Miller RPC-IP Manuel utilisateur

RPC-IP





Multiprocess W

elding

Remote Pendant Control



April 1993

f. w/Serial Number JJ487350

isit our website at

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OM-533 Page 1

SECTION 1 – INTRODUCTION

5-3/4 in.

(141 mm)

9-3/8 in.

(238 mm)

5 in.

(123 mm)

ST-109 521-A

Figure 1-1. Dimensions

1-1. GENERAL INFORMATION AND SAFETY

A. General

Information

presented in this manual and on various

bels, tags, and plates provided on this unit pertains to

equipment

design,

installation, operation, maintenance,

and

troubleshooting which should be read,

understood,

and

followed for the safe and ef

fective use of this equip

ment.

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

installed, operated, and maintained only by qualified

persons

in accordance with

this manual and all applica

ble

codes such as, but not limited to, those listed in Arc

Welding

Safety Precautions Section in the welding pow

er source Owner’s Manual.

Safety

instructions specifically pertaining to this unit ap

pear throughout this manual highlighted by the signal

words

WARNING

and

CAUTION

which identify dif

ferent

levels of hazard.

WARNING statements include installation, operation,

and maintenance procedures or practices which if not

carefully

followed could result in serious personal injury

or loss of life.

CAUTION statements include installation, operation,

and maintenance procedures or practices which if not

carefully

followed could result in minor personal injury or

damage to this equipment.

third signal word,

IMPORTANT

, highlights instructions

which

need special emphasis to obtain the most ef

ficient

operation of this equipment.

1-2. RECEIVING-HANDLING

Before

unpacking equipment,

check carton for any dam

age that may have occurred during shipment. File any

claims for loss or damage with the delivering carrier.

Assistance for filing or settling claims may be obtained

from the distributor and/or the equipment manufactur-

er’s Transportation Department.

When requesting information about this equipment, al-

ways

provide the Model Description and Serial Number

1-3.

DESCRIPTION

This

unit is a Remote Pendant Control for the Intellipulse

welding

power source. When properly connected to

the

welding

power source this unit provides arc control, con

tactor

control, voltage/amperage control, CV/CC selec

tion, and pulse frequency selection.

OM-533 Page 2

SECTION 2 – INSTALLATION

elding Power

Source Remote

Control Receptacle

RPC-IP

Receptacle

ST-109 782-B

Figure 2-1. Power Source/Remote Control Connections

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Shut down welding power source, and be

sure it cannot be accidentally energized before

making remote Pendant Control connections.

•

Place CONTACTOR switch in OFF position.

2-1. WELDING POWER SOURCE REMOTE CON-

TROL

RECEPT

ACLE CONNECTIONS (Figure 2-1)

The Remote Pendant Control connects to a 17-socket

Amphenol

receptacle on the welding power source

front

panel

(see OM-286). Insert 17-pin Amphenol plug

from

the interconnecting cable fully into the receptacle and

rotate collar clockwise.

2-2. RPC-IP RECEPTACLE CONNECTIONS

(Figure 2-1)

The interconnecting cable from the welding power

source connects to a 17-pin Amphenol receptacle on

the

remote control. Insert the 17-socket plug from the

terconnecting

cable fully into the receptacle, and rotate

collar clockwise.

2-3. 650/1000 AMPERE MODEL SELECTOR

SWITCH

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Shut down welding power source, and dis-

connect the Remote Pendant Control before

changing position of dip switches.

ELECTROSTATIC DISCHARGE (ESD) can

damage circuit boards.

•

Put on properly grounded wrist strap BE-

FORE handling circuit boards.

•

Perform

work only at a static-safe work area.

This Remote Pendant Control is designed to be used

with either a 650 or 1000 ampere intellipulse welding

power source. A dip switch is located on circuit board

PC5

to set up the Remote Pendant Control for operation

with 650 or 1000 ampere models. The unit is shipped

from

the factory set up for

operation with the 650 ampere

models.

Proceed as follows to set up the Remote Pen

dant Control for operation with 1000 ampere models:

1. Remove cover.

2. Place

both dip switches in the down position for op

eration with 1000 ampere models. Place both dip

switches in up position for operation with 650 am-

pere models (see Figure 2-2).

