Miller ROBOT INTERFACE NSPR 8945 Owner's Manual

Millerfi
December 1990
FORM: OM-138 426-A
MODEL: Robot Interface
(Per NSPR 8945)
OWNERS
MANUAL
IMPORTANT: Read and understand the entire contents of both this manual
and the power source manual used with this unit, with special emphasis on
the safety material throughout both manuals, before Installing, operating, or
maintaining this equipment. This unit and these instructions are for useonly
by persons trained and experienced In the safe operation of weiding 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 Muir
Mfg. Co.
Grc,~ Ltd., Con~ny
P.O. Box 1079
WI 54912 USA
Tel. 414-734-9821
Appleton,
PRINT~D IN U.S.A.
liE
L
LIMITED WARRANTY
EFFECTIVE: AUGUST 8, 1990
This warranty
supersedes all previous MILLER warranties
LIMITED WARRANTY
Subject to the
and is exclusive with
terms and conditions
hereof, MILLER Electric Mfg. Co., Appleton, Wisconsin
rants
to
its
Distributor/Dealer that all
new
and
war
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 respect to
engines, trade accessories or other items manufactured by
others. Such engines, trade accessories and other items are
sold subject to thewarranties of their respective manufacturers,
if any. All 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
components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding wire
including nozzles and nozzle insulators where failure doas not
result from defect in workmanship or material.
no
other guarantees
or
warranties
expressed or implied.
In the case of MILLERs breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at MILLERs option (1) repair or (2) replacementor, 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 option of repair or replacement will be
FOB., Factory at Appleton, Wisconsin, or FOB. at a MILLER
authorized service facility, therefore, no compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apparent defect or failure, MILLER shall instruct the
claimant on the warranty claim procedures to be followed.
to
MILLER shall be required to honor warranty claims on war
ranted 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.
Arc welders, power
components
2.
Loadbanks
3.
Original main
4.
5.
6.
7.
sources,
robots, and
lyear
power rectifiers
(labor 1 year only)
All welding guns, feeder/guns and torches
All other MILLERMATIC Feeders
Replacement or repair parts, exclusive of labor
Batteries
provided that MILLER is notified in
of the date of such failure.
1 year
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 OR OF FITNESS FOR PARTICULAR PURPOSE,
WITH
RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
3 years
90 days
1 year
60 days
6 months
writing within thirty (30) days
As a matter of general policy only, MILLER may honor claims
submitted by the original user within the foregoing periods.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
WARRANTIES DO NOT
CONSUMER USE. MILLERS
EXTEND TO, AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLERS WARRANTIES TO, ANY CONSUMER.
WRITING,
:I~l
oI~.I3a42eA- 1V9O
RECEIVING-HANDLING
Before unpacking equipment, checkcartonforanydamage that may have occurred during shipment. File any
claims for loss or damage with the delivering carTler.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufacturers
Use the following spaces to record the Model Designa
hon and Serial or Style Number of your unit. The intor
mation is located on the data card or the nameplate.
Model______________________________
Transportation Department.
Serial
When requesting information about this equipment, al
ways provide the Model Description and Serial or Style
Number.
or
Style No.___________________
Date of Purchase
____________________
TABLE OF CONTENTS
Section No.
Page No.
SECTION 1- SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1.
General Information And
1-2.
Safety
Alert
Symbol
And
Safety
Signal Words
I
1
SECTION 2- SPECIFICATIONS
2-1.
Description
1
SECTiON 3-INSTALLATION
3-1.
Site Selection
2
3-2.
Equipment Installation
Gas/Current Sensing Control Interconnections
Voltage Sensing Connections
Robot Interface
Welding Power Source Connections
2
3-3.
3-4.
3-5.
3-6.
Robot Interface
3-7.
Arc Failure
3-8.
Welding
Robot Control Unit Connections
Light Terminal Strip Connections
Wire Installation
3
3
4
4
5
5
SECTION 4-OPERATOR CONTROLS
4-1.
Power Switch
4-2.
Jog
6
6
Push Buttons
4-3.
Purge Push Button
6
4-4.
Voltmeter
6
4-5.
Wire
7
4-7.
Speed Meter
Peak Amps/Inductance
Indicator Ughts
4-8.
Bumback Control
4-6.
SECTION 5SEQUENCE
5-1.
5-2.
Meter
7
7
7
OF OPERATION
Input Signals From Robot Control Unit
Output Signals From Robot Interface
7
7
Section No.
Page
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
Routine Maintenance
6-2.
Overload Protection
6-3.
Reinstallation Of Hub
7
8
Assembly
8
Board PC4 Meter Check
6-4.
Display
6-5.
Circuit Board
8
Precautions
Handling
9
SECTION 7- ELECTRICAL DIAGRAMS
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
SECTION 8
Figure
Figure
Figure
Figure
Figure
7-1. Circuit
7-2. Circuit
7-3. Circuit
7-4. Circuit
7-5. Circuit
7-6. Circuit
7-7. Circuit
7-8. Circuit
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
For Robot Interface
For
Voltage Control Board PCi
10
11
For Motor Control Board PC2
12
For Interface Board PC3
14
For Meter
14
Display
Board PC4
For Interface Board PC5
15
For Wire Touch Board PC6
15
For Gas/Current Control
16
PARTS LIST
8-1. Circuit Card,
Voltage Control PCi
Speed Digital PC2
22
8-2. Circuit Card, Motor
24
8-3. Circuit Card, Meter PC4
26
8-4. Circuit
27
Card, Isolation/Amplifier PC5
8-5. Circuit Card, Wire Touch PC6
28
No.
SECTION 1
-
SAFETY PRECAUTIONS AND SIGNAL WORDS
SAFETY
WORDS
1-2.
GENERAL INFORMATION AND SAFETY
1-1.
ALERT
SYMBOL
AND
SIGNAL
General
A.
The
Information
presented
following safety alert symbol and signal words are
used throughout this manual to call attention to and iden
tify different levels of hazard and special instructions.
in this manual and on various la
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed forthe safe and effective
use
of this
equipment.
4A
This
safety alert symbol is used with the signal
words WARNING and CAUTION to call atten
tion to the safety statements.
a
WARNING statements identify procedures or
practices which must be followed to avoid seri
Safety
B.
The installation, operation, maintenance, and trouble
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in
ous
or
loss of life.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
4~
stalled, operated, and maintained only by qualified per
Sons ~fl 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 Weld
ing Power Source in the welding power source Owners
personal injury
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip
ment.
Manual.
SECTION 2- SPECIFICATIONS
Table 2-1.
SpecIficatIons
Dimensions
Width
Depth
Net
22-1/2 ifl.
16-1/2 in.,
6-1/4 in.~
38 lbs.
(572 mm)
(419 mm)
(159 mm)
(17 kg)
Component
Robot Interface
Weight
Height
Ship
Gas/Current
4-1/2 in.
8-3/4 in.
14 in.
5 lbs.
Total 61 lbs.
Sensing Control
(108 mm)
(222 mm)
(355 mm)
(2.3 kg)
(27.7 kg)
Spool Support
Assembly+
13-3/4 in.
8-3/4 in.
