remove

Align

selected

support

brake

Reinstall

until

Install

hex

keyway

holeinhub

depends

washers

hex

a

slight welding

caught,

cable

control.

be

must

control

Installation

mounting

installation.

control,

in

the

welding

(Figure

is

supplied

assembly

nut

from

and

insert

on

are

properly

nut

onto

felt

is

drag

wire

according

cords

must

pinched,

must

be

routedsothat

or

other

any

brackets

hardware.

Secure

and

all

area.

3-1)

with

the

from

the

shipping

end

of

hub

support

spool

while

Hole

seated

shaft.

turning

to

support.

wire

support

be

routed

strained

or

routedtothe

it

does

grounded

or

adapter

Prepare

weld

other

equipment

robot

interface.

carton,

in

shaft

Be

the

shaft.

hub.

support

selection

size.

Tighten

hub.

Section

3-8.

that

so

during

Gas/

not

con

equip

plates

struc

control,

and

through

in

hub

the

sure

hex

nut

2.

Gas/Current

Hub

3.

4.

5.

and

Spindle

ft.

10

(3

Support

m)

Interconnecting

6.

lOft.

(3m)

7.

B.

When

ft.

10

(3

m)

Equipment

deciding

lowing:

1.

The

equipment

of

pable

2.

The

equipment

can

ing

equipment

OM-135

supporting

lead

be

located.

optional

582

Page

Sensing

Spindle

Assembly

Weld

Control

Cords

Gas

Hose

Voltage

Location

on

lengths

will

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equipment

must

the

of

limit

the

Some

extension

distributor).

2

Control



location,

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mounted

weight

the

cords

area

cords

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to

of

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supplied

in

which

be

can

(check

Power

consider

structure

a

equipment.

with

the

equipment

extended

with

Source

the fol

ca

the

us

by

welding

Hub

Figure

Hub

Assembly

Support

Shaft

3-1.

Hub

Assembly

Washer

Hub

Installation

Hex

Nut

Support

SA-126

870

3-3.

a

GAS/CURRENT

CONNECTIONS

down

and

ELECTRIC

touch

disconnect

WARNING:



Do

not



Shut

robot,

lockout/tagging

connections.

Lockout/tagging

line

ing

moving

red-tagging

ing

disconnect

fuses

circuit

device.

SENSING

(Figure

live

electrical

unit,

welding

procedures

switch

from

fuse

breaker

CONTROL

3-2)

SHOCK

input

before

in

box,

or

parts.

power

consist

open

or

shutting

other

INTER

kill.

can

source,

employing

making

of

padlock

position,

off

disconnect

and

inter

re

and

A.

Robot

Connections

1.

Align

receptacle

threaded

2.

Align

receptacle

and

rotate

B.

Gas/Current

tions

1.

Align

into

matching

control,

ing

wise.

Interface

keyways,

RC9

collar

keyways,

RC16

threaded

keyways,

and



Gas/Current

insert

14-pin

on

robot

clockwise.

fully

insert

16-pin

on

gas/current

collar

Sensing

insert

Control

14-pin

receptacle

rotate

threaded

Amp

interface,

Amp

fully

plug

RC7

on

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into

plug

and

into

plug

sensing

clockwise.

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Motor

from

motor

gas/current

collar

fully

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matching

rotate

matching

control,

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cord

sens

clock

Gas/Current

Control

Volts

115

Control

SensIng

Receptacle

14-PIn

AC/Contactor

Receptacle

RC9

RC13

2.

Align

control

from

motor,

wise.

C.

Weld

For

Electrode

from

welding

minal,

through

drive

wire

terminal

(see

location).

D.

Gas

Connections

Connect

supplied)

ing

to

must

at

3-4.

hose

control.

on

fitting

be

accurately

the

source.

VOLTAGE

3-2

at

And

WARNING:

a



robot,

lockout/tagging

connections.

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ing

moving

red-tagging ing

keyways,

cord

into

and

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Connections

Positive/Reverse

power

the

gas/current

assembly,

Motor/Drive

from

gas

source

gas

Connect

gas/current

controlled

SENSING

3-3)

Do

not

touch

Shut

down

and

disconnect

line

disconnect

fuses

circuit

device.

insert

14-socket

matching

threaded

rotate

free-hanging

plug

collar

Polarity,

source

POSITIVE

sensing

and

connect

Assembly

cable

Owners

regulator/flowmeter

IN

to

hose

gas

sensing

ELECTRIC

live

unit,

welding

procedures

switch

from

fuse

breaker

on

fitting

from

wire

control.

a

by

regulator/flowmeter

CONNECTIONS

SHOCK

electrical

input

parts.

power

before

consist

in

open

or

box,

or

gas/current

other

from

receptacle

fully

route

weld

output

control,

weld

to

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(customer

drive

assembly

The

gas

(Figures

kill.

can

source,

employing

making

of

padlock

position,

shutting

disconnect

motor

clock

cable

to

cable

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inter

off

ter

the

for

flow

and

re

and

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ing

proper

are

control

cord

Figure

several

interconnections.

for

3-2.

cords

the

following

Side

Right

supplied

Examine

connections.

View

for

gas/current

and

TG-tt9

select

sens

646

the

1.

2.

3.

Align

keyway,

ceptacle

threaded

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nalonthe

3-3.

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RC12

collar

lead

wire

lead

insert

fully

with

drive

with

4-socket

robot

on

clockwise.

terminal

ring

assembly

clamp

plug

interface,

to

as

to

workpiece.

into

weld

shown

OM-135

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and

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cable

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582

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re

3

Nut

3-6.

ROBOTINTERFACE-ROBOTCONTROLUNIT

CONNECTIONS

(Figures

3-2

And

3-4)

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Lead

Terminal Location

Figure

ROBOT

3-5.

SOURCE

There

are

the

tween

amine

and

nections.

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REMOTE

1.

Align

receptacle

threaded

2.

Align

ceptacle

threaded

B.

REMOTE

1.

Align

receptacle

threaded

2.

Align

ceptacle

thread

C.

REMOTE

1.

Align

receptacle

threaded

2.

Align

on

collar

If

the

welding

switch,

though

REMOTE

OM.135

Ring

3-3.

Voltage

three

robot

select

14

keyway,

collar

keyway,

on

collar

17

keyway,

collar

keyway,

on

collar

10

keyway,

collar

keyway,

the

welding

clockwise.

fully

be

connections

582

power

sure

17

receptacles.

Page

Sensing

Drive

INTERFACE

CONNECTIONS

cords

supplied

interface

the

proper

Connections

insert

RC13

on

fully

insert

welding

fully

Connections

insert

RC16

on

fully

insert

welding

clockwise.

fully

Connections

insert

RC15

on

fully

insert

power

source

the

switch

made

are

4

Connections

Assembly



for

and

welding

cords

14-socket

robot

clockwise.

14-pin

power

clockwise.

17-socket

robot

clockwise.

17-pin

power

10-socket

robot

clockwise.

into

plug

source,

is

equipped

in

is

to

Cable

Location

WELDING

power

the

plug

into

plug

into

plug

rotate

14

position,

REMOTE

3-2)

source.

following

into

and

matching

and

into

and

matching

and

into

and

receptacle

with

(Figure

interconnections

for

interface,

plug

source,

interface,

plug

source,

interface,

matching

and

the

both

Lug

TA-109

093

At

Wire

POWER

be

Ex

con

matching

rotate

re

rotate

matching

rotate

re

rotate

matching

rotate

threaded

14/17

a

even

14

and

a

1.

Obtain

supplied).

2.

Connect

ate

3.

Align

ceptacle

lar

4.

Route

cord

The

input

RC17

are

as

Socket

WARNING:



Do

not



Shut

robot,

touch

down

and

ELECTRIC

unit,

disconnect

lockout/tagging

connections.

