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Millerfi
October 1991
MODEL:
FORM: OM-141 438
DUAL TORCH SYSTEM
Computer Interfaces
(per NSPR 9288)
F!ILE COPY
RETURN TO FOLDER
OWNERS
IMPORTANT:
-
MANUAL
Read and understand the entire contents of both this manual
and the power source manual used with this unit, with special
the safety material throughout both manuals, before installing,
emphasis on
operating, or
maintaining this equipment. This unit and these instructions are for use only
by persons trained and experienced in the safe operation of robotic equipment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor if you do not fully understand these instructions.
ST-150 613
MILLER ELECTRIC
A Miller
Mfg. Co.
Group Ltd., Company
P.O. Box 1079
WI 54912 USA
Appleton,
Tel. 414-734-9821
PRINTED IN U.S.A.
UI
I
L
-J
LIMITED WARRANTY
EFFECTIVE: AUGUST 6, 1990
4
This warranty
supersedes
all
MILLER warranties and is exclusive with
previous
LIMITED WARRANTY
Subject
to the terms and conditions
hereof. MILLER Electric Mfg. Co.. Appleton, Wisconsin war
rants to its Distributor/Dealer that all new and unused
Equipment furnished by MILLER is free from defect in
workmanship and material as of the time and place of delivery
by MILLER. No warranty is made by MILLER with respect to
engines, trade accessories or other items manufactured by
others. Such engines, trade accessories and other items are
sold subject to the warranties of their respective manufacturers,
if any. All engines are warrantied by their manufacturer for two
years from date of original purchase, except Deutz engines
which have a one year. 2000 hour warranty.
Except as specified below, MILLERs warranty does not apply
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding wire
including nozzles and nozzle insulators where failure does not
result from defect in workmanship or material.
MILLER shall be required to honor warranty claims on war
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of
Equipment to the original user:
1.
Arc welders, power
components
sources,
2.
Load banks
3.
4.
Original main power rectifiers
(labor 1 year only)
All welding guns, feeder/guns and torches
5.
All other MILLERMATIC Feeders
6.
Replacement
7.
Batteries
or
repair parts, exclusive
As
a
matter of
by
1 year
3 years
.
.
.
90
days
1 year
of labor
60
days
6 months
provided that MILLER is notified in
of the date of such failure.
submitted
1 year
robots, and
writing within thirty (30) days
general policy only, MILLER may honor claims
original user within the foregoing periods.
the
In the
with
other
no
case
respect
guarantees
of MILLERs
to the
or
warranties
expressed
or
implied.
breach of warranty or any other duty
any goods, the exclusive remedies
quality of
therefore shall be, at MILLERs option (1) repair or
ment or, where authorized in writing by MILLER in
(2) replace
appropriate
replacement at an
(3) the reasonable cost of repair or
authorized MILLER service station or (4) payment of or credit
for the purchase price (less reasonable depreciation based
upon actual use) upon return of the goods at Customers risk
and expense. MILLERs option of repair or replacement will be
FOB., Factory at Appleton, Wisconsin, or FOB. at a MILLER
cases.
authorized service facility, therefore, no compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apparent defect or failure, MILLER shall instruct the
claimant on the warranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF MERCHAN
TABILITY OR OF F!TNESS FOR PARTICULAR PURPOSE,
ANY
EQUIPMENT
WITH
AND
ALL
RESPECT TO
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
EXPRESSLY PROVIDED BY MILLER IN
PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIALIINDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
WARRANTIES DO NOT
CONSUMER USE. MILLERS
EXTEND TO, AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLERS WARRANTIES TO, ANY CONSUMER.
EXCEPT AS
WRITING,
MILLER
U
OM-141 438- 10/91
RECEIVING-HANDLING
unpacking equipment, check carton for any damthat
age
may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Before
Assistance for
spaces to record the Model Designa
Style Number of your unit. The infor
mation is located on the rating label or the nameplate.
Use the
settling claims may be obtained
equipment manufacturers Transportation Department.
filing
following
tion and Serial
or
or
from the distributor and/or the
Model
________________________________
Serial
requesting information about this equipment, al
ways provide the Model Description and Serial or Style
or
Style
No.
____________________
When
Date of Purchase
_____________________
Number.
TABLE OF CONTENTS
Section No.
SECTION 1
Page
SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1.
General Information And
1-2.
Safety
SECTION 2
2-1.
SECTION 3
Alert
Symbol
Safety
Signal Words
1
1
INTRODUCTION
Description
1
INSTALLATION
3-1.
Location
3-2.
Wire Stick Check
3-3.
And
1
Options
FIeld Installation Instructions For
2
Computer Interlace
Dual Torch
Adapter Panel
2
3-4.
Field Installation Instructions For Second Wire Drive
3-5.
Field Installation Instructions For
3-6.
3-7.
3-8.
3-9.
SECTION 4
Assembly
Guns On Robot
Welding
Connecting Touch Sensor
Field Installation Instructions For Supplied Display Module
Connections For Computer Interlaces
Welding Power Source Computer Interface Connections
Field Installation Instructions For
4
4
Leads
5
5
6
7
OPERATOR CONTROLS
4-1.
Computer Interlace Pilot Light
8
4-2.
Remote Pendant Control
8
SECTION 5
SEQUENCE OF OPERATION
5-1.
Gas Metal Arc Welding (GMAW)
9
5-2.
9
5-3.
Shutting Down
Operation Of Computer
5-4.
Wire Stick Check
Interfaces
9
9
No.
Section No.
SECTION 6
Page
MAINTENANCE & TROUBLESHOOTING
6-1.
Inspection And Upkeep
6-2.
Overload Protection
6-3.
Circuit Board
6-4.
6-5.
SECTION 7
10
11
Handling
Troubleshooting
Use Of Indicator Lights For Troubleshooting
Precautions
11
11
14
ELECTRICAL DIAGRAMS
Diagram
7-1. Circuit
Diagram
For
Computer
Interface With Dual Torch
Adapter Panel
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
SECTION 8
7-2. Circuit
Diagram
14
For Dual Torch
7-3. Circuit
For
7-4.
For
Diagram
Circuit Diagram
7-5. Circuit
Computer
Adapter Board PC7
Voltage Board PCi
Interface
For Motor Board PC2
Diagram
Diagram For Interface Board PC4
7-7. Circuit Diagram For Display Module
7-8. Circuit Diagram For Display Module Meter Board PCi
7-9. Circuit Diagram For Display Module LED Board PC2
7-10. Circuit Diagram For Gas/Motor Control Box
7-6. Circuit
15
16
17
18
19
19
20
20
21
PARTS LIST
Figure
Figure
Figure
Figure
Figure
8-1. Main
Figure
Figure
8-6.
8-7. WCR Box
34
Figure
8-8. Control Box, Gas/Motor
35
Figure
Figure
Figure
8-9. MTX 3502 Air Cooled Gun
36
8-10. Motor/Drive
38
8-11. Inlet Cable
40
Assembly
22
8-2. Circuit Card, Interface PC4
25
8-3. Circuit Card, Dual Torch
26
8-4.
28
8-5.
Adapter PC7
Circuit Card, Motor Speed PC2
Circuit Card, Voltage Control PCi
Display Pendent
Assembly
System
30
32
LIST OF CHARTS AND TABLES
Chart 5-i.
Sequence Of Operation Timing
Chart 5-2. Wire Stick Check Timing
Table 6-1. Troubleshooting
10
10
13
No.
SECTION 1
SAFETY PRECAUTIONS AND SIGNAL WORDS
GENERAL INFORMATION AND SAFETY
1-1.
SAFETY
1-2.
SYMBOL
ALERT
AND
SIGNAL
WORDS
General
A.
The
Information
presented
in this manual and
on
various la
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective
B.
use
of this
equipment.
tify different
a
This
levels of hazard and special instructions.
safety
alert
symbol is
used with the
signal
words WARNING and CAUTION to call atten
tion to the
safety
statements.
Safety
The installation, operation, maintenance, -and trouble
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
safety
sons
ifl accordance with this manual and all
Power Source in the
welding power
a
WARNING statements
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
applicable
codes such as, but not limited to, those listed at the end
of Section 1
Safety Rules For Operation Of Arc Weld
ing
following safety alert symbol and signal words are
throughout this manual to call attention to and iden
used
source
Owners
Manual.
identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
IMPORTANT
statements
identify special
instructions
necessary for the most efficient operation of this equip
ment.
SECTION 2INTRODUCTION
DESCRIPTION
2-1.
The dual torch system allows
use
of two
welding gunsl
torches that connect to two separate welding power
sources for simultaneous welding by a single robot. The
system provides wire feed speed and voltage control cir
cuitry,
wire stick check
terface
a
second
A second
circuitry, and other circuitry to in
welding system with the Robot Control.
Display Module for the additional welding sys
SECTION 3
3-1.
LOCATION
room
The
design application of the dual torch system is for use
Welding (GMAW) process.
in the Gas Metal Arc
INSTALLATION
drive
The location of the Dual Torch
face should allow
provides display of wire feed speed, voltage, and
peak amperage. Peak amperage and arc inductance
can be set at both Display Modules. Indicator lights in
clude power, gas, contactor, wire feed, and WCR (weld
current relay). A second WCR Box is supplied for use
with the additional welding system.
tern
System Computer
to remove cover and side
Inter
~aneIs
for maintenance and repair.
assembly. Cord and cable lengths must be consid
installing components for the dual torch sys
ered when
tem.
The location should also
provide the following:
-
-
-
-
-
Mounting holes are provided in the Dual Torch System
Computer Interface base for securing in a permanent 10cation. Install the Dual Torch System Computer Interface near the welding power source. The supplied Dis
play Module installs onto the module stand. The
supplied WCR box should be installed in a location that
will allow the weld cable from a welding power source to
be easily routed through the box and to the second wire
1.
