Home

safety - Lincoln Electric

1. O 9 E 8 pr O i 1 FIGURE 6 ST450 5 X 5 CROSS SLIDE MOUNTING DIMENSIONS GENERAL INFORMATION 201329 001 REV D mu 450 10 x hol mounting holes o 8 places e co o Q Q A mio 40 9 lo gt 9 00 o 3 13 5 00 MIB 18 00 8 36 1 e 5 B 0 O O O 1 5 19 9 mig 400 10 50 400 24 26 7 54 FIGURE 7 1450 10 10 CROSS SLIDE MOUNTING DIMENSIONS GENERAL INFORMATION 201329 001 REV D FIGURE 8 CONTROL UNIT MOUNTING DIMENSIONS 10 201329 001 REV D GENERAL INFORMATION 2 460 3 835 4 000 FIGURE 9 CONTROL PENDANT MOUNTING DIMENSIONS 11 GENERAL INFORMATION 201329 001 REV D AX x SS A SOR 5 020
2. ITEM PART 5 X5 PART 10 X 10 DESCRIPTION 1 2 000 EA 0600 0034 0600 0036 UNIVERSAL BASE ST250 2 4 000 EA 0600 0366 0600 0366 BEARING BLOCK O RING 3 3 000 EA 0600 0302 0600 0302 UNIVERSAL BRG BLK ST250 4 1 000 EA 0600 0372 0600 0372 4 BOLT ST250 BRG BLOCK 5 3 000 EA 2320 0244 2320 0244 BEARING BALL ANLR CONT 6 1 000 EA 0600 0123 0600 0123 BALL BEARING ST250 7 2 000 EA 2380 0128 2380 0128 SEAL OIL 375X1 125X 312 9 2 000 EA 0600 0346 0600 0346 NUT HOUSING INSERT ST250 10 2 000 EA 0600 0339 0600 0339 NUT HOUSING PLATE ST250 11 2 000 EA 0600 0336 0600 0336 NUT HOUSING ST250 12 2 000 EA 0600 0380 0600 0374 ST250 SCREW ACTUATOR ASSY 13 2 000 EA 0600 0064 0600 0068 TRACK COVER LOWER LEFT 14 2 000 EA 0600 0065 0600 0069 TRACK COVER LOWER RIGHT 15 4 000 EA 0600 0159 0600 0098 SCREW COVER ASSY ST250 16 1 000 EA 0600 0058 0600 0058 FACEPLATE 17 1 000 EA 0600 0048 0600 0048 END PLATE LOWER 18 2 000 EA 1112 0211 1112 0211 COVER SEAL BEARING 19 2 000 EA 0600 0373 0600 0373 2 STAND OFF 20 4 000 EA 0600 0279 0600 0282 RAIL ST250 21 8 000 EA 2360 0561 2360 0561 WHEEL GUIDE DUAL VEE 22 4 000 EA 0600 0054 0600 0054 ADAPTOR BUSHING ADJUSTABLE 23 2 000 EA 2320 1151 2320 1151 INSERT COUPLING 24 4 000 EA 2320 1160 2320 1160 COUPLING HALF 3 8 IN 25 1 000 EA 0600 0111 0600 0111 MOTOR ASS
3. AE UR fit RO BA EL 36 SB 8 sy I J EE oso HAY ETSMI7 BHC TON call Gl gl lass J al gly Sand qul cial lala cm Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O BIR e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground 9 No toque las partes los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Beriihren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da 9 Isole se da peca e terra o E FORA ZIEHE FTRANCHTANZUIE 7 Z 5 EHESS DO 20 ERE RAE E E CRM ML HR ecran suse EF uu 43x e HAS HER OAR JM d Quali Y AMJ DL dali JA du ule Y O e Keep flammable materials away e Mantenga el mater
4. TABLE 23 DRIVE SIGNAL TEST POINTS DESCRIPTION VALUES ITEM QTY PART DESCRIPTION TP1 20 VDC 20 VDC 1 0 VDC 4 2 2120 0263 Fuse TP2 15 VDC 15 VDC 0 5 VDC 2 1 2100 0086 Power Lamp TP3 Logic Ground 3 1 0600 0388 Main Board TP4 20 VDC 20 VDC 1 0 VDC 4 2 1110 2093 Insulator TP5 15 VDC 15 VDC 0 5 VDC 5 1 2702 0186 Rectifier TP6 6 VDC 6 VDC 0 5 VDC 6 1 1103 0491 Transistor Kit REF DESCRIPTION VALUES UP 12 5 VDC R25 Vertical Error HE DN 12 5 VDC RIGHT 12 5 VDC R26 Horizontal Error VE LEFT 12 5 VDC 44 TROUBLESHOOTING 201329 001 REV D Heatsink Motor Driver Assembly 5 Motor Drivers Cross Slide Transformer Assembly Power Circuit All Control Voltages 110 220 50 60Hz Pendant Main Board Assembly Motorized Slide Control Enclosure Assembly Servo Amplifier Circuit FIGURE 25 MOTORIZED SLIDE SIGNAL FLOW 45 TROUBLESHOOTING 201329 001 REV D 46 201329 001 REV D CIRCUIT DESCRIPTIONS CIRCUIT DESCRIPTIONS WARNING For use by Qualified Service Technicians The APA Motorized Slide system s elec tronic circuitry consists primarily of two nearly identical servo systems one for the horizontal axis and one for the vertical axis Signals received from the pendant assemb
5. 42 201329 001 REV D TROUBLESHOOTING TROUBLESHOOTING The following list describes typical problems and sug gested corrective procedures The CIRCUIT DESCRIPTIONS section which in cludes block diagrams and schematics will also be a helpful reference for troubleshooting Full line voltage is exposed inside the control unit Do nat turn power On when the Main board is re moved partially removed or disconnected Many of the Integrated Circuits 1675 on the board are CMOS logic and require standard CMOS precautions against damage by static electricity dis charge RECOMMENDED SPARES FOR TROUBLE SHOOTING This manual was written in a manner to provide enough detail to identify individual components and parts for maintenance purposes A recommended spare parts lists is given in Table 24 Recommended Spare Parts on page 44 For troubleshooting the fol lowing items are recommended to isolate most prob TABLE 21 TROUBLESHOOTING lems Lamp bad PROBLEM DESCRIPTION CAUSE SOLUTION Unit unplugged Plug unit into an appropriate Problem 1 L t lit Blown Fuse Source Lamp Off Replace Fuse Replace Lamp Problem 2 No Power Switch and Indicator Lamp are Cables disconnected from the control to other components of the system are disconnected inside Check cables from the control to oth
6. MAINTENANCE MAINTENANCE REQUIREMENTS APA Motorized Slide Systems are designed for trou ble free operation and normally require only minimal preventive care and cleaning This section of the users manual provides instructions for maintaining user serviceable items The suggested repair proce dure for all user serviceable items 1 to remove and replace defective assemblies or parts Service per sonnel employed by the user should be familiar with electrical and electronic equipment or else service problems should be corrected by factory authorized representatives CONTROL UNIT ASSEMBLY The control unit assembly on page consists of an enclosure housing the major electronic assemblies of the seam tracker system Maintenance is generally limited to periodic dusting of the enclosure The user should ensure that the unit is not operated with the access door open and or option plates and cable con nector mounting holes open The user should exer cise caution in operating the unit if it has been inadvertently exposed to excessive dust or liquid con tamination since such conditions may cause electrical shorting and or malfunctioning of the electrical elec tronics assemblies The user should consult with the factory if such conditions have occurred Repair of the control unit assembly is generally limited to a remove and replace operation NOTE If the user should decide to repair unau thorized items then the user should ex
7. ZS A A AD S KS FIGURE 11 SIDE VIEW ST250 amp ST450 TABLE 4 ST40 LOAD SPECIFICATIONS Inches 6 7 8 9 W Ibs 40 30 20 10 Inches 6 7 8 9 C Inches 3 3 5 4 4 5 D Inches 2 2 2 2 TABLE 5 ST250 LOAD SPECIFICATIONS Inches 12 16 20 24 W Ibs 250 190 130 70 B Inches 12 16 20 24 C Inches 4 4 4 4 D Inches 3 3 3 3 TABLE 6 ST450 LOAD SPECIFICATIONS Inches 12 16 20 24 W Ibs 450 340 230 120 Inches 12 16 20 24 C Inches 4 4 4 4 D Inches 3 3 3 3 FIGURE 12 LOAD SPECIFICATIONS ENVELOPE TOP VIEW NOTE 1 gt Center of Gravity CG of load W to be within en velope 2 gt ST600B Load Ratings determined with the lower axis positioned horizontally and upper axis positioned vertically 12 201329 001 REV D OPERATION OPERATION DRIVE CABLE The drive cable connects the cross slide assembly to the control unit It is used to transmit signals and power between the units The standard drive cable is 10 feet long for longer lengths consult our factory CROSS SLIDE ASSEMBLY The seam tracker cross slide assemblies are light weight compact designs consisting of two motorized linear slides mounted at right angles to provide X Y axis
8. CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical
9. P15 J15 Ol Y Wht Yel 717 5 To sele 27 55 Wht m 414 Gm Wht 1 I P14 J14 Blu Bi 818 Red Yel zes Reavel 5 ed Yel B a 12 20 20 lt Secondary n MEE E y 2 WON Cv Y 5 Primary 110 110 a 2 Bik Wht ES Wht BIk Wht Bik 2 2 111 16 216 Voltage Selector 52 Red 9 66 A 2b 1b Wht x 515 220 2 4 a 110 TA Org 414 B 2 Wht 212 u EMI RFI El Ol a BK GIN rg L Filter 33 gt N Muht 111 Gm HS DRIVE SIGNALS HS POWER ASSEMBLY P N 1101 2002 8 P N 1101 2002 2 amp INPUT POWER ASSEMBLY P N 1101 2002 6 Motorized Slide Control Main Board Assembly P N 0600 0388 FIGURE 27 MOTORIZED SLIDE CONTROL BLOCK DIAGRAM 50 201329 001 REV D SCHEMATICS AND BLOCK DIAGRAMS o 29 22 mz A 2 See Control Pendant am lt ST40B Cross Slide Reference Only P2 ST40B Cross Slide Assembly Vertical Horizontal 5 Motors Z Blk Brn Bik L Red 2 M eng F E Yel H Blk D N Sm B J2gP2 1 44 Gm Jl Cable Assembly J 4 43 P3 1114 0017 M Brakes WhUBIk OF Whiotors if ordered o gt Wht Red m 5
10. i Brn 59 Gm p Blk ng m s Org Bk 5 5 Og W Vertical E Vel 5 Bik a Horizontal w ee A 2 em s Gm e Ek a Blk Yel 6 6 Blu HH Gm c li Blu D Wht N ue B Blk Org Cross Slide Assembly for ST40B see insert FIGURE 28 MOTORIZED SLIDE CONTROL BLOCK DIAGRAM CONT 51 201329 001 REV D SCHEMATICS AND BLOCK DIAGRAMS y eseud OVASLL OVASLL Ala pay 50 wanum 8 9 1408922 S8c9NC KID IUM KZ c8c9NC 14089 19 SWUO 552 0 007 t z002 LOLL zy quuessy YuIsIesH UOLULOJ UOLIWOJ AWA JWE JIN3 ZuoH AINA ZUOH EJUOZUOH OGA 0c OGA OZ Jewog eyelg FIGURE 29 MOTOR DRIVER HEATSINK SCHEMATIC DIAGRAM 52 201329 001 REV D SCHEMATICS AND BLOCK DIAGRAMS 53 OPTIONAL EQUIPMENT 201329 001 REV D OPTIONAL EQUIPMENT ROTARY TABLE BRACKET Engineered and designed for use with ST250 seam tracker systems the Rotary Table Bracket allows the user to position equipment at any point through 360 degrees and lock it into place Used primarily for fillet weld applica tions where angling of the torch is necessary or for operat
11. FIGURE 29 MOTOR DRIVER HEATSINK SCHEMATIC DIAGRAM OPTIONAL EQUIPMENT FIGURE 30 ROTARY TABLE BRACKET SAFETY 201329 001 REV D SAFETY SAFETY PRECAUTIONS THIS MANUAL HAS BEEN DESIGNED FOR EXPE RIENCED WELDING AND CUTTING EQUIPMENT OPERATORS AND MUST BE READ COMPLETELY BEFORE USING THIS EQUIPMENT IF YOU LACK EXPERIENCE OR ARE UNFAMILIAR WITH THE PRACTICES AND SAFE OPERATION OF WELDING AND CUTTING EQUIPMENT PLEASE CONSULT YOUR FOREMAN DO NOT ATTEMPT TO INSTALL OPERATE OR PERFORM MAINTENANCE ON THIS EQUIPMENT UNLESS YOU ARE QUALIFIED AND HAVE READ AND UNDERSTOOD THIS MANUAL IF IN DOUBT ABOUT INSTALLING OR OPERATING THIS EQUIPMENT CONTACT YOUR DISTRIBUTOR OR THE CUSTOMER SERVICE DEPARTMENT OF ARC PRODUCTS DEFINITIONS Throughout this manual NOTE CAUTION WARNING and DANGER are inserted to call attention to particular information The methods used to identify these highlights and the purpose for which each is used are as follows Operational procedural and background in formation which aids the operator in the use of the machine helps the service personnel in the performance of maintenance and prevents damage to the equipment gt m CAUTION An operational procedure which if not fol lowed may cause minor injury to the opera tor service personnel and or bystanders WARNING An operational procedure which if not fol lowed may cause severe injury to the oper
