OHIO MODEL RD-1W AUTO / MANUAL DROP MAGNET CONTROLLER

DESCRIPTION OHIO MODEL RD-1W AUTO / MANUAL DROP MAGNET CONTROLLER Th RD-1W Automti Controllr is hvy uty mgnt ontrollr us or mgnts whos ol urrnt rngs rom 0 A to 100 A. Col urrnt rrns th urrnt lowing through th mgnt whn th mgnt tmprtur is C throughout. AUTOMATIC DROP A rvrs urrnt justmnt provis or st, ln rop o th mgnt ovr omplt rng o mgnti mtril with on movmnt o th mstr swith or push utton. MANUAL DROP Allows or prtil ropping o th lo y ontrolling th mount o rvrs urrnt to th mgnt. A rop position on th mstr swith or push utton tht is spring rturn to o, givs th oprtor omplt ontrol o th rop yl. INSTALLATION PROCEDURES INSTALLATION, MAINTENANCE, AND PARTS BULLETIN OPERATING RANGE 0-100 A (COLD MAGNET CURRENT) Mount th ontrollr to soli sur with th mounting rs provi. Th ontrollr must mount vrtilly with th TOP up to oprt proprly. Mount th ontrollr wy rom sours o ht n irt xhust o ngins. Allow nough room roun th ontrollr or ir irultion. Rout ltril wirs through ottom o th nlosur n onnt surly to th trminls. Controllr is polrity snsitiv. Th positiv lin must onnt to L+ n th ngtiv to L- to nsur propr oprtion. All ltril iruits must r rom grouns n shorts. Rmov shipping mtril rom th r shils or oprting th ontrollr. Ajust th rvrs urrnt ontrol rhostt to provi nough rvrs urrnt to lnly rop th mgnt lo. Prour Strt with th il st t low rng. Pik up n rop lo o th mtril to hnl. I th mtril os not ompltly ll o th mgnt, inrs th justmnt n try nothr lo. I th mtril rops o n thn som jumps k up to th mgnt or it n ll r, ru th justmnt n try nothr lo. Whn ll th mtril lls lnly rom th mgnt, th ontrollr is proprly st.

RD-1W SUBASSEMBLIES 79 7 0 018B14A 9 71 6 7 79 018C016X 60 60 9 6 g 90 100 (COMPLETE ASSEMBLY) k g 71 4 018B668C 1 018B14B h

1 018B966Y 9 r g q 87 (COMPLETE ASSEMBLY) 44 44 g h n 46 9 t 46 s 87 * COMPONENT OF ASSEMBLY q 9 9 018B017X 7 018D19B

OHIO MODEL RD-1W AUTO/MANUAL DROP MAGNET CONTROLLER RD-1W CONTROLLER EXPLODED ASSEMBLY VIEW (AUTOMATIC) 71 8 8 74 79 84 69 6 96 8 47 8 9 8 0 70 77 6 NOTES: HARDWARE APPEALING BETWEEN SYMBOL AND ARROW IS LOCATED ON BACK OF PANEL 0 1 81 86 8 4 6 47 8 49 7 8 81 86 4 8 87 8 6 8 16 14 11 10 1 81 86 1 6 67 1 74 67 79 84 8 88 7 88 9 19 9 89 64 18 7 8 89 64 7 1 8 17 11 0 1 1 7 4 9 81 6 79 1 86 94 9 1 1 7 SYMBOL AND MATCHING LETTERS INDICATE PARTS ALIGNING THRU HOLES 4