Adequate ventilation and fresh
2.
No flammables
3.
A clean and
4.
supply
area
Proper temperature that avoids
or
5.
dry
air
extremes of hot
cold
Proper
airflow around the unit.
OM-141 438
Page
1
WIRE STICK CHECK OPTIONS
3-2.
(Figure 3-1)
FIELD INSTALLATION INSTRUCTIONS FOR
3-3.
COMPUTER
The
Interface is equipped with two DIP
switches found on the Interface circuit board PC4.
Computer
These switches
are
factory
set to
provide
no
voltage
ramp during wire stick check. If either of these selections
need to be changed for a particular welding application,
proceed
as
INTERFACE
DUAL
TORCH
ADAPTER PANEL
a
WARNING:
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Shut down robot and welding power source,
and disconnect input power employing lock
follows:
out/tagging procedures before inspecting
installing.
0
or
Lockout/tagging procedures Consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
0
a
CAUTION:
(ESD)
Put
can
on
ELECTROSTATIC DISCHARGE
circuit boards.
damage
properly grounded
wrist strap BE
FORE handling circuit boards.
Transport circuit
shielding carriers
Perform work
boards in proper staticor
packages.
only at a
static-safe work
area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
CR1
-Q__
a
Be
sure
JG
that
plugs
are
properly
installed and
aligned.
R9
EXCESSIVE PRESSURE
board.
can
break circuit
SA.137 112.A
Use
only minimal pressure and gentle move
when disconnecting or connecting
board plugs and removing or installing board.
ment
Figure
3-1. DIP Switch Location And Information
Communications
Board
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Power
Shut down robot and welding power source,
and disconnect
input power employing lock
out/tagging procedures
installing.
before
inspecting
or
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Computer Interface
1.
Remove
2.
Locate DIP switches
PC4 (see
3.
Supply
on
Terminal
Strip iT
left side panel.
Interface circuit board
Figure 3-1).
Reposition appropriate DIP switch using a
pointed tool, such as the edge of a small screw
ST.150 294
driver.
Figure
4.
Reinstall left side panel.
OM-141 438 Page 2
3-2.
Right Side
Interface
View Of
Original Computer
Components
Remove
1.
original Computer
and both side
Interface top
cover
panels.
Mark and disconnect connectors from Communi
2.
cation board (see
Figure 3-2).
Remove Communication board from center baffle
3.
inside
Computer
Interface.
4.
supplied dual adapter board to lower four
standoffs on center baffle.
snap-in
nylon
5.
Reconnect connectors removed in Step 2 to
matching locations on dual adapter board. Physi
Install
cal location of connectors is the
board
same on
dual
the Communication board
adapter
(see Figure 3-5). Connect plug on end of supplied
wiring harness to matching receptacle on dual
adapter board.
as on
Install Dual Torch
6.
Computer
Adapter frame onto right side of
Interface with sheet metal
screws.
Terminal
Strip 21
Motor Control
Board
Communications
Board
Figure
7.
Dual
ST-150 291
3-4. Ground Lead Connection On Left Side
Of Computer Interface
Reinstall
Communication
onto
board
center
baffle of frame (see Figure 3-3). Fiber optic link
connector on board must point toward front of
frame. Reconnect fiber optic wave guide to fiber
Adapter
optic link connector
Board
8.
on
board.
Connect connectors from dual adapter board and
adapter frame receptacle RC 19 to matching
locations on Communication board. Connector
from receptacle RC1 9 installs to receptacle RC 2
dual
Terminal
Strip iT
on dual adapter board. Connectors from dual
adapter wiring harness install to matching con
nectors on Communication board (see Figure
3-3).
Ground
Lead
9.
Route green
ground
lead from stud
on
Dual Torch
Adapter frame through bushing in center baffle,
and connect ring terminal on end of lead to ground
stud on center baffle (see Figures 3-3 and 3-4).
Ground
Stud
10.
ST-150 295
Install
frame.
supplied right side panel onto dual adapter
Original right side panel can be retained or
discarded.
Figure
Right Side View Of Computer Interface
Components After Adding Frame
3-3.
11.
Reinstall left side panel, and install
cover onto unit.
supplied top
OM-141 438
Page3
Receptacle RC7
Receptacle RC1
Receptacle RC3
Receptacle
RC2
Receptacle RC9
Receptacle
Receptacle RCB
Receptacle RC6
SB-140 778-A
Figure
3-5. Connectors On Dual
FIELD INSTALLATION INSTRUCTIONS FOR
3-4.
Adapter Board PC7
6.
SECOND WIRE DRIVE ASSEMBLY
WARNING: ELECTRIC SHOCK
a
can
Connect
on
plug
on
end of motor cord to receptacle
Gas/Motor Control box.
kill.
3-5.
Do not touch live electrical parts.
FIELD INSTALLATION INSTRUCTIONS FOR
WELDING GUNS ON ROBOT
Shut down robot and welding power source,
and disconnect input power employing lock
out/tagging procedures before inspecting or
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
installing.
Shut down robot and welding power source,
and disconnect input power employing lock
out/tagging procedures before inspecting or
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
1.
Remove spindle and hub
support
2.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging Circuit breaker or other disconnect
ing device.
assembly from spool
arm.
3/8 in. (10 mm) drill bit and drill lower hole
brace plate on inside of spool support
channel using existing hole in channel as a
Use
installing.
a
through
1.
Remove
original welding gun
from
insulating
2.
Install customer-supplied dual torch
bracket.
mounting
3.
Reinstall
supplied
(see Figure 3-6).
4.
Install supplied welding
mounting bracket.
insulating strip between motor/
drive assembly mounting bracket and motor/drive as
sembly housing. Housing installs to outside front surface
of bracket with insulating strip between metal surfaces.
5.
arm
guide.
3.
Install motor/drive assembly mounting bracket
using the two holes in the spool support arm and
top
rear
hole in
original motor/drive assembly
Figure 3-6).
bracket (see
mounting
4.
Install Gas/Motor Control box to
motor/drive assembly
IMPORTANT:
5.
plate
bracket
rear
of
Install
Install motor/drive assembly to mounting bracket.
Use insulated shoulder washers on bolts to se
cure
motor/drive assembly to bracket.
OM-141 438 Page 4
Axis 5 output hub.
on
original welding gun
mounting bracket.
gun
onto dual torch
onto
dual torch
Install supplied outlet cable to supplied motor/
drive
assembly housing (see motor/drive
bly Owners Manual).
6.
7.
assem
Install remaining end of outlet cable to supplied
welding gun (see welding gun Owners Manual).
Use cable ties to
original
secure
outlet cable.
supplied outlet cable
to
Bolts And Insulated
Shoulder Washers
Original
Drive
Wire
Assembly
ST.150 320-A
Figure
3-6.
a
Assembly
3-6. Installation Of Second Wire Drive
FIELD INSTALLAT1ON INSTRUCTIONS FOR
CONNECTING TOUCH SENSOR LEADS
WARNING: ELECTRIC SHOCK
can
kill.
3.
Install
supplied male friction terminals
onto ends
of black leads.
4.
Remove
plug from supplied outlet cable by cut
as close to plug housing as possible.
ting leads
Do not touch live electrical parts.
Shut down robot and welding power source,
and disconnect input power employing lock
out/tagging procedures before inspecting or
5.
installing.
6.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Touch Sensor Leads
From Supplied
Outlet Cable
Strip insulation back 1/4
(6mm) at.end of both
leads.
Install
supplied female friction terminals
onto end
of both leads.
7.
Connect friction terminals on touch sensor leads
of supplied outlet cable to frition terminals in
stalled in
3-7.
4~
Friction
Terminals
in.
_____
Step
3
(see Figure 3-7).
FIELD INSTALLATION INSTRUCTIONS FOR
SUPPLIED DISPLAY MODULE
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Shut down robot and welding power source,
and disconnect input power employing lock
out/tagging procedures before inspecting or
Black
Lead
installing.
Lockout/tagging procedures
Friction
Terminals
Leads
From Robot
red-tagging circuit breaker
ing device.
1.
Connectors
Touch Sensor Leads From
Original Outlet Cable
White
Lead
2.
ST-150 292
Figure
1.
3-7. Connection Of Touch Sensor Leads
Cut black touch
sensor
(25 mm) above plug
Figure 3-7).
2.
Strip insulation
black lead.
on
(6 mm)
pad
or
other disconnect
supplied Display Module from
mounting plate (see Figure 3-8).
Disassemble
Remove
original Display
Module from module
stand.
-3.
lead approximately 1 in.
original outlet cable (see
back 1/4 in.
consist of
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
original Display Module onto rear of mount
ing plate for supplied Display Module using exist
ing holes (see Figure 3-8).
Install
4.
Reassemble supplied
mounting plate.
5.
Install
at both ends of
mounting plate
Display
Module
onto
onto module stand.
OM-141 438
Pages
5.
Connect plug on end of supplied WCR box to re
ceptacle RC8 on Dual Torch Computer Interface.
IMPORTANT:
Be
that weld cable from
sure
weld output terminal
through opening in WCR
tor/drive assembly.
6.
box before
connecting
routed
to mo
Connect weld cable from positive weld output ter
minal on welding power source to stud on motor!
drive
assembly housing (see motor/drive
bly Owners Manual).
7.
positive
welding power source is
on
assem
Connect weld cable from negative weld output
on welding power source to workpiece or
fixture.
terminal
8.
Connect
plug
end of
on
receptacle RC14
ST-150 293
3-8. Installation Of
voltage sensing leads to
Computer Inter
Dual Torch
face.
Supplied
Display Module
FIgure
on
IMPORTANT:
Voltage sensing
be installed
top of weld cable lug
on
lead
ring
terminal must
at motor/drive as
sembly.
