Miller Electric NSPR 8989 Specifications

Millerfi
November 1990 FORM: OM-135 582B
MODEL: Robot Interface
(per
OWNERS
NSPR
8989)
MANUAL
iMPORTANT: Read and understand the entire contents of both this manual
and the power source manual used with this unit, with special emphasis on
the safety material throughout both manuals, before Installing, operating, or
maintaining this equipment. This unit and these Instructions are for use only
by persons trained and experienced In the safe operation of welding equip
ment. Do not allow untrained persons to Install, operate, or maintain this unit.
Contact your distributor If you do not fully understand these Instructions.
MILLER ELECTRIC
A MIter
Mfg.
Co.
Group Ltd.. Con~any
P.O. Box 1079
54912 USA
Appleton, WI
Tel. 414-734-9821
PRINTED IN U.S.A
ii
Ui
MILLERS
TRUE BLUETM LIMITED WARRANTY
(Equipment
This limited warranty
with
Effective January 1, 1992
serial number preface of KC
supersedes all previous MILLER warrantIes and
is
exclusive with
Subject
MIg. Co., Appleton, Wisconsin. warrants to its original retail purchaser that new
MIl.LER equipment sold after the effective date of this limited warranty is tree of de
fects in material and workmanship at the tune it is shipped by MILLER. THIS WARPANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
other
guarantees
or
warranties
warranty periods listed below, MILLER
wilt
repair
or
replace any
Limited
,
Items fUrnished
implied.
Warranty
by MILLER,
shall not
apply
to:
but manufactured
are
covered
by Others, such as engines or
by the manufacturers warranty, if
any
war-
ranted parts or components that fail due to such detects in material or workmanship.
MILLER must be notified in writing within thirty 30) days of such detector failure, at
which time MILLER will provide instructions on the warranty claim procedures lobe
or
TM
MILLER S True Blue
trade accessories. These items
Within Inc
expressed
Replacement Parts
1
NESS-
no
newer)
Accessory Kits
to the terms and conditions below, MILLER Electric
LIMITED WARRANTY
or
a
Consumable components: such
2
and
as contact
tips, cutting noZzles. contactors
relays
followed.
Equipment
3.
and are
1.
as
2.
on
and necessary maintenance, or equipment which has been used for operation
outside of the specifications for the eQuipment
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAUINOUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT
5 Years Parts -3 Years Labor
main
power rectifiers
Parts and Labor
3 Years
In the event of a
Transformer/Rectifier Power Sources
Plasma Arc
Cutting
-
4
-
Motor Driven Guns
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
Process Controllers
DAMAGES
Water Coolant
*
cases.
engine manufacturer)
Parts and Labor
I Year
*
the
appropriate
Went St an authorized MILLER service station: or
Parts and Labor
Engine Driven Welding Generators
(NOTE Engines are warranted separately by
by MILLER in
(3) the reasonable cost of repair or replace(4) payment of or credIt for the pur
chase price (less reasonable depreciation based upon actual use) upon return of the
Customers
and
at
risk
MILLERS
goods
expense.
option of repair or replacement
will be F 0 B ,Factory at Appleton, Wisconsin, or F 0 B at a MILLER authorized ser
vice facility as determined by MILLER Therefore no compensation or reimburse.
merrt for transportation costs of any kind will be allowed
writing
Power Sources
Robots
2 Years
warranty claim covered by this warranty, the exclusive remedies
option: (I) repair: or (2) replacement: Or, where authorIzed in
shall be. at MILLERS
Semi-Automatic and AutOrr~atic Wire Feeders
3.
by any parry other than MILLER, or equipbeen improperly installed, improperly Operated or misused
has not had reasonable
or equiprnentwhich
based upon industry standards,
follows:
Original
that has been modified
rnent that has
warranted equipment listed below in the
event of such a failure within the warranty time periods. All warranty time periods
delivered to the original retail purchaser,
that
the
date
the
was
start on
equipment
MILLER shall honor warranty claims
)INCLUDfNG LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR.
Grids
Spot
PANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE. AND ANY
FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
REMEDY
Welders
THEORY WHICH. BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION.
Load Banks
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN.
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
SOX Transformers
-
.
.
ear
unning
rai era
,
Field Options
(NOTE. Field options
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
are
covered under True Blue
warranty period of the product they
one
5.
6 Months
6.
90
Days
year
whichever is
Batteries
Paris and Labor
MIG Guns/TIC Torches
*
Plasma
Cutting Torches
Remote Controls
greater.)
are
for the
installed in, or for
a
remaining
minimum ~t
Some states
in
the U.S.A. do not allow limitations of how
long
an
implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you This warranty provides ape
cifiC
legal rights,
and Other
rights
may be available, but may vary from state to state.
In
Canada, legislation in
or
remedies other than as stated herein, and to the extent that
some
provincea provides for certain additional warranties
Waived, the limitations and exclusions set out above may not
Warranty provides specific legal rights. and
vary from province to province.
olher
rights may
they may not be
apply. This Limited
be available, but may
~1~
ERRATA SHEET
After this manual
to data
printed,
was
refinements in
equipment design
occurred. This sheet lists exceptions
later in this manual.
appearing
AMENDMENT TO SECTION 3
INSTALLATION
Amend Section 3-5B. ROBOT INTERFACE
-
WELDING POWER SOURCE CONNECTIONS:
REMOTE 17
Connections
For units used with Pulstar 450
3.
interface. Proceed
tk
as
welding
power source, it is necessary to
change internal connections in the robot
follows:
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
______
Shut down unit,
and robot, and disconnect
welding power source,
input power employing lockouVtagging
procedures.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing
or shutting off and red-tagging circuit breaker or other disconnecting device.
fuses
from fuse box,
a.
Open
panel
access
door.
b.
Locate lead 72 at pin F of REMOTE 17 receptacle RC16.
c.
Cut lead 72
d.
Splice lead
e.
Cover splice with electrical tape
f.
Close and
a
Be
Figure
a
as
close to
receptacle
as
possible.
72 to lead 77 at REMOTE 14
secure
front panel
or
receptacle RC13 pin
D.
other insulation.
access
door.
CAUTION: WELDING POWER SOURCE may not respond with output corresponding to set value.
See
Add
front
sure
welding
welding
3-7.
power
power
source
DIP Switch
factory
set for
3-7 for DVC DIP switch
use a
0 to
+
10 volt command.
Manual for modification procedure.
Setting
Label
INCORRECT DVC BOARD DIP SWITCH POSITION
DVC DIP switch is
Figure
main control board has been modified to
Owners
Voltage Control Board
CAUTION:
See
source
operation with Delta weldfi 451
setting
when
can cause
equipment
welding power source.
using another welding power source.
malfunction.
DVC SWITCH SETTINGS
Si
S2
1
2
1
DELTAWELD 300
2
3
ON
ON
ON
ON
DELTAWELD 451
0
ON
DELTAWELD 651
0
ON
5
4
ON
ON
ON
MAXTRON 300, 400
ON
ON
MAXTRON 450
ON
XMT200/300
ON
ON
ON
ARC PAK35O
ON
ON
ON
ON
SHOPMASTER 300
DIMENSION 400
On For
O
On For
ON
ON
Optional Soft Start.
Optional Hot Start.
Figure
ON
ON
Turn Off Si -3.
S~15o864A
3-7. DVC DIP Switch
Setting
Label
Add Section 3-10. SETTING DIP SWITCHES ON VOLTAGE CONTROL BOARD PCi
DIP switch Si and S2 on voltage control board PCi allow setting the proper command signal voltage level for control
ling voltage output at a welding power source. To change factory set position of DIP switches from a Deltaweldfi 451 to
another welding power source, proceed as follows:
a
WARNING:
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
welding power source, and wire feeder, and disconnect input power employing lockout/
tagging procedures before setting DIP switches.
Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
Shut down unit,
ELECTROSTATIC DISCHARGE
Put
on
Perform work
2.
Loosen
Locate
can
damage circuit boards.
properly grounded wrist strap BEFORE handling circuit boards.
Transport circuit boards
1.
(ESD)
screws
only
static-shielding
carriers or
packages.
at a static-safe work area.
securing
voltage control
in proper
front
access
door, and open door.
board PCi in lower left
portion of component mounting panel inside robot interface
con
trol.
3.
Set position of DIP switches Si and S2 according to label inside unit and Figure 3-7 for appropriate welding
power source.
4.
Close and
secure access
door.
Add Section 3-11. VOLTAGE CONTROL BOARD MODIFICATION FOR EARLY MODEL WELDING POWER
SOURCE
If the robot interface control is to be used with
number JJ400026,
OM-135 5828 Page 2
proceed
as
follows:
an
early
model Deltaweld 450
or
650
welding power source prior to serial
a
WARNING: ELECTRIC SHOCK
kill.
can
Do not touch live electrical parts.
Shut down unit, welding power source, and wire feede~ and disconnect input power
tagging procedures before making circuit board modifications.
employing
Iockout/
Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing
or shutting off and red-tagging circuit breaker or other disconnecting device.
fuses
from fuse box,
ELECTROSTATIC DISCHARGE
i
Put
on
properly grounded
Transport
(ESD)
wrist strap BEFORE
circuit boards in proper
Perform work only at
a
damage circuit boards.
can
handling
static-shielding
static-safe work
circuit boards.
carriers
or
packages.
area.
IMPORTANT: A customer-supplied cord (Miller #042562) is required to connect the
welding power source
to the weld
control.
1.
Loosen
2.
Locate
securing front
screws
voltage
access
door, and open door.
control board PCi in lower left
portion of component mounting panel inside robot interface
con
trol.
3.
Mark and disconnect leads from
4.
Mark and disconnect
5.
Note
6.
Place circuit board
7.
