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Millerfi - Miller Welding | Manualzz

Millerfi

March 1992 FORM: OM-152 308

MODEL:

Computer

Interface

(Per

NSPR

9860)

flLE

RETURN

COPY

TO

FOLDER

OWNERS MANUAL

IMPORTANT: Read and understand the entire contents of both this manual and the the power source manual used with this unit, with

special emphasis

on

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 Miller Group Ltd., Company

Mfg.

Co.

P.O. Box 1079

Appleton, WI 54912 USA

Tel. 414.734.9821

PRINTED IN US A

L.

LIMITED WARRANTY

EFPECTIVE: AUGUST 6. 1990

This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY Subiect to the terms and conditions hereof.

MILLER Electric rants to its

Mfg.

Co., Appleton.

Wisconsin war

Distributor/Dealer that all new and unused

Equipment furnished by

MILLER is free from defect in workmanship and material as of the time and place of delivery by MILLER.

No warranty is made by MILLER with resoect to engines, trade accessories or other items manufactured by others.

if any.

Such

All engines, trade accessories and other items are sold subject to the warranties of their respective manufacturers, engines are warrantied by their manufacturer for two years from date of original purchase, except Deutz engines which have a one year,

2000 hour warranty.

Except as specified below. MILLERs warranty does not apply to components having normal useful life of less than one

(1) year.

such as spot welder tips, relay and contactor

MILLERMATIC parts that come in contact with the points.

welding wire including nozzles and nozzle insulators where failure does not result from defect in workmanship or material.

MILLER shall be ranted required to honor warranty claims on war

Equipment in the event of failure resulting from a defect within the following periods from the date of delivery of

Equipment to the original user:

-

1.

2.

7.

Arc welders, power sources, robots, and components

Load banks

3.

Original main power rectifiers

(labor 1 year only)

4.

All welding guns, feeder/guns and torches

.

.

5.

All other MILLERMATIC Feeders

6.

Replacement or repair parts, exclusive of labor

Batteries

1 year

1 year

3 years

90 days

1 year

60 days

6 months provided that MILLER is notified in writing within thirty (30) days of the date of such failure.

As a matter of general policy only.

MILLER may honor claims submitted by the original user within the foregoing periods.

In the case of with respect

MILLERs breach of to the warranty or any other duty quality of any goods.

the exclusive remedies therefore shall be, at MILLERs option (1) repair or

(21 replace.

ment or, where authorized in writing by MILLER in appropriate cases,

(3) the reasonable cost of repair or replacement at an authorized MILLER service station or (4) payment of or credit for the purchase price

(less reasonable depreciation based upon actual use) upon return of the goods at Customers risk and expense. MILLERs

FOB..

option of repair or replacement will be

Factory at Appleton, Wisconsin, or

F O.B.

at a MILLER authorized service facility, therefore, no compensation for transportation costs of any kind II be allowed.

notice of

Upon receipt of apparent defect or failure.

MILLER shall instruct the claimant on the warranty claim procedures to be followed.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY. GUARANTY OR REPRE

SENTATION AS TO PERFORMANCE. AND ANY REMEDY

FOR BREACH OF CONTRACT WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION. OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING.

INCLUDING ANY IMPLIED WARRANTY OF MERCHAN

TABILITY

WITH

OR OF FITNESS FOR PARTICULAR PURPOSE.

RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN

WRITING, MILLER PRODUCTS ARE INTENDED FOR

ULTIMATE PURCHASE BY COMMERCIALJINDIJSTRIAL

USERS AND FOR OPERATION BY PERSONS TRAINED

AND EXPERIENCED IN THE USE AND MAINTENANCE OF

WELDING EQUIPMENT

CONSUMER USE.

AND NOT FOR

MILLERS

CONSUMERS

WARRANTIES DO

OR

NOT

EXTEND TO.

AND NO RESELLER IS

EXTEND MILLERS

AUTHORIZED TO

WARRANTIES TO.

ANY CONSUMER.

i_U

RECEIVING-HANDLING

Before unpacking equipment, check carton for any damage that may have occurred during shipment.

File any claims for loss or damage with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers Transportation Department.

When requesting information about this equipment, always provide Model Designation and Serial or

Style Number.

Use the following spaces to record Model Designation and Serial or

Style Number of your unit. The information is located on the rating label or nameplate.

Model

__________

Serial or

Style

No.

Date of Purchase

91

QM.152 308 392

RECEIVING-HANDLING

Before unpacking equipment, check carton for any damUse the following spaces to record the Model

Designa

age that may have claims for loss or occurred damage

during

shipment.

File any tion and Serial or

Style

Number of your unit. The infor with the

delivering

carrier.

mation is located on the rating label or the nameplate.

Assistance for filing or settling claims may be obtained from the distributor and/or the equipment manufacturModel

________________________________ ers

Transportation Department.

Serial or

Style

No.

_____________________

When requesting information about this equipment, al ways provide

Number.

the Model

Description

and Serial or

Style

Date of Purchase

______________________

TABLE OF CONTENTS

Section No

SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1.

1-2.

General Information And

Safety

Safety

Alert Symbol And

Signal

Words

SECTION 2 SPECIFICATIONS

2-1.

Description

SECTION 3 INSTALLATION

3-1.

3-2.

3-3.

3-4.

3-5.

3-6.

3-7.

3-8.

3-9.

Site Selection

Equipment Installation

Gas/Current

Sensing

Control Interconnections

Voltage

Sensing

Connections

Robot Interface

Welding

Power Source Connections

Robot Interface Robot Control Unit Connections

Arc Failure Light Terminal Strip Connections

Welding

Wire Installation

Setting

DIP Switches On DVC Board PCi

SECTION 4-OPERATOR CONTROLS

4-1.

4-2.

4-3.

4-4.

4-5.

4-6.

4-7.

4-8.

4-9.

4-10.

Power Switch

Jog Push Buttons

Purge

Push Button

Voltmeter

Wire Speed Meter

Inductance Meter

Indicator Lights

Standard/Optima Switch

Inductance Control

Preflow, Postflow, And Burnback Time Presets

SECTION 5 SEQUENCE OF OPERATION

5-1.