8-1/2 in.
6 lbs.
(349 mm)
(222 mm)
(216 mm)
(2.7 kg)
Add
Add
2-1.
2-1/4 in.
7/8
(57 mm) for brake resistor.
in. (22 mm) for front panel knob.
DESCRIPTION
The robot interface control is
designed to interface with a
Automatix robot and an Arc Pak 350, Deltaweld, Max
tron, or Pulstar 450 welding power source. This unit pro
vides digital display of weld volts,wire feed speed, and
+Spool Support
peak amperage
The
without
or
optional wire
reel.
inductance.
gas/current sensing control contains the gas valve,
contactor, and current sensing reed relay.
These components function with the robot system when
using the Gas Metal Arc Welding (GMAW) process.
OM-138 426
Page
1
SECTION 3- INSTALLATION
SITE SELECTION
3-1.
Select
installation site which
an
interconnecting cords must be routed so that
they are not caught, pinched, or strained during
welding operations.
4.
One weld output cable must be routed
Gas/Current Sensing control.
5.
Welding wire
provides the following:
input power supply (see unit data card)
1.
Correct
2.
Shielding gas supply (if applicable)
3.
Water
supply (if applicable)
The
3.
Adequate ventilation and fresh air supply
5.
No flammables
6.
A clean and
dry
the
must be routed so that it does not con
tact the weld control or any other
4.
through
grounded equip
ment.
C.
Equipment
Installation
Obtain
area
appropriate mounting brackets or adapter plates
necessary and mounting hardware. Prepare struc
ture for equipment installation. Secure weld control,
Gas/Current Sensing control, and all other equipment
onto structures in the welding area.
as
7.
Proper temperature
that avoids extremes of heat or
cold
8.
Proper airflow around unit
9.
to open and remove cover and
for
maintenance, and repair
installation,
wrapper
functions.
Adequate space
provide the capability to install and se
cure the system components in a permanent location.
Table 2-1 gives overall dimensions.
holes
Mounting
as
1.
Weld Control with Gas/Current
Cord and Motor Cord
2.
Gas/Current
3.
Hub and
4.
Spindle Support
5.
install it
10 ft.
2.
Align keyway and
standard and re
3.
Reinstall hex nut onto support shaft. Tighten hex nut
until a slight drag is felt while turning hub.
Sensing Control
4.
Install
10 ft. (3m) Gas Hose
7.
Voltage Sensing Cord
B.
Equipment
When
deciding
lowing:
The lead
insert hub support shaft through
selected hole in hub support. Hole selection in hub
support depends on wire spool size. Be sure the
brake washers are properly seated in the hub.
welding
wire
according
to Section 3-8.
Hub Support
Shaft
Welding
Power Source
Cords
6.
2.
follows:
Spindle Assembly
(3 m) Weld Control
The
as
Remove hex nut from end of hub support shaft.
Sensing Control
Interconnecting
1.
(Figure 3.1)
1.
Supplied Equipment
The following equipment is supplied
quires installation or assembly:
Hub Installation
The hub assembly is supplied with the robot interface.
Remove the hub assembly from the shipping carton, and
EQUIPMENT INSTALLATION
3-2.
A.
D.
Location
on
Brake Washer
Hex Nut
Hub
Assembly
equipment location, consider the fol
equipment must be mounted to a structure ca
pable of supporting the weight of the equipment.
Hub
of the cords supplied with the
will limit the area in which the equipment
lengths
equipment
be located. Some cords can be extended by us
ing optional extension cords (check with welding
equipment distributor).
Support
can
OM-138 426
Page
2
SA.128 870
Figure
3-1. Hub
Assembly InstallatIon
3-3.
GAS/CURRENT SENSING CONTROL INTER
A.
CONNECTIONS (Figure 3-2)
Connections
WARNING: ELECTRIC SHOCK
a
Robot Interface
1.
receptacle RC9 on robot interface, and rotate
threaded collar fully clockwise.
Do not touch live electrical parts.
2.
Align keyways, insert 16-pin Amp plug into matching
receptacle RC16 on gas/current sensing control,
locko uttagging procedures before making inter
connections.
Lockoutltaggirtg procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting oft and
red-tagging circuit breaker or other disconnect
ing device.
Sensing Control
Align keyways, insert 14-pin Amp plug into matching
can kill.
Shut down unit, welding power source, and
robot, and disconnect input power employing
Gas/Current
and rotate threaded collar
B.
fully
clockwise.
Weld Cable Connections
For Electrode Positive/Reverse Polarity, route one cable
from welding power source POSITIVE weld output ter
minal to the gas/current sensing control, and connect to
the contactor. Connect second weld cable to remaining
terminal on contactor, route through the current sensing
reed relay, to the wire drive assembly, and connect cable
to weld cable terminal (see Motor/Drive Assembly Own
ers
Manual for
C.
Gas Connections
location).
Connect hose from gas regulator/fiowmeter (customer
supplied) at gas source to IN fitting on gas/current sens
ing control. Connect gas hose from wire drive assembly
to
fitting
must be
gas/current sensing control. The gas flow
accurately controlled by a regulator/fiowmeter
on
at the source.
D.
Motor Connection
Gas/Current
Control
14-Pin
sensing
Receptacle RC9
Receptacle
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.
RC13
Nut
10-Socket
Flat Washer
Receptacle
RC19 Location
Weld Cable Lug
Location
10-PIn
Receptacle
RC15 Location
Arc Sensing
Receptacle RC12
S-0401
FIgure
3-3.
Voltage Sensing Connections
Assembly
At Wire Drive
24-Socket
Receptacle
3-4.
RC17
VOLTAGE SENSING CONNECTIONS (Figure
3-3)
1.
T~-119 ~
2.
Align keyway, insert 4-socket plug into matching re
ceptacle RCI2 on robot interface, and rotate
threaded collar fully clockwise.
Connect lead with
ring terminal to wire drive
assem
bly, along with the weld cable from the welding pow
er
Figure
3-2.
Right Side View
3.
source, as shown in
Connect lead with
Figure 3-3.
clamp to the workpiece.
OM-138 426
Page
3
ROBOT
3-5.
INTERFACE
WELDING
-
POWER
3-6.
SOURCE CONNECTIONS (FIgures 3-2 And
3-3)
ROBOT INTERFACE ROBOT CONTROL UNIT
CONNECTIONS (Figure 3-2)
-
a
locko ut/tagging procedures before making inter
connections.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
locko ut/tagging procedures before making inter
Lockout/tagging procedures Consist of padlock
ing line disconnect switch in open position, re
moving luses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
connections.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
1.
are
three cords
2.
Connect conductors at
ate sockets in
plug.
Align keyway,
insert
one
plug
end of cord to appropri
into
matching receptacle
robot interface, and rotate threaded collar fully
clockwise.
on
for interconnection be
supplied
welding power source. Ex
tween the robot interface and
amine cords and select proper cord for the connection.
Obtain proper cords,10-pin, and 24-pin Amphenol
plugs (not supplied).
3.
There
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
WARNING: ELECTRIC SHOCK can kill.
4~
WARNING: ELECTRIC SHOCK can kill.
4.