RD-1W HARDWARE PARTS LIST ITEM PART NUMBER REQ REQ REQ REQ REQ REQ DESCRIPTION A0 M0 0-0 A11 M11 0-11 1 A-900118-1 4 4 4 4 4 4 FLATWASHER: /8 A-9001-0 4 4 4 4 4 4 CABLE CONNECTOR: # - #8 A-9008-01 1 1 1 1 RHEOSTAT DIAL 4 A-9009-01 1 1 1 1 RHEOSTAT MOUNTING KIT A-900-1 1 1 1 1 RHEOSTAT: 1.0 Ω; 0 W 6 A-900-0 1 1 1 1 RHEOSTAT KNOB 7 018A01X BLOWOUT BOLT WITH STUD 8 018A014X BLOWOUT BOLT 9 018A0140C 1 1 1 1 1 1 ARM PIN: Φ1. mm 10 018A011F 1 1 1 MAIN COIL: 0 V 10 018A011D 1 1 1 MAIN COIL: 11 V 11 018A01X INSULATING WASHER 1 018A014A 1 1 1 1 1 1 CORE ASSEMBLY 1 018A017D SHUNT ASSEMBLY 14 018A144A 1 1 1 1 1 1 REVERSE FRAME ASSEMBLY 1 018A966Z 1 1 1 1 CONTROL DIODE ASSEMBLY 16 018A61X 1 1 1 1 1 1 SPACER WASHER 17 018A67X 1 1 1 1 1 1 SPRING WASHER 18 018A641A 1 1 1 1 1 1 ARM PIN 19 018A70A SHUNT ASSEMBLY 0 018A866X 1 1 1 1 1 1 CLAMP WASHER 1 018A977X SEPERATOR WASHER 018A67A 1 1 REVERSE SWITCH CORE 018A000B 1 1 1 1 REVERSE SWITCH CORE 018A010X 10 8 10 10 8 10 TERMINAL STUD 4 018A8A 4 4 4 4 4 4 TERMINAL STUD:. in 6 mm 018A8X TERMINAL STUD:.7 in 70 mm 6 018A88X TERMINAL STUD 7 100A01B1 1 1 1 1 1 1 NAME PLATE 8 018B0116A 1 1 1 1 1 1 MAIN FRAME 9 018B017X BLOWOUT COIL ASSEMBLY: MAIN 9 018A01X CONTACT TIP 0 018B14A 1 1 1 1 1 1 BLOWOUT COIL ASSEMBLY RIGHT 0 018A0X ARC SHIELD SIDE 0 018A144X 1 1 1 1 1 1 CONTACT TIP 0 018A10X 1 1 1 1 1 1 ARC SHIELD SPACER 0 018A1X 1 1 1 1 1 1 DOWEL 0 018A661A 1 1 1 1 1 1 INSULATING SUPPORT 0 018B77A 1 1 1 1 1 1 COIL ASSEMBLY (REVERSE BLOWOUT) 1 018B14B 1 1 1 1 1 1 BLOWOUT COIL ASSEMBLY LEFT 1 018A0X ARC SHIELD SIDE 1 018A144X 1 1 1 1 1 1 CONTACT TIP 1 018A10X 1 1 1 1 1 1 ARC SHIELD SPACER 1 018A1X 1 1 1 1 1 1 DOWEL 1 018A661B 1 1 1 1 1 1 INSULATING SUPPORT 1 018B77B 1 1 1 1 1 1 COIL ASSEMBLY (REVERSE BLOWOUT) ITEM PART NUMBER REQ REQ REQ REQ REQ REQ DESCRIPTION A0 M0 0-0 A11 M11 0-11 018B966Y 1 1 1 1 1 1 DIODE/HEATSINK ASSEMBLY A-9006-17 1 1 1 1 1 1 HEAT SINK: DRILLED A-9000-6 1 1 1 1 1 1 DIODE MODULE 018A966Q MOV SUPPRESSOR ASSEMBLY 018B00A 1 1 1 1 REVERSE SWITCH COIL: AUTOMATIC 018A108J 1 REVERSE SWITCH COIL: MANUAL 0 V 018A108C 1 REVERSE SWITCH COIL: MANUAL 11 V 4 018B668C 1 1 1 1 1 1 REVERSE SWITCH ARM ASSEMBLY 4 018A144X 1 1 1 1 1 1 CONTACT TIP 4 018A604A 1 1 1 1 1 1 CONTACT BRACKET 4 018A60A 1 1 1 1 1 1 CONTACT BRACKET 4 018B074A CONTACT SHAFT ASSEMBLY 4 018A614X CONTACT ARM ASSEMBLY 4 018A6X CONTACT SPRING 4g 018A61X SPACER WASHER 4h 018B96C 1 1 1 1 1 1 REVERSE SWITCH ARM MACHINED 4k 018B618C 1 1 1 1 1 1 REVERSE ARM SHAFT 018C016X ARC SHIELD ASSEMBLY: MAIN 018A010X 4 4 4 4 4 4 BLOWOUT EAR 018A016X SPACER WASHER 018A010X 4 4 4 4 4 4 STUD: φ.1 in mm 018A019X 4 4 4 4 4 4 WASHER 018A16X 16 16 16 16 16 16 PANEL 7 018D19B 1 1 1 1 1 1 ARM ASSEMBLY 7 A-9001-0 HAIR PIN CLIP: φ0.8 in 10 mm 7 018A0104X 1 1 1 1 1 1 SPRING: LEFT 7 018A0118X CONTACT ARM: MACHINED 7 018A011X 1 1 1 1 1 1 SPRING RIGHT 7 018A01X CONTACT TIP 7 018A018A ARM INSULATION 7g 018A019X