Miller Electric Welder RPC IP User Manual

OMĆ533A  
April 1993  
Eff. w/Serial Number JJ487350  
Processes  
Multiprocess Welding  
Description  
Remote Pendant Control  
RPC-IP  
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SECTION 1 – INTRODUCTION  
and followed for the safe and effective use of this equip  
-
ment.  
B. Safety  
The installation, operation, maintenance, and trouble-  
shooting of arc welding equipment requires practices  
and procedures which ensure personal safety and the  
safety of others. Therefore, this equipment is to be  
installed, operated, and maintained only by qualified  
5-3/4 in.  
(141 mm)  
persons in accordance with this manual and all applica  
-
ble codes such as, but not limited to, those listed in Arc  
Welding Safety Precautions Section in the welding pow  
er source Owner’s Manual.  
-
Safety instructions specifically pertaining to this unit ap  
-
pear throughout this manual highlighted by the signal  
words WARNING and CAUTION which identify different  
levels of hazard.  
9-3/8 in.  
(238 mm)  
WARNING statements include installation, operation,  
and maintenance procedures or practices which if not  
carefully followed could result in serious personal injury  
or loss of life.  
CAUTION statements include installation, operation,  
and maintenance procedures or practices which if not  
carefully followed could result in minor personal injury or  
damage to this equipment.  
A
third signal word, IMPORTANT, highlights instructions  
which need special emphasis to obtain the most efficient  
operation of this equipment.  
5 in.  
(123 mm)  
1-2. RECEIVING-HANDLING  
Before unpacking equipment, check carton for any dam  
-
age that may have occurred during shipment. File any  
claims for loss or damage with the delivering carrier.  
Assistance for filing or settling claims may be obtained  
from the distributor and/or the equipment manufactur-  
er’s Transportation Department.  
ST-109 521-A  
Figure 1-1. Dimensions  
When requesting information about this equipment, al-  
ways provide the Model Description and Serial Number  
.
1-1. GENERAL INFORMATION AND SAFETY  
A. General  
1-3. DESCRIPTION  
This unit is a Remote Pendant Control for the Intellipulse  
welding power source. When properly connected to the  
Information presented in this manual and on various la  
-
bels, tags, and plates provided on this unit pertains to  
equipment design, installation, operation, maintenance,  
and troubleshooting which should be read, understood,  
welding power source this unit provides arc control, con  
tactor control, voltage/amperage control, CV/CC selec  
tion, and pulse frequency selection.  
-
-
OM-533 Page 1  
 
SECTION 2 – INSTALLATION  
Welding Power  
Source Remote  
Control Receptacle  
RPC-IP  
Receptacle  
ST-109 782-B  
Figure 2-1. Power Source/Remote Control Connections  
WARNING: ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Shut down welding power source, and be  
sure it cannot be accidentally energized before  
making remote Pendant Control connections.  
2-3. 650/1000 AMPERE MODEL SELECTOR  
SWITCH  
WARNING: ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Shut down welding power source, and dis-  
connect the Remote Pendant Control before  
changing position of dip switches.  
Place CONTACTOR switch in OFF position.  
ELECTROSTATIC DISCHARGE (ESD) can  
damage circuit boards.  
Put on properly grounded wrist strap BE-  
FORE handling circuit boards.  
2-1. WELDING POWER SOURCE REMOTE CON-  
TROL RECEPTACLE CONNECTIONS (Figure 2-1)  
Perform work only at a static-safe work area.  