Supplied Display
Module
9.
One lead with
to
3-8.
CONNECTIONS
FACES
FOR
COMPUTER
INTER
cable from
WARNING: ELECTRIC SHOCK
can
kill.
out/tagging procedures
installing.
before
Connect
power
Shut down robot and welding power source,
and disconnect input power employing lock
inspecting
source
is connected.
remaining
lead to the
workpiece or fix
welding
11.
source.
Connect
12.
device.
matching plug on supplied cord tO recep
on Dual Torch Computer Interface.
tacle RC12
or
Lockout/tagging procedures Consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing
power
ture near weld cable connection from
Do not touch live electrical parts.
_____
welding
(Figure 3-9)
10.
4~
terminal should be connected
ring
supplied motor/drive assembly where weld
Connect
Display
13.
Connect
to
14.
top
plug
on
Module
fitting
remaining
on
on
end of
connector on
end of cord to bottom
module stand.
supplied short gas hose
Gas/Motor Control box.
Connect
remaining end of short gas hose to
fitting on rear of motor/drive assembly
housing by sliding end of hose onto barbed fitting.
barbed
1.
2.
Connect
matching plug on end of supplied inter
connecting cord to receptacle RC1 9 on Computer
Interface Dual Torch Adapter panel.
Connect
ing
plug
cord to
on
remaining
15.
16.
end of supplied motor
Dual Torch Computer
17.
on
puter Interface.
3.
Connect
matching plug
receptacle RC9
Interface.
cord to
4.
Connect
on
on
plug on remaining end of motor
receptacle on Gas/Motor Control box.
OM-141 438
Page
6
fitting
on
end of
supplied long gas hose
Gas/Motor Control box.
end of interconnect
Dual Torch Com
receptacle RC2O
Connect
to bottom connector on
remaining end of long gas hose
meter/regulator at shielding gas source.
Remove inlet
to flow-
guide on short inlet cable from origi
assembly.
nal motor/drive
18.
cord to
Connect
Install inlet
guides
on
ends of inlet cables from
supplied dual spindle and hub assemblies to both
motor/drive assemblies.
Computer
Dual
Torch
Interface
Adapter
Dual Torch
Computer
Interface
Voltage
Sensing
Leads
RC1 4
~____
RC9
To Gas/Motor
Control Box
To Display
Module
RC12
RC8
To WCR
Box
ToWCR
Box
RC1 3
RC2O
Use
Appropriate
Receptacle
For Welding
Power Source
To Dual
Torch
Application
Adapter
Panel
To Dual
Torch
Computer
Interface
S-0648
Figure
WELDING POWER SOURCE
3-9.
3-9. Connections At
COMPUTER
a
can
kill.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before making inter
connections.
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
three
There
are
ferent
welding
circuit breaker
to
end of the interconnecting cord connects
REMOTE receptacle on the welding power
remaining
the
collar
Align keyway,
fully clockwise.
If the
welding power
or
other disconnect
insert
and rotate threaded
is equipped with both a 14
receptacle, make connections
source
and 17-socket REMOTE
to both and
plug,
place the REMOTE 14/17 switch
in the 14
position.
receptacles
power
The
source.
Lockoutitagging procedures consist of padlock
red-tagging
ing device.
10-pin receptacle, RC1O is a 17-pin receptacle and
a 14-pin receptacle. Determine which recep
tacle is required for the welding power source being
used, select appropriate interconnecting cord, and
make connections as follows: Align keyway, insert plug,
and rotate threaded collar fully clockwise.
RC11 is
INTERFACE CONNECTIONS (Figure 3-9)
WARNING: ELECTRIC SHOCK
Computer Interfaces
to accommodate use of dif
sources:
Receptacle RC13 is
a
multi-process welding power sources, rotate MAXI
MUM GTAW OUTPUT control to maximum.
For
OM-141 438
Page
7
SECTION 4
OPERATOR CONTROLS
Digital
Display
Pilot
Computer Interface
Receptacle RCI
(See Section 3.8)
Light
Display
Select Switch
Fuse Fl
Peak Am psi
Inductance
Control
(See Section 6-2)
Indicator
Lights
Computer
Interface
Display
Module
SC-136 571
SA-136 572
4-1. Front Panel Views
Figure
COMPUTER INTERFACE PILOT LIGHT
4-1.
The
pilot light turns on when 115 vac power is supplied to
Computer Interface from the welding power source.
the
A.
Digital Display
The
digital display
shows either
voltage, wire feed
inductance depending on
speed, peak amperage, or
the setting of the Selector switch.
digital display.
on
The switch also selects whether the
associated control is
setting peak amperage
PURGE Switch
E.
Indicator
There
are
Lights
five indicator
The POWER
The Selector switch is used to select what appears
the
D.
power source connected to the
inductance.
uses
lights on the interface. These are
visual indications of various process functions.
DISPLAY SELECT Switch
B.
Computer
Interface
Pressing the PURGE switch energizes the gas valve on
the robot. Use the PURGE switch to purge the gas line
before beginning welding.
REMOTE PENDANT CONTROL
4-2.
welding
tion and the
or
induc
the
light
Computer
The GAS
light turns on when the gas
shielding gas flow.
to indicate
C.
The CONTACTOR
This control sets peak amperage when the Selector
switch is in the PEAK AMPERAGE position and the
welding power source connected to the Computer
uses peak amperage.
The WIRE FEED
energized
pow
weld
light turns on when the wire drive motor
The control sets inductance in percentage (0 to 100%)
when the Selector switch is in the INDUCTANCE posi.
The WCR
light turns
energized
to indicate that
8
valve is
output is available.
is
Page
to
Display
light turns on when the welding
energized to indicate that
face
OM-141 438
supplied
the
contactor is
er source
Inter
thereby
Module.
tance.
PEAK AMPS/INDUCTANCE Control
turns on when 115 vac is
Interface control and
energized
to indicate that wire is
on
feeding.
when the current detect
an arc is established.
relay
is
SECTION 5
a
SEQUENCE OF OPERATION
ELECTRIC SHOCK can kill;
WARNING:
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
Do not touch live electrical parts.
Keep all covers and panels
operating.
Do not touch
in
3.
Wear
The welding wire and all metal parts in contact
with it carry weld output when the welding power
is
energized.
clothing.
to
5.
Turn
and
6.
Energize
7.
Wear
on
place while
welding wire or any metal part in
welding.
and
Prepare for welding by connecting work clamp(s)
clean, bare metal at workpiece.
4.
adjust shielding gas
robot
%~
at its
source.
system.
welding helmet with
cording to ANSI Z49.1.
contact with it while
source contactor
dry insulating gloves
proper filter lens
WARNING: ELECTRIC SHOCK
can
ac
kill.
Do not touch live electrical parts.
_____
is void if any of the equipment is oper
ated with any portion of the outer enclosure
removed.
Do not touch electrode wire or any metal part
in contact with it while welding.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
The electrode welding wire and all metal parts in
contact with it carry weld output when the weld
ing power source contactor is energized.
Warranty
hearing.
Wear correct eye, ear, and
FUMES AND GASES
your health.
Keep your head
Ventilate to
body protection.
seriously harm
can
out of the fumes.
keep
from
fumes and
breathing
8.
Begin welding.
SHUTTING DOWN
5-2.
1.
Stop welding.
2.
Shut down robot system.
3.
Turn off all associated
3.
Turn off
gases.
If ventilation is
breathing
WELDING
wounds.
inadequate,
use
approved
device.
WIRE
can
puncture
cause
a
HOT
METAL, SPATTER,
AND
SLAG
can
Shut off gas
The
fire extinguisher
how to use it.
Do not
use near
when not in
use.
(Chart 5-1)
Watch for fire.
a
supply
OPERATION OF COMPUTER INTERFACES
5-3.
tire and burns.
Keep
at the source.
WARNING:
HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
Do not point gun toward any part of the body,
any conductive surface, or other personnel.
cause
shielding gas
equipment.
nearby,
and know
Computer Interfaces use signals from the welding
source(s) and Robot Control to control the gas
power
valves, weld output, and wire feed speed.
flammable material.
Allow work and equipment to cool before
handling.
5-4.
1.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
Wearers should consult their doctor before
going neararc welding, gouging, orspot weld
WIRE STICK CHECK
signal from the robot control indicates
Computer Interface that the welding
A
contactor is open at the end of a
source
2.
(Chart 5-2)
A
voltage
command
signal is
sent to the
to the
power
weld.
welding
that ramps up from the value of the
power
burnback setting. This increasing voltage com
source
ing operations.
See Section 1
Safety Rules For Operation Of
Arc Welding Power Source in the welding power
source Owners Manual for basic welding safety
-
mand
signal
lasts until 100 milliseconds after the
wire is freed.
information.
3.
The stick check
current
5-1.
GAS METAL ARC WELDING
1.
Install and connect robot system
Owners Manuals.
relay
Connect
tion 3.
Computer
Interfaces
enabled after the weld
opens at the end of the weld.
(GMAW)
IMPORTANT:
2.
circuitry. is
according
according
to its
Wire stick check
applies if DIP switches
(see Section 3-2).
are
timing
sequence
only
set to enable this function
to Sec
4.
There is
a
delay of approximately
8 milliseconds.
OM.141 438
Page
9
Chart 5-1.
Sequence
I
Weld Start Relay
Wire Feed
Of
Operation Timing
7.
If the Computer Interface sees the weld current
relay close, it cycles through another 50 millisec
ond period of pulsing the contactor. The voltage
command signal continues to ramp up.
8.