Lockout/tagging

line

device.

a

proper

conductors

keyway,

on

clockwise.

and

the

to

and

output

means

Digital

ets

Arc

Touch

Current

Weld

Circuit

A;

point.

Gas

Circuit

H,K,M,

Touch

Circuit

H,

Wire

Circuit

H,

Wire

Circuit

H,K,M,

Voltage Voltage

disconnect

fuses

from

circuit

cord

in

plug.

insert

robot

interface,

connect

robot

control

signals

of

the

common

and

C,

B,

failure

Sense/Wire

detect

start

Common

all

circuit

valve

common

P,

Sense/Wire

common

K,M,P~

inch

positive

common

K,M,P,

inch

negative

common

P,

control

input

ing moving red-tagging ing

sockets

fully

by

follows:

A:

B:

C:

G:

H:

J:

K:

L:

M:

N:

P:

0:

R:

S:

T:

U:

SHOCK

live

electrical

welding

input

procedures

switch

fuse

box,

breakerorother

and

24-pin

end

at

one

24-pin

conductors

robot

output

unit.

at

for

G.

plug

and

the

sockets

interface

output

signal.

stick

output

input

signal.

for

Sockets

voltages

signal.

for

input

R

and

stick

for

input

A

and

(+)

for

input

R.

and

()

for

andR

input

positive

connection.

wiper

parts.

power

before

consist

in

open

or

shutting

Amphenol

of

cord

into

rotate

at

remaining

control

signals

output

signal.

H,

referenced

signals

input signals

input

signal.

signals

input

signal.

signals

connection.

(+)

kill.

can

source,

employing

making

position,

inter

of

padlock

off

disconnect

plug

to

appropri.

matching

threaded

end

of

receptacle

circuitry

Sock

at

signal.

K,M,P,

to

at

Sockets

signal.

Sockets

at

Sockets

at

Sockets

and

re

and

(not

re

col

of

and

this

Socket

V:

W:

X:

Y:

IMPORTANT:

used.

not

are

Voltage

Wire

feed

Wire

feed

Wire

The

(

control

negative

speed

speed speed

remaining

positive

connection.

wiper

negative

sockets

0

connection.

()

connection.

(+)

connection.

()

in

the

receptacle

2.

For

is

a.

b.

c.

d.

robot

used

Route

panel

nections

Obtain

CR1,

Route

side

contact

Connect

open

control

(Figure

cord

of

robot

to

115

a

and

install

and

connect

of

the

and

+24

robot

units

when

115

3-5):

through

1TL

or

strain

interface,

and

1TM.

24

vac,

into

or

robot

and

remaining

normally-open

ground.

vdc

to

control

remaining

contact.

relay

24

or

relief

make

24

vdc

control.

end

robot

side

24

or

vac,

on

right

proper

isolation

of

cord

control

of

normally-

vdc

side

con

relay

to

one

relay

Figure

Receptacle

3-7.

ARC

NECTIONS

j~

______

There

are

for

control

unit

on cess

nections.

and

cedure

right

door,

close

___________________________

Front

3-4.

View

With

FAILURE

LIGHT

(Figure

WARNING:



Do

not



Shut

robot,

lockout/tagging

connections.

Lockout/tagging

line

ing

moving

red-tagging

device.

ing

two

connections.

side

and

Tighten

and

is

finished.

touch

down

and

disconnect

fuses

circuit

terminal

panel

locate

screws

secure

ELECTRIC

live

unit,

procedures

from

strips

Loosen

if

applicable,

appropriate

front

Of

24-Socket

Socket

TERMINAL

3-5)

electrical

welding

input

switch

fuse

breaker

inside

strain

on

panel

0

Amphenol

Designations

STRIP

SHOCK

in

box,

or

screws

terminal

access

parts.

power

before

consist

open

or

shuthng

other

the

open

relief

can

source,

making

position,

disconnect

robot

on

front

strip

if

door

S.0291

CON

kill.

and

employing

inter

of

padlock

re

off

and

interface

relief

strain

ac

panel

for

con

necessary,

when

pro

e.

f.

Common

Ii

So

+24V0C

Common

If

So

To

Voltage

(115VAC,

Connect

coil

to

Connect

vac,

remaining

Robot

Terminal

Equipped

I

Terminal

Equipped

Source

24VAC,

weld

24

or

Control

Robot

24VDC)

lead

a

alarm

proper

vdc)

side

Unit

Control

from

terminal.

voltage

between

of

robot

Weld

Unit

Weld

one

Robot

If

side

source

common

control

Interface

Alarm

So

Equipped

1TM

Alarm

So

Equipped

of

robot

(115

terminal

relay

Terminal

Indicator

Terminal

Arc

control

vac,

coil.

Failure

24

and

Light

The

ARC

el

is

turnedonand

unit.

Obtain

for

this

1.

For

3-5):

a.

b.

c.

FAILURE

proper

connection,

robot

control

Route

panel

nections

Route

weld the

Connect

minal.

of

alarm

robot

cord

robot

to

and

+24

light

off

by

length

and

units

through

interface,

1TL

connect

terminal

control

vdc

the

on

a

signal

of

18

proceed

when

strain

1TM.

and

remaining

and

unit.

to

common

robot

interface

from

the

front

robot

control

gauge/2-conductor

follows:

as

24

vdc

is

used

(Figure

relief

on

and

make

ground

relay

right

proper

endofcord

connection

contact

pan

cord

side

con

ter

to

at

+24VDC

Figure

Isolation

E-j

3-5.

Relay

Robot

Arc

CR1

Control

CR1

Failure

Robot

1TM

Light

Interface

Arc

Indicator

Connections

OM-135

582

Failure

Light

S-0292

Page

5

WELDING

3-8.

A.

Installation

1.

Remove

2.

Slide bottom

Rotate

3.

Slide

flange

4.

Reinstall

B.

Installation

Wire

Type

1.

Remove

assembly

2.

Lay

Remove

3.

4.

Remove

Be

5.

Reinstall

reel.

Slide

6.

sembly

7.

Reinstall

spool

of

wire

sure

wire

WIRE

Of

retaining

wire

of

spool.

until

spool

onto

the

hub.

retaining

Of

retaining

from

reel

assembly

spanner

wire

retainer,

that

wire

retainer

wire

reel

until

hub

retaining

Retaining

INSTALLATION

Spool-Type

ring.

hub

onto

in

hole

hub

spool

until

onto

ring

Optional

and,

ring

hub.

flat

from

nut

and

feeds

off

and

assembly

guide

ring

Ring

onto

Wire

that

so

aligns

it

seats

hub.

Wire

Reel

if

applicable,

table

on

a

reel

wire

install

wire

bottom

spanner

hub,

is

seated

hub.

Retainer

(Figure

wire

feeds

with

against

And

wire

floor.

or

assembly.

wire

onto

of

reel.

nut

onto

and

rotate

in

reel.

Wire

/

3-6)

in

hub.

back

Reel-

reel.

wire

Reel

oft

reel

as

C.

Adjustment

Check

or

should lash

loosen

port

3-9.

Burnback

Circuit

between

The

from

the

The

reel.

be

when

or

shaft

BURNBACK

Board

burnback

sticking

guished.

the

welding

has

stopped

wire

ing

the

workpiece

WARNING:

a



robot,

locko

installing. Lockout/tagging

ing

moving

red-tag9ing

ing

Of

hub

tension

wire

should

sufficient

the

tighten

wire

to

feed

the

accordingly.

