Miller SP-1 User manual

Millerﬁ

January

1991

FORM:

OM-531C

Effe

ctive

With

Serial

No.

JK674521

MODEL:

SP-1

SP-2

SP-3

P-3-50

SP-4

P-4-50

~OLDP,~

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

both

this

manual

and

the

power

source

manual

used

with

this

unit,

with

special

emphasis

the

safety

material

throughout

both

manuals,

before

installing,

operating,

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

operation

welding

equip

ment.

not

allow

untrained

persons

install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

MILLER

ELECTRIC

Mfg.

Miller

Group

Ltd..

Company

Co.

P.O.

Box

1079

Appleton,

54912

USA

Tel.

414-734-9821

TC-046

483

PRINTED

U.SA.



LIMITED

WARRANTY

EFFECTIVE:

AUGUST

1990

This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

and

conditions

hereof.

MiLLER

Electric

Mfg.

Co..

Appleton.

Wisconsin

war

rants

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

MILLER

free

from

defect

workmanship

and

material

the

time

and

place

delivery

MILLER.

warranty

made

MILLER

with

respect

engines,

trade

accessories

other

items

manufactured

others.

Such

engines,

trade

accessories

and

other

items

are

sold

subject

the

warranties

their

respective

manufacturers.

any.

All

engines

are

warrantied

their

manufacturer

for

two

years

from

date

original

purchase.

except

Deutz

engines

which

have

one

year.

2000

hour

warranty.

Except

specified

below.

MILLERs

warranty

does

not

apply

components

having

normal

useful

life

less

than

one

(1)

year,

such

spot

welder

tips.

relay

and

contactor

points.

MILLERMATIC

parts

thatcome

contactwith

the

welding

wire

including

nozzles

and

nozzle

insulators

where

failure

does

not

result

from

defect

workmanship

material.

MILLER

shall

required

honor

warranty

claims

war

ranted

Equipment

the

event

failure

resulting

from

defect

within

the

following

periods

from

the

date

delivery

Equipment

the

original

user:

Arc

welders,

power

sources,

robots,

and

year

components

Load

banks

year

Original

main

power

rectifiers

years

(labor



year

only)

4. All

welding

guns.

feeder/guns

and

torches

. .

days

All

other

MILLERMATIC

Feeders

year

Replacement

repair

parts,

exclusive

labor

days

Batteries

months

provided

that

MILLER

notified

writing

within

thirty

(30)

days

the

date

such

failure.

matter

general

policy

only.

MILLER

may

honor

claims

submitted

the

original

user

within

the

foregoing

periods.

the

case

MILLERs

breach

warranty

any

other

duty

with

respect

the

quality

any

goods,

the

exclusive

remedies

therefore

shall

be.

MILLERs

option

(1)

repair

(2)

replace

ment

or.

where

authorized

writing

MILLER

appropriate

cases.

(3)

the

reasonable

cost

repair

replacement

authorized

MILLER

service

station

(4)

payment

credit

for

the

purchase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

the

goods

Customers

risk

and

expense.

MILLERs

option

repair

replacement

will

FOB..

Factory

Appleton.

Wisconsin.

F.O.B.

MILLER

authorized

service

facility,

therefore,

compensation

for

transportation

costs

any

kind

will

allowed.

Upon

receipt

notice

apparent

defect

failure,

MILLER

shall

instruct

the

claimant

the

warranty

claim

procedures

followed.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WARRANTY,

GUARANTY

REPRE

SENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

WHICH.

BUT

FOR

THIS

PROVISION.

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW.

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHAN

TABILITY

FlTNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

EXCEPT

EXPRESSLY

PROVIDED

MILLER

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

ULTIMATE

PURCHASE

COMMERCIAL/INDUSTRIAL

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

AND

EXPERIENCED

THE

USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

CONSUMER

USE.

MILLERS

WARRANTIES

NOT

EXTEND

TO,

AND

RESELLER

AUTHORIZED

EXTEND

MILLERS

WARRANTIES

TO,

ANY

CONSUMER.

I



OM-531C



1/91

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

dam-

Use

the

following

spaces

record

the

Model

Designa

age

that

may

have

occurred

during

shipment.

File

any

tion

and

Serial

Style

Number

your

unit.

The

infor

claims

for

loss

damage

with

the

delivering

carrier.

mation

located

the

data

card

the

nameplate.