This process of checking the weld current relay
and pulsing the contactor continues until the wire
Arc Initiation
Close
Open
Speed
~ 10
to
is free of the weld or, at the end of 500 millisec
a weld abnormal code appears on the robot
onds,
Weld
I
Voltage Command
Oto10V~~~cter
Program Module,
If
~1
~nchln~-~
Open
Crater
~
ror
code is
i
~ee~!oto~flJ
likely
no
(disabled),
I
continue
Postf low Time
0.2 to 0~3 sec.
Gas Valve
Time~j
to appear in this instance.
Interface may detect wire stuck even
is free of the weld. Reset the robot and
Computer
though the wire
1
nearest
operation. If this
Factory
occurs
frequently,
contact the
Authorized Service Station.
~
~
Chart 5-2. Wire Stick Check
Wire Stick Check
Timing
afl~-
I
(at Arc End)
Start
80 Milliseconds
Shortest Stick
Check
Time
S-0384
5.
en
Data 3.
Data 3 Wire Stick Check is set to
System
The
Wire Stick Check
System
the robot may try to move even after the Computer Inter
face detects that the wire is stuck. A Weld Abnormal er
Close
Preflow
if the wire stick function is
abled in the Robot
The welding power source contactor pulses on for
a 50 to 75 millisecond time span. The weld current
relay closes. During this pulse of the contactor, a
signal is sent to the robot control indicating that
current is flowing.
Voltage
Contactor
~
500 Milliseconds
Longest Stick
Check
~1~1
8
20
50
Time
*Tha number of contactor pulses varies
with the welding power source used.
(In Milliseconds)
S-0385
6.
The robot looks for
a
20 millisecond
period
of time
that the weld current relay remains open. This in
dicates that the wire is free of the weld and the ro
bot can continue.
SECTION 6
maintained
Voltage ramp only applies if DIP switches
enable this function and the wire stick check
(see Section 3-2).
MAINTENANCE & TROUBLESHOOTING
IMPORTANT: Every six months inspect the labels
this unit for
IMPORTANT:
are set to
on
legibility. All precautionary labels must be
in a clearly readable state and replaced
a
when necessary. See Parts List for part number of
precautionary labels.
Lockout/tagging procedures
locking line disconnect switch
HOT SURFACES
Usage and shop conditions will
determine the
and type of maintenance. At minimum,
ment every three months as follows:
a
frequency
can
OM-141 438
Page
10
serious
injury.
moving parts.
can cause severe
cooling period
before
burns.
servicing.
kill.
Shut down robot and welding power source,
and disconnect input power employing lock
out/tagging procedures before inspecting,
servicing.
of pad
position,
Maintenance and troubleshooting to be per
formed only by qualified persons.
Do not touch live electrical parts.
or
Allow
inspect equip
WARNING: ELECTRIC SHOCK
maintaining,
can cause
Keep away from
INSPECTION AND UPKEEP
in open
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
MOVING PARTS
6-1.
consist
1.
Inspect all interconnecting cords for damage
to or
breaks in the insulation
jacket, particularly at the
plugs. Repair or replace the cord(s) as necessary.
2.
Remove grease and dirt from components and
moisture from electrical parts and cables.
OVERLOAD PROTECTION
6-2.
f~
WARNING: ELECTRIC SHOCK
can
kill.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging
ing, maintaining, or seriicing.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
procedures before inspect.
IMPROPER FUSE
can
can
ELECTROSTATIC DISCHARGE
damage circuit boards.
properly
handling
grounded wrist
circuit boards.
strap
Transport circuit boards in proper
shielding carriers or packages.
static-
Perform work
only at a
static-safe work
area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
Be
sure
that
plugs
are
properly installed
and
aligned.
unit.
damage
Be sure replacement fuse is
and rating (see Parts List).
(ESD)
Put on
BEFORE
Do not touch live electrical parts.
_____
CAUTION:
a
same
EXCESSIVE PRESSURE
board.
size, type,
can
break circuit
Use
A.
ment
WARNING: Read and follow safety informa
tion at beginning of Section 6-2 before pro
a
ceeding.
Circuit breaker CB1 protects the wire drive motor from
overload. If CB1 opens, the wire feed circuit shuts down.
If the breaker trips, correct the problem, and manually
reset CB1.
B.
only minimal pressure and gentle move
when disconnecting or connecting
board plugs and removing or installing board.
Wire Drive Motor Circuit Breaker CB1
6-4.
TROUBLESHOOTING
Main Fuse Fl
WARNING: ELECTRIC SHOCK
WARNING: Read and follow safety informa
tion at beginning of Section 6-2 before pro.
a
Shut down robot and welding power source,
and disconnect input power employing lock
Fuse Fl protects the Computer Interface from an inter
nal short or excessive overload If fuse Fl opens, the
out/tagging procedures
maintaining, or servicing.
.
rect the
1.
problem
shuts down. If the fuse opens, cor
replace Fl as follows:
Pull out fuse with
2.
cover
cover counter
when fuse holder
cover
is
free.
Troubleshooting
3.
Insert
4.
Install fuse with fuse holder
5.
Depress
new
fuse into fuse holder
and rotate fuse holder
formed
cover.
cover
before
inspecting,
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
and
Depress and rotate fuse holder
clockwise.
kill.
Do not touch live electrical parts.
ceeding.
Computer Interface
can
of internal parts to be per
only by qualified
persons.
back into unit.
cover
clockwise
until cover is secure.
6-3.
CIRCUIT BOARD HANDLING PRECAUTIONS
a
WARNING:
ELECTRIC SHOCK
It is assumed that proper installation has been made ac
the operator isfamil
iar with the function of controls, the unit was working
cording to Section 3 of this manual,
can
kill.
properly, and that the trouble is not related to the welding
process. The following chart is designed to diagnose
provide remedies for
develop in this unit.
and
Do not touch live electrical parts.
Shut down robot and welding power source,
and disconnect input power employing lock
out/tagging procedures before inspecting,
maintaining, or ser1.icing.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
some
of the troubles that may
Use this chart in
while
conjunction with the circuit diagram
performing troubleshooting procedures. If the
trouble is not remedied after
dures,
contact the nearest
performing
Factory
these proce
Authorized Service
Station. In all cases of equipment malfunction,
follow the manufacturers recommendations.
OM-141 438
strictly
Page
11
Table 6-1.
Troubleshooting
PROBABLE CAUSE
TROUBLE
Unit does not operate.
REMEDY
Check Fl, and replace if necessary (see Section
6-2). Correct overload problem before continuing
Fuse Fl open.
operation.
Circuit breaker CB1 tripped.
No meter
display
on
Display
Meter not
Check CB1, and reset if necessary. Correct
load problem before continuing operation.
over
Replace meter (see Section 6-3 and contact Factory
Station).
working.
Authorized Service
Module.
Meter board PCi not
working.
Replace PCi (see Section 6-3 and
contact
Factory
and contact
Factory
Replace PC4 (see Section 6-3 and contact
Authorized Service Station).
Factory
Station).
Authorized Service
Relay CR1
No wire feed.
not
working.
Motor board PC2 not
working.
Replace CR1.
Replace PC2 (see Section 6-3
Station).
Authorized Service
Interlace board PC4 not work-
ing.
Wire feeds at maximum.
Tach board at wire drive motor
not
No
arc
voltage control.
Replace tach board. See wire drive assembly Owners
working.
Manual.
Check and
secure
connections (see Section 3-8).
Voltage sensing connections.
Check and
secure
connections
Position of Remote Voltage
controlswitchonweldingpower
source must
Voltage
control connections.
Remote
Voltage
(see Section 3-3).
control switch
be in
position
on welding power
to allow remote control.
source.
Voltage board PCi
not
working.
Incorrect robot command volt-
age.
Robot
moves
when
welding
speed
Factory
Check robot command voltage to voltage board
PCi. Command voltage should be 0-10 Vdc be
tween 3TC and 3TB (common).
Welding
power source MAXIMUM GTAW OUTPUT control.
Rotate control to maximum position.
Interface board PC4 not work-
ing.
Replace PC4 (see Section 6-3 and contact
Authorized Service Station).
Wire stick check DIP switches.
Be
wire is stuck.
Wire
Replace PCi (see Section 6-3 and contact
Authorized Service Station).
sure
DIP switches are in desired
Factory
position (see
Section 3-2).
meter goes to
zero.
Current sensing connections.
Check and
Incorrect robot command volt-
Check robot command voltage to motor board PC2.
Signal should be 0-10 vdc between 1TE and 1TC
age.
secure
connections (see Section 3-3).
(common).
Motor board PC2 not
No wire retract.
working.
Communication board PC3 not
working.
Incorrect robot command volt-
age.
Replace PC2 (see Section 6-3 and contact
Authorized Service Station).
Factory
Replace PC3 (see Section 6-3 and contact
Authorized Service Station).
Factory
Check robot command voltage at motor board PC2.
Signal should be 0-10 vdc between 1TE and 1TC
(common).
Robot shuts down.
Looseweldoutputconnections.
Clean and
Interconnecting
Check all
cords.
tighten
connections.
interconnecting cords for breaks; repair or
replace. Check and
Communication board PC3 not
working.
OM-141 438
Page
12
secure
all connections.
Replace PC3 (see Section 6-3 and contact
Authorized Service Station).
Factory
6-5.
USE OF INDICATOR LIGHTS FOR TROUBLE
SHOOTING
Gas Indicator
On
Off
Light
I
________
Gas flows:
System
normal
(on.)
Gas does not flow
Gas flows:
Gas does not flow
Check gas valve operation.
Check gas valve operation
and gas line for leaks.
System
normal
(off).
Check interface board PC3.
On
Contactor Indicator Light
Off
I
Contactor closed:
System
normal (on).
Contactor open:
Contactor open:
Check
cords.
System
interconnecting
normal
(off).
Check interface board PC4.
On
~
Wire Feed Indicator
~
Light
Off
I
I
I
Wire feeds:
System
normal
(on).
