June
1981
FORM:
OM-551A
hullER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON
WI
54912
USA
Effective
With
Serial
No.
HJ201583
MODEL
ELECTROSLOPE
3
OWN
ERî‚’S
MANUAL
PRINTED
IN
U.S.A
LIMITED
WARRANTY
EFFECTIVE:
JUNE
1.
1979
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY-Subject
to
the
terms
and
conditions
As
a
matter
of
general
policy
Only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
(î‚‘
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millerî‚’s
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
rarity
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millerî‚’s
option
(11
repair
or
(21
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
t
engines,
trade
accessories
and
other
items
are
sold
sublect
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
?
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase,
return
of
the
goods
at
Customerî‚’s
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
~î‚‘
Except
as
specified
below,
Millerî‚’s
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to.be
followed.
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
~
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WAR~NTY,
GUARANTY
OR
REPRESENTA-
~
wire
including
nozzles
and
nozzle
insulators
where
failure
does
lION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
f~
MIGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment
to
the
original
user:
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
~,
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
(
6.
Batteries
6
months
WELDING
EOUIPMENT
AND
NOT
FOR
CONSUMERS
OR
~
CONSUMER
USE.
MILLERî‚’
WARRANTIES
DO
NOT
EXTEND
~
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
~
of
the
date
of
such
failure.
MILLERî‚’S
WARRANTIES
TO,
ANY
CONSUMER.
~.
~.
~
~
ERRATA
SHEET
After
this
manual
was
printed,
refinements
In
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
3î‚—OPERATiON
Amend
Figure
3-3.
Circuit
Diagram
5fl~
0
0
0 0
0
0
0 0
0
0
536
535
579
565
566
567
568
589
52T
0
0
0
0
0
0
0
536
535
578
577
560
570
Circuit
Diagram
No.
A-123
179
DOWN
SLOPE
FINAL
RATE
CURRENT
Figure
3-3.
Circuit
Diagram
Add
Figure
3-4.
Circuit
Diagram
For
Circuit
Board
PCi
Circuit
Diagram
No.
A-123
180
Figure
3-4.
CIrcuit
Diagram
For
Circuit
Board
PCi
Dia.
Part
Replaced
**
Mkgs.
No.
With
Description
Quantity
4-
019666
097922
KNOB
4
4-
R90
030
984
085
778
POTENTIOMETER,
WW
1
turn
3
watt
100
ohm
1
**First
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-551A
Page
2
SECTION
1
-
INTRODUCTION
Model
Input
Voltage
AC
For
Control
Currents
Starting
Current
Adjustable
Upsiope
Rate
Adjustable
Downslope
Rate
Adjustable
Final
Current
Adjustable
Weight
Overall
Dimensions
Electroslope
3
30V
u
to
5
i~m
~
p
Mm
to
Weld
*2..20
Sec.
*2..2o
Sec
Weld
to
Mm.
28
lbs.
8-1/2î‚”
High
7-1
/2î‚”
Wide
12-1/4î‚”
Long
*These
figures
are
approximate
and
may
vary
due
to
the
welding
power
source
characteristics
and
settings.
Figure
1-1.
Specifications
1-1.
GENERAL
-
This
manual
has
been
prepared
especially
for
use
in
familiarizing
personnel
with
the
design,
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment.
All
information
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1-2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
-
The
Electroslope
series
elec
tronic
slope
controls
are
designed
for
use
with
an
elec
trically
controlled
welding
power
source
which
has
a
30
volt
ac
control
voltage.
They
can
be
factory
installed
on
new
machines
or
shipped
as
separate
units
for
field
in
stallation.
By
proper
adjustment
of
the
controls,
a
gradual
increase
of
current
can
be
obtained
at
the
beginning
of
a
weld,
and
a
gradual
decrease
at
the
end
of
a
weld,
sometimes
referred
to
as
cratering
out.
The
Electroslope
can
be
furnished
with
10
turn
dials
in
place
of
any
or
all
of
the
standard
1
turn
dials
where
desirable
for
increased
accuracy
of
settings.
1-4.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front
of
the
welding
power
source
or
welding
generator
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
folloing
definitions
apply
to
NOTE
blocks
found
in
this
manual:
iî‚’i~l~
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2
-
INSTALLATION
2-1.
