REV ISSUE SHEET SHEETS
PART NO: 595609-TAB
PROCESS SUMMARY PART NAME: 9000 POWER KIT * 019 1 11
ROUTING LOG REVISION LOG
SEQ DESC W/C STD HRS TAB REV
010 BUILD LV111 0.50 -012 AC
020 INSP -014 AA
030 TEST -015 AA
040 ACCPT -016 AB
050 PACK -017 AB
-018 AB
MAINTENANCE LOG
ISSUE DATE ORIG C.O. REASON FOR ISSUE
019 03/13/00 NK 52271 Rev AC. Incorrect Label (Item 23) called out on -012 LM. Process called out correct label.
018 02/24/00 NK 52031 Rev AB. Delete System ID Plate from UltraForm Power Panels.
017 1/21/99 EM 46019 Rev AA. Change FCC Label to 804363-003
016 45976 Rev Z. Change to Buart TUV Label on Tab -018.
11/11/98 NK 45916 Rev Y. Change TUV/GS Label on Tab -014 and -018.
015 05/22/98 NK 45448 Rev W. Add UL, CUL, and TUV/GS Labels.
014 3/12/98 SLC - Correct error on Tab –018, item 26 had been omitted
013 11/13/97 SLC 44471 Rev. V - Add item 32 to Tabs -005, -014, -015, and –017
012 8/6/97 SLC 44079 Rev. U - Remove incorrect labels on Tabs -012 & -017
011 6/5/97 SLC 43760 Rev. T - Create TAB -018 for Int’l UltraForm
010 11/4/96 SLC 42924 Rev. S - Add “CE” Label
009 10/17/96 SLC 42689 Rev. R - Change labels
008 4/22/96 SLC 42455 Rev. P - Add TUV labels
PRODUCT STATUS NOTES PE DE* QE* END USER
9000 A
* MAY NOT BE REQUIRED
007 1/31/96 SLC 41733 Rev. N - LM change
41892 Rev. M - Add tabs -016 and -017 for UltraForm
Release initial process
595609-TAB ISSUE SHEET
DataCard
CONTROLLED PROCESS 9000 POWER KIT 019 2
Tooling Required
#2 Phillips Screw Driver
Slotted Screw Driver
2 - Channel Lock Pliers
11/32 Wrench
Emery Cloth
595609-TAB ISSUE SHEET
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CONTROLLED PROCESS 9000 POWER KIT 019 3
1. REMOVE SECOND SWITCH KNOCKOUTS:
(-012, -014, -016, -017, -018 ONLY)
1.1. Remove two switch knockouts from the bottom of
1, AC Controller Enclosure (595600-002).
2. CONTROLLER ENCLOSURE PREPARATION:
2.1. Roughen the outside surface of 1, Controller
Enclosure in the area where 27, Bracket, mounts
using emery cloth. This is to ensure good
grounding contact between the two parts.
595609-TAB ISSUE SHEET
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CONTROLLED PROCESS 9000 POWER KIT 019 4
3. ATTACH STRAIN RELIEF PLATE:
3.1. Attach 6, Strain Relief Plate to 1, Enclosure, using
(4) 21, Screws (805693-206).
For -012, use 6, Strain Relief Plate (593174-005)
For -014, use 6, Strain Relief Plate (593174-004)
For -015, use 6, Strain Relief Plate (593174-005)
For -016, use 6, Strain Relief Plate (593174-005)
For -017, use 6, Strain Relief Plate (593174-005)
For -018, use 6, Strain Relief Plate (593174-004)
3.2. Attach 12, Ground Symbol Label (584322-001).
3.3. Attach 28, Ground Symbol Label (584322-002).
3.4. Attach 29, Electrical Shock Label (592338-001).
3.5. Attach 27, Mount Bracket (595599-001), to 3, AC
Power PWB (595742-004), using (4) 17, Screws
(805693-104).
595609-TAB ISSUE SHEET
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CONTROLLED PROCESS 9000 POWER KIT 019 5
4. ATTACH AC POWER PWA:
4.1. Mount 3, AC Power PWB, to 1, Enclosure, using
(2) 21, Screws (805693-206), into 27, Bracket
and (8) 17, Screws (805693-104), into the
Switches. NOTE: For -015, use only (4) 17,
Screws.
