Miller | KF812826 | Owner Manual | Miller ROBOTIC INTERFACE II User manual

Miller ROBOTIC INTERFACE II User manual
June 1995
Form: OM-172 324
Effective With Serial No. KF812826
OWNER’S
MANUAL
Robotic Interface II
Controls Welding Power Source For Robotic Welding Applications
For GMAW, Standard GMAW-P, And Adaptive GMAW-P Welding
Requires Installation Of Interface Panel For Robot In Use
Welding Power Source Must Have 14-Pin Remote Control Capability
Programmable Weld Parameters
Overload Protection
Read and follow these instructions and all
safety blocks carefully.
Give this manual to the operator.
Have only trained and qualified persons
install, operate, or service this unit.
For help, call your distributor
Call your distributor if you do not understand
the directions.
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912
414-734-9821
cover 5/94 – ST-801 077-A
 1995 MILLER Electric Mfg. Co.
PRINTED IN USA
ARC WELDING SAFETY PRECAUTIONS
WARNING
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, and
all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw off pieces of metal or slag.
NOISE
1. Use approved ear plugs or ear muffs if noise level is high.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
7. When making input connections, attach proper grounding
conductor first – double-check connections.
8. Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced cables.
11. Do not drape cables over your body.
12. If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
14. Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
3. Wear approved safety glasses with side shields.
4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
4.
5.
6.
7.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
9. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
sr1.1.1 2/94
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly off
from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
WARNING
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
1. Use equipment outside in open, well-ventilated areas.
Engines produce harmful exhaust gases.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
ENGINE FUEL can cause fire or
explosion.
3. Do not overfill tank – allow room for fuel to expand.
4. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
Engine fuel is highly flammable.
1. Stop engine and let it cool off before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY
GASES TO EXPLODE; BATTERY
ACID can burn eyes and skin.
Batteries contain acid and generate explosive
gases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when engine is cold
to avoid scalding.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
1. If the engine is warm and checking is needed, follow steps 2
and 3.
2. Wear safety glasses and gloves and put a rag over cap.
3. Turn cap slightly and let pressure escape slowly before
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
sr1.1.1 2/94
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
EMF INFORMATION
NOTE
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 – SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2-1.
2-2.
2-3.
Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Optional Emergency Stop Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
4
SECTION 3 – OPERATIONAL TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
SECTION 5 – INTRODUCTION TO PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
5-1.
5-2.
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Panel Microprocessor Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
10
SECTION 6 – GETTING STARTED FOR PULSE WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
SECTION 7 – TEACHING A PULSE WELDING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
7-1.
7-2.
7-3.
7-4.
Pulse Waveform Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Teach Points Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Teaching A Pulse Welding Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing To Adaptive Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
17
18
21
SECTION 8 – TEACHING A MIG WELDING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
8-1.
8-2.
Changing To MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Sequence MIG Welding Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
24
SECTION 9 – USING THE OPTIONAL DATA CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
9-1.
9-2.
Installing Data Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using The Data Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
OM-172 324 – 6/95
SECTION 10 – SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Setup Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Using Setup Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Selecting Welding Power Source Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Selecting Security Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Selecting Or Changing Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Selecting Voltage Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Selecting Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Selecting Purge Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. Selecting Voltage Sensing Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10. Selecting Regular Or Hot Arc Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11. Resetting Arc Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12. Selecting Units For Wire Feed Speed And Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-13. Selecting Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-14. Selecting Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-15. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-16. Selecting Arc Start/Volt Sense Error Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-17. Selecting Program Name Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-18. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-19. Stick Check Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-20. Jog Wire Feed Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-21. Robot Type Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-22. Arc Failure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-23. Arc Voltage Error Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-24. Software Version Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
32
33
34
35
36
37
37
38
38
39
39
40
40
41
41
42
42
43
43
44
44
45
45
45
SECTION 11 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
11-1.
11-2.
11-3.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
46
47
SECTION 12 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
SECTION 13 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-1. Case Section w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-3. Panel, Center w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-4. Panel, Rear w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-5. Motor & Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
64
66
67
68
70
SECTION 1 – SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1
2
2
WARNING
3
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
CAUTION
MOVING PARTS can injure.
4
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
1
Safety Alert Symbol
2
Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And Result
4
Safety Instructions To Avoid
Hazard
5
6
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
5
Hazard Symbol (If Available)
6
Safety Banner
Read safety blocks for each symbol shown.
7
7
NOTE
Turn Off switch when using high frequency.
NOTE
Special instructions for best operation – not related to safety.
Figure 1-1. Safety Information
OM-172 324 Page 1
SECTION 2 – INSTALLATION
2-1. Connection Diagram
The proper interface kit must be installed in the interface
unit to allow it to be connected to the robot.
1
Robot (Will Vary According To
Application)
2
Motor/Drive Assembly
3
Positive (+) Voltage Sensing
Lead
4
Gas Cylinder
5
Gas Hose
6
Robot Control
7
Robot Input/Output Cable
8
Remote Program Select
Cable (Optional)
9
Gas And Motor Control Cable
10 Interface Unit
11 Welding Power Source
6
12 17-Socket Plug And Interconnecting Cord
2
3
13 14-Socket Plug And Interconnecting Cord
4
14 Negative (–) Weld Cable
5
15 Workpiece
1
16 Negative (–) Voltage Sensing
Lead
17 Positive (+) Weld Cable
7
8
17
15
9
10
16
11
12
13
14
ST-801 078-A
Figure 2-1. Connection Diagram
OM-172 324 Page 2
2-2. Rear Panel Connections
1
2
B
C
A
M
L
K
J
P NT
R S
D
E
FG
1
Receptacle
2
Keyway
3
14-Pin Receptacle (Connection To Welding Power
Source)
4
17-Pin Receptacle (Connection To Welding Power Source
With 17-Pin Receptacle)
5
19-Socket Receptacle (Motor/
Shielding Gas Control
Connection To Motor Drive
Assembly)
6
10-Socket Receptacle (Optional Remote Program Select
Connection To Robot Control)
H
Example Receptacle
To connect matching interconnecting cord to one of the above receptacles, align keyway, insert plug,
and tighten threaded collar. Connect remaining end of cord to
matching receptacle on applicable
equipment (see Figure 2-1).
8
7
7
4-Pin Receptacle (Optional
External Voltage Sensing
Connection)
To connect interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
3
6
Cord for voltage sensing connection divides in two. Secure ring terminal on one cord to clamp and attach clamp to work. Secure ring terminal on remaining cord to motor/
drive assembly where weld cable is
connected.
8
5
4
If optional external voltage sensing connections are used,
remove jumper link from across terminals D and E on internal terminal strip 2T and install jumper link across terminals C and D. See Figure 2-3 for the location of 2T.
Interface Panel (Robot Control Connection)
Receptacle will vary according to
the robot control being used with
the system. Follow connection
directions included with interface
panel kit.
Ref. S-0003-A / ST-800 962-A
Figure 2-2. Rear Panel Connections
OM-172 324 Page 3
2-3. Connecting Optional Emergency Stop Push Button
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
Turn Off robot, welding power source, and interface unit, and disconnect input power before inspecting or installing.
swarn1.1* 2/93
Terminal strip 2T provides connection points for an optional normally
closed Emergency Stop (E-stop)
push button. To make connections,
proceed as follows.
Remove top cover.
2
1
Terminal Strip 2T
2
Strain Relief
Loosen strain relief and insert leads
from normally closed E-stop push
button. Route leads to 2T.
1
Remove jumper link across terminals A and B on 2T. Keep for future
use.
Connect one lead from E-stop
switch to terminal A and the remaining lead to terminal B.
Tools Needed:
1/4 in
Tighten strain relief and reinstall top
cover.
ST-801 146
Figure 2-3. Connecting Optional Emergency Stop Push Button
SECTION 3 – OPERATIONAL TERMS
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Adaptive Pulse Welding
When the “adaptive pulse” welding process is selected, the unit will automatically regulate pulse frequency in order to maintain a constant arc length, regardless of change in welding wire stickout.
Abk (Background
Amperage)
Abk is the low weld current. Background current preheats welding wire and
maintains the arc. When background current is too low, the arc is unstable and
hard to maintain.
Apk (Peak Amperage)
Apk is the high pulse of welding current. Peak current melts the welding wire
and forms a droplet. The droplet is forced into the weld puddle.
In short circuit GMAW welding, an increase in inductance will decrease the
number of short circuit metal transfers per second (provided no other changes
are made) and increase the arc-on time. The increased arc-on time makes the
pool more fluid.
Inductance
PPS (Pulses Per Second)
PWms (Pulse Width in
Milliseconds)
PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse
rate of 60 Hz means 60 pulses of current are produced each second.
PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time
must be long enough to form a droplet of welding wire. The stiffness or fluidity
of the molten weld puddle is controlled by PWms.
Synergic
Synergic refers to the unit’s ability to use preprogrammed pulse parameters to
determine the actual pulse settings of Peak Amperage, Background Amperage,
Pulse Frequency and Pulse Width at any specific wire feed speed setting.
Trim
Term used to represent arc length adjustments in pulse programs. Increasing
trim increases the actual arc length. Likewise, decreasing trim shortens arc
length. Trim is replaced by volts in MIG programs.
OM-172 324 Page 4
Pulse Panel Terms:
Card Mode
Is used to select use of the optional data card storage and retrieval capabilities.
Process Mode
Is used to select the type of process to be used, including Pulse, Adaptive
Pulse, or Mig.
Sequence Mode
Is used to select and program the weld sequences which include preflow, runin, weld, crater, burnback, and postflow.
Setup Screen Terms:
Access Code
NOTE: The optional Data Card is required to activate this feature. With code
off, access to the setup displays is not restricted. With code on, the operator
must know and enter the access code to access or change any of the setup
displays.
To use code, press Parameter Select button to enter access code. When the
correct letter is entered, the indicator automatically moves to the next character. When the final access code letter is entered, the display automatically
changes to the initial setup display.
Arc Start
NOTE: Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Use
the Hot Start mode for pulse welding with 450 Ampere Inverter Model when
high initial weld current is necessary to start large diameter welding wires.
When in Hot Start, the 450 Ampere Inverter Model starts the arc in the CV
mode and switches to CC once the arc is started. Do not use Hot Start unless
using 450 Ampere Inverter Model.
Arc Time
Allows actual arc time up to 9,999.99 hours and weld cycles up to 999,999 to
be accumulated and displayed on the digital display, and can be reset to zero
as required.