Locate
8.
Use
plugs
from PCi.
position of circuit board
a
jumpers
Ji thru J8
sharp tool to
and remove from unit.
stationary
on a
remove
control board PCi.
voltage
work surface
surface of board
on
so
that component side is
facing
up.
(see Figure 3-8).
sealant coating from all jumper locations, and
remove
foil jumper between pads at J2,
J4, J6, and J8.
9.
Apply
a
small amount of solder to
10.
Apply
a
sealant
11.
Reinstall circuit board into unit in its
original position.
12.
Reconnect marked leads and
to
Receptacle
coating
over
all
bridge
jumper
plugs
the foil
pads
at
jumper Ji, J3, J5, and J7.
locations.
appropriate locations.
RC1 6 leads 76, 77, and 78 must be
as follows:
changed
at
plug
PLG1 4 connected to receptacle RC1
on
voltage
con
trol board PCi
IMPORTANT: See receptacle RC1 pin
1.
Locate and disconnect
designations etched
on
plug PLG14 from receptacle RC1
circuit board to
on
identify plug openings.
voltage control board PCi.
Mark and remove leads 76, 77, and 78 from plug PLG1 4 by inserting end of a small, flat-tip screwdriver into
on side of plug to bend down locking tab, and pull contact attached to lead from plug.
2.
window
locking tabs
3.
Bend
4.
Insert lead contacts into
lead contacts Out
plug
a.
Lead 76 to
plug opening 10.
b.
Lead 77 to
plug opening 8.
c.
Lead 78 to
plug opening
5.
Reconnect
6.
Close and
Add
on
Figure
3-8.
plug PLG14
to
secure access
as
50
thatthey
secure
contacts when inserted into
plug.
follows:
9.
receptacle RC1
on
voltage
control board PCi.
door.
Jumper Locations On Voltage Control Board PCi
OM-1355828Page3
Ret. SD148
Figure
AMENDMENT TO SECTION 7
Amend
Delete
This
Diagram
Diagram
diagram
no
7-1. Circuit
7-2. Circuit
3-8.
Jumper Locations On Voltage Control
Board PCi
ELECTRICAL DIAGRAMS
Diagram
For Robot Interface
(see page
8
on
this Errata
Sheet)
Diagram For Voltage Board PCi
longer applies effective
with Serial No. KC231 859
Amend
Diagram
7-3. Circuit
Diagram For Motor Control Board PC2 (see pages 6 and
Amend
Diagram
7-4. Circuit
Diagram For
OM-135 582B
Page
4
Interface Board PC3
(see page 9
on
7 on this Errata
this Errata
Sheet)
Sheet)
322
AMENDMENT TO SECTION 8
Amend Parts List
as
follows:
Part
No.
Dia.
Mkqs.
.
19-
028 291
CR4
.
19-
.
19-
.
.
Replaced
.
.
028 291
..
.
.
095 521
.
049 970
.
.
048 588
..
079 844
.
.
079 844
..
.
.
.
.
048 029
..
.
.
026 202
..
.
.
19-
027811
19-
048 029
.
19-
026 202
.
..
PCi
.
.
137695
.
.
19-
.
..
PC4
.
.
117 836
.
.
20-
.
.
.
.
PLG25
RC13
Added
20-
.
109 768
.
19-
.
20-
.
20-
.
.
..
.
111 122
.
2020-
116 964
.
20-
111 123
.
20-
.
20-
.
2121-
.
027811
148320
.
..
..
+149 339
..
.
117 037
..
.
094 480
..
.
141 162
134 731
.
.
Description
With
Added
.
.
.
PARTS LIST
073 739
.
.
.
.
Deleted
152 370
..
.
.
..
.
.
..
CAPACITOR, (qty chg & dia. mkg. chg) (C2-4 is now C6-10)
RELAY, end 24VDC 4PDT
BRACKET, mtg relay
SPRING, (qty chg)
SOCKET, (qtychg)
CLIP, (qty chg)
DIODE, (qty chg) (added D4)
CIRCUIT CARD, (qtychg)
CIRCUIT CARD, meter (Eff w/KB113874)
HOUSING, term hdr 2skt
RECEPTACLE, 14 pin MS-3102A-20-27P (Effw/KC217109)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin sz 16 18-14 wire
CLAMP, cable strain relief sz 17
CLAMP, (now md. w/housing plug & pins)
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 18-14 wire
CLAMF~ strain relief sz 17
SHAFT, spool support
RING, retaining ext .625shaftx .O5Othk
..
.
.
079 534
.
.
..
079 739
.
.
..
072 292
.
.
154 098
..
Added
.
.
141 700
..
Added
.
.
Quantity
(mci. w/hub & spindle assy)
.
21-
605941
..
.
5
1
1
2
2
2
3
1
1
1
.
1
1
14
2
1
14
2
1
1
WASHER,flatstl.64OIDx1.OOD
(md. w/hub & spindle assy)
1
**First
digit represents page no digits following dash represent item no.
+Eff w/KB1 13874. Parts on page 27 may not represent actual board.
BE SURE TO PROVIDE MODEL AND NSPR NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582B
Page
5
ALL
fi~
'111_
_nrL
fi
ft_ill
fi~
W
S
V
V
A
A
L~i
052 ~
R
s
J
B
3V.
Diagram
OM-135 582B
Page
6
7-3. Circuit
Diagram
WAVEFOPIlS
AT
300
IPW-MOTOP
PUNNING
ALL VOLTAGES MEASIJPED WITH PESPECT TO
COM)OJ POINT
J. EXCEPT ~4. MEASURE
H
WITH RESPECT TO POINT ~I(.
For Motor Control Board PC2
M
D
F
C
P
150
C??
Circuit
Diagram
No. SD-083 388-B
OM-135 5828
Page
7
CIS4TP12.
H
L
14
2
PC9
K
0
J
/0/
H
/00
L
/2
K
J8
U
0
68
84
H
0
78
0
76
0
52
69
5
2
0
0
0
JI
0
F
75
F
E
72
o
75
p
0
J2
~
No.
Diagr m
S
/1
GE 0
J5
0
12
C
65
S.
88
ITO
4
I
B
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-
52
B
STICK
52
P
2T
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-
A
,k19
A~
P
PC6
-
A
J
A
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A
SENR/WI 9d0/REGSO
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RC9
10
9dB RCI9
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PC3
U
CS,~jC41j~, SWeirtiahl
Efectiv
Interfac
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I
BOARD
Ill?
No.
2
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C
K
K
INTERFA~
P
H
~~
P
p~
C,
For
L
N
Diagr m
a
I
PC
124
1-18
8910
CO
Circuit
P
7-i.
A
IET P
1831
liii
v~ t
Diagram
G
I
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PC4
III
AiPS/
p5~(
DO.~tTA# 1111
II
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VI3T5
r
ARC
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Li
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7
PCI
RCI6
PCI
C
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0
A
B
Robot
S
657 80*80 RCI/PL04 RC6/PLG2S
VTLAGE
E
KC231859
ARt/T~Lu SENSE
CI3TROI_
~\
J
Circuit
184
C
0
SC-i
> ~< 1>> B>)
E
C
54
FE D
WIRE
S
~
3
H
42
U
6
230
SPE D
Y
1AOTER FEOBA<
JO
-I
H
on99
9
POIJER/GROUHO NETS FOR CHIPS
RI
i~GND 8
UI
8.5140
IS)
I6~ISU
Circuit
Diagram
7-4. Circuit
Diagram
Diagram
No. SB-141 311-A
For Interface Board PC3
OM-135 5828
Page
9
OM-135 5829-11/90
RECEIVING-HANDLING
unpacking equipment, check carton for any damthat
age
may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Before
settling
claims may be obtained
from the distributor and/or the
Assistance for
manutactur-
ers
filing
or
equipment
Transportation Department.
Use the following spaces to record the Model Designa~
tion and Serial or Style Number of your unit. The infor
mation is located on the data card or the nameplate.
Model
_______________________________
Senal
requesting information about this equipment, al
provide the Model Description and Serial or Style
or
Style
No.
____________________
When
ways
Number.
Date of Purchase
_____________________
TABLE OF CONTENTS
Section No.
SECTION 1
1-1.
1-2.
SECTION 2
2-1.
-
Page
SAFETy PRECAUTIONS AND SIGNAL WORDS
General Information And
Safety
Alert
Symbol
And
Safety
Signal Words
1
1
SPECIFICATIONS
Description
1
SECTION 3INSTALLATION
3-1.
Site Selection
3-2.
Equipment
3-3.
Gas/Current
3-4.
Voltage Sensing Connections
Robot Interface
Welding Power Source Connections
4
4
3-5.
2
Installation
Sensing
3-6.
Robot Interface
3-7.
Arc Failure
3-8.
Welding
3-9.
Burnback Control
Light
2
Control Interconnections
Robot Control Unit Connections
Terminal
Strip Connections
Wire Installation
3
3
5
6
6
SECTION 4- OPERATOR CONTROLS
4-1.
Power Switch
7
4-2.
Jog Push Buttons
Purge Push Button
7
4-4.
Voltmeter
7
4-5.
Wire
7
4-3.
4-6.
4-7.
SECTION 5
5-1.
5-2.
Speed Meter
Amps/lnductanc~ Meter
Indicator Lights
7
7
7
SEQUENCE OF OPERATION
Input Signals From Robot Control Unit
Output Signals From Robot Interface
8
8
No.
Section No.
Page
MAINTENANCE & TROUBLESHOOTING
SECTION 6
6-1.
Routine Maintenance
8
6-2.
Overload Protection
9
6-3.
Reinstallation Of Hub
Assembly
9
Board PC4 Meter Check
6-4.
Display
6-5.
Circuit Board Handling Precautions
10
6-6.