595609-TAB ISSUE SHEET
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CONTROLLED PROCESS 9000 POWER KIT 019 6
5. ATTACH FILTER AND POWER CABLE:
5.1. Mount 4, EMI Filter (805683-001), to 1, Enclosure,
using (4) 20, Lock Washers (800506-004), and (4) 18,
Nuts (800074-004). Note orientation of 4, Filter.
5.2. Attach Line Wire and Neutral Wire from 3, PWB, to 4,
Filter, using supplied Hardware.
5.3. Attach 7, Strain Relief to 2, Power Cable. Insert the
Cable through the Strain Relief so that about 3/4” of
insulation extends beyond the end of the Strain Relief.
Tighten the outer nut of the Strain Relief, and line up
the flats with the inner nut.
For -012, use 7, Strain Relief (805904-003),
and 2, Power Cable (593300-007)
For -014, use 7, Strain Relief (805904-002),
and 2, Power Cable (593300-008)
For -015, use 7, Strain Relief (805904-003),
and 2, Power Cable (593300-005)
For -016, use 7, Strain Relief (805904-003), and 2,
Power Cable (593300-007)
For -017, use 7, Strain Relief (805904-003), and 2, Power Cable (593300-005)
For -018, use 7, Strain Relief (805904-002), and 2, Power Cable (593300-008)
5.4. Insert the Cord through the Plate, then attach using supplied Nut the Strain Relief.
595609-TAB ISSUE SHEET
DataCard
CONTROLLED PROCESS 9000 POWER KIT 019 7
6. ATTACH GROUND CABLES AND COVER:
6.1. Attach “Chassis” Wire from 2, Power Cord, to Enclosure,
by placing, 20, Lock Washer (800506-004), “Chassis”
Wire from Cord, and 20, Lock Washer (800506-004), on
the ground lug. Secure with 18, Nut (800074-004).
6.2. Next install 20, Lock Washer (800506-004), 8, Chassis
Ground Cable (593748-001), and 20, Lock Washer
(800506-004),on the ground lug. Secure using 18, Nut
(800074-004).
6.3. Attach 8, Ground Cable, to Filter, center Gnd terminal.
6.4. Attach Black “Line” Wire to Filter, right Line terminal.
6.5. Attach White “Neutral” Wire to Filter, left Neutral
terminal.
6.6. Attach 9, Chassis Ground Cable (593748-002), to
Enclosure, by placing 20, Lock Washer (800506-004), 9,
Ground Wire, and 20, Lock Washer (800506-004), on
the ground lug. Secure using 18, Nut (800074-004).
6.7. Attach 5, AC Shield Enclosure (593566-001), over 4,
Filter using (4) 20, Lock Washers (800506-004), and (4)
18, Nuts (800074-004).
595609-TAB ISSUE SHEET
DataCard
CONTROLLED PROCESS 9000 POWER KIT 019 8
7. ATTACH LABELS FOR 595609-012
(NORTH AMERICA):
7.1. Attach 13, Current Leakage Label (593921-001),
14, System ID Plate (593922-004), 16, Patent
Label (593933-001), 23, FCC Label (804363-003),
24, UL Label (803584-003), and 31, Canada UL
Label (803584-004), as shown.
8. ATTACH LABELS FOR 595609-016
(NORTH AMERICA-ULTRAFORM):
8.1. Attach 13, Current Leakage Label (593921-001),
16, Patent Label (593933-001), 23, FCC Label
(804363-003), 24, UL Label (803584-003), 30, 2
Cord Label (578872-001), and 25, Canada UL
Label (803584-004).
8.2. Attach 30, Caution Label (578872-001), to the
9000 AC Panel.
595609-TAB ISSUE SHEET
DataCard
CONTROLLED PROCESS 9000 POWER KIT 019 9
9. ATTACH LABELS FOR 595609-014
(INTERNATIONAL):
9.1. Attach 13, Current Leakage Label (593921-001),
14, System ID Plate (593922-004), 16, Patent
Label (593933-001), 23, FCC Label (804363-
003), 26, TUV Label (805979-001), 31, CE Label
(598586-002), and 32, Japanese Current
Leakage Label (593921-002), as shown.
