Miller SP-1 User manual

Millerfi
January
1991
FORM:
OM-531C
Effe
ctive
With
Serial
No. JK674521
MODEL: SP-1
SP-2
SP-3
S
P-3-50
SP-4
S
P-4-50
~OLDP,~
OWNERS
MANUAL
IMPORTANT:
Read
and
understand the
entire
contents
of
both
this
manual
and the
power
source
manual used with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing, operating,
or
maintaining
this
equipment.
This unit
and
these instructions
are
for
use
only
by
persons
trained and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these instructions.
MILLER ELECTRIC
Mfg.
A
Miller
Group
Ltd..
Company
Co.
P.O.
Box 1079
Appleton,
WI
54912 USA
Tel.
414-734-9821
TC-046
483
PRINTED
IN
U.SA.


LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
This
warranty
supersedes
all
previous
MILLER
warranties and is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
.
LIMITED WARRANTY

Subject
to
the
terms
and
conditions
hereof.
MiLLER Electric
Mfg.
Co..
Appleton.
Wisconsin
war
rants to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of the time and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers.
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date of
original
purchase.
except
Deutz
engines
which
have
a one
year.
2000
hour
warranty.
Except
as
specified
below. MILLERs
warranty
does not
apply
to
components
having
normal
useful
life of
less
than
one
(1)
year,
such
as
spot
welder
tips. relay
and
contactor
points.
MILLERMATIC
parts
thatcome
in
contactwith
the
welding
wire
including
nozzles and
nozzle
insulators
where failure does
not
result from defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of failure
resulting
from
a
defect
within
the
following periods
from the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4. All
welding
guns.
feeder/guns
and torches
. . .
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of labor
60
days
7.
Batteries
6
months
provided
that MILLER is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such failure.
As
a
matter
of
general policy only.
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be.
at
MILLERs
option
(1) repair
or
(2)
replace
ment
or.
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB..
Factory
at
Appleton.
Wisconsin.
or
F.O.B.
at
a
MILLER
authorized
service
facility,
therefore, no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY OR
REPRE
SENTATION AS TO
PERFORMANCE,
AND ANY REMEDY
FOR BREACH
OF
CONTRACT
WHICH.
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF LAW.
CUSTOM
OF
TRADE
OR COURSE
OF
DEALING,
INCLUDING ANY
IMPLIED
WARRANTY OF MERCHAN
TABILITY
OR OF FlTNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT TO
ANY
AND ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY PROVIDED
BY MILLER IN
WRITING,
MILLER
PRODUCTS
ARE INTENDED FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN THE
USE
AND
MAINTENANCE
OF
WELDING EQUIPMENT
AND
NOT
FOR CONSUMERS OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO NOT
EXTEND
TO,
AND
NO RESELLER IS
AUTHORIZED
TO
EXTEND
MILLERS WARRANTIES
TO,
ANY
CONSUMER.
_1
I
.
I
.1


OM-531C

1/91
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use the
following spaces
to
record the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion and
Serial
or
Style
Number
of
your
unit. The
infor
claims
for
loss
or
damage
with
the
delivering
carrier.
mation
is
located
on
the data card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from the distributor
and/or
the
equipment
manufactur-
Model
________________________________
ers
Transportation
Department.
Serial
or
Style
No.
____________________
When
requesting
information about this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of Purchase
______________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1

SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2 SPECIFICATIONS
2-1.
Description
2
SECTION
3
INSTALLATION
3-1.
Field Installation
Instructions
For
Installing Programmer
Onto
Welding
Power
Source
2
3-2.
Field
Installation Of Pulser
Into
SP-1
And
SP-3
Programmers
3
3-3.
Remote
Emergency
Stop
Switch
Connections
(Switch
Not
Supplied)
6
3-4.
Remote
Downslope
Initiation
Switch
Connections
(SP-3
And
SP-4
Models)
(Switch
Not
Supplied)
6
3-5. Remote Hand
Switch
Connections
(SP-1
And
SP-2
Models)
7
3-6. Remote
Start Control
Connections
(SP-3
And
SP-4)
(Switch
Not
Supplied)
7
3-7.
Timed
Normally-Open
And
Normally-Closed
Contacts
(SP-3
And
SP-4
Models)
7
SECTION
4OPERATOR
CONTROLS
4-1.
Programmer
Switch
8
4-2.
Starting
The
Unit
8
4-3.
Stopping
The
Unit
8
4-4.
Electroslope
(All
Models)
9
4-5.
Remote
Downslope
Initiation
Switch
(SP-3
And
SP-4
Models)
10
4-6.
Pulser
(SP-2
And
SP-4
Models)
10
4-7.
Sequencer
(SP-3
And
SP-4
Models)
11
4-8.
SMAW/GTAW
Switch
(SP-1
And
SP-2
Models)
11
4-9.
Auto/Manual
Switch
(SP-3
And
SP-4
Models)
11
4-10.
Remote Hand Switch
RHS-46
(SP-1
And
SP-2
Models)
11

Section
No.
Page
No.
SECTION 5
SEQUENCE OF
OPERATION
5-1.
Control
Setup
Checklist
12
5-2.
Gas
Tungsten
Arc
Welding
(GTAW)
12
5-3.
Shielded
Metal
Arc
Welding
(SMAW)
14
5-4.
Shutting
Down
14
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ElectronicTimers
14
6-2.
Circuit
Board
Replacement
Procedures
15
6-3.
Troubleshooting
16
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-i.
Circuit
Diagram
For
SF-i Models 18
Diagram
7-2
.
Circuit
Diagram
For
SP-2
Models
19
Diagram
7-3.
Circuit
Diagram
For
SP-3
And
SP-4
Models
20
Diagram
7-4.
Circuit
Diagram
Far
SF-i
Model
Sloper
Circuit
Board
PC500
.
21
Diagram
7-5.
Circuit
Diagram
For
SP-2
Model
Sloper
Circuit
Board
PC500
.
22
Diagram
7-6.
Circuit
Diagram
For
SP-3
Model
Sloper
Circuit
Board
PC500
.
23
Diagram
7-7.
Circuit
Diagram
For
SP-4
Model
Sloper
Circuit Board
PC500
.
24
Diagram
7-8.
Circuit
Diagram
For Pulser
Circuit
Board
25
SECTION
8
PARTS
LIST
Figure
8-1.
Main
Assembly
26
Figure
8-2.
Circuit
Card
(Sloper
And
Pulser
Illustrated)
28
Figure
8-3.
Pulser Control
31
V
LIST
OF
CHARTS AND
TABLES
Table
2-i.
Specifications
1
Chart
4-i.
Weld
Cycle
Timing
9
Table
5-i.
Welding
Power Source
Control Checklist
13
Table 5-2.
Programmer
Control
Check!ist
13
Table
6-i
.Troubleshooting
17
S

SECTION
1

SAFETY
PRECAUTIONS
AND
SIGNAL WORDS
1-1.
GENERAL INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe and effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance with this
manual
and all
applicable
codes such
as,
but
not
limited
to,
those
listed at
the
end
of
Section
1

Safety
Rules For
Operation
Of
Arc
Weld
ing
Power
Source
in
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
to
call attention
to
and iden
tify
different
levels
of
hazajd
and
special
instructions.
a
a
a
This
safety
alert
symbol
is
used
with the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal injury
or
loss
of
life.
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2 SPECIFICATIONS
Table
2-1.
Specifications
Power
Weight
Net
I
Ship
75
lbs.
78
lbs.
(34
kg)
(35.4
kg)
Operates
From
Welding
Power
Source
Control
Voltages
TC-046
483
Figure
2-1.
Specifications
OM-531
Page
1

2-1.
DESCRIPTION
The
SP
series
is
designed
to
program
specific
functions
of the
Syncrowave
welding
power
source.
All
of
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
is
equipped
with
Electroslope.
The
SP-1 must
be
manually
advanced
through
the
welding
cycle.
The
SP-2
is
equipped
with
Electroslope,
and Pulser
which
provides
background output
control,
pulse
per
cent
on
time,
and
pulse
frequency
control. This
program
mer
must
also
be
manually
advanced
through
the
weld
ing
cycle.
The
SP-3
is
equipped
with
Electroslope,
and
a
Sequenc
er
which
provides
electronic
control
of
initial
output
time,
upslope
and
weld
time,
and
downslope
and
final
output
time.
The
SP-4
is
equipped
with
Electroslope;
Pulser,
the
same
as
SP-2;
and
Sequencer,
the
same
as
SP-3.
The
locking
rear
compartment
on
the
Programmer
is de
signed
for
tool
and
torch
storage.
The
welding
power
source
lifting
eye
can
be
accessed
through
this
compart
ment.
The
welding
power
source
and
Programmer
are
referred
to
as
the
unit
in this
manual. When
ordered
as a
factory
option,
the
SP
is
installed
on
and
wired into
the
welding
power
source.
Field
installation
is
possible
and instruc
tions
are
included
in
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)
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live electrical
parts.

