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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,~
OWNERS
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.
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Summary of Contents for Miller SP-1
- Page 1 Millerfi FORM: OM-531C January 1991 Effe ctive With Serial No. JK674521 MODEL: SP-1 SP-2 SP-3 S P-3-50 SP-4 P-4-50 ~OLDP,~ OWNERS MANUAL IMPORTANT: Read and understand the entire this manual contents both MILLER ELECTRIC Mfg. and the manual used with this...
- Page 2 LIMITED WARRANTY EFFECTIVE: AUGUST 1990 This MILLER warranties and is exclusive with warranty supersedes previous other implied. guarantees warranties expressed LIMITED WARRANTY Subject and conditions of MILLERs breach of terms In the any other duty warranty case hereof. MiLLER Electric Mfg.
- Page 3 SPECIFICATIONS SECTION 2-1. Description SECTION INSTALLATION Onto 3-1. Field Installation Instructions For Installing Programmer Welding Power Source 3-2. Field Installation Of Pulser Into SP-1 SP-3 Programmers 3-3. Remote Emergency Stop Switch Connections (Switch Supplied) SP-4 3-4. Remote Downslope Initiation Switch Connections...
- Page 4 Section No. Page SECTION SEQUENCE OF OPERATION Control 5-1. Setup Checklist 5-2. Tungsten Welding (GTAW) Shielded 5-3. Metal Arc Welding (SMAW) 5-4. Shutting Down SECTION MAINTENANCE & TROUBLESHOOTING 6-1. ElectronicTimers Circuit Board 6-2. Replacement Procedures 6-3. Troubleshooting SECTION ELECTRICAL DIAGRAMS Diagram 7-i.
- Page 5 SECTION SAFETY PRECAUTIONS AND SIGNAL WORDS GENERAL INFORMATION 1-1. AND SAFETY 1-2. SAFETY ALERT SYMBOL SIGNAL WORDS General following safety alert symbol signal words this manual used throughout call attention and iden Information presented in this manual and various la different levels of instructions.
- Page 6 Programmer is de compartment rear for tool and torch welding signed storage. power SP-1 is equipped with The SP-1 Electroslope. must this be accessed through lifting compart source manually advanced through welding cycle.
- Page 7 109 to lead 109 coming from 9-socket INSTALLATION PULSER INTO 3-2. FIELD PLG4. plug SP-1 AND SP-3 PROGRAMMERS (Figures 3-1 thru 3-3) Locate leads 107 at Ri. Unsolder leads from Ri. WARNING: ELECTRIC SHOCK kill. Solder lead from PLG2to Ri where...
- Page 8 RC5O Figure 3-1. Receptacle switch S52. Locate the hole to the the elec right troslope controls. Mark location onto nameplate For SP-1 Models: applying pressure from with sharp tool. rear Insert the following supplied loose leads into size in the...
- Page 9 TA-046 964 switch S52 Connect short lead (see Figure 3-3). Figure 3-2. Electrical Installation Electroslope 1 to (see Figure 3-3). Switch S52 SP-1 MODELS Remove jumper link between terminals 71 and 50T. terminal strip Disconnect existing lead 32 from SR3. Connect...
- Page 10 Locate follows: switch SlO partition. from SlO. lead Disconnect existing SP-1 and SP-2 Models: Connect leads from 50T. terminals 31 and switch piggy Reconnect lead (from Step link For SP-3 and SP-4 Models: Remove jumper lead 114.
- Page 11 REMOTE 3-5. HAND SWITCH CONNECTIONS WARNING: ELECTRIC SHOCK kill. And SP-2 (SP-1 Models) touch live electrical parts. supplied remote hand switch, RHS-46, connects Shutdown welding powersource, and discon the remote control receptacle...
- Page 12 And Weld Final Amperage Time Amperage Control % On Time Control Amperage Time Pulses Per Second Control *SMAW/GTAW Switch On SP-1 And SP-2 Modela TC-046 Figure 4-1. Front Panel Controls PROGRAMMER SWITCH 4-1. (Figure switch connected welding 4-1) remote start source, source.