Troubleshooting
11
6-7.
Use Of Indicator
Lights
For
9
Troubleshooting
13
SECTION 7- ELECTRICAL DIAGRAMS
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
SECTION 8
Figure
Figure
Figure
Figure
Figure
Figure
-
7-1. Circuit
7-2. Circuit
7-3. Circuit
7-4. Circuit
7-5. Circuit
7-6. Circuit
7-7. Circuit
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
For Robot Interface
14
For
15
Voltage Board PCi
Motor Control Board PC2
16
For Interface Board PC3
17
For
17
Display
Board PC4
For Arc Failure Board PC5
For Touch Sense/Wire Stick Board PC6
18
.
.
.
.
18
PARTS LIST
8-1. Circuit Card,
Voltage Control PCi
Speed Digital PC2
22
8-2. Circuit Card, Motor
24
8-3. Circuit Card, Interface PC3
26
8-4. Circuit Card, Meter PC4
27
8-5. Circuit Card, Interface PC5
28
8-6. Circuit Card, Wire Touch PC6
29
LIST OF CHARTS AND TABLES
Table 2-1.
Table 6-1.
Specifications
Troubleshooting
1
12
No.
SECTION 1
-
SAFETY PRECAUTIONS AND SIGNAL WORDS
AG enera I
Information
presented
in this manual and
on
use
of this
SYMBOL
SIGNAL
~
equipment.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten
tion to the safety statements.
Safety
B.
WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
CAUTION statements identify procedures
and maintained
personal
Sons
Power Source in the welding power
Manual.
ing
source
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip
Owners
ment.
SECTION 2
SPECIFICATIONS
Table 2-1.
SpecIfications
Weight
Dimensions
Component
Height
Gas/Current
Sensing Control
Spool Support
Assembly+
Add
2-1/4 in.
*Add 7/8 in.
2-1.
Width
38 lbs.
(419 mm)
(17 kg)
5-1/2 in.
10-1/2 in.
5 lbs.
Total 61 lbs.
(108 mm)
(140 mm)
(267 mm)
(2.3 kg)
(27.7 kg)
13-3/4 in.
8-3/4 in.
8-1/2 in.
6 lbs.
(349 mm)
(222 mm)
4-1/2 in.
16-1/2in.
for front
panel
Panasonic
robot and
Pulstar 450
an
designed
to interface with
Arc Pak 350, Deltaweld,
welding power source. This unit
provides digital display of weld volts,wire feed speed,
or
without
optional
wire reel.
knob.
and
The robot interface control is
(2.7 kg)
(216 mm)
+Spool Support
DESCRIPTION
Maxtron,
Ship
6~1/4in.*
(572 mm)
(57 mm) for brake resistor.
(22 mm)
Net
Depth
(159 mm)
22-1/2 in.
Robot Interface
or
must be followed to avoid minor
injury or damage to this equipment.
practices which
only by qualified perin accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1
Safety Rules For Operation Of Arc Weldstalled, operated,
a
AND
The following safety alert symbol and signal words are
used throughout this manual to call attention to and iden
tify different levels of hazard and special instructions.
various Ia-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective
ALERT
SAFETY
WORDS
1-2.
GENERAL INFORMATION AND SAFETY
1-1.
peak amperage
or
inductance.
The gas/current sensing control contains the gas valve
and current sensing reed relay.
These components function with the robot system when
using the Gas Metal Arc Welding (GMAW) process.
OM-135 582
Page
1
SECTION 3INSTALLATION
SITE SELECTION
3-1.
Select
installation site which provides the
an
Correct input power supply (see unit nameplate)
2.
Shielding
3.
Water
4.
One weld output cable must be routed to the Gas/
Current Sensing control.
5.
Welding
gas supply (if applicable)
supply (if applicable)
4.
Adequate ventilation and fresh air supply
5.
No flammables
6.
A clean and
Proper
The
following:
1.
7.
3.
dry
interconnecting cords must be routed so that
they are not caught, pinched, or strained during
welding operations.
wire must be routed
so
that it does not
tact the weld control or any other
ment.
C.
area
temperature that avoids extremes of heat
or
cold
8.
Proper airflow
9.
to open and remove cover and
for
installation,
maintenance, and repair
wrapper
functions.
around unit
Adequate space
con
grounded equip
Equipment Installation
Obtain appropriate
as necessary and
mounting
mounting
brackets
or
adapter plates
hardware. Prepare struc
ture for equipment installation. Secure weld control,
Gas/Current Sensing control, and all other equipment
onto structures in the
welding
D.
(Figure 3-1)
Hub Installation
The hub
area.
assembly is supplied with the robot interface.
assembly from the shipping carton, and
Remove the hub
holes
Mounting
cure
provide the capability
to install and se
the system components in a permanent location.
gives overall dimensions.
install it
A.
Remove hex nut from end of hub support shaft.
2.
Align keyway
and insert hub
Supplied Equipment
brake washers
following equipment is supplied
quires installation or assembly:
as
Weld Control with Gas/Current
support shaft through
selected hole in hub support. Hole selection in hub
support depends on wire spool size. Be sure the
EQUIPMENT INSTALLATION
The
1.
follows:
1.
Table 2-1
3-2.
as
standard and
Sensing
are
properly
seated in the hub.
re
3.
Reinstall hex nut onto support shaft. Tighten hex nut
until a slight drag is felt while turning hub.
Control
4.
Install
welding
wire
according
to Section 3-8.
Cord and Motor Cord
2.
Gas/Current Sensing Control
3.
Hub and
4.
Spindle Support
5.
10 ft.
Hub Support
Shaft
Spindle Assembly
Weld Control
(3 m)
Welding
Power Source
Interconnecting Cords
6.
lOft. (3m) Gas Hose
7.
10 ft.
B.
Equipment
When
Washer
(3 m) Voltage Sensing Cord
deciding
Location
on
Hub
Assembly
Hex Nut
equipment location, consider the fol
lowing:
1.
The
2.
The lead
equipment must be mounted to a structure ca
pable of supporting the weight of the equipment.
lengths of the cords supplied with the
equipment will limit the area in which the equipment
can be located. Some cords can be extended by us
ing optional extension cords (check with welding
equipment distributor).
OM-135 582
Page
2
Hub
Support
SA-126 870
Figure
3-1. Hub
Assembly
Installation
3-3.
GAS/CURRENT SENSING CONTROL INTER
A.
CONNECTIONS
Connections
a
(Figure 3-2)
WARNING: ELECTRIC SHOCK
can
kill.
Align keyways, insert 14-pin Amp plug into matching
receptacle RC9 on robot interface, and rotate
threaded collar fully clockwise.
2.
Align keyways,
B.
Gas/Current
lockout/tagging procedures before making inter
connections.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Gas/Current Sensing Control
1.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
Robot Interface
insert 16-pin Amp plug into matching
RC16
on gas/current sensing control,
receptacle
and rotate threaded collar fully clockwise.
Sensing
Control
Motor Connec
tions
1.
Align keyways, insert 14-pin plug from motor cord
into matching receptacle RC7 on gas/current sens
ing control, and rotate threaded collar fully clock
wise.
2.
Align keyways,
insert 14-socket
control cord into
from motor, and
wise.
C.
plug from motor
matching free-hanging receptacle
rotate threaded collar fully clock
Weld Cable Connections
For Electrode Positive/Reverse
Polarity, route cable
welding power source POSITIVE weld output ter
minal, through the gas/current sensing control, to the
from
wire drive
assembly, and connect cable to weld cable
(see Motor/Drive Assembly Owners Manual for
location).
terminal
SensIng
Receptacle RC9
Gas/Current
Control
D.
Connect hose from gas
regulator/flowmeter (customer
fitting on gas/current sens
ing control. Connect gas hose from wire drive assembly
to fitting on gas/current sensing control. The gas flow
must be accurately controlled by a regulator/flowmeter
14-PIn
115 Volts AC/Contactor
Control
Gas Connections
supplied)
Receptacle RC13
at gas source to IN
at the source.
3-4.
VOLTAGE SENSING CONNECTIONS
3-2 And 3-3)
a
WARNING: ELECTRIC SHOCK
can
(Figures
kill.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before making inter
connections.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
1.
Align keyway,
insert 4-socket
ceptacle RC12
TG-tt9 646
Figure
There
ing
are
3-2.
several cords
Right
Side View
supplied for gas/current
threaded collar
2.
following
connections.
plug into matching
interface,
and
re
rotate
ring terminal
assembly
the wire drive
to weld cable termi
as
shown in
Figure
3-3.
control interconnections. Examine and select the
proper cord for the
on
robot
fully clockwise.
Connect lead with
nal
sens
on
3.
Connect lead with
clamp
to
workpiece.
OM-135 582
Page
3
Nut
3-6.
ROBOTINTERFACE-ROBOTCONTROLUNIT
CONNECTIONS (Figures 3-2 And 3-4)
a
Sensing
Lead Ring
Terminal
Lug
connections.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
TA-109 093
3-3.
Voltage Sensing Connections
Drive Assembly
At Wire
1.
ROBOT
INTERFACE
SOURCE CONNECTIONS
There
are
three cords
WELDING
Obtain
proper cord and
a
24-pin Amphenol plug (not
supplied).
2.
3-5.
Do not touch live electrical parts.
lockout/tagging procedures before making inter
Location
Figure
kill.
can
Shut down unit, welding power source, and
robot, and disconnect input power employing
Location
Cable
WARNING: ELECTRIC SHOCK
ate sockets in
POWER
(Figure 3-2)
Connect conductors at
3.
supplied for interconnections be
welding power source. Ex
one
end of cord to
appropri.
plug.
insert 24-pin plug into matching re
ceptacle on robot interface, and rotate threaded col
Align keyway,
lar
fully
clockwise.
tween the robot interface and
amine and select the proper cords for the
nections.
following
con
4.