LOCATION
(Figure
2-1)
-
The
Electroslope
Unit
can
be
mounted
on
the
welding
power
source
or
used
remotely.
For
field
installation
refer
to
Field
Installation
Instructions
shipped
with
Electroslope
U
flits.
TA-040
258-1
2-2.
ELECTROSLOPE
TO
WELDING
POWER
SOURCE
CONNECTIONS
(Figure
2-2)
-
A
wire
bun
dle
containing
the
necessary
leads
to
connect
the
welding
power
source
to
the
Electroslope
extend
out
of
the
rear
panel
of
the
welding
power
source.
If
the
elec
troslope
was
not
factory
mounted
and
connected,
mount
in
a
suitable
place
and
connect
the
numbered
leads
of
the
wire
bundle
to
the
terminal
block
on
the
rear
of
the
electroslope
as
shown
in
Figure
2-2.
2-3.
UPSLOPE
&
DOWNSLOPE
SWITCHES
(Figure
2-2)
-
Two
normally-open
momentary-contact
switches
or
one
double
momentary
switch
with
center
off
may
be
used
for
controlling
the
upslope
and
downslope
of
welding
current
on
the
Electroslope
3.
Connect
a
momentary
contact
switch
across
terminals
566
and
567
on
the
Electroslope
for
UPSLOPE
control.
Figure
2-1.
Dimensional
Drawing
OM-551
Page
1
S36
~
0
INPUT
____________
30
VA.C
OUTPUT
A.C.
~
0
TO
CONTROL
CIR
579~
~O
0
S
565
~O
0
RELAY
ESET
I
CLOSE
TO
i
566î‚—
0
0
I
INITIATE
F
IU~S~O~E
î‚‘-567...
~
0
0
I
CLOSE
TO
_____________
0
IINITIATE
___________
z.
z
î‚‘
568
Qo
0
-
~oo
-
~oO
GRD
I~5R9..
~
0
0
î‚°I
Figure
2-2.
Electroslope
Connections
Connect
a
momentary
contact
switch
across
terminals
566
and
568
on
the
Electroslope
for
DOWNSLOPE
Control.
When
the
Electroslope
3
is
attached
to
a
welding
power
source
with
a
sequence
control
the
upslope
and
downslope
switches
are
not
required
because
upslope
and
downslope
is
initiated
automatically
by
the
se
quence
control.
SECTION
3-
OPERATION
3-1.
ELECTROSLOPE
ON-OFF
SWITCH
-
All
welding
power
sources
that
have
a
factory
installed
Electroslopes
are
equipped
with
an
Electroslope
ON
OFF
switch.
On
most
welding
power
sources
this
switch
is
located
on
the
front
panel
or
nameplate.
When
the
Electroslope
ON-OFF
switch
is
in
the
OFF
position,
the
Electroslope
will
be
bypassed
or
out
of
the
welding
power
source
control
circuit.
When
the
Elec
troslope
ON-OFF
switch
is
in
the
ON
position,
the
Elec
troslope
will
be
connected
into
the
welding
power
source
control
circuit.
3-2.
STARTING
CURRENT CONTROL
(Figure
3-1)
-
Adjust
the
STARTING
CURRENT
control
for
the
approximate
starting
current
desired.
Due
to
the
characteristics
of
the
welding
power
source
control
cir
cuit,
this
control
is
not
linear
and
its
settings
must
be
adjusted
by
trial
and
error.
The
STARTING
CURRENT
control
will
vary
the
current
from
minimum
of
the
cur
rent
range
used,
to
the
setting
of
the
Weld
Current
con
trol
on
the
welding
power
source.
Figure
3-1.
Upslope
Controls
TA-013
045
For
example:
If
the
Range
switch
is
set
for
a
range
of
100
to
500
amperes
and
the
Weld
Current
control
is
set
for
300
amperes,
the
setting
of
the
STARTING
CUR
RENT
control
on
the
Electroslope
will
then
determine
the
starting
current
between
100
and
300
amperes.
If
the
STARTING
CURRENT
control
is
set
at
50,
pre-heat
current
will
rise
to
approximately
200
amperes
and
re
main
at
this
amperage
until
the
UPSLOPE
switch
is
energized.