Do
not
allow
untrained
persons
to
install this
unit.

Shutdown
welding
powersource,
and discon
nect
input
power
employing
lockout/tagging
procedures
before
beginning
this installation.
Lockout/tagging
procedures
consist of
padlock
ing
line disconnect switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
methods
of
working
on
welding
equipment.
IMPORTANT:
All
directions
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
welding
power
source
and
Programmer
front
panels.
Retain all hardware
re
moved
during
this
procedure
for reinstallation.
a
CAUTION:
METAL
FILINGS
AND/OR
TOOL
CONTACT
WITH
INTERNAL
COMPONENTS
can
damage
unit.

Cover internal
components.

Clean
unit,
and
remove
internal
covering
ma
terial before
resuming
operation.
A.
Mechanical Procedures
1.
Remove
top
cover
from
Programmer.
2.
Remove
both
side
panels
from
welding
power
source.
3. Place
Programmer
on
top
of
welding
power
source
with front
control
panels
facing
same
di-
rection,
and
align
four
mounting
holes and
lead
access
hole
in
Programmer
with holes
in
top
cov
er
of
welding
power
source.
4.
Using
the
Programmer
as
a
template,
mark four
mounting
holes and
lead
access
hole
onto
weld
ing
power
source
top
cover.
5.
Remove
Programmer
from
top
of
welding
power
source.
6. Remove
welding
power
source
top
cover.
7.
Drill
four
9/32
in.
(7
mm)
mounting
holes
in
weld
ing
power
source cover.
8.
Drill
or
punch
a
2-1/4
in.
(57 mm)
lead
access
hole
in
welding
power
source
cover.
B
.
Electrical
Connections
1.
Locate
terminal
strip
iT
in
the
welding
power
source.
2.
Connect
the
following
leads
from 12-socket
plug
PLG2
to
corresponding
terminals
on
iT:
11
to
1T11
20
to
1T20
32
to
1T32
68
to
1T68
IMPORTANT:
It
may
be
necessary
to cut
wiring
harness
ties
to
locate
leads.
3.
Locate
leads
Bi
and
4
coming
from
pilot
light
PL1.
Slide
sleeving
back
on
these
leads
to
expose
splices.
a
CAUTION:
SOLDER
can
damage
unit.

Do
not
allow solder
to
fall into unit.

Cover
exposed
areas
of
unit when
soldering
or
unsoldering
connections.

Remove
covers
and
clean
unit
before
resum
ing
operation.
.
OM-531
Page
2

4. Solder
leads
Bi
and
4
from
PLG2
to
correspond
ing
leads
from
PL1.
Slide
sleeving
back
into
posi
tion
after
soldering.
5.
Locate
lead
11
coming
from
remote
control
recep
tacle
RC2.
Cut
lead
11
approximately
6
in.
(152
mm)
from
RC2.
6.
Splice
lead
144
from
PLG2
to
lead
11
coming
from
RC2.
7. Insulate
free
end
of lead
11
and tie
into
wiring
har
ness.
8.
Locate
lead 31
at
contactor
control
switch S4.
Connect
lead
31
from
PLG2
to
S4
as
follows:
a.
Disconnect
existing
lead
31
from
S4.
b.
Reconnect lead
31
(from
Step
a)
to
piggyback
connector
on
new
lead
31.
c.
Install
piggyback
connector
onto
S4
where
lead
31
was
removed
in
Step
a.
9. Locate
lead
109
at
main
amperage
control
Ri.
Unsolder lead
from
Ri.
10.
Solder
lead
123
from
PLG2
to
Ri
where
lead
109
was
removed.
11.
Splice
lead
109
to
lead
109
coming
from
9-socket
plug
PLG4.
Locate
leads 107
at
Ri.
Unsolder
leads
from Ri.
13.
Solder
lead
115
from
PLG2to
Ri
where
leads
107
were
removed.
14.
Splice
leads 107
to
lead
107
coming
from
PLG4.
15.
Locate lead
114
at start
amperage
switch
SlO.
Connect
lead
114
from
PLG4 to
510
as
follows:
a.
Disconnect
existing
lead
114
from
510.
b.
Reconnect
lead
114
(from
Step
a)
to
piggyback
connector
on
new
lead
114.
c.
Install
piggyback
connector
onto SlO
where
lead
114
was
removed
in
Step
a.
16.
Connect
the
following
leads
from
PLG4 to
corre
sponding
terminals
on
iT:
86
to
1T86
81
to
1T81
17.
Locate
control
transformer
T2
just
behind
right
end
of
1
T.
Green
transformer leads
are
leads
117

and
118.
Slide
sleeving
back
on
these
leads
to
ex
pose
the
splices.
18.
Splice
leads
117
and
118 from
PLG4
to
corre
sponding
leads from
T2.
IMPORTANT:
If
the
welding
power
source
is
equipped
with
Pulser,
insulate
end
of
lead
160
coming
from
PLG4,
and
tie
into
Programmer wiring
harness.
19.
Locate
receptacle
RC3
at
circuit
board
PCi.
Lo
cate
hole
27
on
RC3.
20.
Insert lead
160
from
PLG4
into
hole
27
at
RC3.
Be
sure
terminal
on
lead
160 is locked
in
RC3.
21.
Connect lead
42
(ground)
coming
from
PLG4
to
one
of
the
mounting
bolts
holding
circuit
board
en
closure
in
place.
22.
Tape
or
tie
leads
to
existing
wiring
harness
to
maintain lead
dress
and
to
avoid
contact
with
hot
or
moving
parts.
C.
Final Installation Procedures
1.
Reinstall
the
welding
power
source
cover.
2.
Place
the
Programmer
on
top
of the
welding
pow
er
source,
and
secure
with
supplied
mounting
screws.
3.
Route
12-pin plug
PLG1
and
9-pin
plug
PLG3
from
Programmer
through
lead
access
hole into
welding
power
source.
4. Connect
PLG1
from
Programmer
to
PLG2
in
welding
power
source.
5.
Connect
PLG3
from
Programmer
to
PLG4
in
welding
power
source.
6.
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)
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
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 of
padlock
ing
line disconnect
switch
in
open
position,
re
moving
fuses
from fuse
box,
or
shutting
off
and
red-tagging
Circuit
breaker
or
other disconnect
ing
device.
This
unit
and these
instructions
are
for
use
only
by
persons
trained and
experienced
in
the
safe
methods
of
working
on
welding
equipment.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
welding
power
source
and
Programmer
front
panels.
Retain hardware
removed
during
this
procedure
for
reinstallation.
A.
Mechanical
Procedures
1.
Remove
top
cover
from
Programmer.
2.
Remove both side
panels
from
the
welding
power
source.
a
CAUTION~
METAL
FILINGS
AND/OR
TOOL.
COI~3TACT
WITh
INTERNAL
COMPONENTS
can
damage-unit.

Cover
internal
components.

Clean
unit
and
remove
internal
covering
ma
terial
before
resuming
operation.
12.