This Remote Pendant Control is designed to be used  
with either a 650 or 1000 ampere intellipulse welding  
power source. A dip switch is located on circuit board  
PC5 to set up the Remote Pendant Control for operation  
with 650 or 1000 ampere models. The unit is shipped  
from the factory set up for operation with the 650 ampere  
The Remote Pendant Control connects to a 17-socket  
Amphenol receptacle on the welding power source front  
panel (see OM-286). Insert 17-pin Amphenol plug from  
the interconnecting cable fully into the receptacle and  
rotate collar clockwise.  
models. Proceed as follows to set up the Remote Pen  
dant Control for operation with 1000 ampere models:  
-
2-2. RPC-IP  
(Figure 2-1)  
RECEPTACLE  
CONNECTIONS  
1. Remove cover.  
2. Place both dip switches in the down position for op  
-
The interconnecting cable from the welding power  
source connects to a 17-pin Amphenol receptacle on  
eration with 1000 ampere models. Place both dip  
switches in up position for operation with 650 am-  
pere models (see Figure 2-2).  
the remote control. Insert the 17-socket plug from the in  
-
terconnecting cable fully into the receptacle, and rotate  
collar clockwise.  
3. Reinstall cover.  
OM-533 Page 2  
 
Mounting  
Screws (5)  
Dip  
Switch  
Cover  
Front  
Panel  
Both dip switches down for  
1000 ampere model operation  
Circuit  
Board  
PC5  
Both dip switches up for  
650 ampere model operation  
ST-113 509-A  
Figure 2-2. Dip Switch Positions And Locations  
SECTION 3 – OPERATOR CONTROLS  
3-1. MODE SELECTOR SWITCH (Figure 3-1)  
approached. When this control is set at some value  
above 0, the current begins to increase when arc volt-  
age drops below 20 volts.  
The Mode Selector switch allows selection of CC  
(constant current), CV (constant voltage), or pulsed out  
put from the welding power source.  
-
When the control is set at 10 (MAX.), the short-circuit  
current is considerably higher than normal welding cur  
rent (see welding power source volt-ampere curve for  
CC mode). This provides extra current for arc starting in  
out-of-position welds as well as for certain types of elec  
trodes.  
-
The CC position provides a constant current output spe  
-
cifically designed for Shielded Metal Arc (SMAW) and  
Gas ungsten Arc (GT W) Welding processes. The CC  
T
A
-
position is also normally used for Air Carbon Arc Cutting  
(CAC-A) and gouging processes.  
When the control is set at 0 (SOFT), short-circuit current  
is the same as normal welding current. The 0 position  
provides current characteristics associated with the Gas  
Tungsten Arc Welding (GTAW) process.  
The CV position provides a constant voltage output de  
-
signed for wire feeding applications such as Gas Metal  
Arc (GMAW), Flux Cored Arc (FCAW), or Submerged  
Arc (SAW) Welding.  
When pulsed output is desired for Gas Metal Arc Weld-  
ing - Pulsed Arc (GMAW-P), place switch at the desired  
When the control is set at 5, short-circuit current is  
approximately half that of the 10 (MAX.) position but still  
number of pulses per second: 60, 90, 120 or 180.  
higher than normal welding current. The 5 position pro-  
vides a moderate current increase for arc starting nec-  
essary for certain types of electrodes and applications.  
3-2. ARC CONTROL AND PILOT LIGHT (Figure 3-1)  
IMPORTANT: The ARC CONTROL potentiometer and  
pilot light are disabled in the CV (Constant Voltage) and  
pulsed modes.  
Select a setting best suited for the application.  
The Arc Control pilot light turns on when the Mode Se-  
lector switch is in the CC position indicating that the ARC  
CONTROL is active.  
The ARC CONTROL potentiometer provides variable  
selection of short-circuit current to suit individual weld-  
ing conditions. Rotating this control clockwise causes  
the current to increase as the short-circuit condition is  
IMPORTANT: The ARC CONTROL can be adjusted  
while welding.  
OM-533 Page 3  
 
Voltmeter  
Ammeter  
Volts/Peak  
Control And  
Pilot Light  
Amps/Bkgd  
Control And  
Pilot Light  
Mode  
Selector  
Switch  
Ammeter  
Switch  
Arc  
Control  
Arc Control  
Pilot Light  
Contactor  
Switch  
ST-109 521-A  
Figure 3-1. Front Panel View  
3-4. AMMETER SWITCH (Figure 3-1)  
3-3. CONTACTOR SWITCH (Figure 3-1)  
The AMMETER switch provides selection of reading  
PEAK weld amperage or Average (AVG) weld amper-  
age on the Remote Control digital ammeter.  