CONTROL

is

provided

PC3

inside

and

0.25

0

circuitry

the

to

The

burnback

wire

from

feeding.

back

burn

to

the

or

Do

Shut

not

down

and

touch

disconnect

ut/tagging

line

disconnect

fuses

device.

circuit

Hub

Tension

by

slowly

unwind

wire

keep

hex

by

seconds.

in

If

stops.

nut

on

potentiometer

unit.

the

this unit

workpiece

circuitry

0to0.25

This

to

a

contact

ELECTRIC

live

unit,

action

delay

whereitneither

point

tube.

electrical

welding

input

procedures

switch

from

fuse

breaker

(Figure

and

the

but

prevent

rotating

freely,

taut

adjustment

the

keeps

after

keeps

seconds

of

end

R32onInterface

Burnback

the

weld

after

permits

SHOCK

can

parts.

power

before

consist

in

open

or

box,

or

other

shutting

3-1)

wire

spool

hub

tension

back

is

required,

the

hub

sup

be

extin

is

output

the

weld

sticks

kill.

set

wire

on

wire

to

and

can

welding

arc

source,

employing

inspecting

of

position,

disconnect

or

padlock

re

off

and

Spanner

Nut

FIgure

OM-135

3-6.

582

OptIonal

6

Page

Hub

Wire

Reel

Installation

Support

And

SC-1V

Reel-Type

Wire

a

1.

2.

CAUTION:

(ESD)



BEFORE



Open

Locate

Put

Perform

front

potentiometer

can

damage

on

handling

work

access

ELECTROSTATIC

circuit

properly

door

circuit

only

R32

grounded

at

a

and

boards.

static-safe

PC3.

locate

in

upper

DISCHARGE

wrist

work

left

corner

strap

area.

of

PC3.

308

3.

4.

Rotate

Close

R32

clockwisetoincrease

and

secure

front

access

burnback

door.

time.

Gas

Indicator

Light

SECTION

4

OPERATOR

CONTROLS

Circuit

Section

Power

Switch

Purge

Button

Breaker

6.2)

Push

Switch

Contactor

Light

4-1.

POWER

robot

weld.

to

shuts

JOG

wire

REV,

the

PURGE

button

the

interface.

When

feeds

gun.

This

the

Placing

the

bot

tion

4-2.

The

switches.

ing

JOG

into

4-3.

The switch.

purges

push

energizing

4-4.

VOLTMETER

The

voltmeter

volt

of

4-5.

The

the

a

WIRE

wire

nearest

while

speed

Indicator

SWITCH

POWER

Placing

down

the

PUSH

push

the

out

buttons

PUSH

push

switch

shielding

allows

the

welding

displays welding

SPEED

meter

inch

per

(Figure

switch

The

interface

POWER

the

interface.

BUTTONS

buttons

JOG

of

the

gun.

are

pushed,

BUTTON

button

energizes

gas

flow

the

circuit.

(Figure

weld

and

METER

displays

minute

in

the

(Figure

are

FWD

When

is

line

meter

4-1)

voltage

preset

(Figure

while

Figure

4-1)

ON

position

must

be

on

in

switch

the

4-1)

momentary-contact

switch

welding

of

is

pushed,

the

JOG

wire

feeds

(Figure

a

the

4-1)

momentary-contact

solenoid

gas

The

gun.

be

to

adjusted

to

the

nearest

voltage

while

4-1)

feed

wire

preset

welding

and

4-1.

Front

energizes

the

for OFF

FWD

ro

posi

weld

and

back

and

PURGE

without

tenth

idling.

to

speed

Ac-

idling.

Panel

and

tual

wire

4-6.

When meter

When

meter

When

meter

this

4-7.

There visual

The

indicate

to

The

source

er

output

WIRE

The

is

energized

The

relay

The connected there

Controls

feed

wire

preset

feed

speed

feedback

AMPS/INDUCTANCE

with

used

displays

used

displays

used

INDICATOR

are

indicationsofvarious

GAS

CONTACTOR

is

available.

CURRENT

is

energized

ARC

the

weld

with

the

inductance

with

the

blank.

is

five

indicator

turns

light

shielding

contactor

FEED

light

indicate

to

light

FAILURE

Pulstar

peak

Arc

Deltaweld

LIGHTS

on

gas

light

is

indicate

to

light

according

is

an

arc

outage

speed

circuit.

METER

welding

amperage.

Pak

welding

in

percentage.

(Figure

on

lights

process

when

the

flow.

turns

on

energized

turns

on

that

wire

turns

on

that

turns

to

instructions

while

welding.

the

are

welding

interface.

the

gas

when

to

when

is

when

an

on

Location

Push

Button

Ref.

same

(Figure

source,

power

source,

power

4-1)

functions.

valve

is

the

welding

indicate

the

wire

drive

feeding.

the

current

is

established.

arc

when

only

in

Section

OM-135

Of

REV

Jog

Switch

645

TB-119

the

to

due

4-1)

the

source,

These

are

energized

pow

that

weld

motor

detect

properly

and

3-6,

Page

7

582

Unit

Robot

to

Interface

control

Computer

Wire

Output

Peak

Control

Gas

Contactor

Wire

Output

Shielding

Feed

Speed

0-1OV=0-50V

Volts

0-1OV

Amps

Control

Stuckilouch

Voltage

Gas

SECTION

0-1OV

=

0-500

Sense

=

0-1

Amps

5-

000

SEQUENCE

1PM

Output

OPERATION

OF

Stick/Touch

Wire

(Figure

interface

control,

gas

also

It

SIGNALS

receives

INPUT

5-1.

UNIT

The

robot

control,

current.

6-1.

ROUTINE

IMPORTANT: this

unit

for

legibility.

maintained

when

precautionary

Usage

and

type

ment

OM-135

in

necessary

and

shop

of

maintenance.

three

every

582

Page

labels.

Sense

5-1)

receives

jog,

SECTION

MAINTENANCE

six

Every

All

a

clearly

See

conditions

months

8

Voltage

Figure

FROM

welding

a

signal

input

volts,

to

ROBOT

signals

initiate

6-

months

inspect

precautionary

readable

Parts

At

as

state

List

determine

minimum,

follows:

for

5-1.

Input

CONTROL

for

contactor

wire

speed,

check

a

to

MAINTENANCE

the

labels

must

and

replaced

number

part

the

frequency

inspect

equip

And

and

see

on

be

of

Output

if

5-2.

The

control

4A



stuckto

SIGNALS

5-1)

for

current

not

down

and

Chart

the

sends

ELECTRIC

touch

disconnect

Signal

the

wire

Timing

is

OUTPUT

(FIgure

robot

interface

unit

TROUBLESHOOTING

&

WARNING:



Do



Shut

robot,

lockout/tagging maintaining,orservicing.

Lockout/tagging

line

locking removing red-tagging

device.

ing

disconnect

fuses

circuit

Abnormal



workpiece

FROM ROBOT

output

live

electrical

welding

wire

sense,

unit,

procedures

switch

from

fuse

breakerorother

at

signals

stuck,

SHOCK

power

input

box,

the

endofthe

and

parts.

power

before

consist

in

open

or

shutting

TA-094

382-A

weld.

INTERFACE

the

arc

kill.

robot

failure.

and

to

can

source,

employing

inspecting,

of

pad

position,

off

and

disconnect

MOVING



Keep

HOT



Allow

Maintenance

persons.

1.

Repairorreplace,asrequired,

particular

give

and

lation

2.

Remove

from

ture

OVERLOAD

6-2.

WARNING:

a



Do Shut

robot,

lockout/tagging

PARTS

away

SURFACES

cooling

attention

areas

grease

electrical

PROTECTION

touch

not

down

and

disconnect

can

from

can

period

be

to

where

and

grime

parts

ELECTRIC

live

unit,

procedures

maintaining,orservicing.

procedures

disconnect

from

circuit

breakerorother

FUSE

replacement

Parts

(see

Circuit

A.

Lockout/tagging

locking

line

removing

red-tagging

device.

ing

INCORRECT



Use

rating

Drive

only

Motor

and

Wire

fuses

4-1)

a

WARNING:

tion

at

Read

beginning

ceeding.