5-2.

Input

Signals

From Robot Control Unit

Output Signals

From Robot Interface

Page

No.

1

1

1

7

7

7

7

7

8

7

7

7

8

8

8

2

2

3

3

4

5

6

4

4

Section No.

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1.

6-2.

6-3.

6-4.

6-5.

6-6.

6-7.

Routine Maintenance

Overload Protection

Reinstallation Of Hub Assembly

Display

Board PC4 Meter Check

Circuit Board Handling Precautions

Troubleshooting

Use Of Indicator

Lights

For

Troubleshooting

SECTION 7ELECTRICAL DIAGRAMS

Diagram

7-1.

Circuit

Diagram

For Robot Interface

Diagram 7-2.

Circuit Diagram For Gas/Current

Sensing

Control

SECTION 8 PARTS LIST

LIST OF CHARTS AND TABLES

Table 2-1.

Specifications

Table 6-1.

Troubleshooting

Page

No.

10

10

9

9

8

8

12

13

14

15

1

11

SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1.

GENERAL INFORMATION AND SAFETY 1-2.

SAFETY ALERT SYMBOL AND SIGNAL

WORDS

A.

General

Information presented in this manual and on various Iabels, 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 use of this equipment.

The following safety alert symbol and signal words are used throughout this manual to call attention to and den

tify

different levels of hazard and special instructions.

J\~

This

safety

tion to the alert symbol is used with the

safety

statements.

signal words WARNING and CAUTION to call atten

B.

Safety

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 installed, operated, and maintained only

by

qualified persons in 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 Welding Power Source in the welding power source

Owners

Manual.

CAUTION statements practices which must be followed to avoid minor personal injury or

IMPORTANT statements

identify

procedures or damage to this equipment.

identify

special instructions necessary for the most efficient operation of this equip ment.

SECTION 2SPECIFICATIONS

Component

Robot Interface

Height

22-1/2 in.

(572 mm)

Gas/Current

Sensing

Control

Spool Support

Assembly+

4-1/2 in.

(108 mm)

13-3/4 in.

(349 mm)

Add 2-1/4 in.

(57 mm) for brake resistor.

Add 7/8 in.

(22 mm) for front panel knob.

Table 2-1.

Specifications

Dimensions

Width

16-1/2in.

(419 mm)

5-1/2 in.

(140 mm)

8-3/4 in.

(222 mm)

Weight

Depth

6~1/4in.*

(159 mm)

Net

38 lbs.

(17

kg)

Ship

10-1/2 in.

(267 mm)

5 lbs.

(2.3

kg)

8-1/2 in.

(216 mm)

6 lbs.

(2.7

kg)

+Spool Support without optional wire reel.

Total 61 lbs.

(27.7 kg)

2-1.

DESCRIPTION

The robot interface control is

designed

to interface with a

Hitachi/GE robot and a

Maxtron 450 (NSPR 9863), Arc

Pak 350, source.

Deltaweld, or

Maxtron 300

This unit provides welding power digital display of weld volts,wire feed speed, and peak tance.

amperage or induc

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-152 308 Page 1

SECTION 3INSTALLATION

3-1.

SITE SELECTION

Select an installation site which provides the

following:

1.

Correct input power supply (see unit rating label)

2.

3.

4.

5.

Shielding

gas supply (if applicable)

Water

supply (if

applicable)

Adequate ventilation and fresh air supply

No flammables

6.

7.

8.

9.

A clean and dry area

Proper temperature that avoids extremes of heat or cold

Proper airflow around unit

Adequate space to open and remove cover and wrapper for installation, maintenance, and repair functions.

Mounting holes provide the capability to install and se cure the system components in a permanent location.

Table 2-1 gives overall dimensions.

3-2.

EQUIPMENT INSTALLATION

A.

Supplied Equipment

The

following

equipment is supplied as standard and re quires installation or assembly:

1.

Weld Control with Gas/Current

Sensing

Control

Cord and Motor Cord

2.

3.

4.

5.

6.

7.

Gas/Current Sensing Control

Hub and Spindle

Assembly

Spindle Support

10 ft.

(3m) Weld

ControlWelding

Power Source

Interconnecting Cords

10 ft.

(3 m) Gas Hose

Voltage

Sensing

Cord

B.

Equipment Location

When

deciding

on

equipment

location, consider the fol lowing:

1.

The equipment must be mounted to a structure capable of supporting the ment.

weight

of the equip

2.

The lead

lengths

of the cords supplied with the equipment will limit the area in which the equip ment can be located.

Some cords can be ex tended by using optional extension cords (check with

welding

equipment distributor).

OM-152 308 Page 2

3.

4.

5.

Welding wire must be routed so that it does not contact the weld control or any equipment.

other grounded

C.

Equipment

Installation

Obtain appropriate mounting brackets or adapter plates as ture necessary and for equipment mounting hardware.

installation.

Secure

Prepare weld struc control,

Gas/Current

Sensing

control, and all other equipment onto structures in the

welding

area.

0.

Hub Installation

(Figure

3-1)

The hub assembly is supplied with the robot interface.

Remove the hub

assembly

from the

shipping

carton, and install it as follows:

1.

2.

The

interconnecting

cords must be routed so that they are not caught, pinched, or strained during welding operations.

One weld the output cable must be routed

Gas/Current

Sensing

control.

through

Remove hex nut from end of hub support shaft.

Align

keyway and insert hub support shaft through selected hole in hub support.

Hole selec tion in hub support depends on wire spool size.

Be sure the brake washers are properly seated in the hub.

3.

4.

Reinstall hex nut onto support shaft.

nut until a

Tighten

hex

slight drag

is fe!t while turning hub.

Install welding wire according to Section 3-8.

Hub Support

Shaft

Hub Assemby

Figure 3-1.

Hub

Brake Washer

Hex Nut

Hub Support

Assembly

Installation

~A26 870

3-3.

a

GAS/CURRENT SENSING CONTROL INTER

CONNECTIONS

(Figure

3-2)

WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Shut down unit, welding power source, robot, and disconnect input power and employing lockout/tagging procedures before making interconnections.

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.