WARNING: ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Do not touch the weld output terminals when  
the contactor is energized.  
Normally the AVG switch position is used for reading  
weld amperage during Gas Metal Arc (GMAW), Flux  
Cored Arc (FCAW), Submerged Arc (SAW), Shielded  
Do not touch electrode holder (or gun wire)  
and work clamp at the same time.  
Metal Arc (SMAW), Gas Tungsten Arc (GTAW) Welding  
and Air Carbon Arc (CAC-A) Cutting and gouging pro-  
cesses.  
If the Remote Control CONTACTOR switch is in the ON  
position, open-circuit voltage will be present at the out  
put terminals whenever the welding power source  
POWER switch ON button is depressed.  
-
While welding using the Gas Metal Arc Welding - Pulsed  
Arc (GMAW-P) process, the AVG switch position is used  
when display of the average (background and peak)  
weld amperage is desired. The AMMETER switch can  
be placed in the PEAK position when display of peak  
weld amperage is desired.  
IMPORTANT: Although the term CONTACTOR is used  
on the nameplate and throughout this manual, the weld  
output is not switched on or off by a physical secondary  
contactor; rather, the weld output is controlled by solid-  
state circuitry in the welding power source.  
3-5. AMPS/BKGD CONTROL AND PILOT LIGHT  
(Figure 3-1)  
This control presets weld amperage for constant current  
applications and background amperage for GMAW-P  
applications.  
If contactor control by means of a wire feeder is desired,  
place the Remote Control CONTACTOR switch in the  
OFF position. Open-circuit voltage will be present at the  
weld output terminals whenever the gun switch is  
closed.  
When the Mode Selector switch is in the CC position or  
one of the pulses per second positions, the AMPS/  
BKGD pilot light turns on.  
The OFF position is normally used with all wire feeding  
processes (GMAW, GMAW-P, FCAW, SAW) and the  
Gas Tungsten Arc Welding (GTAW) process. The ON  
position is normally used with the Shielded Metal Arc  
This control is disabled when the Mode Selector switch  
is in the CV position.  
Welding (SMAW) and the Air Carbon Arc (CAC-A) Cut  
ting and gouging processes.  
-
Rotating the control clockwise increases amperage.  
IMPORTANT: The AMPS/BKGD control can be ad-  
Lift end of toggle switch to change switch positions.  
justed while welding.  
OM-533 Page 4  
 
3-6. VOLTS/PEAK CONTROL AND PILOT LIGHT  
(Figure 3-1)  
IMPORTANT: The VOLTS/PEAK control can be ad-  
justed while welding.  
This control presets weld voltage for constant voltage  
applications and peak voltage for GMAW-P applica-  
tions.  
3-7. METERS (Figure 3-1)  
The voltmeter displays weld voltage to the nearest tenth  
of a volt while welding and preset voltage when unit is  
idling. When welding using the pulsed GMAW process,  
the meter displays peak voltage.  
When the Mode Selector switch is in the CV position or  
one of the pulses per second positions, the VOLTS/  
PEAK pilot light turns on.  
The ammeter displays weld amperage to the nearest  
ampere while welding and preset amperage when unit is  
idling. When welding using the pulsed GMAW process,  
the meter displays background amperage.  
This control is disabled when the Mode Selector switch  
is in the CC position.  
Rotating the control clockwise increases voltage.  
SECTION 4 – SEQUENCE OF OPERATION  
WARNING: ELECTRIC SHOCK can kill;  
MOVING PARTS can cause serious injury;  
IMPROPER AIR FLOW AND EXPOSURE TO  
ENVIRONMENT can damage internal parts.  
4-1. GAS METAL ARC WELDING - PULSED ARC  
(GMAW-P)  
WARNING: Read and follow safety informa  
-
tion at beginning of entire Section 4 before  
proceeding.  