Circuit

overload

Should

follows:

as

1.

Check

correct

If

2.

motor

drive

Check

3.

rolls,

4.

Reset

cooling

breaker

Resume

5.

B.

Main

a

breaker

a

WARNING:

tion

If

CB1

.

motor

for

jammed

problem.

overload

motor.

for

binding

and

correct

circuit

period

can

operation.

Fuse

at

CB1

protects

If

wire

occurs

the

occur

wire

drive

opens,

overload

problem.

breaker

be

may

be

reset.

Fl

(Figure

Read

beginning

ceeding.

Fl

Fuse

shortorexcessive

protects

robot

the

overload.

cause

moving

parts.

cause

before

performed

to

frayed

it

enters

from

and

cable.

SHOCK

electrical

welding

input

switch

fuse

box,

can

damage

fuse

List).

Breaker

follow

and of

Section

the

wire

feed

wire

and

or

clogged

often,

jams

often,

repair

or

gear

by

depressing

necessary

4-1)

follow

and

Section

of

interface

If

fuse

serious

severe

injury.

burns.

setvicing.

qualified

by

only

hose

and

cracked

all

and

equipment.

components;

kill.

can

parts.

power

before

consist

in

open

or

shutting

of

same

safety

6-2

drive

motor

open,

gun

replace

or

source,

employing

inspecting,

of

position,

disconnect

unit.

size,

CB1

informa

before

motor

would

proceed

liner,

gun

replace

power

CB1

misaligned

the

button.

safety

before

6-2

from

opens,

the

Informa

an

the

before

Fl

cable;

insu

mois

and

pad

off

and

type,

(Figure

pro

from

stop.

and

liner.

wire

drive

A

circuit

pro

internal

robot

interface

lem

1.

2.

3.

4.

5.

6-3.

If

it

shuts

and

replace

Depress

wise.

Pull

out

free.

Insert

Install

Depress

cover

REINSTALLATION

ure

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

Install

5.

DISPLAY

6-4.

6-2)

Check

points

checking

ters.

WARNING:

a



procedures

safety



meterortest

ELECTROSTATIC

damage



proper



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new

fuse

is

down.

and

fuse

with

and

secure.

Fl

as

rotate

with

into

fuse

rotate

the

follows:

cover

6-1)

necessary

hub

the

assembly

reinstall

discarding

the

following

items

given.

Washer

keyway,

hex

welding

and

holeinhub

onto

nut

a

slight

drag

wire

BOARD

are

provided

supply

power

ELECTRIC

Do

Be

not

sure

touch

that

are

practices.

down

unit

Shut

equipment

electronic

Put

BEFORE

a

on

properly

Transport

handling

all

static-shielding

Perform

work

fuse

opens,

fuse

holder

cover

fuse

when

fuse

holder

fuse

OF

to

replace

new

from

worn

insert

holder

hub

or

onto

hub

cover.

cover

HUB

ASSEMBLY

part

assembly

hub

support,

broken

the

support

support.

hub

support

felt

is

while

METER

the

input

to

display

command

according

PC4

on

and

SHOCK

live

electrical

personnel

familiar

before

performing

with

and

makingorchanging

lead

DISCHARGE

components.

grounded

circuit

boards.

static-sensitive

carriers

at

static-safe

only

a

correct

back

the

counterclock

holder

or

cover

into

clockwise

all

of

follows:

as

and

parts.

hub

support

shaft

shaft.

Tighten

turning

Section

hub.

3-8.

CHECK

board

for

kill.

can

parts.

follow

standard

connections.

(ESO)

wrist

strap

components

and

packages.

work

OM-135

582

prob

is

unit.

until

(Fig

the

hub

disas

shaft

through

hex

(Figure

PC4

for

the

me

testing

can

in

area.

9

Page

Retaining

Ring



spanner

Nut



OPTIONAL

Wire

Retainer

Fiber



Wire

Washer

Reel

Spring

Keyed

Brake

Washer

Brake

Washer

Hub

Fiber

Washer

Hex

Nut

1.

2.

3.

4.

5.

OM-135

Command

Input

Ammeter

robot

Open

Locate

Check

If

meter

a

correct

ter

(see

thorized

If

the

power

replace

contact

tion).

582

-.O.1V=100A

interface

display

voltage

power

the

and

Section

Service

supply

display

nearest

10

Page

Figure

For

Figure

door.

board

access

PC4.

accordingtoFigure

and

meter

6-5

supply

is

and

not

working,

contact

command

nearest

Station).

command

or

board

Factory

PC4

voltage

(see

Authorized

6-2.

replace

Factory

is

Section

Service

6-1.

Hub And

Input

Wire

Speed

0.8V

Display

the

6-5

is

me

Au

and

Sta

voltage

incorrect,

Command

=

800

Board

Reel

1PM

6-5.

a

Hub

Assemblies

For

Meter

Checks

CIRCUIT

WARNING:



Do

not



Shut

robot,

and

lockout/tagging

maintaining,

Lockout/tagging

line

ing

moving

red-tagging

device.

ing

Input

Volts

BOARD

ELECTRIC

touch

live

down

unit,

disconnect

or

servicing.

disconnect

fuses

from

circuit

Command

Meter

O.5V=50V

Power

Volts

Meter

HANDLING

SHOCK

electrical

welding

input

procedures

switch

fuse

box,

breaker

For

Supply

And

0-5VDC

PRECAUTIONS

can

parts.

power

before

consist

in

open

or

shutting

other

or

SC-l27

Ref.

Ammeter

source,

For

Ref.

SD-ill

kilt.

328

838-B

and

employing

inspecting,

of

padlock

off

re

and

position,

disconnect

a

TROUBLESHOOTING

6-6.

a

CAUTION:

(ESD)



Put

BEFORE



Transport

shielding



Perform

INCORRECT

plugs



Be

sure

can

damage

on

handling

carriers

work

can

damage

that

ELECTROSTATIC

properly

circuit

only

INSTALLATION

plugs

aligned.

EXCESSIVE

board.



Use

only

when

ment

and

plugs

WARNING:



Do

not



Shut

and

robot,

lockout/tagging

PRESSURE

minimal

disconnectingorconnecting

removingorinstalling

ELECTRIC

touch

live

down

unit,

disconnect

procedures

servicing.

circuit

grounded

circuit

boards

or

packages.

at

a

circuit

are

pressure

electrical

welding

input

DISCHARGE

boards.

in

proper

static-safe

or

board.

properly

break

can

and

board.

SHOCK

parts.

power

before

wrist

work

strap

static-

area.

misaligned

installed

gentle

can

source,

and

circuit

move

board

kill.

and

employing

inspecting

Lockout/tagging locking

removing

line

fuses

red-tagging

device.

ing

MOVING



Keep

HOT



Allow

PARTS

away

SURFACES

cooling

Troubleshooting qualified

assumed

Itis

Section

to

ing

the

with

working

welding

The

remedies this circuit

dures.Ifthe

these

ized

or

tion,

instructions.

function

properly,

process.

following

robot

interface.

diagram

procedures,

Service

strictly

that

for

some

Station.

follow

persons.

the

3ofthis

of

and

table

while

trouble

procedures

disconnect

from

fuse

breaker

circuit

can

from

moving

can

period

to

unit

was

manual,

controls,

that

the

is

designed

of

the

troubles

Use

this

table

performing

not

is

contact

the

In

all

cases

manufacturers

switch

cause

before

be

properly

the

trouble

to

remedied

nearest

Consist

in

or

box,

or

other

serious

shutting

parts.

severe

servicing..

performed

installed

the

operator

robot

is

not

diagnose

that

may

in

conjunction

troubleshooting

after

Factory

of

equipment

procedures

of

position,

open

disconnect

Injury.

burns.

only

accord

is

familiar

interface

provide

develop

with

performing

Author

malfunc

pad

off

and

was

to

proce

by

the

in

the

and

OM-135

582

Page

11

Table

6-1.