Assistance

for

filing

settling

claims

may

obtained

from

the

distributor

and/or

the

equipment

manufactur-

Model

________________________________

ers

Transportation

Department.

Serial

Style

No.

____________________

When

requesting

information

about

this

equipment,

ways

provide

the

Model

Description

and

Serial

Style

Date

Purchase

______________________

Number.

TABLE

CONTENTS

Section

No.

Page

No.

SECTION



SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

General

Information

And

Safety

1-2.

Safety

Alert

Symbol

And

Signal

Words

SECTION

2

SPECIFICATIONS

2-1.

Description

SECTION

3

INSTALLATION

3-1.

Field

Installation

Instructions

For

Installing

Programmer

Onto

Welding

Power

Source

3-2.

Field

Installation

Pulser

Into

SP-1

And

SP-3

Programmers

3-3.

Remote

Emergency

Stop

Switch

Connections

(Switch

Not

Supplied)

3-4.

Remote

Downslope

Initiation

Switch

Connections

(SP-3

And

SP-4

Models)

(Switch

Not

Supplied)

3-5.

Remote

Hand

Switch

Connections

(SP-1

And

SP-2

Models)

3-6.

Remote

Start

Control

Connections

(SP-3

And

SP-4)

(Switch

Not

Supplied)

3-7.

Timed

Normally-Open

And

Normally-Closed

Contacts

(SP-3

And

SP-4

Models)

SECTION

4OPERATOR

CONTROLS

4-1.

Programmer

Switch

4-2.

Starting

The

Unit

4-3.

Stopping

The

Unit

4-4.

Electroslope

(All

Models)

4-5.

Remote

Downslope

Initiation

Switch

(SP-3

And

SP-4

Models)

4-6.

Pulser

(SP-2

And

SP-4

Models)

4-7.

Sequencer

(SP-3

And

SP-4

Models)

4-8.

SMAW/GTAW

Switch

(SP-1

And

SP-2

Models)

4-9.

Auto/Manual

Switch

(SP-3

And

SP-4

Models)

4-10.

Remote Hand

Switch

RHS-46

(SP-1

And

SP-2

Models)

Section

No.

Page

No.

SECTION

5

SEQUENCE

OPERATION

5-1.

Control

Setup

Checklist

5-2.

Gas

Tungsten

Arc

Welding

(GTAW)

5-3.

Shielded

Metal

Arc

Welding

(SMAW)

5-4.

Shutting

Down

SECTION

6

MAINTENANCE

TROUBLESHOOTING

6-1.

ElectronicTimers

6-2.

Circuit

Board

Replacement

Procedures

6-3.

Troubleshooting

SECTION

7

ELECTRICAL

DIAGRAMS

Diagram

7-i.

Circuit

Diagram

For

SF-i

Models

Diagram

7-2

Circuit

Diagram

For

SP-2

Models

Diagram

7-3.

Circuit

Diagram

For

SP-3

And

SP-4

Models

Diagram

7-4.

Circuit

Diagram

Far

SF-i

Model

Sloper

Circuit

Board

PC500

Diagram

7-5.

Circuit

Diagram

For

SP-2

Model

Sloper

Circuit

Board

PC500

Diagram

7-6.

Circuit

Diagram

For

SP-3

Model

Sloper

Circuit

Board

PC500

Diagram

7-7.

Circuit

Diagram

For

SP-4

Model

Sloper

Circuit

Board

PC500

Diagram

7-8.

Circuit

Diagram

For

Pulser

Circuit

Board

SECTION

8

PARTS

LIST

Figure

8-1.

Main

Assembly

Figure

8-2.

Circuit

Card

(Sloper

And

Pulser

Illustrated)

Figure

8-3.

Pulser

Control

LIST

CHARTS

AND

TABLES

Table

2-i.

Specifications

Chart

4-i.

Weld

Cycle

Timing

Table

5-i.

Welding

Power

Source

Control

Checklist

Table

5-2.

Programmer

Control

Check!ist

Table

6-i

.Troubleshooting

SECTION



SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

GENERAL

INFORMATION

AND

SAFETY

General

Information

presented

this

manual and

various

bels,

tags,

and

plates

the

unit

pertains

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

read,

understood,

and

followed

for

the

safe

and

effective

use

this

equipment.

Safety

The

installation,

operation,

maintenance,

and

trouble

shooting

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

others.