Keep all covers and panels in place while op  
-
erating.  
Warranty is void if the welding power source is  
operated with any portion of the outer enclosure  
removed.  
1. Install and prepare welding power source according  
to its Owner’s Manual.  
2. Install Remote Control as instructed in Section 2.  
ARC RAYS, SPARKS, AND HOT SURFACES  
can burn eyes and skin; NOISE can damage  
hearing.  
3. Install and prepare wire feeder according to its Own  
-
er’s Manual.  
Wear correct eye, ear, and body protection.  
FUMES AND GASES can seriously harm  
your health.  
4. Wear dry insulating gloves and clothing, and wear  
welding helmet with proper filter lens according to  
ANSI Z49.1.  
Use enough ventilation to keep fumes and  
5. Prepare for welding as follows:  
gases from the breathing zone.  
a. Connect work clamp to clean, bare metal at  
workpiece.  
WELDING WIRE can cause puncture  
wounds.  
b. Select and obtain proper welding wire, and  
thread as instructed in wire feeder Owner’s  
Manual.  
Do not point gun toward any part of the body  
or other personnel.  
HOT METAL, SPATTER, AND SLAG can  
cause fire and burns.  
6. Depress welding power source POWER switch ON  
button.  
Watch for fire.  
Have a fire extinguisher nearby and know  
7. Place Mode Selector switch to desired pulses per  
second (60, 90, 120, or 180) position (see Section  
3-1).  
how to use it.  
MAGNETIC FIELDS FROM HIGH CURRENTS  
can affect pacemaker operation.  
Wearers should consult with their doctor be-  
fore going near arc welding, gouging, or spot  
welding operations.  
8. Place CONTACTOR switch in OFF position (see  
Section 3-3).  
9. Place AMMETER switch in the desired position (see  
Section 3-4).  
See Arc Welding Safety Precautions Section in  
the welding power source Owner’s Manual.  
10. Preset AMPS/BKGD control to desired background  
amperage setting (see Section 3-5). Pilot light  
should be on.  
OM-533 Page 5  
 
11. Preset VOLTS/PEAK control to desired peak volt-  
age setting (see Section 3-6). Pilot light should be  
on.  
4. Place Mode Selector switch in CC position (see  
Section 3-1).  
5. Place ARC CONTROL to desired position (see Sec  
tion 3-2). Pilot light should be on.  
-
12. Make adjustments to wire feeder.  
13. Turn on shielding gas supply.  
14. Begin welding.  
6. Place CONTACTOR switch in ON position (see  
Section 3-3).  
7. Place AMMETER switch in AVG (Average) position  
(see Section 3-4).  
4-2. GAS METAL ARC AND FLUX CORED ARC  
WELDING (GMAW AND FCAW)  
8. Preset AMPS/BKGD control to desired weld amper  
-
age setting (see Section 3-5). Pilot light should be  
on.  
WARNING: Read and follow safety informa  
-
tion at beginning of entire Section 4 before  
proceeding.  
9. Wear dry insulating gloves and clothing, and wear  
welding helmet with proper filter lens according to  
ANSI Z49.1.  
1. Install and prepare welding power source according  
to its Owner’s Manual.  
10. Prepare for welding as follows:  
2. Install Remote Control as instructed in Section 2.  
a. Connect work clamp to clean, bare metal at  
workpiece.  
3. Install and prepare wire feeder according to its Own  
-
er’s Manual.  
b. Select and obtain proper electrode, and insert  
into electrode holder.  
4. Wear dry insulating gloves and clothing, and wear  
welding helmet with proper filter lens according to  
ANSI Z49.1.  
11. Begin welding.  
4-4. SUBMERGED ARC WELDING (SAW)  
5. Prepare for welding as follows:  
WARNING: Read and follow safety informa  
-
tion at beginning of entire Section 4 before  
proceeding.  
a. Connect work clamp to clean, bare metal at  
workpiece.  
b. Select and obtain proper welding wire, and  
thread as instructed in wire feeder Owner’s  
Manual.  