Do
not
allow
untrained
persons
to
install this
OM-531
Page
3

3.
Holes
are
provided
in
the front
panel
but
not
in the
nameplate
for
mounting
the
Pulser
controls.
Lo
cate
the
four
prepunched
holes
in
the
lower
right
corner
of the front
panel.
Mark
locations
onto
nameplate by
applying
pressure
from
rear
with
a
sharp
tool.
Punch
or
drill
holes
of
the
same
size
in
the
nameplate.
4.
Install the Pulser
assembly
from the
rear
of
the
front
panel/nameplate,
and
secure
with
supplied
hardware.
5.
Apply
the
large
label
with
control
callouts
onto
the
nameplate.
Apply
label with
model
designation
onto
lower
right
corner
of
nameplate.
6.
Rotate
Pulser
controls
fully
counterclockwise,
and install
supplied
knobs
onto shafts
with
point
ers
at
zero
(0)
or
minimum.
7.
A
hole is
provided
in
the
front
panel
but
not
in
the
nameplate
for
mounting
the
ELECTROSLOPE
switch
S52.
Locate
the
hole
to
the
right
of
the
elec
troslope
controls.
Mark
location
onto
nameplate
by
applying
pressure
from
rear
with
sharp
tool.
Punch
or
drill hole of
same
size
in
the
nameplate.
8. Install
the
switch
onto
the
front
panel/nameplate
from
rear
with
switch
keyway
down.
9.
Apply
ELECTROSLOPE
label
over
switch
onto
nameplate.
10.
For SP-1 Models
only:
Install control
relay
CR56
to
the
front
of the
center
partition
in
the
Program
mer
under
CR56
label
using
supplied
hardware.
11.
Locate
circuit
board
PC500
on
right
side of
center
partition
in
the
Programmer.
Remove and discard
PC500.
B.
Electrical Procedures
In
Programmer
a
CAUTION: SOLDER
can
damage
unit.

Do
not
a/low solder
to
fall
into unit.

Cover
exposed
areas
of
unit when
soldering
or
unsoldering
connections.

Remove
covers
and
clean
unit
before
resum
ing
operation.
1.
Remove
header
RC5O
from
mounting
bracket.
a
CAUTION:
IMPROPER
LEAD
INSERTION
can cause
equipment
damage.

Be
sure
that lead
terminals
are
inserted into
correct
receptacle
hole.
If
a
terminal does
not
lock
in
place
when
inserted
into
the
recep
tacle,
rotate
terminal 180 and reinsert.
2.
Insert the
following
leads from
the
pulser
circuit
board
into
RC5O
(see
Figure
3-1):
Lead
83
to
RC5O
Hole
28
Lead
84
to RC5O
Hole
29
Lead
134
to
RC5O
Hole
24
3.
For SP-1 Models:
1
3
5
7
11
13
15
17
19
21
23
25
27
29
4
Lead
84
a.
Insert
the
following supplied
loose
leads into
RC5O
(see Figure
3-1).
Lead
164
to
RC5O
Hole 6
Lead 501
to
RC5O
Hole 26
b.
Connect
remaining
end of
lead
164
to
terminal
7
on
relay
CR56.
c.
Connect
remaining
end
of lead
501
to
the
center
terminal
on
the
PULSER
switch
S400.
d.
Connect
supplied
loose lead
31
to
ELECTRO
SLOPE
switch
S52
(see
Figure
3-2).
Solder
re
maining
end
of lead
31
to
the
common
terminal
of
STOP
push
button
switch
PB51.
e.
Cut
existing
lead 1394
in.
(102
mm)
from
RC5O.
Disconnect
remaining
end
from
CR55
and dis
card.
Splice supplied
lead
139
to
existing
lead
139
at
RC5O
and insulate
splice.
Connect
re
maining
end
of
new
lead
139
to
S52
(see Figure
3-2).
f.
Disconnect
existing
lead
144
from
rectifier
SR3.
Slide
the
supplied
tubing
onto
lead
144.
Con
nect
the
female
terminals
from
existing
lead
144
to
the
male
terminals
on
supplied
lead 144.
Slide
tubing
over
connection.
Connect
remain
ing
end
of
lead
144
to S52
(see
Figure
3-2).
Connect
short
lead
144
to
S52
(see Figure
3-2).
g.
Connect
supplied
lead 156
to
terminal
on
SR3
where
lead
144
was
removed.
Connect
remain
ing
end
of lead
156
to
S52
(see
Figure
3-2).
h.
Connect
supplied
lead
155
to
terminal
A
on
CR56.
Connect
remaining
end
of
lead
155
to
S52
(see
Figure 3-2).
i.
Connect
supplied
lead
157
to
terminal
A
on
CR55. Connect
remaining
end
of lead
157
to
S52
(see
Figure
3-2).
.
_______
0
8100
10100
1210
14
100
16 100
18~0
20100
22
10
Leadl34
~i.24IQ0
LeadbOl
912610
Leacj83
28
Figure
3-1.
Receptacle
RC5O
TA.046
965
OM-531
Page
4

Lead
Figure
3-2. Electrical
Installation
Of
Electroslope
Switch S52
in
SP-1
MODELS
j.
Disconnect
existing
lead
32
from SR3.
Connect
the female
terminals from
existing
lead
32
to
the
male
terminals
on
supplied
lead 32.
Connect
re
maining
end
of
new
lead
32
to
terminal
B
on
CR56.
k.
Connect
supplied
lead 109
to
terminal
5
on
CR56. Connect
remaining
end
of
lead 109
to
PROGRAMMER
switch
S50
as
follows:
1.
Disconnect
existing
lead 109
from
S50.
2.
Connect
lead 109
(from
Step
1)
to
piggy
back
connector
on
new
lead 109
3.
Install
piggyback
connector
onto
S50
where lead
109
was
removed
in
Step
1.
Cut off
existing
lead
130
4
in.
(102
mm)
from
RC5O.
Unsolder
remaining
end of
existing
lead
130
from
the
FINAL
AMPERAGE
control
R50
and discard.
Solder
supplied
lead
130
to
R50
where
lead 130
was
removed.
Connect
remain
ing
end
of
new
lead
130
to
terminal
4
on
CR56.
m.
Splice
supplied
lead
158
to
existing
lead
130
at
RC5O,
and insulate
splice.
Connect
remaining
end
of
lead
158
to
terminal
12
on
CR56.
n.
Cut off
existing
lead
133
4
in.
(102
mm)
from
RC5O.
Disconnect
remaining
end of
lead
133
from
S50
and
discard.
Splice
supplied
lead
133
to
existing
lead 133
at RC5O
and
insulate
splice.
Connect
remaining
end
of
new
lead
133
to
ter
minal
3
on
CR56.
a.
Connect
supplied
lead
165
to
the terminal
on
S50
where lead 133
was
removed. Connect
re
maining
end of
lead 165
to
terminal
11
on
CR56.
p.
Cut
existing
lead
1324 in.
(102 mm)
from
RC5O.
Disconnect
remaining
end
of
lead 132
from S50
and
discard.
Splice
supplied
lead
159
to
existing
lead
132
at
RC5O
and
insulate
splice.
Connect
one
of the
remaining
ends
of
new
lead 159
to
terminal
2
on
CR56.
Connect
remaining
end of
new
lead
159
to
terminal
1
on
CR56.
q.
Connect
supplied
lead 163
to the
terminal
on
S50
where lead
132
was
removed.
Connect
re
maining
end of lead 163
to
terminal
9
on
CR56.
For
SP-3
Models
Connect
supplied
lead
501
to
terminal 2
on
CR55. Connect
remaining
end
of lead
501
to
center
terminal
of PULSER
switch
S400.
b.
Connect
supplied
lead
81
to
terminal 8
on
CR55. Connect
remaining
end of
lead
81
to
the
top
terminal
of
S400.
c.
Connect
supplied
long~lead
1
to
terminal
13
on
INITIAL
AMPERAGE
timer
TD51.
Connect
re
maining
end
of
lead
1
to ELECTROSLOPE
switch S52
(see
Figure
3-3).
Connect
short
lead
1
to
S52
(see Figure 3-3).
d.
Remove
jumper
link
between
terminals
71
and
161
on
terminal
strip
50T.
e.
Connect
supplied
lead
71
to
50T71
.
Connect
re
maining
end
of
lead
71
to
S52
(see
Figure
3-3).
f.
Connectsupplied
lead
161
to5OTl6l.Connect
remaining
end
of lead
161
to
S52
(see
Figure
3-3).
g.
Disconnect
existing
lead
155
from
terminal
3
on
CR50
and
terminal
A
on
CR56
and
discard.
Connect
supplied
lead 155
as
follows:
1.
Connect terminal
with
two
leads
to
termi
nal
A
on
CR56.
2.
Connect
shorter lead
to
terminal
3
on
CR50.
3.
Connect
remaining
lead
to S52
(see
Figure
3-3).
h.
Connect
supplied
lead
157
to
terminal
9
on
TD51.
Connect
remaining
end
of
lead 157
to
S52
(see Figure
3-3).
5.
Connect
supplied
lead
160
to
terminal
6
on
CR56.
Route
remaining
end of
lead 160
through
access
hole
in
bottom
of
Programmer
into
welding
power
source.
Rear View
Of
Switch
Top
I
V~F
-l
TA-046 963
Figure
3-3.
Electrical
Installation
Of
Electroslope
Switch
S52
in
SP-3
Models
Top
Lead
144-(Iong)
4.
a.
Rear View
Of
Switch
Lead
156
TA-046 964
Lead
155
Lead
161
H
Lead 71
t~r