Mig Type (Voltage
Correction)
With DVC Voltage Correction On, the unit uses closed-loop feedback from the
17-pin cord or voltage sensing leads to maintain set voltage parameters. With
DVC Voltage Correction Off, feedback from the arc is not used for closed-loop
feedback to maintain voltage parameters. Feedback from the arc is still used
for other functions.
Be sure voltage sensing leads are connected or voltage feedback is available
through the 17-pin receptacle via the welding power source.
Name Feature
When using the optional Data Card and turning the name feature on, programs
written to the card can be identified by name, number, job number, etc.
Program Reset
By selecting program reset in the memory reset mode, the unit defaults to original factory program settings for the program last active. All other program and
setup information remains the same.
Range
The interface requires that the voltage and amperage range of the welding
power source be entered. Obtain this information from the welding power
source Owner’s Manual.
Security
NOTE: The optional Data Card is required to activate this feature. Is used to
limit what the operator can control. This includes accessing the number of the
program, 1 through 8, and the range of welding parameters within the program.
Software Screen
Selection of this function will display the software version of the unit. When
talking with factory service personnel, this number may be required.
System Reset
By selecting system reset in the memory reset mode, the unit defaults to original factory settings for all programs and all set up excluding System, Arc Time,
and Model Type.
Voltage (Control Feedback)
Allows voltage to be monitored at the output terminals by two methods. This
can be selected through the 17-pin cord connection if the welding power source
has a 17-pin receptacle, or through the unit’s external voltage sense lead.
If the 17 Pin setting is used, it is recommended that the voltage sensing terminals on the welding power source be used to monitor arc voltage at the workpiece.
When using the V. Sense setting, arc voltage feedback is through the voltage
sense leads connected to the feeder. Use this setting when there is more than
50 ft (15 m) of weld cable used.
OM-172 324 Page 5
Arc Start/Volt Sense
Shutdown
When this feature is on, the system immediately shuts down if no arc voltage is
sensed. An error message is displayed. When this feature is off, wire feeds
even when there is no arc voltage sensed.
Wire Feed Mode
Allows the selection of inches per minute or meters per minute for wire feed
speed. This mode is also used to select motor type; standard speed, low
speed, or high speed. High speed motor is available as factory option.
SECTION 4 – OPERATION
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Keep all panels and covers securely in place.
•
•
MOVING PARTS can cause injury.
FUMES AND GASES can be hazardous
to your health.
•
•
•
•
•
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
Keep away from pinch points such as drive rolls.
Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
•
•
WELDING can cause fire or explosion.
•
•
•
•
•
Wear welding helmet with correct shade of filter.
Wear correct eye, ear, and body protection.
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near any welding operations.
See Safety Precautions at beginning of manual for basic welding safety information.
wfwarn3.1 8/92
1
2
3
Wear the following while welding:
1
Dry, Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
Figure 4-1. Safety Equipment
1
1
Tools Needed:
Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1* 2/93
Figure 4-2. Work Clamp
OM-172 324 Page 6
Front Panel
3
2
1
1
Display
2
Reset Button
After clearing an error, press this
button to reset the display.
3
Purge Button
Push to energize gas valve. If a
purge time value is programmed,
the gas will flow for the programmed
length of time. If a value is not programmed, the gas flows until the
Purge button is released.
8
7
This button allows purging of air
from gun shielding gas line, and adjusting shielding gas regulator without energizing the welding circuit.
6
5
Front panel and pulse panel controls, and the gun trigger do not
work when the Purge button is
pressed.
4
4
Front Panel
Contactor On Light
Lights when welding power source
contactor is energized.
9
5
10
Wirefeed On Light
Lights when wirefeed motor is On.
11
6
Gas On Light
Lights when gas flow is On.
7
12
8
13
Retract Button
Push to retract welding wire without
energizing welding circuit or shielding gas valve.
Advance Button
Push to feed welding wire without
energizing welding circuit or shielding gas valve.
Pulse Panel
14
9
Display
10 Data Card Slot
Insert optional data card here. See
Section 9 for information on using
the data card.
Pulse Panel
11 Increase Button
12 Decrease Button
13 Parameter Select Button
15
14 Mode Select Button
See Section 5 for information on using pulse panel controls.
Rear Panel
15 Power Switch
User power switch to tun unit On
and Off.
Rear Panel
ST-800 755-B / ST-800 962-A
Figure 4-3. Controls
OM-172 324 Page 7
WARNING
BUILDUP OF SHIELDING GAS can harm health or kill.
•
Shut off shielding gas supply when not in use.
warn1.1 9/91
1
Shielding Gas Cylinder
2
2
Valve
1
Open valve on cylinder just before
welding.
Close valve on cylinder when finished welding.
sb5.1* 6/92 – S-0621-C
Figure 4-4. Shielding Gas
Install & Connect
Interface Into
Welding System
Put On
Personal Safety
Equipment
Adjust Weld
Parameters
As Needed
Turn On
Welding System
Equipment
Turn On Shielding
Gas
Set All Controls
And Verify
Program Selection
Perform Test
Weld
Begin
Welding
ssb6.1* 9/92
Figure 4-5. Sequence Of Gas Metal Arc (GMAW), Gas Metal Arc - Pulse (GMAW-P),
And Flux Cored Arc Welding (FCAW)
Set switches as shown for all
welding processes when using
this interface unit.
Ref. ST-150 171-C / Ref. SC-154 197
Figure 4-6. Setting Switches On 450 Ampere Inverter Model Welding Power Source
OM-172 324 Page 8
SECTION 5 – INTRODUCTION TO PROGRAMMING
5-1. Programs
A. General
1
1
Interface Unit
The interface unit is designed for
use in pulse MIG welding (adaptive
or standard), or MIG welding.
The unit is factory-equipped with
eight programs for pulse MIG welding (see Figure 5-2). The programs
contain parameters that maximize
welding performance for each combination of wire and shielding gas.
The unit also provides memory for
the creation of up to eight MIG programs (see Section 8).
The weld programs require the user
to enter information specific to the
welding application. This information is entered as a part of program
development (see Section 6 for
pulsed MIG information), and during setup (see Section 10).
ST-801 077-A
Figure 5-1. Interface Unit
B. Pulse MIG Programs
The eight pulse programs are
shown in the table. Each program
can be used in standard pulse MIG
or adaptive pulse MIG.
Program
Hardwire Selected*
Softwire Selected*
1
.035” Steel, Argon – Oxy
.045” 4043, Argon
2
.045” Steel, Argon – Oxy
.045” 5356, Argon
3
.035” Steel, Argon – CO2
.035” 4043, Argon
4
.045” Steel, Argon – CO2
.035” 5356, Argon
5
.035” 309, Argon – CO2
1/16” 4043, Argon
6
.045” Steel, 309, Argon – CO2
1/16” 5356, Argon
7
3/64” 5356, Argon
.045” Steel, Argon – CO2
8
.035” SIB, Argon
.045” Steel, Argon – Oxy
In an adaptive pulse MIG program,
the unit manipulates certain weld
variables to hold arc voltage
constant. This feature is described
in Section 7-4.
The factory-set parameters for
each program can be changed to
customize them for an application
(see Section 7).
Selecting hardwire or softwire is
done during setup (see Section 10)
Figure 5-2. Pulse MIG Programs
OM-172 324 Page 9
5-2. Pulse Panel Microprocessor Push Buttons
WARNING
ELECTRIC SHOCK can kill.
•
•
WELDING WIRE can cause puncture
wounds.
Do not touch live electrical parts.
Control circuit and interface operational power are
On when using or changing the microprocessor
settings.
•
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire can be electrically live and move out of
the gun during programming.
1
Mode Display
2
Mode Select Button
Press Mode Select button to move
indicator in left window display.
Go to Figure 5-4.
Pulse Panel
1
>P r o c e s s
Ca r d
Sequence
P r oces s
>C a r d
Sequence
> Pr g 1
Pu l s e
03 5 ” S t e e l
Ar g o n–Ox y
2
Ref. ST-154 109
Figure 5-3. Mode Select Button
OM-172 324 Page 10
1
Parameter Display
2
Moving Line
Moving line is under value that can
be changed.
3
Pulse Panel Parameter Select
Button
Press pulse panel parameter select
button to move indicator in right window display.
Pulse Panel
1
2
>P r o c e s s
Ca r d
Sequence
> Pr
Pu
03
Ar
g 1
l se
5 ”S t ee l
g on – Ox y
P r
>P u
03
A r
g 1
l se
5 ”S t ee l
g on – Ox y
Pu
03
A r
>T e
l
5
g
a
se
”S t ee l
on – Ox y
c h Off
3
Ref. ST-154 109
Figure 5-4. Pulse Panel Parameter Select Button
OM-172 324 Page 11
Use mode select button to select
mode to be changed (see
Figure 5-3).
Use pulse panel parameter select
button to select parameter to be
changed (see Figure 5-4).
1 Increase Button
Press button to increase value that
is underlined by the moving line.
2 Decrease Button
Press button to decrease value that
is underlined by the moving line.
Pulse Panel
1
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
>P r
Pu
04
A r
g 2
l se
5 ”S t ee l
g on – Ox y
Increase
Increase
2
>P r
Pu
05
A r
g 3
l se
2 ”S t ee l
g on – Ox y
Decrease
>P r
Pu
04
A r
g 2
l se
5 ”S t ee l
g on – Ox y
Ref. ST-154 109
Figure 5-5. Pulse Panel Parameter Increase And Decrease Buttons
OM-172 324 Page 12
SECTION 6 – GETTING STARTED FOR PULSE WELDING
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Do not touch live electrical parts.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Keep all panels and covers securely in place.
•
•
MOVING PARTS can cause injury.
FUMES AND GASES can be hazardous
to your health.
•
•
•
•
•
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
See Safety Precautions at beginning of manual for basic welding safety information.
wfwarn6.1 8/92
Weld Time
Crater Time
Start
Speed
Weld Speed
Preflow Time
Arc
Start
Burnback Time
Crater
Speed
Wire Speed
•
•
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
Start Time
Weld
Start
Keep away from pinch points such as drive rolls.
Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
WELDING can cause fire or explosion.
•
•
•
•
•
Wear welding helmet with correct shade of filter.
Wear correct eye, ear, and body protection.
Weld
Stop
Postflow Time
Arc
Out
Time
Ref. S-0271
Figure 6-1. Weld Cycle
NOTE
The type of robot being used is defined during the setup process (see Section 10).
The Robot type indicates which parts of the weld cycle the robot controls.
When the Robot type selected is Control of Power Source, Wire, Gas, & Analog,
there are no programmable sequences for Pulse welding.