The
starting
current
can
never
be
higher
than
the
setting
of
the
Weld
Current
control
on
the
welding
power
source.
3-3.
UPSLOPE
RATE
CONTROL
(Figure
3-1)
-
The
UPSLOPE
RATE
control
is
calibrated
in
percent
and
can
be
adjusted
for
an
upslope
rate
of
approximately
2
to
20
seconds.
With
the
control
set
at
minimum
starting
cur
rent
will
rise
immediately
to
weld
current
setting
of
the
welding
power
source
Weld
Current
control.
When
the
UPSLOPE
RATE
control
is
set
at
50,
it
takes
approx
imately
10
seconds
for
starting
current
to
reach
welding
current
provided
the
difference
between
starting
cur
rent
and
weld
current
is
great
enough.
By
increasing
the
control
setting
to
100,
the
upsiope
rate
will
be
approx
imately
20
seconds.
3-4.
DOWNSLOPE
RATE
CONTROL
(Figure
3-2)
-
The
DOWNSLOPE
RATE
control
is
calibrated
in
percent
and
can
be
adjusted
for
a
downslope
rate
of
ap
proximately
2
to
20
seconds.
The
settings
of
this
con
trol
are
comparable
to
the
UPSLOPE
RATE
control
and
determines
the
time
rate
at
which
weld
current
will
decrease
to
the
setting
of
the
FINAL
CURRENT
control
or
post
heat
level.
DOWN
SLOPE
CONTROLS
20.-
IT_//
o~
/
î‚‘_~~
+
-IT
\
90
/~0I0T
(~S\
~
î‚•~
~
~
2T-
I0î‚’~
0/
T~
+
~o
~
90
9,~oo
DOWN
SLOPE
RATE
FINAL
CURRENT
Figure
3-2.
Downslope
Controls
TA-013
045
3-5.
FINAL
CURRENT
CONTROL
(Figure
3-2)
-
The
FINAL
CURRENT
control
controls
the
welding
current
at
the
finish
of
the
weld
and
operates
on
the
same
principle
as
the
STARTING
CURRENT
control.
The
finish
current
cannot
be
higher
than
the
setting
of
the
Weld
Current
control
on
the
welding
power
source.
UP
SLOPE
CONTROLS
TO
00
I
/
~
70
30
î‚“
î‚“
10
-1~
20;
+
:00
00;
+
:80
SO
~,
~
00
0
~
90
0/
~~soo
~
~~oo
STARTING
CURRENT
UP
SLOPE
RATE
Page
2
3-6.
COMPUTING
UPSLOPE
&
DOWNSLOPE
SETTINGS
Iiî‚’i.~1i~
This
formula
will
not
give
an
exact
setting
due
to
the
we/ding
power
source
particular
characteristics
and
various
amperage
settings
but
it
will
give
an
approx
imate
figure
as
to
where
the
dials
should
be
positioned.
If,
for
example,
it
is
desired
to
start
heating
the
material
with
100
amps
and
slope
up
to
250
amps
in
8
seconds.
At
the
end
of
the
weld
it
is
desired
to
slope
down
from
weld
to
a
final
current
of
75
amps
in
10
seconds.
The
Starting
Current
control
is
not
linear.
Therefore,
its
setting
must
be
determined
by
trial
and
error.
However,
once
the
setting
has
been
established
it
is
possible
to
obtain
the
Upslope
Rate
control
setting
to
obtain
8
seconds.
Assuming
that
the
Starting
Current
control
has
to
be
set
at
20
to
obtain
a
starting
current
of
100
amps,
this
for
mula
can
be
used
to
obtain
the
Upslope
Rate
control
setting:
In
order
to
obtain
the
Downslope
Rate
control
setting,
the
Final
Current
control
setting
must
be
know.
Since
it
is
known
that
a
Starting
Current
control
setting
of
20
gave
100
amps,
the
Final
Current
setting
can
next
be
obtained
using
this
formula:
Final
Current
Setting
=
(Starting
Current
Setting)
Final
Current
-
Mm.
Current
of
Range
Starting
Current
-
Mi
Current
of
Range
Final
Current
Setting
(20)
75
-
50
=20
x
25=
10
100-50
50
The
Downslope
Rate
Control
setting
can
be
found
from
this
formula:
Downslope
Rate
Setting
=
Time
in
seconds
x
500
For
Example:
100
-
Final
Current
Setting
589j
ORD.