I
Wire does not feed:
Wire feeds:
Wire does not feed
Check circuit breaker CB1
Check
System
relay CR1.
normal
(off).
Check relay CR1.
Check input signal from
robot to motor board PC2.
should be 0-10 vdc
between 1TE and 1TC
Signal
(common).
Check interface board PC4.
Check motor board PC2.
On
WCR Indicator
Off
Light
I
I
Arc started:
System
No
normal
On
(on).
~
Interface Control On:
Normal.
Arc started:
arc:
Replace weld
relay.
Replace weld
relay.
current
Power Indicator
.
No
current
Light
Interface Control On:
Check connections between
Interface Control and Display
Module.
arc:
System
~
normal
(off).
Off
Interface Control Off:
System
normal
OM-141 438
(off).
Page
13
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Diagr m
AC!>
~S
AC!
AC!)
PUJER GROIfr~ NETS FOR CHIPS
UI
(8.GND,I6..ISU)
Al
14.-ISU,8..ISUI
Circuit Diagram No. SB-i 37 113
Diagram
MB
7-6. Circuit
K
Diagram
U
For Interface Board PC4
H
L
A
CD
E
F
PC I
/
32
-~.-,t~-t~
3456
PC2
LED
INDUCTANCE
PEAK
1-6
ON
BOARD
RCI/PLG4
AMPS
1PM
VOLTS
7
d
5
ITO
0
0
A
B
C
Circuit Diagram No. SA-134 047-A
Diagram
7-7. Circuit
Diagram
For
Display Module
OM-141 438
Page
19
PLG7
+8U
PLG?
GND
POL.JER AND GROUND
Al
ui
7-8. Circuit
Diagram
For
Display
8134
395
(4z8LJ.8+8L1)
~
(3~GND,8=+8LJ)
Circuit
Diagram
I
Diagram
No. SB-i 34 395
Module Meter Board PCi
+
5V.
~
PLI
L__
_1
/
CNI
6
5
\/
4
/
-~
3
\/
2
Circuit
Diagram
OM-141 438 Page 20
7-9. Circuit
Diagram
For
Diagram
Display Module LED Board PC2
No. SA-129 640
RC I 6
RC7
55-
I>
-~I2
56
3>
-~I4
8>413
9>
4~1
6RA
3
GS I
A
B
C
tJ
E
5T0
0
0
0
0
I0
6968
Circuit
Diagram
7-10. Circuit
Diagram
Diagram
No. SA-141 554
For Gas/Motor Control Box
OM.141 438
Page
21
C/) ni C.) -l 0 z
-1 U) I- U) I
328
SC-136
Rel.
30
Product)
25
Actual
2324
33
Refl ct
2012
Not
34
May
And
35
19
Only
36
ii
14
17
16
1:
38
1o~
11
39
40
41
Refrnce
9
15
8
42
.7
Asembly
6
8-4
Fig
3
46
1
29
52
0
C.)
-D 8) Ca CD
rs3
43
Main
44
8-1.
45
Figure
5
4
8-2
Fig
51
50
49
(For
48
Dia.
Item
No.
Mkgs.
Part
No.
Description
Figure
1
2
PC2
RC5
.7..
RC14,PC5
142634
RC9
RC12
039718
073515
084171
038861
038832
8
9....
10
FL1
11
3T
2T
12
13
14
15
16
17
18
.19
20
21
22
23
24
25
26
27
28
29
....
....
RC13
RC1O
PLG2O
601 219
035704
048029
049970
027811
095033
079844
031692
006426
079497
073914
030651
010301
030941
109006
035759
036135
110375
052 964
073 973
026 202
133867
133870
038772
125966
148596
030170
133872
044176
133861
089646
097867
135635
PLG21
114656
131 054
SRi
CR2
Ci
R3
Ri
....
R2
CR1
Ti
T2
CR4,5
RC2O
D4,5
30
31
32
33
iT
PSi
...
C4
34
35
36
37
38
39
40
41
134464
133862
071642
083147
117374
031251
C2
RC8,PC6
...
...
..
...
RC11
CB1
113746
094480
011991
42
43
1338710009288
44
046432
*012655
074188
137110
115094
113746
131056
45
46
....
47
....
48
..
49
..
Fl
PL1
PC4
PLG3
PLG2
113746
50
..
PLG1
079748
8-1. Main
Quantity
Assembly
LABEL, warning general precautionary
1
COVER
CIRCUIT CARD, motor speed
GROMMET, scr No 8/10
1
digital (Fig 8-4)
1
2
HOUSING, term conn 22posn
BRACKET, mtg connector
RECEPTACLE, w/components
RECEPTACLE, l0skt MS-3102A-18-1S
RECEPTACLE, 11 skt 97-31 02A-20-33S
FILTER, line pwr 115/250V 50-400Hz
BLOCK, term 20A 3P
BLOCK, term 20A 9P
LINK, jumper term blk 20A
RECTIFIER, integ 30A 600V
CLIP, retaining socket relay
BRACKET, mtg relay
SOCKET, relay 14 pin
RELAY, end 24VAC 4PDT
SPRING, hold down relay
CAPACITOR, elctlt 750uf 200VDC
CLAMP, capacitor 2.000dia
RESISTOR, WW fxd 25W 2K ohm
WASHER, centering .437dia
RESISTOR, WW fxd 25W 10 ohm
BUSHING, al .140 ID x .250 OD x .312
RESISTOR,WWfxdlOOW5ohm
RELAY,encI24VACDPDT
TRANSFORMER, control mintr 115/36VCT
TRANSFORMER, control 115/24VAC 50/60hz
STAND-OFF SUPPORT, PC card No. 6scr
RELAY, end 24VDC DPDT
RECEPTACLE, l4skt MS-3102A-22-19S
DIODE, rect 1A 400V SP
PANEL, rear
1
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
4
1
.2
1
1
1
1
8
2
1
2
1
BASE
BLOCK,
1
term 20A 6P
POWER SUPPLY,
CAPACITOR
1
switching 85-132VAC/iiO-17OVDC
1
1
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
PANEL, mtg components
CAPACITOR, cer disc .Oluf 1000VDC
RECEPTACLE, w/components
RECEPTACLE, 10 pin MS-3102A-18-1P
RECEPTACLE, 17 pin MS-3102A-20-27P
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 24-18 wire
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 24-l8wire
RECEPTACLE, 14 pin MS-3102A-20-27P
CIRCUIT BREAKER, man reset 1 P 1 .5A 250V
PANEL, front
NAMEPLATE, (order by model and serial number)
HOLDER, fuse mintr .250 x 1 .250 panel mtg
FUSE, mintr cer 1 OA 250V
LIGHT, md red lens
CIRCUIT CARD, interface (Fig 8-2)
HOUSING PLUG & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 24-18 wire
HOUSING, term hdr 18 pin posn
3
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
.
1
4
1
14
1
OM-141 438
Page
23
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
52
137695
133868
133863
094481
116964
110015
094 482
133864
097 868
116964
604910
097 866
133865
089 647
073 332
073140
039716
133866
073 686
039 828
133859
083184
070 584
084286
1343080009288
039716
073 332
134242
048 598
079534
TERMINAL, female lskt 18-14 wire
140 840
116 964
056
010
010
051
056
603
127
010
056
056
604
423
603
606
297
112
106
750
..
.
CABLE, interconnecting (consisting of)
PLUG, 11 pin 97-3106A-20-33P
CLAMP, cable AN-3057-12
CABLE, port No. 20 12/c (order by if)
PLUG, llskt MS-3108B-20-33S
CABLE, combination (consisting of)
CABLE/CONDUIT, 7ff
LINER, monocoil .030-035 wire
GUIDE, wire outlet .030-.035
CABLE, interconnecting (consisting of)
CABLE, pwr shld 1 8ga 15/c (order by if)
PLUG, 14 pin MS-3106A-22-19P
.
....
.
.
.
Page
24
5ff
1
2
5ff
2
5ff
70ff
2
1ff
l.ft
23ff
16
2
26ff
8ff
..
PLUG, l4skt MS-3106A-22-19S
CLAMP, cable 97-3057-1012
HOSE, gas (consisting of)
FITTING, hose brs barbed nipple 1/4tbg
FITTING, hose brs nut .625-18RH
.
2
....
.
.
.
.
.
.
.
.
2
ADAPTER
FITTING, hose brs ferrule .475 ID x .718 Ig
HOSE, nprn brd No. 1 x .250 ID (order by if)
HOSE, gas (consisting of)
FITTING, hose brs nut .625-18RH
FITTING, hose brs ferrule .425 ID x .718 Ig
FITTING, hose brs baibed nipple 3/1 6tbg
HOSE, nprn brd No. 1 x .187 ID (order by if)
....
.
.
..
..
.
.
.
.
..
.
.
..
33ff
.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438
1
2
....
606.
108
851
550
18
CLAMP, strain relief
079 739
134471
073517
039 734
134240
134106
1264930009288
1264980009288
084 594
049310
1408550009288
096 813
073 982
Assembly (Continued)
TERMINAL, contact hdr 24-18 wire
CIRCUIT CARD, voltage control (Fig 8-5)
PANEL, side
CABLE, interconnecting (consisting of)
PLUG, 14 pin MS-3106A-20-27P
CLAMP, cable 97-3057-1012
CABLE, port No. 18 7/c
PLUG, l4skt 3106A-20-27S
CABLE, interconnecting (consisting of)
PLUG, l7skt MS-3106A-20-29S
CLAMP, cable 97-3057-1012
CABLE, pwr shld 2Oga 5/c (order by if)
PLUG, 17 pin MS-3106A-20-29P
CABLE, interconnecting (consisting of)
PLUG, 1OSKTMS-3106A-18-15
CLAMP, cable AN-3057-1 0
CABLE, port No. 18 10/c (order by ft)
PLUG, lapin MS-3106A-18-1P
CABLE, volt sense (consisting of)
PLUG, 4skt 97-3106A-145-2S
CLAMP, cable AN-3057-6
CABLE, coaxial 1 8ga 1/c 60C 300V (order by if)
TERMINAL, ring tng .500 stud 22-16 wire
TUBING, gI acrylic No. 9 (order by ft)
TUBING, htshnk .25Odia (order by if)
CABLE, interconnecting (consisting of)
PLUG, 10 pin MS-3106A-18-IP
CLAMP, cable AN-3057-10
CABLE, port No. 18 10/c (order byft)
HOUSING PLUG & SOCKETS, (consisting of)
079 747
.51....PC1
8-1. Main
Quantity
3ff
Mkgs.