When the Robot type selected is Control of Arc On & Analog Inputs, only preflow
and postflow are programmable.
When the Robot type selected is Arc On & No Analog Inputs, preflow, weld, crater,
and postflow are programmable.
OM-172 324 Page 13
1
P r oces s
Ca r d
>S e q u e n c e
Mode Select Button
When unit is turned On, Process is
the default mode, at other times,
use mode select button to select
Sequence.
>P r e f l o w
0 . 0 Sec
2
Parameter Select Button
Use parameter select button to select parameters.
3
2
1
Preflow Parameters Display
Preflow can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Preflow sequence.
Go to Figure 6-3.
Parameter
Select
Mode Select
3
>P r e f l o w
0 . 0
Sec
P r e f l ow
>0 . 0
Sec
Parameter
Select
>P r e f l o w
1 . 2
Sec
Set Desired Time
Parameter
Select
Increase/
Decrease
Increase
Proceed to next figure.
Figure 6-2. Setting Preflow Sequence Display
Set Desired Weld
Sequence Trim
1
We l d
>5 0
200
Trim (Arc Length), 0-99
T r im
I PM
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
Go to Figure 6-4.
Parameter
Select
We l d
60
>2 0 0
T r im
I PM
Increase/
Decrease
Parameter
Select
We l d
60
300
T r im
I PM
Increase
Proceed to next figure.
Figure 6-3. Setting Weld Sequence Display
OM-172 324 Page 14
Weld Parameters Display
Parameter ranges are as follows:
Increase/
Decrease
Set Desired Weld Sequence
Wire Feed Speed
1
1
1
Crater Parameters Display
Parameter ranges are as follows:
>C r a t e r
0 . 00 Sec
50
T r im
200
I PM
Set Desired
Time
Parameter
Select
Seconds, 0-2.50 Sec. If value set is
zero (0), there is no Crater
sequence.
Cr a t e r
0 . 20 Sec
>5 0
T r im
200
I PM
Cr a t e r
>0 . 0 0 S e c
50
T r im
200
I PM
Parameter
Select
Trim (Arc Length), 0-99
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
Set Desired
Trim
Increase/
Decrease
Increase/
Decrease
>C r a t e r
0 . 20 Sec
60
T r im
150
I PM
Cr a t e r
0 . 20 Sec
60
T r im
>1 5 0
I PM
Go to Figure 6-5.
Parameter
Select
Set Desired
Parameter Wire Feed Speed
Select
Increase
Proceed to next figure.
Increase/
Decrease
Figure 6-4. Setting Crater Sequence Display
1
1
>P o s t f l o w
0 . 0
Sec
Po s t f l ow
>0 . 0
Sec
Parameter
Select
Postflow Parameters Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Set Desired Time
Increase/
Decrease
>P o s t f l o w
1 . 2
Sec
Parameter
Select
Increase
Proceed to next figure.
Figure 6-5. Setting Postflow Sequence Display
OM-172 324 Page 15
SECTION 7 – TEACHING A PULSE WELDING PROGRAM
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
Control circuit and interface operational power are
On when using or changing the microprocessor
settings.
NOTE
WELDING WIRE can cause puncture
wounds.
•
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire can be electrically live and move out of
the gun when programming.
See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more
information.
7-1. Pulse Waveform Explained
The interface, not the welding power source, controls weld output for
pulsed welds.
1
ApK – Peak Current Of
100-565 Amperes
ApK is the high pulse of welding
current. Peak current melts the
welding wire and forms a droplet.
The droplet is forced into the weld
puddle.
2
AbK – Background Current Of
10-200 Amperes
AbK is the low weld current. Background current preheats welding
wire and maintains the arc. When
background current is too low, the
arc is unstable and hard to
maintain.
3
Amps (Current)
3
PPS – Pulses Per Second Of
20-400
PPS, pulse rate, and frequency
(Hz) are used interchangeably. A
PPS or pulse rate of 60 Hz means
60 pulses of current are produced
each second.
4
1
2
4
Time
PWms – Pulse Width Of
1.0-5.0 Milliseconds
PWms is the time spent at peak current (1.2 ms is .0012 seconds). This
time must be long enough to form a
droplet of welding wire. The stiffness or fluidity of the molten weld
puddle is controlled by PWms.
Ref. S-0259
Figure 7-1. Pulse Waveforms And Explanation Of Terms
OM-172 324 Page 16
7-2. Teach Points Explained
IPM
780
750
700
650
600
550
Example Of A Synergic
Setting For 425 IPM With
All Teach Points Set At
50 IPM Increments
500
450
400
350
300
250
200
ApK
AbK
150
PPS
100
PWms
50
150
10
30
1
180
20
55
210
30
80
240
40
105
270
50
130
2
The teach mode allows the user to create
custom pulse MIG welding programs. The
teach mode has 15 teach points. At each
teach point, the user can adjust four parameters: peak amperage (ApK), background amperage (AbK), pulses per second (PPS), and
pulse width in milliseconds (PWms) to shape
the pulse waveform of the weld output.
Wire feed speed teach points can range from
the minimum to the maximum wire feed
speed of the feeder. When using a standard
speed motor, wire feed speed teach points
typically range from 50 to 750 ipm. The feeder
uses pulse parameters at teach points to establish the pulse parameters at any wire feed
speed setting.
Below the wire feed speed of the lowest teach
300
60
160
330
70
185
360
80
210
3
370
90
235
420
100
260
450
110
290
point, and above the wire feed speed of the
highest teach point, the unit may limit wire
feed speed settings in pulse MIG to maintain
all pulse parameters within the capability of
the unit.
Pulse MIG programs made by the manufacturer have pulse waveform information entered for all 15 teach points. The operator can
relocate and modify the setting of one, or any
number of the 15 teach points if the factory
set information is not appropriate for a specific application.
After the parameters for each teach point are
established, an arc must be struck and maintained for at least 5 seconds in teach mode.
This allows the wire feeder to learn the arc
voltage length associated with the taught
480
120
315
510
130
340
540
140
365
4
565
150
400
5
ApK
AbK
PPS
PWms
pulse parameters. To ensure a proper arc
length reading, electrode stick-out must be
carefully maintained.
The taught arc length represents a Trim (arc
length) setting of 50. Increasing the value of
Trim, increases the actual arc length. Likewise, decreasing the value of Trim will
decrease actual arc length.
In the Pulse mode, the unit does not maintain
a constant arc length with variations in electrode stick-out. In the Adaptive Pulse mode,
the unit adjusts pulse frequency to maintain a
constant arc length regardless of variations
in electrode stick-out.
Proceed to next section to teach a pulse MIG
program.
Figure 7-2. Typical Teach Point Settings And Resulting Synergic Setting
OM-172 324 Page 17
7-3. Teaching A Pulse Welding Program
READ SAFETY BLOCKS at start of
Section 7 before proceeding.
WARNING
A. Selecting Teach Point Wire Feed Speed
1
1
2
2
>P r o c e s s
Ca r d
Sequence
Pu l se
035 ”S t ee l
>P r g 1
Pu l se
035 ”S t ee l
>T e a c h
Mode
Select
Of f
Parameter
Select
Increase/
Decrease
3
Process Display
When unit is first turned On, Process is the default screen, at other
times use mode select button to select Process.
Teach Display
Use parameter select button to select Teach.
Use increase/decrease buttons to
select On.
3
IPM (Teach Point)
The parameters associated with
this wire feed speed teach point can
be modified. The wire feed speed
value itself cannot be changed from
this unit.
To set or adjust teach point parameters, go to Figure 7-4.
T e a c h On
>4 0 0
I PM
340
Apk
70
Abk
>T e a c h O n
400
I PM
340
Apk
70
Abk
Parameter
Select
Figure 7-3. Selecting Teach Point Wire Feed Speed
OM-172 324 Page 18
B. Setting Teach Point Parameters On The Pulse Panel
Increase/
Decrease
>P r o c e s s
Ca r d
Sequence
T e a c h On
>4 5 0
I PM
340
Apk
70
Abk
T e a c h On
450
I PM
Apk
>3 4 0
70
Abk
Parameter
Select
Or
T e a c h On
450
I PM
>3 4 3
Apk
70
Abk
1
Parameter
Select
Increase/
Decrease
Increase/
Decrease
34
9
>2 8
1 .
3
2
0
9
Apk
Abk
PPS
P Wm s
34
9
>1 6
1 .
3
2
0
9
450
343
> 92
160
Apk
Abk
PPS
P Wm s
I PM
Apk
Abk
PPS
450
343
> 70
160
I PM
Apk
Abk
PPS
2
Parameter
Select
3
Parameter
Select
Increase/
Decrease
34
9
28
>1 .
3
2
0
9
Apk
Abk
PPS
P Wm s
34
9
28
>3 .
3
2
0
6
Apk
Abk
PPS
P Wm s
Weld for
5 seconds
Pu
03
A r
>T e
>T e a c h O n
450
I PM
343
Apk
92
Abk
l
5
g
a
se
”S t ee l
on -Ox y
ch Of f
Increase/
Decrease
Parameter
Select
4
Parameter
Select
5
P r
Pu
03
A r
When the Process Teach mode is On, and
one of the following pulse parameters is selected: ApK, AbK, PPS, or PWms, the pulse
panel displays the selected pulse parameter
instead of Trim (arc length). When the pulse
parameter is selected, the value can be
changed with the pulse panel controls as follows:
1 ApK Display
2
AbK Display
Turn Teach mode Off.
3
PPS Display
5
4
PWms Display
When values have been set for a teach point,
strike and maintain an arc for five seconds.
Repeat procedure at each teach point until
custom program is complete (see
Figure 7-2).
g
l
5
g
1
C
se
”S t ee l
on -Ox y
Custom Pulse Screen
The letter C will appear in the upper right corner of all customized programs.
Customized programs can be reverted back
to factory-set values through memory reset
(see Section 10-15).
Figure 7-4. Setting Teach Point Parameters On The Pulse Panel
OM-172 324 Page 19
NOTE
Make copies of this chart for future use.
Program #
Wire Size/Type
Gas
Program Name
Card #
Gun Model
Flowrate
IPM
ApK
AbK
PPS
PWms
COMMENTS
Preflow:
Sec.
Run-In Trim:
IPM:
Sec.:
Crater Trim:
IPM:
Sec.:
Postflow:
Sec.
OM-172 324 Page 20
CFM
7-4. Changing To Adaptive Pulse Welding
READ SAFETY BLOCKS at start of
Section 7 before proceeding.