4
Lead
157
Lead
1
(long)
Lead
1
(short)
OM-531
Page
5

6.
Connect
lead
42
from
the
pulser
module
to
the
threaded
mounting
spacer
for
Programmer
circuit
board
PC500.
7. Connect
lead
132
from
the
pulser
module
to
ter
minal 10
on
CR56.
8.
Reinstall
RC5O.
9.
Align
supplied
PC500
and
insert
into
RC5O.
Se
cure
PC500
to
standoffs.
10.
Thread
leads
81,
86,
and
114
from
the
pulser
module,
through
the
access
hole
in the
bottom
of
the
programmer,
and
into
the
welding
power
source.
C.
Welding
Power
Source
Electrical
Connections
For
Models
Prior
To
Serial
No.
JA432849:
a.
Splice
supplied
leads
81,
86,
114,
and
160
to
corresponding
leads
routed
into
the
welding
power
source
from the
Programmer.
b.
Connect
leads 81
and
86
to
corresponding
ter
minals
on
terminal
strip
iT
in
the
welding
power
source.
c.
Connect
lead
114
to
the
START
AMPERAGE
switch
SlO
as
follows:
1.
Disconnect
existing
lead
114
from
SlO.
2.
Reconnect
lead
114
(from
Step
1)
to
piggy
back
connector
on
new
lead
114.
3.
Install
piggyback
connector
onto
SlO
where
lead
114
was
removed
in
Step
1.
d.
Locate
edge
connector
receptacle
RC3
at
cir
cuit
board
PCi.
Insert
lead
160
into
hole
27
on
RC3.
Be
sure
that
terminal
on
lead
160
has
locked
into
RC3.
2.
For
Models
Effective
With
Serial
No.
JA432849:
a.
Discard
supplied
loose
leads
81, 86,
114,
and
160.
b.
Insert
leads
from
Programmer
into
plug
PLG3
as
follows:
Lead
81
to
Socket
8
Lead
86
to
Socket 6
Lead
114
to
Socket
5
Lead
160
to
Socket
7
3.
Tape
or
tie
new
leads
to
existing
wiring
harness.
Be
sure
that
leads
will not
touch
hot or
moving.
4.
Reinstall
the
welding
power
source
side
panels
and
Programmer
top
cover.
3-3.
REMOTE
EMERGENCY
STOP
SWITCH
CON
NECTIONS
(Switch
Not
Supplied)
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
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
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
welding
power
source
and
Programmer
front
panels.
Retain
all
hard
ware
removed
during
this
procedure
for
reinstallation.
A
remote
emergency
stop
switch
may
be
installed
into
the
Programmer.
If remote
emergency
stop
capability
is
desired,
obtain
switch
and
proceed
as
follows:
1.
For
SP-1
and
SP-2
Models:
Obtain
a
normally-
open,
momentary-contact
switch.
For
SP-3
and
SP-4
Models:
Obtain
a
normally-closed,
momen
tary-contact
switch.
2.
Remove
Programmer
top
cover.
3.
Route
leads
from
switch
through
access
hole
on
left
side
of
Programmer.
4.
Locate
terminal
strip
50T on
left
side
of
center
partition.
5.
For
SP-1
and
SP-2
Models:
Connect
leads
from
switch
to
terminals
31
and
148
on
50T.
6.
For
SP-3
and
SP-4
Models:
Remove
jumper
link
between
terminals
66
and
77
on 50T,
and
connect
switch
leads
to
50T66
and
50T77.
7.
Reinstall
Programmer
top
cover.
8.
Resume
operation.
3-4.
REMOTE
DOWNSLOPE
INITIATION
SWITCH
CONNECTIONS
(SP-3
And
SP-4
Models)
(Switch
Not
Supplied)
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
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
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker or
other
disconnect
ing
device.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
welding
power
source
and
Programmer
front
panels.
Retain
all
hard
ware
removed
during
this
procedure
for
reinstallation.
A
normally-open,
momentary-contact
switch
may
be
used
for
remote
downslope
initiation
of
the
Programmer.
.
OM-531
Page
6

This switch
may
be
manually
operated
or
may
be
a
fix
a-mounted
limit switch.
If
remote
downslope
initiation
~
desired,
obtain switch and
proceed
as
follows:
1. Remove
Programmer
top
cover.
2.
Route leads from switch
through
access
hole
in
left
rear
of
Programmer.
3. Locate terminal
strip
50T
on
left
side
of
Program
mer
rear
panel.
4.
Remove
jumper
links
between
terminals 64 and
162
on
50T.
5.
Connect
leads from
switch to
terminals
31
and
64
on
terminal
strip
50T.
6.
Reinstall
Programmer
top
cover.
7.
Resume
operation.
3-5.
REMOTE
HAND
SWITCH
CONNECTIONS
(SP-1
And
SP-2
Models)
The
supplied
remote
hand
switch,
RHS-46,
connects
to
the
remote
control
receptacle
on
the
welding
power
source.
To
make
connections,
align
keyways,
insert
plug,
and
rotate
collar
fully
clockwise.
3-6.
REMOTE START CONTROL
CONNECTIONS
(SP-3
And
SP-4)
(Switch
Not
Supplied)
A
normally-open,
momentary-contact
switch
may
be
used
for
remote start
control of
the
Programmer.
If
re
mote
start
control is
desired,
obtain
switch
and
make
connections
between
pins
A
and B of
five-pin
Amphenol
plug supplied
with
welding
power
source.
Align key-
ways,
insert
plug,
and
rotate threaded
collar
clockwise.
3-7.
TIMED
NORMALLY-OPEN
AND
NORMALLY-
CLOSED CONTACTS
(SP-3
And
SP-4
Mod
els)
(Figure
3-4)
All
timers
have
relay
contacts
available
for
control of
ex
ternal
equipment
such
as
movable fixtures.
Equipment
can
only
be
connected
to
timer
relay
contacts
that
are
not
already
in
use.
Each
timer
has
instantaneous
con
tacts
that
close
when
power
is
applied
to
the
timer,
and
0
0
0
delayed
contacts
that
close
when the
timer times
out.
Timer
terminal
functions
are as
follows:
Terminals:
1,2
&
15
Provide Power
To
Timer
14
&
10
Instantaneous
N.C.*
14
&
9
Instantaneous N.O.~
11
&
13
Delayed
NO.
12&11
DelayedN.C.
6
&
8
Instantaneous
NO.
7
&
6
Instantaneous
N.C.
5
& 4
Delayed
NC.
4
&
3
Delayed
NO.
*Normally

Closed Contacts
~NormaIIy

Open
Contacts
To make
connections
to
the
timer
relay
contacts,
pro
ceed
as
follows:
a
WARNING: ELECTRIC SHOCK
can
kill.