Troubleshooting

No

arc

Wire goes

Unit

No

meter

No

wire

Wire

only,

TROUBLE

voltage

speed

to

zero.

does

feed.

feeds

control.

(1PM)

not

operate.

display.

at

maximum

meter

PROBABLE

Output

Arc

control

sensing

Voltage

Incorrect

Board

Motor

Fl

Fuse

Circuit

Meter

Display

Robot

Relay

Motor

Tach

breaker

~

not

Board

signal.

CR1

Board

board

working.

connections.

Board

robot

PC2

Open.

working.

not

PC2

wire

at

CAUSE

connections.

PCi

not

working.

command

not

working.

CB1

tripped.

PC4

not

working.

not

working.

drive

motor

voltage.

not

Check

3-4).

Check

3-4).

Replace

est

Factory

Check

PCi.

Command

sockets

tween

Check

PC2.

Signal

B

and

(common)

Replace

est

Factory

Check

Correct

6-2).

operation.

ing

Check

Correct

6-2).

operation.

ing

check

Use

if

mine

If

6-4).

Section

rized

Use

able

okay,

nearest

Check

PC2.

and

check

Service

check

(see

replace

Signal

B

(common)

Replace

est

Factory

Replace

Owners

and

secure

and

secure

PCi

(see

Authorized

command

robot

command

shouldbe0-10

PC2

(see

Authorized

and

Fl,

overload

and

CB1,

overload

points

power

is

points

6-5

and

Station).

points

Section

PC4

Factory

input

signal

should

CR1.

PC2

(see

Authorized

tach

board

Manual).

REMEDY

connections

Section

voltage

V

(common)

RC5.

at

Section

replace

reset

on

Display

available

are

contact

to

determine

6-4).

(see

Authorized

from

be

RC5.

on

Section

(see

6-5

and

Service

voltage

at

should

and

voltage

vdc

6-5

and

Service

if

necessary

problem

if

necessary

problem

Board

to

meter

okay,

replace

nearest

If

check

Section

0-10

Service

points

Service

robottoMotor

vdc

6-5

and

motor/drive

Section

(see

Section

(see

contact

Station).

Voltage

0-10

be

U

at

between

RC17.

at

Motor

contact

vdc

pins

Station).

Section

(see

before

if

6-5

continu

(see

continu

PC4

to

(see

meter

Factory

power

is

do

and

Section

Autho

not contact

Station).

Board

between

contact

pins

Station).

assembly

near

Board

be

Board

K

near

deter

(see

avaii

test

K

near

OM-135

582

Page

12

6-7.

1~

Gas

System

USE

flows:

normal

OF

On

INDICATOR

(on.)

LIGHTS

Gas

Check

does

gas

FOR

TROUBLESHOOTING

Gas

flow

not

valve

operation.

Indicator

Light

Gas

Check

and Check

flows:

gas

line

gas

interface

valve

for

operation

leaks.

PC3.

board

Gas

does

System

Off

normal

not

flow

(off).

~1~

Contactor

System

Wire

feeds:

System

On

closed:

normal

On

normal

On

(on).

~

Contactor Check

cords.

Check

Wire

Check Check Check

interconnecting

interface

does

circuit

relay

interface

open:

not

CR1.

Contactor

board

Wire

feed:

breaker

board

Current

PC3.

Feed

CB1

PC3.

Indicator

Contactor

Check

Indicator

Wire

Check

robot

Signal

between

(common)

Check

Indicator

Light

closed:

display

board

Light

feeds:

input

signal

motor

pins

at

board

K

RC5.

board

to

shouldbe0-10

motor

Light

and

PC4.

from

B

PC2

PC2.

vdc

~Off

Contactor

System

DOff

Wire

does

System

~

.

Off

open:

normal

not

normal

(off).

feed:

(off).

~1~

Arc

started:

System

~1~

No

arc:

Check

normal

On

weld

parameters.

(on).

~

No

arc:

Replace

Arc

started:

Check

Signal

between

Check

reed

from

signal

should

terminals

display

relay.

Arc

be 24

board

Failure

robot.

vdc

1TL

PC4.

and

hr

Arc

Replace

Indicator

Jr

No

Normal

1TM.

started:

reed

arc:

relay.

Light

during

idling.

No

arc:

System

~

Arc

Normal

OM-135

3

normal

Off

3

started:

while

582

(off).

welding.

13

Page

C/)mC)-I0

z

-.1

mIm

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39

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7-2.

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PCi

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No.

C-135

518

OM-135

582

Page

15

388-A

SD-083

No.

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nuL

Diagram

No.

OM-135

SB-ill

582

Page

341

17

Rd

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BYPASS

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Failure

Board

IOU

Circuit

PC5

Diagram

No.

B-132

087-A

OM-135

582

RI

Page

PQI~R/GRIYJND

l~GND

18

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POR

9~.l5U

Diagram

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8140

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Touch

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Circuit

Stick

Board

CR2

Diagram

PC6

No.

SB-140

~~

I,

022

SECTION

-

PARTS

8

LIST

Mkgs.

PLG16

PLG1

PLG

PLG15

PLG1

PLG2O

PLG24

Dia.

Cl

C2-4

CB1 CR1 CR2 CR3

D2

Fl

PB1-3

PCi

PC2

PC3

PC4

PC5

PC6

PLG9

14,19

,3

Part

No.

Main

Assembly

031

692

006426

028

291

011

991

006

109 052964

095033

049 970 079

844

027811

048 029 026202

*012

655

046432

021

105

695

137

110

375

110391

071

642

147

083 141

308

117

836

089

032

073 756

090

132 140

021

109

041

047

636

079535

079

739 096813 048

598

079 534

049

989

2

8

073

039828

600848

604 601 601

600

079 079

089 089

073

039716 079

079

081 081 084

081

686

109

226

228

750

748 747

870

647

332

140

760

747

379 378

198

378

CAPACITOR,

CLAMP,

capacitor

CAPACITOR,

CIRCUIT

BREAKER,

RELAY,encI24VACDPDT

24VDC

RELAY,

BRACKET

SPRING,

SOCKET

CLIP,

DIODE, FUSE,

HOLDER,

SWITCH,

CIRCUIT

end

24VAC

end

mtg

hold

relay14pin

retaining

1A

rect

minatceri0A250V

fuse

PB

CARD,

STAND-OFF

GUIDE,

CIRCUIT

mtg-circuit

CARD,

GROMMET,scrNo.8/10

CIRCUIT

LENS,

LED

CARD, CARD,

4341

STAND-OFF,

CIRCUFI

CIRCUIT

CABLE,

HOUSING

CARD,

interconnecting

PLUG

~TERMINAL,maIe1

CLAMP,

CABLE,

HOUSING

cable pwr

PLUG

TERMINAL,

CABLE,

PLUG,

CLAMP,

WIRE,

volt

sensing

97-3106A-14S-2S

4skt

cable

lead

mot

lead

INSULATOR,

CLAMP,

univ

~TERMINAL, HOUSING, TERMINAL, CABLE,

PLUG,

CLAMP,

CABLE,

PLUG,

HOUSING,

TERMINAL,

HOUSING,

TERMINAL,

HOUSING,

TERMINAL,

term

contact

interconnecting

lOskt

cable

port

10

term

contact

term

female

term

female

Descnption

750uf

elctlt

2.000dia

uf

.1

disc

cer

man

DPDT

4PDT

relay

down

relay

skt

relay

SP

400V

.250x1.250

minat

SPDT

card

control

PC

speed

(Fig

.625

x

touch

voltage

SUPPORT,

motor

interlace

meter

red

No.