10. ATTACH LABELS FOR 595609-018
(INTERNATIONAL-ULTRAFORM):
10.1. Attach 13, Current Leakage Label (593921-001),
16, Patent Label (593933-001), 23, FCC Label
(804363-003), 26, TUV Label (805951-001), 30,
2 Cord Label (578872-001), 31, CE Label
(598586-002), and 32, Japanese Current
Leakage Label (593921-002),as shown.
10.2. Attach 30, Caution Label (578872-001), to the
9000 AC Panel.
595609-TAB ISSUE SHEET
DataCard
CONTROLLED PROCESS 9000 POWER KIT 019 10
11. ATTACH LABELS FOR 595609-015
(JAPAN):
11.1. Attach 13, Current Leakage Label (593921-001),
14, System ID Plate (593922-003), 16, Patent
Label (593933-001), 23, FCC Label (804363-
003), and 32, Japanese Current Leakage Label
(593921-002), as shown.
12. ATTACH LABELS FOR 595609-017
(JAPAN-ULTRAFORM):
12.1. Attach 13, Current Leakage Label (593921-001),
16, Patent Label (593933-001), 23, FCC Label
(804363-003), 30, 2 Cord Label (578872-001),
and 32, Japanese Current Leakage Label
(593921-002), as shown.
12.2. Attach 30, Caution Label (578872-001), to the
9000 AC Panel.
595609-TAB ISSUE SHEET
DataCard
CONTROLLED PROCESS 9000 POWER KIT 019 11
KIT,POWER,230V,HP,USA,ION (595609-012)
Item Part Description Qty Part Number Rev
1 ENCLOSURE,AC CONTROLLER,2CB 1 595600-002 K
2 CABLE ASSY,PWR,230V,24AMP,NA 1 593300-007 F
3 PWB ASSY,POWER AC 1 595742-004 J
4 FILTER-EMI,30A,250VAC 1 805683-001
5 ENCLOSURE,SHIELD AC 1 593566-001 A
6 PLATE,STRAIN,RLF,LGE,PAINTED 1 593174-005 E
7 STRAIN RLF-PWR CORD,.545-.709 1 805904-003 C
8 CABLE ASSY,GND,CHASSIS 1 593748-001 F
9 CABLE ASSY,GND,CHASSIS 1 593748-002 E
12 LABEL, GROUND 1 584322-001 B
13 LABLE,CURRENT,LEAKAGE 1 593921-001 B
14 PLATE,SYSTEM ID 1 593922-004 D
16 LABEL,PATENT 1 593933-001 B
17 SCREW-SEMS,PAN HEAD,6-32X.25 12 805693-104 F
18 NUT, HEX MACH, STL 8-32UNC 11 800074-004
20 WASHER, LOCK, EXT TOOTH 8 14 800506-004
21 SCREW-SEMS,PH,8-32 X 3/8 6 805693-206 F
22 RIVET, POP, .125 DIA 4 803518-001
23 LABEL,FCC COMPLIANCE CLASS A 1 804363-003 F
24 LABEL UL EDP 87YO 1 803584-003 F
25 LABEL,UL EDP 87YO,CANADA 1 803584-004 F
27 BRKT,PWB MOUNT 1 595599-001 A
28 LABEL,SYMBOL,GND 1 584322-002 C
29 LABEL, SHOCK HAZZARD 1 592338-001 A
KIT,POWER,230V,HP,INTL,ION (595609-014)
Item Part Description Qty Part Number Rev
1 ENCLOSURE,AC CONTROLLER,2CB 1 595600-002 K
2 CABLE ASSY,PWR,230V,24AMP,I.H. 1 593300-008 F
3 PWB ASSY,POWER AC 1 595742-004 J
4 FILTER-EMI,30A,250VAC 1 805683-001
5 ENCLOSURE,SHIELD AC 1 593566-001 A
6 PLATE,STRAIN,RLF,MED,PAINTED 1 593174-004 E