00000

)0000

00000

)0000C

00000

)0000

00000

)0000~

00000

)0000

00000

)0000~

0

0

0~0 0

~b 0

00000

__________

B.

Weld Cable Connections

For Electrode Positive/Reverse

Polarity,

route cable from welding power source

POSITIVE weld output ter minalto the

gas/current

sensing control, through the cur rent sensing reed relay, to the wire drive assembly, and connect cable to weld cable terminal (see Motor/Drive

Assembly Owners Manual for location).

C.

Gas Connections

Connect hose from gas regulator/flowmeter (customer supplied) at gas source to IN

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 at the source.

D.

Motor Connection

Align keyways, insert 14-pin plug from motor cord into matching receptacle RC7 on gas/current sensing con trol, and rotate threaded collar

fully

clockwise.

Gas/current Sensing

Control Receptacle RC9

14-Pin Receptacle RCI3

Strain Relief

Weld Cable

Location

Lug

S 04 0 I

17. Pin Receptacle RCI6

Figure 3-3.

Voltage

Sensing

At Wire Drive

Connections

Assembly

Voltage Sensing

Receptacle RC12

A.

Robot Control-

Robot Interface

Receptacle RC12

Figure 3-2.

Right

Side View

Robot Interface

Connections

Gas/Current

Sensing

Control

2.

Align keyways, insert 14-pin Amp plug into matching receptacle RC9 on robot interface, and rotate threaded collar fully clockwise.

Align

keyways, insert 16-pin Amp

plug

into matching receptacle RC16 on gas/current sens

ing

control, and rotate threaded collar

fully

clock wise.

3-4.

VOLTAGE SENSING CONNECTIONS (Figure

3-3)

1.

Align keyway, insert 4-socket plug into matching receptacle RC12 on robot interface, and rotate threaded collar

fully

clockwise.

2.

3.

Connect lead with ring terminal to wire drive as

sembly, along

with the weld cable from the weld ing power source, as shown in Figure 3-3.

Connect lead with clamp to the workpiece.

OM-152 308 Page 3

3-5.

ROBOT INTERFACE WELDING

SOURCE CONNECTIONS

(Figures

POWER

3-2 And

3-3) 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 lockout/tagging procedures before making interconnections.

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.

There are three cords supplied for interconnection be tween the robot interface and welding power source.

Ex amine cords and select proper cord for the connection.

A.

REMOTE 14 Connections

1.

Align keyway,

insert 14-socket plug into

matching

receptacle RC13 on robot interface, and rotate threaded collar fully clockwise.

B.

2.

Align keyway, insert 14-pin plug into matching re ceptacle on welding power source, and rotate threaded collar fully clockwise.

REMOTE 17 Connections

1.

2.

Align

keyway, insert 17-socket plug into matching receptacle RC16 on robot interface, and rotate threaded collar

fully

clockwise.

Align

keyway, insert 17-pin

plug

into matching re ceptacle on welding power source, and rotate thread collar

fully

clockwise.

When used with the power source

Maxtron

OUTPUT

450, place the welding

(CONTACTOR) switch in the

17/14 position, the ARC/INDUCTANCE AND CC/CV switch in the 17 position, the A/V switch in the 14 posi tion, and the Mode switch in the GMAW position.

If another welding power source is used and is equipped with a

REMOTE 14/17 selector switch, place the switch in the REMOTE 14 position.

Make connections to both

REMOTE 14 and REMOTE

17 receptacles.

3-6.

ROBOT INTERFACE

-

ROBOT CONTROL

UNIT CONNECTIONS

(Figure

3-2) 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 lockout/tagging

procedures before making interconnections.

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.

OM-152 308 Page 4

1.

2.

3.

4.

Obtain a proper cord and 24-socket

Amphenol plug (not supplied).

Connect conductors at one end of cord to appro priate sockets in

plug.

Align keyway, insert 24-socket plug into

matching

receptacle on robot interface, and rotate threaded collar fully clockwise.

Route and connect conductors at remaining end of cord to the robot control unit.

The input and output

RC17 by means of

signals

at the pins of receptacle the robot interface control circuitry are as follows:

Pin A:

Pin B:

Pin C:

Pin D:

Pin E:

Pin F:

Pin G:

Pin H:

Pin J:

Pin K:

Pin L:

Digital common for Pins B, C, 0, E, F, and K.

Weld

Standby

signal; contact closure with re spect to Pin A.

Current Detect

signal

contact closure with re spect to Pin A.

Arc Failure;

normally-open

contact.

Wire Stuck spect to

signal;

contact closure with re

Pin A.

Torch Contact; normally-open contact.

Cooling

Water

Shortage;

terminal strip con nection provided for customer use.

Low Gas; terminal strip connection provided for customer use.

Weld Wire

Shortage;

terminal strip connection provided for customer use.

Torch Contact; normally-closed contact.

Circuit Common.

Pin M:

Pin N:

Pin P:

Pin 0:

Pin R:

Pin S:

Pin T:

Pin U:

Pin V:

Arc On

signal.

Jog

FWD

signal.

Jog

REV, signal.

Wire Stick Check

signal.

Arc Failure normally-closed contact.

Terminal strip connection.

Terminal strip connection.

Terminal strip connection.

Wire feed positive signal.

Common for Pins V and X.

Pin W:

Pin X:

Pin Y:

Arc voltage positive signal.

Arc Failure normally-closed contact.

IMPORTANT: The remaining sockets in the receptacle are not used.

3-7.

ARC FAILURE LIGHT TERMINAL STRIP

CONNECTIONS

(Figure

3-4)

There are two terminal strips inside the robot interface for control connections. Loosen screws on strain relief on unit right side panel if applicable, open front panel ac

cess door, and locate appropriate terminal strip for con nections.

Tighten

screws on strain relief if necessary, and close and secure front panel access door when pro cedure is finished.

The ARC FAILURE el is turned on and light on the robot interface front pan off by a signal from the robot Control unit.

Obtain proper length of 18 gauge/2-conductor cord for this connection, and proceed as follows:

Robot Control Unit Robot Interface

If So Equipped

Weld Alarm Terminal

Common Terminal

\

If So

\c~J_2T

Equipped

+24VDC

4~ WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

______

Shut down unit,

welding

power source, and robot, and disconnect input power employing

lockouVtagging

procedures before making interconnections.