WARNING
Welding parameters are the same
for both a Pulse and an Adaptive
Pulse welding program. While
welding adaptively, the unit uses
feedback to attempt to maintain a
constant arc length. To change to
Adaptive Pulse welding, proceed
as shown:
1
Pulse Panel Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
Mode Select
1
>P r o c e s s
Ca r d
Sequence
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Parameter
Select
>P r o c e s s
Ca r d
Sequence
P r
>P u
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Increase/
Decrease
>P r o c e s s
Ca r d
Sequence
P r
>A d
03
A r
g 1
a p tP u l s e
5 ”S t ee l
g o n –Ox y
Figure 7-5. Changing To Adaptive Pulse Welding
OM-172 324 Page 21
SECTION 8 – TEACHING A MIG WELDING PROGRAM
WARNING
ELECTRIC SHOCK can kill.
WELDING WIRE can cause puncture
wounds.
Do not touch live electrical parts.
Control circuit and interface operational power are
On when using or changing the microprocessor
settings.
•
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire can be electrically live and move out of
the gun when programming.
Weld Time
Start Time
Wire Speed
Crater Time
Weld Speed
Start
Speed
Preflow Time
Weld
Start
Arc
Start
Burnback Time
Crater
Speed
•
•
Weld
Stop
Postflow Time
Arc
Out
Time
Ref. S-0271
Figure 8-1. Weld Cycle
NOTE
The type of robot being used is defined during the setup process (see Section 10).
The Robot type indicates which parts of the weld cycle the robot controls.
When the Robot type selected is Control of Power Source, Wire, Gas, & Analog,
only the start time, level, and speed are programmable.
When the Robot type selected is Control of Arc On & Analog Inputs, preflow; start
time, level, and speed; burnback time and level; and postflow are programmable.
When the Robot type selected is Arc On & No Analog Inputs, preflow; start time,
level, and speed; weld level and speed; crater time, level, and speed; burnback
time and level; and postflow are programmable.
OM-172 324 Page 22
8-1. Changing To MIG Welding
1
Pulse Panel Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
Go to Figure 8-3.
Mode Select
1
>P r o c e s s
Ca r d
Sequence
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Parameter
Select
>P r o c e s s
Ca r d
Sequence
P r
>P u
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Increase/
Decrease
>P r o c e s s
Ca r d
Sequence
P r g
>M I G
1
Figure 8-2. Changing To MIG In The Process Mode
OM-172 324 Page 23
8-2. Setting Sequence MIG Welding Parameters
READ SAFETY BLOCKS at start of
Section 8 before proceeding.
WARNING
1
1
>P r o c e s s
Ca r d
Sequence
>P r g
MIG
1
2
Parameter Select Button
Use parameter select button to select parameters.
3
Preflow Parameters Display
Preflow can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Preflow sequence.
2
Mode
Select
P r oces s
Ca r d
>S e q u e n c e
Pulse Panel Display
When unit is turned On, Process is
the default mode. Use mode select
button to select Sequence.
Go to Figure 8-4.
>P r e f l o w
0 . 0
Sec
Parameter
Select
3
P r e f l ow
>0 . 0
Sec
Set Desired Time
Increase/
Decrease
Figure 8-3. Setting Preflow Sequence Display
OM-172 324 Page 24
>P r e f l o w
1 . 2
Sec
Parameter
Select
Increase
Proceed to next figure.
1
1
>S t
0 .
24
9
Start Parameters Display
Parameter ranges are as follows:
a r t
2 Sec
. 0Vo l t
0 I PM
S t
>0 .
24
9
Parameter
Select
a r t
5 Sec
. 0Vo l t
0 I PM
S t
0 .
>1 8
9
Set Desired Time
Parameter
Select
Set Desired Voltage
Seconds, 0-2.5 Sec. If value set is
zero (0), there is no Run-In
sequence.
Volts, 10.0-38.0 Volts
Wire Feed Speed, 50-780 inches
per minute, IPM
Go on to Figure 8-5.
Increase/
Decrease
>S t
0 .
18
20
a r t
5 Sec
. 0Vo l t
0 I PM
Increase/
Decrease
a r t
5 Sec
. 0Vo l t
0 I PM
S t
0 .
18
>2 0
Increase
Proceed to next figure.
Parameter
Select
Parameter
Select
a r t
5 Sec
. 0Vo l t
0 I PM
Set Desired
Wire Feed Speed
Increase/
Decrease
Figure 8-4. Setting Start Sequence Display
1
1
Weld Parameters Display
Parameter ranges are as follows:
Set Desired Voltage
We l d
Volts, 10.0-38.0 Volts
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
>1 8 . 0 V o l t
2 0 0 I PM
Go to Figure 8-6.
Increase/
Decrease
Parameter
Select
Set Desired Wire Feed Speed
We l d
20 . 0Vo l t
>2 0 0 I P M
Increase/
Decrease
Parameter
Select
>We l d
20 . 0Vo l t s
4 2 0 I PM
Increase
Proceed to next figure.
Figure 8-5. Setting Weld Sequence Display
OM-172 324 Page 25
1
Crater Parameters Display
Parameter ranges are as follows:
1
Seconds, 0-2.50 Sec. If value set is
zero (0), there is no Crater
sequence.
>C r a t e r
0 . 02Se c
24 . 0Vo l t
9 0 I PM
Volts, 10.0-38.0 Volts.
Wire Feed Speed, 50 to 780 inches
per minute, IPM.
Go to Figure 8-7.
Parameter
Select
Cr a t e r
>0 . 1 2 S e c
24 . 0Vo l t
90
I PM
Set Desired Time
Cr
0 .
>1 8
9
Parameter
Select
Increase/
Decrease
a t e r
12Se c
. 0Vo l t
0 I PM
Set Desired
Voltage
Cr
0 .
18
>2 0
Parameter
Select
Increase/
Decrease
a t e r
12Se c
. 0Vo l t
0 I PM
Set Desired
Wire Feed Speed
Parameter
Select
Increase/
Decrease
>C r
0 .
18
20
a t e r
12Se c
. 0Vo l t
0 I PM
Increase
Proceed to next figure.
Figure 8-6. Setting Crater Sequence Display
1
Burnback Parameters Display
Parameter ranges are as follows:
Volts, 10.0-38.0 Volts
Seconds, 0-0.25 seconds. If value
set is zero (0), there is no Burnback
sequence.
1
>B u r n b a c k
0 . 00 Sec
18 . 0 Vo l t
Go to Figure 8-8.
Bu r nbac k
>0 . 1 2 S e c
18 . 0 Vo l t
Parameter
Select
Set Desired Time
Increase/
Decrease
Bu r nbac k
0 . 12 Sec
>1 6 . 0 V o l t
Parameter
Select
Set Desired
Burnback Volts
Increase/
Decrease
Figure 8-7. Setting Burnback Sequence Display
OM-172 324 Page 26
>B u r n b a c k
0 . 12 Sec
16 . 0 Vo l t
Parameter
Select
Increase
Proceed to next figure.
1
1
>P o s t f l o w
0 . 0
Sec
Po s t f l ow
>0 . 0
Sec
Parameter
Select
Set Desired Time
>P o s t f l o w
1 . 2
Sec
Postflow Parameters Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Parameter
Select
Increase/
Decrease
Figure 8-8. Setting Postflow Sequence Display
OM-172 324 Page 27
SECTION 9 – USING THE OPTIONAL DATA CARD
9-1. Installing Data Card
Label
1
2
3
4
5
7
6
8
9
11
10
12
13
14
1
Peel backing from label and apply
to data card with THIS SIDE UP by
metal pins.
THIS SIDE UP
Write the names of the programs
stored on the card on the label.
Write the name of the piece of
equipment the card is used with on
the label.
2
Data Card
3
Card Slot
Insert card into slot. To format card,
turn On power to the unit. Select
Card from menu. Data card formats
when unit enters Card mode. Exit
Card mode and turn Off power.
60-M Data Card
3
2
1
ST-156 266-B / Ref. S-155 823
Figure 9-1. Installing Data Card
9-2. Using The Data Card
1
P r oces s
>C a r d
Sequence
P r ess
Be l ow
Parameter
Select Once
2
1
Card Display
2
Write
Used to transfer program data from
unit to card. The program card can
hold up to 32 programs. When writing to the card, the next available
program number is automatically
assigned.
3
>W r
Re
De
Do
4
i
a
l
n
t e
d
e t e
e
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Delete
Used to delete program data from
card.
5
Done
Used to exit card display.
6
5
Read
Used to transfer program data from
card to unit.
4
3
Moving Line
Moving line is under value that can
be changed.
6
Figure 9-2. Card Displays
OM-172 324 Page 28
Use Mode Select button to select
Card.
NOTE
All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card
and retrieved.
1
1
P r oces s
>C a r d
Sequence
2
t e
d
e t e
e
Name Display
If no name is desired, press
Parameter Select button to continue the write procedure.
Parameter
Select
2
i
a
l
n
Moving Line
Moving line is under value that can
be changed. Use increase or
decrease button to change value.
P r es s
Be l ow
3
>W r
Re
De
Do
Card Display
Use Mode Select button to select
Card.
#1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Allowable characters include: 0 thru 9, :, ;, <, =,
>, ?, @, A thru Z, [, Ψ, ], ^, _,‘, a thru z, !, ”, #, $, %,
&, ’, (, ), *, +, –, ., /,
3
Parameter
Select
N ame ? N o
035 ”S t ee l
A r g o n –Ox y
P r es s
Increase/
Decrease
N ame ? Y e s
035 ”S t ee l
A r g o n –Ox y
P r ess
Yes
N ame ? Y e s
035 ”S t ee l
A r g o n –Ox y
⇒P r e s s
N ame ? Y e s
5007992
F r ame
_
⇒P r e s s
Increase
No
Parameter
Select
Parameter
Select
Parameter
Select
Wr i t eDo n e
P r g 1 t o
Ca r dP r g 1
P r es s
Wr i t eDo n e
P r g1 t o
Ca r d P r g1
P r ess
N ame ?
No
5007992
F r ame
P r ess
N ame ? Y e s
5007992
F r ame
P r ess
Increase
Parameter
Select
Parameter
Select
#1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r es s
Parameter
Select
#1 Pu l se
5007992
F r ame
P r ess
Figure 9-3. Naming Programs And Writing To Card
OM-172 324 Page 29
1
P r ocess
>C a r d
Sequence
Use Mode Select button to select
Card.