STOP WASHER 7h 018A018X 1 1 1 1 1 1 STOP 7n 018A084X SPRING PIN 7p A-90098-0 BEARING: SELF LUBRICATIONG 7q 018B019A CONTACT ARM ASSEMBLY 7r 018B081X 1 1 1 1 1 1 ARM SHAFT 7s 018C99A 1 1 1 1 1 1 MAIN ARM MACHINED 7t A-90098-0 BEARING: SELF LUBRICATIONG 44 A-900007-0 4 4 4 4 4 4 SCR HEX HEAD: /16-18 x 0.7 UNC STEEL 46 A-900007-0 4 4 4 4 4 4 SCR HEX HEAD: /16-18 x 1. UNC STEEL 47 A-900007-06 4 4 4 4 4 4 SCR HEX HEAD: /16-18 x 1. UNC STEEL 49 A-900007-08 1 1 1 1 1 1 SCR HEX HEAD: /16-18 x.0 UNC STEEL 0 A-900008-08 1 1 1 1 1 1 SCR HEX HEAD: /8-16 x 1.7 UNC STEEL 1 A-900010-09 1 1 1 1 1 1 SCR HEX HEAD: 1/-1 x. UNC STEEL A-900416-0 SCR PAN HEAD: M4 x 0.7 x 10 mm STEEL A-9000-07 4 4 4 4 4 4 SCR RH SLOTTED: 10- x 0.88 UNF STEEL ITEM PART NUMBER 6 A-9000-09 6 4 6 6 4 6 SCR RH SLOTTED: 10- x 1. UNF STEEL 7 A-9000-11 SCR RH SLOTTED: 10- x 1.7 UNF STEEL 8 A-9000-1C SCR RH SLOTTED: 10- x 0.1 UNF BRASS 9 A-9000-14 8 6 8 8 6 8 SCR RH SLOTTED: 10- x 0.8 UNF BRASS 60 A-9000-1 SCR RH SLOTTED: 10- x 0.0 UNF BRASS 6 A-9000- SCR RH SLOTTED: 10- x 1.7 UNF BRASS 64 A-9000-16 SCR RH SLOTTED: 1/4-0 x 0.8 UNC BRASS 6 A-9000-17 4 4 4 4 4 4 SCR RH SLOTTED: 1/4-0 x 0.0 UNC BRASS 67 A-9000-4 4 4 4 4 4 SCR RH SLOTTED: 1/4-0 x 1.7 UNC BRASS 69 A-900086-04 SCR SLT FLT HD: #10- x 0.87 70 A-900106-8 NUT HEX: M4 x 0.7 STEEL 71 A-900106-0 NUT HEX: #10- UNF STEEL 7 A-900106-0 4 4 4 4 4 4 NUT HEX: 1/4-0 UNC STEEL 74 A-900108-11 1 17 1 1 17 1 NUT HEX JAM: 1/4-0 NC BRASS 7 A-900108-1 1 1 1 1 1 1 NUT HEX JAM: /16-18 NC BRASS A-90011-07 4 4 NUT HEX JAM: /8-16 NC BRASS 77 A-900116-11 LOCKWASHER INTERNAL TOOTH: M4 STEEL A-90011-0 1 14 1 1 14 1 LOCKWASHER SPLIT: #10 STEEL 79 A-90011-0 1 1 LOCKWASER SPLIT: ¼ STEEL A-90011-06 14 14 14 14 14 14 LOCKWASHER SPLIT: /16 STEEL 81 A-90011-07 9 10 9 9 10 9 LOCKWASHER SPLIT: /8 STEEL 8 A-90011-09 1 1 1 1 1 1 LOCKWASHER SPLIT: ½ STEEL 8 A-900118-0 4 4 4 4 4 4 FLATWASHER: #10 STEEL 84 A-900118-0 19 17 19 19 17 19 FLATWASHER: ¼ STEEL 8 A-900118-06 6 6 6 6 6 6 FLATWASHER: /16 STEEL 86 A-900118-07 9 10 9 9 10 9 FLATWASHER: /8 STEEL 87 A-900118-09 FLATWASHER: ½ STEEL 88 A-900118-18 1 10 1 1 10 1 FLATWASHER: #10 BRASS 89 A-900118-6 FLATWASHER: ¼ BRASS 90 A-90001- SCR RH SLOTTED: #8- x 0.7 UNF BRASS 9 A-90019-06 EXTERNAL RETAINER RING: SHAFT /8 STEEL 94 A-90019-09 EXTERNAL RETAINER RING: SHAFT ½ STEEL 9 A-90041-08 SCREW ASSEMBLY: M x 0.8 x 16 mm STEEL 96 A-900117-0 #10- EXT TTH LOCKWASHER (FORMED) STEEL WIRE KITS: REQ REQ REQ REQ REQ REQ DESCRIPTION A0 M0 0-0 A11 M11 0-11 10B009C01 1 1 MAIN PANEL WIRE KIT AUTOMATIC 10B009C0 1 1 MAIN PANEL WIRE KIT MANUAL 10B009D 1 1 MAIN PANEL WIRE KIT VARIABLE 10B01B01 1 1 1 1 1 1 RESISTOR TO PANEL WIRE KIT N-01/IP- 10B01B0 1 1 1 1 1 1 RESISTOR TO PANEL WIRE KIT N1/IP-6