- Page 13 Chart Weld Cycle Timing 4-1. Operation Automatic Using Electronic Timers Manual Operation Using Remote Hand Switch (RHS-46) TB-046 POINT FUNCTION AMPERAGE FINAL control active. Pulsing ends. Programmer START button pressed. Final time. amperage Preflow timer in the welding power source gins time.
- Page 14 UPSLOPE Control TIME The U PSLOPE TIME control sets the time takes for the weld from the of the output slope setting Programmer 50% On Time Peak INITIALAMPERAGE control to the setting of the welding Amperage AMPERAGE CONTROL. power source Background clockwise increases Rotating...
- Page 15 SMAW/GTAW SWITCH (SP-1 And SP-2 Mod 4-8. els) (Figure 4~1) SEQUENCER And SP-4 4-7. (SP-3 Models) (Fig SMAW When the switch is in the position, weld...
- Page 16 SECTION SEQUENCE OF OPERATION WARNING: ELECTRIC SHOCK kill; Install and Section connect unit according 3 of MOVING PARTS serious injury; can cause this manual and the welding power source IMPROPER AIR FLOW EXPOSURE TO ers Manual. ENVIRONMENT damage internal parts. touch live electrical Wear insulating...
- Page 17 Table Power Source Control Checklist 5-1. Welding Welding Power Source Controls SMAW GTAW CONTACTOR Switch AMPERAGE Switch As Desired As Desired AMPERAGE CONTROL As Desired As Desired HIGH FREQUENCY Switch As Desired CRATER FILL Switch As Desired AMPERAGE Switch As Desired AMPERAGE Control As Desired Apphpable...
- Page 18 SHIELDED 5-3. METAL ARC WELDING (SMAW) For MANUAL mode: The Start switch must held closed the entire program. Releas during WARNING: Read and follow safety informa- Start switch ends Pulsing program. tion beginning of entire Section before Start switch closed starts as soon as proceeding.
- Page 19 Time Down & lime Unit 60 Hertz Pin 50 Hertz Stop Changing Timer Operations Figure 6-1. CIRCUIT BOARD REPLACEMENT PROCE 6-2. IMPORTANT: directions, such left right, DURES (Figure 6-2) with facing the unit front panel. respect operator this Retain all hardware removed during procedure circuit board...
- Page 20 Ret. TD-046 484-A Circuit Board Figure 6-2. Replacement 6-3. TROUBLESHOOTING (Table 6-1) process. The following table is designed diagnose provide remedies for of the troubles that may de some WARNING: ELECTRIC SHOCK kill. velop in this unit. touch live electrical parts.
- Page 21 See welding source power source troubleshooting in~ormation. Owners Manual for Relay CR52, CR53, and/or Replace relay(s). CR55. Sloper board PC500 (SP-1 PC500 Section Replace (see 6-2). SP-2 models). minimum weld output. Welding func- Turn Programmer off and check welding...
- Page 22 SECTION ELECTRICAL DIAGRAMS EM ERG STOP PLO1 >2 >3 >~ SLOPER CIRCUII BOARD PC500 PLC~3 Circuit Diagram C-044 Circuit For SP-1 Models Diagram 7-1. Diagram OM-531 Page...
- Page 23 EMERG. STOP 50 T Circuit Diagram No. C-044 Diagram Circuit For SP-2 Models 7-2. Diagram OM-531 Page...
- Page 24 37464 REMOVE CLOSE JUMPER REMOTE 648 162 INITIATION DOWNSLOPE RMT. EMERG. S-TOP qpSoT REMOVE 57-4 CR51 1~~~ iNITIAL ELECTROSLOPE CR50 SP-4 ONLY~ OFFOI CRSO -~~j.,g~__!__.2 UPSLOPE T051 WELD CR54 CR50 PROGRA~5MER CR52 Tfi \~aJfi FINAL I1,12 1053 ~0~_I 2,7,8 r~fi~ _~162 8,13 ~fiI...
- Page 25 Dl-24--.J Li__tlbs_22 IN2_14_1 l____h14-INI SI-3EjI ~$314-S2 13-NC bla-vu GRD3 12-V1 ICsa I209EF 690._S NC-a Il-NC I1-S~ S4_6 10-sj 10-03 9-01 22-6 1N49 9-1N3 9000F Ciruit Diagram No. C-083 530 For SP-1 Model Sloper Circuit Board PC500 Circuit Diagram Diagram 7-4.