Do
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
of
padlock
ing
line disconnect switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other disconnect
ing
device.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator facing
the
welding
power
source
and
Programmer
front
panels.
Retain,
all
hard
ware
removed
during
this
procedure
for
reinstallation.
IMPORTANT:
Equipment
can
only
be
connected
to
re
lay
contacts
that
are
not
already
in
use.
1.
Remove
Programmer
top
cover.
2.
Route leads
from
external
equipment
through
ac
cess
hole
in
left
rear
of
Programmer.
3.
Locate
appropriate
timer
and make connections
(see
Figure
3-4).
4.
Reinstall
Programmer
top
cover.
TA.114 384
Figure
3-4.
Timer Rear
View
~STANTKKE0US
CO~~TKC~S
0
0
C)
14
13
12 11
10
9
8
7
0
0
OELKVED
COCCTKC~S
OWER SU~LV
CLOCK
1
2
3
4
5
6
15
0
16
OM-531
Page
7

SECTION
4
OPERATOR CONTROLS
4-1.
PROGRAMMER SWITCH
(Figure
4-1)
When
the
PROGRAMMER
switch is in
the
ON
position,
the
Programmer
is
energized
and
ready
to
be
pro
grammed
for
the
welding
sequence.
When
in
the
OFF
position,
the
programmer
functions
are
not
available
and
only
the
welding
power
source
controls
are
functional.
a
CAUTION:
INCORRECT
SWITCH POSITION
can
cause
equipment
damage
and
personal
injury.

Place
AUTO/MANUAL
switch
in the
MANUAL
position
when
the
PROGRAMMER
switch is
in
the OFF
position.
The
AUTO
position
causes
the
Programmer
to
automatically cycle through
the
preset
program
when
the
welding
power
source
contactor
is
closed
regardless
of
the
PROGRAMMER
switch
position.
4-2.
STARTING
THE
UNIT
(Figure
4-1)
There
are
three
ways
to
start
the
program:
1.)
START
push
button
switch
on
the
Programmer,
2.)
Remote
Hand Switch
RHS-46
connected
to
welding
power
source,
3).
remote
start
switch
connected
to
welding
power
source.
The
weld
cycle begins
when
the
START
push
button
on
the
Programmer
is
pressed.
The
START
push
button
is
also
used
to
cycle
the
Programmer
through
the various
weld
conditions.
The weld
cycle
can
be
started
by
using
momentarily
pressing
the
RHS-46. See Section
3-5 for
switch
specifi
cations
and connections.
4-3.
STOPPING
THE
UNIT
(Figure
4-1)
When
a
normal
weld
program
is
run,
the
Programmer
automatically
resets
to
OFF
at
the end
of
the
weld.
There
are
two ways
to
stop
the
unit
while
welding:
1.)
the
STOP
push
button
switch
on
the
Programmer,
and
2.)
a
remote
emergency
stop
switch
internally
connected
to
terminal
strip
iT
in
the
Programmer.
The weld
cycle
stops
and
the
unit
resets
when the
STOP
switch
on
the
Programmer
is
pressed.
The weld
cycle
can
be
stopped
using
a
remote
emer
gency
stop
switch.
See
Section
3-3
for
switch
specifica
tions
and
connections.
Programmer
Initial
Amperage
Upslope
Time
Downslope
Time
Final
Amperage
Electroslope
Switch
Control Control
Control
Control
Switch
Auto-Manual
Switch
Start
Push
Button
Stop
Push.
Button
*SMAW/GTAW
Switch
On
SP-1
And
SP-2 Modela
Upslope
And Weld
Downslope
And
Background
Amperage
Time
Final
Amperage
Time
Amperage
Control
Pulses
Per
Second
Control
Pulser Switch
% On
Time
Control
Figure
4-1.
Front
Panel Controls
.
TC-046
482
OM-531
Page
8

r
Chart
4-1.
Weld
Cycle
Timing
Automatic
Operation
Using
Electronic
Timers
POINT
FUNCTION
A
Programmer
START
button
pressed.
B
Preflow
timer
in
the
welding
power
source
be
gins
to
time.
C Preflow ends.
Welding
power
source
contactor
closes.
High frequency
available.
D Arc
started.
INITIAL
AMPERAGE
and
INITIAL
AMPERAGE
TIME
controls active.
E
Initial
amperage
time.
F
UPSLOPE
TIME
and
UPSLOPE
AND WELD
AMPERAGE
TIME
controls
active.
Pulsing
starts
if
Pulser is ON.
G
Upslope
time.
H
Weld time
starts.
Weld condition reached. Pul
ser
controls
may
be
adjusted.
I
Weld
time.
J
DOWNSLOPE
TIME
and
DOWNSLOPE
AND
FINAL
AMPERAGE
TIME
controls active.
K
Downslope
time.
TB-046
960
L FINAL
AMPERAGE
control active.
Pulsing
ends.
M
Final
amperage
time.
N
Arc
extinguished.
Postffow
timer
in
welding
power
source
begins
to
time.
0 Postflow
time.
P
Weld
sequence
ends.
Unit
resets.
POINT SEQUENCE
1.
Preflow
timer
in
the
welding
power
source
times.
Welding
power
source
contactor
closes.
High
fre
quency
available.
Arc
starts
and INITIAL
AM
PERAGE control
is active.
2.
UPSLOPE
TIME
control
active.
Pulsing
starts
if
Pulser
is
on.
Weld condition reached. Pulser
con
trols
may
be
adjusted.
3.
DOWNSLOPE
TIME
control active.
FINAL
AM
PERAGE control
active.
Pulsing
ends.
4.
Arc
extinguished.
postflow
timer
in
welding
power
source
times.
Weld
sequence
ends. Unit
resets.
4-4.
ELECTROSLOPE
(Figures
4-1
And
4-2)
(All
Models)
The
electroslope
allows
the
operator
to
preset
the
initial
weld
condition,
an
upslope
time,
a
downslope
time,
and
a
final
weld condition.
A.
ELECTROSLOPE
Switch
When
the
ELECTROSLOPE
switch
is
in
the
ON
posi
tion,
all
Programmer
controls
are
functional.
When the
switch
is
in
the
OFF
position,
the
Electroslope
controls
are
not
functional.
B.
INITIAL
AMPERAGE Control
The Initial
Amperage
circuitry
allows
the
operator
to
set
a
starting
output
that
is
above
or
below
the
setting
of
the
AMPERAGE
CONTROL
on
the
welding
power
source.
Rotating
the control
clockwise
increases
output.
The
scale
surrounding
the
INITIAL
AMPERAGE
control
rep
resents
a
percentage
of
the
welding
power
source
AM
PERAGE
CONTROL
and
not
an
actual
amperage
value.
J
Manual
Operation
Using
Remote Hand Switch
(RHS-46)
OM-531
Page
9