Route and connect conductors at remaining end of
cords to the robot control unit.
A.
REMOTE 14 ConnectIons
1.
Align keyway, insert 14-socket plug into matching
receptacle RC13 on robot interface, and rotate
threaded collar fully clockwise.
2.
B.
1.
2.
Align keyway, insert 14-pin plug into matching re
ceptacle on welding power source, and rotate
threaded collar fully clockwise.
REMOTE 17 ConnectIons
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.
C.
REMOTE 10 Connections
1.
Align keyway, insert 10-socket plug into matching
receptacle RC1 5 on robot interface, and rotate
threaded collar fully clockwise.
The
input and output signals at the sockets of receptacle
RC1 7 and RC1 9 by means of the robot interface control
circuitry are as follows:
Receptacle RC17
Socket A:
Peak
Socket B:
Peak
Socket C:
Amps/Inductance signal positive.
Amps/Inductance signal common.
Peak Amps/inductance signal wiper. Sig
nal vanes 0-4.8 volts for Pulstar
or
0-10
volts for Arc Pak
Socket F:
Circuit Common.
Socket G:
Jog signal with respect
Socket L:
Circuit Common.
Socket M:
Weld Start with respect to socket N.
Socket N:
Circuit Common.
Socket P:
Wire Feed
Socket 0:
Socket R:
Wire Feed Speed
Wire Feed Speed
ries 0-8 volts.
Socket S:
Arc
Socket 1:
Arc
to socket F.
Speed signal positive.
signal common.
signal wiper. Signal
va
Socket U:
Voltage signal positive.
Voltage signal common.
Arc Vo~age signal wiper. Signal varies
Socket V:
Arc Failure contact.
Socket W:
Arc Failure contact.
Socket X:
Current detect contact.
Socket Y:
Current detect contact.
0-10 volts.
2.
Align keyway, insert plug into matching receptacle
on the welding power source, and rotate threaded
collar fully clockwise.
IMPORTANT: The remaining sockets in the receptacle
are not used.
Receptacle RC19
If the welding power source is equipped with a REMOTE
14/17 selector switch, place the switch in the REMOTE
Socket A:
Torch Position signal with respect to socket
0.
position. Make connections to both REMOTE 14 and
REMOTE 17 receptacles.
Socket D:
Torch Position
A.
14
OM-138 426
Page
4
signal with respect to socket
Socket F:
Torch Position initiate
to socket F.
Socket G:
Connect +24 vdc to
d.
Circuit common.
signal
open robot control
with respect
Socket I:
Circuit
Socket J:
Gas control with respect to socket ~.
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.
common.
Robot Control Unit
ARC FAILURE LIGHT TERMINAL STRIP CONNECTIONS (FIgure 34)
contact.
e.
IMPORTANT: The remaining sockets in the receptacle
are not used.
3~7.
remaining side of normallyrelay
Robot Interface
Weld Alarm Terminal
if SO Equipped
Common Terminal
it So Equipped
~
iT
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,
Arc Failure
Indicator Light
_________________________
and close and secure front
panel access doorwhen pro-
1TM
cedure is finished.
light on the robot interface front panand
off
turned
is
on
el
by a signal from the robot control
unit. Obtain proper length of 18 gaugel2-conductor cord
for this connection, and proceed as follows:
Robot Control Unit
The ARC FAILURE
~
WARNING: ELECTRIC SHOCK can kIll.
To Volta
(115VAC,
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
e
Isolation
I
Relay CR1
~
(
Robot interface
Robot Control
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re-
CR1
424~~C
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
For robot control units when 24 vdc is used
I
Source
2~&AC, 24V0C)
locko ut/tagging procedures before making inter
connections.
1.
Weld Alarm Terminal
if So Equipped
Common Terminal
If So Equip
11
~O~1 h0~~
(Figure
_________________________
3-4):
a.
b.
c.
Route cord through strain relief on right side
panel of robot interface, and make proper connections to 1TL and 1TM.
Route and connect remaining end of cord to
weld alarm terminal and ground connection at
the robot control unit.
Connect +24 vdc to common
minal.
relay
so~
Figure
3-8.
3-4. Arc Failure
a.
(Figure 3-5)
Spool-Type Wire
A.
Installation Of
1.
Remove
2.
Slide spool of wire onto hub
retaining ring.
contact ter
For robot control units when 115 or24 vac, or24 vdc
is used
Light Connections
WELDING WIRE INSTALLATION
bottom of
2.
Arc Failure
Indicator Light
1TM
(Figure 3-4):
Route cord through strain relief on right side
of robot interface, and make proper connections to 1TL and ITM.
panel
b.
Obtain a 115 or 24 vac, or 24 vdc isolation
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.
relay
so
that wire feeds off
spool.
3.
Rotate spool until hole in spool aligns with pin in hub.
Slide spool onto hub until it seats against back
flange of the hub.
4.
Reinstall
B.
InstallatIon Of
retaining ring
onto hub.
Optional
Wire Reel And Reel-
Type Wire
1.
retaining ring and,
assembly from hub.
2.
Lay wire reel assembly flat
Remove
if
applicable,
on a
table
or
wire reel
floor.
OM-138 426
Page
5
Wir. Retainer
Retaining Ring
3.
Remove spanner nut from wire reel assembly.
4.
Remove wire retainer, and install wire onto wire reel.
Be sure that wire feeds ott bottom of reel.
5.
Reinstall wire retainer and spanner nut onto wire
reel.
6.
Slide wire reel assembly onto hub, and rotate
sembly until hub guide pin is seated in reel.
7.
Reinstall
C.
Adjustment Of Hub Tension (FIgure 3-1)
Wire Reel
Spinner
Nut
Hub
retaining ring
as
onto hub.
Check the hub tension by slowly rotating the wire spool
reel. The wire should unwind freely, but hub tension
should be sufficient to keep wire taut and prevent back
lash when the wire feed stops. If adjustment is required,
loosen or tighten the hex nut on the end of the hub sup
port shaft accordingly.
or
Hub
Figure
3-5.
OptIonal
Support
Wire Reel And
installation
Reel-Type
Wire
SECTION 4- OPERATOR CONTROLS
Wire
Voltmeter
Peak
Sped
1PM Meter
Fuse
Amps/
Inductance Meter
Circuit Breaker
(See
Section
6-2)
Wire Feed
Indicator
Light
Current Indicator
Light
Light
Jog Push
Jog Rev Push
Button Switch
Button Switch
Wire Touch
Arc Failure
Indicator
Indicator
Light
Psi. TB-Its 645
Figure
4-1.
POWER SWITCH
4-1. Front Panel Controls
(FIgure 4-1)
contactor.
reverse
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 and JOG REV push buttons are momentarycontact switches. The JOG buttons energize the wire
feed motorwithout energizing the welding power source
OM-138 426
Page
6
4-3.
Holding
both JOG buttons allows the wire to
into the gun.
PURGE PUSH BUTTON
(Figure 4-1)
PURGE push button is a momentary-contact
switch. This switch energizes the gas solenoid and
purges the shielding gas line of the gun. The PURGE
push button allows the flow meter to be adjusted without
energizing the welding circuit.