P r es s
Be l ow
t e
d
e t e
e
Parameter
Select Once
Moving Line
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
P r g1 Wi l l
Be Los t
Lose? Yes
P r ess
Read Display
Use increase or decrease button to
select feeder program number
where the card program goes.
3
Read Ca r d
t o Feede r
P r g 1
P r ess
Parameter
Select
WA R N I N G :
2
Moving line is under value that can
be changed. Use increase or decrease button to select program
number to read from card to feeder.
2
i
a
l
n
Card Display
3
Mode
Select
Twice
Wr
>R e
De
Do
1
Parameter
Select
P r g1 Wi l l
Be Los t
Lo s e? No
P r ess
No
Yes
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Increase
Parameter
Select
Parameter
Select
Read Done
Ca r d P r g1
t o P r g 1
P r ess
Parameter
Select
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Figure 9-4. Reading From Card
1
1
Wr
>R e
De
Do
i
a
l
n
t e
d
e t e
e
Warning Display
If there are no programs on the
card, this series of displays appear.
WA R N I N G :
C a r d Emp t y
P r ess
Be l ow
Parameter
Select Once
Wr
Re
De
>D o
i
a
l
n
t e
d
e t e
e
>P r o c e s s
Ca r d
Sequence
>P r g
MIG
P r es s
Parameter
Select
Figure 9-5. Reading (Or Deleting) From An Empty Card
OM-172 324 Page 30
2
Use Mode Select button to select
Card.
1
P r ess
Be l ow
Mode
Select
Twice
i
a
l
n
Card Display
2
Moving Line
Moving line is under value that can
be changed.
P r oces s
>C a r d
Sequence
Wr
Re
>D e
Do
1
3
Delete Display
Select program number to be deleted from card.
Parameter
Select Once
t e
d
e t e
e
#
2
MIG
WA R N I N G :
P r ess
Parameter
Select
2
3
De l e t e
Ca r d P r g2
Lose? Yes
P r ess
De l e t e
Ca r d P r g2
Lo s e? No
P r ess
No
Increase
Yes
#2
MIG
P r ess
Parameter
Select
Parameter
Select
Ca r d P r g2
De l e t ed
#3
P r ess
MIG
P r ess
Parameter
Select
Figure 9-6. Deleting Programs From Card
OM-172 324 Page 31
SECTION 10 – SETUP
10-1. Setup Flow Chart
1
>R a
Se
Ac
Mi
nge
cu r i t y
ces s
g Type
Vo l t
10 . 0
Mi n
Vo l t
2
1
Display Selections
2
Features
3
Settings
To set up features that customize
operation, use the setup displays.
Features that can be customized
are as follows:
3
Example Of Pulse Panel Setup Display
Display
Selection
>Range
Features
Settings
Volt Min
0.0 - 25.0 V
Volt Max
25.0 - 99.9 V
Amp Min
0 - 50 A
Amp Max
50 - 999 A
Section
Display
Selection
Features
>Wiretype
Wire Type
In Feeder
>Display
>Memory
Program
Number
Lock
Off/On
Code
Off/On
10-5
>Mig Type
Voltage
Correction
DVC On/Off
10-6
>Inductance
Level
0.0 - 99
10-7
>Purge
Time
0.0 - 25.0
10-8
>Voltage
Control
17-Pin
10-9
Feedback
Volt Sense
Arc Start Type
Standard
Hot Start
Soft Start
10-10
0–9999.99 Hours
0–999,999 Cycles
10-11
>Arc Time
Run Hours
Hardwire/Softwire
10-13
Actual
Amps
Control
10-14
No Reset
10-15
Reset
10-4
>Access
>Arc Start
Section
10-3
Press Mode Select
To Go To Next Setup Display
>Security
Settings
>Shutdown
Arc Start/
Volt Sense
Off/On
10-16
>Name
Card Programs
Off/On
10-17
>Program
Remote
Program
Off/On
10-18
>Stick
Stick Check
Off/On
10-19
>Jog IPM
IPM
50 - 780
10-20
>Robot
>Arc Fail
>Monitor
10-21
Timer
Off/On
Time
0.0 - 10.0
Arc Volt Error
Off/On
Range
0.1 - 9.9
10-22
10-23
No Reset
Reset
>Wire Feed
Display
>Software
IPM/MPM
10-12
Figure 10-1. Setup Flow Chart
OM-172 324 Page 32
Version Number
10-24
10-2. Using Setup Displays
1
2
3
Mode
Select
Front Panel Setup Display
Front panel display during setup.
Parameter
Select
2
Pulse Panel Mode And Parameter Select Buttons
3
Power Switch On Rear Panel
Press and hold down both buttons
while turning On unit.
4
Pulse Panel Setup Display
Follow this procedure any time access is required. Once in the setup
displays, use the Mode Select button to select a particular display.
To save any or all of the changes
made while in the setup displays,
and/or to exit the setup displays,
turn power to the unit Off and back
On.
1
4
S e t u p
Front Panel Display
>R a
Se
Ac
Mi
nge
cu r i t y
cess
g
Type
Vo l t
10 . 0
Mi n
Vo l t
Pulse Panel Display
Figure 10-2. Accessing Setup Displays
OM-172 324 Page 33
10-3. Selecting Welding Power Source Range
NOTE
Welding power source minimum and maximum voltage values are always
required. Amperage values are required for pulse welding.
1
>R a
Se
Ac
Mi
Access
Setup
Display
nge
cu r i t y
cess
g
Type
1
>V o l t M i n
10 . 0Vo l t
Range Display
See welding power source Owner’s
Manual for voltage and amperage
ranges. Set values to match welding power source ranges.
2
Minimum Voltage Display
Range is 0 to 25.0 volts.
3
Press Mode
Select
Maximum Voltage Display
Range is 25.0 to 99.9 volts.
4
Parameter
Select
Minimum Amperage Display
(Available When System Set
For Pulse/Mig)
Range is 0 to 50 amperes.
Default values are for 450 Ampere Inverter Model.
Do not change values if using 450 Ampere
Inverter Model.
5
Vo l t Mi n
>1 0 . 0 V o l t
Maximum Amperage Display
(Available When System Set
For Pulse/Mig)
Range is 150 to 999 amperes.
2
Increase/Decrease
Vo l t Mi n
> 8 . 0Vo l t
Parameter
Select
Increase
>V o l t M a x
38 . 0Vo l t
*Use Parameter Select button to
select voltage or amperage.
Use Increase/Decrease buttons
to change value.
5*
>A m p
565
Parameter
Select
Ma x
Amp
>A m p
10
Mi n
Amp
Parameter
Select
Figure 10-3. Range Display
OM-172 324 Page 34
3*
4*
10-4. Selecting Security Lock
NOTE
Security lock works only when a data card is inserted (see Section 9-1).
1
Security Display
Use this display to lock a program’s
weld parameters so that changes
can not be made using pulse panel
controls.
Access
Setup
Display
1
2
2
Program Number
Choose the program number (1
through 8) to be locked.
Ra
>S e
Ac
Mi
nge
cu r i t y
ces s
g
Type
>P r o g
Lock
1
Of f
3
Press Mode
Select
Increase
P r og
>L o c k
T r im
I PM
2
On
0
0
P r og
>L o c k
2
Of f
Increase
Program Lock Display
When lock is off a program, the operator can change all weld parameters of that program without
restriction.
>P r o g
Lock
Parameter
Select
2
Of f
With lock on a program, the operator can change parameters of that
program but the range of change is
restricted.
In the example displays in this figure, the operator could change the
value of trim ±10% and wire feed
speed ±100 ipm from programmed
values. If the settings are left at 0,
the operator cannot change values
from those programmed.
3
Parameter
Select
P r og
Lock
>T r i m
I PM
P r og
Loc k
>T r i m
I PM
2
On
0
0
2
On
10
0
Increase/
Decrease
P r og
Loc k
T r im
>I PM
2
On
10
0
Parameter
Select
Increase/
Decrease
>P r o g
Lock
3
Of f
>P r o g
Loc k
T r im
I PM
Increase
2
On
10
100
P r og
Lock
T r im
>I PM
2
On
10
100
Parameter
Select
Figure 10-4. Security Display
OM-172 324 Page 35
10-5. Selecting Or Changing Access Code
NOTE
Access code works only when a data card is inserted (see Section 9-1).
1
Access
Setup
Display
Code Display
With code off, access to the setup
displays is not restricted.
1
With code on, the operator must
know and enter the access code to
access or change any of the setup
displays.
Ra
Se
>A c
Mi
nge
cu r i t y
ces s
g Type
Co d e
>O f f
2
Press Mode
Select
Press Parameter Select button to
enter access code. When the correct letter is entered, the indicator
automatically moves to the next
character. When the final access
code letter is entered, the display
automatically changes to the initial
setup display.
Increase
Code
>O n
AAA
Parameter
Select
Co d e
On
>A A A
⇒P r e s s
Increase/Decrease
To Set Code
Parameter Select
To Move
Indicator
Co d e
On
>Z WX
⇒P r e s s
Turn Power Off And Back On
And Access Security Display
2
En t e r
Ac ces s
Code
>C o d e
⇒P r
AAA
ess
Figure 10-5. Access Code Display
OM-172 324 Page 36
Access Display
With a code set, this display appears when power is turned on
while holding the pulse panel Mode
and Parameter Select buttons.
10-6. Selecting Voltage Correction
1
Mig Type Display
With DVC Voltage Correction On,
the unit uses closed-loop feedback
from the 17-pin cord or voltage
sensing leads to maintain set voltage parameters.
With DVC Voltage Correction Off,
feedback from the arc is not used
for closed-loop feedback to maintain voltage parameters. Feedback
from the arc is still used for other
functions.
Be sure voltage sensing leads are
connected or voltage feedback is
available through the 17-pin receptacle via the welding power source.
1
Access
Setup
Display
Press
Mode Select
Se
Ac
>M i
I n
cu r i t y
ces s
g Type
duc t .
Vo l t a g e
Co r r e c t i o n
>D V C O n
Vo l t a g e
Co r r e c t i o n
>D V C O f f
Increase
Figure 10-6. Mig Type Display
10-7. Selecting Inductance
1
1
Access
Setup
Display
Press
Mode Select
Ac c
Mi
>I n
Pu
ess
g Type
duc t .
r ge
Le v e l
30
Inductance Display
The inductance level can be varied
between 0 (zero) and 99.
Increase
Le v e l
99
Figure 10-7. Inductance Display
OM-172 324 Page 37
10-8. Selecting Purge Time
1
Use Purge only when a weld
program is not running.
