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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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