Lockoutltagging

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.

For robot control units when 24 vdc is used (Fig ure

3-4): a.

Route cord through strain relief on right side panel of robot interface, and make proper con nections to 2TE and 2TF.

b.

Route and connect remaining end of cord to weld alarm terminal and ground connection at the robot control unit.

c.

Connect +24 vdc to common relay contact ter minal.

2.

For robot control units when 115 or

24 vac, or

24 vdc is used (Figure 3-4): a.

Route cord

through

strain relief on

right

side panel of robot interface, and make proper con nections to 2TE and 2TF.

b.

Obtain a

115 or

24 vac, or

24 vdc isolation relay

CR1, and install into robot control.

c.

Route and connect

remaining

end of cord to one side of the normally-open robot control relay contact and ground.

d.

Connect +24 vdc to remaining side of normallyopen robot control relay contact.

e.

Connect a lead from one side of robot control coil to weld alarm terminal.

f.

Connect proper

voltage

source

(115

vac,

24 vac, or

24 vdc) between common terminal and remaining side of robot control relay coil.

~

2TF

Arc Failure

Indicator Light

Common Terminal

If So Equipped

Robot Control Unit

Weld Alarm Terminal

If So Equipped

I

To Voltaae

(1I5VAc.

Source

241/AC,

24VDC)

IsolatIon Relay CR1

<0-0-0

Robot Control Robot Interface

24V0C

~0-1

CR1

Io--

2TE

2TF o.J144p-~

Arc Failure

Indicator Light

Figure 3-4.

Arc Failure Light Connections

S 0292

3-8.

WELDING WIRE INSTALLATION (Figure 3-5)

A.

Installation Of

Spool-Type

Wire

1.

2.

Remove retaining

ring.

Slide spool of wire onto hub so that wire feeds off bottom of spool.

Retaining Ring

Spanner

Nut

Wire Reel

SC-I 27 308

Figure

3-5.

Optional

Wire Reel And

Reel-Type

Wire

Installation

OM-152 308 Page 5

3.

Rotate hub.

spool until hole in spool aligns

Slide with pin in spool onto hub until it seats against back

flange

of the hub.

B.

4.

1.

Reinstall retaining ring onto hub.

Installation Of

Type Wire

Optional

Wire Reel And Reel-

Remove retaining ring and, if applicable, wire reel assembly from hub.

2.

3.

4.

Lay wire reel assembly flat on a table or floor.

Remove spanner nut from wire reel assembly.

Remove wire retainer, and install wire onto wire reel. Be sure that wire feeds off bottom of reel.

5.

Reinstall wire retainer and spanner nut onto wire reel.

6.

Slide wire reel

assembly

onto hub, and rotate as sembly until hub guide pin is seated in reel.

7.

C.

Reinstall retaining ring onto hub.

Adjustment Of Hub Tension

(Figure

3.1)

Check the hub tension by slowly rotating the wire spool or reel. The wire should unwind should be sufficient to freely, but hub tension 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 port shaft

accordingly.

3-9.

SETTING DIP SWITCHES ON DVC BOARD

PCi

(Figure

3-6)

DIP switches Si And S2 on

DVC board PCi allow set

ting

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

Maxtron 450 to another welding power source, proceed as follows:

f~

WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

_____

2.

3.

4.

Shut down welding power source, and robot, and disconnect input power employing

lockout/tagging procedures

before setting

DIP switches

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.

ELECTROSTATIC STATIC DISCHARGE

(ESD)

can

damage

circuit boards.

Put on

FORE

properly

grounded wrist strap BE

handling

circuit boards.

Perform work only at a static-safe work area.

Open Computer Interface front panel access door.

Locate DVC board PCi on rear panel inside the interface.

Set position of DIP switches Si and S2 according to label inside interface and

Figure

3-6 for appro priate

welding

power source.

Close and secure door.

CAUTION: INCORRECT DVC BOARD DIP

SWITCH POSITION can cause equipment malfunction.

DVC DIP switch is with Maxtron 450

factory

set for operation welding power source.

See

Figure

3-6 for DVC DIP switch

setting

when using another welding power source.

DVC SWITCH SETTINGS

S2 Si

1 2 1 2 34

ON

ON

5

ON DELTAWELD 300

DELTAWELD 451 0

DELTAWELD 651

MAXTRON 300, 400

MAXTRON 450

XMT 200/300

ON

ON

0

ON ARC PAK35O

SHOPMASTER 300

DIMENSION 400 ON

ON

ON ON

ON

ON

ON

ON

ON

ON

ON

ON

ON ON

ON

ON

ON

O On For

Optional

Soft Start. Turn Off Si -3.

A

On For

Optional

Hot Start.

S-ISO 864-A

Figure 3-6.

DVC DIP Switch

Setting

Label

OM-152 308 Page 6

SECTION 4

OPERATOR CONTROLS

4-1.

POWER SWITCH (Figure 4-1)

Placing the POWER switch in the ON position energizes the robot interface. The interface must be on for the ro bot to weld.

Placing the POWER switch in the OFF posi tion shuts down the interface.

4-2.

JOG PUSH BUTTONS

(Figure

4-1)

The JOG FWD and JOG REV push buttons are momen tary-contact switches.

Pushing

either JOG button ener gizes the wire feed motor without

energizing

the welding power source contactor.

4-3.

PURGE PUSH BUTTON (Figure 4-1)

The PURGE push button is a momentary-contact switch.

This switch purges the energizes the gas solenoid and shielding gas line of the gun.

The PURGE push button allows the flow meter to be adjusted without energizing the welding circuit.

4-4.

VOLTMETER

(Figure

4-1)

The voltmeter displays weld voltage to the nearest tenth of a volt while welding and preset voltage while idling.

4-5.

WIRE SPEED METER (Figure 4-1)

The wire speed meter displays preset wire feed speed to the nearest inch per minute while welding and idling.

Ac tual and preset wire feed speed are the same due to the wire feed speed feedback circuit.

4-6.