Route and connect conductors at
remaining
end of
cord to the robot control unit.
The input and output signals at the sockets of receptacle
RC17 by means of the robot interface control circuitry
A.
REMOTE 14 Connections
1.
Align keyway, insert 14-socket plug into matching
receptacle RC13 on robot interface, and rotate
threaded collar fully clockwise.
are as
follows:
Socket A:
Digital
ets
for output
common
signals
at Sock
B, C, and G.
Socket B:
14-pin plug into matching re
ceptacle on welding power source, and rotate
threaded collar fully clockwise.
Arc failure output
Socket C:
Touch Sense/Wire stick output
Socket G:
Current detect output signal.
B.
REMOTE 17 Connections
Socket H:
Weld start
1.
Align keyway,
Socket J:
Circuit Common for Sockets H, K, M, P, and
A; all circuit voltages referenced to this
2.
Align keyway,
insert
insert 17-socket
plug into matching
receptacle RC16 on robot interface,
fully clockwise.
and
rotate
Align keyway,
ceptacle
on
thread collar
C.
1.
2.
signal.
input signal.
point.
threaded collar
2.
signal.
Socket K:
Gas valve
Socket L:
Circuit
input signal.
insert
17-pin plug into matching re
welding power source, and rotate
fully
common
for input
signals at Sockets
H, K, M, P, and R
clockwise.
Socket M:
Touch Sense/Wire stick
Socket N:
Circuit
input signal.
REMOTE 10 Connections
insert 10-socket plug into matching
receptacle RC15 on robot interface, and rotate
threaded collar fully clockwise.
Align keyway,
Align keyway, insert plug into matching receptacle
on the welding power source, and rotate threaded
collar fully clockwise.
If the
though
connections
REMOTE 17
OM.135 582
are
Wire inch positive
Socket 0:
Circuit
Page
4
input signals
at Sockets
common
for
(+) input signal.
input signals at Sockets
H, K, M, P, and R.
Socket R:
Wire inch
Socket S:
Circuit
negative () input signal.
common
for
input signals at Sockets
H, K, M, P, andR
Socket T:
Voltage
control
positive (+) connection.
Socket U:
Voltage
control
wiper connection.
made to both REMOTE 14 and
receptacles.
for
Socket P:
welding
power source is equipped with a 14/17
switch, be sure the switch is in the 14 position, even
common
H, K, M, P~ and A
Socket V:
Voltage
control
negative ()
connection.
2.
Socket W:
Wire feed speed positive
Socket X:
Wire feed
speed wiper connection.
Socket Y:
Wire feed
speed negative () connection.
IMPORTANT: The
are
remaining
For robot control units when 115
is used
(+) connection.
a.
sockets in the receptacle
or
24 vac,
or
24 vdc
(Figure 3-5):
Route cord through strain relief on right side
panel of robot interface, and make proper con
nections to 1TL and 1TM.
b.
not used.
Obtain
a
115
or
24 vac,
24 vdc isolation
or
relay
CR1, and install into robot control.
c.
(
Route and connect
side of the
0
contact and
d.
e.
remaining end of cord to one
normally-open robot control relay
ground.
Connect +24 vdc to remaining side of normallyopen robot control relay contact.
Connect
a
lead from
one
side of robot control
coil to weld alarm terminal.
0
S.0291
___________________________
Figure
3-4. Front View Of 24-Socket Amphenol
Receptacle With Socket Designations
ARC FAILURE LIGHT TERMINAL STRIP CON
NECTIONS (Figure 3-5)
3-7.
j~
WARNING:
ELECTRIC SHOCK
can
f.
Connect proper voltage
vdc) between
remaining
side of robot control
Robot Control Unit
Common Terminal
Ii So Equipped
kill.
source
vac, or 24
common
(115
vac, 24
terminal and
relay
coil.
Robot Interface
Weld Alarm Terminal
If So Equipped
Do not touch live electrical parts.
______
Shut down unit, welding power source, and
robot, and disconnect input power employing
+24V0C
lockout/tagging procedures before making inter
connections.
Lockout/tagging procedures
consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shuthng off and
red-tagging circuit breaker or other disconnect
ing device.
I
1TM
Arc Failure
Indicator Light
Robot Control Unit
There
are two terminal strips inside the robot interface
for control connections. Loosen screws on strain relief
on
unit
cess
right side panel
door, and
nections.
applicable, open front panel ac
locate appropriate terminal strip for con
Tighten
and close and
if
strain relief if necessary,
access door when pro
screws on
secure
front panel
cedure is finished.
The ARC FAILURE
el is turned
on
light on the robot interface front pan
by a signal from the robot control
length of 18 gauge/2-conductor cord
as
To Voltage Source
(115VAC, 24VAC, 24VDC)
Isolation
follows:
Relay CR1
Robot Control
For robot control units when 24 vdc is used
(Figure
3-5):
a.
Weld Alarm Terminal
If So Equipped
and off
unit. Obtain proper
for this connection, and proceed
1.
Common Terminal
If So Equipped
Route cord
CR1
+24VDC
through
strain relief
right
side
panel of robot interface, and make proper
con
on
Robot Interface
E-j
nections to 1TL and 1TM.
b.
Route and connect
remaining end of cord
ground connection
weld alarm terminal and
to
1TM
at
Arc Failure
Indicator Light
the robot control unit.
S-0292
c.
Connect +24 vdc to
minal.
common
relay
contact ter
Figure
3-5. Arc Failure
Light Connections
OM-135 582
Page
5
WELDING WIRE INSTALLATION
3-8.
A.
Installation Of
1.
Remove
2.
Slide
(Figure 3-6)
Wire
Spool-Type
onto hub
so
that wire feeds oft
bottom of
3.
Rotate spool until hole in spool aligns with pin in hub.
Slide spool onto hub until it seats against back
flange of the hub.
4.
Reinstall
B.
Installation Of
Type
1.
Adjustment Of Hub Tension (Figure 3-1)
Check the hub tension by slowly rotating the wire spool
reel. The wire should unwind freely, but hub tension
should be sufficient to keep wire taut and prevent back
lash when the wire feed stops. If adjustment is required,
loosen or tighten the hex nut on the end of the hub sup
or
retaining ring.
spool of wire
spool.
C.
port shaft accordingly.
BURNBACK CONTROL
3-9.
onto hub.
retaining ring
Wire Reel And Reel-
Optional
Wire
Remove retaining ring and,
assembly from hub.
if
applicable, wire
Burnback is provided by potentiometer R32 on Interface
Circuit Board PC3 inside the unit. Burnback can be set
between 0 and 0.25 seconds.
reel
circuitry in this unit keeps the welding wire
sticking to the workpiece after the arc is extin
guished. The burnback circuitry keeps weld output on
the welding wire from 0 to 0.25 seconds after the wire
has stopped feeding. This delay action permits the weld
ing wire to burn back to a point where it neither sticks to
the workpiece or the contact tube.
The burnback
from
wire reel
flat
assembly
table
floor.
2.
Lay
3.
Remove spanner nut from wire reel
4.
Remove wire retainer, and install wire onto wire reel.
Be sure that wire feeds off bottom of reel.
5.
on a
or
assembly.
Reinstall wire retainer and spanner nut onto wire
reel.
6.
7.
Slide wire reel assembly onto hub, and rotate
sembly until hub guide pin is seated in reel.
Reinstall retaining
ring
as
a
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
onto hub.
locko ut/tagging procedures before inspecting or
Retainer
Retaining Ring
installing.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
Wire Reel
/
red-tag9ing circuit
a
Spanner
Nut
CAUTION:
(ESD)
FIgure
3-6.
OptIonal
Wire Reel And
Installation
OM-135 582
Page
6
Support
or
other disconnect
ELECTROSTATIC DISCHARGE
damage circuit boards.
Put on properly grounded wrist
BEFORE handling circuit boards.
can
Perform work
Hub
breaker
ing device.
only at a
static-safe work
strap
area.
1.
Open
2.
Locate
PC3.
3.
Rotate R32 clockwise to increase burnback time.
4.
Close and
front
access
door and locate PC3.
potentiometer R32
in upper left
corner
of
SC-1V 308
Reel-Type
Wire
secure
front access door.
SECTION 4
OPERATOR CONTROLS
Circuit Breaker
Section 6.2)
Power
Switch
Gas Indicator
Purge
Light
Push
Button Switch
Contactor Indicator
Light
Location Of Jog REV
Push Button Switch
Ref. TB-119 645
Figure
POWER SWITCH
4-1.
4-1. Front Panel Controls
(Figure 4-1)
Placing the POWER switch
in the ON
position energizes
the robot interface. The interface must be on for the ro
the POWER switch in the OFF posi
tion shuts down the interface.
bot to weld.
tual and preset wire feed speed are the
wire feed speed feedback circuit.
4-6.
Placing
JOG PUSH BUTTONS (Figure 4-1)
The
JOG
push
buttons
momentary-contact
switches. When the JOG FWD switch is pushed, weld
ing wire feeds out of the gun. When the JOG FWD and
JOG REV, buttons are pushed, welding wire feeds back
are
When used with the Pulstar
displays
(Figure 4-1)
PURGE
push button is a momentary-contact
energizes the gas solenoid and
purges the shielding gas line of the gun. The PURGE
push button allows the flow meter to be adjusted without
energizing the welding circuit.
The
switch. This switch
displays
meter
source, the
welding power source, the
inductance in percentage.
When used with the Deltaweld
welding
power source,
this meter is blank.
4-7.
PURGE PUSH BUTTON
welding power
weld peak amperage.
When used with the Arc Pak
into the gun.