12. 8 REPEAT 7 STEP 9 VERIFY READING AND NO MOVEMENT STEP 10 CONNECT OSCILLOSCOPE STEP 11 ADJUST TRIMPOT COUNTER CLOCK WISE STEP 12 ADJUST HI TRIMPOT CLOCK WISE NE STEP tt 13 VERIFY READING STEP tt 14 REPEAT STEP 13 STEP 15 VERIFY READING AND NO MOVEMENT DRAWINGS AND PARTS LISTS DRAWINGS AND PARTS LISTS TROUBLESHOOTING TROUBLESHOOTING RECOMMENDED SPARES FOR TROUBLESHOOTING PROBLEM 1 LAMP OFF PROBLEM 2 NO OPERATION PROBLEM 3 HORIZONTAL DRIFT PROBLEM 4 VERTICAL DRIFT PROBLEM 5 SYSTEM OSCILLATION PROBLEM 6 SLIDES WILL NOT DRIVE PROBLEM 7 SLIDES DRIVE ONE DIRECTION PROBLEM 8 SLIDES DRIVE BOTH DIRECTION PROBLEM 9 MOTOR OSCILLATION CIRCUIT DESCRIPTIONS 43 43 43 43 43 43 44 44 CIRCUIT DESCRIPTIONS SYSTEM WIRING DIAGRAM MAIN BOARD ASSEMBLY VOLTAGE REGULATION CONTROL CIRCUITRY DESCRIPTION PENDANT CONTROL SERVO AMPLIFIER SCHEMATICS AND BLOCK DIAGRAMS 47 47 47 47 48 SCHEMATICS AND BLOCK DIAGRAMS OPTIONAL EQUIPMENT 49 OPTIONAL EQUIPMENT ROTARY TABLE BRACKET 54 54 vi 201329 001 REV D TABLE OF CONTENTS INDEX INDEX 55 vii TABLE TABLES 201329 001 REV D Table of Tables MOTORIZED SLIDE CONTROL SYSTEM GENERAL INFORMATION 3 TABLE 1 MS40 SYSTEM SPECIFICATION
13. Arc Products IM 6101 Aw A Lincoln Electric Company 201329 001 Rev D MOTORIZED SLIDE SYSTEM IMPORTANT For Your Safety Read this manual before installing or using this equipment Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL AND SERVICE MANUAL Copyright O Lincoln Global Inc LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distibutors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP
14. V vee 13 18 vertical 14 16 18 43 44 47 48 vibrates gt AB vibration 14 view c c 1418 voltage 13 43 44 47 48 Voltage 43 47 48 W Weights 8 5 wheel EEG 13 18 wiring 2 9 6 9 17 x X Yaxis 3 13 56 706 706 PARTS LIST FOR Arc Products Replacement Parts Cross Reference List ARC PRODUCTS REPLACEMENT PARTS CROSS REFERENCE LIST LINCOLN 706 1 Indicates a change this printing P 706 C 1 DESCRIPTION ARC PRODUCTS NO LECO NO 1 5 Axis Probe Bracket Assembly 1100 0258 K52026 1 2 Sensor Cable Assembly 1114 0378 K52033 1 3 1 8 Diameter Round 1106 1923 KP52028 1 4 Insulator Omni Guide 1110 2093 KP52029 1 5 1 16 Diameter Round 1106 1974 KP52047 1 6 1 Diameter Ball 1106 1982 KP52048 1 7 3 4 Diameter Ball 1106 1991 KP52049 1 8 5 8 Diameter Ball 1106 2008 KP52050 1 9 11 2 Diameter Ball 1106 2016 KP52051 1 10 3 8 Diameter Ball 1106 2024 KP52052 1 11 11 4 Diameter Ball 1106 2032 KP52053 1 12 3 Extension Tip 1110 2107 KP52055 1 13 Remote Panel Harness Asbly APC 1103 2002 3 S29276 38 14 APA St Pendant Adv Prog Option 1101 2004 529276 39 15 St Panel and Overlay Assembly 0600 0381 S29276 41 16 Upper Mtr
15. la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place THANK YOU for purchasing Arc Products Equipment Our commitment to you is to vide an ever expanding family of quality arc positioning equipment controllers and accessories Please take a moment to read the following pages as they con tain important information regarding proper use of this product and of weld ing cutting safety and procedures WHO DO CONTACT For help Contact your distributor For additional information such as Technical Manuals Service and Parts Circuit and Wire Diagrams User s Guides Distributor Direc tories Contact your distributor To file a claim for loss or damage during shipment Contact your delivering carrier For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Trans portation Department Call Fax E mail Write How to contact Arc Products 619 628 1022 619 628 1028 sales arc
16. x 3 5 15 17 43 47 Schedule v w 18 E Manual 14 15 17 schematics 17 43 47 earth 14 Mechanical 15 sealed 13 14 electrolytic gt SE 47 mechanical play 43 seam gt 13 15 17 47 54 Electro Magnetic Ir Interference 47 Minimum Envelope gt gt gt 3 5 Seam 13 15 17 47 EMF 48 momentary gt 0 xi 16 Seam Sensor gt gt gt gt 14 EMI 47 motor gt gt 13 18 43 44 47 48 secondary gt 47 motorized gt gt 13 selector gt gt 47 55 INDEX 201329 001 REV D sensor s s s e 14 service 8 x 17 Service z oue 17 47 See Also Troubleshooting serviceable 692 17 servo 47 48 shield xi xii 14 shields doe 14 Slide 3 6 13 15 18 24 26 43 sluggish Po we 48 source 5 2 m y 47 Specifications 3 5 speed 43 44 48 ST250 4 7 12 14 24 26 47 54 5740 3 6 12 15 22 23 47 ST450 8 9 12 14 28 30 stable Doc 43 54 static electricity discharge 43 stop 16 44 48 54 Stroke Length 3 5 switches 14 16 T Technicians 47 test points 43 47 torch x 16 54 TP4 44 47 TP5 44 47 transistors gt 17 43 See Also Heat Sink Assembly travel er xi 14 18 trimpot 48 Troubleshooting 43 46 U Up 13 47
17. 201329 001 REV D adjust the amplitude of the signal to the main board and ultimately adjust the speed of the cross slides movement The toggle switch on the pendant Speed Range se lects either maximum speed of the cross slides no adjustment or adjustable speed range set by the po tentiometers Servo Amplifier The primary purpose of the Servo Amplifier Circuitry is to amplify the signals generated by the pendant to the appropriate levels required by the complementary Darlington Push Pull Transistors located on the heatsink assembly used to drive the motors and to regulate the motor current What is actually required of the Servo Amplifier is that it produces a motor speed proportional to the error signal voltage from the pendant Motor speed is reg ulated by measuring back EMF from the motor The technique used to regulate motor speed is known as IR Compensation Motor Speed is made up of two parts Voltage and Current The resistance from one motor to another will vary The motor resistance can be accommo dated by adjusting R2 Vertical IR Comp and R3 Hori zontal IR Comp An EMF Sense Resistor 0 1 ohms for each axis is used as a shunt to accurately mea sure and limit the motor current The adjustment procedure 1 to turn R2 and coun ter clockwise until the horizontal slide oscillates or vi brates Then turn them clockwise to the point where oscillations stop which should be checked by alter nately driv
18. Standard Safety in Welding and Cutting B Bulletin No F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting Containers and Piping that have held Hazardous Substances OSHA Safety and Health Standards 29CFR 1910 available from the United States Department of Labor Washington DC 20210 D NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes avail able from the National Fire Protection Associ ation 470 Atlantic Avenue Boston MA 00210 201329 001 REV D SAFETY NEMA Standards Publication No EW1 1989 Electric Arc Welding Apparatus approved as ANSI C87 1 1989 Available from National Electrical Manufacturers Association 155 E 44th Street New York NY 10017 xiii SAFETY 201329 001 REV D 201329 001 REV D Motorized Slide Control Motorized Slide Control System 201329 001 REV D 201329 001 REV D GENERAL INFORMATION GENERAL INFORMATION MOTOR DRIVEN CROSS SLIDES CONTROL UNIT AND DRIVE CABLE FIGURE 1 540 SYSTEM COMPONENTS TABLE 1 MS40 SYSTEM SPECIFICATIONS DESCRIPTION SPECIFICATIONS RATING Load Capacity 6 152 mm from Faceplate 40 Ibs 18 Kg Standard Stroke Length Vertical x Horizontal 3 76 mm x 3 76 mm Non Standard Stroke Length Vertical x Horizontal 6 152 mm x 6 152 mm M
19. e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e Nao opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e EXTENSO EF BRAT YF OFTEN e HEAT ER AHS AL aL J uit oes Juill abl e Do not operate with panel open or guards off 9 No operar con panel abierto guardas quitadas e N op rez pas avec les panneaux ouverts avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas ONAMPIN AEBUVALEER CREATES RAR E Ko eto Yel cals 13 jal 114 aki Y e AlE wydaj Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese BIR Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 62 p QIR E CHA C F SU EUTRHORARME IC o uv RA EE
20. 0544 2040 0544 GEAR CLAMP SPLIT HUB 30 4 000 EA 2320 0112 2320 0112 BEARING BALL 31 1 000 EA 989009 004 989009 004 CLAMP CABLE 1 8 ID 32 4 000 EA 981007 003 981007 003 STDOFF M F 6 32 X 250 X 562 LG A 33 AR EA 933001 105 933001 105 SHRINK TUBING 3 16 PVC BLK 34 AR EA 974031 103 974031 103 WSR F 505 X 317 X 005 SBZ 36 8 000 EA 974005 006 974005 006 WSR F 74 468 X 255 X 032 SBZ 37 8 000 EA 972014 008 972014 008 NUT 1 4 20 H SS NL 38 6 000 EA 970043 300 970043 300 SCR SET 6 32 X 12 HHC SBZ 39 4 000 EA 970000 302 970000 302 SCR 6 32 X 25 CR1P SBZ 40 5 000 EA 970000 402 970000 402 SCR 8 32 X 25 CR1P SBZ 41 6 000 EA 970015 306 970015 306 SCR 6 32 X 50 HSC SBZ 42 10 000 EA 970015 404 970015 404 SCR 8 32 X 38 HSC SBZ 43 16 000 EA 970015 406 970015 406 SCR 8 32 X 50 HSC SBZ 44 8 000 EA 970015 410 970015 410 SCR 8 32 X 75 HSC SBZ 45 4 000 EA 970015 502 970015 502 SCR 10 32 X 25 HSC SBZ 46 4 000 EA 970015 604 970015 604 SCREW 1 4 20 X 38 HSC SBZ 47 4 000 970015 608 970015 608 SCR 1 4 20 X 62 HSC SBZ 48 8 000 970039 616 970039 616 SCR 1 4 20 X 1 25 SBZ G8 49 1 000 932009 005 932009 005 LUG SOLDER 8 X 5 8 23 201329 001 REV D DRAWINGS AND PARTS LISTS FIGURE 15 ST250 CROSS SLIDE EXPLODED VIEW 24 201329 001 REV D DRAWINGS AND PARTS LISTS TABLE 8 ST250 CROSS SLIDE PARTS LIST
21. AMP 3 1 000 EA 2208 0551 CONN RECT PLUG 6 PIN 200 P 4 5 000 EA 2212 0152 TERMINAL CRIMP PIN 18 24 GA 5 1 000 EA 2120 0000 FUSE CARRIER 1 4 X 1 1 4 FEK 6 1 000 EA 2120 0263 FUSE 7 1 2A 250V 1 000 EA 2340 0618 TERM RING 1 4 22 16 RED 40 201329 001 REV D DRAWINGS AND PARTS LISTS J2 PE 18 gauge PE Lie wire 4 3 FIGURE 23 DRIVE HARNESS EXPLODED VIEW TABLE 19 DRIVE CONNECTOR HARNESS ASSEMBLY PARTS LIST ITEM UM PARTNUMBER DESCRIPTION 1 1 000 EA 930014 001 CONN CIRC BOX RCPT 20 27S 2 1 000 EA 2208 0211 CONN RECT PLUG 14CKT 3 1 000 EA 2212 0018 TERMINAL CRIMP PIN 18 24 GA 4 1 000 EA 2340 0588 TERM RING INSUL 6 X 92 LG 41 DRAWINGS AND PARTS LISTS 201329 001 REV D J1 18 gauge wire EX N 3 17 pl TABLE 20 PENDANT HARNESS ASSEMBLY PARTS LIST FIGURE 24 PENDANT CONNECTOR HARNESS EXPLODED VIEW ITEM UM PART NUMBER DESCRIPTION 1 1 000 EA 930014 015 CONN CIRC BOX RCPT 22 14S 2 1 000 EA CONN RECT PLUG 6 CKT 3 17 000 EA 2212 0018 TERMINAL CRIMP PIN 18 24 GA 4 1 000 EA 2340 0588 TERM RING INSUL 6 X 92 LG
22. Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information E SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment le
23. ator service personnel or others in the operating area gt gt DANGER An operational procedure which if not fol lowed will cause severe injury or even death to the operator service personnel or bystanders gt SAFETY INFORMATION Safety is a combination of good judgment and proper training Operation and maintenance of any arc weld ing and cutting equipment involves potential hazards Individuals who are unfamiliar with cutting and weld ing equipment use faulty judgment or lack proper training may cause injury to themselves and others Personnel should be alerted to the following potential hazards and the safeguards necessary to avoid possi ble injury In addition before operating this equipment you should be aware of your employer s safety regula tions Z BE SURE TO READ THIS MANUAL BE FORE INSTALLING OR USING THIS el EQUIPMENT BE SURE TO READ AND FOLLOW ALL AVAILABLE SAFETY REGULATIONS BE FORE USING THIS EQUIPMENT ELECTRIC SHOCK e THE VOLTAGES PRESENT IN THE D WELDING AND CUTTING ENVIRONMENT CAN CAUSE SEVERE BURNS TO THE BODY OR FATAL SHOCK THE SEVERITY OF ELECTRICAL SHOCK IS DETER MINED BY THE PATH AND THE AMOUNT OF CURRENT THROUGH THE BODY A Install and continue to maintain equipment according to USA Standard C1 National Elec tric Code B Never allow live metal parts to touch bare skin or any wet clothing Use only dry gloves C When welding or cutting in a damp area