Therefore,

this

equipment

stalled,

operated,

and

maintained

only

qualified

per

sons

accordance

with

this

manual

and

all

applicable

codes

such

as,

but

not

limited

to,

those

listed

the

end

Section



Safety

Rules

For

Operation

Arc

Weld

ing

Power

Source

the

welding

power

source

Owners

Manual.

1-2.

SAFETY

ALERT

SYMBOL

AND

SIGNAL

WORDS

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

call

attention

and

iden

tify

different

levels

hazajd

and

special

instructions.

This

safety

alert

symbol

used

with

the

signal

words

WARNING

and

CAUTION

call

atten

tion

the

safety

statements.

WARNING

statements

identify

procedures

practices

which

must

followed

avoid

seri

ous

personal

injury

loss

life.

CAUTION

statements

identify

procedures

practices

which

must

followed

avoid

minor

personal

injury

damage

this

equipment.

IMPORTANT

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

this

equip

ment.

SECTION

2

SPECIFICATIONS

Table

2-1.

Specifications

Power

Weight

Net

Ship

lbs.

(34

kg)

(35.4

kg)

Operates

From

Welding

Power

Source

Control

Voltages

TC-046

483

Figure

2-1.

Specifications

OM-531

Page

2-1.

DESCRIPTION

The

series

designed

program

specific

functions

the

Syncrowave

welding

power

source.

All

the

mod

els

are

equipped

with

Electroslope

which

provides

initial

output

selection,

upslope

time

control,

downslope

time

control,

and

final

output

selection.

The

SP-1

equipped

with

Electroslope.

The

SP-1

must

manually

advanced

through

the

welding

cycle.

The

SP-2

equipped

with

Electroslope,

and

Pulser

which

provides

background

output

control,

pulse

per

cent

time,

and

pulse

frequency

control.

This

program

mer

must

also

manually

advanced

through

the

weld

ing

cycle.

The

SP-3

equipped

with

Electroslope,

and

Sequenc

which

provides

electronic

control

initial

output

time,

upslope

and

weld

time,

and

downslope

and

final

output

time.

The

SP-4

equipped

with

Electroslope;

Pulser,

the

same

SP-2;

and

Sequencer,

the

same

SP-3.

The

locking

rear

compartment

the

Programmer

signed

for

tool

and

torch

storage.

The

welding

power

source

lifting

eye

can

accessed

through

this

compart

ment.

The

welding

power

source

and

Programmer

are

referred

the

unit

this

manual.

When

ordered

factory

option,

the

installed

and

wired

into

the

welding

power

source.

Field

installation

possible

and

instruc

tions

are

included

Section

3-1.

SECTION

3INSTALLATION

3-1.

FIELD

INSTALLATION

INSTRUCTIONS

FOR

INSTALLING

PROGRAMMER

ONTO

WELD

ING

POWER

SOURCE

(Figures

3-1

And

3-2)

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



not

allow

untrained

persons

install this

unit.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

beginning

this

installation.

Lockout/tagging

procedures

consist

padlock

ing

line

disconnect

switch

open

position,

moving

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnect

ing

device.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

methods

working

welding

equipment.

IMPORTANT:

All

directions

such

left

right,

are

with

respect

the

operator

facing

the

welding

power

source

and

Programmer

front

panels.

Retain

all

hardware

moved

during

this

procedure

for

reinstallation.

CAUTION:

METAL

FILINGS

AND/OR

TOOL

CONTACT

WITH

INTERNAL

COMPONENTS

can

damage

unit.



Cover

internal

components.



Clean

unit,

and

remove

internal

covering

terial

before

resuming

operation.

Mechanical

Procedures

Remove

top

cover

from

Programmer.

Remove

both

side

panels

from

welding

power

source.

Place

Programmer

top

welding

power

source

with

front

control

panels

facing

same

di-

rection,

and

align

four

mounting

holes

and

lead

access

hole

Programmer

with

holes

top

cov

welding

power

source.

Using

the

Programmer

template,

mark

four

mounting

holes

and

lead

access

hole

onto

weld

ing

power

source

top

cover.

Remove

Programmer

from

top

welding

power

source.

Remove

welding

power

source

top

cover.

Drill

four

9/32

in.

mm)

mounting

holes

weld

ing

power

source

cover.

Drill

punch

2-1/4

in.

(57

mm)

lead

access

hole

welding

power

source

cover.