7 STAIN RLF-PWR CORD,.394-.551 1 805904-002 C
8 CABLE ASSY,GND,CHASSIS 1 593748-001 F
9 CABLE ASSY,GND,CHASSIS 1 593748-002 E
12 LABEL, GROUND 1 584322-001 B
13 LABLE,CURRENT,LEAKAGE 1 593921-001 B
14 PLATE,SYSTEM ID 1 593922-004 D
16 LABEL,PATENT 1 593933-001 B
17 SCREW-SEMS,PAN HEAD,6-32X.25 12 805693-104 F
18 NUT, HEX MACH, STL 8-32UNC 11 800074-004
20 WASHER, LOCK, EXT TOOTH 8 14 800506-004
21 SCREW-SEMS,PH,8-32 X 3/8 6 805693-206 F
22 RIVET, POP, .125 DIA 4 803518-001
23 LABEL,FCC COMPLIANCE CLASS A 1 804363-003 F
26 LABEL-TUV/GS 1 805979-001
27 BRKT,PWB MOUNT 1 595599-001 A
28 LABEL,SYMBOL,GND 1 584322-002 C
29 LABEL, SHOCK HAZZARD 1 592338-001 A
31 LABEL, CE, 1.00 X .50 1 598586-002 C
32 LABLE,CURRENT,LEAKAGE 1 593921-002 C
KIT,POWER,100V,HP,JAPAN,ION (595609-015)
Item Part Description Qty Part Number Rev
1 ENCLOSURE,AC CONTROLLER,2CB 1 595600-002 K
2 CABLE ASSY,PWR,100V,30AMP,JAP 1 593300-005 C
3 PWB ASSY,POWER AC 1 595742-004 J
4 FILTER-EMI,30A,250VAC 1 805683-001
5 ENCLOSURE,SHIELD AC 1 593566-001 A
6 PLATE,STRAIN,RLF,LGE,PAINTED 1 593174-005 E
7 STRAIN RLF-PWR CORD,.545-.709 1 805904-003 C
8 CABLE ASSY,GND,CHASSIS 1 593748-001 F
9 CABLE ASSY,GND,CHASSIS 1 593748-002 E
12 LABEL, GROUND 1 584322-001 B
13 LABLE,CURRENT,LEAKAGE 1 593921-001 B
14 PLATE,SYSTEM ID 1 593922-003 D
16 LABEL,PATENT 1 593933-001 B
17 SCREW-SEMS,PAN HEAD,6-32X.25 8 805693-104 F
18 NUT, HEX MACH, STL 8-32UNC 11 800074-004
20 WASHER, LOCK, EXT TOOTH 8 14 800506-004
21 SCREW-SEMS,PH,8-32 X 3/8 6 805693-206 F
22 RIVET, POP, .125 DIA 4 803518-001
23 LABEL,FCC COMPLIANCE CLASS A 1 804363-003 F
27 BRKT,PWB MOUNT 1 595599-001 A
28 LABEL,SYMBOL,GND 1 584322-002 C
29 LABEL, SHOCK HAZZARD 1 592338-001 A
32 LABLE,CURRENT,LEAKAGE 1 593921-002 C
KIT,POWER,230V,HP,UF,USA (595609-016)
Item Part Description Qty Part Number Rev
1 ENCLOSURE,AC CONTROLLER,2CB 1 595600-002 K
2 CABLE ASSY,PWR,230V,24AMP,NA 1 593300-007 F
3 PWB ASSY,POWER AC 1 595742-004 J
4 FILTER-EMI,30A,250VAC 1 805683-001
5 ENCLOSURE,SHIELD AC 1 593566-001 A
6 PLATE,STRAIN,RLF,LGE,PAINTED 1 593174-005 E
7 STRAIN RLF-PWR CORD,.545-.709 1 805904-003 C
8 CABLE ASSY,GND,CHASSIS 1 593748-001 F
9 CABLE ASSY,GND,CHASSIS 1 593748-002 E
12 LABEL, GROUND 1 584322-001 B
13 LABLE,CURRENT,LEAKAGE 1 593921-001 B
14 PLATE,SYSTEM ID,230V 1 598311-002 B
16 LABEL,PATENT 1 593933-001 B
17 SCREW-SEMS,PAN HEAD,6-32X.25 12 805693-104 F
18 NUT, HEX MACH, STL 8-32UNC 11 800074-004
20 WASHER, LOCK, EXT TOOTH 8 14 800506-004
21 SCREW-SEMS,PH,8-32 X 3/8 6 805693-206 F