- Page 26 Ej4D-c- cscD~4J IN;i ..~JI4INl Dr2~j.~ Li_his_so IN2~I GRD3~ c i , 41 ~I2Ve SI-3Cj_-_f 13-NC bI3-v IC5~ Il-NC coo-sq ~I2-VoEr pbii-ss 0-NI 10-03 1N48 51N3 Circuit C-083 Diagram Circuit For SP-2 Model Diagram 7-5. Diagram Sloper Circuit Board PC500...
- Page 27 1C51 ]15-DZ ]14-S2 GRD.-3t V2-4 ]13- Vi NC-4C 1C52 ~!ft GRD.-5C 310-Si S4-6 ~11-S3 19Di 02-6 V27C 8VF~r 04-1 310-03 o~_j No. C-049 834-A Circuit Diagram 19IN3 1N4-8 Circuit Board PC500 For SP-3 Model Sloper Diagram Circuit Diagram 7-6.
- Page 28 Circuit Diagram No. C-049 835-A Diagram 7-7. Circuit Diagram For SP-4 Model Sloper Circuit Board PC500...
- Page 29 >506 >502 3)503 a> > 6> 7> BASE JTTER~,~3,COLLECTOR Q400&Q40l Circuit Diagram No. A-072 938 Circuit For Pulser Circuit Board Diagram 7-8. Diagram OM-531 Page...
- Page 30 SECTION PARTS LIST 28-~ 484-A TD-046 Figure 8-1. Main Assembly Quantity Model Item Dia. Part (SP-3 I Mkgs. Description sP--i SP-2 SP-4 8-1. Main Figure Assembly +008 872 COVER, top ++052 302 COVER, top 134 327 LABEL, warning general precautionary BUSHING, 004 214 snap 1-5/8...
- Page 31 Quantity Model Item Dia. Part ISP-3 f Description SP-1 SP-2 SP-4 )No. Mkgs. 8-1. Main Assembly (Continued) Figure 24VAC CR56 049 181 RELAY, 4PDT CR56 049 180 RELAY, 2OVAC 4PDT RECTIFIER, integ 30A 600V 035 704 NUT, speed 12-24 605 670...
- Page 32 C-ill Figure 8-2. Circuit Card (Sloper And Pulser Illustrated) OM-531 Page...
- Page 33 Quantity Model Dia. Part Description Mkqs. sP-i SP-2 SP-3 SP-4 Figure 8-2. Circuit Card (Fig 8-1 Item 035 845 linear 307 A51,52 008971 IC,Iinear74i A51-55 008 971 linear C50,51 000 859 CAPACITOR, elctlt 220uf 35VDC C52,53 035 832 CAPACITOR, mylar .OOi5uf 100VDC C54,55 035 839...
- Page 34 Quantity Model Dia. Part ISP~3I Description kgs. sP-i SP-2 SP-4 8-2. Circuit Card Figure (Fig 6-1 Item (Continued) 039 108 RESISTOR, CF .25W82Kohm 078429 RESISTOR, .25W lOOK ohm R67,70 030 044 RESISTOR, MF .25W 100K ohm R67,70,76,78,85,86 030 044 RESISTOR, MF .25W 100K ohm 009 391 POTENTIOMETER,...
- Page 35 Quantity -Model Item Dia. Part Description SP-2,SP-4 Mkgs. 008 508 8-3. Pulser Control (Fig 8-1 Item Figure 003 513 STRIP, mtg controls 9/64 106 625 SPACER, 1 in C l/T R422 POTENTIOMETER, 2W 1000 ohm 072 811 CIRCUIT CARD, pulser (consisting of) A400-402 linear 307 C400...
- Page 37 1992 FORM: OM-531C ERRATA SHEET After this refinements occurred. This sheet lists manual printed, equipment design exceptions to data later this manual. appearing AMENDMENT TO SECTION OPERATOR CONTROLS Amend the last Section 4-6D. PULSER (SP-2 And SP-4 Models): Background Control paragraph Amperage BACKGROUND...