4-3.
due to the
AMPS/INDUCTANCE METER (Figure 4-1)
meter
4-2.
same
INDICATOR LIGHTS
(Figure 4-1)
are five indicator lights on the interface. These
visual indications of various process functions.
There
The GAS
light turns on when the gas
shielding gas flow.
valve is
are
energized
to indicate
The CONTACTOR
er source
light turns
contactor is
on
when the
energized
welding
pow
to indicate that weld
output is available.
VOLTMETER
4-4.
(Figure 4-1)
The WIRE FEED
The voltmeter
of
volt
a
4-5.
displays weld voltage to the nearest tenth
while welding and preset voltage while idling.
WIRE SPEED METER
(Figure 4-1)
is
energized
light turns on when the wire drive motor
feeding.
to indicate that wire is
The CURRENT
light
relay is energized
The ARC FAILURE
displays preset wire feed speed to
nearest inch per minute while welding and idling. Ac-
The wire
the
speed
meter
connected
there is
according
an arc
turns on when the current detect
to indicate that an arc is established.
light
turns
on
only when properly
to instructions in Section
3-6, and
outage while welding.
OM-135 582
Page
7
SECTION 5- SEQUENCE OF OPERATION
Wire Feed
Output
Peak
Speed 0-1OV
Volts 0-1OV
Amps 0-1OV
=
=
=
0-1 000 1PM
0-50V
0-500
Amps Output
Robot control
Unit to
Computer
Interface
Gas Control
Contactor Control
Wire Stuckilouch Sense
Output Voltage
Shielding Gas
Wire
Stick/Touch Sense Voltage
Abnormal
TA-094 382-A
Figure
5-1.
INPUT SIGNALS
UNIT
5-1.
Input
And
Output Signal Timing
FROM ROBOT CONTROL
Chart
if the wire is stuckto the workpiece at the end of the weld.
(Figure 5-1)
5-2.
The robot interface receives
input signals for contactor
control, gas control, jog, welding volts, wire speed, and
current. It also receives a signal to initiate a check to see
OUTPUT SIGNALS FROM ROBOT INTERFACE
(FIgure 5-1)
The robot interface sends output signals to the robot
control unit for current sense, wire stuck, and arc failure.
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
ROUTINE MAINTENANCE
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary See Parts List for part number of
precautionary labels.
Usage and shop conditions determine the frequency
and type of maintenance. At minimum, inspect equip
ment every three months as follows:
OM-135 582
Page
8
4A
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures
maintaining, or servicing.
before
inspecting,
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
MOVING PARTS
Keep
can cause
away from
HOT SURFACES
injury.
serious
moving parts.
can cause severe
burns.
interface shuts down. If the fuse opens, correct the
lem and replace Fl as follows:
1.
Depress and
rotate fuse holder
cover
prob
counterclock
wise.
Allow
cooling period
before
setvicing.
2.
Maintenance to be
performed only by qualified
Pull out fuse with
cover
when fuse holder
cover
is
free.
persons.
Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked insu
lation and areas where it enters equipment.
1.
Remove grease and
2.
ture from electrical
grime from components;
3.
Insert
4.
Install fuse with fuse holder
5.
Depress and
a
ure
ELECTRIC SHOCK
can
Do not touch live electrical parts.
INCORRECT FUSE
can
damage
1.
2.
Wire Drive Motor Circuit Breaker CB1
(Figure
WARNING: Read and follow safety informa
tion at beginning of Section 6-2 before pro
ceeding.
Circuit breaker CB1 protects the wire drive motor from
If CB1 opens, the wire feed motor would stop.
Should
as
1.
a
motor overload occur and CB1 open,
Spring
b..
Keyed
c.
Fiber Washer
d.
Brake Washer
e.
Hub
f.
Brake Washer
g.
Fiber Washer
proceed
or clogged gun liner, and
jams often, replace gun liner.
Check for jammed wire
problem.
If wire
If motor overload
Check for
occurs
often, repair or replace wire
drive gear
binding
problem.
cooling period may
breaker
or
misaligned
drive
correct
Reset circuit breaker
support shaft
Washer
and insert hub support shaft
selected hole in hub support.
3.
Align keyway,
4.
Install hex nut onto hub support shaft. Tighten hex
nut until a slight drag is felt while turning hub.
5.
Install
welding
wire
6-4.
according
through
to Section 3-8.
DISPLAY BOARD PC4 METER CHECK
(Figure
can
by depressing
the button. A
be necessary before the circuit
be reset.
Check points are provided on the display board PC4 for
checking power supply and input command for the me
ters.
a
WARNING: ELECTRIC SHOCK
5.
Resume operation.
B.
Main Fuse Fl
WARNING: Read and follow safety Informa
tion at beginning of Section 6-2 before pro
ceeding.
Fuse Fl protects the robot interface from an internal
short or excessive overload. If fuse Fl opens, the robot
kill.
Be sure that personnel performing testing
procedures are familiar with and follow standard
safety practices.
Shut down unit before
equipment
ELECTROSTATIC
(Figure 4-1)
can
Do not touch live electrical parts.
meter or test
a
onto the hub
6-2)
rolls, and
4.
a.
follows:
drive motor.
3.
following items
given.
.
correct
2.
Slide the
in order
unit.
4-1)
assembly from hub support, and disas
discarding worn or broken parts.
Remove hub
semble
Use only replacement fuse of same size, type,
and rating (see Parts List).
overload
(Fig
6-1)
assembly,
lockout/tagging procedures before inspecting,
maintaining, or servicing.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
a
rotate fuse holder cover clockwise until
If it becomes necessary to replace part or all of the hub
reinstall the new hub assembly as follows:
kill.
Shut down unit, welding power source, and
robot, and disconnect input power employing
A.
back into unit.
REINSTALLATION OF HUB ASSEMBLY
OVERLOAD PROTECTION
WARNING:
cover
parts and cable.
6-3.
6-2.
cover.
is secure.
cover
mois
fuse into fuse holder
new
damage
Put
making
or
changing
lead connections.
DISCHARGE
(ESO)
can
electronic components.
on a
BEFORE
properly grounded wrist strap
handling circuit boards.
Transport all static-sensitive components in
static-shielding carriers and packages.
proper
Perform work
only at a static-safe
work
OM-135 582
area.
Page
9
Wire
Retainer
Wire Reel
Retaining
Ring
spanner
Nut
Spring
Keyed
Washer
Brake Washer
Hub
Fiber Washer
Fiber Washer
Hex Nut
Brake
Washer
OPTIONAL
Hub
Ref. SC-l27 328
Figure
6-1. Hub And Reel Assemblies
Input Command For
Speed 1PM Meter
Input Command
Wire
0.8V
Input Command
Ammeter -.O.1V
=
=
Volts Meter O.5V
800 1PM
For
=
50V
For
100A
Power Supply For
Volts Meter And Ammeter
0-5VDC
Ref. SD-ill 838-B
Figure
1.
Open
2.
Locate
display
3.
Check
voltage according
4.
robot interface
access
If a meter power
supply
to
Figure
6-2.
and command
voltage
is
replace the me
Station).
supply or command voltage is incorrect,
replace display board PC4 (see Section 6-5 and
contact nearest Factory Authorized Service Sta
tion).
OM-135 582
Page
10
CIRCUIT BOARD HANDLING PRECAUTIONS
a
(see Section 6-5 and contact nearest Factory Au
If the power
Board Meter Checks
6-5.
board PC4.
thorized Service
5.
Display
door.
correct and the meter is not working,
ter
6-2.
WARNING: ELECTRIC SHOCK
can
kilt.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before inspecting,
maintaining, or servicing.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
a
ELECTROSTATIC DISCHARGE
CAUTION:
(ESD)
can
Lockout/tagging procedures Consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
damage circuit boards.
Put on properly grounded
BEFORE handling circuit boards.
wrist
strap
red-tagging circuit breaker
ing
Transport circuit boards in proper staticshielding carriers or packages.
Perform work
only
MOVING PARTS
at a static-safe work area.
sure
that
plugs
are
properly
can
Allow
installed and
plugs
and
removing
or
installing
Injury.
burns.
cooling period before servicing..
Itis assumed that the unit
board.
serious
can cause severe
Troubleshooting to
qualified persons.
break circuit
Use only minimal pressure and gentle move
ment when disconnecting or connecting board
can cause
HOT SURFACES
aligned.
EXCESSIVE PRESSURE
board.
other disconnect
Keep away from moving parts.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
Be
or
device.
was
be
performed
only
by
properly installed accord
to Section 3 of this
manual, the operator is familiar
with the function of controls, the robot interface was
working properly, and that the trouble is not related to the
ing
welding process.
6-6.
The
TROUBLESHOOTING
following
remedies for
a
WARNING:
ELECTRIC SHOCK
can
kill.
table is
designed
to
diagnose and provide
of the troubles that may develop in
this robot interface. Use this table in conjunction with the
circuit
some
while
lockout/tagging procedures before inspecting or
performing troubleshooting proce
performing
these procedures, contact the nearest Factory Author
ized Service Station. In all cases of equipment malfunc
tion, strictly follow the manufacturers procedures and
servicing.
instructions.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
diagram
dures. If the trouble is not remedied after
OM-135 582
Page
11
Table 6-1.
REMEDY
PROBABLE CAUSE
TROUBLE
No arc
Troubleshooting
voltage control.
Output
control connections.
Check and
secure
connections
secure
connections (see Section
(see Section
3-4).
Check and
sensing connections.
Arc
3-4).
Voltage
Board PCi not
working.
Replace PCi (see Section 6-5 and contact near
Factory Authorized Service Station).
est
Wire
speed (1PM)
meter
Incorrect robot command
voltage.
Check robot command voltage at Voltage Board
PCi. Command voltage should be 0-10 vdc be
tween sockets V (common) and U at RC17.