Electrical

Connections

Locate

terminal

strip

the

welding

power

source.

Connect

the

following

leads

from

12-socket

plug

PLG2

corresponding

terminals

iT:

1T11

1T20

1T32

1T68

IMPORTANT:

may

necessary

cut

wiring

harness

ties

locate

leads.

Locate

leads

and

coming

from

pilot

light

PL1.

Slide

sleeving

back

these

leads

expose

splices.

CAUTION:

SOLDER

can

damage

unit.



not

allow

solder

fall

into

unit.



Cover

exposed

areas

unit

when

soldering

unsoldering

connections.



Remove

covers

and

clean

unit

before

resum

ing

operation.

OM-531

Page

Solder

leads

and

from

PLG2

correspond

ing

leads

from

PL1.

Slide

sleeving

back

into

posi

tion

after

soldering.

Locate

lead

coming

from

remote

control

recep

tacle

RC2.

Cut

lead

approximately

in.

(152

mm)

from

RC2.

Splice

lead

144

from

PLG2

lead

coming

from

RC2.

Insulate

free

end

lead

and

tie

into

wiring

har

ness.

Locate

lead

contactor

control

switch

S4.

Connect

lead

from

PLG2

follows:

Disconnect

existing

lead

from

S4.

Reconnect

lead

(from

Step

piggyback

connector

new

lead

31.

Install

piggyback

connector

onto

where

lead

was

removed

Step

Locate

lead

109

main

amperage

control

Ri.

Unsolder

lead

from

Ri.

10.

Solder

lead

123

from

PLG2

where

lead

109

was

removed.

11.

Splice

lead

109

lead

109

coming

from

9-socket

plug

PLG4.

Locate

leads

107

Ri.

Unsolder

leads

from

Ri.

13.

Solder

lead

115

from

PLG2to

where

leads

107

were

removed.

14.

Splice

leads

107

lead

107

coming

from

PLG4.

15.

Locate

lead

114

start

amperage

switch

SlO.

Connect

lead

114

from

PLG4

510

follows:

Disconnect

existing

lead

114

from

510.

Reconnect

lead

114

(from

Step

piggyback

connector

new

lead

114.

Install

piggyback

connector

onto

SlO

where

lead

114

was

removed

Step

16.

Connect

the

following

leads

from

PLG4

corre

sponding

terminals

iT:

1T86

1T81

17.

Locate

control

transformer

just

behind

right

end

Green

transformer

leads

are

leads

117



and

118.

Slide

sleeving

back

these

leads

pose

the

splices.

18.

Splice

leads

117

and

118 from

PLG4

corre

sponding

leads

from

T2.

IMPORTANT:

the

welding

power

source

equipped

with

Pulser,

insulate

end

lead

160

coming

from

PLG4,

and

tie

into

Programmer

wiring

harness.

19.

Locate

receptacle

RC3

circuit

board

PCi.

cate

hole

RC3.

20.

Insert

lead

160

from

PLG4

into

hole

RC3.

sure

terminal

lead

160

locked

RC3.

21.

Connect

lead

(ground)

coming

from

PLG4

one

the

mounting

bolts

holding

circuit

board

closure

place.

22.

Tape

tie

leads

existing

wiring

harness

maintain

lead

dress

and

avoid

contact

with

hot

moving

parts.

Final

Installation

Procedures

Reinstall

the

welding

power

source

cover.

Place

the

Programmer

top

the

welding

pow

source,

and

secure

with

supplied

mounting

screws.

Route

12-pin plug

PLG1

and

9-pin

plug

PLG3

from

Programmer

through

lead

access

hole

into

welding

power

source.

Connect

PLG1

from

Programmer

PLG2

welding

power

source.

Connect

PLG3

from

Programmer

PLG4

welding

power

source.

Reinstall

side

panels

onto

welding

power

source

and

cover

onto

Programmer.

3-2.

FIELD

INSTALLATION

OF PULSER

INTO

SP-1

AND

SP-3

PROGRAMMERS

(Figures

3-1

thru

3-3)

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.

unit.



Shut

down

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

beginning

this

installation.

Lockout/tagging

procedures

consist

padlock

ing

line

disconnect

switch

open

position,

moving

fuses

from

fuse

box,

shutting

off

and

red-tagging

Circuit

breaker

other

disconnect

ing

device.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

methods

working

welding

equipment.