24. in a better understanding and more effective and accurate troubleshooting of the system The Figure 13 Motor ized Slide Control Main Board Layout on page 21 is a drawing of the board to assist in placement of the Test Points for better understanding and troubleshooting In addition to the board layout drawing Figure 25 Motorized Slide Signal Flow on page 45 illustrates very simply the flow of signals in the motorized Slide system Voltage Regulation The Main board contains control circuitry for the sys tem and also performs primary input voltage and con trol voltage regulation Input voltage to the control unit is supplied to the Main board through a fuse and Radio Frequency Interference and Electro Magnetic Interference RFI EMI filter and voltage selector switch mounted on the bottom of the enclosure The system will operate from 110 220 VAC 50 60 Hz at less than 3 amps input power The voltage into the control unit is brought to the Main board and is then routed through the power On Off switch located on the door of the enclosure Once the switch is in the On position voltage is passed through the transformer to step down the primary input voltage to approximately 30VAC with a Center Tap two sec ondaries at 15 VAC and a third secondary of approx imately 10 VAC is not used A fourth 115VAC secondary winding is routed directly to the heatsink assembly and is rectified to 130VDC for used with a cross slide assembly w
25. positioning Guidance along each axis is accom plished through the use of ball bearing vee wheels rid ing on hardened steel tracks which are in turn mounted to thick wall aluminum channel sections forming the basic structure Wheels and tracks are factory adjusted to remove play and provide smooth uniform motion along the full stroke ADC gear motor coupled to a drive screw pro vides linear motion along each axis The drive screws are ball bearing mounted Damage to the motors and control unit is minimized because of current voltage limits set in the control unit should the unit reach the end of stroke However care should be taken to re duce or eliminate the controller from continuing to command the drive in a stalled condition at end stroke end The Motorized Slide control system s model numbers indicate the acceptable load rating of the cross slide assembly e g MS40 is rated at 40 lbs Load see Table 1 MS40 System Specifications and Table 5 ST250 Load Specifications beginning on page 12 Some cross slide models such as the ST250 include a brake mounted on the vertical motor shaft With power removed either by switching power off or dis connecting the control cable the brake is actuated and prevents creep in the slides when heavy loads are applied In some cases special adjustment may be required see Troubleshooting Section Electrical connections are made at the junction box or the motor cover mounted to the low
26. products com service arc products com Arc Products Attn Customer Service 1245 30th Street San Diego CA 92154 ALWAYS PROVIDE MODEL NAME AND PART NUMBER OVERVIEW 201329 001 REV D Overview OVERVIEW IV TABLE OF CONTENTS TABLE TABLES VIII TABLE OF FIGURES IX SAFETY SAFETY PRECAUTIONS X ADDITIONAL SAFETY HAZARDS XII MOTORIZED SLIDE CONTROL SYSTEM GENERAL INFORMATION 3 OPERATION 13 INSTALLATION 14 MAINTENANCE 17 DRAWINGS AND PARTS LISTS 21 TROUBLESHOOTING 43 CIRCUIT DESCRIPTIONS 47 SCHEMATICS AND BLOCK DIAGRAMS 49 OPTIONAL EQUIPMENT 54 INDEX INDEX 55 PARTS LIST FOR ARC PRODUCTS REPLACEMENT PARTS CROSS REFERENCE LIST P 706 201329 001 REV D TABLE OF CONTENTS Table of Contents OVERVIEW E IV TABLE OF CONTENTS ag M TABLE TABLES VIII TABLE OF FIGURES IX SAFETY SAFETY PRECAUTIONS DEFINITIONS X NOTE X CAUTION X WARNING X DANGER X SAFETY INFORMATION X ELECTRIC SHOCK X FIRE SAFETY XI ADDITIONAL SAFETY HAZARDS FIRE AND EXPLOSION XII FALLING EQUIPMENT XII HOT PARTS XII MOVING PARTS Musee MAGNETIC FIELDS AFFECT PACEMAKERS WELDING WIRE XII FLYING PIECES OF METAL OR DIRT XII OVERHEATED EQUIPMENT XII HIGH FREQUENCY SAFETY REFERENCES MOTORIZED SLIDE CONTROL SYSTEM GENERAL I
27. unrestricted air flow over the cooling fins to assure adequate cooling during opera tion A chassis ground lug is located near the power cord RFI Filter connection Care must be taken that this be connected to a solid earth ground Protective Earth or PE in a high noise environment All system components except the seam sensor and control pen dant are connected to chassis ground through cable shields WELD HEAD INSTALLATION Weld head installation is made by bolting the weld head to the cross slide assembly adapter plate This plate can have additional holes drilled to accommo date the users weld head as required The user must ensure that any added holes or hole patterns permit proper orientation of the weld head and torch axis to the drive axis Review on page 6 prior to assembly of the weld head to the adapter plate and before drilling any additional holes SYSTEM INTERCONNECTION Once the cross slide assembly and control unit are properly mounted the cables can be connected for operation On page shows connector arrangement on the control unit Connect the control pendant to J1 on the control unit The drive cable connects to J2 14 201329 001 REV D INSTALLATION NOTE Model ST40 drive cable is permanently attached to the slide assembly On all other models it is a separate cable as sembly which also has a connector at the slide WARNING 7 i For your own safety and to ensure proper g operatio
28. 0 23 22 ce o8 354 output gt xii 48 20 VDC 47 Fiter gt 14 45 23 fuse holder s s 17 P PB 44 PA es 8 ox accidental 15 GND panels xi adapter 13 14 See ground parallel A adequate xii 14 15 ground x 14 47 parts ligte 33633 1843 adjustment 13 18 43 44 48 guide 22 22 18 patterns 14 14 15 17 47 4 x Xli 14 33 35 automatic 222 214 See Protective Earth Pendant 3 5 11 13 15 17 34 35 43 47 49 B Handheld 35 17 18 barrel xi dE perpendicular 14 eatsink 17 43 47 48 planas ox es 414 brake 13 18 47 held RO on power switch 14 17 horizontal 14 16 18 43 44 47 48 Pre amplifier 47 Precautions e x Cable 3 5 13 15 17 43 Precision Screw 3 5 calibration gt 43 IO A s da preventive 17 carriage Integrated Circuits 43 primary 47 48 case 13 48 input w os 47248 Problem 005 43 44 center 16 18 instability 43 Programmable Logic Controllers xii chassis 14 Installation 14 16 proportional 48 clearance 14 insulated 5 X Protective Earth 8 14 CMOS 43 Integrated Circuits 43 protrusio
29. 0 SYSTEM COMPONENTS FIGURE 3 MS450 SYSTEM COMPONENTS FIGURE 4 ST40 CROSS SLIDE MOUNTING DIMENSIONS FIGURE 5 57250 CROSS SLIDE MOUNTING DIMENSIONS FIGURE 6 57450 5 5 CROSS SLIDE MOUNTING DIMENSIONS FIGURE 7 57450 10 X 10 CROSS SLIDE MOUNTING DIMENSIONS FIGURE 8 CONTROL UNIT MOUNTING DIMENSIONS FIGURE 9 CONTROL PENDANT MOUNTING DIMENSIONS FIGURE 10 SIDE VIEW ST40 FIGURE 11 SIDE VIEW ST250 amp 57450 E FIGURE 12 LOAD SPECIFICATIONS ENVELOPE TOP VIEW INSTALLATION MAINTENANCE DRAWINGS AND PARTS LISTS FIGURE 13 MOTORIZED SLIDE CONTROL MAIN BOARD LAYOUT FIGURE 14 ST40 CROSS SLIDE EXPLODED VIEW FIGURE 15 ST250 CROSS SLIDE EXPLODED VIEW FIGURE 16 ST450 CROSS SLIDE EXPLODED VIEW FIGURE 17 MOTORIZED SLIDE CONTROL EXPLODED VIEW FIGURE 18 CONTROL PENDANT EXPLODED VIEW FIGURE 19 POWER SWITCH ASSEMBLY EXPLODED VIEW FIGURE 20 TRANSFORMER ASSEMBLY EXPLODED VIEW FIGURE 21 MOTOR DRIVER HEATSINK ASSEMBLY EXPLODED VIEW FIGURE 22 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW FIGURE 23 DRIVE CONNECTOR HARNESS EXPLODED VIEW FIGURE 24 PENDANT CONNECTOR HARNESS EXPLODED VIEW TROUBLESHOOTING FIGURE 25 MOTORIZED SLIDE SIGNAL FLOW CIRCUIT DESCRIPTIONS FIGURE 26 PENDANT SCHEMATIC SCHEMATICS AND BLOCK DIAGRAMS FIGURE 27 MOTORIZED SLIDE CONTROL BLOCK DIAGRAM FIGURE 28 MOTORIZED SLIDE CONTROL BLOCK DIAGRAM CONT
30. 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do nat touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the el
31. 15 INSTALLATION 201329 001 REV D INITIAL SET UP INSTRUCTIONS To take full advantage of slide assemblies stroke ca pability the cross slide assembly should be positioned at the center of both horizontal and vertical strokes Weld torch mounting should be such that it is approxi mately in its nominal welding position relative to the weld joint This then allows for error compensation in all directions during welding There are exceptions to this however For example you may want the majority of the vertical stroke to be available for manually driving the slides upward and clear of the part after welding for inspec tion part removal and insertion of a new part OPERATING SEQUENCE Operations Operating the system controlled by the user at the control pendant The user selects the speed of slide adjustment for both vertical and horizontal modes and using the joystick positions the slide at the de sired location A provision is also given to allow the system to travel at maximum speed if needed by se lecting the appropriate position on the toggle switch These switches are momentary switches and will cause the indicated movement to occur only when de pressed and held Release of the switch causes the movement to stop The Speed Range Toggle switch is not momentary and selects the Maximum Speed or Adjustable speed for both Horizontal and Vertical movement 16 201329 001 REV D MAINTENANCE
32. 178 RECTIFIER BRIDGE 2AMP 200V 9 1 000 EA 2208 0202 CONN RECT PLUG 12 CKT 10 1 000 EA 2208 0172 CONN RECT PLUG 6 CKT 11 18 00 EA 2212 0019 TERMINAL CRIMP MOLEX 18 20 156 12 2 000 EA 2500 0692 CAP CER 680PF NOT SHOWN 13 8 000 EA 970015 412 SCREW 8 32 X 88 HSC SBZ 14 0 000 AR 3070 0058 THERMAL COMPOUND 38 201329 001 REV D DRAWINGS AND PARTS LISTS TABLE 17 MOTOR DRIVER HEATSINK ASSEMBLY PARTS LISTS CONT ITEM UM PARTNUMBER DESCRIPTION 15 4 000 EA 2716 0034 TRANSISTOR SOCKET TO 3 16 6 000 EA 970000 103 SCREW 2 56 X 31 CR1P SBZ 17 6 000 EA 974010 001 WASHER SPLIT LOCK 2 20 2 000 EA 970000 308 SCREW 6 32 X 62 CR1P SBZ 21 10 000 EA 974010 003 WASHER SPLIT LOCK 6 27 1 000 EA 970000 502 SCREW 10 32 X 25 CR1P SBZ 30 1 000 EA 974010 005 WASHER SPLIT LOCK 10 38 1 000 EA 989009 005 CABLE CLAMP 3 16 PVC BLACK 39 DRAWINGS AND PARTS LISTS 201329 001 REV D 3 EMI RFI H Ld H y JJ J d Fj R o 5 pl FIGURE 22 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW TABLE 18 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST ITEM QPA UM PART NUMBER DESCRIPTION 1 1 000 EA 920035 001 SLIDE SW 2 POS LINE VOLT SEL 2 1 000 EA 2120 0123 FILTER RFI PWR LINE 3