Incorrect robot command
voltage.
Check robot command voltage at Motor Board
PC2. Signal should be 0-10 vdc between pins K
and B (common) at RC5.
goes to zero.
Motor Board PC2 not
working.
Replace PC2 (see Section 6-5 and contact
Factory Authorized Service Station).
near
est
Unit does not operate.
Fuse Fl
Check Fl, and replace if necessary (see Section
6-2). Correct overload problem before continu
Open.
ing operation.
Circuit breaker CB1
tripped.
~
Check CB1, and reset if necessary (see Section
6-2). Correct overload problem before continu
ing operation.
No meter
display.
Meter not
Use check points on Display Board PC4 to deter
mine if power is available to meter (see Section
6-4). If check points are okay, replace meter (see
working.
Section 6-5 and contact nearest
rized Service Station).
Display Board PC4
No wire feed.
Robot
signal.
Relay
CR1 not
not
working.
Use check points to determine if power is avaii
able (see Section 6-4). If check points do not test
okay, replace PC4 (see Section 6-5 and contact
nearest Factory Authorized Service Station).
working.
working.
Replace CR1.
Replace PC2 (see Section 6-5 and contact
est
feeds
at
only,
OM-135 582
maximum
Tach board at wire drive motor not
working.
Page
12
Autho
Check input signal from robot to Motor Board
PC2. Signal should be 0-10 vdc between pins K
and B (common) on RC5.
Motor Board PC2 not
Wire
Factory
Factory
Authorized Service
near
Station).
Replace tach board (see motor/drive assembly
Manual).
Owners
6-7.
USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING
Gas Indicator Light
On
Off
1~
Gas flows:
System
normal
(on.)
Gas does not flow
Gas flows:
Gas does not flow
Check gas valve operation.
Check gas valve operation
and gas line for leaks.
System
normal
(off).
Check interface board PC3.
On
Contactor Indicator
Light
~Off
~1~
Contactor closed:
Contactor open:
Contactor closed:
Contactor open:
System
Check
Check
System
normal
(on).
interconnecting
display
board PC4.
normal
(off).
cords.
Check interface board PC3.
On
Wire Feed Indicator
Wire feeds:
System
normal
(on).
DOff
Light
Wire does not feed:
Wire feeds:
Wire does not feed:
Check circuit breaker CB1
Check input signal from
robot to motor board PC2.
Signal should be 0-10 vdc
System
Check relay CR1.
Check interface board PC3.
pins K and
(common) at RC5.
between
normal
(off).
B
Check motor board PC2
On
Current Indicator Light
~
~1~
Off
3
hr
Arc started:
System
No
normal
On
(on).
arc:
Replace
reed
~
relay.
Arc started:
No
Replace reed relay.
System
Arc Failure Indicator
~1~
No
~
.
Light
arc:
Arc started:
Check
signal
No
from robot.
~
normal
(off).
Off
3
Jr
Check weld parameters.
arc:
Arc started:
arc:
Normal
during idling.
Normal while
welding.
should be 24 vdc
between terminals 1TL and 1TM.
Signal
Check
display
board PC4.
OM-135 582 Page 13
C/) m C) -I 0 z -.1
m I m C) -l
C)
I 0
C)
U)
0 0-A
39
SC-i
No.
Diagram
Circuit
Interfac
Robot
For
Diagram
FLH
H)
F0
CD
F
A
/0 1.56
4265.
2T0.
H
FL
.1
OH
(F
CO
F
A
0
/7
/7
I7/~O
.5
~ 17/.
00
ITO
.5
4
/
Circuit
7-1.
Diagram
I T I ~I
~T~T
~I ~I ~I I,
T~T T
T
Circuit
Diagram
7-2. Circuit
Diagram
For
Diagram
No. C-135 518
Voltage Board PCi
OM-135 582 Page 15
38 -A
SD-083
No.
Diagram
Circuit
PC2
Board
Control
Motor
For
Diagr m
UJ~ flT SCAS
TO
~4-.o1m Win. Toga
~
OW
CIrcuit
IAS~ .J.
UAS~ ~ TODWY~fliynT
~
TO
AT
7-3.
Oi~
MS MS .14.
fi~l1Mftl Th fiLJLJ /J fil Lil _ilML l ~
fi
fi
Diagr m
L~
18>
POUE~IGROUND ~ETS F~ CkI#S
Al
4.GAD 8~.ISU
UI
8.GAD
IS.. cu
Circuit
Diagram
A-P
ON
PC2O
AA-AF
ON
PC24
7-4. Circuit
Diagram
Diagram
No. SB-141 311
For Interface Board PC3
,
Z
n
r
m
0
L~O3
86
I
A
A
A
A
A
fl\ ,ri
U
#C23
A
A
A
8C21
~z.
I
A
AAAAA
=
Circuit
Diagram
7-5. Circuit
nuL
#C22
Diagram
No. SB-ill 341
Diagram For Display Board PC4
OM-135 582
Page
17
Rd
~
Lii~
24V
(
~C8
BYPASS FOR Al
POWER AND GROU~
lIEN
*24V
~
Al
8
4
Circuit
Diagram
7-6. Circuit
Diagram
Diagram
No. B-132 087-A
For Arc Failure Board PC5
21U
Ru
.l5U
IOU
Di
C
CR2
PQI~R/GRIYJND ~IS
POR dRIPS
8140
Diagram
Page
I,
022
Circuit
OM-135 582
~~
l~GND 9~.l5U
RI
18
7-7. Circuit
Diagram
Diagram
For Touch Sense/Wire Stick Board PC6
No. SB-140 022
SECTION 8
Dia.
Mkgs.
Part
No.
C2-4
CB1
CR1
CR2
CR3
D2 ,3
Fl
PB1-3
PCi
PC2
PC3
PC4
PC5
PC6
PLG9
PLG16
PLG1 2
PLG 14,19
PLG15
PLG1 8
PLG2O
PLG24
031 692
006426
028 291
011 991
109 006
052964
095033
049 970
079 844
027811
048 029
026202
*012 655
046432
021 105
137 695
110 375
110391
071 642
083 147
141 308
117 836
089 032
073 756
132 090
140 021
109 041
047 636
079535
079 739
096813
048 598
079 534
049 989
073 686
039828
600848
604 109
601 226
601 228
600 750
079 748
079 747
089 870
089 647
073 332
073 140
039716
079 760
079 747
081 379
081 378
084 198
081 378
PARTS LIST
Descnption
Main
Cl
-
Quantity
Assembly
CAPACITOR, elctlt 750uf 200VDC
CLAMP, capacitor 2.000dia
CAPACITOR, cer disc .1 uf 500 VDC
CIRCUIT BREAKER, man reset 1 P 1 .5A 250V
RELAY,encI24VACDPDT
RELAY, end 24VDC DPDT
RELAY, end 24VAC 4PDT
BRACKET mtg relay
SPRING, hold down relay
1
1
3
1
1
1
1
1
1
SOCKET
relay 14 pin
CLIP, retaining skt relay
1
DIODE, rect 1A 400V SP
FUSE, minatceri0A250V
HOLDER, fuse minat .250 x 1.250 panel mtg
2
SWITCH, PB SPDT
CIRCUIT CARD, voltage control (Fig 8-1)
STAND-OFF SUPPORT, PC card No. 6 screw
3
1
1
1
1
8
3
GUIDE, mtg-circuit card
CIRCUIT CARD, motor speed digital (Fig 8-2)
GROMMET,scrNo.8/10
CIRCUIT CARD, interlace (Fig 8-3)
CIRCUIT CARD, meter (Fig 8-4)
LENS, LED 4341 red
STAND-OFF, No. 6-32 x .625 Ig
CIRCUFI CARD, interlace (Fig 8-5)
CIRCUIT CARD, wire touch (Fig 8-6)
CABLE, interconnecting (consisting of)
HOUSING PLUG & PINS, (consisting of)
~TERMINAL,maIe1 pinszl6l8-l4wire
CLAMP, cable
CABLE, pwr shld 1 8ga 15/c (order by ft)
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 14-18 wire
CABLE, volt sensing (consisting of)
PLUG, 4skt 97-3106A-14S-2S
CLAMP, cable AN-3057-6
WIRE, lead mot 1 2ga strd (order by 11)
WIRE, lead 1 6ga strd (order by It)
INSULATOR, vinyl clamp univ 25A
CLAMP, univ 25A
~TERMINAL, ring tng .500 stud 16-l4wire
HOUSING, term header 18 pin
TERMINAL, contact header 24-18 wire
CABLE, interconnecting (consisting of)
PLUG, lOskt MS-3106A-18-1S
CLAMP, cable 97-3057-10
CABLE, port No.18 10/c (order by ft)
PLUG, 10 pin MS-3106A-18-1P
HOUSING, term header 12 pin
TERMINAL, contact header 24-18
HOUSING, term header 12 pin
TERMINAL, female lskt 22-18 wire
HOUSING, term header 6 pin
TERMINAL, female lskt22-l8wire
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
1
2
lOft
1
1
12
1
12
1
6
OM-135 582
Page
19
Part
No.
Dia.
Mkgs.