INDUCTANCE METER

(Figure

4-1)

Inductance is power source

displayed

in percentage when welding is in CV (GMAW) mode.

4-7.

INDICATOR LIGHTS

(Figure

4-1)

There are five indicator lights on the interface. These are visual indications of various process functions.

The GAS

light

turns on when the gas valve is

energized

to indicate

shielding

gas flow.

The CONTACTOR

light

turns on when the

welding

pow er source contactor is energized to indicate that weld output is available.

The WIRE FEED

light

turns on when the wire drive motor is energized to indicate that wire is

feeding.

The CURRENT light turns on when the current detect relay is energized to indicate that an arc is established.

The ARC FAILURE there is an arc light turns on only when properly connected according to instructions in Section 3-7, and outage while welding.

4-8.

STANDARD/OPTIMA SWITCH

Place this switch in the OPTIMA position when the weld ing power source

Optima circuitry is used for pulsed

welding.

(When

using

Optima circuitry, place inductance controls to minimum.) Place the switch in the STAN

DARD position for non-pulsed welding.

Contactor

Indicator Light

Gas

Indicator Light

Voltmeter

/

\ e

I I

_

Wire Speed

1PM Meter Inductance Meter

\

_e\

__ __

Fuse

(See

Se~tion

6-2)

0/

Circuit Breaker

(See Section

6-2)

/

/

Power

Switch

/

Purge Push

Button Switch

/

Jog REV.

Push

Button Switch Wire Feed

Indicator Light

Current

Indicator Light

Arc Failure

Indicator Light

Standard/Optima

Switch Location

Figure

4-1.

Front Panel Controls

Jog FWD. Push

Button Switch

Ref SB- 119 645-A

OM-152 308 Page 7

4-9.

INDUCTANCE CONTROL

This unit is shipped for use with a

two-analog

channel robot. This means that inductance can be set at the inter face using potentiometer R4. R4 is located beneath the snap-in blank on the lower left corner of the interface front door.

4-10.

PREFLOW, POSTFLOW, AND BURNBACK

TIME PRESETS

On the left side of the interface control are three snap-in blanks. Beneath these snap-in blanks are screwdriver adjustable potentiometers.

The top potentiometer sets

preflow

time from 0 to 6 seconds. The middle potentiom eter sets postflow time from 0 to 6 seconds. The bottom potentiometer sets burnback time from approximately 5 to 250 milliseconds.

SECTION 5 SEQUENCE OF OPERATION

5-1.

INPUT SIGNALS FROM ROBOT CONTROL

UNIT

The robot interface receives input signals for contactor control, gas control, jog, welding volts, and wire speed.

5-2.

OUTPUT SIGNALS FROM ROBOT INTER-

FACE

The robot interface sends output signals control unit for current sense, wire to stuck, the and robot weld standby.

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 and type of maintenance.

At minimum, ment every three months as follows:

frequency

inspect equip 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

lockout/tagging

procedures before inspect

ing, maintaining,

or

servicing.

Lockoutltagging 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 can cause serious injury.

Keep away from

moving

parts.

HOT SURFACES can cause severe burns.

Allow

cooling

period before

servicing.

Maintenance to be performed only by qualified persons.

1.

Repair or replace, as required, all hose and cable; give particular attention to frayed and cracked in sulation and areas where it enters equipment.

2.

Remove grease and moisture from electrical grime from components; parts and cable.

OM.152 308 Page 8

6-2.

OVERLOAD PROTECTION 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

lockout/tagging

procedures before ins pect ing, 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.

INCORRECT FUSE can damage unit.

Use only replacement fuse of same size, type, and rating (see Parts List).

A.

Wire Drive Motor Circuit Breaker CB1 (Figure

4-1) a WARNING: Read and follow tion at safety informa beginning of Section 6-2 before pro

ceeding.

Circuit breaker CB1 protects the wire drive motor from overload

.

If CB1 opens, the wire feed motor would stop.

Should a motor overload occur and CB1 open, proceed as follows:

1.

Check for jammed wire or

clogged

gun liner, and correct problem.

If wire jams often, replace gun liner.

2.

3.

If motor overload occurs often, repair or replace wire drive motor.

Check for

binding

drive gear or misaligned drive rolls, and correct problem.

4.

Reset circuit breaker

by

depressing the button. A

cooling

period may be necessary before the cir cuit breaker can be reset.

5.

Resume operation.

B.

Main Fuse Fl (Figure 4-1) a WARNING: Read and follow tion at

safety

informa 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 interface shuts down. If the fuse opens, correct the prob lem and replace Fl as follows:

1.

Depress and rotate fuse holder cover counter clockwise.

2.

3.

4.

5.

Pull out fuse with cover when fuse holder cover is free.

Insert new fuse into fuse holder cover.

Install fuse with fuse holder cover back into unit.

Depress and rotate fuse holder cover clockwise until cover is secure.

6-3.

REINSTALLATION OF HUB ASSEMBLY

(Fig

ure

6-1)

If it becomes necessary to replace part or all of the hub assembly, reinstall the new hub assembly as follows:

1.

Remove hub disassemble assembly from hub support, and discarding worn or broken parts.

2.

a.

b.

c.

Slide the

following

items onto the hub support shaft in order

given.

Spring

Keyed Washer

Fiber Washer

Wlre Retainer d.

Brake Washer

Hub e.

f.

Brake Washer

3.

4.

5.

g.

Fiber Washer

Align keyway, and insert hub support shaft through selected hole in hub support.

Install hex nut onto hub support shaft.

Tighten

hex nut until a slight drag is felt while

turning

hub.

Install welding wire according to

Section 3-8.

6-4.

DISPLAY BOARD PC4 METER CHECK (Fig ure

6-2)

Check points are provided on the display board PC4 for checking power supply and input command for the me ters.

ELECTRIC SHOCK can kill.

a WARNING:

Do not touch live electrical parts.

Be sure that personnel

performing

testing procedures are familiar with and follow stan dard safety practices.

Shut down unit before

making

or

changing

meter or test equipment lead connections.

ELECTROSTATIC DISCHARGE damage Circuit boards.