C. UPSLOPE
TIME
Control
The
U
PSLOPE
TIME
control
sets
the
time
it
takes for the
weld
output
to
slope
from
the
setting
of the
Programmer
INITIALAMPERAGE
control
to
the
setting
of
the
welding
power
source
AMPERAGE CONTROL.
Rotating
the
control
clockwise increases
time.
The
scale
surrounding
the
control
is calibrated
directly
in
seconds
(0
to
10).
D.
DOWNSLOPE
TIME Control
The
DOWNSLOPE
TIME
control
sets
the time
it
takes
for
the
weld
output
to
slope
from the
setting
of
the
weld
ing
power
source
AM
PERAGE
CONTROL
to
the
setting
of
the
Programmer
FINAL
AMPERAGE CONTROL.
Rotating
the
control
clockwise
increases time.
The
scale
surrounding
the
control
is calibrated
directly
in
seconds
(0
to
10).
E.
FINAL
AMPERAGE
Control
The
Final
Amperage circuitry
allows the
operator
to
set
an
output
that
is above
or
below the
setting
of
the
AM
PERAGE
CONTROL
on
the
welding
power
source
for
finishing
the
weld.
Rotating
the
control
clockwise increases
output.
The
scale
surrounding
the FINAL
AMPERAGE
control
repre
sents
a
percentage
of
the
welding
power
source
AM
PERAGE
CONTROL
and
not
an
actual
amperage
val
ue.
4-5.
REMOTE DOWNSLOPE INITIATION
SWITCH
(SP-3
And
SP-4
Models)
If
remote
control
of
downslope
initiation
is
desired,
ob
tain
and
install
switch
according
to
Section
3-4.
When
the
Remote
Downslope
Initiation Switch
is
closed,
downslope
starts.
This
allows
the
operator
to
manually
control the main
weld time.
4-6.
PULSER
(SP-2
And
SP-4
Models)
(Figures
4-1
And
4-2,
And Chart
4-1)
Pulsing
refers
to
the
alternate
raising
and
lowering
of
the
weld
output
at
a
periodic
rate.
The raised
portions
of the
weld
output
are
controlled
in
width,
frequency,
and
height,
forming
pulses
of weld
output.
These
pulses
and
the
lower
output
between
them
(called
the
background
amperage)
alternately
heat and chill
the
molten weld
puddle.
The combined
effect
gives
the
operator
better
control of
penetration,
bead
width,
crowning,
undercut
ting,
and
puddle
sag
in
out-of-position
welding,
especial
ly
vertical-up.
When
the
Electroslope
is
used
with
the
Pulser,
the
initial
and
final
output
are
not
pulsed.
Pulsing
begins
at
upsiope,
continues
through
the weld
portion
of
the
cycle,
and ends
when
downslope
is
finished.
IMPORTANT: The Pulser
controls
may
be
adjusted
while
welding.
Peak
Amperage
-


Background

I
Amperage
Li
Li
80%
On Time
-
J
20%
On Time
________Pulses
Per_________
Second
SA-112
022
Figure
4-2.
Pulsed
Output
A.
PULSER
Switch
Placing
the
PULSER
switch
in
the
ON
position
activates
the
pulsing circuitry
in
the
Programmer.
The %
ON
TIME,
PULSES
PER
SECOND,
and
BACKGROUND
AMPERAGE
controls must
be
adjusted
to
provide
the
proper
pulse
width,
frequency,
and
height.
When this
switch is
in
the OFF
position,
the
Pulser controls
are
not
functional.
B.
%
ON
TIME
Control
The
%
ON
TIME
control
provides
pulse
width selection
and is
active
only
when the
PULSER switch
is
ON.
Rotating
the
%
ON
TI
ME
control clockwise increases
the
peak
output
time
in
relation
to
the
entire
pulse
time.
The
scale
surrounding
this
control
is
calibrated
in
percent
(5
to
95)
and
represents
peak
output
on
time
during
One
pulse.
C. PULSES
PER
SECOND
Control
The
PULSES
PER
SECOND
control
provides
pulse
fre
quency
selection
and
is
active
only
when
the
PULSER
switch
is
ON.
Rotating
this
control clockwise
increases
pulse
frequen
cy.
The scale
surrounding
the
PULSES
PER
SECOND
is
calibrated
in
pulses
per
second from 0.5
to
10
PPS.
D.
BACKGROUND AMPERAGE
Control
The
BACKGROUND
AMPERAGE
control
sets
the
weld
output
background
level.
The
AMPERAGE
CONTROL
on
the
welding
power
source
sets
the
peak
output
level
during
pulsed
welding.
These
controls
act
independently;
therefore,
it
is
possi
ble to
set
a
background
amperage
higher
than
the
peak
output.
50%
On
Time
S
OM-531
Page
10

Rotating
the
control
clockwise
increases
background
amperage.
The
scale
surrounding
the
BACKGROUND
AMPERAGE
control
is
calibrated
in
percentage
and
should not
be
read
as an
amperage
value.
4-7. SEQUENCER
(SP-3
And
SP-4
Models) (Fig
ure
4-1
and
Chart
4-1)
The
Sequencer
times
the
initial
output,
starts
the
upslope
timer
in
the
Electroslope,
times
the
weld
portion
of
the
cycle,
starts
the
downslope
timer
in
the
Electro
slope,
and times
the
final
output.
To set
desired
time,
press
the
lever
directly
below each
digit.
The
levers
can
be
pressed
down
or
pushed
up.
These timers
are
factory
set
for the
time
down and
stop
mode of
operation.
IMPORTANT:
1/10
(0.1)
minute
equals
6 seconds.
1/100
(0.01)
minute
equals
0.6 seconds.
A
setting
of
2.21 minutes
equals
2
minutes
and 12.6
seconds.
A.
INITIAL
AMPERAGE
TIME
The
IN ITIAL
AMPERAGE
TI
ME
control allows
the
oper
ator
to
choose the
length
of time
that the INITIAL AM
PERAGE
control
on
the
Programmer
is
active.
The INITIAL
AMPERAGE
TIME
control
can
be
set
for
0.0099.9 seconds. When this
control times
out,
the
UPSLOPE
TIME
control
in
the
Electroslope
is
activated.
B.
UPSLOPE
AND
WELD
AMPERAGE
TIME
The
UPSLOPE
AND
WELD
AMPERAGE
TIME
control
sets
the
entire time between the
start
of
upslope
and
the
beginning
of
downslope.
To
determine
the
proper
time,
add the
setting
of
the
Electroslope
UPSLOPE
TIME
con
trol
to
the
desired weld
time. The
total time should be
set
on
the UPSLOPE
AND WELD
AMPERAGE
TIME
con
trol.
The
UPSLOPE
AND WELD
AMPERAGE TIME
control
can
be
set
for
00.099.9
minutes.
When
this
control
times
out,
the
DOWNSLOPE
TIME
control
in
the EIec
troslope
is
activated.
C.
DOWNSLOPE
AND
FINAL
AMPERAGE
TIME
The
DOWNSLOPE
AND
FINAL
AMPERAGE TIME
control
sets
the entire time
between
the
start
of
down-
slope
and
the
beginning
of
postflow.
To
determine
the
proper
time,
add the
setting
of
the
Electroslope
DOWN-
SLOPE
TIME
control
to
the
desired final
amperage
time.
The
total
time should
be
set
on
the
DOWNSLOPE
AND
FINAL
AMPERAGE TIME
control.
The
DOWNSLOPE
AND
FINAL
AMPERAGE
TIME
control
can
be
set
for 00.099.9
seconds.
When
this
control times
out,
postflow
starts.
4-8.
SMAW/GTAW
SWITCH
(SP-1
And
SP-2
Mod
els)
(Figure
4~1)
When
the
switch
is
in
the
SMAW
position,
weld
output
re
mains
at
the
level
set
for the
sequence
when
the
arc
is
broken
during
any
portion
of
the
program.
When
the switch is
in
the
GTAW
position,
weld
output
re
sets
to
the
INITIAL
AMPERAGE
control
setting
when the
arc
is
broken
during
the
weld,
downslope,
or
final
por
tions
of
the
program.
4-9.
AUTO/MANUAL
SWITCH
(SP-3
And
SP-4
Models)
(Figure 4-1)
WARNING: UNEXPECTED WELD
OUTPUT
can cause
serious
personal
injury
or
dam
age
to
weidment
or
equipment.

If
use
of the
Programmer
is
not
desired,
AL
WAYS
place
the
AUTO/MANUAL
switch
in
the
MANUAL
position.

If
in
AUTO
position, closing
the
remote
con-
factor
device
or
pressing
the
Programmer
START button
will
energize
the
welding
power
source,
and it will
NOT
deenergize
unless
one
of
the
following
is done:
1.
Place
AUTO/MANUAL
switch in
MANU
AL
position
2.
Press
STOP
button
on
Programmer
3.
Turn off
welding
power
source.
When
the switch
is
in the
AUTO
position,
the
unit
auto
matically cycles
through
all
programmed
sequences
when
the
START
push
button switch is
pressed.
Weld
output
is determined
by
the
amperage
setting
for
the
se
quence.
When the switch is
in
the
MANUAL
position,
the
program
consists
of
the
initial
condition,
upslope,
and
an
untimed
weld condition.
The
START
push
button
switch
or re
mote start
switch
must
be
maintained
closed
while
weld
ing.
4-10.
REMOTE
HAND
SWITCH
RHS-46
(SP-1
And
SP-2
Models)
(Chart
4-1)
It
is
necessary
to
press
the
Remote
Hand
Switch
RHS-46
each
time
a
new
or
different
weld
condition
is
desired. This
switch allows
the
operator
to
manually
control
the selection
of the
welding
condition
and
the du
ration
of that condition
from
a
remote
station.
a
OM-531
Page
fl

SECTION
5
SEQUENCE
OF OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
IMPROPER
AIR
FLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
internal
parts.