3. Reinstall cover.

OM-533 Page 3

ST-113 509-A

Mounting

Screws (5)

Front

Panel

Cover

Dip

Switch

Circuit

Board

PC5

Both dip switches down for

1000 ampere model operation

Both dip switches up for

650 ampere model operation

Figure 2-2. Dip Switch Positions And Locations

SECTION 3 – OPERATOR CONTROLS

3-1. MODE

SELECT

OR SWITCH (Figure 3-1)

The Mode Selector switch allows selection of CC

(constant

current), CV (constant voltage),

or pulsed out

put from the welding power source.

The

CC position provides a constant current output spe

cifically designed for Shielded Metal Arc (SMAW) and

Gas

ungsten Arc (GT

W) W

elding processes. The CC

position

is also normally used for Air Carbon Arc Cutting

(CAC-A) and gouging processes.

The

CV position provides a constant voltage output de

signed

for wire feeding applications such as Gas Metal

Arc (GMAW), Flux Cored Arc (FCAW), or Submerged

Arc

(SA

W) Welding.

When

pulsed output is desired for Gas Metal Arc W

eld-

ing

- Pulsed Arc (GMA

-P), place switch at the desired

number of pulses per second: 60, 90, 120 or 180.

3-2. ARC

CONTROL AND PILOT LIGHT

(Figure 3-1)

IMPORTANT:

The ARC CONTROL potentiometer and

pilot

light are disabled in the CV (Constant V

oltage) and

pulsed modes.

The ARC CONTROL potentiometer provides variable

selection of short-circuit current to suit individual weld-

ing conditions. Rotating this control clockwise causes

the current to increase as the short-circuit condition is

approached. When this control is set at some value

above 0, the current begins to increase when arc volt-

age drops below 20 volts.

When the control is set at 10 (MAX.), the short-circuit

current

is considerably

higher than normal welding cur

rent (see welding power source volt-ampere curve for

mode). This provides extra current for arc starting in

out-of-position

welds as well as for certain types of elec

trodes.

When

the control is set at 0 (SOFT), short-circuit current

is the same as normal welding current. The 0 position

provides

current characteristics associated

with the Gas

Tungsten Arc Welding (GTAW) process.

When the control is set at 5, short-circuit current is

approximately

half that of the 10 (MAX.) position but still

higher

than normal welding current. The 5 position pro

vides a moderate current increase for arc starting nec-

essary

for certain types of electrodes and

applications.

Select a setting best suited for the application.

The Arc Control pilot light turns on when the Mode Se-

lector

switch is in the CC position indicating that the ARC

CONTROL is active.

IMPORTANT:

The ARC CONTROL can be adjusted

while welding.

OM-533 Page 4

ST-109 521-A

Voltmeter

Ammeter

Volts/Peak

Control And

Pilot Light

Amps/Bkgd

Control And

Pilot Light

Mode

Selector

Switch

Ammeter

Switch

Arc

Control

Arc Control

Pilot Light

Contactor

Switch

Figure 3-1. Front Panel View

3-3. CONTACTOR SWITCH (Figure 3-1)

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

not touch the weld output terminals when

the contactor is energized.

•

Do not touch electrode holder (or gun wire)

and work clamp at the same time.

the Remote

Control CONT

ACT

OR switch is in the ON

position,

open-circuit voltage will be present at the out

put terminals whenever the welding power source

POWER switch ON button is depressed.

IMPORTANT:

Although the term CONT

ACT

OR is used

the nameplate and throughout this manual, the

weld

output is not switched on or off by a physical secondary

contactor;

rather

, the weld output is controlled by

solid-

state circuitry in the welding power source.

contactor control by means of

a wire feeder is desired,

place the Remote Control CONTACTOR switch in the

OFF

position. Open-circuit voltage will be present at the

weld output terminals whenever the gun switch is

closed.

The

OFF position is normally used with all wire feeding

processes (GMAW, GMAW-P, FCAW, SAW) and the

Gas Tungsten Arc Welding (GTAW) process. The ON

position is normally used with the Shielded Metal Arc

Welding

(SMA

W) and the Air Carbon Arc (CAC-A)

Cut

ting and gouging processes.

Lift end of toggle switch to change switch positions.

3-4. AMMETER SWITCH (Figure 3-1)

The AMMETER switch provides selection of reading

PEAK weld amperage or Average (AVG) weld amper-

age on the Remote Control digital ammeter.