The
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
The CURRENT
(Figure 4-1)
The wire speed meterdisplays 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.
METER
AMPS/INDUCTANCE
PEAK
4-6.
(Figure
4-1)
is established.
The ARC FAILURE light turns on only when properly
connected according to instructions in Section 3-7, and
there is an arc
outage while welding.
The WI RE TOUCH light turns on when the torch position
initiate contact at socket G of RC19 is closed and the
welding wire touches the workpiece during torch posi
and set up.
source, the
tioning
displays preset peak weld amperage
to the near
The WELD ENABLE light turns on when the system is
energized and remains on unless the torch position initi
ate contact at pin G of RC19 is closed.
est ampere while
welding
and
When used with the Arc Pak
ductance is
4-7.
the current detect
arc
welding power
When used with the Pulstar
meter
light turns on when
relay is energized to indicate that an
displayed
in
idling.
source, in
welding power
percentage.
INDICATOR LIGHTS
4-8.
(Figure 4-1)
BURNBACK CONTROL
The burnback control is
located beneath the
There are seven indicator lights on the interface. These
are visual indications of various process functions.
of the front
a screwdriver adjustable control
snap-in blank in the lower left corner
panel.
Burnback time
light turns on when the gas
indicate shielding gas flow.
The GAS
to
The CONTACTOR
er source
valve is
energized
light turns on when the welding
energized to indicate that
contactor is
pow
weld
output is available.
The WIRE FEED light turns on when the wire drive motor
is energized to indicate that wire is feeding.
SECTION 5
5-1.
INPUT SIGNALS
can be adjusted between 5 and 250 milli
seconds. Rotate the control clockwise to increase burnback time.
the control properly, the welding wire will
neither freeze in the weld puddle or the contact tube of
the gun. lithe welding wire freezes to the work, increase
bumback time. If the welding wire burns back into the
By adjusting
contact tube, decrease burnback time.
SEQUENCE OF OPERATION
FROM ROBOT CONTROL
5-2.
OUTPUT SIGNALS FROM ROBOT INTERFACE
UNIT
The robot interf ace receives
input signals for
contactor
control, gas control, jog, welding volts, peak amperage,
inductance, torch positioning, and wire speed.
The robot interface sends output signals to the robot
control unit for current sense, arc failure, and torch
positioning.
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
ROUTINE MAINTENANCE
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
IMPORTANT:
Every six months inspect the labels on
legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
red-tag9ing circuit
this unit for
ing
when necessary. See Parts List for part number of
precautionary labels.
MOVING PARTS
Keep away
Allow
ment every three months as follows:
a
1.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures
maintaining, or servicing.
before
inspecting,
serious injury.
moving parts.
cooling period before servicing.
performed only by qualified
persons.
can kill.
Do not touch live electrical parts.
other disconnect
can cause severe burns.
Maintenance to be
WARNING: ELECTRIC SHOCK
or
can cause
from
HOT SURFACES
Usage and shop conditions determine the frequency
and type of maintenance. At minimum, inspect equip
breaker
device.
2.
Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked insu
lation and areas where it enters equipment.
Remove grease and
ture from electrical
grime from components;
mois
parts and cable.
OM-138 426
Page
7
OVERLOAD PROTECTION
6-2.
~
ure
WARNING: ELECTRIC SHOCK
Do not touch live electrical
can
kill.
maintaining,
or
pacts.
ser.icing.
Lockoutltagging procedures consist
can
damage
Remove hub assembly from hub support, and disas
semble discarding worn or broken parts.
2.
Slide the following items onto the hub support shaft
in order given.
of
a.
Spring
b.
Keyed Washer
c.
Fiber Washer
d.
Brake Washer
e.
Hub
f.
Brake Washer
g.
Fiber Washer
unit.
Wire Drive Motor CircuIt Breaker CBI
(Figure
4-1)
WARNiNG: Read and follow safety information at beginning of Section 6-2 before pro-
Align keyway, and insert hub support shaft through
selected hole in hub support.
3.
ceeding.
install hex nut onto hub support shaft. Tighten hex
slight drag is felt while turning hub.
4.
Circuit breaker CB1 protects the wire drive motor from
overload If CB1 opens, the wire feed motorwould stop.
.
motor overload occur and CBI open,
as follows:
Should
1.
2.
a
nut until a
Install
5.
Check for
rolls, and
4.
binding drive gear
correct problem.
repair or replace wire
Reset circuit breaker
cooling period may
or
misaligned
by depressing
Resume
B.
Main Fuse Fl
a
drive
~
WARNING: ELECTRIC SHOCK
be necessary before the circuit
Shut down unit before making or changing
equipment lead connections.
meter or test
ELECTROSTATIC DISCHARGE (ESD) can
damage circuit boards.
Put on a properly grounded wrist strap
BEFORE handling circuit boards.
(Figure 4-1)
Transport a!! static-sensitive components in
proper static-shielding carriers and packages.
ceeding.
Depress
can kill.
Do not touch five electrical parts.
Be sure that personnel performing testing
procedures are familiar withandfollowstandard
safety practices.
the button. A
Fuse Fl protects the robot interface from an internal
short or excessive overload. If fuse Fl opens, the robot
interfaceshutsdown. Ifthefuseopens,correcttheprob-
1.
(Figure
ters.
operation.
replace
to Section 3-8.
Check points are provided on the display board PC4 for
checking power supply and input command for the me-
WARNING: Read and follow safety Informatlon at beginnIng of SectIon 6-2 before pro
tern and
according
6-2)
breaker can be reset.
5.
wire
DISPLAY BOARD PC4 METER CHECK
6-4.
drive motor.
3.
welding
proceed
Check for jammed wire or clogged gun- liner, and
correct problem. If wire jams often, replace gun liner.
if motor overload occurs often,
replace part or all of the hub
hub assembly as follows:
new
1.
Use only replacement fuse of same size, type,
and rating (see PartsList).
a
reinstall the
assembly,
padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
INCORRECT FUSE
6-1)
If it becomes necessary to
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before inspecting,
A.
REINSTALLATION OF HUB ASSEMBLY (Fig
6-3.
Fl as follows:
and rotate fuse holder cover counterciock-
Perform work
only at a static-safe
work
area.
robot interface access door.
1.
Open
2.
Locate
3.
Check voltage according to
4.
voltage is
replace the me
ter (see Section 6-5 and contact nearest Factory Au
thorized Service Station).
display
board PC4.
Figure
6-2.
wise.
2.
Pull out fuse with cover when fuse holder
free.
3.
Insert
4.
Install fuse with fuse holder
5.
new
fuse into fuse holder
cover
is
cover.
cover
back into unit.
Depress and rotate fuse holder cover clockwise until
cover
OM-138 426
is secure.
Pages
If
a
meter power
supply
and command
correct and the meter is not working,
5.
If the power supply or command voltage is incorrect,
replace display board PC4 (see Section 6-5 and
contact nearest Factory Authorized Service Sta
tion).