Do
not
touch
live
electrical
parts.

Keep
a//covers
and
panels
in
p/ace
while
op
erating.
Warranty
is
void
if
the unit is
operated
with
any
portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin,
NOISE
can
damage
hearing.

Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.

Ventilate
to
keep
from
breathing
fumes
and
gases.

If
ventilation
is
inadequate,
use
approved
breathing
device.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.

Watch for
fire.

Have fire
extinguisher
nearby,
and
know how
to
use
it.

Allow
work
and
equipment
to
cool
before
han
dling.
MAGNETIC
FIELDS
FROM
HIGH AMPER
AGES
can
affect
pacemaker
operation.

Wearers
should
consult with their
doctor be
fore
going
near
arc
welding,
gouging,
or
spot
welding
operations.
See
Section
1

Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source in
the
welding
power
source
Owners
Manual
for
basic
welding
safety
information.
5-1.
CONTROL SETUP CHECKLIST
(Tables
5-1
And
5-2)
The
following
tables
provide
the
operator
with
a
quick
checklist
approach
to
setting
switch
positions
and
con
trols
for
the
Shielded
Metal
Arc
(SMAW)
and Gas
Tung
sten
Arc
(GTAW)
Welding
processes.
Specific
control
settings depend
on
the
process
application.
IMPORTANT: See
the
we/ding
power
source
Owners
Manual
for
information
on
function
of
controls.
1.
Install and
connect
unit
according
to
Section
3
of
this
manual
and
the
welding
power
source
Own
ers
Manual.
2.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
3.
Prepare
for
welding
as
follows:
a.
Connect
work
clamp
to
clean,
bare metal
at
workpiece.
b.
Select
and obtain
proper
tungsten
electrode.
c.
Prepare
tungsten
electrode
according
to
weld
ing
power
source
Owners
Manual,
and insert
into torch.
4.
Program
the
weld
sequence
by
setting
switches
and controls
according
to
Section
5-1.
5.
Turn
on
the
shielding
gas.
6.
Place PROGRAMMER
switch in
the
ON
position.
7.
Place
welding
power
source
power
switch
in
the
ON
position.
8.
Push
Programmer
START
push
button
or
remote
switch
(see
Sections
3-5, 3-6,
and
4-2).
a.
For
GTAW
mode: The
START
push
button
switch
or
Remote
Hand
Switch
RHS-46
must
be
momentarily
closed each
time
a
new
sequence
is
desired.
b.
For
AUTO
mode:
Once
the
Start
switch
is
mo
mentarily
closed,
the unit
automatically
cycles
through
the weld
program.
c.
For MANUAL
mode:
The
Start
switch
must
be
held
closed
during
the
entire
program.
The
IN
ITIAL
AMPERAGE
TIME
and
PERCENTAGE
UPSLOPE
RATE
controls function
but the
weld
time
is
manually
controlled.
The
unit
stops
and
resets
as
soon
as
the
Start
switch
is
opened (no
downslope
or
final
conditions).
IMPORTANT:
For
SP- 1
and
SP-2
models:
If
an
arc
out
age
occurs
at
any
point
in
the
program,
the
amperage
setting
reverts
to
that
of the
INITIAL
AMPERAGE
control
for
arc
starting.
For
SP-3
and
SP-4
models:
If
an
arc
out
age
occurs
during
the
initial,
upslope,
or
weld
conditions,
the
welding
power
source
contactor
opens
and
weld
out
put
is
not
available. The
Programmer
continues
to
the
end of the
cycle
and
resets.
9. Adjust controls
as
necessary.
S
5-2.
GAS
TUNGSTEN
ARC
WELDING
(GTAW)
a
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of
entire
Section
5
before
proceeding.
S
OM-531
Page
12

Table
5-1.
Welding
Power
Source Control Checklist
Welding
Power
Source Controls SMAW GTAW
CONTACTOR
Switch OFF ON
AMPERAGE
Switch
As
Desired
As Desired
AMPERAGE CONTROL
As Desired As Desired
HIGH
FREQUENCY
Switch
OFF
As Desired
CRATER
FILL
Switch
As
Desired
OFF
AMPERAGE
Switch
As Desired OFF
AMPERAGE
Control
As Desired
Not
Apphpable
AC
BALANCE Control
As Desired As
Desired
*POST FLOW
TIME
control
0
As Desired
*SPOT
TIMER
Switch
OFF
OFF
*SPOT
TIME
Control
Not
Applicable
Not
Applicable
PRE-FLOW
TIME
Switch
OFF As
Desired
PRE-FLOW
TIME
Control
Not
Applicable
As Desired
*PULSER Switch
OFF
OFF
*%
ON
TIME
Control
Not
Applicable
Not
Applicable
PULSES
PER
SECOND Control
Not
Applicable
Not
Applicable
*BACKGROUND
AMPERAGE
Control
Not
Applicable
Not
Applicable
AC/DC
Selector
Switch
As
Desired
As Desired
RANGE
Switch
As Desired
As
Desired
POLARITY
Switch
As
Desired
As
Desired
*If
so
equipped.
Table
5-2.
Programmer
Control Checklist
Programmer
Controls SMAW
GTAW
PROGRAMMER
Switch
+ON
OFF
SMAW/GTAW
Switch
SMAW
GTAW
or
.
AUTO/MANUAL
Switch
MANUAL
As Desired
INITIAL
AMPERAGE Control
Not
Applicable
As Desired
*INITIAL
AMPERAGE
TIME
Not
Applicable
As Desired
UPSLOPE
TIME
Control
Not
Applicable
As
Desired
*UPSLOPE
AND
WELD
AMPERAGE
TIME
Not
Applicable
As
Desired
DOWN SLOPE
TIME
Control
Not
Applicable
As
Desired
*DOWNSLOPE
AND FINAL
AMPERAGE
TIME
Not
Applicable
As Desired
FINAL
AMPERAGE
Control
Not
Applicable
As Desired
*ELECTROSLOPE
Switch
OFF
ON**
*PULSER
Switch
ON
As
Desired
*%
ON
TIME
Control
As
Desired
As
Desired
*PULSES
PER
SECOND
Control
As
Desired
As Desired
BACKGROUND
AMPERAGE Switch
As
Desired
As
Desired
*lf
so
equipped.
+If
pulsing
is
desired.
If
a
remote
control
is
used,
both
the
peak
output
and
background
output
are
varied
by
the
remote
control
in
the
same
proportion
as
the
settings
of the
Programmer
BACKGROUND
AMPERAGE
control and
the
welding
power
source
AMPERAGE
CONTROL.
**If
Electroslope
is
not
used,
welding
power
source
START AMPERAGE
circuit
may
be used.
OM-531
Page
13