IMPORTANT:

All

directions,

such

left

right,

are

with

respect

the

operator

facing

the

welding

power

source

and

Programmer

front

panels.

Retain

hardware

removed

during

this

procedure

for

reinstallation.

Mechanical

Procedures

Remove

top

cover

from

Programmer.

Remove

both

side

panels

from

the

welding

power

source.

CAUTION~

METAL

FILINGS

AND/OR

TOOL.

COI~3TACT

WITh

INTERNAL

COMPONENTS

can

damage-unit.



Cover

internal

components.



Clean

unit

and

remove

internal

covering

terial

before

resuming

operation.

12.



not

allow

untrained

persons

install this

OM-531

Page

Holes

are

provided

the

front

panel

but

not

the

nameplate

for

mounting

the

Pulser

controls.

cate

the

four

prepunched

holes

the

lower

right

corner

the

front

panel.

Mark

locations

onto

nameplate

applying

pressure

from

rear

with

sharp

tool.

Punch

drill

holes

the

same

size

the

nameplate.

Install

the

Pulser

assembly

from

the

rear

the

front

panel/nameplate,

and

secure

with

supplied

hardware.

Apply

the

large

label

with

control

callouts

onto

the

nameplate.

Apply

label

with

model

designation

onto

lower

right

corner

nameplate.

Rotate

Pulser

controls

fully

counterclockwise,

and

install

supplied

knobs

onto

shafts

with

point

ers

zero

(0)

minimum.

hole

provided

the

front

panel

but

not

the

nameplate

for

mounting

the

ELECTROSLOPE

switch

S52.

Locate

the

hole

the

right

the

elec

troslope

controls.

Mark

location

onto

nameplate

applying

pressure

from

rear

with

sharp

tool.

Punch

drill

hole

same

size

the

nameplate.

Install

the

switch

onto

the

front

panel/nameplate

from

rear

with

switch

keyway

down.

Apply

ELECTROSLOPE

label

over

switch

onto

nameplate.

10.

For

SP-1

Models

only:

Install

control

relay

CR56

the

front

the

center

partition

the

Program

mer

under

CR56

label

using

supplied

hardware.

11.

Locate

circuit

board

PC500

right

side

center

partition

the

Programmer.

Remove

and

discard

PC500.

Electrical

Procedures

Programmer

CAUTION:

SOLDER

can

damage

unit.



not

a/low

solder

fall

into

unit.



Cover

exposed

areas

unit

when

soldering

unsoldering

connections.



Remove

covers

and

clean

unit

before

resum

ing

operation.

Remove

header

RC5O

from

mounting

bracket.

CAUTION:

IMPROPER

LEAD

INSERTION

can

cause

equipment

damage.



sure

that

lead

terminals

are

inserted

into

correct

receptacle

hole.

terminal

does

not

lock

place

when

inserted

into

the

recep

tacle,

rotate

terminal

180

and

reinsert.

Insert

the

following

leads

from

the

pulser

circuit

board

into

RC5O

(see

Figure

3-1):

Lead

RC5O

Hole

Lead

RC5O

Hole

Lead

134

RC5O

Hole

For

SP-1

Models:

Lead

Insert

the

following

supplied

loose

leads

into

RC5O

(see

Figure

3-1).

Lead

164

RC5O

Hole 6

Lead

501

RC5O

Hole

Connect

remaining

end

lead

164

terminal

relay

CR56.

Connect

remaining

end

lead

501

the

center

terminal

the

PULSER

switch

S400.

Connect

supplied

loose

lead

ELECTRO

SLOPE

switch

S52

(see

Figure

3-2).

Solder

maining

end

lead

the

common

terminal

STOP

push

button

switch

PB51.

Cut

existing

lead

1394

in.

(102

mm)

from

RC5O.

Disconnect

remaining

end

from

CR55

and dis

card.

Splice

supplied

lead

139

existing

lead

139

RC5O

and

insulate

splice.

Connect

maining

end

new

lead

139

S52

(see

Figure

3-2).

Disconnect

existing

lead

144

from

rectifier

SR3.

Slide

the

supplied

tubing

onto

lead

144.

Con

nect

the

female

terminals

from

existing

lead

144

the

male

terminals

supplied

lead

144.

Slide

tubing

over

connection.

Connect

remain

ing

end

lead

144

S52

(see

Figure

3-2).