Wire Retainer
Retaining Ring
Wire Reel
Spanner
Nut
Keyed Washer
Brake Washer
Hub
Hub
Fiber Washer
Support
Shaft
Hex Nut
Brake
Washer
OPTIONAL
Hub
Support
Ref. SC-I 27 328
FIgure
6-1. Hub And Reel Assemblies
Input Command For
Volts Meter ..-O.5V ~ 50V
Input Command For
Ammeter O.1V = bOA
Power Supply For
Volts Meter And Ammeter
O-5VDC
Ref. SO.117 838-B
Figure
6-5.
6-2.
DIsplay
CIRCUIT BOARD HANDLING PRECAUTIONS
a
WARNING: ELECTRIC SHOCK can kIll.
Do not touch live electrical parts.
maintaining, or seriicing.
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.
4A
(ESO)
can
Put
on
BEFORE
ELECTROSTATIC DISCHARGE
damage circuit boards.
properly grounded
handling circuit boards.
Transport circuit boards in proper staticshielding carriers or packages.
Perform work
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before inspecting,
CAUTION:
Board Meter Checks
wrist
only at a
static-safe work
area.
INCORRECT INSTALLATION or misaligned
can damage circuit board.
plugs
Be
sure
that plugs
are
properly installed and
aligned.
EXCESSIVE PRESSURE
can
break circuit
board.
Use
only minima/pressure and gentle move
disconnecting or connecting board
plugs and removing or installing board.
ment when
strap
OM-138 426 Page 9
SECTiON 7- ELECTRICAL DIAGRAMS
I
3
Cl)
0
z
(5
.0
0
0
E
(5
I
2
aol
C.)
~0
z0l
20l
1.01
I
U? I
461
201
20
~
101
01
1.0
Wa
o0
001
6~
40%
OM-138 426
Pace
10
.0
~
518
35
SC-i
No.
Diagram
Circuit
PCi
Board
Control
For
Diagram
Circuit
7-2.
Diagram
-Ip,
0
:3 0) -ł 0 0
fillAilllllllllflIH
M.I. ~A~S AT ro ~ ~IIW
VTTW ~T TO
~so4 ~NT ~J
W WITH ~T TO P~gT
fi1
'
K
HI
/~/1.
_HPL
fi
JIIILJfflIIL
A
L
Diagram 7-3. CircuIt Diagram
OM-138 426
Page
12
For Motor Control Board PC2
N
0
F
C
P
Circuit
Diagram
No. SD-083 388-A
OM-138 426 Page 13
JUU fuc
Circuit
Diagram
7-4. CircuIt
Diagram
Diagram
No. SB-i 23 201
For Interface Board PC3
A-P ~ R~O
U-IF D4 R~4
aA-eQ ~4 Rc27
I~1
A A A A A
,i:i~ X1
r
UU
A A A A
A A A A A
Circuit
DIagram
OM-138 426
Page
14
7-5. Circuit
Diagram For Meter Display
fl\ U
Diagram
Board PC4
No. SB-114 483-A
Lj~j
.2W
BYPfISS FOR Pt
xmi
+2W
At
S
CS
4
Circuit
Diagram
7-6. CircuIt
Diagram
A
AA
S
14
HE
P
N
L
Circuit
DIagram
7-7. Circuit
Diagram
No. SB-i 32 087-A
For Interlace Board PC5
B
AB
Diagram
Diagram
No. SA-114 815
For Wire Touch Board PC6
OM-138 426
Page
15
RC 6
RC7
d
-~.
I>
12
.7
-~I4
3>a
-~4
p
9>7
>
5
>
/0
.-~
5
-~.
6
-57
-5
-L
REWTMIT
2
:3
DI
I0
I>
88
8
>
Circuit
Diagram
OM-138 426
Page
16
7-8. CircuIt
Diagram For Gas/Current Control
Diagram
No. SA-1 38742
SECTION 8- PARTS LIST
OM-138 426
Page
17
Part
No.
Dia.
Mkgs.
Description
Main
Cl
031 692
006 426
028 291
011 991
109 006
052 964
C2-4
CBI
CR1
CR2
CR3
CR4
095 033
093 558
048 588
079 844
027 811
048 029
026 202
D2,3
*012 655
Fl
046 432
021 105
PB1-3
137 695
PCi
110 375
110391
071 642
PC2
083 147
1185470008525
PC3
Al
009159
073 739
Cl -7,15
083 973
C8
031 677
C9
Cli ,i 2
000 348
072 130
C13
000 859
C14
073 714
C16
095 521
CR1 ,2
CR3-6
099 018
079 844
091 861
028 351
Dl 13-17
026 202
D2-8
Ji-lO
092648
037 200
028
Al ,4,8,9
035 826
R2
039 332
035 827
R3,5,6
035 825
R7,31
R10-14,17-22,29 039331
A 15,23
039 329
R16
039 336
053 572
R24-27
035 884
R28
R30
035 823
079 759
RC18
079 749
RCI9
UI
094 594
081 832
VRI
135635
114 656
1178360008945
PC4
089 032
073 756
132 090
PC5
OM-138 426
Page
18
Assembly
CAPACITOR, elctlt 750uf 200VDC
CLAMP, capacitor 2.000dia
CAPACITOR, cer disc .luf 500 VDC
CIRCUIT BREAKER, man reset 1P l.5A250V
RELAY, end 24VAC DPDT
RELAY, end 24VDC DPDT
RELAY, end 24VAC 4PDT
RELAY, end 12OVAC 4PDT
BRACKET, mtg relay
SPRING, hold clown relay
SOCKET, relay 14 pin
CLIP, retaining skt relay
DIODE, rect 1A 400V SP
FUSE, minat cer 1OA 250V
HOLDER, fuse minat .250 x 1.250 panel mtg
SWITCH, PB SPDT
CIRCUIT CARD, voltage control (Fig 8-1)
STAND-OFF SUPPORT, PC card No. 6 screw
GUIDE, mtg-circuitcard
CIRCUIT CARD, motor speed digital (Fig 8-2)
GROMMET~ scr No. 8/10
CIRCUIT CARD, interface (consisting of)
iC, Iinear358
CAPACITOR, cer mono .luf 5OVDC
CAPACITOR, elctlt l000uf 35VDC
CAPACITOR, tantim 5.6uf 35VDC
1
3
1
1
i
1
1
1
2
2
2
2
1
1
3
1
6
3
1
2
I
1
8
1
I
2
CAPACITOR, elctlt 220uf 35VDC
1
1
CAPACITOR, tantim .22uf 35V
1
24VDC 4PDT
end 24VDC SPDT
SPRING, hold down relay
2
SOCKET, relay
DIODE, sig .020A 75V SP
DIODE, rect 1 A 400V SP
RESISTOR, WWfxd zero ohm
TRANSISTOR, NPN 200MA 40V
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 15K ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, CF .25W4.7K ohm
RESISTOR, CF .25W 2.7K ohm
RESISTOR, CF .25W 220K ohm
RESISTOR, MF .25W 12.1K ohm
RESISTOR, CF .25W lOOK ohm
2
end
RESISTOR, CF .25W 100 ohm
header 12
header 18
.
1
CAPACITOR, tantlm .47uf 35V
CAPACITOR, taritlm luf 35VDC
RELAY,
RELAY,
.