(ESD)

can

Put on a

BEFORE properly grounded wrist strap

handling

circuit boards.

Transport all static-sensitive components in proper

static-shielding

carriers and pack ages.

Perform work only at a static-safe work area.

1.

2.

3.

Open

robot interface access door.

Locate display board PC4.

Check voltage

according

to

Figure

6-2.

Retaining Ring

Wlre Reel

Spanner

Nut

OPTIONAL

Spring

Hub

Support

Shaft

Fiber Washer

Keyed Washer

Brake Washer

Hub

Fiber Washer

Hub

Support

Ref SC.127~28

Figure

6-1.

Hub And Reel Assemblies

OM-1 52 308 Page 9

REAR VIEW OF DISPLAY BOARD PC4

Input Command For

Wire Speed 1PM Meter

O.8V

1PM

Input Command

For

Volts Meter ...O.5V

=

50V

4.

5.

6-5.

Input

Command For

AmmeterO.1V= bOA

If a meter power correct supply and command voltage is and the meter is not working, replace the meter (see Section 6-5 and contact nearest Fac tory

Authorized Service Station).

If the power rect, supply or command voltage is incor replace display board PC4 (see Section 6-5 and contact nearest Factory Authorized Service

Station).

Power Supply For

Volts Meter And Ammeter

0

-

5VDC

Ret. SO-117 838-8

Figure 6-2.

Display Board Meter Checks

EXCESSIVE PRESSURE can break circuit board.

Use only minimal pressure and gentle move ment when disconnecting or

connecting

board plugs and

removing

or installing board.

AA

CIRCUIT BOARD HANDLING PRECAUTIONS

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 before inspect ing, maintaining, or ser..icing.

Lockoutitagging

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 CAUTION: ELECTROSTATIC DISCHARGE

(ESD)

can damage circuit boards.

Put on

BEFORE properly

grounded

wrist strap

handling

circuit boards.

Transport circuit boards in proper staticshielding carriers or

packages.

Perform work only at a static-safe work area.

INCORRECT INSTALLATION or plugs can damage circuit board.

misaligned

Be sure that plugs are properly installed and aligned.

6-6.

TROUBLESHOOTING

J~ 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 before inspecting 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.

MOVING PARTS can cause serious

injury.

Keep away from

moving

parts.

HOT SURFACES can cause severe burns.

Allow cooling period before servicing.

Troubleshooting

to be performed only by

qualified

persons.

It is assumed that the unit was

properly

installed accord ing 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

welding

process.

The

following

table is

designed

to

diagnose

and provide remedies for some of the troubles that this robot interface. Use this table in may develop in conjunction with the circuit diagram while dures.

If the

performing

troubleshooting trouble is not remedied after proce performing these ized procedures, contact the nearest

Factory

Author

Service Station.

In all cases of equipment malfunc tion,

strictly

follow the manufacturers procedures and instructions.

OM-152 308 Page 10

P.

Table 6-1.

Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No arc voltage control.

Output control connections.

Check and secure connections

3-4).

(see Section

Wire speed (1PM) meter goes to zero.

Unit does not operate.

No meter display.

No wire feed.

Wire feeds at maximum only.

Voltage Board PCI not working.

Replace PCi (see Section 6-5 and contact near est

Factory

Authorized Service Station).

Incorrect robot command voltage.

Incorrect robot command voltage.

Check robot command voltage at Isolation Board

P05. Command voltage should be 0-10 vdc be tween pins X (common) andY at RC17.

Check robot command

PC2.

voltage at Motor Board

Signal

should be 0-10 vdc between pins K and B (common) at RC5.

Motor Board PC2 not working.

Replace PC2 (see Section 6-5 and contact near est

Factory

Authorized Service Station).

Fuse Fl Open.

Circuit breaker CB1 tripped.

Check Fl and replace if necessary (see Section

6-2).

Correct overload problem before continu ing operation.

Check CB1 and reset if necessary (see Section

6-2).

Correct overload problem before continu ing operation.

Meter not working.

Display

Board PC4 not

working.

Use check points to determine if power is avail able (see Section 6-4).

If check points do not test okay, replace P04 (see Section 6-5 and contact nearest

Factory

Authorized Service Station).

Robot signal.

Use check points on Display Board P04 to deter mine if power is available to meter (see Section

6-4).

If check points are okay, replace meter (see

Section 6-5 and contact nearest

Factory

Autho rized Service

Station).

Check

P02.

input signal from robot to Motor Board

Signal

should be 0-10 vdc between pins K and B (common) on

RC5.

Relay CR1 not working.

Replace CR1.

Motor Board P02 not working.

Replace PC2 (see Section 6-5 and contact near est Factory Authorized Service Station).

Tach board at wire drive motor not working.

Replace

Owners tach board

Manual).

(see motor/drive assembly

OM-152 308 Page 11

6-7.

USE OF INDICATOR LIGHTS FOR TROUBLE

SHOOTING

On Gas Indicator

Light

Off

Gas flows:

System

normal (on.)

Gas does not flow

Check gas valve operation.

Gas flows:

Check gas valve and gas line for operation leaks.

Check interface board PC3.

On

Contactor closed:

System normal (on).

Contactor Indicator Light~

Contactor open:

Check cords.

interconnecting

Check interface board PC3.

Ir

Contactor closed:

Check display board PC4.

Gas does not flow

System normal (off).

~ Off

Contactor open:

System

normal (off).

£

On

Wire feeds:

System

normal (on).

Wire Feed Indicator Light

Wire does not feed:

Check circuit breaker CB1

Check relay CR1.

Check interface board PC3.

~1~

Wire feeds:

Check input signal from robot to motor board PC2.

Signal

should be 0-10 vdc between pins K and B

(common) at RC5.

Check motor board PC2

On Current Indicator

Light

Arc started:

System

normal (on).

No arc:

Replace reed relay.

Arc started:

Replace reed relay.

Off

Wire does not feed:

System

normal (off).

Off

No arc:

System

normal (off).

On Arc Failure Indicator Light

No arc:

Arc started: No arc:

Check weld parameters.

Check

signal

from robot.

Signal

should be 24 vdc between terminals 2TE and 2TF.

Normal

during idling.