Access
Setup
Display
Press
Mode Select
1
Mi
I n
>P u
Vo l
g Type
duc t .
r ge
t age
Purge Display
The purge time can be varied between 0.0 (zero) and 25.0 seconds.
Increase
Ti me
0 . 0
Ti me
25 . 0
Figure 10-8. Purge Display
10-9. Selecting Voltage Sensing Method
1
Voltage Feedback Display
When using the 17 Pin setting, arc
voltage feedback is through the
welding power source and the feedback signal is sent through the
17-pin cord to the feeder.
If the 17 Pin setting is used, it is recommended that the voltage sensing terminals on the welding power
source be used to monitor arc voltage at the workpiece.
When using the V. Sense setting,
arc voltage feedback is through the
voltage sense leads connected to
the feeder. Use this setting when
there is more than 50 ft (15 m) of
weld cable used.
1
Access
Setup
Display
Press
Mode Select
I n
Pu
>V o
A r
duc t .
r ge
l t age
cS t a r t
Co n t r o l
Fe e d b a c k
>1 7 P i n
Increase
Figure 10-9. Voltage Feedback Display
OM-172 324 Page 38
Co n t r o l
Fe e d b a c k
>V . S e n s e
10-10. Selecting Regular Or Hot Arc Start
NOTE
Arc Start selection is not used when welding in non-pulsed MIG.
Do not use the Hot Start setting for .035 in (9 mm) or smaller wire.
1
1
Access
Setup
Display
Press
Mode Select
Pu
Vo
>A r
A r
r ge
l t age
cS t a r t
c T i me
Ar c S t a r t
Ty p e
>S t a n d a r d
Ar c S t a r t
Ty p e
>H o t S t a r t
Arc Start Display
Use the Hot Start mode for pulse
welding with 450 Ampere Inverter
Model when high initial weld current
is necessary to start large diameter
welding wires. When in Hot Start,
the 450 Ampere Inverter Model
starts the arc in the CV mode and
switches to CC once the arc is
started. Do not use Hot Start unless
using 450 Ampere Inverter Model.
Increase
Ar c S t a r t
Ty p e
>S o f t S t a r t
Figure 10-10. Arc Start Display
10-11. Resetting Arc Time
1
Arc Time Display
The unit accumulates arc hours up
to 9999.99 hours or 999999 weld
cycles before rolling over to zero
(0). The arc timer can be reset using
this display.
1
Access
Setup
Display
Press
Mode Select
Vo
A r
>A r
Wi
l t age
c S t a r t
c T i me
r e f eed
0 . 0 0H r s
0Cy c l
>N o R e s e t
Increase
0 . 0 0H r s
0Cy c l
>R e s e t
P r ess
Figure 10-11. Arc Time Display
OM-172 324 Page 39
10-12. Selecting Units For Wire Feed Speed And Motor Type
1
Wire Feed Display
The displayed unit of wire speed
(IPM or MPM) can be changed
along with the wire feed motor type
(Standard, Low Speed, or High
Speed).
1
Access
Setup
Display
Press
Mode Select
A r
A r
>W i
Wi
cS t a r t
c T i me
r e f eed
r e t ype
Di s p l a y
>I PM
Mo t o r T y p e
S t anda r d
Increase
Di s p l a y
I PM
Mo t o r T y p e
>L o w S p d
Di s p l a y
I PM
Mo t o r T y p e
>H i g h S p d
Increase
Di s p l a y
I PM
Mo t o r T y p e
>S t a n d a r d
Di s p l a y
>MP M
Mo t o r T y p e
S t anda r d
Parameter Decrease
Select
Increase
Figure 10-12. Wire Feed Display
10-13. Selecting Wire Type
NOTE
If wire type is changed, perform a memory reset (see Section 10-15) immediately
after selecting wire type to bring up the correct welding programs.
1
Wire Type Display
Select soft wire when using aluminum wire in the wire feeder. Select
hard wire when using any other kind
of wire.
1
Access
Setup
Display
Press
Mode Select
A r
Wi
>W i
D i
c T i me
r e f eed
r e t ype
sp l ay
Wi r e Type
I n Feede r
>H a r d w i r e
Wi r e Type
I n Feede r
>S o f t w i r e
Increase
Figure 10-13. Wire Type Display
OM-172 324 Page 40
10-14. Selecting Display
1
1
Display Select Display
The display can show amps, actual
reading or print out command..
Access
Setup
Display
Press
Mode Select
Wi r e
Wi r e
>D i s p
Memo
f
t
l
r
eed
ype
ay
y
C o mm a n d
Increase
Increase
Ac t ua l
Amp s
Figure 10-14. Display Select
10-15. Resetting Memory
1
No Reset
Memory cannot be reset.
Access
Setup
Display
Press
Mode Select
1
Wi r e
D i sp
>M e m o
Shu t
t
l
r
d
ype
ay
y
own
>N o
2
Re s e t
3
Increase/
Decrease
>P r o g r a m
Re s e t
4
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
gon Ox y
System Reset
Press Parameter Select button to
reset programs and setup to original factory settings. System, Arc
Time, and Model Type settings are
not affected by the system reset.
1
P r ess
>P r o c e s s
Sequence
Ca r d
Program Reset
Press Parameter Select button to
reset last active program to original
factory program settings. All other
program and setup information remains the same.
4
Reset (Default) Displays
2
Parameter
Select
Increase/
Decrease
>S y s t e m
Re s e t
3
P r ess
Parameter
Select
Figure 10-15. Resetting Memory
OM-172 324 Page 41
10-16. Selecting Arc Start/Volt Sense Error Shutdown
1
Voltage Shutdown Display
With Arc Start/Volt Sense on, the
unit shuts down when no arc voltage is sensed. If the unit shuts
down, an error message appears
(see Section 11-3).
With Arc Start/Volt Sense off, the
unit continues to feed wire even
when there is no arc voltage
sensed.
1
Access
Setup
Display
Press
Mode Select
D i sp l ay
Memo r y
>S h u t d o w n
N ame
Increase
Ar c S t a r t /
Vo l t S e n s e
>O n
Ar c S t a r t /
Vo l t S e n s e
>O f f
Figure 10-16. Voltage Shutdown Display
10-17. Selecting Program Name Feature
1
Name Display
When a data card is used, the programs written from the unit to the
card can be named.
1
Access
Setup
Display
Press
Mode Select
Memo r y
Sh u t d own
>N a m e
P r o g r am
Ca r d
Pr o g r a m s
>O n
Ca r d
Pr o g r a m s
>O f f
Increase
Figure 10-17. Naming Card Programs
OM-172 324 Page 42
10-18. Remote Program Select
NOTE
Remote Program Select is in binary code, with “A” the least significant bit, and “C”
the most significant bit.
1
Program Display
When Program is On, a remote device may be used to select programs. When Off, program selection must be done from robot Teach
Pendant or interface pulse panel.
1
Access
Setup
Display
Press
Mode Select
Sh u t d own
N ame
>P r o g r a m
S t i c k
Re m o t e
Pr o g r a m
>O f f
Re m o t e
Pr o g r a m
>O n
Increase
Figure 10-18. Program Display
10-19. Stick Check Selection
1
Stick Check Display
When stick check is On, a stick
check routine is performed at the
end of each weld. When Off, no
stick check is done.
1
Access
Setup
Display
Press
Mode Select
N ame
P r o g r am
>S t i c k
J o g I PM
St i c k
Ch e c k
>O n
St i c k
Ch e c k
>O f f
Increase
Figure 10-19. Stick Check Display
OM-172 324 Page 43
10-20. Jog Wire Feed Speed Selection
1
This feature is only used with
arc-On style robots.
Jog IPM Display
Jog wire feed speed can be varied
between 50 and 780 inches per
minute, IPM.
1
Press
Mode Select
Access
Setup
Display
P r
S t
>J o
Ro
o g r am
i c k
g I PM
bo t
I PM
>7 8 0
I PM
>5 0
Increase
Figure 10-20. Jog Speed Display
10-21. Robot Type Selection
1
1
Access
Setup
Display
Press
Mode Select
S t
Jo
>R o
A r
i c k
g I PM
bo t
c Fa i l
Co n t r o l o f
>A r c O n
&An a l o g
I npu t s
Increase
Co n t r o l o f
>A r c O n
NoAna l og
I npu t s
Increase
Co n t r o l o f
>P S, W i r e ,
Ga s &
Ana l og
Figure 10-21. Robot Display
OM-172 324 Page 44
Robot Type Display
This interface can be programmed
to work with three different types of
robot controllers.
The robot has control of arc on but
the interface has control of weld sequences. There are two analog
channel for the robot to use.
The robot has control of arc on but
the interface has control of weld sequences. There are no analog
channels for the robot to use.
The robot has control of arc on, the
welding power source contactor,
wire feed speed, gas valve and two
analog channels.
The setting of robot type affects the
programming capabilities of the interface. See Sections 6 and 8.
10-22. Arc Failure Shutdown
1
This feature can be turned on and
off. If the feature is On, a time can be
selected after which the weld is
aborted.
1
Access
Setup
Display
Press
Mode Select
Jo
Ro
>A r
Mo
g I PM
bo t
c Fa i l
n i t o r
Arc Fail Display
Ti me r
>O f f
Ti me
0 . 0
Ti me r
>O n
Ti me
0 . 7
Increase
Figure 10-22. Arc Fail Display
10-23. Arc Voltage Error Selection
1
Provides a means to enable/disable the arc voltage error feature
and to set an acceptable range of
deviation from set arc voltage or arc
length (trim) before the error will actuate.
When a system reset is done, Monitor is set to Off.
Access
Setup
Display
Press
Mode Select
When this feature is off, arc voltage
or arc length variations will not
cause an error or shut the unit
down.
1
Ro
A r
>M o
So
bo t
c Fa i l
n i t o r
f t wa r e
Monitor Display
Ar c V o l t s
>O n
2 . 0 Vo l t s
1 . 0 Sec
A r c
>O f f
When this feature is on and a range
of deviation is set (±0.1 – 9.9 volts
from desired weld voltage), arc voltage or arc length variations outside
of the range for a period of time
longer than that set by the Arc Error
timer, causes either the error relay
to energize or the unit to shut down
depending on the Arc Start/Volt
Sense shutdown error setting.
Vo l t s
Increase
Figure 10-23. Monitor Display
10-24. Software Version Number
1
Access
Setup
Display
Press
Mode Select
Ro
A r
Mo
>S o
bo t
c Fa i l
n i t o r
f t wa r e
Ve r s i o n
#1 2 3 4 5 6 Z
1
Example Version Number Display
When talking with service personnel, this number may be required.