Dia.
Part
No.
PC4
137 110
Figure
114 176
IC, linear 353
CAPACITOR, elctlt 330uf 5OVDC
CAPACITOR, polye met film 1 .Ouf 5OVDC
CAPACITOR, cer mono .luf 5OVDC.
CAPACITOR, elctlt l000uf 35VDC
RELAY, end 24VDC SPDT
DIODE, sig .020A 75V SP
DIODE, rect 1A 400V SP
RESISTOR, WW fxd zero ohm
TRANSISTOR, NPN 200MA 40V
TRANSISTOR, PNP 200MA 40V
RESISTOR, CF .25W 10K ohm
RESISTOR, MF .25W 61.9K ohm
RESISTOR, ME .25W 619K ohm
RESISTOR, CF .25W 100 ohm
RESISTOR, MF .25W 1.21K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, ME .25W 20K ohm
RESISTOR, MF .25W 332 ohm
RESISTOR, CF .25W 2.2K ohm
RESISTOR, MF .25W 10K ohm
RESISTOR, MF .25W 20K ohm
RESISTOR, CF .25W lOOK ohm
RESISTOR, MF .25W 1 meg ohm
TERMINAL, header 4 pin
TERMINAL, header 14 pin
SWITCH, DIP SPST 2posn
IC, digital 4538B
118460
125500
C7-9,11-13....
....C10
122723
083 973
CR1,2
099018
Dl -5.8,10-12
028351
D6,7,9
026 202
092 648
037 200
Q3
037201
R1,7,11,22,26
035 827
R2
000 007
R3
052 146
R4,13
R5,6,14
R8,21
035 823
R9
052 138
044 633
035825
....R10
044 634
....R12
035 888
R15,16
089175
R17-19
089176
R20,24,25
035 884
....R23
094040
....RC1
....RC2
113748
117864
109481
131 089
Quantity
Description
8-2. Circuit
Card, Interface (Fig 8-1 Item 47)
2
9
.3
.6
.2
.1
.5
.1
.1
.2
.3
.2
.1
1
1
2
3
3
1
1
1
1
W
N~
~-
N.
-,
L)
~ ~ U) 0)
~ (J~L)
-c
~
R24
N.
~
ji
A
~
~
~~J
~~J
Al
R2I
OFF
DISABLE UOLTAGE RAMP
fLJ
ON ENABLE UOLTAGE RAMP
A
ON DISABLE STICK
OFF ENABLE STICK
CHECKING
CHECKING
SA-137 112.A
Figure
8-2. Circuit
Card, Interface PC4
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM141
438
Page
25
123
0
0
F-
LA
0
0
~
CR?
CR3
o~
~
~
~
C
iA~1
-,
2
j4~
CR6
CR6
JIB
31?
12
.~
~
I
I
C
J38
C-
C
R26
314
E~1
~
C
328
~
R26
1J-R22
ci
GJ328
C
C
0
321
_____
U3
-,
C
C
322
323
0
SB-140 778.A
Figure
OM-141 438
Page
26
8-3. Circuit
Card, Dual Torch Adapter PCi
Dia.
Mkgs.
Part
No.
Description
1214050009288
Figure
1065360009288.
PC7
C5
C6
CR1 ,2,5-8
....CR3
....CR4
093192.
134 436
039 346.
028351
J1-45
092 648
01,2,4-7
03,8-10
037 200
....RC8
....U1,2.
....U3,4.
PLG1
PLG3
136 175
1
1
8
3
45
6
035 826.
035 825.
RESISTOR;
7
039331
3
3
CF .25W 1K ohm
RESISTOR, CF .25W 100 ohm
RESISTOR, CF .25W 47K ohm
035 823.
039 335.
2
1
114425.... TERMINAL, hdr 16 pin
117864.... TERMINAL, hdr 14 pin
117038.... TERMINAL, hdr 2
140 775.... TERMINAL, hdr 5
140774.... TERMINAL, hdr 3
140776.... TERMINAL, hdr 7
1
1
pin
pin
pin
pin
1
2
2
1
IC, digital 4011
094 347.... IC, digital 4069
008 970
HOUSING RECEPTACLE & SOCKETS,
113 746
TERMINAL, female lskt 24-18 wire
131 056.. HOUSING RECEPTACLE & SOCKETS,
113746.... TERMINAL, female lskt24-l8wire
131 054.. HOUSING RECEPTACLE & SOCKETS,
131 052..
.
.
2
2
(consisting of)
1
16
.
(consisting of)
1
14
(consisting of)
1
2
141 666..
TERMINAL, female lskt 24-18 wire
HOUSING, term plug nyl 5cont
TERMINAL, contact box shaped leaf 22-18 wire
HOUSING, term plug nyl 3cont
TERMINAL, contact box shaped leaf 22-18 wire
HOUSING, term plug nyl 7cont
TERMINAL, contact box shaped leaf 22-18 wire
STAND-OFF SUPPORT, PC card No. 6scr
CASE SECTION, front/bottom
PANEL, side
PANEL, rear
139465..
COVER
1
..
133 890..
..
128 336..
125 748..
PLG68
1
6
4
125 748
PLG7,9
1
TRANSISTOR, NPN 200MA 40V
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 6.8K ohm
113 746
PLG4,6
1
4
DIODE, sig .020A 75V SP
RESISTOR, ww fxd zero ohm
TRANSISTOR, IGBT module 18A 600V
.
PLG2.
1
CAPACITOR, elctlt 470uf 16V
RELAY, end 24VDC DPDT
RELAY, end 12VDC DPOT
RELAY,encI24VDCDPDT
DIODE, rect 1A 400V SP
071 229
D10-12
RC4,6
RC7,9
BRACKET, mtg PC board
.
CIRCUIT CARD, dual torch adapter (consisting of)
122723.... CAPACITOR, cer mono .luf 5OVDC
031 677
CAPACITOR, tantlm 5.6uf 35VDC
026 202
....R25
....RC1
....RC2
....RC3
Adapter
140 777..
D1-7,9
R3,8,9
R12,17,18
R19-22,26-28
R23,24
8-3. Panel, Dual
Quantity
133 889..
125 748..
126368..
141 667..
141 449..
.
.
2
1
2
3
1
7
6
1
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438
Page
27
380-E
SC-093
PC2
Spe d
Motor
Card,
Circuit
8-4.
Figure
Mkgs.
Part
No.
PC2
071 642
Figure
A50-53
009 159
IC, linear 358
CAPACITOR, elctlt 1 OOuf 35VDC
CAPACITOR, polye film .0022uf 200VDC
CAPACITOR, cer mono .1 uf 5OVDC
CAPACITOR, polye film .033uf 1 OOVDC
CAPACITOR, tantim 2.2uf 20V
CAPACITOR, cer disc .01 uf 500VDC
CAPACITOR, polye film .Ol5uf 200VDC
CAPACITOR, elctlt 1 Ouf 35V
CAPACITOR, polye met film 4uf 200V
CAPACITOR, polye film .47uf 400VDC
CAPACITOR, pofye film .22uf 200VDC
RELAY, end 24VAC 4PDT
SOCKET, relay l4skt
SPRING, hold down relay
DIODE, rect 1A 400V SP
DIODE, zener 1 5V 5W
IC, interface 2907
TRANSISTOR, NPN 200MA 40V
THYRISTOR, SCR 7.4A 200V
TRANSISTOR, UJT 15MA4OV
RESISTOR, WW fxd 5W220 ohm
Dia.
....C50
....C51
-.
039 482
031 699
C52,61
C53,62
073 739
....C54
C55, 66-7577
005 023
....C56
....C57
....C60
073 549
C63,64
....C65
CR50
035 833
031 643
007 742
035561
044602
031 721
095 033
091 861
079 844
D50-54,56-60.
026 202
....055
080910
....1C50
081 800
050,53
037 200
....Q51
....Q52
....R50
R51 ,54,55,57,67
037 824
039 355
68,74,75,82,89
035 827
R52,56,61
052 138
.
.
...R53
R58,62,65,66
71,72,76,90
....R59
R60,87,88
R63,79
030 839
039 332
IC, linear 78L12
039 106
...R70
049 015
039328
....R77
052 142
....R78
039 108
....R80
035 886
...R85
....R86
....T50
VR5O
...VR51
035 825
030 937
030 090
092 648
085 399
4
1
1
2
2
1
12
1
1
1
2
1
1
1
1
10
1
1
2
1
1
1
RESISTOR, CF .25W 10K ohm
RESISTOR, MF .25W 20K ohm
RESISTOR, CF .25W 15K ohm
047 272
039 335
Quantity
Card, Motor Speed (Fig 8-1 Item 3)
081 799
030 007
039 331
R81,84
8-4. Circuit
RESISTOR, CF .25W 100K ohm
POTENTIOMETER, cermet trmr 1 5/T .75W 50K ohm
RESISTOR, CF .25W 47K ohm
RESISTOR, CF .25W 470 ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 10 meg ohm
RESISTOR, CF .25W 1.5K ohm
RESISTOR, MF .25W 121K ohm
RESISTOR, CF .25W 82K ohm
RESISTOR, CF .25W 22K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, C .5W 10 ohm
RESISTOR, C .5W 47 ohm
RESISTOR, WW fxd zero ohm
TRANSFORMER, pulse
IC, linear 78L08
035 884
....R64
R73,83
Description
10
3
3
2
1
2
2
1
1
15
1
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438
Page
29
cso
0
0_i
(
lI~
N.