1. Install and prepare welding power source according  
to its Owner’s Manual.  
2. Install Remote Control as instructed in Section 2.  
6. Depress welding power source POWER switch ON  
button.  
3. Install flux system according to its Owners Manual.  
4. Install and prepare wire feeder according to its Own  
-
7. Place Mode Selector switch in CV position (see  
Section 3-1).  
er’s Manual.  
5. Wear dry insulating gloves and clothing, and wear  
safety goggles with correct filter shade according to  
ANSI Z49.1.  
8. Place CONTACTOR switch in OFF position (see  
Section 3-3).  
6. Prepare for welding as follows:  
9. Place AMMETER switch in AVG (Average) position  
(see Section 3-4).  
a. Connect work clamp to clean, bare metal at  
workpiece.  
10. Preset VOLTS/PEAK control to desired weld volt-  
age setting (see Section 3-6). Pilot light should be  
on.  
b. Select and obtain proper welding wire, and  
thread as instructed in wire feeder Owner’s  
Manual.  
11. Make adjustments to wire feeder.  
12. Turn on shielding gas supply if applicable.  
13. Begin welding.  
c. Select and obtain proper flux, and put into flux  
system.  
7. Depress welding power source POWER switch ON  
button.  
4-3. SHIELDED METAL ARC WELDING (SMAW)  
8. Place Mode Selector switch in CV position (see  
Section 3-1).  
WARNING: Read and follow safety informa  
-
tion at beginning of entire Section 4 before  
proceeding.  
9. Place CONTACTOR switch in OFF position (see  
Section 3-3).  
1. Install and prepare welding power source according  
to its Owner’s Manual.  
10. Place AMMETER switch in AVG (Average) position  
(see Section 3-4).  
2. Install Remote Control as instructed in Section 2.  
11. Preset VOLTS/PEAK control to desired weld volt-  
age setting (see Section 3-6). Pilot light should be  
on.  
3. Depress welding power source POWER switch ON  
button.  
OM-533 Page 6  
 
12. Make adjustments to wire feeder.  
13. Turn on flux supply system.  
4-6. AIR CARBON ARC CUTTING AND GOUGING  
(CAC-A)  
WARNING: Read and follow safety informa  
-
14. Begin welding.  
tion at beginning of entire Section 4 before  
proceeding.  
4-5. GAS TUNGSTEN ARC WELDING (GTAW)  
WARNING: Read and follow safety informa  
-
1. Install and prepare welding power source according  
to its Owner’s Manual.  
tion at beginning of entire Section 4 before  
proceeding.  
2. Install Remote Control as instructed in Section 2.  
3. Connect compressed air supply.  
1. Install and prepare welding power source according  
to its Owner’s Manual.  
4. Depress welding power source POWER switch ON  
button.  
2. Install Remote Control as instructed in Section 2.  
3. Install and prepare High-Frequency unit according  
to its Owner’s Manual if applicable. Scratch start  
5. Place Mode Selector switch in CC position (see  
Section 3-1).  
GTAW does not require the use of external high fre  
quency.  
-
6. Set ARC CONTROL to desired position (see Sec-  
tion 3-2). Pilot light should be on.  
4. Depress welding power source POWER switch ON  
button.  
7. Place CONTACTOR switch in ON position (see  
Section 3-3).  
5. Place Mode Selector switch in CC position (see  
Section 3-1).  
8. Place AMMETER switch in AVG (Average) position  
(see Section 3-4).  
6. Set ARC CONTROL to MIN. (see Section 3-2). Pilot  
light should be on.  
9. Preset AMPS/BKGD control to desired amperage  
setting (see Section 3-5). Pilot light should be on.  
7. Place CONTACTOR switch in ON position (see  
Section 3-3).  
10. Wear dry insulating gloves and clothing, and wear  
welding helmet with proper filter lens according to  
ANSI Z49.1.  