(Check actual unit display for number.) The factory keeps this number
on file with the serial number of the
unit.
Figure 10-24. Version Number Display
OM-172 324 Page 45
SECTION 11 – MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
•
•
HOT PARTS can cause severe burns.
•
Do not touch live electrical parts.
Allow cooling period before servicing gun or unit.
Turn Off robot, interface, and welding power source,
and disconnect input power before inspecting,
maintaining, or servicing.
MOVING PARTS can cause injury.
•
•
Keep away from moving parts.
Keep away from pinch points such as drive rolls.
Maintenance to be performed only by qualified
persons.
wfwarn4.1
8/92
11-1. Routine Maintenance
3 Months
Turn Off all power before maintaining.
6 Months
Tape Or
Replace
Cracked
Weld
Cable
3 Months
Replace
Unreadable
Labels
OR
Blow Out
Or
Vacuum
Inside
During Heavy Service,
Clean Monthly
Replace
Cracked
Parts
14-Pin Cord
Gas Hose
Gun Cable
Figure 11-1. Maintenance Schedule
11-2. Overload Protection
READ SAFETY BLOCKS at start of
Section 11 before proceeding.
WARNING
1
Turn Off robot, interface, and welding power source.
1
Circuit Breaker CB1
CB1 protects the interface from
overload. If CB1 trips, the unit shuts
down.
Allow cooling period and manually
reset breaker.
2
Fuse F1
F1 protects the interface from overload. If F1 opens, the unit shuts
down.
Replace F1 with fuse of the same
type, size, and rating.
2
ST-800 962-A
Figure 11-2. Overload Protection
OM-172 324 Page 46
11-3. Front Panel Error Displays
1
Memory CRC Error Display
Corrupted program data has been
detected or loaded. The “X” value indicates the program number.
1
Memo r y
P r g
CRC
E r r o r
X
2
Memo r y
P r g
X
R a n g e
E r r o r
3
May be caused by incompatible information on the data card or bad
memory.
2
May be caused by improper range
settings or improper data loaded into
the interface unit.
3
N o
E r r o r
4
May be caused by an inability to establish an arc in the pulse schedule,
or a lack of voltage feedback.
4
N o
T a c h
S e n s e d
E r r o r
5
May be caused by obstructions in the
wire feed system or a faulty wire drive
system.
Arc Stop Error Display
Trouble is occurring at arc end.
E r r o r
6
May be caused by obstructions in the
wire feed system or a faulty wire drive
system.
6
A r c
S t a r t
No Tach Sensed Error Display
The motor tachometer feedback is
not reaching the control.
5
A r c
S t o p
No Volt Sensed Error Display
The arc voltage sense circuit did not
receive feedback within the required
time after an arc was established.
V o l t
S e n s e d
Memory Range Error Display
Improper welding power source
range is selected. The “X” value indicates the program number.
Arc Start Error Display
Trouble is occurring at arc start.
E r r o r
May be caused by obstructions in the
wire feed system or a faulty wire drive
system.
Figure 11-3. Error Displays
OM-172 324 Page 47
1
1
S t o p
We l d
E r r o r
C y c l e
D e t e c t e d
2
2
Error Card Read Display
The card reader is not working
properly.
May be caused by a bad data card, a
bad data card reader, a faulty microprocessor circuit board, or a wiring
problem.
E r r o r
C a r d
R e a d
3
Robot E-Stop Display
The robot E-Stop is active. The interface unit will remain in a locked stated
until the E-Stop is released.
3
R o b o t
4
E – S t o p
Ground Current Detect Error
Display
Weld current has been detected in
the earth ground connection.
4
G r o u n d
C u r r e n t
D e t e c t
E r r o r
5
May be caused by a conductor making connection to the unit chassis.
5
Wire Stick Error Display
The welding wire has stuck to the
workpiece at the end of the weld.
May be caused by poor weld
conditions.
W i r e
6
S t i c k
An arc was not established within the
allotted time.
E r r o r
6
A r c
O u t
Arc Fail Time Out Error Display
May be caused by an inoperable wire
drive, absence of shield gas, or improperly operating welding power
source.
F a i l
T i me
E r r o r
Figure 11-4. Error Displays (Continued)
OM-172 324 Page 48
Stop Weld Cycle Error Display
An error has been detected and the
robot hasn’t stopped the weld cycle,
causing the interface unit to stop the
weld cycle and wait for the robot to
stop.
1
Diagnostic LED’s Cover
Remove cover.
2
Interface Board PC5
Diagnostic LED’s are visible inside
unit, located on edge of Interface
Board PC5 facing front of unit.
Refer to Table 11-1 for information on
diagnostic LED’s.
Reinstall cover after checking diagnostic LED’s.
1
LED5
LED4
LED3
LED6 LED7 LED8 LED9
LED2
LED1
2
ST-800 755-B / ST-801 094
Figure 11-5. Location Of Diagnostic LED’s
Table 11-1. Diagnostic LED’s On Interface Board PC5
LED
Status
1
On
Indicates +15 volts dc present on interface board PC5 with respect to power source common.
Off
If LED 1 is off and LED’s 2 thru 5 are on, replace interface board PC5. If LED 1 is off and LED’s 2 thru 5
are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1, SR1, and
PC1 if necessary.
On
Indicates –15 volts dc present on interface board PC5 with respect to power source common.
Off
If LED 2 is off and LED’s 1, 3, 4, and 5 are on, replace interface board PC5. If LED 2 is off and LED’s 1,
3, 4, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
On
Indicates +15 volts dc present on interface board PC5 with respect to dc circuit common.
Off
If LED 3 is off and LED’s 1, 2, 4, and 5 are on, replace interface board PC5. If LED 3 is off and LED’s 1,
2, 4, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
On
Indicates –15 volts dc present on interface board PC5 with respect to dc circuit common.
Off
If LED 4 is off and LED’s 1, 2, 3, and 5 are on, replace interface board PC5. If LED 4 is off and LED’s 1,
2, 3, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
On
Indicates +5 volts dc present on interface board PC5 with respect to dc circuit common.
Off
If LED 5 is off and LED’s 1 thru 4 are on, replace interface board PC5. If LED 5 is off and LED’s 1 thru 4
are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1, SR1, and
PC1 if necessary.
On
Indicates contactor is not energized, normal standby mode.
Off
Indicates contactor is energized.
On
Indicates CV mode is selected.
Off
Indicates CC mode is selected.
On
Indicates gas valve GS1 is not energized, normal standby mode.
Off
Indicates gas valve GS1 is energized.
On
Indicates wire feed motor M1 is not running, normal standby mode.
Off
Indicates wire feed motor M1 is running.
2
3
4
5
6
7
8
9
Diagnosis
OM-172 324 Page 49
SECTION 12 – ELECTRICAL DIAGRAMS
Figure 12-1. Circuit Diagram For Robotic Interface Unit
OM-172 324 Page 50
SD-171 360-A
OM-172 324 Page 51
Figure 12-2. Circuit Diagram For Microprocessor Board PC1
OM-172 324 Page 52
SD-161 039-A
OM-172 324 Page 53
Figure 12-3. Circuit Diagram For Motor Board PC3
OM-172 324 Page 54
SD-083 388-B
OM-172 324 Page 55
Figure 12-4. Circuit Diagram For Customer Interface Board PC4
OM-172 324 Page 56
SD-166 275
OM-172 324 Page 57
Figure 12-5. Circuit Diagram For Interface Board PC5
OM-172 324 Page 58
SD-165 466
OM-172 324 Page 59
SB-159 412
Figure 12-6. Circuit Diagram For Filter Board PC6
OM-172 324 Page 60
SC-165 462-A
Figure 12-7. Circuit Diagram For Display Board PC7
OM-172 324 Page 61
SA-156 626-A
Figure 12-8. Circuit Diagram For Data Card Board PC8
SA-158 163
Figure 12-9. Circuit Diagram For Pulse Display Board PC8
OM-172 324 Page 62
NOTES
OM-172 324 Page 63
SECTION 13 – PARTS LIST
1
2
7
6
3
5
24
13
4
14
8
23
9
10
22
15
12
11
16
17
21
20
2
19
18
ST-801 142
Figure 13-1. Case Section w/Components
OM-172 324 Page 64
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Case Section w/Components
. . . 1 . . . . PC3 . . . . . 071 642
. . . 2 . . . . . . . . . . . . . . . 098 691
. . . 3 . . . . . C1 . . . . . . 031 692
. . . 4 . . . . . . . . . . . . . . . 006 426
. . . 5 . . . . . R3 . . . . . . 079 497
. . . 6 . . . . . . . . . . . . . . . 605 741
. . . 7 . . . . . R2 . . . . . . 030 941
. . . 8 . . . . . R1 . . . . . . 030 651
. . . 9 . . . . . . . . . . . . . . . 166 357
. . . . . . . . . . . . . . . . . . . . +166 512
. . . . . . . . . . . . . . . . . . . . . 134 327
. . . 10 . . . . PLG7 . . . . . 165 897
. . . . . . . . . . . . . . . . . . . . . 111 030
. . . 11 . . . . . . . . . . . . . . . 009 335
. . . 12 . . . . . . . . . . . . . . . 155 022
. . . 13 . . . . . . . . . . . . . . . 169 923
. . . 14 . . . . PC1 . . . . . 171 525
. . . . . . . . . PLG11 . . . . 115 092
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG13 . . . . 163 467
. . . . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . PLG15 . . . . 153 501
. . . . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . PLG17 . . . . 115 093
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG18 . . . . 162 382
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . 15 . . . . . . . . . . . . . . . 155 629
. . . 16 . . . . . . . . . . . . . . . 126 689
. . . 17 . . . . PC5 . . . . . 165 463
. . . . . . . . . PLG51 . . . . 158 720
. . . . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . PLG52,58 . . . 158 719
. . . . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . PLG53 . . . . 131 204
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG54 . . . . 148 439
. . . . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . PLG55 . . . . 115 092
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG56 . . . . 115 093
. . . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG57 . . . . 164 900
. . . . . . . . . . . . . . . . . . . . . 147 995
. . . 18 . . . . . . . . . . . . . . . 019 663
. . . 19 . . . . . T2 . . . . . . 090 465
. . . 20 . . . . . T1 . . . . . . 169 063
. . . 21 . . SR1,SR2 . . . 035 704
. . . 22 . . . . . C2 . . . . . . 169 080
. . . 23 . . . . . 1T . . . . . . 157 169
. . . . . . . . . . . . . . . . . . . . . 108 023
. . . 24 . . . . CR1 . . . . . 109 006
. . . . . . . . . . . D1 . . . . . . 171 386
. . CIRCUIT CARD ASSEMBLY, motor speed control . . . . . . . . . . . . . . . . . .