RD-1W WIRING DIAGRAMS RD-1W AUTOMATIC CONTROLLER RD-1W AUTOMATIC CONTROLLER WIRE DIAGRAM P/N: 018B1AP (AUTOMATIC) WIRE DIAGRAM P/N: 018B1AH VARIABLE VOLTAGE RESISTOR ASSEMBLY RESISTOR DIAGRAM SCHEMATIC DIAGRAM SCHEMATIC DIAGRAM CONTROLLER PANEL REAR VIEW WIRING DIAGRAM SYSTEMS DIAGRAM RD-1W MANUAL CONTROLLER CONTROLLER PANEL REAR VIEW WIRING DIAGRAM SYSTEMS DIAGRAM WIRE DIAGRAM P/N: 018B1AM (MANUAL) TABLE OF EQUIPMENT (018B1AP) RESISTOR DIAGRAM SCHEMATIC DIAGRAM SYSTEMS DIAGRAM SYMBOL D L RH R1-R4 R-R DESCRIPTION REVERSE CONTACT MAIN CONTACT.0 RHEOSTAT 1 RESISTOR 8 RESISTOR FUNCTION DROP LIFT DROP CONTROL DROP RESISTOR DISCHARGE RESISTOR DM1 Z1-Z CR DIODE MODULE MOV SUPPRESSOR CONTROL DIODE BLOCKING DIODE DIODE PROTECTION ANTI-REVERSE PROTECTION TABLE OF EQUIPMENT (018B1AM) PANEL REAR VIEW WIRING DIAGRAM SYMBOL D L DESCRIPTION REVERSE CONTACT MAIN CONTACT FUNCTION DROP LIFT R1-R4 8 RESISTOR DISCHARGE/DROP RESISTOR DM1 Z1-Z CR DIODE MODULE MOV SUPPRESSOR CONTROL DIODE BLOCKING DIODE DIODE PROTECTION ANTI-REVERSE PROTECTION TABLE OF EQUIPMENT (018B1AH) VARIABLE VOLTAGE SYMBOL D L RH R1-R4 R-R DESCRIPTION REVERSE CONTACT MAIN CONTACT.0 RHEOSTAT 1 RESISTOR 8 RESISTOR FUNCTION DROP LIFT DROP CONTROL DROP RESISTOR DISCHARGE RESISTOR DM1 Z1-Z DIODE MODULE MOV SUPPRESSOR BLOCKING DIODE DIODE PROTECTION 6

STEP BY STEP CONTROLLER OPERATION AUTOMATIC CONTROLLER 1. Whn lit signl is givn y losing th ontts twn trminls F n U, th L oil is nrgiz.. This loss th L ontts whih supplis ull powr to th mgnt.. Whn rop signl is givn th F to U ontt is rokn n th L oil is nrgiz. 4. This opns th L ontts n t th sm tim ishrg iruit is st up through rsistors R n R, DM1 n 4 wining o th D oil nrgizing th D oil.. This uss th nrgy in th mgnt to issipt through th R & R rsistors, n th D ontts to los. 6. Rvrs voltg is thn ppli to th mgnt through th R1 n R4 rsistors. 7. Whn th propr mount o rvrs urrnt to th mgnt, (s just y th rhostt), is msur y th 4, wining o th D oil, it nls th t o th 1, wining o th D oil n th D ontts opn. 8. This stops th low o rvrs urrnt through th mgnt. 1 1 11 1 6 6 7 8 4 NO. QTY PART NUMBER DESCRIPTION M RD-1W RESISTOR ASSEMBLY CONTROLLER P/N: 018A141J 0 V- AUTOMATIC WITH DIODE 1 1 018A149X MOUNTING BRACKET 1 018A1496X MOUNTING BRACKET 018B14G RESISTOR: 1 4 018B14A RESISTOR: 8 4 1900A06400 THRD ROD: M8 x 1. x mm 6 8 018A100X WASHER 7 8 A-90011-1 LOCKWASHER: M8 8 8 A-900106-41 HEX NUT: M8 x 1. 