Quantity
TERMINAL,
TERMINAL,
IC, digital 4098
IC, linear 78M15
pin
pin
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 24-18 wire
4
2
6
7
10
7
4
1
3
2
12
2
1
4
1
1
1
I
1
1
1
2
CIRCUIT CARD, meter (Fig 8-3)
1
LENS, LED 4341 RED
STAND-OFF, NO. 6-32 X .625 LG
CIRCUIT CARD, interface (Fig 8-4)
5
11
1
Part
No.
Dia.
Mkgs.
Descnption
Main
PC6
PLG3
0937270008267
PLG9
131 054
113 746
109 041
047 636
079535
079 739
PLG1 6
096 813
048 598
079534
PLGI 2
PLG 14,19
PLG15
PLG18
PLG2O
PLG24
PLG25
PLG28
PLG5O
PLG5I
RI
R2
R3
R4
RC5
RC9
RC12
RC13
RC15
RC16
049
073
039
600
604
601
601
600
079
079
089
089
073
073
989
686
828
848
109
226
228
750
748
747
870
647
332
140
039 716
079 760
079 747
081 379
081 378
084 198
081 378
083 172
081 378
115 091
113 746
092 159
081 378
135 557
079747
030 651
605 741
030 941
030949
010199
079 683
056 170
010 193
057 084
079 497
082 708
117374
009 335
047637
079 534
076 624
094480
089646
097 867
Quantity
Assembly (Continued)
CIRCUIT CARD, wire touch (Fig 8-5)
HOUSING RECEPTACLE & SOCKETS, (consisting of)
i
TERMINAL, female lskt 24-18 wire
CABLE, ipterconnecting (consisting of)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pinsz 16 18-14 wire
2
CLAMP, cable
CABLE, pwr shid l8ga 15/c (order by 11)
HOUSING PLUG & SOCKETS, (consisting of)
TERM:NAL, female lskt 14-18 wire
CABLE, volt sensing (consisting of)
PLUG, 4skt 97-31 06A-1 4S-2S
.
CLAMP, cable AN-3057-6
WIRE, lead mot 1 2ga strd (order by ft)
WIRE, lead l6ga strd (order by 11)
INSULATOR, vinyl clamp univ 25A
CLAMP, Univ 25A
TERMINAL, ring tng .500 stud 16-14 wire
HOUSING, term header 18 pin
TERMINAL, contact header 24-18 wire
CABLE, interconnecting (consisting of)
PLUG, lOskt MS-3106A-18-1S
CLAMP, cable 97-3057-10
CABLE~ pQrt No. 1810/c (order byft)
PLUG, 10 pin MS-3106A-18-1P
HOUSING, term header 12 pin
TERMINAL, contact header 24-18
HOUSING, term header 12 pin
TERMINAL, female lskt22-l8wire
HOUSING, term header 6 pin
TERMINAL, female lskt 22-18 wire
HOUSING, term header 4 pin
TERMINAL, female lskt 22-18 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING, term header 16 pIn
TERMINAL, female 1 SM 22-18 wire
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, contact header 24-18 wIre
RESISTOR, WW fxd 25W 10 ohm
CLIP, mtg resistor .312 ID
RESISTOR, WW fxd 100W 5 ohm
HEATSINK,rect
TUBING,stl.275lDx1.000
HEAT
St~JK,
resistor
SHIELD, resistor
TUBING, stl .375 OD x .250
BUSHING, snap-in nyl .250 ID x .375 mtg hole
RESISTOR, WW fxd 25W 2K ohm
POTENTIOMETER, C sltd sft l/T 1W 1 meg ohm
HOUSING, term conn 22posn
STAND-OFF, No. 4-40 x .625 Ig
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 14-18 wire
RECEPTACLE, 4 pin MS-3102A-14S-2P
RECEPTACLE, 14 pin MS-3102A-20-27P
RECEPTACLE, 10 pin MS-3102A-18-1P
RECEPTACLE, 17 pin MS-3102A-20-29P
1
I
I
14
2
l8ft
I
16
1
1
1
35ft
1911
1
1
1
2
18
1
1
2
lOft
1
1
12
1
12
1
6
1
4
1
10
1
16
1
2
I
4
1
1
2
1
1
4
1
1
1
I
2
1
14
1
1
1
I
OM-138 426 Page 19
Part
No.
Dia.
Mkgs.
Desciiption
Main
RC1 7
RC19
Si
SRi
094
039
011
035
035
036
038
038
592
718
609
704
759
135
T2,4
856
1T,2T
772
3T
601 219
1324810008945
107983
1124730008933
+1169690008945
045 852
123 154
010855
010853
073 487
TI ,3
121 594
Dl
GS1
RC7
RC16
REED
WI
111 122
109770
116 964
110 015
111123
109771
071 006
047 636
079 535
079 739
073 139
071 892
079 534
048 144
1338640008989
097 868
116964
604 910
097 866
056 462
604 550
010 606
056 108
056 851
0831530008945
026 202
109293
047637
079 534
090 246
079535
136 595
021 795
605 855
034 260
0830840007751
601 158
085 359
OM-138 426
Page
20
Quantity
Assembly (Continued)
RECEPTACLE, 24skt MS-31 02A-24-28S
RECEPTACLE, loskt MS-31 02A-1 8-IS
SWITCH, tgi SPDT 15A 125VAC
RECTIFIER, integ 30A 600V
TRANSFORMER, control mintr 115/36VCT
i
I
1
2
TRANSFORMER, control
BLOCK, term 20A 14P
BLOCK, term 20A 6P
2
LINK, jumper term bik 20A
6
2
1
CABINE1 control
1
BLANK, snap-in nyl .500 mtg hole
PANEL, mtg components
DOOR, access cabinet
CLIP, component .687dia mtg adh back
LABEL, warning general precautionary
RETAINER, scrNo.2
4
FASTENER, scr sltd hd No. 2
NUT, speed No. 2
2
1
1
2
1
2
2
NAMEPLATE
1
CABLE, interconnecting (consisting of)
1
HOUSING PLUG & PINS,
(consisting of)
TERMINAL,malelpinsz45l6-22wire
CLAMP, cable 97-3057-1 012
CABLE, port No.18 7/c (order by ft)
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 16-22 wire sz 45
CABLE, motor (consisting of)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male I pin $216 18-14 wire
CLAMP, cable strain relief sz 17
CABLE, port No. 166/c (orderbyft)
RECEPTACLE w/SOCKETS, (consisting of)
TERMINAL, female lskt 14-18 wire
TERMINAL, male 1 pin plug keying
CABLE, interconnecting (consisting of)
PLUG, l7skt MS-3106A-20-29S
~CLAMP,cable97-3057-1012
CABLE~ pwr shld 2Oga 5/c (order by ft)
PLUG, 17 pin MS-3106A-20-29P
HOSE, gas (consisting of)
HOSE, nprn brd No. 1 x .187 ID (order by ft)
FITTING, hose brs nut .625-18RH
FITTING, hose brs ferrule .425 ID x .718 Ig
FITTING, hose brs barbed nipple 3/l6tbg
SHUNT CONTROL, (consisting of)
DIODE, rect 1A 400V SP
.