8. Place AMMETER switch in AVG (Average) position  
(see Section 3-4).  
11. Prepare for welding as follows:  
9. Preset AMPS/BKGD control to desired weld amper  
-
a. Connect work clamp to clean, bare metal at  
workpiece.  
age setting (see Section 3-5). Pilot light should be  
on.  
b. Select and obtain proper carbon electrode, and  
insert into torch.  
10. Wear dry insulating gloves and clothing, and wear  
welding helmet with proper filter lens according to  
ANSI Z49.1.  
12. Turn on air supply.  
13. Begin cutting/gouging process.  
4-7. SHUTTING DOWN  
1. Stop welding.  
11. Prepare for welding as follows:  
a. Connect work clamp to clean, bare metal at  
workpiece.  
2. Depress the welding power source POWER switch  
OFF button.  
b. Select and obtain proper tungsten electrode.  
c. Prepare tungsten electrode according to weld-  
ing power source Owner’s Manual, and insert  
into torch.  
3. Turn off the shielding gas and water supplies if appli  
-
cable.  
WARNING: HIGH CONCENTRATION OF  
SHIELDING GASES can harm health or kill.  
Shut off gas supply when not in use.  
12. Turn on shielding gas and water supplies as appli-  
cable.  
13. Turn on and adjust High-Frequency unit if applica-  
ble.  
4. Turn off flux supply and compressed air supply if ap  
-
14. Begin welding.  
plicable.  
OM-533 Page 7  
 
SECTION 5 – MAINTENANCE & TROUBLESHOOTING  
5-1. MAINTENANCE  
A. General  
Usage and shop conditions will determine the frequency  
and type of maintenance. Inspect equipment as follows:  
It is assumed that proper installation has been made,  
according to Section 2 of this manual, and that the unit  
has been functioning properly until trouble developed.  
WARNING: ELECTRIC SHOCK can kill.  
B. Troubleshooting  
Do not touch live electrical parts.  
Troubleshooting to be performed only by qualified per-  
sons.  
Shut down welding power source, and dis-  
connect remote control before inspecting, main  
-
taining, or servicing unit. Power to the remote  
The following information is supplied to diagnose and  
provide remedies for some of the troubles that may de  
velop in this unit. Check welding power source Owner’s  
Manual for possible problems caused by welding power  
source malfunctions.  
control should be disconnected before attempt  
-
-
ing repair or replacement of internal compo-  
nents.  
1. Inspect interconnecting cord for damage to or  
breaks in the insulation jacket, particularly at the  
plugs. Repair or replace cord as necessary.  
Use this information in conjunction with the circuit dia-  
gram while performing troubleshooting procedures. If  
the trouble is not remedied after performing these pro-  
cedures, the nearest Factory Authorized Service Sta-  
tion/Service Distribuitor should be contacted. In all  
cases of equipment malfunction, the manufacturer’s  
recommendations should be strictly followed.  
2. Remove grease and grime from components; mois  
ture from electrical parts and cable.  
-
5-2. TROUBLESHOOTING  
WARNING: ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Problems with this unit fall into four categories:  
1. Front panel components  
2. Circuit board PC5  
Shut down welding power source, and dis-  
connect remote control before inspecting, main  
-
taining, or servicing unit. Power to the remote  
control should be disconnected before attempt  
-
3. Interconnecting cable  
ing repair or replacement of internal compo-  
nents.  
4. Welding power source.  
If everything on the remote control functions except a  
particular switch, meter, or control, the problem can be  
attributed to a broken component. Replace the broken  
component.  
CAUTION: ELECTROSTATIC DISCHARGE  
(ESD) can damage circuit boards.  
Put on properly grounded wrist strap BE-  
FORE handling circuit boards.  
If the problem is still present, replace PC5. If the remote  
control is entirely non-functional, replace PC5. If erratic  
conditions occur and the welding power source was  
working properly, replace PC5.  
Transport circuit boards in proper static-  
shielding carriers or packages.  