Ci
i~
ol
XIIHH_
0
~
Ir~~
I
Li_i
u_i
Li
D6S
=
~
H0
R63
~
R83
U~)
P78
ri
Ji
_____
~J3
PSi
0
=
N.
N
~
CR50
N
_______
0_i
~
I
II
1C~_i
U
0_i
Q53i ~
n
0_i
~
C58
J2
0_i
0_i
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D60
EJN.
~.
(01
~LrJ
f
~89AS2R7S
u_i
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tr~~_J
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-E::Jc::~-~
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P53
\
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0~I
P68
R58
~
I
(01
~
~
_~C56
-E:~
2~
U_iL)
If)
J12
IN
R53~
~
C52
R85
(0
c:::i
-c::874p57
~
LI_i ~ (0(0
~
D5~~
1._i
NJ
/
LI_i
=
P87
C62~ OD~ ~
u_i
~C2
C_i
Ci
IN
N.
C_i
Li
Ci
~
II
LI_i
L)
o~~
~.~Llio_i
R4
P54
~
~
I(~_iN.
~
(0
II
=
=
I-_i
IN
____
I_FDS2
H__
I~
DS~~~
-I
H_~D53
0
SB-13S 520-B
Figure
OM-141 438
Page
30
8-5. Circuit
Card, Voltage Control PCi
Mkgs.
Part
No.
PCi
137 695
Dia.
Description
Figure
8-5. Circuit Card,
096 275
A51,52,54
114176
....A53...
009159
Cl-4,53,
55-59,68
C50,60,69-73
122723
cer mono
000340
cer
.
8-1 Item
51)
IC, linear 324
IC, linear 353
IC, linear 358
....A50...
.
Voltage Control (Fig
Quantity
1
3
1
..
..
....C52...
....C54...
....C61...
....C62...
....C63...
C64,65
C66,74
067,75
CR50...
CAPACITOR,
CAPACITOR,
031677.. CAPACITOR,
000861
CAPACITOR,
005023.. CAPACITOR,
009577
CAPACITOR,
053992
CAPACITOR,
093558
028351
092 648
047034
035 842
037 200
R1,2
089174
R3
089176
R4,5,67,76.
089 175
R51 ,80,86,87
039331
R52,91
R53,73
R55-57,85
R58,61
R59,60,95-97...
R62,68,82
R63,78
035 888
078431
035 827
039 336
035 826
035 825
097 110
108437
000 038
009173
052 137
....R77
039 333
....R79
039 330
....R81
035 886
....R83
084 205
....R84
000 885
081 833
....R90
035 885
....R93
....R94
091 799
....R98
039329
....R99
108433
035 823
RiCO
117134
R102
121 714
....RC1
1
cer
disc .001 uf 1 000VDC
1
2
J1-15
0050
R88,92
1
tantlm 27uf 35V
CAPACITOR, tantim .47uf 35V
CAPACITOR, ploye met film .47uf 1 OOV
RELAY, end 12OVAC 4PDT
SOCKET, relay l4skt
SPRING, hold down relay
DIODE, rect 1A 400V SP
DIODE, sig .020A 75V SP
RESISTOR, WW fxd zero ohm
IC, interface 4N26
TRANSISTOR, PNP .6A 40V
TRANSISTOR, NPN 200MA 40V
RESISTOR, MF .25W 100K ohm
RESISTOR, MF .25W 20K ohm
RESISTOR, MF .25W 10K ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 2.2K ohm
RESISTOR, C .25W 330 ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 220K ohm
RESISTOR, CF .25W 6.8K ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, MF .25W 1K ohm
RESISTOR, MF .25W 4.75K ohm
POTENTIOMETER, cermet trmr 25/T .5W 2K ohm
POTENTIOMETER, cermet trmr 201T .5W 5K ohm
RESISTOR, MF .25W5.liKohm
RESISTOR, CF .25W 18K ohm
RESISTOR, CF .25W 3.9K ohm
RESISTOR, CF .25W 22K ohm
RESISTOR, MF .25W 3.32K ohm
RESISTOR, ME .25W 10K ohm
RESISTOR, CF .25W 2.7 meg ohm
RESISTOR, CF .25W 68K ohm
RESISTOR, MF .25W 8.25K ohm
RESISTOR, CF .25W 100 ohm
RESISTOR, CF .25W 2.7K ohm
RESISTOR, MF .25W 2.43K ohm
RESISTOR, MF .25W 24.3K ohm
RESISTOR, MF.25W51.lKohm
TERMINAL, header 18 pin
SWITCH, DIP SPST 2posn
IC, linear 7515
IC, linear 7915
121684..
055-66
R74,103
R75,89
tantlm 2.2uf 20V
000348
026 202
....R71
1
elctlt 33uf 35V
2
.051-54
....R69
7
tantlm 5.6uf 35VDC
CAPACITOR, elctlt 330uf 5OVDC
079 844
....050
Q51-53
11
118460
091 861
.
.luf 5OVDC
disc .01 uf 5OVDC
079 749
092 367
VR5O
083 772
...VR51
046 932
2
I
1
1
4
12
15
1
1
3
2
4
4
2
2
4
2
5
3
2
1
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438
Page
31
Circuit
Card,
Meter PCi
NBI_I~~B
LrJ
1
5
(
11
13
L
14
18
16
17
15
Ref. A.134 394
SB136
Figure
OM-141 438 Page 32
8-6.
Display Pendent
517
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
1339800009288
PCi
1
134 396
009159
083 182
000 348
072 935
007 742
122 723
Al
Cl
C2
C3
..
.
C5,6
C7,9
Ji ,2
.
..
..
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
092 648
108453
LCD1
Ri
095 823
R2
095 822
094 040
R3,7-10
Ru
097 110
121 085
RC5
Ui
110 325
VR1
071 248
135 635
114 656
109 161
111 500
PLG5
073 356
Si
134 117
R3
603 856
S2
113333..
RI ,2
030 938
PLG6
131 054
113 746
1340130009288
Dl
026 202
11
038 785
AC1
077 175
PLG4
134 859
125 748
PC2
139 646
098 691
134 017
..
..
.
.
.
.
.
.
.
....
3
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
....
..
.
9
..
11
..
.
12
13
....
..
...
..
.
14
15
16
.
.
...
.
..
..
17
18
.
..
10
.
.
097922
..
1
.1uf5OVDC
CAPACITOR, tantim .47uf 35V
CAPACITOR, elctlt 33uf 35VDC
CAPACITOR, elctlt 1 Ouf 35V
CAPACITOR, cer mono .1uf5OVDC
RESISTOR, ~ fxd zero ohm
1
cer mono
1
1
2
2
2
METER,digitalOto2VDC
1
1
1
5
1
1
IC, interface 7662
IC, interface 78M05
1
HOUSING PLUG & PINS, (consisting of)
TERMINAL, male 1 pin 24-18 wire
TERMINAL, header l3skt
1
1
2
1
CONNECTOR, plug 5posn
STAND-OFF, No. 6-32 x .625 Ig
SWITCH, rotary
POTENTIOMETER, WW sltd sft lOfT 2W 10K ohm
SWITCH,PBMCNOSPST1A115VAC
RESISTOR, C .5W 1.2K ohm
HOUSING RECEPTACLE & SOCKETS, (consisting of)
..
..
8
CAPACITOR,
.
.
..
7
1
.
.
..
5
..6
(consisting of)
IC,linear358
RESISTOR, MF .25W 44.8K ohm
RESISTOR, MF .25W 5K ohm
RESISTOR, MF .25W 1 meg ohm
RESISTOR, MF .25W 1K ohm
TERMINAL, header 5 pin
..
..
4
Pendent
.
.
2
Display
CIRCUIT CARD, meter
..
.
8-6.
Quantity
1
2
1
1
1
2
1
TERMINAL, female lskt 24-18 wire
BRACKET, mtg control box
DIODE, rect 1A 400V SP
STRIP, terminal 3P
RECEPTACLE, 11 pin MS-3012A-20-33P
2
.
1
1
1
1
HOUSING PLUG & SOCKETS,
.
(consisting of)
TERMINAL, contact box-shaped leaf 22-18 wire
CIRCUIT CARD, display
STAND-OFF, No. 6-32 x .500 Ig
1
6
.
1
2
CASE SECTION, front/sides
1
NAMEPLATE, (order by model and serial number)
KNOB, pointer
2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438
Page
33
Dia.
Item
No.
Part
No.
Mkgs.
Figure
133 981
1
+134 015
.
.
2
131 515
.
.
3
007 501
.
.
.
.
.
.
.
RS1
140 786
.
.
5
010 494
.
.
6
057 358
.
.
7
134 014
.
.
4
....
8
Ri
9
iT
.
.
.
.
...
.
074 051
.
.
.
.
038 861
.
.
..
10
134 016
11
123 531
.
.
12
134 241
.
.
039 828
.
.
047 544
.
.
13
14
...
PLG1
..
.
Quantity
Description
.
.