33. 21 0600 0121 STANDOFF 8 32 X 1 4 X 1 00 42 1 000 EA 0600 0429 0600 0429 ST450 UPPER MTR ASSY 44 1 000 EA 0600 0094 0600 0094 BRAKE ASSY 45 1 000 EA 930014 013 930014 013 CONN CIRC BOX RCPT 20 27P 46 1 000 EA 930014 010 930014 010 CONN CIRC BOX 145 65 47 2 000 EA 976000 005 976000 005 GROMMET RUBBER 5 16ID X 5 8 OD 48 1 000 EA 0600 0127 0600 0127 NAME PLATE AP AUTOMATION 49 2 000 EA 2414 0201 2414 0201 SCR HD U DRV 2 1 4 29 DRAWINGS AND PARTS LISTS 201329 001 REV D TABLE 11 ST450 CROSS SLIDE PARTS LIST ITEM UM PART 5 X 5 PART 10 X 10 DESCRIPTION 50 8 000 EA 970039 606 970039 606 SCREW 1 4 20X 50 H SBZ G8 51 28 000 EA 970000 402 970000 402 SCREW 8 32X 25 CR1P SBZ 52 10 000 EA 970015 618 970015 618 SCREW 1 4 20X1 50 HSC SBZ 53 8 000 EA 970015 402 970015 402 SCREW 8 32X 25 HSC SBZ 54 12 000 EA 970010 608 970010 608 SCR 1 4 20X 62 CR1F SBZ 55 6 000 EA 970015 610 970015 610 SCR 1 4 20X 62 HSC SBZ 56 2 000 EA 970039 725 970039 725 DOWEL PIN 1 4 X 1 58 4 000 EA 0600 0159 0600 0098 SCREW COVER ASSY 5 ST250 450 59 2 000 EA 1112 0211 1112 0211 COVER SEAL BEARING 60 2 000 EA 970000 202 970000 202 SCREW 4 40X 25 CR1P SBZ 62 2 000 EA 970043 400 970043 400 SCR SET 8 32X 12 HHC SBZ 63 1 000 EA 0600 0099 0600 0099 MTR CVR ASSY LWR ST250 450 64 2 000 IN 2360 0862 2360 0862 KEY STOCK 3 32 SQ 65 2 000 FT 0600 0359 0600 0359 MOTOR CA
34. 329 001 REV D INSTALLATION Figure 9 Control Pendant Mounting Dimensions on INFORMATION page 11 The control pendant has a standard cable ALL INSTALLATIONS TO BE MADE WITH AC POWER OFF Atypical APA Motorized Slide system inter connection diagram is shown in on page 6 The ma jor system components are listed below When unpacking check all items for damage and make tain nothing is missing Seam Tracker Cross Slide Assembly Adapter Plate Drive Cable Control Pendant Control Unit Manual Power Cord All required lubrication has been performed at the fac tory and needs no further attention at this time The interconnecting cables are standard length however other lengths may be ordered if needed CROSS SLIDE ASSEMBLY MOUNTING APA Cross Slide models ST40 Figure 4 ST40 Cross Slide Mounting Dimensions on page 6 ST250 Figure 5 ST250 Cross Slide Mounting Dimensions on page 7 and ST450 Figure 6 ST450 5 x 5 Cross Slide Mounting Dimensions outline drawings show the size and location of the holes for mounting the unit in any required position The mounting surface must be nearly flat to assure that no twist will be applied to the base of the slide assembly when it is bolted down causing a bind in operation Also the mounting surface must be rigid to prevent movement or vibration of the unit during operation For proper operation the slide assembly must be ori ented correctly with respect t
35. 6 125 46 Sensor Module 1106 0838 529276 128 47 Conductor Power Supply Cord 929000 001 529276 129 48 Collar Insulating 1110 0406 529276 131 49 Sensor Rebuild Kit See Kit BOM s S29080 50 CS40 3 in Strk Rebuild Kit See Kit BOM s S29081 51 540 Strk Rebuild Kit See Kit BOM s S29082 52 CS250 5 in Strk Rebuild Kit See Kit BOM s S29083 ARC PRODUCTS REPLACEMENT PARTS CROSS REFERENCE LisT 02 24 2012 LINCOLN 706 2 706 2 Indicates a change this printing DESCRIPTION ARC PRODUCTS NO LECO NO 53 CS250 10 in Strk Rebuild Kit See Kit BOM s S29084 54 CS450 5 in Strk Rebuild Kit See Kit BOM s S29085 55 CS450 10 Strk Rebuild Kit See Kit BOM s S29086 56 Probe Bracket Assembly Rebuild Kit See Kit BOM s S29087 REBUILD BOM s Sensor Rebuild Kit Includes S29080 Lower Rod 1110 1054 1 Support Lever Arm 1110 1208 1 Arm Lever 1110 1216 1 Arm Lever 1110 1224 1 Pin Elliptical Adjust 1110 1241 1 Sphere 1 8 in Chrome Steel G25 2360 0030 1 Clamp Rod 1110 1101 1 ST40 3 Rebuild Kit Includes S29081 Bar Rail Adj 1110 0121 1 Assembly SCR Actr ST40 1116 0042 1 Cover Retainer ST40 1110 0180 1 Motor ST40 1117 0587 1 Set SCR Half Dog Mod 1116 0115 2 Cover Telescoping 50 x 1 0 x 3 0 Strk 2000 0015 2 Wheel Guide Dual Vee 2 2360 0552 4 Gear Clamp Split Hub 2040 0544 2 Bearing Ball 2320 0112 2 ST40 6 Rebuild Kit Includes S29082 Bar Rai
36. 6 FEET RUBBER 6 1 000 EA 2060 0071 SWITCH TOGGLE DTSP 7 2 000 EA 903002 011 POT 10K LINEAR 10 3T CERMET 8 2 000 EA 940024 001 KNOB SM SKIRT LT GRAY POINTER 9 8 000 EA 970021 404 SCR 8 32X 38 HSBC SBZ 10 1 000 EA 900007 003 CER 1UF 500V 80 20 SHOWN 11 1 000 EA 0600 0433 APA MTRZD SLIDE PNDT CBL ASSY NOT SHOWN 35 DRAWINGS AND PARTS LISTS 201329 001 REV D Power Switch Ww a u 7 4 1 18 gauge 2 4 5 6 pl FIGURE 19 POWER SWITCH ASSEMBLY EXPLODED VIEW TABLE 14 POWER SWITCH ASSEMBLY PARTS LIST ITEM UM PART NUMBER DESCRIPTION 1 1 000 EA 2066 0171 SWITCH SELECT 1 3 16 RED 2 1 000 EA 2100 0086 INCANDESCENT LAMP 28V 3 2 000 EA 2068 0172 BLOCK CONTACT N O 4 1 000 EA 2208 0181 CONN RECT PLUG 8CKT 5 6 000 EA 2212 0018 TERMINAL CRIMP PIN 18 24 GA 36 201329 001 REV D DRAWINGS AND PARTS LISTS T1 TABLE 15 TRANSFORMER ASSEMBLY PARTS LIST SPAN P11 LIT N a 7 gt 4 pl D L 1 18 gauge A N wire 4 VA 4 2 5 3 6 2 pl FIGURE 20 TRANSFORMER ASSEMBLY EXPLODED VIEW ITEM QPA UM PART NUMBER DESCRIPTI
37. 70039 712 970039 712 3 8 16 FLANGE LOCKNUT 11 3 000 EA 0600 0302 0600 0302 UNIVERSAL BRG BLK 250 450 12 2 000 EA 0600 0336 0600 0336 NUT HOUSING ST250 450 13 2 000 EA 0600 0346 0600 0346 NUT HOUSING INSERT ST250 450 14 1 000 EA 0600 0372 0600 0372 4 BOLT ST250 450 BRG BLOCK 15 2 000 EA 0600 0339 0600 0339 NUT HOUSING PLATE ST250 450 16 2 000 EA 0600 0380 0600 0374 ST250 450 SCREW ACT ASSY 17 3 000 EA 2320 0244 2320 0244 BEARING BALL ANLR CONT 18 4 000 EA 0600 0366 0600 0366 BEARING BLOCK O RING 20 2 000 EA 2380 0128 2380 0128 SEAL OIL 375X1 125X 312 21 2 000 EA 2320 1151 2320 1151 INSERT COUPLING BF7 22 2 000 EA 2320 1160 2320 1160 COUPLING HALF3 8 IN 23 1 000 EA 0600 0123 0600 0123 BALL BEARING ST250 450 24 1 000 EA 0600 0052 0600 0052 MOTOR PLATE UPPER UNIVERSAL 25 1 000 EA 0600 0048 0600 0048 MOTOR PLATE LOWER 26 3 000 EA 1112 0105 1112 0105 COVER WHEEL 27 1 000 EA 0600 0418 0600 0418 ADAPTER PLATE ST450 28 1 000 EA 0600 0513 0600 0513 GEAR MOTOR 50 1 OUTBD 30 1 000 EA 0600 0432 0600 0432 WHEEL COVER DEEP ST450 31 1 000 EA 0600 0419 0600 0419 PHENOLIC PLATE ST450 32 8 000 EA 1110 0406 1110 0406 COLLAR INSULATING 33 8 000 EA 970039 714 970039 714 SCR 5 16 18X1 00 H SBZ G8 36 2 000 EA 970039 713 970039 713 3 8 16 X 1 25 FLANGE HEAD BOLT 38 1 000 EA 0600 0377 0600 0377 UPPER MTR CVR ST250 450 3 5 39 1 000 EA 1116 0298 1116 0298 MOTOR COVER LOWER 40 2 000 EA 0600 0289 0600 0289 STAND OFF 8 32 X 1 4 X 2 00 41 2 000 EA 0600 01
38. 863 2360 0863 3 32 X 375 SQ KEY 52 2 000 EA 970043 401 970043 401 SET SCREW 8 32x 19 HHC SBZ 53 8 000 EA 970000 003 970000 003 WASHER 5 16 55 6 000 EA 970015 610 970015 610 SCREW 1 4 20X 75 HSC SBZ 56 10 00 EA 970015 618 970015 618 SCREW 1 4 20X1 50 HSC SBZ 57 1 000 EA 0600 0052 0600 0052 END PLATE UPPER UNIVERSAL 58 8 000 EA 970015 402 970015 402 SCREW 8 32X 25 HSC SBZ 59 1 000 EA 0600 0099 0600 0099 MTR CVR ASSY LWR ST250 26 201329 001 REV D DRAWINGS AND PARTS LISTS 27 201329 001 REV D DRAWINGS AND PARTS LISTS FIGURE 16 ST450 CROSS SLIDE EXPLODED VIEW 28 201329 001 REV D DRAWINGS AND PARTS LISTS TABLE 10 ST450 CROSS SLIDE PARTS LIST ITEM UM PART 5 X 5 PART 10 X 10 DESCRIPTION 1 2 000 EA 0600 0074 0600 0076 BASE ST450 2 1 000 EA 0600 0078 0600 0078 FACEPLATE ST450 3 1 000 EA 0600 0079 0600 0079 INTERMEDIATE PLATE ST450 4 4 000 EA 0600 0430 0600 0431 RAIL ST450 5 4 000 EA 2360 0242 2360 0242 BUSHING ADPTR STNRY 3 8X7 8 L 6 9 000 EA 2360 0277 2360 0277 BUSHING ADPTR ADJ 3 8X7 8 L 7 8 000 EA 2360 0579 2360 0579 WHEEL GUIDE DUAL VEE 4 8 10 000 EA 970039 711 970039 711 3 8 16 X 2 5 GR8 FLANGE HD 9 3 000 EA 970039 822 970039 822 SCREW 3 8 16X2 00 H SBZ G8 10 13 000 EA 9
39. BACK 75IN SQ SHOWN 16 0 417 FT 2040 0536 GROMMET CATERPILLAR NOT SHOWN 17 4 000 EA 974006 005 WSR F 10 374X 195X 032 18 7 000 EA 974010 004 WSR SL 8 293X 175X 040 SBZ 19 6 000 EA 974000 004 WSR F 8 438X 188X 049 SBZ 20 4 000 EA 974010 005 WSR SL 10 334 202 047 SBZ 21 6 000 EA 972000 003 NUT 6 32 H SBZ 22 8 000 EA 974010 004 WSR SL 8 293 175 040 SBZ 23 8 000 EA 970000 404 SCR 8 32X 38 CR1P SBZ 24 1 000 EA 1175 0079 LABEL CAUTION 110 220VAC NOT SHOWN 25 0 625 EA 999005 005 TAPE NEO FOAM ADH 1 8INX1 4THK 26 8 000 EA 972000 002 NUT 4 40 H SBZ 27 5 000 EA 979001 001 CABLE TIE 75 BUNDLE DIA NOT SHOWN 28 4 000 EA 972000 005 NUT 10 32 H SBZ 29 15 000 EA 970000 406 SCR 8 32X 50 CR1P SBZ 30 1 000 EA 929000 001 3 CONDCTR PWR SPLY CORD NOT SHOWN 31 4 000 EA 970000 204 SCR 4 40X 38 CR1P SBZ 32 8 000 EA 974010 002 WSR SL 4 209X 121X 025 SBZ 33 201329 001 REV D DRAWINGS AND PARTS LISTS FIGURE 18 CONTROL PENDANT EXPLODED VIEW 34 201329 001 REV D DRAWINGS AND PARTS LISTS TABLE 13 CONTROL PENDANT PARTS LIST ITEM UM PARTNUMBER DESCRIPTION 1 1 000 EA 0600 0383 MOTORIZED SLIDE PENDANT ENCLOSURE 2 1 000 EA 0600 0288 MOTOROIZED SLIDE PENDANT FACEPLATE 3 1 000 EA 2066 0112 SW JOY STICK 9 POS SNGL POLE 4 1 000 EA 2040 0579 CBL FTTNG W NUT amp BSH 375 500 5 4 000 EA 0600 002
40. BLE 4 COND 66 36 000 EA 970039 710 970039 710 SCR 5 16 18X 75 H SBZ G8 30 201329 001 REV D DRAWINGS AND PARTS LISTS 31 DRAWINGS AND PARTS LISTS 201329 001 REV D FIGURE 17 MOTORIZED SLIDE CONTROL EXPLODED VIEW 32 201329 001 REV D DRAWINGS AND PARTS LISTS TABLE 12 MOTORIZED SLIDE CONTROL PARTS LIST ITEM PARTNUMBER DESCRIPTION 1 000 1101 2002 4 MOTOR DRIVER ASSY 2 1 000 1101 2002 6 quem Figure 22 Voltage Selector Switch assembly Ex 3 1 000 1101 2002 6 n nr E Figure 22 Voltage Selector Switch as 4 4 000 EA 1101 2002 6 7 M MES See Figure 22 Voltage Selector Switch 5 4 000 EA 1101 2002 2 ASSY See Figure 20 Transformer Assembly 6 1 000 EA 0600 0426 CONTROL ENCLOSURE 7 1 000 1101 2002 5 5 ASSY See Figure 23 Drive Connector Harness Ex 8 1 000 1101 2002 6 NACE An See Figure 22 Voltage Selector Switch assembly Exploded View 9 1 000 EA 0600 0388 MAIN BOARD ASSY 10 1 000 EA 0600 0425 CONTROL DOOR 1 000 1101 2002 8 a ASSY See Figure 19 Power Switch Assembly Exploded View 12 1 000 EA CONTROL DOOR LATCH 13 1 000 0600 0435 2 2 See Figure 24 Pendant Connector Har 14 1 000 EA 0600 0424 APA MS OVERLAY 15 1 000 EA 989003 001 CBL TIE MNT ADH
41. Bearing ST250 0600 0123 1 Screw Cover Assembly ST250 0600 0159 2 ST450 10 Rebuild Kit Includes S29086 Wheel Guide Dual Vee 4 2360 0579 6 ST250 Screw Actuator Assembly 0600 0374 1 Bearing Ball Cont 2320 0244 2 Ball Bearing ST250 0600 0123 1 Screw Cover Assembly ST250 0600 0098 2 Probe Bracket Assembly Rebuild Kit Includes S29087 Nut Drive Lower Axis 1110 3898 1 Nut Drive Upper Axis 1110 3901 1 GIB Slide 1 1 2 in Str 1112 0156 ARC PRODUCTS REPLACEMENT PARTS CROSS REFERENCE LIST 02 24 2012 LINCOLN e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone 9 Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria jk THS U CF uv 9 553515 1 85 E 88 HF A 885 155 e dzaTE 2474 e S X COEHE SE 48 AIH5P AS 2174214 55718 ASEAN R Res ye dul sul e ci gia bic 1 Jarl lis SI 2 HYMNAL
42. CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 h To avoid scalding do not remove the not remove th powered equipment i y en pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated 3 areas or vent the engine exhaust fumes GA outdoors 4 ELECTRIC AND SR MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to preven
43. Cvr ST250 3 5 0600 0377 S29276 53 17 Switch Select 1 3 16 Red 2066 0171 S29276 64 18 Pot 10K Linear 10 STCERMET 903002 011 529276 69 19 Switch Sidetrack 1116 0352 S29276 70 20 Advanced Program Control Assembly 1103 2002 1 529276 72 21 Control Transformer Assembly 1101 2002 2 S29276 74 22 Lamp Lens Translucent Red Sm 941000 101 S29276 78 23 Lamp 387 941000 011 529276 81 24 Lamp Holder LH73 1 941000 200 S29276 202 25 Switch PB 10 Amp Black 2062 0081 S29276 247 26 Switch Toggle 2060 0071 S29276 248 27 Main Board Assembly 0600 0388 S29276 304 28 Lens Translucent Yellow Sm 941000 103 S29276 85 29 Mtr Cvr Assembly Lwr ST250 0600 0099 S29276 91 30 Gear Motor 25 1 1116 0123 S29276 96 31 Sw Mushroom Stop St Pendant 1116 0400 529276 98 32 Switch Auto Man 1116 0387 S29276 99 33 Std Off HXx M F 8 32 x 25 x 1 12 SS 981002 004 529276 106 34 Knob Sm Skirt Lt Gray Pointer 940024 001 S29276 108 35 Shield Seam Sensor 1110 1062 529276 110 36 Slide Assembly Probe 1106 0692 S29276 111 37 Brake Assembly 0600 0094 S29276 113 38 Motor Driver Assembly 1101 2002 4 S29276 117 39 Main Board Assembly 1101 2002 3 529276 118 40 Assembly ST250 Upper 0600 0111 529276 119 41 Transistor Socket to 3 2716 0034 529276 120 42 Pivot Machined 1110 0805 529276 121 43 Sw Joystick 9 Pos Single Pole 2066 0112 S29276 122 44 Arm Assembly Probe Adjust 1106 0684 S29276 124 45 Transistor Replacement Kit 1103 0491 52927
44. DIEGO CA 92154 3477 619 628 1022 619 628 1028 FAX sales arc products com service O arc products com www ap automation com www arc products com Copyright O Lincoln Global Inc LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distibutors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
45. ISTS TABLE 7 ST40 CROSS SLIDE PARTS LIST ITEM UM PART 3 X3 PART 6 DESCRIPTION 1 1 000 EA 1110 0007 1110 0066 BASE UPP ST40 2 1 000 EA 1110 0015 1110 0074 BASE LWR ST40 3 2 000 EA 1110 2310 1110 2310 PLATE END ST40 4 4 000 EA 1116 0000 1116 0034 SEAM TRACKER RAIL ST40 6 2 000 EA 1110 0121 1110 0155 BAR RAIL ADJ 8 2 000 EA 1116 0042 1116 0077 ASSY SCR ACTR ST40 10 2 000 EA 1110 0180 1110 0091 COVER RETAINER ST40 12 2 000 EA 1112 0008 1112 0016 COVER RETAINER 14 2 000 EA 1110 0198 1110 0198 BEARING HOUSING ST40A 15 2 000 EA 1110 0210 1110 0210 NUT HOUSING ST40A 16 1 000 EA 1110 0171 1110 0171 FACEPLATE ST40 17 1 000 EA 1110 0236 1110 0236 ADAPTER PLATE ST40 18 2 000 EA 1117 0587 1117 0587 MOTOR ST40 19 4 000 EA 1116 0115 1116 0115 SET SCR HALF DOG MOD 20 2 000 EA 1116 0107 1116 0107 COVER GEAR ST40 21 1 000 EA 1106 0048 1106 0048 JUNCTION BOX ASSY ST40 22 4 000 EA 2000 0015 2000 0058 COVER TELESCOPING 50 X 1 0 X 3 5 STRK 24 8 000 EA 2360 0552 2360 0552 WHEEL GUIDE DUAL VEE 2 25 8 000 EA 2360 0226 2360 0226 BUSHING ADPTR STNRY 74 X 9 16 L 26 2 000 EA 2416 0157 2416 0157 RING RTNG BOWED E RING 025 THK 27 2 000 EA 2320 0139 2320 0139 GEAR SPUR 36T 32P 28 2 000 EA 2320 0147 2320 0147 GEAR SPUR 60T 32P SS 29 4 000 EA 2040
46. ND BLOCK DIAGRAMS 201329 001 REV D P1 i St Joystick i Switch Yi i i f N C EE 2 i i Vertical Speed i C Vertical Speed piwne EE Adjustment Pot Selector I i BE 2 MaxSpeed R1 N C yo 10K Pot Adjustable i o 9 i i 182 15 20 cw i Io fe Xi a 1 i i I I i i 1 R2 Horizontal Signal i CW 40K Pot gt Gin Logic Ground Horizontal Speed Adjustment Pot i i A F Vertical Signal 8 D 15 VDC v j Red A 15 VDC wc E Not Used i i i i i i i el 2 i T boim mimm immi Earth PE 49 FIGURE 26 PENDANT SCHEMATIC SCHEMATICS AND BLOCK DIAGRAMS 201329 001 REV D White 1 Black 110 26 Green 80 50Hz PE Chassis Ground Stud PE Motor Driver Heatsink Assembly 2112 1101 2002 4 Gry 1111 Gry ele G 77 E Org o Bk z 5 E o Bk 3 Red 3 3 Wht Brn 2 2 Wht Gry 4 4 P13 413 66 Org 515 u Blk 44 x Red s s x o Wht 2 2 5 Gry 11 Power Switch 1 u E ff
47. NFORMATION OPERATION GENERAL INFORMATION OPERATION DRIVE CABLE CROSS SLIDE ASSEMBLY CONTROL PENDANT AND CABLE ASSEMBLY SPECIAL LENGTH CABLE ASSEMBLIES INSTALLATION 13 13 13 13 INSTALLATION ZSEE CROSS SLIDE ASSEMBLY MOUNTING CONTROL PENDANT INSTALLATION CONTROL UNIT INSTALLATION WELD HEAD INSTALLATION SYSTEM INTERCONNECTION WITH THE POWER OFF DURING OPERATION NOTE 6 o4 us DURING MECHANICAL ADJUSTMENTS DURING ELECTRICAL ADJUSTMENTS INITIAL SET UP INSTRUCTIONS OPERATING SEQUENCE OPERATIONS 14 14 14 14 15 15 15 15 16 16 TABLE OF CONTENTS 201329 001 REV D MAINTENANCE MAINTENANCE REQUIREMENTS CONTROL UNIT ASSEMBLY CONTROL PENDANT AND CABLE ASSEMBLY CROSS SLIDE ASSEMBLY PREVENTIVE MAINTENANCE SCHEDULE MONTHLY MAINTENANCE CROSS SLIDES PROPER FUNCTION TEST STEP 1 CENTER THE SLIDES STEP 2 CHECK FOR PLAY HORIZONTAL STEP 3 CHECK FOR PLAY VERTICAL QUARTERLY MAINTENANCE CONTROL UNIT ASSEMBLY SERVO AMPLIFIER CIRCUITRY CALIBRATION TOLLS REQUIRED STEP 1 ADJUST HI AND VI FULL CLOCK WISE STEP 2 MONITOR TP2 AND TPS STEP t 3 CONNECT OSCILLOSCOPE TO R5 STEP 4 VERIFY READING STEP t 5 ADJUST VI TRIMPOT COUNTER CLOCK WISE STEP 6 ADJUST VI TRIMPOT CLOCK WISE STEP 7 VERIFY READING STEP
48. ON 1 1 000 EA 1117 1118 XFRMR 115 230VAC 30VCT 10 5VAC 2 1 000 EA 2208 0199 CONN RECT PLUG 10CKT 3 9 000 EA 2212 0018 TERMINAL CRIMP PIN 18 24 GA 4 2 000 EA 970000 426 SCR 8 32X2 50 CR1P SBZ 5 2 000 EA 972001 004 NUT 8 32 FH SBZ SL GB 6 2 000 EA 974010 004 WSR SL 8 293X 175X 040 SBZ 37 DRAWINGS AND PARTS LISTS 201329 001 REV D a 16 20 16 7 8 5 2 4 4 4 UN III 29 gt lt 18 gt lt gt 43 2 pl 13 2 pl 43 2 pl 14 As Required 14 As Required 14 Required 45 1 15 ERE 45 1 45 Li Il Qf 1 2p 21 2 pl 21 2 pl P12 7 rm Note re 01 03 2N6285 ed 40 9 2 6287 11 6 pl 11 12 pl 028 Q4 2N6282 2N6283 or 2N6284 FIGURE 21 MOTOR DRIVER HEATSINK ASSEMBLY EXPLODED VIEW TABLE 16 MOTOR DRIVER HEATSINK ASSEMBLY PARTS LISTS ITEM UM PART NUMBER DESCRIPTION 1 2 000 EA 1103 0491 TRANSISTOR REPLACEMENT KIT CONSISTING OF 2 2 000 EA 2708 0081 XSTR 2N6282 PWR 60V NPN ALT 2N6283 OR 2N6284 3 2 000 EA 2708 0103 XSTR 2N6285 PWR 80V PNP ALT 2N6286 OR 2N6287 4 4 000 EA 2716 0000 INSULATOR MICA TO 3 5 2 000 EA 902004 019 RES WW 1 OHM 3 SW 6 1 000 EA 2702 0186 RECITIFIER BRIDGE CBR35 01P 1 000 2610 1093 RES WW 250 OHM 3 10W 8 1 000 EA 2702 0
49. S 3 TABLE 2 MS250 SYSTEM SPECIFICATIONS 4 TABLE 3 5450 SYSTEM SPECIFICATIONS 5 TABLE 4 ST40 LOAD SPECIFICATIONS 12 TABLE 5 ST250 LOAD SPECIFICATIONS 12 TABLE 6 ST450 LOAD SPECIFICATIONS 12 OPERATION 13 INSTALLATION 14 MAINTENANCE 17 DRAWINGS AND PARTS LISTS 21 TABLE 7 ST40 CROSS SLIDE PARTS LIST 23 TABLE 8 ST250 CROSS SLIDE PARTS LIST 25 TABLE 9 ST250 CROSS SLIDE PARTS LIST 26 TABLE 10 ST450 CROSS SLIDE PARTS LIST 29 TABLE 11 57450 CROSS SLIDE PARTS LIST 30 TABLE 12 MOTORIZED SLIDE CONTROL PARTS LIST 33 TABLE 13 CONTROL PENDANT PARTS LIST 35 TABLE 14 POWER SWITCH ASSEMBLY PARTS LIST 36 TABLE 15 TRANSFORMER ASSEMBLY PARTS LIST 37 TABLE 16 MOTOR DRIVER HEATSINK ASSEMBLY PARTS LISTS 38 TABLE 17 MOTOR DRIVER HEATSINK ASSEMBLY PARTS LISTS 39 TABLE 18 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST 40 TABLE 19 DRIVE CONNECTOR HARNESS ASSEMBLY PARTS LIST 41 TABLE 20 PENDANT CONNECTOR HARNESS ASSEMBLY PARTS LIST 42 TROUBLESHOOTING 43 TABLE 21 TROUBLESHOOTING 43 TABLE 22 VOLTAGE TEST POINTS 44 TABLE 23 DRIVE SIGNAL TEST POINTS 44 TABLE 24 RECOMMENDED SPARE PARTS 44 CIRCUIT DESCRIPTIONS 47 SCHEMATICS AND BLOCK DIAGRAMS 49 OPTIONAL EQUIPMENT 54 viii 201329 001 REV D TABLE OF FIGURES Table of Figures MOTORIZED SLIDE CONTROL SYSTEM GENERAL INFORMATION OPERATION FIGURE 1 MS40 SYSTEM COMPONENTS FIGURE 2 MS25
50. Y ST250 UPPER 26 4 000 EA 2360 0234 2360 0234 BUSHING ADAPTER 27 8 000 EA 970039 718 970039 718 SCR 5 16 18X1 50 H SBZ G8 28 1 000 EA 1116 0123 1116 0123 GEAR MOTOR 25 1 29 2 000 EA 981002 004 981002 004 STDOFF HX M F 8 32X 25X1 12 SS 30 1 000 EA 0600 0377 0600 0377 UPPER MTR CVR ST250 3 5 32 1 000 EA 1110 0392 1110 0392 ADAPTER PLATE 34 1 000 EA 0600 0094 0600 0094 BRAKE ASSY 35 36 00 EA 970000 402 970000 402 SCREW 8 32 25 CR1P SBZ 36 4 000 EA 1110 0406 1110 0406 COLLAR INSULATING 37 1 000 EA 1112 0237 1112 0237 PLATE INSULATING 38 1 000 EA 1115 0705 1115 0705 NAMEPLATE SEAM TRACKER 40 4 000 EA 970039 710 970039 710 SCR 5 16 18X 75 H SBZ G8 41 2 000 EA 970039 725 970039 725 DOWEL PIN 1 4 X 1 42 28 00 EA 970039 610 970039 610 SCREW 1 4 20X 75 H SBZ G8 43 8 000 EA 970039 606 970039 606 SCREW 1 4 20X 50 H SBZ G8 44 1 000 EA 930014 013 930014 013 CONN CIRC BOX 20 27P 45 1 000 EA 930014 010 930014 010 CONN CIRC BOX 145 65 46 1 000 EA 976000 005 976000 005 GROMMET RUBBER 5 16ID X 5 8 OD 47 1 000 EA 0600 0060 0600 0060 MOTOR COVER LOWER 25 DRAWINGS AND PARTS LISTS 201329 001 REV D TABLE 9 ST250 CROSS SLIDE PARTS LIST ITEM PART 5 X5 PART 10 X 10 DESCRIPTION 49 12 00 EA 970010 608 970010 608 SCR 1 4 20X 62 CR1F SBZ 50 2 000 EA 2414 0201 2414 0201 SCR HD U DRV 2 1 4 51 2 000 EA 2360 0
51. atter or metal SH FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating pro
52. awdust gasoline kerosene paints solvents natural gases acetylene pro pane and similar articles Do not weld cut or perform other hot work on used barrels drums tanks or other con tainers until they have been completely cleaned There must be no substances in the container which might produce flammable or toxic vapors C For fire protection have suitable extin guishing equipment for instant use WELDING AND CUTTING FUMES AND GASES PARTICULARLY IN CONFINED SPACES CAN CAUSE DISCOMFORT AND PHYSICAL HARM IF INHALED OVER AN EXTENDED PERIOD OF TIME At all times provide adequate ventilation in the welding and cutting area by either natural or mechanical means Do not weld or cut on galvanized zinc lead beryllium or cadmium materials unless positive mechanical ventila tion is provided to prevent inhaling fumes and gases from these materials B Do not weld or cut in locations close to chlorinated hydrocarbon vapors coming from degreasing or spraying operations The heat of arc rays can react with solvent vapors to form phosgene a highly toxic gas and other irritant gases Cr you develop momentary eye nose or throat irritation during welding or cutting it is an indication that the ventilation is not ade quate Stop work and take the necessary steps to improve ventilation in the welding or cutting area Do not continue to weld or cut if physical discomfort persists D Use an air supplied re
53. ch procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN
54. d ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY gt 5 SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available MJ WELDING and CUTTING Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that su
55. ded Remove the mounting screws and the Main board Install an other Main board and tighten the mounting screws un til snug do not over tighten as damage to the board and enclosure standoffs may result Replacement of heatsink assembly is accomplished by the removal of six screws and the disconnection of the appropriate connectors Replace with a working assembly Individual transistors may be replaced by removing two screws and the defective part easiest if heatsink is out of the control unit The replacement part may then be installed in the existing socket pro vided using heatsink compound Thermal Com pound on the transistors to ensure good heat transfer and long life Secure the replaced transistors with the two screws Replacement of other user serviceable items is to be performed according to normal maintenance and re pair standards usually involving the removal of mounting hardware unplugging the old unit mounting the replacement part and reconnecting the connec tors CONTROL PENDANT AND CABLE ASSEMBLY Maintenance of the control pendant and cable assem bly is to periodically remove dust soot metal parti cles slag etc from the face plate Repair of the control pendant and cable assembly is limited to replacement of defective units see Figure 18 Control Pendant Exploded View on page 34 A wiring diagram includes control pendant schematics for troubleshooting purposes see Figure 26 Pen dant Schematic
56. ectrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 VE ARC RAYS can burn 4 8 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 f LINCOLN 8 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot sp
57. er cise caution when repairing the control unit subassemblies and printed circuit boards since these repairs can void the war ranty WARNING When repairing the control unit assembly disconnect A C power from the unit be fore opening the access door and turn the power switch to OFF Assemblies and parts which are authorized for user replacement are listed in Table 12 Motorized Slide Control Parts List on page 33 Replacement should be performed after the user has determined that the part or assembly to be replaced is the cause of a sys tem problem see Troubleshooting on page 43 Replacement of the fuse does not require access to the housing interior however the blowing of the fuse may indicate other system problems The fuse is re placed by unscrewing the fuse holder lid removing and replacing the blown fuse with a new fuse Then restore power and turn On system to perform a test run Replacement of the printed circuit board the Main board involves disconnecting the connectors to the board removing the mounting screws and replacing the Main board with another The service person should exercise care in removing the Main board to ensure that excessive force is not placed on the connectors or components on the board and that the mounting screws are not over tightened The Main board is held by eight screws to stand offs mounted in the enclosure Disconnect all necessary cabling at the connection plugs provi
58. er components of the system Check connectors inside the control Operation ON but nothing works the control unit Main board voltages are not present Check Main board voltages 20VDC 15VDC and 6VDC Problem 3 lide drifts hori Main board is out of calibration Calibrate the Servo Amplifier Circuitry Horizontal Drift ross slide drifts horizontally on the Main board Problem 4 Ver Cross slide drifts vertically Main board Vertical Offset may need adjustment Adjust Vertical Offset on the Main board Slides will not Drive Cross slides will not drive in one or more directions Main board is faulty Heatsink assembly is faulty tical Drift Main board is out of calibration Calibrate the Servo Amplifier Circuitry on the Main board The system is mounted on a fixture Check the fixture for rigidity and elimi Problem 5 that is not stable nate the instability System System oscillates while operating The cross slides have mechanical Check the cross slides for mechanical Oscillation play in the horizontal and or vertical play or looseness and eliminate it axes Switches on the pendant assembly Switch commands from the pendant are faulty assembly are not getting to the main Problem 6 board Check Test Points on the Main board to verify the signals are being re ceived and sent to the motors on the cross slides see the following tables Problem 7 Slides Drive One D
59. er slide depending on the model Connectors are provided for attaching the control An adapter plate is furnished which mounts to the face plate of the cross slides Insulation is provided between the face plate and adapter plate Holes can be added to the adapter plate for mounting wire feeder weld head torch wire spool etc Optional mounting bracketry is also available on certain mod els CONTROL PENDANT AND CABLE ASSEMBLY The Motorized Slide control pendant has two ptoentiometers a toggle switch and one sealed joy stick switch mounted in an aluminum housing suitable for handheld or mounted operation The deescriptions of each component are Potentiometer Vertical Speed Adjustment Horizontal Speed Adjustment Toggle Switch Maximum Speed or Adjustable Speed adjustment Se lector Switch Joystick Switch MANUAL Up Down and Left Right The control pendant connects to the control unit with a 10 foot standard cable attached SPECIAL LENGTH CABLE ASSEMBLIES Special length cables and extension cables can be made to order for the control pendant to the control unit in lengths to 60 feet and for the cross slide as sembly to the control unit up to 95 feet NOTE Long length non standard cables normally re quire heavier gauge conductors to reduce volt age drop Consult factory before making cable length changes from standard as system perfor mance may be affected 13 INSTALLATION 201
60. hand slide of the horizontal lower axis on most cross slides Using your other hand push the cross slides face plate adaptor plate toward the motor and then pull it back away from the motor assembly If no play is felt go on to step 2 If you feel any play on the lower axis notice the drive screw if it moves back and forth not spin ning the assembly needs shimmed Step 2 Check for Play Horizontal If the drive screw does not move back and forth try to spin the dual vee wheels without the slide moving If they do not spin go to step 3 If both the wheels do not spin and the drive screw does not move back and forth and there is still play in the lower axis the drive screw is showing wear and may need to be replaced Step 3 Check for Play Vertical Check the vertical upper axis using the same proce dure starting with Step 1 Quarterly Maintenance Control Unit Assembly Be sure the control unit is turned off and unplug Using clean dry air blowout dust from the inside of the control unit Be sure all other connections in the control unit are seated firmly in their receptacles and reconnect the power cord to an electrical outlet Turn power on and check for proper operation SERVO AMPLIFIER CIRCUITRY CALIBRATION This procedure describes the calibration techniques needed to for regular maintenance This is useful and may become necessary to perform when a motor or heatsink transistor is rep
61. ial combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos CRA PTVCHEND TDERIH GEXELTIAUEEA e 18 9 Z VAM iS AT 248 do AIX nig ay 5 gll a e e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo e B ERUAFBLAERELTE No e ARR HRAEBSHRRAR ex 119 0A HSE did y due le Lily day 2 3 READ AND UNDERSTAND THE MANUFACTURER 5 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN rc Products Lincoln Electric Company ARC PRODUCTS INC 1245 30TH STREET SAN
62. ing manual Cross Slide Cable Standard Length 10 3 M Power Cable Standard Length 6 1 8 M Pendant Cable Standard Length 10 3 M Weights Cross slide Assembly 5 x 5 65 Ibs 30 Kg Control Unit power cable incl 33 Ibs 15 Kg Remote Control Pendant cable incl 4 Ibs 1 8 Kg GENERAL INFORMATION 201329 001 REV D 5 50 1 25 N 1 4 20 UNC 6 HOLES 6 12 lt a 4 HOLES FIGURE 4 140 CROSS SLIDE MOUNTING DIMENSIONS GENERAL INFORMATION 201329 001 REV D thru hole 41 4 places thru hele 318 15 4 places thru thread 3 5 siroke lengih not used en 5 e 5 75 stroke length 10 2 stroke length 8 x stroke length 1 05 is Pe 11 25 stroke length 1 49 2 09 1 90 6 40 FIGURE 5 ST250 CROSS SLIDE MOUNTING DIMENSIONS GENERAL INFORMATION 201329 001 REV D 7 54 T 18 00 s o 5 lt w pos lt 5 i Ollo oO 8 N i e 8 A co o Wm 5 5 19 20
63. ing the slides using the joystick with normal operating weight on the cross slides When this point has been established turn these potentiometers R2 8 R3 clockwise an additional four turns to allow a margin for circuit variations due to temperature etc NOTE If R2 and R3 is backed off too far Clock wise the servo will have sluggish re sponse The signal through R8 1 derived from motor current which can be sensed directly The Motor s DC resis tance enters in as a constant factor the exact value of which is accounted for by trimpot adjustment as described later Motor current is sensed as a voltage across the 0 1 ohm horizontal EMF sense resistor The resistor s voltage drop is fed to the differential in puts pins 5 amp 6 of amplifier U2 The signal is further amplified when it reaches the output of U2 pin 8 where it is connected through trimpot R3 to drive R8 R3 adjusts the amount of motor current proportional voltage fed back for correct compensation The vertical and horizontal channels are identical ex cept for the R2 trimpot on the vertical channel R2 is normally adjusted completely clockwise which makes the circuit completely the same as the horizontal channel With heavy loads the vertical slide may creep down while the control is turned On and at idle In this case R1 is adjusted counter clockwise just enough to offset the creep 48 SCHEMATICS AND BLOCK DIAGRAMS SCHEMATICS A
64. inimum Envelope Standard Stroke 3 76 mm x 3 76 mm 12 305 mm Diameter Drive System Precision Ball Screw Control Unit Enclosure Standard NEMA Style Sealed enclosure Remote Control Pendant Enclosure Handheld or mounted steel enclosure containing manual Cross Slide Cable Standard Length 10 3 M Power Cable Standard Length 6 1 8 M Pendant Cable Standard Length 10 3 M Weights Cross slide Assembly cable incl 10 Ibs 4 1 Kg Control Unit power cable incl 33 lbs 15 Kg Remote Control Pendant cable incl 4 lbs 1 8 Kg GENERAL INFORMATION 201329 001 REV D MOTOR ORIVEN CROSS SLIDES CONTROL UNIT AND DRIVE CABLE REMOTE CONTROL PENDANT FIGURE 2 5250 SYSTEM COMPONENTS TABLE 2 MS250 SYSTEM SPECIFICATIONS DESCRIPTION SPECIFICATIONS RATING Load Capacity 12 305 mm from Faceplate 200 Ibs 91 Kg Derated 15 Ibs inch 6 8 Kg 25 4 mm beyond 12 305 mm Standard Stroke Length Vertical x Horizontal 5 127 mm x 5 127 mm or 10 254 mm X 10 254 Non Standard Stroke Length Vertical x Horizontal 10 254 mm x 10 254 mm Inboard Drive Assy 24 610 mm x 24 610 mm Outboard Drive Assy Minimum Envelope Standard Stroke 5 127 mm x 5 127 mm 17 431 mm Diameter Drive System Precision Ball Screw Control Uni
