Specifications

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
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3