Perform work only at a static-safe work area.  
INCORRECT INSTALLATION or misaligned  
plugs can damage circuit board.  
A
break in the interconnecting cable can interrupt power  
or command signal between welding power source and  
remote control. Replace interconnecting cable if lack of  
continuity is suspected.  
Be sure that plugs are properly installed and  
aligned.  
EXCESSIVE PRESSURE can break circuit  
board.  
Use only minimal pressure and gentle move-  
ment when disconnecting or connecting board  
plugs and removing or installing board.  
Printed circuit board PC1 in the welding power source  
sends and receives signals from the remote control. If all  
other components of the system are functioning, re-  
place welding power source PC1 according to instruc-  
tions in welding power source Owner’s Manual.  
OM-533 Page 8  
 
SECTION 6 – ELECTRICAL DIAGRAMS  
Circuit Diagram No. SB-107 993-B  
Diagram 6-1. Circuit Diagram For Pendant Control  
Circuit Diagram No. SB-124 223  
Diagram 6-2. Circuit Diagram For Circuit Board PC5  
OM-533 Page 9  
 
OM-533 Page 10  
 
SECTION 7 – PARTS LIST  
Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 7-1. Main Assembly  
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1
2
3
4
5
6
7
8
9
. . . . . . . . . . . 108 056 . . . CASE SECTION, front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . 109 779 . . . CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . R6,7 . . 603 856 . . . POTENTIOMETER, WW 10 turn 2 watt 10K ohm . . . . . . . . . . . . . . . . . . . . . .  
. . . . S7 . . . . 011 770 . . . SWITCH, toggle SPDT 5 amp 125 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . S8 . . . 079 722 . . . SWITCH, toggle SPDT 0.4 amp 2-4 volts dc . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
2
1
1
3
1
1
1
1
1
2
1
1
1
1
1
2
4
2
4
4
1
1
2
. . LED1-3  
.
083 850 . . . LIGHT, indicator - red lens 2 volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . RC3 . . 097 867 . . . RECEPTACLE, 17 pin MS-3102A-20-29P . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model & style number) . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . R8 . . . 009 156 . . . POTENTIOMETER, carbon 1 turn 2 watt 2.5K ohm . . . . . . . . . . . . . . . . . . . . .  
. . 10 . . . . S6 . . . 108 944 . . . SWITCH, rotary - 0.5 amp 115 volts ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . 11 . . . . . . . . . . . 108 903 . . . SHIELD, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . 12 . . . A&V . . 108 453 . . . METER, DC 0-200 MV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 108 904 . . . ANCHOR, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . PC5 . . . 124 002 . . . CIRCUIT CARD, pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 038 785 . . . STRIP, terminal 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 072 566 . . . CONNECTOR, rect 8skt plug Amp 87159-8 . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 081 380 . . . CONNECTOR, rect 14skt plug Amp 1-87159-3 . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 108 907 . . . CONNECTOR, rect 13skt 1 row plug Amp 2-87499-3 . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 097 922 . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 019 663 . . . MOUNT, 15/16 OD x 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 097 132 . . . STAND-OFF, No. 6-32 x 3/8 inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 094 484 . . . STAND-OFF, No. 6-32 x 1 inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 108 863 . . . CABLE, interconnecting (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 097 868 . . . . CONNECTOR, circ 17skt plug Amphenol MS-3106A-20-29S . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 039 734 . . . . CONNECTOR, circ clamp str rlf Amphenol AN-3057-12 . . . . . . . . . . . . . . .  
. . . . . . . . . . . . . . . . 090 263 . . . . CABLE, pwr No. 18ga 18/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ft  
. . . . . . . . . . . . . . . . 097 866 . . . . CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P . . . . . . . . . .  
1
. Hardware is common and  
1
not available unless listed.  
2
12  
11  
10  
3
4
9
8
7
6
ST-109 521  
5
Figure 7-1. Main Assembly  
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-533 Page 1  
1
 

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