VALVE,24VDC2wayl/4IPSportl/8orf
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 14-18 wire
RECEPTACLE, w/PINS, (consisting of)
TERMINAL, male 1 pinsz 1618-14 wire
RELAY, current
TUBING, stl .375 OD x l8ga wall x .750
CONTACTOR, def prp 40A 3P 120V
LINK, connecting contactor terminal
SHIELD, heat
BLANK, snap-in metal .875 mtg hole
GROMMET, rbr .750 ID x .937 mtg hole
.
1
14
2
loft
1
14
1
1
14
2
lOft
1
14
2
1
1
2
1 Oft
1
1
lift
1
1
1
1
1
1
1
14
1
16
1
2
1
2
1
2
1
Dia.
Part
No.
Mkgs.
Descnptlon
Main
010
602
010
083
604
934
190
083
0830870008267
+083 086
047 497
072 094
058428
058 628
010 191
601 844
057 971
010 233
072 292
058 427
092 989
121 316
Recommended
Quantity
Assembly (Continued)
FITTING, hose brs bushing 1/4NPT x .625-1SRH
FITTING, pipe gaiv coupling .25ONPSC
FITTING, pipe gaiv nipple L .25ONPT x 10.000
2
BRACKET, mtg control
CONTROL BOX, shunt
2
WRAPPER
1
1
1
1
LABEL, warning general precautionary
HUB & SPINDLE, (consisting of)
~HUB, spool
WASHER, brake stl
WASHER, fbr .656 ID x 1.500 OD x .1 25thk
NUT, sti stf 1kg hex mscr 4-40
WASHER, flat stl keyed 1 .500dia x .l25thk
1
1
i
2
2
1
1
SPRING, cprsn .970 00 x 1.250
SHAFT, spool support
RING, retaining spool
SUPPORT, spindle (consisting of)
LABEL, warning general precautionary
1
1
1
1
1
Spare Parts.
component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
+When
ordering
a
OM-138 426
Page
21
C50
C)
(Do, a,
L3~~
=
c__:) ~
~
~rZ~X L
IX
I
I
I
!
D65H__]
-c::i-
:~
1~-~~3ASO
0
=
C)
i::jn
CR50
__
___
______
AS 1
I
,/~1:
U
E1
a,
I~)~
__________
~
+1
t~1~:
.
a,
Q53
(-3
C58
~JS
060
EJ---
CS2~ Oc~O~~
rL,QO~
__
~
~
0~
C..)
IJ) ~ coa
-~-
=
liii R?4R6~99A52R76
=
~
D-
IJ-~64
c..J
AR?
EJ-~
-c:::J-
-E~J
~
R8S-~
J13
c::~
~
___
A53
.-_c~=...% CS6
L~_J
063
R58
AS?
~
~S2~
J12
c::i-
R53
a~1J
(~0
(-3
C521__
CS?
~J~9
-3
(I
r
(0(0
~OJ~'L~
~
ft
-C~J
1~1(0
LTJLfl
Li
==
DS2Æ~IX ~
054 I
URSI
C74
B
051
~
053
0
0
S8-135 520-8
FIgure 8-1. CIrcuit Card, Voltage Control PCI
OM-138 426
Page
22
Dia.
Mkgs.
pci
Part
No.
137 695
Descnptlon
Quantity
Figure 81. CIrcuit Card, Voltage Control
A50
A51 ,52,54
A53
Cl -4,53,
096 275
114 176
009 159
IC,Iinear324
1
IC, linear 353
IC, linear 358
3
55-59,68
C50,60,
122 723
CAPACITOR,
cer mono
69-73
C52
C54
000 340
031 677
000861
005 023
009 577
053 992
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
cer
C61
C62
C63
C64,65
C66,74
C67,75
CR50
D51 -54
D55-66
J1-15
0C50
Q50
Q51 -53
R1,2
R3
R4,5,67,76
R51 ,80,86,87
R52,91
R53,73
A 55-57,85
R58,61
R59,60,95-97
R62,68,82
R63,78
R69
R71
R74,1 03
R75,89
R77
R79
R81
R83
R84
R88,92
R90
R93
R94
R98
R99
Ri 00
Ri 02
RC1
Si
VR5O
VR51
118
000
121
093
091
460
348
684
558
861
079 844
026 202
028351
092 648
047 034
035 842
037200
089 174
089 176
089 175
039 331
035 888
078431
035 827
039336
035 826
035 825
097 110
108437
000 038
009 173
052 137
039 333
039330
035886
084 205
000 885
081 883
035 885
091 799
035 823
039 329
108 433
117 134
121 714
079 749
092 367
083 772
046 932
I
.iuf 5OVDC
11
disc .Oluf 5OVDC
tantlm 5.6u1 35VDC
elctlt 33uf 35V
7
1
1
tantlm 2.2uf 20V
tantlm 27uf 35V
car disc .OOiuf 1000VDC
elcflt 330u1 5OVDC
tantim .47uf 35V
CAPACITOR, potye met film .47u1 boy
RELAY, end 12OVAC 4PDT
SOCKET, relay l4skt
SPRING, hold down relay
DIODE, rect 1A 400V SP
DIODE, sig .020A 75V SP
RESISTOR, WW fxd zero ohm
IC, interface 4N26
TRANSISTOR, PNP .6A 40V
TRANSISTOR, NPN 200MA 40V
RESISTOR, MF .25W lOOK ohm
RESISTOR, MF .25W 20K ohm
RESISTOR, MF .25W 10K ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 2.2K ohm
RESISTOR, C .25W 330 ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 220K ohm
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, MF .25W 1K ohm
RESISTOR, MF .25W 4.75K ohm
POTENTIOMETER, cermet trmr 25/T .5W 2K ohm
POTENTIOMETER, cermet trmr 20/1 .5W 5K ohm
RESISTOR, MF .25W5.11K ohm
RESISTOR, CF .25W 18K ohm
RESISTOR, CF .25W 3.9K ohm
RESISTOR, CF .25W 22K ohm
RESISTOR, MF .25W 3.32K ohm
RESISTOR, MF .25W 10K ohm
RESISTOR, CF .25W 2.7 meg ohm
RESISTOR, CF .25W 68K ohm
RESISTOR, MF .25W 8.25K ohm
RESISTOR, CF .25W 100 ohm
RESISTOR, CF .25W 2.7K ohm
RESISTOR, MF .25W 2.43K ohm
RESISTOR, MF .25W 24.3K ohm
RESISTOR, MF .25W 51.1K ohm
TERMINAL, header 18 pin
1
1
I
2
2
2
1
1
1
4
12
15
1
1
3
2
1
4
4
2
2
4
2
5
3
2
1
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
SWITCH, dip SPST 2posn
IC,Iinear78l5
IC,iinear79l5
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-138 426 Page 23
380-E
SC-093
PC2
Dig tal
Spe d
Motor
Card,
CircuIt
8-2.
Figure
Dia.
Part
No.
Mkgs.