6-32

interlace

wire

(consisting

&

PINS,

pinszl6l8-l4wire

1

shld

female

15/c

8ga

&

SOCKETS,

lskt

(consisting

AN-3057-6

1

strd

2ga

1

strd

6ga

vinyl

25A

ring

clamp

tng

header

(order

.500

18

(consisting

MS-3106A-18-1S

97-3057-10

No.18

10/c

MS-3106A-18-1P

header

12

header

12

lskt

22-18

6

lskt22-l8wire

200VDC

VDC

500

1P1

reset

panel

(Fig

card

No.

digital

8-3)

(Fig

8-4)

Ig

8-5)

(Fig

8-6)

of)

(consisting

(order

(consisting

wire

14-18

of)

(order

by

It)

by

univ

25A

stud

16-l4wire

24-18

wire

of)

(order

by

ft)

24-18

wire

.5A

8-1)

(Fig

by

11)

6

of)

ft)

250V

mtg

screw

8-2)

of)

OM-135

Quantity

1 1

3

1

1 1 1

1

2

1

3

1

8

3

1

2

1 1

5

7

1 1 1 1

14

2

1

8ft

1

16

1

1 1

35ft

1

9ft

1

1 1

2

18

1

2

lOft

1

12

1

12

1

6

582

Page

19

Dia.

Mkgs.

Part

No.

Descnption

Quantity

OM-135

PLG28

PLG5O

Ri

R2

R3

R4

RC5

RC9

RC12

RC13

RC15 RC16 RC17

Si

SRi

Ti

T2,4

iT~2T

0937270007459

1065360008908

,3

0923690008267

1324810008989

+1169690008908

582

Page

20

115

091 746

113

159

092

378

081

651

030

605741

941

030 030949

010199

079683

170

056

010

193

057

084

079

497

856

603

117

374

009

335 637

047

534

079

076

624

109

768

089

646

097 867

011

609 035 704 035

759 036

135

783

038 601

219 010

916

107

983

112

473

045 852

327

134

010855

010

853~ 073

487

121

594

111

122

770

109

116964 110

015

111

123

771

109

071

006

047

636

079535 079

739

073

139

071

892

079

534

Main

Assembly

HOUSIN.3

TERMINAL,

HOUSING,

TERMINAL,

RESISTOR,

CLIP,

mtgresistor.312

RESISTOR,

(Continued)

PLUG

female

hdr

term

female

WWfxd

fxd

WW

&

SOCKETS,

lskt

16

lskt

25W

ID

100W5ohm

24-18

22-18

10

HEATSINK,rect

TUBING,stl.275lDx1.000

HEATSINK, SHIELD,

TUBING,

BUSHING, RESISTOR,

POTENTIOMETER,

BRACKET, HOUSING,

STAND-OFF,

HOUSING

TERMINAL,

RECEPIACLE, RECEPTACLE, RECEPTACLE, RECEPTACLE,

RECEPTACLE

resistor

.37500

stl

snap-in

WW

mtg

pot

term

conn

No.

RECEPTACLE

female

4

14

10

17

.250

x

.250

nyl

fxd

25W

WW

2K

sltd

22posn

4-40

.625

x

&

14-18

lskt

MS-3102A-14S-2P

97-4102A-20-27P

MS-3102A-18-1P

MS-3102A-20-29P

ID

SOCKETS,

SWITCH,tgISPDT15A125VAC

RECTIFIER, TRANSFORMER, TRANSFORMER,

TUBING, BLOCK,

stl

term

integ

.250

20A

30A

control

ID

x

12P

mintr

115/24VAC

l6ga

wallx1.937

600V

LINK,jumpertermblk2OA

cable

CONNECTOR,

CABINET, BLANK,

PANEL,

DOOR,

CLlP~

LABEL,

snap-in

mtg

access

component

warning

clamp

control

nyl

components

cabinet

general

RETAINIR,scrNo.2

sltd

FASTENER,

NUT,

speed

NAMEPLATE

CABLE,

HOUSING

TERMINAL,

CLAMP~ CABLE,

HOUSING

TERMINAL,

CABLE,

.

HOUSING

TERMINAL,

CLAMP,

.

CABLE,

.

RECEPTACLE

TERMINAL,

scr

2

No.

interconnecting

PLUG

male

97-3057-1012

cable

No.18

port

PLUG

female

motor

(consisting

PLUG

male

strain

cable

No.

port

w/SOCKETS,

female

.500

.687dia

hd

&

PINS,

1pm

7/c

&

SOCKETS,

&

PINS,

1

166/c

.750

mtg

precautionary

No.

2

(consisting

4516-22

sz

(order

lskt

16-22

of)

(consisting

1618-14

pinsz

relief

sz

(orderbyft)

iskt

14-18

(consisting

wire

ohm

.375

x

ohm

sft

10/T

mtg

2W

Ig

wire

115/36VCT

50/60

hole

black

adh

back

of)

wire

by

ft)

(consisting

wiresz45

of)

wire

17

(consisting

wire

of)

hole

10K

ohm

(consisting

Hz

of)

1

10

1

16

1

4

1 1

2

1

4

1 1

1

1 1

2

1

14

1 1 1

1

1 1 1 2 2 2

2

3

1 1

4

1 1

2

1

2

2 2

1 1

1

14

2

lOft

1

14

1

14

2

lOft

1

14

Dia.

Mkgs.

Part

No.

Description

Quantity

Di

GS1

RC7

RC1

REED

51

1338640008989

6

048

097868

116

604910 097

056 604

010 606 056

056

137

026

109293

047

079534

090

079 135 038

115

010

057

010

602

079

079 574

137

+079682

134

072

058

010191

135 057971

010233 072

058

092

134464

144

964

866 462

550

108 851

114

202

637

246

535

130

839

104 494 358

604 934

573

121

327

094

428

628

205

292 427 989

MaIn

Assembly

.

TERMINAL,

CABLE,

.

PLUG,

.

CLAMP,

CABLE, PLUG,

HOSE,

.

gas

HOSE, FITTING,

.

FITTING,

.

FITTING,

CONTROL

.

DIODE,

interconnecting

l7sktMS-3106A-20-29S

cable

pwr

17

nprn

rect

(Continued)

1

male

97-3057-1012

shld

2Oga

MS-3106A-20-29P

(consisting

brd hose hose

hose

BOX,

1A

1

No.

brs

nut

brs

ferrule barbed

brs

gas/current

400V

keying

plug

(consisting

5/c

(orderbyft)

of)

x

(order

ID

.187

.625-18RH

ID

.425

nipple

sensor

SP

of)

.718

x

3/i

6tbg

(consisting

~VALVE,24VDC2wayi/4IPSport1/8ort

HOUSING

RECEPTACLE

&

SOCKETS,

~TERMINAL,femalelskti4-i8wire

RECEPTACLE

TERMINAL,

.

RELAY,

BLOCK,

.

CONNECTOR, BUSHING, BUSHING,

FITTING,

FITTING, FITTING,

.

BRACKET

.

CASE

SECTION,

WRAPPER

LABEL,

HUB

&

HUB,

SPINDLE,

spool

.

WASHER,

current

warning

w/PINS,

male

20A

term

clamp

snap-in

brs

hose

pipe galv

pipe

galv

mtg

brake

(consisting

1

5P

nyl nyl

bushing

coupling

nipple

component

frontlbottorWrear

general

(consisting

stl

1618-14

sz

.500

cable

1.375

1.000

l/4NPTx.625-18RH

.25ONPSC

L

.25ONPTx6.000

precautionary

of)

ID

of)

1

x

.75Omtg

1

x

.375mtg

~WASHLR,fbr.656IDx1.5O0ODx.i25thk

.