Figure
3-3.
Circuit
Diagram
Circuit
Diagram
No.
CA-040
258-iC
Upsiope
Rate
Setting
=
Time
in
seconds
x
500
100
-
Starting
Current
Setting
=
8x50050
100-20
If
the
answer
exceeds
100,
then
either
the
time
desired
is
too
long
or
the
starting
current
is
too
high.
Downslope
Rate
Setting
=
lOx
500
100-
10
=
5000
56
90
If
this
answer
exceeds
100,
then
the
downslope
time
desired
is
too
long
or
the
Final
Current
is
too
high.
VOLTAGE
SENSING
~Et
î‚—
RELAY
~
t/SLOPE
tW.
CONTACTOR
INTERLOCK.~-~
u~-o
COLLECTOR
B
BASE
EeC
EMITTER
TRANSISTOR
LEAD
END
VIEW
SiT
0536
0535
0579
0565
o
566
0567
0568
o
0589
EXIT
FROM
P.C.
BOARD
OM-551
Page
3
Dia.
Part
Mkgs.
No.
Description
Quantity
MA5O,T50
036
706
AMPLIFIER,
magnetic
(consisting
of)
1
52T
038
832
.
BLOCK,
terminal
20
amp
9
pole
1
R81,87
030
109
POTENTIOMETER,
ceramic
1
turn2
watt
5000
ohm
2
R83,89
030
840
POTENTIOMETER,
ceramic
1
turn
2
watt
250
ohm
2
019
666
KNOB,Jine-indicator
4
S50
603
941
SWITCH,
SPDT
1
SR51
037
744
RECTIFIER,
selenium
1
103
753
BRACKET,
mounting
-
rectifier
1
51
T
038
782
BLOCK,
terminal
20
amp
10
pole
1
014
332
COVER,
block-terminal
1
038 209
CIRCUIT
BOARD
ASSEMBLY
(consisting
of)
1
C56
031
656
.
CAPACITOR,
electrolytic
1000
uf
50
volts
dc
1
C57,58
031
651
.
CAPACITOR,
tantalum
68
uf
20
voltsdc
2
CR50
039 346
.
RELAY,
enclosed
24
volts
dc
DPDT
1
CR51
004
855
.
RELAY,
enclosed
24
volts
dc
4PDT
1
D52
037
735
.
DIODE,
zenerlOvolts
l0watt
1
D53,59-62
026 202
.
DIODE,
1
amp
400
volts
straight
polarity
5
Q58-60
037
200
.
TRANSISTOR,
200
MA4O
volts
NPN
3
Q61
037
201
.
TRANSISTOR.
200
MA4O
volts
PNP
1
R76
030 763
.
RESISTOR,
WW
fixed
5
watt
2
ohm
1
R77
030 630
.
RESISTOR,
WWfixedll
watt
100
ohm
1
R78,85
030
712
.
RESISTOR,
carbon
1
watt
1000
ohm
2
R79,84
030 800
.
POTENTIOMETER,
WW
15
turn
0.5
watt
200
ohm
2
R80,88
030
802
.
RESISTOR,
carbon
1
watt
22
ohm
2
R82
030 983
.
POTENTIOMETER,
WW
1
turn
2
watt
50
ohm
1
R86
030
008
.
POTENTIOMETER,
cermet
l5turn0.75
watt
5000
ohm
1
R90
030
984
.
POTENTIOMETER,
WW1
turn2watt75
ohm
1
104058
.HEATSINK
1
010243
TUBING,nylon.l5OlDxl/4ODx3/8
4
015712
GROMMET,
rubber5/81D7/8hoIel/l6groove
1
103597
WRAPPER
1
059
341
PANEL,
front
1
059
342
PANEL,
rear
1
059
339
BASE
1
Optional
Equipment
R81,87
030
793
POTENTIOMETER,WWl0turn2watt5000ohm
2
R83,89
030
792
POTENTIOMETER,
WW
10
turn
2
watt
250
ohm
2
019 678
HELIPOT,
beckman
duo
dials
RB
4
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page
4
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