11 1 018A8114B BUS BAR 1 1 018A8114A BUS BAR NO. QTY PART NUMBER DESCRIPTION MANUAL CONTROLLER 1. Whn lit signl is givn y losing th ontts twn trminls F n U, th L oil is nrgiz.. This loss th L ontts whih supplis ull powr to th mgnt.. Whn rop signl is givn th F to U ontt is rokn n th L oil is -nrgiz. 4. This opns th L ontts n t th sm tim ishrg iruit is st up through rsistors R n R, n DM1.. Enrgy in th mgnt is issipt through th R & R rsistors. 6. Moving th mstr swith to th rop position or pushing th rop utton, loss th ontt twn trminls F n D, nrgizing th D oil. 7. This loss th D ontts n provis rvrs voltg to th mgnt, through rsistors R1 n R. 8. To stop th uil up o rvrs urrnt, rls th mstr swith ontrol n it will rturn to th o position, or rls th rop push utton. 9. This rks th ontt twn th F n D trminls, -nrgizs th D oil, (opning th D ontts), n stops th low o rvrs urrnt through th mgnt. 1 11 10 4 6 1 1 018A149X MOUNTING BRACKET 1 018A1496X MOUNTING BRACKET 018B14A RESISTOR: 8 4 4 1900A06400 THRD ROD: M8 x 1. x mm 8 018A100X WASHER 6 8 A-90011-1 LOCKWASHER: M8 7 8 A-900106-41 HEX NUT: M8 x 1. 10 1 018A8114B BUS BAR 11 1 018A8114A BUS BAR 1 6 7 M RD-1W RESISTOR ASSEMBLY CONTROLLER P/N: 018A141F 11 V- AUTOMATIC WITH DIODE 11; 0 V- MANUAL WITH DIODE 7

MAINTENANCE AND TROUBLE SHOOTING Chk ll ontt tips or xss wr or urning. Rpl i n. Chk r shils or urnt rs. Rpl ny tht r ly urn. Chk or urn or mg insultion on shunts or wirs. Rpl i oun. Chk or ron trking on th s pnl n insulting prts. I oun, rmov y iling or srping. I ron n not rmov, rpl th prt. Chk gp ( 4" (0 mm) opning) twn min ontts (#7 n #). Ajust y loosning srw (#46) on prt (#) n turning th ssmly. All pin onntions shoul mov sily, n ontt springs shoul provi or whn ontts r los. I springs o not provi ontt or, rpl thm. Chk Powr Dio Intgrity (DM1) with stnr Digitl Volt Mtr (DVM), st to th io hk untion. (S ownrʼs mnul or tils.) Disonnt ls to th io n rmov supprssors MOV (Z1 n Z) to isolt rom th iruit. Pl th r l o mtr on Trminl 1 o io (numr is stmp nxt to trminl) n th lk l on Trminl. Mtr shoul r <1.0. Rvrs ls n mtr shoul r 1.(00). Rpt or Trminls (r) n 1 (lk). I th io rs, rpl. Ronnt wirs n MOVS (Z1 n Z). NOTE: Z1 n Z r MOV supprssors to hlp limit voltg spiks ppli to DM1 n using mg. EMERGENCY SPARE PARTS KITS AND/OR KITS Automti #ESP-018M7016A1 Contins th prts most likly to il u to systm prolm or high voltg spik. It is rommn tht on o ths kits kpt on hn to voi unnssry own tim. Convrsion Kit 018M966U Convrts ol styl ontt rm to io. OHIO MAGNETICS PERFORMANCE ENGINEERED OHIO MAGNETICS, INC. 400 Dunhm Ro Mpl Hights, OH 4417-687 0/486-6446 Phon: 16/66-8484 Fx: 16/66-96 16/66-911 16/66-118 Sls Compny Enginring E-mil: sls@ohiomgntis.om Wsits: www.ohiomgntis.om www.hinustris.om OM-1966 1/01 Print in U.S.A.