NU1

stl

sif

WASHER,

1kg

flat

hex

stl

reg

keyed

.625-11

1.500diax

.i25thk

~SPRlNG,cprsn.97OODx1.250

SHAFT,

RING,

SUPPORT,

LABEL,

spool

support

retaining

spool

spindle

warning

general

(consisting

of)

precautionary

ft)

by

Ig

(consisting

wire

hole

of)

2

1 1 2

lOft

1

lift

1

1 1

14

I

16

1 1

1

2

1

2

1

2

1 1 1 I

1

*Recommended

+When

BE

ordering

SURE

TO

Spare

a

component

PROVIDE

Parts.

MODEL

originally

AND

displaying

SERIAL

a

precautionary

NUMBER

WHEN

label,

ORDERING

the

label

should

REPLACEMENT

also

be

PARTS.

OM-135

ordered.

582

Page

21

0

C5g

r~

~

cx

>-

0

R8?

J13

(N

Q~N-

T~

N

~~J

E::::J-

R63

c:::~

C

RS

J3

_______

U)

L)

OM-135

582

Page

0

C74

0

SB-135

520-8

8-1.

Figure

22

Circuit

Card,

Voltage

Control

PCi

4

1215

13214422425

2

Dia.

M

kqs.

-

PCi

A50

A51,52,54

A53

Cl

-4,53,

55-59,68

C50,60,

69-73

C52 C54 C61 C62 C63

C64,65

C66,74

C67,75

CR50

D51

-54

D55-66

J1-15

OC5O

050

051-53

R1,2

R3

R4,5,67,76

R51

80,86,87

R52,91

R53,73

R55-57,85

R58,61

R59,60,95-97

R62,68,82

R63,78

R69

R71

R74,103

R75,89

R77

R79

R81

R83 R84

R88,92

R90 R93

R94

R98

R99

R100

R102

RC1

Si

VR5O

VR51

Part

No.

695

137

096

114

009159

122

000 340

031 000

005

009 053

118

000

121

093 091 861 079 844

026 028 092648 047

035

037

089

089 039

035

078

035

039 035 035

097

108

000

009 052 039 333 039 330 035 084 000

081 035

091

035

039

108

117

121

079 092

083

046932

275

176

723

677 861 023 577 992

460

348

684

558

202

351

034

842 200

174

176 175

331

888

431

827

336

826

825

110

437

038 173

137

886

205 885

833 885 799

823

329

433

134

714

749 367

772

Description

Figure

linear

IC,

linear

IC,

8-1.

324

353

Card,

Circuit

IC,linear358

cer

tantim

elctlt

tantlm tantlm

cer

elctlt

tantlm

polye

12OVAC

down

1A

.020A

mono

disc

5.6uf

33uf

2.2uf 27uf

disc

330uf

.47uf

met

4PDT

l4skt

relay

400V

75V

CAPACITOR,

CAPACITOR, CAPACITOR, CAPACITOR,

CAPACITOR,

RELAY,

end

SOCKE1~

SPRING,

DIODE,

rect

sig

relay

hold

RESISTOR,WWfxdzeroohm

interface

IC,

TRANSISTOR, TRANSISTOR,

RESISTOR, RESISTOR,

RESISTOR,

RESISTOR, RESISTOR, RESISTOR,

RESISTOR,

POTENTIOMETER, POTENTIOMETER, RESISTOR,

RESISTOR,

RESISTOR, RESISTOR,

RESISTOR, RESISTOR, RESISTOR, RESISTOR, RESISTOR,

RESISTOR, RESISTOR,

TERMINAL,

SWITCH,

linear

IC,

dip

7815

4N26

PNP

NPN

MF

.25W lOOK

ME

.25W

MF

.25W

CF

.25W

CF

.25W

C

.25W

CF

.25W

CF

.25W

CF

.25W

CF

.25W1K

MF

.25W

MF

.25W

ME

.25W

CF

.25W

CF

.25W

CF

.25W

MF

.25W

MF

.25W

CF

.25W

CF

.25W

MF

.25W

CF

.25W

CF

.25W

MF

.25W

MF

.25W24.3Kohm

MF

.25W51.lKohm

header

SPST

.6A

200MA

330

cermet cermet

18

2posn

IC,Iinear7gl5

Voltage

.1uf5OVDC

uf

.01

35VDC

35V

20V

35V

uf

.001

5OVDC

35V

film

SP

40V

20K

ohm

10K

ohm

4.7K

2.2K

ohm

10K

ohm

220K

6.8K

ohm

1K

ohm

4.75K

5.11K

18K

ohm

3.9K

22K

ohm

3.32K 10K

ohm

2.7

meg

68K

ohm

8.25K

100

ohm

2.7K

2.43K

5OVDC

1

.47uf

40V

ohm

trmr

ohm

Control

000VDC

100V

25/1 20/1

ohm

.5W

2K

5K

ohm

Quantity

1

3

1

11

7

1

2 2 2

1 1 1

3

2

1

1 2

2

1 1

1

1 1

1

I 1 1

1

I

1

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-135

582

Page

23

380-E

SC-c93

PC2

Digital

Speed

Motor

Card,

Circuit

8-2.

Figure

0

C.)

01 01

-u

I)

N.)

a

ca

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

Q50,53

Q51 Q52

R50

1

Note

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

071

642

009159

482

039 031

699

073

739

035

833 023

005

031

643

073

549

742

007

561

035 044

602

721

031

095033

091

861

079

844 026202 080910 081

800 037

200

037

824

039 355

030

839 035

827

052

138

039332

035

884 030

007

039 335 039

106

039

331

049

015

039

328

052

142

039

108

035

886

035825 030937

030

090

092

648

085

399

047272 081

799

FIgure

8-2.

Card,

CircuIt

IC,Iiriear358

tantlm

cer

polye mylar

24VAC4PDT

end

relay

hold

1A400VSP

elctlt1OOuf

.0022uf

mylar

.luf

cer

.033uf

mylar

2.2uf

.Oluf

.Ol5uf

mylar

eictlt

lOut

4uf

mylar

film

.22uf

down-relay

CAPACITOR, CAPACITOR, CAPACITOR,

CAPACITOR,

CAPACITOR, CAPACITOR,

CAPACITOR,

CAPACiTOR, CAPACITOR, CAPACITOR,

CAPACITOR,

RELAY,

SOCKET,

SPRING,

DIODE,

DIODE,zenerl5V5W

interface

IC, TRANSISTOR, THYRISTOR,

TRANSISTOR,

RESISTOR,

POTENTIOMETER,

RESISTOR,

2907

SCR

WW

CF

CF CF

CF CF CF CF

CF

NPN

UJT

.25W

.25W .25W

.25W

.25W .25W .25W

fxd

200MA

7.4A

15MA

5W

20K

cermet

47K

470

4.7K

82K

22K

RESISTOR,CF.25WlKohm

RESISTOR,CF.SWlOohm

RESISTOR,

TRANSFORMER,

linear

78L12

78L08

IC, IC,

CF

WW

.5W

fxd

pulse

47

zero

Motor

35VDC

5OVDC

20V

500VDC

35V

200V

.47uf

200

200V

220

10K

ohm

l5Kohm

100K

ohm

lOmeg

1.5K

120K

ohm ohm

ohm

200VDC

100

200V

VDC

40V

ohm

151T

ohm

VDC

400

Speed

VDC

....

.75W

....

DigItal

50K

ohm

4

1

1 2

2

1

12

1 1 1

2

1

10

1 1

2 1 1

..

1

10

3

1

8

1

3 2

1 1

2 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-135

582

Page

25

1

Dia.

M

kgs.

PC3

Al

C1-7,15

C8

C9

C11,12

C13

C14

C16

CR

1,2

CR3-6

01,13-17

D2-8

Ji

-10

02-8

Ri

,4,8,9

R2

R3,5,6

R7,31

Ri

0-14,17-22,29

R15,23

R16

R24-27

R28 R30

R32

RC1

8

RC1

9

Ui

VR1

Part

No.