. . STAND-OFF, No. 6-32 x .500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, elctlt 750uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 25W 2K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, mtg resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 100W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR, WW fxd 25W 10 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CASE SECTION, bottom/sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, edge skt 20-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, No. 4-40 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, ribbon 34posn 12.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, ribbon 24posn 14.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, processor w/prom . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, ribbon 14posn 3.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, No. 6-32 x 1.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, I/O interface . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOUNT, nprn 15/16 OD x 3/8rec 3/16 x 3/8 . . . . . . . . . . . . . . . . . . . . . . .
. . XFMR, signal 115V 24VCT 4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . XFMR, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 20A 16 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
6
1
1
1
4
1
1
1
1
1
1
22
2
1
1
1
1
8
1
9
1
6
1
6
1
20
1
4
1
1
12
1
2
1
3
1
10
1
8
1
6
1
3
4
1
1
2
1
1
3
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-172 324 Page 65
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-2. Panel, Front w/Components
. . . 1 . . DSPL1 . . . 165 459 . . CIRCUIT CARD ASSEMBLY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 166 355 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 057 359 . . BLANK, snap-in nyl .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 164 757 . . GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 169 419 . . COVER, troubleshooting lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 154 109 . . PLATE, ident inner control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 155 024 . . LENS, clear anti glare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . 168 337 . . PANEL, control inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . PC8 . . . . . 156 623 . . CIRCUIT CARD ASSEMBLY, data card . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG60 . . . 153 501 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . DSPL2 . . . 158 160 . . CIRCUIT CARD ASSEMBLY, side display . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . 144 844 . . STAND-OFF, No. 6-32 x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial No.) . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 168 459 . . DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 089 899 . . LATCH, slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . 153 169 . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . 089 032 . . LENS, LED 4341 red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
6
1
8
1
1
1
8
3
8
3
7
4
6
1
9
5
2
10
11
15
14
13
12
ST-801 143-A
Figure 13-2. Panel, Front w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-172 324 Page 66
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-3. Panel, Center w/Components
. . . 1 . . . . . . . . . . . . . 099 037
. . . 2 . . . . . 2T . . . . 157 169
. . . 3 . . . . . . . . . . . . . 038 839
. . . . . . . . . . . . . . . . . . . 108 023
. . . 4 . . . . CR2 . . . 052 964
. . . 5 . . . . . . . . . . . . . 134 201
. . . 6 . . . . . . . . . . . . . 166 354
. . . 7 . . . . PC4 . . . 166 272
. . . . . . . . . . PLG3 . . . 158 768
. . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . . PLG6 . . . 164 467
. . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . PLG70 . . . 115 092
. . . . . . . . . . . . . . . . . . . . 113 746
. . EDGE TRIM, style 62-1/16 black w/clips (order by ft) . . . . . . . . . . . . . . . . .
. . BLOCK, term 20A 16 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 20A 5 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, mtg cmpts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, rect 24P/S 2 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2ft
1
1
2
1
4
1
1
1
24
1
9
1
8
2
1
3
4
5
6
7
ST-801 144
Figure 13-3. Panel, Center w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-172 324 Page 67
3
2
4
3
1
5
13
6
12
10
9
8
7
11
ST-801 145
Figure 13-4. Panel, Rear w/Components
OM-172 324 Page 68
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-4. Panel, Rear w/Components
. . . 1 . . . . . . . . . . . . . 171 363
. . . 2 . . . . . S1 . . . . . 111 997
. . . 3 . . . . . . . . . . . . . 046 432
. . . 4 . . . . . F1 . . . . 012 655
. . . 5 . . . . . . . . . . . . . 139 042
. . . 6 . . . . . . . . . . . . . 171 367
. . . . . . . . . . PC2 . . . 134 560
. . . . . . . . . . . R4 . . . . . 074 110
. . . . . . . . . . RC21 . . . 076 624
. . . 7 . . . . RC9 . . . 152 492
. . . . . . . . . . . . . . . . . . . 134 731
. . . 8 . . . . RC8 . . . 153 884
. . . 9 . . . . CB1 . . . . 011 991
. . . 10 . . . . . . . . . . . . . 073 756
. . . 11 . . . . PC6 . . . 164 709
. . . . . . . . . PLG89 . . 131 204
. . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG82 . . 158 720
. . . . . . . . . . . . . . . . . . . 147 995
. . . 12 . . . . RC20 . . . 139 268
. . . 13 . . . . . FL1 . . . 084 171
. . . . . . . . . . . . . . . . . . . 172 821
. . . . . . . . . . . . . . . . . . . 153 886
. . . . . . . . . . . . . . . . . . . 039 734
. . . . . . . . . . . . . . . . . . . 600 797
. . . . . . . . . . . . . . . . . . . 071 892
. . . . . . . . . . . . . . . . . . . 079 534
. . . . . . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 158 373
. . . . . . . . . . . . . . . . . . . 097 868
. . . . . . . . . . . . . . . . . . . . 116 964
. . . . . . . . . . . . . . . . . . . 600 343
. . . . . . . . . . . . . . . . . . . 097 866
. . . . . . . . . . . . . . . . . . . . 175 115
. . . . . . . . . . . . . . . . . . . 141 162
. . . . . . . . . . . . . . . . . . . 134 731
. . . . . . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 121 274
. . . . . . . . . . . . . . . . . . . 152 370
. . . . . . . . . . . . . . . . . . . 079 534
. . . . . . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 133 866
. . . . . . . . . . . . . . . . . . . 073 686
. . . . . . . . . . . . . . . . . . . 039 828
. . . . . . . . . . . . . . . . . . . 133 859
. . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, rocker spst 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOLDER, fuse mintr .250 x 1.250 panel mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FUSE, mintr cer 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUSHING, strain relief .270/.480 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECEPTACLE, w/components (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . RESISTOR, c 1W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 4 pin rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ pin 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . CONNECTOR, circ 19skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT BREAKER, man reset 1P 1.5A 250VAC . . . . . . . . . . . . . . . . . . . 1
. . STAND-OFF, No. 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . CONNECTOR, circ 10skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, line pwr 115/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, motor/gas (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 19 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CABLE, port No. 16 8/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ft
. . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ skt 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, interconnecting power 10ft (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 17skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . CABLE, port No. 16 5/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft
. . . . CONNECTOR, circ 17 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, interconnecting 10ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ pin 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CABLE, port No. 18 12/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft
. . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ skt 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, volt sense 35ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 4skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CABLE, shld No. 18ga 1/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . 70ft
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-172 324 Page 69
ST-801 153
Figure 13-5. Motor & Drive Assembly
OM-172 324 Page 70
36
37
38
39
40
41
35
34
2
3
4
5
6
7
8
33
32
9
1
14
16
15
34
10 11 12 Includes
Items
13-16
33
17
13
32
14
18
19
20
21
22
24
31
30
25
26
23
27
28
29
29
Item
No.
Part
No.
Description
Quantity
Figure 13-5. Motor & Drive Assembly
. . . 1 . . . . . 046 779 . . DRIVE ASSEMBLY, wire (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . 602 154 . . . . SCREW, cap stl hexhd .250-20 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . 010 224 . . . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . 166 337 . . . . HOUSING, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . 085 242 . . . . FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . 085 244 . . . . WASHER, cupped stl .328 ID x .812 OD x .125 lip . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . 010 231 . . . . SPRING, cprsn .770 OD x .105 wire x 1.225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . 085 243 . . . . KNOB, adjustment tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . 166 071 . . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . 079 634 . . . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . 151 828 . . . . PIN, cotter hair .054 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . 166 338 . . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . 144 172 . . . . FITTING, brs barbed M 3/16tbg x .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . 166 072 . . . . SPACER, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . 604 538 . . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . 079 772 . . . . KNOB, plstc T 1.500 lg x .312-18 x 2.000 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . 070 397 . . INSULATION, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . 173 128 . . BRACKET, mtg motor/gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . 075 150 . . WASHER, shldr nyl 1.000 OD x .375 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . 010 910 . . WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . 602 213 . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . 079 624 . . SCREW, cap stl hexhd slflkg .375-16 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . 173 145 . . MOTOR, gear (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . 047 636 . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 079 535 . . . . . . CONNECTOR, circ pin push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . 079 739 . . CLAMP, cable strain relief sz 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . 172 996 . . CABLE, motor 12.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . 132 611 . . OPTICAL ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . 153 631 . . CIRCUIT CARD, digital tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 131 203 . . CONNECTOR & PINS (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 114 656 . . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 29 . . . . +172 807 . . MOTOR, gear 1/8hp 115VDC 2000RPM (consisting of) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 153 491 . . . . KIT, brush replacement (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 153 492 . . . . . . CAP, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 153 493 . . . . . . BRUSH CARBON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . 092 865 . . KEY, stl .1215/.1230 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . 133 873 . . VALVE, 24VDC 2 way custom port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 605 227 . . NUT, .750-14 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 149 332 . . CLAMP, hose .405-.485clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 604 525 . . CABLE, port No. 18 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 026 202 . . DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . 053 842 . . GEAR, spur insulated w/bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . 079 626 . . SCREW, mach stl filh 10-32 x .875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . 605 518 . . SCREW, cap stl hexhd .250-20 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . 072 010 . . WASHER, shldr nyl .437 OD x .316 ID x .187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . . . . 079 625 . . WASHER, spring stl .500 shakeproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . 000 418 . . SCREW, cap stl hexhd slflkg .250-20 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . 602 241 . . WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . 093 664 . . GEAR, spur insulated drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . 601 872 . . NUT, stl hex full .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . 602 243 . . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 168 589 . . BUSHING, insulating 1.500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 168 590 . . BUSHING, insulating .750dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 080 438 . . BRACKET, ball clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 079 872 . . BRACKET, mtg pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 080 439 . . BRACKET, ball clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 045 767 . . BAR, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
1
2
2
1
2
2
2
2
1
1
1
1
1
1
1
1
1
1
2
2
4
2
1
1
14
1
1
1
1
1
3
1
1
2
2
1
1
1
1ft
1
3ft
1
4
12
4
2
2
1
1
1
2
2
1
3
1
1
1
1
OM-172 324 Page 71
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