Check

display

board PC4.

QM-152 308 Page 12

Off

Arc started:

Normal while welding.

pc~6

C

U) m C) 0 z -J m I m C) -I C) I D C) U)

53

SC-i

281-A

No.

Diagram

Circuit

Robot

For

Diagram

Circuit

7-1.

Diagram

Interface

0000

£

£

C o dl

/0/

,~

/5

CO

0

0 ~

~.t

CO

0

0 as

~ iT

OM-152 308 Page 14

P07

I>

3>~

8>

55

56

12

13

1/

PC 6

>12

>~

6.QN

>~

>6

3

GB

A

5T 0

B C D E

0 0 0 0

52 /2 69 68

8L/(

1

PEED

T

A~HT

52

0/2>2

_

Circuit Diagram No.

SA-138 519

Diagram

7-2.

Circuit Diagram For Gas/Current

Sensing

Control

SECTION

8 PARTS LIST

Dia.

Mkgs.

Cl

.

C3,4

CB1

CR1

CR2

CR3

CR4

.

CR5,6

D1-3

Fl

PB1-3

PCi

PC2

PC3

PC4

PC5

.

PLG9

PLG16

PLG12

PLG14,63

PLG2O

PLG24

PLG25

PLG29,30

PLG61

PLG62

Ri

Part

No.

Description

Main Assembly

031692

006 426

028291

011 991

109006

052 964

095 033

093 558

095521

0499700008841

079 844

027811

048 029

026202

*012655

046 432

021 105

148320

073 756

110391

071 642

083 147

0943620007459

149339

089 032

1185500008052

375

109041

047636

079 535

079 739

096813

048598

079 534

0499890007459

073686

039 828

600 848

604109

601 226

601 228

600 750

079748

079747

081 379

081 378

084198

081 378

131 054

113746

135 787

081 378

135788

079 747

135559

079 747

030651

..

..

.

CAPACITOR, elctlt 750uf 200VDC

CLAMP, capacitor 2.000dia

CAPACITOR, cer disc .luf

500VDC

CIRCUIT BREAKER, man reset 1 P 1 .5A 250V

RELAY, end

24VAC DPDT

RELAY, end

24VDC DPDT

RELAY, end

24VAC 4PDT

RELAY, end

12OVAC4PDT

RELAY,encI24VDC4PDT

BRACKET, mtg relay

SPRING, hold down relay

SOCKET, relay 14 pin

CLIP, retaining skt relay

DIODE, rect 1 A 400V SP

FUSE, mintr cer

1OA 250V

HOLDER, fuse mintr .250

x

1.250

panel mtg

SWITCH, PB SPDT

CIRCUIT CARD, voltage control

STAND-OFF, No. 6-32 x

.625

Ig

GUIDE, mtg PC card

CIRCUIT CARD, motor speed control

GROMMET, scr

No.

8/10 panel hole .312sq

.500

CIRCUIT CARD, relay

CIRCUIT CARD, meter

LENS, LED 4341 red

CIRCUIT CARD, isolation/amplifier

STAND-OFF SUPPORT, PC card No. 6 screw

CABLE, interconnecting

HOUSING PLUG &

(consisting

PINS, of)

(consisting of)

TERMINAL, male 1 pin 18-14 wire

CLAMP, cable strain relief sz

17

high

CABLE, pwr shld

1

HOUSING PLUG &

8ga 15/c (order by ft)

SOCKETS, (consisting of)

TERMINAL, female 1 skt 18-14 wire

CABLE, volt

sensing (consisting

of)

PLUG, 4skt97-3106A-14S-2S

CLAMP, cable AN-3057-6

WIRE, lead mot l2ga strd (order by ft)

WIRE, lead i6ga strd (order by ft)

INSULATOR, vinyl clamp univ 25A

CLAMP, univ 25A

TERMINAL, ring tng .500 stud 16-14 wire

HOUSING, term hdr 18 pin

TERMINAL, contact hdr 24-18 wire

HOUSING, term hdr 12 pin

TERMINAL, female lskt 22-18 wire

HOUSING, term hdr 6 pin

TERMINAL, female 1 skt 22-18 wire

HOUSING RECEPTACLE & SOCKETS

(consisting

of)

TERMINAL, female lskt 24-18 wire

HOUSING PLUG & SOCKETS,

(consisting

of)

TERMINAL, female iskt 22-18 wire

HOUSING PLUG & PINS,

(consisting of)

TERMINAL, contact hdr 24-18 wire

HOUSING PLUG & SOCKETS, (consisting of)

TERMINAL, contact hdr 24-18 wire

RESISTOR, WW fxd 25W 10 ohm

:

.

:

Quantity

.2

15

8

2

4

4

4

3

3

7

1

2

.14

.2

l8ft

116

35ft

44ft

I

12

2

2

7

2

18

4

12

1

OM-152 308 Page 15

Dia.

M kgs.

Part

No.

Description

Main Assembly (Continued)

.

.

R2

.

.

.

.

R3

R4

..

RC5

..

RC9

..

..

..

..

.

.

RC12

RC13

RC16

RC17

Sb

..

.

.

S2

SRi

.

.

.

Ti ,3

T2

T4

.

.

..

.

1T,2T

3T

.

605 741

030 941

030 949

010 199

079 683

056 170

010 193

057 084

079 497

603 856

0937270007459

117 374

009 335

047 637

079 534

076 624

094 480

097 867

094 591

011 609

011 770

035 704

035 759

036 135

084 201

038 856

038 772

601 219

010 916

1324810008989

047 838

107 983

1124730008933

+1169690008908

045 852

010 311

134 327

010 855

010 853

073 487

121 594

094 481

116 964

110 015

094482

045 348

047 636

079 535

079 739

073 139

071 892

079 534

048 144

1338640009860

097 868

116 964

120 032

097 866

.

.

..

.

.

.

.

.

.

CLIP, mtg resistor .312 ID core

RESISTOR, WW fxd 100W 5 ohm

HEAT SINK, rect

TUBING, stl .275 ID x

.048 waIl x

1.000

HEAT SINK, resistor

Ig

.

.

.

.

.

.

..