Main
115 091
PLG28
113 746
092 159
081 378
030 651
PLG5O
Ri
R2
R3
R4
RC5
RC9
RC12
RC13
RC15
RC16
RC17
Si
SRi
Ti ,3
T2,4
iT~2T
605741
030 941
030949
010199
079683
056 170
010 193
057 084
079 497
603 856
0937270007459
117 374
009 335
047 637
079 534
076 624
109 768
089 646
097 867
1065360008908
011 609
035 704
035 759
036 135
0923690008267
038 783
601 219
010 916
1324810008989
107 983
112 473
+1169690008908
045 852
134 327
010855
010 853~
073 487
121 594
111 122
109 770
116964
110 015
111 123
109 771
071 006
047 636
079535
079 739
073 139
071 892
079 534
OM-135 582
Page
20
Quantity
Descnption
Assembly (Continued)
HOUSIN.3 PLUG & SOCKETS, (consisting
TERMINAL, female lskt 24-18 wire
HOUSING, term hdr 16 pin
of)
TERMINAL, female lskt 22-18 wire
RESISTOR, WWfxd 25W 10 ohm
CLIP, mtgresistor.312 ID
RESISTOR, WW fxd 100W 5 ohm
HEATSINK,rect
1
10
1
16
1
4
1
1
TUBING,stl.275lDx1.000
2
HEATSINK, resistor
SHIELD, resistor
TUBING, stl .37500 x .250
BUSHING, snap-in nyl .250 ID x .375 mtg hole
RESISTOR, WW fxd 25W 2K ohm
POTENTIOMETER, WW sltd sft 10/T 2W 10K ohm
BRACKET, mtg pot
HOUSING, term conn 22posn
STAND-OFF, No. 4-40 x .625 Ig
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 14-18 wire
RECEPIACLE, 4 pin MS-3102A-14S-2P
RECEPTACLE, 14 pin 97-4102A-20-27P
RECEPTACLE, 10 pin MS-3102A-18-1P
RECEPTACLE, 17 pin MS-3102A-20-29P
1
1
4
1
1
1
1
1
2
1
14
1
1
1
1
RECEPTACLE
1
SWITCH,tgISPDT15A125VAC
1
1
RECTIFIER, integ 30A 600V
TRANSFORMER, control mintr 115/36VCT
TRANSFORMER, control 115/24VAC 50/60 Hz
TUBING, stl .250 ID x l6ga wall x 1.937
BLOCK, term 20A 12P
2
LINK,jumpertermblk2OA
3
CONNECTOR, clamp cable .750
CABINET, control
BLANK, snap-in nyl .500 mtg hole black
PANEL, mtg components
DOOR, access cabinet
CLlP~ component .687dia mtg adh back
LABEL, warning general precautionary
RETAINIR,scrNo.2
FASTENER, scr sltd hd No. 2
NUT, speed No. 2
1
2
2
2
1
4
1
1
2
1
2
2
2
NAMEPLATE
1
CABLE, interconnecting (consisting of)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1pm sz 4516-22 wire
CLAMP~ cable 97-3057-1012
CABLE, port No.18 7/c (order by ft)
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 16-22 wire sz 45
CABLE, motor (consisting of)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pinsz 1618-14 wire
CLAMP, cable strain relief sz 17
CABLE, port No. 166/c (orderbyft)
RECEPTACLE w/SOCKETS, (consisting of)
TERMINAL, female iskt 14-18 wire
1
.
.
.
1
14
2
lOft
1
14
1
1
14
2
lOft
1
14
Dia.
Part
No.
Mkgs.
Description
MaIn
048 144
1338640008989
097868
116 964
604910
097 866
056 462
604 550
010 606
056 108
056 851
137 114
026 202
Di
GS1
109293
RC7
047 637
079534
090 246
079 535
135 130
038 839
115 104
010 494
057 358
RC1 6
REED
51
010191
135 205
057971
010233
072 292
058 427
092 989
134464
*Recommended
Spare
+When
a
ordering
Assembly (Continued)
TERMINAL, male 1 pin plug keying
CABLE, interconnecting (consisting of)
PLUG, l7sktMS-3106A-20-29S
CLAMP, cable 97-3057-1012
CABLE, pwr shld 2Oga 5/c (order by ft)
PLUG, 17 pin MS-3106A-20-29P
HOSE, gas (consisting of)
HOSE, nprn brd No. 1 x .187 ID (order by ft)
FITTING, hose brs nut .625-18RH
FITTING, hose brs ferrule .425 ID x .718 Ig
FITTING, hose brs barbed nipple 3/i 6tbg
CONTROL BOX, gas/current sensor (consisting of)
DIODE, rect 1A 400V SP
2
.
1
1
.
2
.
lOft
1
1
lift
.
1
.
1
.
1
.
1
1
~VALVE,24VDC2wayi/4IPSport1/8ort
HOUSING RECEPTACLE & SOCKETS, (consisting of)
1
1
~TERMINAL,femalelskti4-i8wire
RECEPTACLE w/PINS, (consisting of)
TERMINAL, male 1 pin sz 1618-14 wire
RELAY, current
BLOCK, term 20A 5P
CONNECTOR, clamp cable .500
BUSHING, snap-in nyl 1.375 ID x 1 .75Omtg hole
BUSHING, snap-in nyl 1.000 ID x 1 .375mtg hole
14
I
16
1
.
1
1
.
010 604
602 934
079 573
079 574
137 121
+079682
134 327
072 094
058 428
058 628
Quantity
.
.
2
2
FITTING, hose brs bushing l/4NPT x .625-18RH
FITTING, pipe galv coupling .25ONPSC
FITTING, pipe galv nipple L .25ONPT x 6.000
2
BRACKET mtg component
CASE SECTION, frontlbottorWrear
WRAPPER
2
1
1
1
1
LABEL, warning general precautionary
HUB & SPINDLE, (consisting of)
HUB, spool
1
1
1
.
WASHER, brake stl
~WASHLR,fbr.656IDx1.5O0ODx.i25thk
2
NU1 stl sif 1kg hex reg .625-11
WASHER, flat stl keyed 1.500diax .i25thk
1
.
2
1
~SPRlNG,cprsn.97OODx1.250
1
SHAFT, spool support
RING, retaining spool
SUPPORT, spindle (consisting of)
LABEL, warning general precautionary
I
1
1
1
Parts.
component originally displaying
a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582
Page
21
>-
C5g
0 ~
r~
0
cx
E::::Jc:::~
R63
C RS
_______
N
(N
Q~N-
J3
T~
U)
L)
R8?
~~J
L)
J13
C74
0
0
SB-135 520-8
Figure
OM-135 582 Page 22
8-1. Circuit
Card, Voltage Control PCi
12
5
4
3
1
15
2
Dia.
Part
No.
Description
Quantity
-
M kqs.
PCi
137 695
Figure
8-1. Circuit
Card, Voltage Control
A50
096 275
IC, linear 324
1
A51,52,54
114 176
IC, linear 353
3
A53
Cl -4,53,
009159
IC,linear358
1
55-59,68
122 723
CAPACITOR,
69-73
000 340
C52
C54
031 677
C61
C62
005 023
C63
053 992
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
C64,65
118 460
CAPACITOR, elctlt 330uf 5OVDC
2
C66,74
C67,75
000 348
CAPACITOR, tantlm .47uf 35V
CAPACITOR, polye met film .47uf 100V
2
121 684
CR50
093 558
RELAY,
091 861
SOCKE1~ relay l4skt
SPRING, hold down relay
.1uf5OVDC
11
disc .01 uf 5OVDC
7
cer mono
C50,60,
000 861
009 577
079 844
D51 -54
026 202
D55-66
028 351
J1-15
092648
OC5O
050
035 842
047 034
051-53
037 200
R1,2
089 174
R3
089 176
R4,5,67,76
R51 80,86,87
R52,91
R53,73
R55-57,85
089 175
R58,61
039 336
R59,60,95-97
035 826
R62,68,82
R63,78
035 825
R69
108 437
R71
000 038
R74,103
R75,89
009 173
R77
039 333
R79
039 330
R81
R83
R84
035 886
R88,92
081 833
R90
R93
R94
035 885
R98
R99
039 329
R100
R102
117 134
121 714
RC1
079 749
Si
092 367
VR5O
083 772
VR51
046932
039 331
035 888
078 431
035 827
097 110
052 137
084 205
000 885
091 799
035 823
108 433
end
cer
tantim 5.6uf 35VDC
1
elctlt 33uf 35V
1
tantlm 2.2uf 20V
1
tantlm 27uf 35V
1
cer
disc .001 uf 1 000VDC
1
2
12OVAC 4PDT
1
1
1
DIODE, rect 1A 400V SP
DIODE, sig .020A 75V SP
RESISTOR,WWfxdzeroohm
IC, interface 4N26
TRANSISTOR, PNP .6A 40V
TRANSISTOR, NPN 200MA 40V
RESISTOR, MF .25W lOOK ohm
RESISTOR, ME .25W 20K ohm
RESISTOR, MF .25W 10K ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 2.2K ohm
RESISTOR, C .25W 330 ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 220K ohm
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 1 K ohm
RESISTOR, MF .25W 1K ohm
RESISTOR, MF .25W 4.75K ohm
POTENTIOMETER, cermet trmr 25/1 .5W 2K ohm
POTENTIOMETER, cermet trmr 20/1 .5W 5K ohm
RESISTOR, ME .25W 5.11K ohm
RESISTOR, CF .25W 18K ohm
RESISTOR, CF .25W 3.9K ohm
RESISTOR, CF .25W 22K ohm
RESISTOR, MF .25W 3.32K ohm
RESISTOR, MF .25W 10K ohm
RESISTOR, CF .25W 2.7 meg ohm
RESISTOR, CF .25W 68K ohm
RESISTOR, MF .25W 8.25K ohm
RESISTOR, CF .25W 100 ohm
RESISTOR, CF .25W 2.7K ohm
RESISTOR, MF .25W 2.43K ohm
RESISTOR, MF .25W24.3Kohm
RESISTOR, MF .25W51.lKohm
TERMINAL, header 18 pin
SWITCH, dip SPST 2posn
3
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
I
1
1
1
IC, linear 7815
IC,Iinear7gl5
I
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582
Page
23
380-E
SC-c93
PC2
Dig tal
Spe d
Motor
Card,
Circuit
8-2.