Connect

short

lead

144

S52

(see

Figure

3-2).

Connect

supplied

lead

156

terminal

SR3

where

lead

144

was

removed.

Connect

remain

ing

end

lead

156

S52

(see

Figure

3-2).

Connect

supplied

lead

155

terminal

CR56.

Connect

remaining

end

lead

155

S52

(see

Figure

3-2).

Connect

supplied

lead

157

terminal

CR55.

Connect

remaining

end

lead

157

S52

(see

Figure

3-2).

_______

8100

10100

1210

100

18~0

20100

10

Leadl34

~i.24IQ0

LeadbOl

912610

Leacj83

28

Figure

3-1.

Receptacle

RC5O

TA.046

965

OM-531

Page

Lead

Figure

3-2.

Electrical

Installation

Electroslope

Switch

S52

SP-1

MODELS

Disconnect

existing

lead

from

SR3.

Connect

the

female

terminals

from

existing

lead

the

male

terminals

supplied

lead

32.

Connect

maining

end

new

lead

terminal

CR56.

Connect

supplied

lead

109

terminal

CR56.

Connect

remaining

end

lead

109

PROGRAMMER

switch

S50

follows:

Disconnect

existing

lead

109

from

S50.

Connect

lead

109

(from

Step

piggy

back

connector

new

lead

109

Install

piggyback

connector

onto

S50

where

lead

109

was

removed

Step

Cut

off

existing

lead

130

in.

(102

mm)

from

RC5O.

Unsolder

remaining

end

existing

lead

130

from

the

FINAL

AMPERAGE

control

R50

and

discard.

Solder

supplied

lead

130

R50

where

lead

130

was

removed.

Connect

remain

ing

end

new

lead

130

terminal

CR56.

Splice

supplied

lead

158

existing

lead

130

RC5O,

and

insulate

splice.

Connect

remaining

end

lead

158

terminal

CR56.

Cut

off

existing

lead

133

in.

(102

mm)

from

RC5O.

Disconnect

remaining

end

lead

133

from

S50

and

discard.

Splice

supplied

lead

133

existing

lead

133

RC5O

and

insulate

splice.

Connect

remaining

end

new

lead

133

ter

minal

CR56.

Connect

supplied

lead

165

the

terminal

S50

where

lead

133

was

removed.

Connect

maining

end

lead

165

terminal

CR56.

Cut

existing

lead

1324

in.

(102

mm)

from

RC5O.

Disconnect

remaining

end

lead

132

from

S50

and

discard.

Splice

supplied

lead

159

existing

lead

132

RC5O

and

insulate

splice.

Connect

one

the

remaining

ends

new

lead

159

terminal

CR56.

Connect

remaining

end

new

lead

159

terminal

CR56.

Connect

supplied

lead

163

the

terminal

S50

where

lead

132

was

removed.

Connect

maining

end

lead

163

terminal

CR56.

For

SP-3

Models

Connect

supplied

lead

501

terminal

CR55.

Connect

remaining

end

lead

501

center

terminal

PULSER

switch

S400.

Connect

supplied

lead

terminal

CR55.

Connect

remaining

end

lead

the

top

terminal

S400.

Connect

supplied

long~lead

terminal

INITIAL

AMPERAGE

timer

TD51.

Connect

maining

end

lead

ELECTROSLOPE

switch

S52

(see

Figure

3-3).

Connect

short

lead

S52

(see

Figure

3-3).

Remove

jumper

link

between

terminals

and

161

terminal

strip

50T.

Connect

supplied

lead

50T71

Connect

maining

end

lead

S52

(see

Figure

3-3).

Connectsupplied

lead

161

to5OTl6l.Connect

remaining

end

lead

161

S52

(see

Figure

3-3).

Disconnect

existing

lead

155

from

terminal

CR50

and

terminal

CR56

and

discard.

Connect

supplied

lead

155

follows:

Connect

terminal

with

two

leads

termi

nal

CR56.

Connect

shorter

lead

terminal

CR50.

Connect

remaining

lead

S52

(see

Figure

3-3).

Connect

supplied

lead

157

terminal

TD51.

Connect

remaining

end

lead

157

S52

(see

Figure

3-3).

Connect

supplied

lead

160

terminal

CR56.

Route

remaining

end

lead

160

through

access

hole

bottom

Programmer

into

welding

power

source.

Rear

View

Switch

Top

V~F

-l

TA-046

963

Figure

3-3.