SHIELD, resistor

TUBING, stl .375 OD x

l8ga

waIl x

.250

Ig

BUSHING, snap-in nyl .250 ID x

.375mtg

hole

RESISTOR, WW fxd 25W 2K ohm

POTENTIOMETER, WW sltd sft biT 2W 10K ohm

..

.

.

.

.

.

.

BRACKET, mtg potentiometer

HOUSING, term conn

22posn

STAND-OFF, No. 4-40 x

.625

HOUSING RECEPTACLE &

Ig

SOCKETS,

..

(consisting

of)

.

.

.

..

..

..

..

..

..

..

..

..

..

..

.

TERMINAL, female lskt 18-14 wire

RECEPTACLE, 4 pin MS-3102A-14S-2P

RECEPTACLE, 14 pin MS-3102A-20-27P

RECEPTACLE, 17 pin MS-3102A-20-29P

RECEPTACLE, 24 pin MS-3102A-24-28P

SWITCH, tgl SPDT 15A 125VAC

SWITCH, tgl SPDT 5A 125VAC

RECTIFIER, integ 40A 800V

TRANSFORMER, control mintr 115/36VCT

TRANSFORMER, control 115/24VAC

TRANSFORMER, signal 16VCT .4A

BLOCK, term 20A 14P

BLOCK, term 20A 6P

..

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

..

.

.

.

.

.

.

..

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

LINK, jumper term

CONNECTOR, blk 20A clamp cable .750

CABINET, control

BLANK,

BLANK, snap-in nyl 1 .000mtg

hole snap-in nyl .500mtg

hole

PANEL, mtg components

DOOR, access cabinet

CLIP, component .687d1a

mtg adh back

CLAMP, nyl .750

clamp dia x

.500 wide

LABEL, warning general precautionary

RETAINER, scr

No.

2

FASTENER, scr sltd hd No. 2

NUT, speed No. 2

NAMEPLATE, (order by model and NSPR number)

.

.

CABLE,

interconnecting

(consisting of)

PLUG, 14

.

pin MS-3i06A-20-27P

CLAMP, cable 97-3057-1012

.

.

.

.

.

.

.

..

CABLE, port No.

187/c (order

PLUG, i4skt97-3106A-20-27S

by

ft)

.

.

CABLE,

motor

(consisting

of)

HOUSING PLUG &

.

PINS,

(consisting

of)

TERMINAL, male 1 pin 18-14 wire

CLAMP, cable strain relief sz

17

.

CABLE, port No. 16 6/c (order by ft)

RECEPTACLE w/SOCKETS, (consisting of)

TERMINAL, female 1 skt 18-14 wire

.

.

.

.

TERMINAL, male 1 pin

CABLE, interconnecting

plug keying

(consisting

of)

PLUG, l7skt MS-3106A-20-29S

.

CLAMP, cable 97-3057-1012

.

.

.

.

CABLE, port No. 18 6/c (order

by ft)

PLUG, 17 pin MS-3iO6A-20-29P

.

.

.

OM-152 308 Page 16

Quantity

1

2

1

14

1

1

1

1

1

4

4

1

1

2

.2

.2

.2

.2

.2

loft

14

.2

28ff

14

2

I Oft

1

.2

.5

I

Dia.

Mkgs.

Part

No.

Description

Main

Assembly (Continued)

Quantity

Dl

GSI

RC7

RCI6

REED

5T

056 462

134 834

010 606

056 108

056 851

137 114

026202

109 293

047 637

079 534

090 246

079535

140786

038 839

010 604

602 934

079 573

079 574

109 021

057 358

010 494

115 104

.

.

.

.

.

.

.

.

.

HOSE, gas (consisting of)

HOSE, SAE .187 ID x

.410

OD (order

FITTING, hose brs nut .625-I8RH

.

by ft)

.

.

.

.

.

.

.

FITTING, hose brs ferrule .425 ID x

.718

Ig

.

.

FITTING, hose brs barbed

CONTROL BOX, nipple 3/l6tbg

gas/current

sensor (consisting of)

DIODE,rectlA400VSP

....

....

....

....

....

VALVE, 24VDC 2 way 1/4 IPS port 1/8 orf

HOUSING RECEPTACLE & SOCKETS, (consisting of)

TERMINAL, female lskt 18-14 wire

RECEPTACLE w/PINS,

(consisting of)

TERMINAL, male 1 pin 18-14 wire

SWITCH, reed

BLOCK, term 20A 5P

....

.

.

.

.

.

.

.

.

...

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

....

FITTING, hose brs bushing 1/4NPT x

.625-18RH

FITTING, pipe

FITTING, pipe galv coupling .25ONPSC

galv nipple L .25ONPT

x

6.000

Ig

BRACKET, mtg control

CASE SECTION, frontJbottom/rear

BUSHING, snap-in nyl 1.000 ID x

1

BUSHING, snap-in nyl 1.375 ID x

.375mtg

1.75Omtg

hole hole

CONNECTOR, clamp cable .500

WRAPPER +079 682

134 327

072 094

.

.

.

.

.

.

LABEL,

HUB & warning general

SPINDLE,

precautionary

(consisting

of)

058428....

HUB, spool

058 628 WASHER, brake stl

.

.

.

.

010191 WASHER,fbr.656IDx1.5000Dx.l25thk

....

135 205

057 971

010 233

072 292

058 427

092 989

134 464

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

NUT, stl

slflkg

hex reg

.625-11

w/nyl

insert

WASHER, flat stl keyed 1.500dia

x

.l25thk

SPRING, cprsn .970

OD x

.120 wire x

1.250

.

.

.

.

.

SHAFT, spool support

RING, retaining spool

SUPPORT, spindle

(consisting

of)

LABEL,

.

warning general

precautionary

Ig

*Recommended

Spare

Parts.

+When

ordering

a component

originally displaying

a precautionary label, the label should also be ordered.

BE SURE TO PROVIDE MODEL AND NSPR NUMBER WHEN ORDERING REPLACEMENT PARTS.

1 lift

1

1

1

1

1

14

1

16

2

2

2

1

1

1

1

2

1

1

1

1

2

2

1

1

OM-152 308 Page 17

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