Description
PC2
071 642
FIgure 8-2. CircuIt Card,
A50-53
C50
C51
009 159
039 482
031 699
073 739
035 833
005 023
031 643
073 549
007 742
035561
044 602
031 721
095 033
091 861
079 844
026 202
080910
081 800
037 200
1C,Iinear358
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACIrOR,
CAPACITOR,
C52,61
C53,62
C54
C55,66-75,77
C56
C57
C60
C63,64
C65
CR50
050-54,56-60
055
IC5O
Q50,53
051
052
R50
Note 1
R52,56,61
R53
R58 62 65 66
,
,
R59
R60,87,88
A 63,79
R73,83
Rfl
R78
R80
R81 ,84
R85
R86
T50
VR1
VR5O
Speed Digital
4
elctit lOOut 35VDC
mylar .0022uf 200VDC
cer .luf 5OVDC
mylar .033u1 100 VDC
tantim 2.2uf 20V
cer .Oluf 500VDC
mylar .Ol5uf 200V
elcttt lOut 35V
mylar 4uf 200V
polye film .47uf 400 VDC
mylar .22ut 200 VOC
RELAY, encI24VAC 4PDT
1
1
2
2
1
12
1
1
1
2
1
1
SOCKET, relay
1
SPRING. hold down-relay
DIODE, 1A400VSP
DIODE, zener 15V 5W
IC, interface 2907
TRANSISTOR, NPN 200MA 40V
THYRISTOR, SCR 7.4A 200V
TRANSISTOR, UJT 15MA 40V
RESISTOR, WW fxd 5W 220 ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 20K ohm
RESISTOR, CF .25W 15K ohm
1
10
1
1
2
1
1
I
10
3
1
,
71,72,76,90
AM
R70
037824
039 355
030839
035 827
052 138
039332
Motor
Quantity
035 884
030 007
039 335
039 106
039331
049015
039 328
052 142
039 108
035886
035 825
030937
030090
092 648
085 399
047 272
081 799
RESISTOR, CF .25W lOOK ohm
POTENTIOMETER, cermet 15ff .75W 50K ohm
RESISTOR, CF .25W 47K ohm
8
1
3
2
RESISTQR, CF .25W 470 ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W lOmeg ohm
1
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
2
1
1
1
CF .25W 1.5K ohm
CF .25W 120K ohm
CF .25W 82K ohm
CF .25W 22K ohm
CF .25W 1K ohm
CF .5W 10 ohm
RESISTOR, CF .5W 47 ohm
RESISTOR, WWfxd zero ohm
1
2
I
1
15
TRANSFORMER, pulse
1
IC,Iinear78Ll2
IC, linear 78L08
1
1
Note: R51 ,54,55,57,67,68,74,75,82,89
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-138 426 Page 25
Part
No.
Dia.
Mkgs.
PC4
1178360008945
C1,2
000
073
028
108
089
C3-5
D1,2
LCD1-3
LEDI ,2,4-7
LED3
097
030
030
003
081
Ri -5,12,13
R6,8,11
R7,9,10
RC2O
RC21-23
RC24
RC27
109
084
084
071
070
VR1,2
348
739
351
453
028
763
028
140
272
381
161
194
193
248
026
Description
FIgure 8-3. CIrcuit Card,
Quantity
Meter
CAPACITOR, tantlm .47u1 35V
CAPACITOR, cer .lut 5OVDC
DIODE, s~g .020A 75V SP
METER, digital
LED, 5330A10 4OMCD
LED, 5330A19 200MCD
RESISTOR, .5W 1.5K ohm
POTENTIOMETER, cer 15ff .75W 200K ohm
RESISTOR, CF .25W imeg ohm
TERMINAL, header 12 pin
2
3
TERMINAL, header l3skt
TERMINAL, header 6 pin
TERMINAL, header 4 pin
IC,Iinear78MO5
STAND-OFF, No. 6-32 x .437
3
2
3
6
I
7
3
3
I
1
1
2
6
LCD;
~n_j
PC231______________
RC2II
VP
~/\
I 01
9.4
LED5
LED
2
~ LfO~
OrnO
LED
0.toi
LEDI
4
~.
0;
02
-1RCZO
(I (Ill I I 111111
.
~I~7
~
IHtOO
~
~PC24
.111111111111
A.U7B3500~945
Figure 6-3. CIrcuit Card, Meter PC4
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-138 426
Page
26
Dia.
Part
No.
Mkqs.
PC5
Descnption
Figure 8-4. Circuit Card, interface
132 090
Al
Cl
C2
C3
C4
CR1 ,2
Dl,4
02,3
Ji
Qi
Ri
R2
R3
R4
R5,7
R6
R8
R9
RCI
VRI
Quantity
009159
039 482
000 348
031 677
122 723
099 018
026202
028 351
092 648
037 200
035 824
009 173
035 825
038 584
035 827
039 332
035 826
039 331
113 747
095269
IC,Iinear3S8
CAPACITOR, elcttt lOOuf 35VDC
CAPACITOR, tantim .47u1 35V
CAPACITOR, tantim 5.6u1 35VDC
CAPACITOR, cer mono .luf 5OVDC
RELAY, end 24VDC SPDT
DIODE, rect 1A400VSP
DIODE, sig .020A 75V SP
RESISTOR, WW txd zero ohm
TRANSISTOR, NPN 200MA 40V
RESISTOR, CF .25W 270 ohm
POTENTIOMETER, cermet trmr 20/T .5W 5K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, CF .25W 470K ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 15K ohm
I
t
1
1
I
2
2
2
1
I
1
1
1
1
2
1
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 4.7K ohm
TERMINAL, hdr 10 pin
1
IC,Iinear3l7T
1
1
1
0
0
ASSE~ELY NO.
~!RS
RI
~R4
rvi
~-
D
a)
0
a)
c~ -
a
0
~A1I
a)
-~
C.,
1~J
ACt
SA-1~ oa~-8
FIgure 8-4. Circuit Card, interface PC5
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-138 426
Page
27
Dia.
Part
No.
Mkgs.
PC6
0937270008267
009 159
090 573
000 348
039 482
073 739
004 855
026202
037 449
037 200
035 827
035 826
039 331
035 888
030 710
092 648
092 160
082 799
083 772
Al
Cl
C2
C3
C4
CRI-4
D1-8
D9
Qi ,2
,5,7
R2,3
Ri
R4
R6,8
R9,10
RC5O
RC51
VR1
Descnption
FIgure 8-5. CIrcuit Card,
Quantity
Wire Touch
IC, linear 358
CAPACITOR, eictlt lOuf 50V
CAPACITOR, tantlm .47u1 35V
CAPACITOR, elctlt lOOuf 35VDC
CAPACITOR, cer mono .luf 5OVDC
RELAY, end 24VDC 4PDT
DIODE, rect 1A400VSP
DIODE, zener 15V 1W SP
i
i
1
1
i
4
8
1
TRANSISTOR, NPN 200MA 40V
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 2.2K ohm
RESISTOR, C 1W 270 ohm
2
3
2
1
2
2
RESISTOR, WW fxd zero ohm
TERMINAL, header 16 pin
TERMINAL, header 2 pin
IC, linear 7815
1
1
t
1
A. t O653~OO8287-A
Figure 8-5. CIrcuit Card,
Wire Touch PC6
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-138 426
Page
28