141

308

159

009

122

723

973

083

677

031

348

000

130

072

859

000

714

073

521

095 099 018

844

079 091 861

35i

028

202

026

648

092

200

037

826

035

332

039

827

035

825

035

33i

039

329

039

336

039

572

053

035

884 823

035 052

152

759

079 079 749

594

094

832

081

Circuit

IC,

8-3.

linear

358

Figure

CAPACITOR, CAPACITOR,

CAPACITOR,

CAPACITOR, CAPACITOR, CAPACITOR, CAPACITOR,

24VDC

RELAY,

SPRING, SOCKET,

DIODE,

RESISTOR,

end end

hold

relay

sig

rect

24VDC

.020A

1A400V

WW

TRANSISTOR,

RESISTOR, RESISTOR,

RESISTOR,

RESISTOR, RESISTOR,

RESISTOR,

RESISTOR, RESISTOR, RESISTOR,

CF CF CF

CF CF CF CF

MF

CF

POTENTIOMETER,

TERMINAL, TERMINAL,

IC,

digital

hdr

4098

IC,Iinear78Mi5

Description

Card,

mono

cer

elctlt

l000uf

56uf

tantlm

.47uf

tantlm

tantlm1uf

elctlt

220uf

.22uf

tantlm

4PDT

SPOT

down

relay

75V

fxd

zero

NPN

200MA

.25W

6.8K

.25W

15K

.25W

10K

1K

.25W

4.7K

.25W .25W

2.7K

.25W

220K

.25W

1

.25W .25W

100

cermet

12

18

Interface

.luf

35VDC 35VDC 35V

35VDC

35V

ohm

12.1K 00K

ohm

50VDC

40V

ohm

ohm.

ohm

ohm.

trmr

25/T

.5Wimegohm

Quantity

2

1

1 1

2

4

2 2 6

7

10

7

4

3

2

12

2

4

1

BE

OM-135

SURE

582

A

TO

Page

0

PROVIDE

26

MODEL

AND

Figure

SERIAL

8-3.

Circuit

NUMBER

Card,

WHEN

Interface

ORDERING

PC3

-~-P1?

E::J

P18

REPLACEMENT

0QS

,J3

PARTS.

0

~

SA.141

309

Dia.

Mkgs.

Part

No.

Description

Quantity

PC4

CI

C3-5

Dl

LCD1-3

LED1

LED3

R1-5

R6,8,11 R7,9,10

RC2O

RC21-23

RC24

VR1,2

,2

2,4,5

ASSE~LY

M~

RC2II

~

LcoI~

~J

v~i

H

117

836

000 348

073739

351

028

108453

089

028

097763

028

030 030

140

003272

081

381

109

161

084

194

071

248

070

026

~I

I

Circuit

FIgure

8-4.

CAPACITOR,

tantlm

Card,

.47uf

CAPACITOR,cer.1uf5OVDC

.020A

DIODE,

sig

75V

METER,digital

LED,

5330A1

O4OMCD

LED,5330A19200MCD

.5W

RESISTOR, POTENTIOMETER,

1.5K

cer

RESISTOR,CF.25Wlmegohm

No.

12

l3skt

6

6-32

Lc02

U

TERMINAL,

linear

IC,

STAND-OFF,

header header

header

78M05

II

R9

SP

ohm

x

Meter

35V

15/T

.437

I

.75W

VR2

101

200K

II

j~

Ii

ohm

RIO

I)

IL

RC231

II

Lc03

ft~

~LI

Lj

2

3

2

3

4

3

2 6

I

BE

SURE

TO

PROVIDE

LEDI

'

MODEL

AND

L~

DI 02

Figure

SERIAL

~

=1

~

I_____________

HHOOO~HVHOOH

CircuIt

8-4.

NUMBER

Card,

WHEN

R3

'

Meter

ORDERING

LED3

RO2O

PC4

DIJIIIHID

REPLACEMENT

RC24

PARTS.

Ref.

SD.117

838-B

OM-135

582

Page

27

Dia.

Mkgs.

Part

No.

Description

Quantity

PC5

Al

Cl

C2

C3

C4

CR1

Di

D2,3

Ji

Qi

Ri R2

R3

R4

R5,7

R6

R8 R9

RC1

VR1

,4

,2

132

090

009159 039 000

031

122

099 026

028

092 037

035

009

035825

038 035

039

035 039

113

095269

482 348

677

723

018 202 351

648

200

824

173

584 827 332

826 331

747

FIgure

8-5.

Card,

CIrcuIt

IC,Iinear35B

lOOuf

end

rect

sig

elctlt

tantim

tantlm

cer

24VDC

1A

.020A

WW

CF

400V

fxd

NPN

.25W

.47uf

5.6uf

mono

SPDT

SP

75V

zero

200MA

270

cermet

CAPACITOR,

CAPACITOR, CAPACITOR,

RELAY,

DIODE, DIODE,

RESISTOR,

TRANSISTOR,

RESISTOR,

POTENTIOMETER,

RESISTOR,CF.25WlKohm RESISTOR,

RESISTOR,

TERMINAL,

CF CF CF

CF CF header

.25W

.25W .25W

470K

6.8K

4.7K

10

IC,Iinear3l7T

35VDC

.luf

SP

10K 15K

Interface

35V 35VDC

5OVDC

ohm

40V

ohm

20/T

trmr

ohm

ohm ohm

ohm

.5W

5K

ohm

1 1 1 1

1 2 2

2

1

1 1

1

2 1

1 1 1 1

0~

0

-~J--RS

UR

0

1

CR2

C,

CR1

0

AC

1

BE

OM-135

SURE

582

TO

Page

PROVIDE

28

MODEL

AND

Figure

SERIAL

8-5.

CIrcuit

NUMBER

Card,

WHEN

Interface

ORDERING

PC5

REPLACEMENT

PARTS.

A-i

32089-A

Dia.

Mkgs.

Part

No.

Description

Quantity

PC6

Al

Cl

C2 C3 C4

CR1-3

Dl-3,5-8

D9

J1,2

Ql

,2

Rl

,5,7

R2,3

R4

R6,8

R9,1O

RC5O

VR1

140

021

009

159

090

573

000

348

039

482

122

723

004

855

026202 037 449

092648

200

037

035 827

035 826 039

331

035 888 030

710

092

160

083772

Figure

IC,

8-6.

linear

358

CAPACITOR,

CAPACITOR, CAPACITOR,

RELAY,

DIODE, DIODE,

end

rect

zener

RESISTOR,

TRANSISTOR,

RESISTOR,

RESISTOR, RESISTOR,

RESISTOR,

TERMINAL,

linear

IC,

7815

QIQ

P2~~

Circuit

elctlt

tantlm elctlt1OOuf

mono

cer

24VDC

1A400V

15V

WW

fxd

NPN

.25W

CF

.25W

CF

.25W

CF

.25W

CF

1W

C

16

hdr

Card,

lOut

.47uf

4PDT

1W

zero

200MA

10K

6.8K

4.7K

2.2K

270

Wire

50V

35V

35VDC

.1uf5OVDC

ohm

40V

ohm

Touch

1

1 1

1

....

I

3

7

1

2 2 3 2

1

2

1

0~

BE

SURE

TO

PROVIDE

D2

1~J E~J

+

oQ~

Figure

AND

MODEL

SERIAL

Dl

f~J--

CR

8-6.

Circuit

NUMBER

CR1

Rcse

Card,

WHEN

CR3

Wire

D3

Touch

ORDERING

J2

PC6

REPLACEMENT

SA.140

020

PARTS.

OM-135

582

Page

29

Miller Electric NSPR 8989 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual