OPERATION MANUAL for ALC-201E Arc Length Control IMPORTAN Read this manual carefully before installing, commissioning or operating this product. Revised January 1998 ee Jetline Engineering, Inc., 15 Goodyear Street, Irvine, CA 92618 Telephone: (949) 951-1515 @ Fax: (949) 951-9237ALGC-201 Arc Length Control eaALC-201 Arc Length Control A Jetline Engineering, Inc., of Irvine, California, U.S.A, warrants all new equipment to be free from defects in material and workmanship for the period of one (1) year, provided that the equipment is installed and operated according to instructions. Jetline Engineering, Inc.'s obligation under this warranty is expressly limited to replacing or repairing any defective part or correcting any manufacturing defect without charge during the warranty period, if Jetline's inspection confirms the existence of such defects. Jetline's option of repair or replacement will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of any kind will be allowed. ‘The warranty period begins on the date of sale to the original-purchase user of the equipment. Jetline Engineering, Inc. will not be liable for any loss or consequential damage or expense accruing directly or indirectly from the use of equipment covered by this warranty. This warranty supersedes all previous Jetline warranties and is exclusive with no other guarantees or warranties expressed or implied.ALC-201 Arc Length Control ‘The installation, operation and maintenance guidelines set out in this manual will enable you to maintain the equipment in peak condition and achieve maximum efficiency with your welding operation. Please read these instructions carefully to become aware of every advantage. is rs 1] famili: i 9) on. of weldin; i ould i thisALC-201 Aro Length Control Table of Contents Section I. Safety Precautions .......-..-+.+++ A. Are Welding ........... Electric Shock Are Rays . . Fumes and Gases EMF Information ........ Principal Safety Standards . chasm oof é E Section IL. Specifications ae mun name arc A ALC-201V6T B. ALC-201B4T . ©. ALC-20IBIT.... 0.0.2. eee Section IIL. Operator Instructions fee A. Introduction . —10— Bi Gequence ofOperstion (fe seis eeene eure eet ee O = CC. Punetion of Controls 0.6.2.0 0.0055 Peer eee —10— D. Initial Set-Up Procedure ...........- Pea == Section IV. Operational Problems ...... ie ea eee 1 16ALC-201 Arc Length Control Section V. Maintenance . Bele ei Stet it ‘A. Equipment Description ........ B. Theory of Operation C. General Circuit Description . . D. ALC Verification Test . E, ALC101-10 Controller ......... F. ALC101-10 Trouble-Shooting G. ALC101-13A Controller H. ALC101-13A Trouble-Shooting L ALC101-40 Heat Sink ..... eee eet J. ALC101-40 Heat Sink Trouble-Shooting . beet eee eee — 28 — Section VI. System Trouble-Shooting ...............s0e0eeee ee paepreseneemeey Je Section VII. Instollation ............. Steet eae A. General Installation ........ eee tees ete Le 81 B. Mechanical Installation . —31— ©. Blectrical Connections... 0.0. 0s ese ceeeeeeeee ens serene S81 D. Interfacing ....... eerie aa dpe esaeeee sere eC —32— E. System Operational Check . eben ewe eeeee Same F. Precautions .........----- eee eens SBE Section VII. Actuator Description ......... ete —35= A. ALC-101-60B Actuator . Sraitscestnia B, ALC-CH4 Actuator .........- C. ALC-CH1 Actuator D. ALC-CHAS Actuator . . . EB. ALC-CHI1S Actuator ...........--ALC-201 Arc Length Control F. Mechanical Maintenance . . Section IX. Parts List eect : 37 Section X. Interconnection Diagrams ... oe S82 ne:ALC-201 Arc Length Control — viii —ALC-201 Arc Length Control Section |. Safety Precautions A. Arc Welding Arc Welding can be hazardous. Protect yourself and others from possible serious injury or death. Keep children away. Pacemaker wearers keep away until consulting your doctor. In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed at the end of this section, Read and follow all Safety Standards. Have all installation, operation, maintenance and repair work performed only by qualified people. B. Electric Shock ‘Touching live electrical parts ean cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on, When using mechanized wire feed, the wire, wire reel, drive roll housing and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard, 1. Do not touch live electrical parts. 10. Wear dry, hole-free insulating gloves and appropriate body protection. Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install and ground this equipment according to the operation manual and national, state and local codes, Always verify the supply ground-check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first - double-check connections. Frequently inspect input power cord for damage or bare wiring. Replace cord immediately if damaged - bare wiring can kill. Turn off all equipment when not in use. If earth grounding of the workpiece is required, ground it directly with a separate cable - do not use work clamp or work cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.ALC-201 Are Length Control 11, Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. 12. Wear a safety harness if working above floor level. 13. Keep all panels and covers securely in place. 14. Clamp work cable with good metal-to- metal contact to workpiece or worktable as near the weld as practical. Cc. Arc Rays Arc rays can burn eyes and skin; noise can damage hearing; flying slag or sparks can injure eyes. Are rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Noise from some processes can damage hearing. Chipping, grinding and weld cooling throw off pieces of metal or slag. 1. Use approved ear plugs or ear mufis if noise level is high. 2 Use a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching. 3. Wear approved safety glasses with side shields. 4. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. 5. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection where necessary. D. Fumes and Gases Fumes and gases can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health, 1. Keep your head out of the fumes. Do not breathe the fumes. 2. If inside, ventilate the area and/or use exhaust at the are to remove welding fomes and gases. 3, If ventilation is poor, use an approved air-supplied respirator. 4, Read the Material Safety Data Sheets (MSDSs) and the manufacturer's instruction for metals, consumables, coatings, cleaners, and degreasers. 5. Work in a confined space only if it is well ventilated, or while wearing an air- supplied respirator. Always have a trained watch person nearby, 6 Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the are can react with vapors to form highly toxic and irritating gases. 7. Do not weld on coated metals, such as galvanized, lead or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while woaring an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.E. Cylinders Cylinders can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part, of the welding process, be sure to treat them carefully. 1. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and ares. 2 Install eylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. 3. Keep cylinders away from any welding or other electrical circuits. 4. Never weld on a pressurized cylinder - explosion will result. 5. Use only correct shielding gas cylinders, regulators, hoses and fittings designed for the specific application; maintain them and associated parts in good condition. 6. Turn face away from valve outlet when opening cylinder valve. 7. Keep protective cap in place over valve except when cylinder is in use or connected for use. 8 Read’ and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. ALC-201 Arc Length Control F. Welding Welding can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. 1. Protect yourself and others from flying sparks and hot metal. 2. Do not weld where flying sparks can strike flammable material. 3. Remove all flammables within 35 ft (10.7 m) of the welding are. If this is not possible, tightly cover them with approved covers. 4, Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. 5. Watch for fire, and keep a fire extinguisher nearby. 6. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWSF4.1 (see safety Standards). 7. Connect work cable to the work as close to the welding area as practical to prevent welding current travelling long, possibly unknown paths and causing electric shock and fire hazards. 8 Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.ALC-201 Arc Length Control G. Moving Parts Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. 1. Keep all doors, panels, covers, and guards closed and securely in place. 2 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. H. EMF Information Considerations About Welding and the Effects of Low Frequency Electric and Magnetic Fields ‘The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Flectric & Magnetic Fields - Background Paper, OTA- BP-E.53 (Washington, DC: U.S. Government Printing Office, May 1989): there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework, Even more frustrating, it does not yet allow us to draw definite conclusions abut questions of possible risk or to offer clear seience-based advice on strategies to minimize or avoid potential risks." To reduce magnetic fields in the work place, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around the body. 4. Keep welding power source and cables as far away as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemaker: ‘The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information. |. Principal Safety Standards Reference as applicable Safety_in_Welding and Cutting, ANSI Standard 249.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, .S. Government Printing Office, Wachington DC. 20402 NFPA Standard 70 from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 ‘Recommended__Safe Practices for _the Containers That Have Held__Hazardous Substances, American Welding Society Standard AWS F4-1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 fae Handling of © : Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 Educational Eye and Face Protection, ANSI Standard 287.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018 Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 ALC-201 Arc Length ControlALC-201 Arc Length Control Section Il. Specifications A. ALC-201V6T Electrical Voltage Range: Sensitivity: Jog Speed P.C. Adjust: Servo Drive: Interface Contact Rating: Power: Front Panel Adjustment Start Delay: Starting Are Gap: Sensitivity Stop Retract: Voltage Set: Mechanical Actuator Stroke: Lifting Weight: Shipping Control Weight: Actuator Weight: 5-50V AC OR DC 40.10 0-30 IPM 15 IPM (Maximum) K3 (Power Supply) 120 VAC @ 154 K2 (ARC ON) 120 VAC @ 1.54 110/220 VAC 50/60 HZ @ 1 AMP 0 to 10 Seconds 0 to % Inches 0 to 1.5 Inches 0 to 50 VOLTS 6 Inches 25 Lbs. (Slide Surface) 25 Lbs. 15 Lbs.B. ALC-201B4T Electrical Voltage Range: Sensitivity: Jog Speed P.C. Adjust: Servo Drive: Interface Contact Rating: Power: Front Panel Adjustment Start, Delay: Starting Are Gap: Sensitivity Stop Retract: Voltage Set: Mechanical Actuator Stroke: Lifting Weight: Shipping Control Weight: Actuator Weight: ALC-201 Arc Length Control 5-50 AC OR DC £01V 0-15 1PM 15 IPM (Maximum) KS (Power Supply) 120 VAC @ 1.54 K2 (Are On) 120 VAC @ 1.54 110/220 VAC 50/60 HZ @ 1 AMP 0 to 10 Seconds 0 to .25 Inches 0 to 1.5 Inches 0 to 50 Volts 4 Inches 10 Lbs. (Slide Surface) 25 Lbs. 8 Lbs.ALC-201 Arc Length Control C.. ALC-201B1T Electrical Voltage Range: Sensitivity: Jog Speed P.C. Adjust: Servo Drive: Interface Contact Rating: Power: Front Panel Adjustments Start Delay: Starting Arc Gap: Sensitivity Stop Retraet: Voltage Set: ‘Mechanical Actuator Stroke: Lifting Weight: Shipping Control Weight: Actuator Weight: 5-50V AC OR DC £0.1V 0-15 IPM 15 IPM (Maximum) K3 (Power Supply) 120 VAC @ 1.54 K2 (Are On) 120 VAC @ 1.54 110/220 VAC 50/60 HZ @ 1 AMP 0 to'10 Seconds 0 to .25 Inches 0 to .5 Inches 0 to 50 Volts Linch 10 Lbs. (Slide Surface) 25 Lbs. 5 Lbs.ALC-201E Figure 1 ALC-201 Arc Length ControlALC-201 Arc Length Control Section Ill. Operator Instructions A. Introduction ‘The main purpose of the arc length control (ALC) is to automatically maintain a con- stant are gap for variations in the workpiece seam, due to fit-up or fixturing. ‘When the ALC is properly connected to a constant current power source the following sequence of operation will occur. B. Sequence of Operation Step1 Ensure that the "Auto/Manual" switch is in the Manual position; the operator manually drives the actuator down. The tungsten will touch the workpiece and retract a distance set ‘on the front panel touch retract control. ‘Step 2 Turn on the power supply. When an arc is established this will be indicated by the voltage lamps switching from set (red) to actual (green); the meter will display the are voltage between the tungsten and the work- piece. When the "In Range Are Voltage” is sensed the start delay timer begins timing. The start delay timer will time out and the drive mode lamps will switch from "Manual" (red) to "Auto" (green). The "voltage set” control may be adjusted, to set the arc length, Turning the "voltage set" clockwise will cause a longer are and the meter reading will in- crease, Step 3 At the completion of the normal weld, turn off the power supply. Step 4 When the arc is extinguished, the torch will retract a distance set by the front panel "stop retract" control. C. Function of Controls 1) Power "On/Off" switch Closing this switch will energize the unit. Wait 10 seconds before setting are gap. 2) "Power" light - green ‘This light should light when "On/Off" switch, is closed. This light is powered by the posi- tive 12 volt power supply and so is an indica- tion that the low voltage supply is working. 8) Drive mode lights - one red, one green ‘The red light indicates the servo is in the ‘Manual mode. It should be on any time you are not welding, any time the "Auto/Manual” switch is in the "Manual" position, anytime the "start delay" timer is timing out, and anytime the unit is "Locked-out" from an outside signal. The green light indicates the servo is in the Auto mode. It should be on during the normal welding process and off anytime the Manual mode light is on. ‘When properly interfaced to a pulsing power supply, these lights will switch between green and red, Red during low pulse. erg4) Voltage lights - one red, one green ‘The red light indicates there is no are and that the reference voltage (the setting by which you predetermine the arc length) may be "set" or adjusted by the "voltage set" con- trol. This "set" voltage is read on the digital voltmeter as long as this light is on. The green light indicates a welding arc. ‘The voltmeter now indicates the “actual” are voltage. When this light comes on, it will start the “start delay" timer. This light should be off anytime "set" light is on. 5) "Touch Retract" ‘At the beginning of each weld pass, after securing workpiece to fixture, it will be neces- sary to position the toreh electrode the proper distance from the workpiece to enable the arc to start. By operating the Manual down switch until the electrode comes into contact with the workpiece, the ALC will sense the contact and the drive will reverse itself for a period of time dictated by the "touch retract” timer setting. The starting arc gap distance is a function of both jog speed (PC board adjustment) and the touch retract setting. As long as these adjustments are not moved, the starting are gap will be consistent from weld to weld. 6) "Voltage Set" ‘When the voltage light indicates “set (red), the control will adjust the voltage level to that which the servo will maintain after the welding process is started. The "voltage set" control can be adjusted (during the welding process) to any desired arc length or voltage (as read on the voltmeter). 7) "Auto/Manual switch" ‘Switching the "Auto/Manual" switch to Manu- al during the welding cycle will disable the Auto drive servo. Anytime this switch is in the "Manual! position, the Manual drive mode light should be "On". ALC-201 Arc Length Control 8) "Voltmeter" ‘The digital voltmeter constantly monitors either the set reference voltage (when voltage Tight indicates "set" - red) when not welding, or the actual arc voltage (when voltage light indicates "actual" - green) when an actual welding arc is established. 9) "Start delay" ‘Whon the welding arc is initiated, it some- times takes a short time for the arc to stabi- ize. If the ALC control is in "Auto" during this time, the torch will follow the voltage variations from the unstabilized arc causing the arc to become even more erratic. In a short period of time, the ALC will either drive the torch into the work or it will trip the burn through detector. During this time, it is desirable to keep the drive disabled until the arc is stable, The "start delay" timer will "lockout" the drive for a period of time indi- cated by the start delay setting. This timer is "0" to approximately "10" seconds. The start delay timer must be set longer than pre-flow plus initial current plus upslope. 10) "Sensitivity" ‘The "sensitivity" controls how fast the ALC drive will respond to an arc voltage fluctua- tion or change. Turning this control clockwise will. increase sensitivity and turning the control counterclockwise will decrease sensi- tivity. 11) "Stop Retract" When the welding process is stopped, it is usually desirable to retract the torch for clearance while removing the workpiece. The drive will automatically retract upon loss of welding arc for the period of time set on the “stop retract” timer. Like "touch retract", the distance traveled is a function of both jog speed and "stop retract” time. aesALC-201 Arc Length Control 12) Overload Protection ‘The fuse on the front panel is the overload protection for the entire control and is rated at 1 amp, 260 vac fast blow. 18) Detector Armed Light This lamp will come on any time K3 is ener- gized and the "Auto/Manual” switch is in the ‘Auto position indicating the burn through detection circuit has been enabled. 14) Manual Up/Down ‘The Manual up/down switch enables the operator to position the torch to workpiece. Maintaining the front panel Manual down will get the are gap distance. This switch is active only when the drive mode lamp is in Manual (red). When the drive mode lamp is in Auto, Manu- al up will turn "off" the detector armed lamp (K3) and the burn through detection circuit. The actuator Manual up/down will not turn on or off the welding power supply. D. Initial Set-Up Procedure 1) Set the "touch retract" and the “stop re- tract timer to zero", 2) Set the power on/off switch to "on", 8) Check for the green "Power" light. b) Check for the red "Manual" light. ight. the Manual up/down switch, check for proper the operation of the drive. ) Check for the red voltage "Set" d) e) Set the "Auto/Manual" switch to "Auto". 3) Run the torch down contacting the work- piece. The torch should touch the work and stop even if the Manual down switch is left in the down position, 4) Turn the “touch retract" control up a little and push the up/down switch to the down position. ‘The torch should push against the workpiece and retract a short distance. Repeat stop 4 until the proper are starting gap is obtained (.030 or .040" will usually get you started). 5) Adjust the "Voltage Set” control until the voltmeter reads the desired arc voltage. If the voltage has not been previously deter- mined, try 11 to 12 volts for the initial test setup. 6) Sot the "Start Delay" timer to % turn clockwise (this should give about 5 or 6 see- onds of start delay). 7) Set "Sensitivity" control 2 divisions short of full clockwise. 8) Set the "Stop Retraet” control % turn clockwise. 9) Turn on the welding power supply, inert gas, water, etc. 10) Set the current control on the power sup- ply to a level that will not burn a hole in the workpiece, if left stationary for a minute or so. Set the power supply to DC, straight polarity. 11) Start the power supply. 12) What you should see: a) As the arc strikes the workpiece, you should see the voltage lights switch from red ("Set") to green ("Actual"). As this happens, the ALC "Start Delay” timer will begin timing out. The voltage you read on the voltmeter will, at this point, indicate the actual arc voltage as set by the touch retract timer (starting arc gap). fore eeb) After about 5 seconds, the "Start Delay" timer will time out. At this point, the drive mode lights will switch from red (Manual) to green (Auto). If there is any difference be- tween the voltage that was indicated on the meter during start delay (initial starting are gap voltage) and the voltage you set prior to arc initiation, the drive will now respond and position the torch until the “set” voltage is, ‘obtained. The speed of the drive response is, determined by the "sensitivity" control. The sensitivity control should be turned up until the desired effect is achieved and no further. If turned up too far, the drive may oscillate up and down under certain circumstances. Unnecessary drive action means unnecessary wear. ©) You may now adjust the "voltage set" control and power supply current. control to obtain the desired arc length/heat. Once this is done, filler may be fed into the weld pud- dio, if it is used in the process. Next, try workpiece to torch tracking along the weld joint or face of a scrap plate. ALC-201 Arc Length Control d) Turn off the travel control, then the wire feed control. Next turn off the welding power source. At the loss of arc, the drive mode lights should switch from green (Auto) to red (Manual). Also the voltage lights should switch from green (actual) to red (set) and the drive should retract the torch away from the workpiece, a distance determined by the "stop retract” timer setting. e) The final settings will have to be deter- mined by experimentation and/or calculation, depending on your particular requirements. geoALC-201 Arc Length Control 0.1 X METER, READING ue -3 ov ON +3 uP+ av oy. ON~ ay.lav (vRa) » 5 ¥ o% y foes 9 59 5 fF ubu 2 ie vROEZ NOs DWAOSZ‘ VE TOVASH az asad | + ir Rama poWae HINBWEUINORY nat! UIMOd DA OFZ. YO ‘SHUM BehdT ANN) UIMOS BASIE 19S ANOLIvA VY ‘OL Uaumu 1 SLON s ontuim wos eA Asr7 Fain Aaa BLMENESS, gt-tol-s1v qvoa ‘9d ol ia 4] YorALC-201 Arc Length Control Part No. ARC LENGTH CONTROL DRIVE MECHANISM ALC-101-60B ACTUATOR Description ALC-101-60B-2 ALC-101-60B-3 ALC-101-60B-4 ‘ALC-101-60B-5 AS-310 ALO-101-60B-7 7998100 18808 07904 ALC-101-60B-12 GMo54B833 ALC-101-60B-14 ALC-101-60-101 ALC-101-60B-16 D2 BK2 we ALC-101-60B-21 ‘ALC-101-60B-27 30 ALC-101-60B-80 34 ALC-101-60B-34 36 4501A 39 ALC-101-60B-39 40 ALC-101-60B-40 41 ALC-101-60B-41 Base . Slide 2 Lead Screw 1.2.2... Nut 2... O-ring Collar . Sealed Ball Bearing’. Flat Washer Roll Pin .. Coupling Bearing Housing... Gear Motor . : Stop Collar ‘Touch Retract Mechanism Cover ...-.4. Adaptor Dual Veo Bushing Guide Wheel... Hex-head Screw, 4 20x1% ‘Track .. Butt Head Screw, 10-2424 Butt Head Screw, 10-24x1% ‘Soc. Head Serew, 10-9214 Butt Head Serew, ¥4-20x1 Butt Head Screw, ¥-20x¥ .. Mounting Plate Flat Head Screw, DHS LYHOR DRADER REE Eee Cable Bracket ..... Butt Head Screw, 10-2445 Strain Relief, 4NPT % to 14 . Lock Nut, 4 NPT... ‘Dual Arrow Sticker SN. Plate Detail . 7 Torch Holder ........ 0... 000+ Hex Nut, 20... Heavy Flat Washer, ADx¥40Dx3/16 thick . Limit Switch and Bracket . .. . Limit Switch Trip Switch and Filter Assembly bbb bese —42—Wel al ee, OMS .9 als WSINVHOAN “BAIN OVALC-201 Arc Length Control ALC-101-60-101 ABOLA Ttem Part No, _No. 2 ALC-CHIA2 3 4398.8 4 ALC-CHI-4 5 ALC.CHL-5 6 — ALC-CHL-6 7 4398-7 8 4398-8 9 ALC-10L-RF 10 GMa7i2-21 11 6A6-20DF01806 12 6B6-057018 18 AS.008 14 FF-303-3 6 16 Ww 18 18 20 21 ALC-CH1-21 22 23 24 B102A-14S-6P 25 26 27 28 ALC COMPACT BEAD, 1" STROKE ALC-CH1A Description Qty Housing ...... Belt Guard . Rear Cover Slide .. Track .... Baw ease Nut . RF Board Assembly Gearhead Motor 40 DP-20 Groove S/i6WxS/161D Pulley ‘Timing Belt . O-ring... 0... Flange Bearing ‘Thrust Washor . Stationary Bushing .. Adjustable Bushing .- Guide Wheel ......+ Flat Washer .- Socket Head Serew . Motor Mount ....... 0.0055 Socket Head Screw ..... Socket Head Screw... ‘Amphenol Connector... 06.0.2 esses Touch Retract Mechanism... Button Head Screw ee ‘Torch Holder ...---+- Flat Head Serow ... WERE HR ORR RAN RODE HEHE ee aa Recommended Spares Level Level 1 1 1 1 1 1aE Boll FF iilALC-201 Arc Length Control ALC COMPACT HEAD, 4" STROKE ALC-CH4A ‘Recommended Spares Item Part Level Level No, _No. Qty I a 2 ALC-CH4A-2 el aa 3 4398.3 ee 4 ALC-CHA4 a 5 ALC-CH4A-5 a 6 — ALC-CH4A-6 22 7. ALC-CHL7 : ‘ ct 8 4398-8 Nut ........ ae oes 1 9 ALC-101-RF RF Board Assembly ae 10 GMg712-21 Gearhead Motor ..-. 2... 0.00.2. 1 1 1 11 6A6-20DF01806 40 DP-20 Groove 3/16Wx3/161D Pulley 2 12 6B6-057018 Bale cestente ase: 7 Seni 1 1 13 AS-008 O-ring ... 7 1 14 FF-303-8 Flange Bearing ...... ek 15 ‘Thrust Washer ..... ie. 16 Stationary Bushing... - 2 Ww ‘Adjustable Bushing .... . : 2 18 Guide Wheel ...-... 4 19 Flat Washer... 4 20 Socket Head Screw... vd 21 ALC-CH1-21 Motor Mount ....... cil: 22 Socket Head Screw . .. 8 23 Socket Head Screw ...... 4 24 $102A-148-6P Amphenol Connector .... ai 25 ALC-101-60-101 Touch Retract Mechanism 1 26 Button Head Screw .. 2 27 4501A Torch Holder .......-. 1 28 Flat Head Screw -....... 3 29 AA-309-5 Bearing .... ae 30 Stand-off .... ie: —46—