Electrical

Installation

Electroslope

Switch

S52

SP-3

Models

Top

Lead

144-(Iong)

Rear

View

Switch

Lead

156

TA-046 964

Lead

155

Lead

161

Lead

t~r



Lead

157

Lead

(long)

Lead

(short)

OM-531

Page

Connect

lead

from

the

pulser

module

the

threaded

mounting

spacer

for

Programmer

circuit

board

PC500.

Connect

lead

132

from

the

pulser

module

ter

minal

CR56.

Reinstall

RC5O.

Align

supplied

PC500

and

insert

into

RC5O.

cure

PC500

standoffs.

10.

Thread

leads

81,

86,

and

114

from

the

pulser

module,

through

the

access

hole

the

bottom

the

programmer,

and

into

the

welding

power

source.

Welding

Power

Source

Electrical

Connections

For

Models

Prior

Serial

No.

JA432849:

Splice

supplied

leads

81,

86,

114,

and

160

corresponding

leads

routed

into

the

welding

power

source

from

the

Programmer.

Connect

leads

and

corresponding

ter

minals

terminal

strip

the

welding

power

source.

Connect

lead

114

the

START

AMPERAGE

switch

SlO

follows:

Disconnect

existing

lead

114

from

SlO.

Reconnect

lead

114

(from

Step

piggy

back

connector

new

lead

114.

Install

piggyback

connector

onto

SlO

where

lead

114

was

removed

Step

Locate

edge

connector

receptacle

RC3

cir

cuit

board

PCi.

Insert

lead

160

into

hole

RC3.

sure

that

terminal

lead

160

has

locked

into

RC3.

For

Models

Effective

With

Serial

No.

JA432849:

Discard

supplied

loose

leads

81, 86,

114,

and

160.

Insert

leads

from

Programmer

into

plug

PLG3

follows:

Lead

Socket

Lead

Socket 6

Lead

114

Socket

Lead

160

Socket

Tape

tie

new

leads

existing

wiring

harness.

sure

that

leads

will

not

touch

hot

moving.

Reinstall

the

welding

power

source

side

panels

and

Programmer

top

cover.

3-3.

REMOTE

EMERGENCY

STOP

SWITCH

CON

NECTIONS

(Switch

Not

Supplied)

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shutdown

welding

power

source,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

beginning

this

installation.

Lockout/tagging

procedures

consist

padlock

ing

line

disconnect

switch

open

position,

moving

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnect

ing

device.

IMPORTANT:

All

directions,

such

left

right,

are

with

respect

the

operator

facing

the

welding

power

source

and

Programmer

front

panels.

Retain

all

hard

ware

removed

during

this

procedure

for

reinstallation.

remote

emergency

stop

switch

may

installed

into

the

Programmer.

remote

emergency

stop

capability

desired,

obtain

switch

and

proceed

follows:

For

SP-1

and

SP-2

Models:

Obtain

normally-

open,

momentary-contact

switch.

For

SP-3

and

SP-4

Models:

Obtain

normally-closed,

momen

tary-contact

switch.

Remove

Programmer

top

cover.

Route

leads

from

switch

through

access

hole

left

side

Programmer.

Locate

terminal

strip

50T

left

side

center

partition.

For

SP-1

and

SP-2

Models:

Connect

leads

from

switch

terminals

and

148

50T.

For

SP-3

and

SP-4

Models:

Remove

jumper

link

between

terminals

and

50T,

and

connect

switch

leads

50T66

and

50T77.

Reinstall

Programmer

top

cover.

Resume

operation.

3-4.

REMOTE

DOWNSLOPE

INITIATION

SWITCH

CONNECTIONS

(SP-3

And

SP-4

Models)

(Switch

Not

Supplied)

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shutdown

welding

powersource,

and

discon

nect

input

power

employing

lockout/tagging

procedures

before

beginning

this

installation.

Lockout/tagging

procedures

consist

padlock

ing

line

disconnect

switch

open

position,

moving

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnect

ing

device.

IMPORTANT:

All

directions,

such

left

right,

are

with

respect

the

operator

facing

the

welding

power

source

and

Programmer

front

panels.

Retain

all

hard

ware

removed

during

this

procedure

for

reinstallation.

normally-open,

momentary-contact

switch

may

used

for

remote

downslope

initiation

the

Programmer.

OM-531

Page

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