8-7. WCR Box
WRAPPER
1
LABEL, warning electric shock
WASHER, flat nylon .265 ID
RELAY,
x
1
.437 OD
x
.l87thk
2
1
current
BUSHING, snap-in nyl 1.375 ID
BUSHING, snap-in nyl 1.000 ID
CASE SECTION, bo~om/sides
RESISTOR, C .5W 100 ohm
BLOCK, term 20A 3P
BRACKET, mtg
x
1
.75Omtg hole
2
x
1
.375mtg
hole
2
1
1
1
2
STRAIN RELIEF, cable flexible
CABLE, port No. 18 2/c (order by ft)
CLAMP, cable AN-3057-6
PLUG, 4skt MS-3106A-14S-2SX
1
6ft
1
1
.8
9
14
12
13
11
10
Figure
+When
ordering
a
component originally displaying
a
SA-136 518
8-7. WCR Box
precautionary label, the label
should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438 Page 34
Item
No.
Dia.
Mkgs.
Part
No.
Description
1371140009288
1
10
.11....RC7
.12
Dl
4T
.13
.14....GS1
RC16
15
...
134327
+079682
109 021
115 104
010 494
057 360
010 604
602 934
079 573
079 574
047 637
079
026
038
109
090
079
534
202
081
293
246
535
Figure
..
..
..
..
..
..
..
..
.
..
..
..
..
8-8. Control Box, Gas/Motor
LABEL, warning general precautionary
1
WRAPPER
CASE SECTION, bottom/front/sides
CONNECTOR, clamp cable .500
BUSHING, snap-in nyl 1.375 x 1 .75Omtg hole
BLANK, snap-in nyl 1 .375mtg hole
FITTING, hose brs bushing 1/4NPT x .625-18RH
FITTING, pipe coupling .25ONPSC
FITTING, pipe-nipple L .25ONPT x 6.000
1
1
1
2
2
2
1
1
BRACKET, mtg component
..
.
Quantity
.
2
HOUSING RECEPTACLE & SOCKETS, (consisting of)
TERMINAL, female lskt 18-14 wire
DIODE, rect 1A 400V SP
BLOCK, term 20A 4P
VALVE, 24VDC 2way 1/4 IPS port 1/8 orf
RECEPTACLE W/PINS, (consisting of)
1
14
.
TERMINAL, male
1
pin
1
1
1
1
18-14 wire
16
7
v8
6
1
11
12
13
10
15
14
Figure
5
-
6
7
Re$. SC-109 680.A
8-8. Control Box, Gas/Motor
+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-141 438
Page
35
2
34
1
\
7
6
9
r
10
18
13
14
17
16
SB-tt4 229-A
Figure
OM.141
43BPage3~
8-9. MTX
3502 Air
Cooled Gun
Item
No.
Part
No.
Description
Figure
113 883
1
115 527
.
.
2
115 526
.
.
3
108 780
.
.
4
114 249
.
.
..
5
115 524
.
.
..
6
108 772
.
.
7
108773
.
.
108 774
.
.
108775
.
.
.
..
..
.
..
..
..
..
..
.
.
.
.
..
.
.
..
.
..
.
..
8
9
.
..
10
108779
11
108766
..
12
108 768
....
13
108776
14
108778
15
108777
108 784
...
.
.
..
....
.
..
16
.
..
16
1i0
854
.
..
16
108
793
16:
108785
..
16
112
471
..
16
112
470
..
16
ii
.
..
16
112
..
..
....
.
.
.
.
..
.
..
.
..
.
..
17
2 469
468
108789
17
108
788
17
108
786
17
108
790
17
129
886
18
19
108767
114251
108770
Quantity
8-9. MTX 3502 Air Cooled Gun
SCREW, cap hexhd 8MM x 1.25 x 15MM
SCREW, cap skt hd M5 x .8 x 14mm
0-RING, (S-25)
ADAPTER, brs
SCREW, cap skt hd 4MM x .7 x 12MM
1
6
1
1
6
MICROSWITCH
PACKING
SWITCH COVER
SHIM
1
1
1
.0-RING, (S-32)
..BOOT,rbr
ADAPTER, tip
..INSULATION,bush
.0-RING, (P12)
..INSULATOR,cer
NOZZLE, (No. 8)
NOZZLE, (No. 7 short)
NOZZLE, (No. 8 long)
..NOZZLE, (No. 10)
NOZZLE, (No. 6 short)
NOZZLE, (No.6 long)
NOZZLE, (No. 7 long)
NOZZLE, (fine)
CONTACT TIP, (00.9)
CONTACT TIP, (Q0.8)
CONTACT TIP, (01.2)
CONTACT TIP, (01.6)
CONTACT TIP, .023 wire
1
NUT
POWER SUPPLY WIRE,
PROTECTION TUBE
2
.
1
1
.
1
1
.
1
.
.
1
.
.
1
.
.
1
.
.
.
.
1
.
.
1
.
.
1
.
.
1
.
.
1
.
.
1
.
.
1
.
.
.
.
.
.
.
..
1
1
1
(consisting of)
1
1
OPTIONAL
OM-141 438
Page
37
798-E
SDO7
32
31
33
30
29
r
28
34
25
35
Asembly
36
37
26
1
27
8-10.
-
Figure
4
*13
38
44
43
42
41
40 39
25-27
Items
*Includes
0
C.)
-U 0) (0 (0 C.)
Motr/Dive
Item
No.
Dia.
Mkgs.
Part
No.
109 366
.3..
.050
D50
0C50
R50
R51
10..
.
11
12..
13..
14..
15..
16..
17..
18..
19..
20..
21
22..
23..
24..
25..
26..
27..
28..
29..
30..
31
32..
33..
34..
35..
36..
37..
38..
39..
..40..
41
42..
..43..
44..
+046 967
047 636
079 535
079 739
081 630
+080 802
080 283
080 282
*080 281
049 033
110738
073739
094 934
094268
052 140
039328
094 464
049 029
049031
110733
049 032
049 030
046 779
601 925
010224
046621
085 242
085 243
010231
085 244
079 669
079 634
604741
046619
079633
604 538
079 772
075150
010910
602213
079 624
092 865
070 396
070 397
053 842
079 626
605518
072010
079 625
000418
602241
093 664
601 872
602 243
++1214070009288
++127 815
++046 781
053 700
056192
056 206
Description
Figure
8-10. Motor/Drive
Quantity
Assembly
MOTOR ASSEMBLY, (consisting of)
HOUSING PLUG & PINS, (consisting
TERMINAL, male 1 pin 18-14 wire
CLAMP, cable
1
1
of)
14
1
CORD, motor l7in
MOTOR, gear 1/8hp 115V 200RPM (consisting of)
COVER, brush
SPRING, brush
1
1
2
2
2
2
1
1
1
1
1
BRUSH
SPACER, housing tach
CIRCUIT CARD, tach (consisting of)
CAPACITOR, cer mono .luf 5OVDC
DIODE, zener5.1V400MW
IC, interface 973N51
RESISTOR, C .5W 330 ohm
RESISTOR, CF .25W 1.5K ohm
1
CORD, tach 15 in
HOUSING, tach feedback
SHAFT, extension armature
1
1
1
1
1
OPTICAL ENCODER DISC
CLAMP, strain relief
COVER, housing tach feedback
WIRE DRIVE, (consisting of)
SCREW, cap stl hexhd .250-20 x .500
PIN, spring CS .187 x 1.000
HOUSING, adapter gun/feeder
FASTENER, pinned
KNOB, adj tension
SPRING, cprsn .770 OD x .105 wire x 1.225p1d
WASHER, cupped stl .328 ID x .812 OD x .125 lip
LEVER, mtg pressure gear
PIN, hinge
PIN,cotterhair.042x.937
LEVER, mtg pressure gear
FITTING, hose barbed nipple 3/l6tbg
WASHER,flatstISAE.312
1
1
2
2
1
2
2
2
2
1
1
1
1
1
1
...KNOB
1
WASHER, shldr nyl 1 .000 OD x .375
WASHER, flat stl SAE .375
WASHER, lock stl split .375
SCREW, cap stl hexhd slflkg .375-16 x 2.250
KEY, .122x.122x.750
STRIP, mtg motor
INSULATION, motor
GEAR, spur insul w/bearing
SCREW, mach stl filh 10-32 x .875
SCREW, cap sti hexhd .250-20 x 1.250
WASHER, shldr nyl .437 OD x .316 ID x .187 lip
WASHER, spring stl .500 shakeproof
SCREW, cap stl hexhd slflkg .250-20 x .500
WASHER, flat stl SAE .250
GEAR, spur
2
2
4
2
1
1
1
4
15
4
2
2
1
1
1
2
2
1
NUT, stl hex full fnsh .375-16
WASHER, flat sti std .375
BRACKET, mtg dual feeder
INSULATOR
KIT, drive roll & guide
1
(consisting of)
1
ROLL, drive V groove .035 wire
GUIDE, wire inlet
GUIDE, wire intermediate
4
1
*Recommended Spare Parts.
+When
ordering a component originally displaying a precautionary label, the label should also be ordered.
++Items not included with Motor/Drive Assembly
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438
Page
39
Part
No.
Item
No.
Quantity
Description
Figure
8-11. Inlet Cable
System
10
010191
11
058 628
12
058 428
RING, retaining spool
REEL, wire (consisting of)
NUT, spanner spool support
RETAINER, spool support
SUPPORT, reel spool
NUT, stl hex full fnsh .625-11
WASHER, flat stl .640 ID x 1.000 OD x l4ga thk
SPRING, cprsn .9700Dx.l2owirexl.2SOpld
WASHER, flat stl keyed 1.500 dia x .l2Sthk
WASHER, fbr .656 ID x 1.500 OD x .1 25thk
WASHER, brake stl
HUB, spool
13
072475
SUPPORT, spindle
1
044 937
BASE, feeder
PLATE, mtg support spindle
1
058 427
108008
124904
124905
124900
085 980
605941
010233
057971
072 298
.
1
1
1
1
1
1
1
2
1
2
4
4
1
1
2
7
8
10
11
12
11
10
13
Ret. SC.111561-A
Figure
8-11. Inlet Cable
System
OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 438
Page
40
.4