22 RIVET, POP, .125 DIA 4 803518-001
23 LABEL,FCC COMPLIANCE CLASS A 1 804363-003 F
24 LABEL UL EDP 87YO 1 803584-003 F
25 LABEL,UL EDP 87YO,CANADA 1 803584-004 F
27 BRKT,PWB MOUNT 1 595599-001 A
28 LABEL,SYMBOL,GND 1 584322-002 C
29 LABEL, SHOCK HAZZARD 1 592338-001 A
30 LABEL, CAUTION-2 CORDS 2 578872-001 B
KIT,POWER,100V,HP,JAPAN,UFRM (595609-017)
Item Part Description Qty Part Number Rev
1 ENCLOSURE,AC CONTROLLER,2CB 1 595600-002 K
2 CABLE ASSY,PWR,100V,30AMP,JAP 1 593300-005 C
3 PWB ASSY,POWER AC 1 595742-004 J
4 FILTER-EMI,30A,250VAC 1 805683-001
5 ENCLOSURE,SHIELD AC 1 593566-001 A
6 PLATE,STRAIN,RLF,LGE,PAINTED 1 593174-005 E
7 STRAIN RLF-PWR CORD,.545-.709 1 805904-003 C
8 CABLE ASSY,GND,CHASSIS 1 593748-001 F
9 CABLE ASSY,GND,CHASSIS 1 593748-002 E
12 LABEL, GROUND 1 584322-001 B
13 LABLE,CURRENT,LEAKAGE 1 593921-001 B
14 PLATE,SYSTEM ID,100V 1 598311-001 B
16 LABEL,PATENT 1 593933-001 B
17 SCREW-SEMS,PAN HEAD,6-32X.25 8 805693-104 F
18 NUT, HEX MACH, STL 8-32UNC 11 800074-004
20 WASHER, LOCK, EXT TOOTH 8 14 800506-004
21 SCREW-SEMS,PH,8-32 X 3/8 6 805693-206 F
22 RIVET, POP, .125 DIA 4 803518-001
23 LABEL,FCC COMPLIANCE CLASS A 1 804363-003 F
27 BRKT,PWB MOUNT 1 595599-001 A
28 LABEL,SYMBOL,GND 1 584322-002 C
29 LABEL, SHOCK HAZZARD 1 592338-001 A
30 LABEL, CAUTION-2 CORDS 2 578872-001 B
32 LABLE,CURRENT,LEAKAGE 1 593921-002 C
KIT,POWER,230V,HP,UF,INTL (595609-018)
Item Part Description Qty Part Number Rev
1 ENCLOSURE,AC CONTROLLER,2CB 1 595600-002 K
2 CABLE ASSY,PWR,230V,24AMP,I.H. 1 593300-008 F
3 PWB ASSY,POWER AC 1 595742-004 J
4 FILTER-EMI,30A,250VAC 1 805683-001
5 ENCLOSURE,SHIELD AC 1 593566-001 A
6 PLATE,STRAIN,RLF,MED,PAINTED 1 593174-004 E
7 STAIN RLF-PWR CORD,.394-.551 1 805904-002 C
8 CABLE ASSY,GND,CHASSIS 1 593748-001 F
9 CABLE ASSY,GND,CHASSIS 1 593748-002 E
12 LABEL, GROUND 1 584322-001 B
13 LABLE,CURRENT,LEAKAGE 1 593921-001 B
14 PLATE,SYSTEM ID,230V 1 598311-002 B
16 LABEL,PATENT 1 593933-001 B
17 SCREW-SEMS,PAN HEAD,6-32X.25 12 805693-104 F
18 NUT, HEX MACH, STL 8-32UNC 11 800074-004
20 WASHER, LOCK, EXT TOOTH 8 14 800506-004
21 SCREW-SEMS,PH,8-32 X 3/8 6 805693-206 F
22 RIVET, POP, .125 DIA 4 803518-001
23 LABEL,FCC COMPLIANCE CLASS A 1 804363-003 F
26 LABEL-TUV,SAFETY,BAUART 1 805951-001
27 BRKT,PWB MOUNT 1 595599-001 A
28 LABEL,SYMBOL,GND 1 584322-002 C
29 LABEL, SHOCK HAZZARD 1 592338-001 A
30 LABEL, CAUTION-2 CORDS 2 578872-001 B
31 LABEL, CE, 1.00 X .50 1 598586-002 C
32 LABLE,CURRENT,LEAKAGE 1 593921-002 C