65. ions requiring the removal of welding equipment away from the immediate work area to provide ample access for inspection part removal etc Convenient indexing detents are provided every 90 degrees and positive positioning of table is achieved by means of a short single stroke of the locking handle Two adjustable stops are also included providing the user the facility to accurately re position equipment after it has been rotated away from the operating position Sturdily constructed from solid aluminum the mounting plate houses a large diameter ball bearing carrying the rotating faceplate on which the welding equipment is mounted SEAM TRACKER CROSS SLIDE ASSEMBLY ROTARY ALTERNATE TORCH POSITIONS Rated Load 300 lbs 136 Kg max at 14 356mm from faceplate FIGURE 30 ROTARY TABLE BRACKET 54 201329 001 REV D INDEX INDEX enclosure 3 5 17 47 N environment gt gt 14 emor s s 1648 noise lt 14 Exploded 18 22 24 32 34 Non Standard 3 5 15 VDC 44 47 extension 13 20 VDC 47 6 VDC 44 47 F offset 3 43 48 15VDC 43 faceplate 8 3 54 On 17443 20VDC 43 factory 13 14 17 oriented lt lt 5 e 14 6VDC 43 faulty x43 44 oscillates 43 48 15 VDC 44 47 A Outboard s 4 5 18
66. irection System continuously drives at full Speed in one direction with no control Main board is faulty Oneor more transistors on the heatsink assembly may be faulty Check the Test Points on the Main board to determine if the Main board is or is not giving commands to drive the system if no commands are given from the main board check the heatsink assembly see the following tables e Check the transistors on the heatsink assembly 43 TROUBLESHOOTING 201329 001 REV D PROBLEM DESCRIPTION CAUSE SOLUTION Problem 8 Slides Drive Both Direction System continuously drives at full speed in two directions with no control One of the regulated voltages on the Main board is faulty Check the voltages on the Main board Replace the Main board Problem 9 Mo One or both of the cross slide motors The IR Compensation Adjustment on the Main board is out of adjustment for vertical or horizontal axes Adjust the IR Compensation Adjustment on the Main board coun terclockwise until the oscillation just tor Oscillation is oscillating continuously and the heatsink assembly is becoming hot stops then continue adjusting the po tentiometer 4 more turns to complete the adjustment TABLE 22 VOLTAGE TEST POINTS TABLE 24 RECOMMENDED SPARE PARTS
67. ith brakes installed on the mo tors or screw shafts No filtration is provided on this voltage due to the brake coil acting as a current filter to smooth the power The 30 VAC is rectified on the heatsink assembly and sent back to the Main board where the 20 VDC 1 20 VDC and TP4 20 VDC is filtered through 8 elec trolytic capacitors The 20 VDC is used as the source voltage for the motor driver circuit and is also regulated down to 15 VDC TP2 15 VDC 5 15 VDC for servo amplification Pre amplifier The 15 VDC is also regulated down to 6 VDC TP6 6 VDC All voltages are referenced to power ground on TP3 GND Control Circuitry Description The following will describe in basic terms how the motorized slide system functions beginning from re mote pendant assembly and Motor Drivers heatsink assembly Pendant Control Moving the joystick switch allows Left Right Up and Down control movement of the cross slides As the operator selects either the Left Right Up or Down manual controls the generated signals can be moni tored at R5 Vertical Error and R8 Horizontal Error The voltages when these manual controls are se lected will generate a 12 VDC 1 0 VDC for Up or Right and 12 VDC 1 0 VDC for Down and Left Signals generated by the Joystick switch are adjust able by the two potentiometers on the pendant as sembly one for each axis These potentiometers 47 CIRCUIT DESCRIPTIONS
68. l Adj 1110 0155 1 Assembly SCR Actr ST40 1116 0077 1 Cover Retainer ST40 1110 0091 1 Motor ST40 1117 0587 1 Set SCR Half Dog Mod 1116 0115 2 Cover Telescoping 50 x 1 0 x 3 0 Strk 2000 0058 2 Wheel Guide Dual Vee 2 2360 0552 4 Gear Clamp Split Hub 2040 0544 2 Bearing Ball 2320 0112 2 ST250 5 Rebuild Kit Includes S29083 Bearing Ball Anlr Cont 2320 0244 2 Ball Bearing ST250 0600 0123 1 Seal Oil 375 x 1 125 x 312 2380 0128 1 ST250 Screw Actuator Assembly 0600 0380 1 Screw Cover Assembly ST250 0600 0159 2 Wheel Guide Dual Vee 2360 0561 4 ARC PRODUCTS REPLACEMENT PARTS CROSS REFERENCE LIST 02 24 2012 LINCOLN P 706 C 3 Indicates a change this printing P 706 C 3 DESCRIPTION ARC PRODUCTS NO LECO QTY ST250 10 Rebuild Kit Includes S29084 Bearing Ball Cont 2320 0244 2 Ball Bearing ST250 0600 0123 1 Seal Oil 375 x 1 125 x 312 2380 0128 1 ST250 Screw Actuator Assembly 0600 0374 1 Screw Cover Assembly ST250 0600 0098 2 Wheel Guide Dual Vee 2360 0561 4 ST250 10 Rebuild Kit Includes S29085 Wheel Guide Dual Vee 4 2360 0579 6 ST250 Screw Actuator Assembly 0600 0380 1 Bearing Ball Cont 2320 0244 2 Ball Bearing ST250 0600 0123 1 Screw Cover Assembly ST250 0600 0159 2 ST250 10 Rebuild Kit Includes 529085 Wheel Guide Dual Vee 4 2360 0579 6 ST250 Screw Actuator Assembly 0600 0380 1 Bearing Ball Cont 2320 0244 2 Ball
69. laced When these compo nents are replaced during troubleshooting or regular maintenance the feedback to this circuitry also changes making this calibration necessary Tolls Required Digital Volt Meter DVM capable of reading 3 places to the right of the decimal point Oscilloscope Step 1 Adjust HI and Full Clock Wise Adjust the Servo Amplifier Circuitry trim pots Horizon tal Current HI and Vertical Current V1 full Clock Wise Step 2 Monitor TP2 and TP5 Monitor the 15 VDC TP2 and 15VDC TP5 test points on main board with a digital volt meter to verify voltage in and out of Servo Amplifier Circuitry on the main board Use test point TP3 GND as reference for the volt meter Step 3 Connect the Oscilloscope to R5 Connect an oscilloscope to the Vertical Error signal lo cation at 5 Step 4 Verify Reading Observe on oscilloscope approximate 0 VDC Step 5 Adjust VI Trimpot Counter Clock Wise Adjust the Vertical Current VI Trim pot Counter Clock Wise CCW until signal on the oscilloscope be gins to oscillate 18 201329 001 REV D MAINTENANCE Step 6 Adjust VI Trimpot Clock Wise Slowly adjust the Vertical Current VI Trim pot Clock Wise CW until the oscillation just stops then adjust the trim pot CW an additional four 4 turns Step 7 Verify Reading On the pendant move the joystick switch up and ob serve the vertical slide moving up and obser
70. lloscope approximately 15 VDC and observe the horizontal slide moving to the left NOTE Step 15 Verify Reading No Movement Release the joystick on the pendant and observe approximately 0 VDC on the oscilloscope and ob serve on the cross slides no drive movement Some ripple may be seen this is typical This completes the Servo Amplifier Circuitry on the main board 19 201329 001 REV D 20 DRAWINGS AND PARTS LISTS 201329 001 REV D DRAWINGS AND PARTS LISTS ANISLYIH 3NIJO YOLOW AN TE 980108 654 Ort UJWUOHSNYUL vir O O0EE 212 070066 62 i 0 0055 82 0 00 92 0 0058 Wes POWER SWITCH 16 VOLTAGE SELECTOR O OOEE 119 00066 42 o M ro en Cio 3300 0 T O 13 nu TO VI uos sjonpoid ay 9002 6 N e 569549 TEZGNT res 0600 0389 Motorized Slide Main Bd Rev A 2 0600 0388 Motorized Slide Main Assy PENDANT Ji D 1N4002 D7 1N4002 e Fe 05 1N4002 e le L e 1918624 EN Q Q a GQ 550 270 TP3 GND FIGURE 13 MOTORIZED SLIDE CONTROL MAIN BOARD LAYOUT 21 DRAWINGS AND PARTS LISTS 201329 001 REV D E FIGURE 14 ST40 CROSS SLIDE EXPLODED VIEW 22 201329 001 REV D DRAWINGS AND PARTS L
71. ly s joystick switch from the operator are transferred to the slides in the form of movements i e left right and up down All controls to operate the motorized slide system are located on the pendant assembly SYSTEM WIRING DIAGRAM The Figure 27 Motorized Slide Control Block Diagram and Figure 28 Motorized Slide Control Block Diagram Cont beginning on page 50 and Fig ure 26 Pendant Schematic on page 49 is a circuit di agram of the entire seam tracker system These diagrams include detailed schematics of all portions of the system except the Main board Schematics of the ST40 and ST250 drives are shown in Figure 27 as well Substituting one drive for the other is the only electrical difference between ST40 and the ST250 Motorized Slide Systems The Figures 26 and 27 show all wires and connector pins in the interfaces between the various assemblies in the control unit Figure 17 Motorized Slide Control Exploded View on page 32 and Figure 18 Control Pendant Exploded View on page 34 identifies the major assemblies covered in Figure 26 and 27 The physical location of sub assemblies packaged inside the control unit assembly are shown in Figure 17 Motorized Slide Control Exploded View Parts lists for each assembly are also included in the Drawings and Parts Lists section beginning on page 21 MAIN BOARD ASSEMBLY This section will describe generally the circuitry signal flows and test points on the Main board to assist
72. n 14 compensation 16 48 inter connection 14 contamination 17 interface em Gg 47 Continuously 5 43 44 interior 17 Control 5 13 MER 7 A counter 44 48 counter clockwise 48 J R coupling 18 2220 048 i 13 48 A Radio Frequency Interference gt 47 Cross 3 6 13 15 18 24 26 43 42 om Ne A Rating 2 3 5 cross slide 13 16 18 22 23 43 44 47 48 junction s s c 13 ed 252 ay current E xi xii 47 48 Regulation gt 47 L Requirements 17 D Lamp 43 44 resistors gt 5 s 48 degrees 54 Left ow w 4 wow 1347 RF or 14 47 depress 16 linear owe uw ote ap See Radio Frequency Interference depressed e 46 liquids Right gt 13 47 diagram 14 17 43 47 Load Capacity KEK 3 5 rigid 628 o ay cet cem oe diagrams 05 43 lug s 14 17 18 43 48 rigidity s 43 Diameter 3 5 rocker oe Down 1347 M rod downward 15 ile gt w S 4 s Q d WE 252 4528 drifts gt mtm Eor 43 Main board 17 43 44 47 S Drive 3 5 13 15 44 47 maintained x 14 18 duration gt i xii Maintenance 17 18 Safety dust xi 17 18 MAN X13 Information x manual
73. n of this equipment read this man ual and all operating precautions before op erating the equipment With the power off a Read this entire Operator s Manual VE prior to operation of the Seam M Tracker System b Be sure that adequate eye protection and n gt ventilation is provided in the vicinity ofthe AN welding area Be sure that all insulators and protective covers on the torch and torch lead con nections are in place Check the following connections on the motorized slide system Control Unit to Cross Slides Control Pendant 4h je Insure that all are properly installed prior to applying power to the control unit 2 Insure all cables are of adequate length 4 clear of moving parts to prevent possible damage during operation DURING OPERATION Keep fingers hands etc away from the cross slides during operation of the seam tracker NOTE When unit is on and in manual mode downward drift may occur under heavy load conditions Di rections for correcting this condition can be found in the Troubleshooting section DURING MECHANICAL ADJUSTMENTS Ensure that the AC power is disconnected from the control unit to prevent possible shock when adjusting the control unit and accidental opera tion of moving parts being adjusted DURING ELECTRICAL ADJUSTMENTS Do not disconnect connectors or remove circuit boards when the power is connected at the con trol unit