Figure
0
C.) 01 01 I) -u ca a N.)
Part
No.
Dia.
Mkgs.
Description
8-2. CircuIt Card, Motor
Quantity
PC2
071 642
FIgure
A50-53
C50
C51
009159
039 482
031 699
073 739
035 833
005 023
031 643
073 549
007 742
035 561
044 602
031 721
095033
IC,Iiriear358
CAPACITOR, elctlt 1 OOuf 35VDC
CAPACITOR, mylar .0022uf 200VDC
CAPACITOR, cer .luf 5OVDC
CAPACITOR, mylar .033uf 100 VDC
CAPACITOR, tantlm 2.2uf 20V
CAPACITOR, cer .Oluf 500VDC
CAPACITOR, mylar .Ol5uf 200V
CAPACiTOR, eictlt lOut 35V
CAPACITOR, mylar 4uf 200V
CAPACITOR, polye film .47uf 400 VDC
CAPACITOR, mylar .22uf 200 VDC
RELAY, end 24VAC4PDT
SOCKET, relay
SPRING, hold down-relay
DIODE, 1A400VSP
DIODE,zenerl5V5W
IC, interface 2907
TRANSISTOR, NPN 200MA 40V
THYRISTOR, SCR 7.4A 200V
TRANSISTOR, UJT 15MA 40V
RESISTOR, WW fxd 5W 220 ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 20K ohm
RESISTOR, CF .25W l5Kohm
C52,61
C53,62
C54
C55,66-75,77
C56
C57
C60
C63,64
C65
CR50
091 861
Q51
Q52
R50
Note 1
079 844
026202
080910
081 800
037 200
037 824
039 355
030 839
035 827
R52,56,61
052 138
R53
039332
D50-54,56-60
D55
1C50
Q50,53
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
035
030
039
039
039
049
884
007
335
106
331
015
039 328
052 142
039 108
035 886
035825
030937
030 090
092 648
T50
VR1
VR5O
Note: R51
085 399
047272
081 799
Speed DigItal
....
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
RESISTOR, CF .25W 100K ohm
POTENTIOMETER, cermet 151T .75W 50K ohm
RESISTOR, CF .25W 47K ohm
RESISTOR, CF .25W 470 ohm
RESISTOR, CF .25W 4.7K ohm
8
1
3
2
1
RESISTOR, CF .25W lOmeg ohm
RESISTOR, CF .25W 1.5K ohm
RESISTOR, CF .25W 120K ohm
RESISTOR, CF .25W 82K ohm
RESISTOR, CF .25W 22K ohm
RESISTOR,CF.25WlKohm
RESISTOR,CF.SWlOohm
RESISTOR, CF .5W 47 ohm
1
2
....
1
1
1
2
1
1
RESISTOR, WW fxd zero ohm
TRANSFORMER, pulse
IC, linear 78L12
IC, linear 78L08
15
1
1
1
,54,55,57,67,68,74,75,82,89
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582
Page
25
1
Dia.
M kgs.
Part
No.
PC3
141 308
Al
009 159
C1-7,15
122 723
C8
083 973
C9
031 677
C11,12
000 348
C13
C14
072 130
C16
073 714
CR 1,2
095 521
CR3-6
099 018
000 859
079 844
091 861
01,13-17
028 35i
D2-8
026 202
Ji -10
092 648
02-8
Ri
037 200
,4,8,9
035 826
R2
039 332
R3,5,6
R7,31
Ri 0-14,17-22,29
R15,23
035 827
035 825
039 33i
039 329
R16
039 336
R24-27
053 572
R28
035 884
R30
R32
RC1 8
RC1 9
035 823
Ui
VR1
094 594
052 152
079 759
079 749
081 832
Quantity
Description
Figure
8-3. Circuit
Card, Interface
IC, linear 358
CAPACITOR, cer mono .luf 50VDC
CAPACITOR, elctlt l000uf 35VDC
CAPACITOR, tantlm 56uf 35VDC
CAPACITOR, tantlm .47uf 35V
CAPACITOR, tantlm 1 uf 35VDC
CAPACITOR, elctlt 220uf 35VDC
CAPACITOR, tantlm .22uf 35V
RELAY, end 24VDC 4PDT
2
1
1
1
2
RELAY, end 24VDC SPOT
SPRING, hold down relay
SOCKET, relay
DIODE, sig .020A 75V
DIODE, rect 1A400V
4
RESISTOR, WW fxd zero ohm
TRANSISTOR, NPN 200MA 40V
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 15K ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 2.7K ohm
10
2
2
6
7
7
4
3
2
12
2
RESISTOR, CF .25W 220K ohm.
RESISTOR, MF .25W 12.1K ohm
RESISTOR, CF .25W 1 00K ohm.
RESISTOR, CF .25W 100 ohm
POTENTIOMETER, cermet trmr 25/T .5Wimegohm
TERMINAL, hdr 12 pin
TERMINAL, hdr 18 pin
IC, digital 4098
IC,Iinear78Mi5
0
-~-P1?
P18
E::J
4
1
1
0QS
,J3
0
~
A
SA.141 309
Figure
8-3. Circuit Card, Interface PC3
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582
Page
26
Part
No.
Dia.
Mkgs.
Quantity
Description
8-4. Circuit
Card, Meter
PC4
117 836
FIgure
CI ,2
C3-5
000 348
073739
028 351
CAPACITOR, tantlm .47uf 35V
CAPACITOR,cer.1uf5OVDC
DIODE, sig .020A 75V SP
3
108453
089 028
METER,digital
3
LED, 5330A1 O4OMCD
LED,5330A19200MCD
RESISTOR, .5W 1.5K ohm
POTENTIOMETER, cer 15/T .75W 200K ohm
4
Dl ,2
LCD1-3
LED1 2,4,5
LED3
097763
030 028
030 140
R1-5
R6,8,11
R7,9,10
071 248
070 026
ASSE~LY
M~
~
LcoI~
2
6
Lc02
II
~J
U
Lc03
II
I I
j~
I)
RIO
Ii
I
RC2II
~LI Lj
IL
I
ft~
RC231
I
VR2
v~i
H I
3
3
TERMINAL, header 12 pin
TERMINAL, header l3skt
TERMINAL, header 6 pin
IC, linear 78M05
STAND-OFF, No. 6-32 x .437
084 194
VR1,2
2
RESISTOR,CF.25Wlmegohm
003272
081 381
109 161
RC2O
RC21-23
RC24
2
~I
101
R9
LEDI
'
L~
DI
02
=1
~
R3
'
LED3
~
I_____________
RO2O
HHOOO~HVHOOH
RC24
DIJIIIHID
Ref. SD.117 838-B
Figure 8-4. CircuIt Card,
Meter PC4
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582
Page
27
Part
No.
Dia.
Mkgs.
Description
8-5. CIrcuIt
Card, Interface
PC5
132 090
FIgure
Al
009159
039 482
000 348
031 677
122 723
099 018
IC,Iinear35B
CAPACITOR, elctlt lOOuf 35VDC
CAPACITOR, tantim .47uf 35V
CAPACITOR, tantlm 5.6uf 35VDC
CAPACITOR, cer mono .luf 5OVDC
Cl
C2
C3
C4
CR1 ,2
Di ,4
026 202
028 351
092 648
D2,3
Ji
Qi
Ri
037 200
035 824
R2
009 173
R3
035825
R4
038 584
035 827
R5,7
039 332
035 826
039 331
113 747
095269
R6
R8
R9
RC1
VR1
Quantity
1
1
1
1
1
RELAY, end 24VDC SPDT
DIODE, rect 1A 400V SP
DIODE, sig .020A 75V SP
2
2
2
RESISTOR, WW fxd zero ohm
TRANSISTOR, NPN 200MA 40V
RESISTOR, CF .25W 270 ohm
POTENTIOMETER, cermet trmr 20/T .5W 5K
RESISTOR,CF.25WlKohm
RESISTOR, CF .25W 470K ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 15K ohm
1
1
1
ohm
1
1
1
2
1
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 4.7K ohm
TERMINAL, header 10 pin
IC,Iinear3l7T
1
1
1
1
0~
0
UR 1
CR2
CR1
C,
-~J--RS
0
0
AC 1
A-i 32089-A
Figure 8-5. CIrcuit Card, Interface PC5
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582
Page
28
Dia.
Mkgs.
Part
No.
Description
8-6. Circuit
Card, Wire Touch
PC6
140 021
Figure
Al
009 159
Cl
090 573
C2
C3
C4
CR1-3
000 348
Dl-3,5-8
026202
D9
037 449
J1,2
Ql ,2
Rl ,5,7
R2,3
092648
R4
039 331
R6,8
R9,1O
035 888
RC5O
092 160
VR1
083772
IC, linear 358
CAPACITOR, elctlt lOut 50V
CAPACITOR, tantlm .47uf 35V
CAPACITOR, elctlt 1 OOuf 35VDC
CAPACITOR, cer mono .1uf5OVDC
RELAY, end 24VDC 4PDT
DIODE, rect 1A400V
DIODE, zener 15V 1W
RESISTOR, WW fxd zero ohm
TRANSISTOR, NPN 200MA 40V
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 2.2K ohm
RESISTOR, C 1W 270 ohm
TERMINAL, hdr 16 pin
IC, linear 7815
039 482
122 723
004 855
037 200
035 827
035 826
030 710
Quantity
1
1
1
1
I
....
3
7
1
2
2
3
2
1
2
2
1
1
QIQ
P2~~
D2
1~J
0~
E~J
CR1
CR
f~J--
Dl
CR3
D3
J2
oQ~
+
Rcse
SA.140 020
Figure
8-6. Circuit
Card,
Wire Touch PC6
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-135 582 Page 29