5-3.
SHIELDED
METAL
ARC WELDING
(SMAW)
b.
For
MANUAL
mode:
The
Start switch
must
be
a
WARNING:
Read
and
follow
safety
informa-
held closed
during
the
entire
program.
Releas
tion
at
beginning
of
entire Section
5
before
ing
the
Start
switch ends
the
program.
Pulsing
proceeding.
starts
as
soon
as
the
Start
switch
is
closed
if
pulsing
is
selected.
1.
Install
and
connect
unit
according
to Section
3
of
IMPORTANT:
If
an arc
outage
occurs,
the
welding
pow-
this
manual and the
welding
power
source
Own-
er source
contactor
remains
closed
and
weld
output
is
ers
Manual.
available
at
the
level
set
by
the
welding
power
source
AMPERAGE
CONTROL
for
restarting
the
arc.
2.
Program
the
weld
sequence
by setting
switches
and controls
according
to
Section
51.
9.
Adjust
controls
as
necessary.
3.
Place PROGRAMMER
switch
in
the
ON
position.
10.
Begin
welding.
4.
Place
the
welding
power
source
switch
in
the
ON
position.
5-4.
SHUTTING
DOWN
5.
Adjust
controls
as
necessary.
1.
Stop
welding
and allow the
Programmer
to
reset.
6.
Wear
dry
insulating
gloves
and
clothing,
and
wear
IMPORTANT:
It
maybe
necessary
to
manually cycle
the
welding
helmet
with
proper
filter lens
according
to
Programmer
to
the end
of
the
weld
program
through
use
ANSI
Z49.
1.
of
the
START
push
button switch
or
Remote Hand
Switch RHS-46.
7.
Prepare
for
welding
as
follows:
a.
Connect
work
clamp
to
clean,
bare
metal
at
2.
Place
PROGRAMMER
switch
in
OFF
position.
workpiece.
3. Place the
welding
power
source
POWER
switch
b.
Select
and obtain
proper
electrode,
and insert
in
the
OFF
position.
into
electrode holder.
4.
Turn
off
shielding
gas
at
source,
if
applicable.
8.
Push
Programmer
START
push
button
or
remote
switch
(see
Sections
3-5,
3-6,
and
4-2).
WARNING:
HIGH CONCENTRATION
OF
SHIELDING
GAS
can
harm health
or
kill.
a.
For
SMAW
mode:
Pulsing
starts
as
soon
as
the
Shut off
gas
supply
when
not
in
use.
Start
switch is
closed
if
pulsing
is
selected.
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
IMPORTANT:
Every
six
months
inspect
the labels
on
down
and
stop
mode,
and either 00.0

99.9
second
or
this unit for
legibility.
All
precautionary
labels must
be
00.0

99.9 minute
timing.
To
change
any
of
these
fea
maintained
in
a
clearly
readable
state
and
replaced
tures,
proceed
as
follows:
when
necessary.
See Parts
List for
part
number
of
pre
cautionary
labels.
1.
Fully
loosen
two
screws
on
timer
faceplate.
2.
Pull
timer
out
of
case.
This
requires
a
firm
grip.
6-1.
ELECTRONIC
TIMERS
(Figure
6-1)
3.
To
change
from 60 Hertz
to
50
Hertz,
reconnect
pin
on
left
side
of
timer
to
50
HZ
pin.
~
WARNING: ELECTRIC SHOCK
can
kill.
4.
To
change
from
the time
down
and
stop
mode,
re

Do
not
touch live
electrical
parts.
connect
pin
on
right
side
of
timer
to
desired termi
nal:
Up
&
Go,
Down
&
Go,
or
Up
&
Stop.

Shut
down
welding
power
source,
and
dis
connect
input
poweremploying
lockout/tag-
5.
To
change
time
unit,
apply
slight
pressure
with
a
ging
procedures
before
inspecting,
main-
pen
or
pencil
point
to
metal
arm
in
slotted
arc
on
taming,
or
servicing,
right
side
of
timer,
and
move
arm
to
appropriate
Lockout/tagging
procedures
consist of
pad-
unit.
locking
line disconnect switch
in
open
position,
removing
fuses from
fuse
box,
or
shutting
off
6. To
change
level
of
accuracy,
use
finger
force
to
and
red-tagging
circuit breaker
or
other
discon-
move
white
plastic
lever
located behind
timer
face
necting
device,
until decimal
point
is
at
desired level.
The electronic
timers
are
factory
set
for
either
50
or
60
7.
Reinstall
timer
into
case,
and
secure
screws
on
Hertz
operation
(depending
on
the
model),
the time
timer
faceplate.
OM-531
Page
14

50
Hertz
Pin
60
Hertz
Pin
lime
Unit
Time
Down
&
Arm
Stop
Pin
Figure
6-1.
Changing
Timer
Operations
6-2.
CIRCUIT
BOARD REPLACEMENT
PROCE
DURES
(Figure
6-2)
If
a
circuit board
is
found
to
be
faulty,
replace
board
using
the
following
procedure.
Do
not
attempt
board
repair.
Contact
the
nearest
Factory
Authorized Service Station

for
correct
replacement
part.
a
WARNING: ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shutdown
we/ding
powersource,
and
discon
nect
input
power
employing
lockouVtagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist of
padlock
ing
line
disconnect switch
in
the
open
position,
removing
fuses from
fuse
box,
or
shutting
off
and
red-tagging
circuit breaker
or
other
disconnect
ing
device.

Put
on
properly grounded
wrist
strap
BE
FORE
handling
circuit boards.

Transport
all
circuit
boards
in
proper
static-
shielding
carriers
or
packages.

Perform
work
only
at
a
static-safe
work
area.
INCORRECT
INSTALLATJON
or
misaligned
plugs
can
damage
circuit
board.

Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE PRESSURE
can
break
circuit
board.

Use
only
minimal
pressure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
unit
front
panel.
Retain
all
hardware
removed
during
this
procedure
for
reinsta//ation.
A.
Sloper
Board
PC500
Replacement
1-.
Remove
Programmer
top
cover.
2.
Locate
and examine
PC500
noting mounting
po
sition and
receptacle
location
(see
Figure
6-2).
3.
Remove
the
screws
securing
PC500 to
unit,
and
pull
PC500
from
receptacle
RC5O.
4.
Align
new
PC500
and insert
into
RC5O. Secure
PC500
using
screws
removed
in
Step
3.
5.
Reinstall
Programmer
top
cover.
B.
Pulser
Board
Replacement
1.
Remove
Programmer
top
cover.
2.
Locate
and
examine
pulser
board
noting
mount
ing
position
and
connector
locations
(see
Figure
6-2).
3.
Pull
plugs
straight
off board and allow
to
hang
free
on
wiring
harness.
4.
Remove
the
nuts and
lock washers
securing
the
board,
and
remove
board
from
standoffs.
5.
Position
new
board
so
that
connectors
are
in
same
location
as
previously
noted.
6.
Install
new
board
using
lock washers
arid
nuts
re
moved
in
Step
4.
7.
Reinstall
plugs
onto
new
board
with
keyways
aligned.
Connectors
only
go
together
completely
one
way.
8.
Reinstall
Programmer
top
cover.
I

~

...
a
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit board.
OM-531
Page
15

6-3.
TROUBLESHOOTING
(Table
6-1)
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shutdown
welding
powersource,
and
discon
nect
input
power employing
lockout/tagging
procedures
before
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
the
open
position,
removing
fusesfrom
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
HOT
SURFACES
can
cause severe
burns.

Allow
cooling
period
before
servicing.
Troubleshooting
to
be
performed
only by
quali
fied
persons.
Itis assumed that the
unit
was
properly
installec.
accord
ing
to
Section
3
of
this
manual,
the
operator
is
familiar
with the function of
controls,
the
unit
was
working
prop
erly,
and
that the
trouble
is
not
related
to
the
welding
process.
The
following
table
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles that
may
de
velop
in
this
unit.
Use
this table
in
conjunction
with the
circuit
diagram
while
performing troubleshooting procedures.
if
the
trouble
is
not
remedied after
performing
these
proce
dures,
contact
the
nearest
Factory
Authorized
Service
Station.
In
all
cases
of
equipment
malfunction,
the
manufacturers recommendations
should be
strictly
fol
lowed.
To
distinguish
between
welding
power
source
problems
and
Programmer
problems, place
PROGRAMMER
switch
in
OFF
position
and
use
welding
power
source
without
Programmer.
if
the
problem
still
exists,
refer
to
welding
power
source
Owners
Manual
or
contact
the
nearest
Factory
Authorized Service
Station.
IMPORTANT:
Before
beginning
troubleshooting
proce
dures,
recheck
al/switch
positions
and
control
settings
and
be
sure
unit is
properly
set
up
for
the
we/ding
appli
cation.
Figure
6-2.
Circuit
Board
Replacement
Ret.
TD-046 484-A
OM-531
Page
16