74. o the weld The lower horizontal axis is mounted parallel to the plane of the weld and the upper vertical axis is mounted perpen dicular to the plane of the weld see on page 6 Once the cross slide assembly has been mounted make certain that adequate clearance is maintained between the moving slides and any protrusion that could restrict the full travel of the slides or interfere with the movement of the electrical cable CONTROL PENDANT INSTALLATION The seam tracker control pendant is constructed from a rugged steel housing with mounting brackets see length of 10 feet Special cable lengths are available upon request Complete control of the seam tracker system is achieved through the sealed rocker switches which are in the cover of the control pendant Manual opera tion of the vertical and horizontal axes sidetrack to the right or left and automatic control as well as the Advance Programming Control option plug in for the Seam Tracker are handled with the control pendant assembly CONTROL UNIT INSTALLATION On page shows the size and location of holes for mounting the control unit in the proper position It should be located for ready access to the power switch and allow clearance for opening the hinged door This allows for inspection replacement of parts or installation of the Advanced Programming Control components when necessary Another important consideration is to make certain that the control unit has
75. on page 49 17 201329 001 REV D CROSS SLIDE ASSEMBLY The cross slide assembly should be maintained by periodic inspections for worn moving parts e g ball screws couplings magnetic brakes Further mainte nance includes removing excess dust weld slag soot etc from the assemblies any connectors parts are damaged during operation the defective parts should be replaced as soon as practical Repair of the cross slide 15 limited to the replacement of defective parts and adjustment of the Dual Vee Guide Rails to remove play between wheels and rails Exploded views of the cross slides in Figures 14 15 and16 and their parts lists in Tables 7 8 and 10 are provided to aid in parts ordering and replacement be ginning on page 22 The Dual Vee Guides are ad justed by loosening their retaining screw adjusting and re tightening the screws PREVENTIVE MAINTENANCE SCHEDULE The following schedule is provided to assist in pre forming timely maintenance to the system to maintain optimum performance from the system Monthly Maintenance Cross Slides Proper Function Verify that the cross slide assembly travels the full length of its stroke on each axis Also it should freewheel at each end of its axis Test Check for axial play on each axis Step 1 Center the Slides Position slides in the center of their strokes Put one hand on the motor assembly on the left
76. or greater and cover plates to protect your eyes face neck and ears from the sparks and rays of the cutting welding arc when cutting welding or observing cut ting welding Warn bystanders not to watch the arc and not to expose themselves to the cutting welding arc rays or to hot metal B Wear flameproof gauntlet type gloves a heavy long sleeve shirt cuff less trousers high topped shoes and a welding helmet or cap for hair protection to protect the skin from arc rays and hot sparks or hot metal C Protect other nearby personnel from arc rays and hot sparks with a suitable non flam mable partition D Always wear safety glasses or goggles when in a cutting or welding area Use safety glasses with side shields or goggles when chipping slag or grinding Chipped slag is hot and may travel a considerable distance By standers should also wear safety glasses or goggles E Compressed gas cylinders are potentially dangerous refer to the suppliers for proper handling procedures F Wear ear plugs or other ear protection de vices when operating cutting or welding equip ment FIRE SAFETY HOT SLAG OR SPARKS CAN CAUSE A SERIOUS FIRE WHEN IN CONTACT WITH COMBUSTIBLE SOLIDS LIQUIDS OR GASES ye Te el R A Move all combustible materials well away from the cutting area or completely cover ma terials with a non flammable covering Com bustible materials include but are not limited to wood clothing s
77. or when standing on metal make sure you are well insulated by wearing dry gloves rubber soled shoes and by standing on a dry board or platform PEAD Do not use worn or damaged welding or torch cables Do not overload the cables Use well maintained equipment E When not welding cutting turn equipment OFF Accidental grounding can cause over heating and create a fire hazard Do not coil or loop the cable around parts of the body F The ground cable should be connected to the work piece as close to the work area as possible Grounds connected to building framework or other locations remote to the 201329 001 REV D SAFETY work area reduce efficiency and increase the potential hazard of electric shock Avoid the possibility of the welding or cutting current passing through lifting chains crane cables or other electrical paths G Keep everything dry you might touch in cluding clothing the work area welding gun torch and welding or cutting machines Fix wa ter leaks immediately Do not operate equip ment standing in water H Never use a cutting torch or welding gun which is damaged or contains cracked hous ing Refer to AWS Z49 1 for grounding recom mendations SKIN AND EYE BURNS RESULTING FROM BODY EXPOSURE TO ELEC TRIC ARC WELDING AND CUTTING RAYS OR HOT METAL CAN BE MORE SEVERE THAN SUNBURN A Usea proper face shield fitted with the cor rect filter 10
78. pinch points such as me chanical slides drive rolls carriage assem blies etc MAGNETIC FIELDS Y PACEMAKERS LR Magnetic Fields from High Currents can af fect pacemaker operation Pacemaker wearers should keep away Wearers of pacemakers should consult their doctors before going near arc welding gouging plasma cutting or spot welding operations WELDING WIRE Welding wire can cause puncture wounds Do not point the gun toward any part of the body other people or any metal when threading welding wire through the gun 4m FLYING PIECES OF METAL OR DIRT 2 D Flying pieces of metal or dirt can injure eyes Wear safety glasses with side shields or face shields OVERHEATED EQUIPMENT High output power for long durations can cause equipment to overheat Allow cooling periods Reduce current or reduce duty cycle before starting to weld again Follow rated duty cycle Le HIGH FREQUENCY High Frequency can cause electrical inter ference Take appropriate precautions to shield sen sitive electronic equipment such as com puters Programmable Logic Controllers etc Be sure to ground each component of the system to one ground point e Earth Ground Earth or Protective Earth SAFETY REFERENCES The following publications provide additional informa tion on important welding safeguards ANSI ASC 249 1 1988 American National
79. s parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent As
80. spirator if ventilation is not adequate to remove all fumes and gases E Beware of gas leaks Welding or cutting gases containing argon are denser than air and will replace air when used in confined spaces Do not locate gas cylinders in con fined spaces When not in use shut OFF the gas supply at its source Refer to AWS Standard 749 1 for specific ventilation recommendations xi SAFETY 201329 001 REV D ADDITIONAL SAFETY HAZARDS Do not press gun trigger until instructed to FIRE AND EXPLOSION do so Fire and Explosion can result from placing units on over or near combustible surfaces Do not install units on over or near com bustible surfaces Do notinstall unit near flammables FALLING EQUIPMENT Falling Equipment can cause serious per sonal injury and equipment damage Use lifting eyes to lift unit only not running gear gas cylinders or any other accesso ries Use equipment of adequate capacity to lift units If using fork lifts to move units be sure forks are long enough to extend beyond opposite side of the unit HOT PARTS Hot parts can cause severe burns MAKA A Do not touch hot parts bare handed Allow cooling period before working on gun or torch MOVING PARTS Moving Parts can cause injury Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Keep away from
81. surer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER o TRANSFORMATEUR ETA a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du onnement de et des projections quand on soude ou quand on regarde 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 8 Relier
82. t Enclosure Standard NEMA Style Sealed enclosure Remote Control Pendant Enclosure Handheld or mounted steel enclosure containing manual Cross Slide Cable Standard Length 10 3 M Power Cable Standard Length 6 1 8 M Pendant Cable Standard Length 10 3 M Weights Cross slide Assembly 5 x 5 38 lbs 16 Kg Control Unit power cable incl 33 lbs 15 Kg Remote Control Pendant cable incl 4 lbs 1 8 Kg 201329 001 REV D GENERAL INFORMATION MOTOR ORIVEN CROSS SLIDES CONTROL UNIT AND ORIVE CABLE REMOTE CONTROL PENDANT FIGURE 3 MS450 SYSTEM COMPONENTS TABLE 3 MS450 SYSTEM SPECIFICATIONS DESCRIPTION SPECIFICATIONS RATING Load Capacity 12 305 mm from Faceplate 450 Ibs 91 Kg Derated 45 Ibs inch 6 8 Kg 25 4 mm beyond 12 305 mm Standard Stroke Length Vertical x Horizontal 5 127 mm x 5 127 mm or 10 254 mm X 10 254 Non Standard Stroke Length Vertical x Horizontal 10 254 mm x 10 254 mm Inboard Drive Assy 24 610 mm x 24 610 mm Outboard Drive Assy Minimum Envelope Standard Stroke 5 127 mm x 5 127 mm 25 431 mm Diameter Drive System Precision Ball Screw Control Unit Enclosure Standard NEMA Style Sealed enclosure Remote Control Pendant Enclosure Handheld or mounted steel enclosure contain
83. t spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan w Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 1 0 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN 8 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d
84. ve on os cilloscope approximately 15 VDC NOTE Some ripple may be seen this is typical Step 8 Repeat Step 7 Perform the same function as in Step 7 but only in the down position on the joystick Observe the verti cal slide moves down and observe on the oscilloscope approximately 15 VDC NOTE Some ripple may be seen this is typical Step 9 Verify Reading and No Movement Release the joystick on the pendant and observe approximately 0 VDC on the oscilloscope and ob serve on the cross slides no drive movement Step 10 Connect the Oscilloscope to R8 Connect an oscilloscope to the Horizontal Error signal location at R8 and observe approximately 0 VDC Step 11 Adjust HI trimpot Counter Clock Wise Adjust the Horizontal Current HI Trim pot Counter Clock Wise CAW until signal on the oscilloscope be gins to oscillate Step 12 Aqjust HI Trimpot Clock Wise Slowly adjust the Horizontal Current HI Trim pot Clock Wise CW until the oscillation just stops then adjust the trim pot CW an additional four 4 turns Step 13 Verify Reading On the pendant move the joystick switch right and observe the horizontal slide move right and observe on the oscilloscope observe approximately 15 VDC NOTE Some ripple be seen this 1 typical Step 14 Repeat Step 13 Perform the same function as in Step 13 but only the left position on the joystick Observe on the osci

safety - Lincoln Electric

Contents

Download Pdf Manuals

Related Search

Related Contents