Normally the AVG switch position is used for reading

weld amperage during Gas Metal Arc (GMAW), Flux

Cored Arc (FCAW), Submerged Arc (SAW), Shielded

Metal

Arc (SMA

W), Gas T

ungsten Arc (GT

W) W

elding

and Air Carbon Arc (CAC-A) Cutting and gouging pro-

cesses.

While

welding using the Gas

Metal Arc W

elding - Pulsed

Arc (GMA

-P) process, the A

VG switch position is

used

when display of the average (background and peak)

weld amperage is desired. The AMMETER switch can

be placed in the PEAK position when display of peak

weld amperage is desired.

3-5. AMPS/BKGD CONTROL AND PILOT LIGHT

(Figure 3-1)

This

control presets weld amperage for constant current

applications and background amperage for GMAW-P

applications.

When

the Mode Selector switch is in the

CC position or

one of the pulses per second positions, the AMPS/

BKGD pilot light turns on.

This

control is disabled

when the Mode Selector switch

is in the CV position.

Rotating the control clockwise increases amperage.

IMPORTANT:

The AMPS/BKGD control can be ad-

justed while welding.

OM-533 Page 5

3-6. VOLTS/PEAK CONTROL AND PILOT LIGHT

(Figure 3-1)

This control presets weld voltage for constant voltage

applications and peak voltage for GMAW-P applica-

tions.

When

the Mode Selector switch is in the

CV position or

one of the pulses per second positions, the VOLTS/

PEAK pilot light turns on.

This

control is disabled

when the Mode Selector switch

is in the CC position.

Rotating the control clockwise increases voltage.

IMPORTANT:

The VOLTS/PEAK control can be ad-

justed while welding.

3-7. METERS (Figure 3-1)

The

voltmeter displays weld

voltage to the nearest tenth

of a volt while welding and preset voltage when unit is

idling.

When welding using the pulsed GMA

W process,

the meter displays peak voltage.

The ammeter displays weld amperage to the nearest

ampere

while welding and preset amperage

when unit is

idling.

When welding using the pulsed GMA

W process,

the meter displays background amperage.

SECTION 4 – SEQUENCE OF OPERATION

WARNING: ELECTRIC SHOCK can kill;

MOVING PARTS can cause serious injury;

IMPROPER AIR FLOW AND EXPOSURE TO

ENVIRONMENT can damage internal parts.

•

Keep

all covers and panels in place while

erating.

Warranty is void if the welding power source 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.

•

Use enough ventilation to keep fumes and

gases from the breathing zone.

WELDING WIRE can cause puncture

wounds.

•

not point gun toward any part of the body

or other personnel.

HOT METAL, SPATTER, AND SLAG can

cause fire and burns.

•

Watch for fire.

•

Have a fire extinguisher nearby and know

how to use it.

MAGNETIC

FIELDS

FROM HIGH CURRENTS

can affect pacemaker operation.

•

Wearers should consult with their doctor be-

fore going near arc welding, gouging, or spot

welding operations.

See

Arc W

elding Safety Precautions Section in

the welding power source Owner’s Manual.

4-1. GAS METAL ARC WELDING - PULSED ARC

(GMAW-P)

WARNING:

Read and follow safety informa

tion at beginning of entire Section 4 before

proceeding.

1. Install

and prepare welding power source according

to its Owner’s Manual.

2. Install Remote Control as instructed in Section 2.

3. Install

and prepare wire feeder according to its Own

er’s Manual.

4. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

5. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select and obtain proper welding wire, and

thread as instructed in wire feeder Owner’s

Manual.

6. Depress

welding power source POWER switch

button.

7. Place Mode Selector switch to desired pulses per

second (60, 90, 120, or 180) position (see Section

3-1).

8. Place CONTACTOR switch in OFF position (see

Section 3-3).

9. Place

AMMETER switch in the desired position (see

Section 3-4).

10. Preset

AMPS/BKGD control to desired

background

amperage setting (see Section 3-5). Pilot light

should be on.

OM-533 Page 6

11. Preset VOLTS/PEAK control to desired peak volt-

age setting (see Section 3-6). Pilot light should be

on.

12. Make adjustments to wire feeder.

13. Turn on shielding gas supply.

14. Begin welding.

4-2. GAS METAL ARC AND FLUX CORED ARC

WELDING (GMAW AND FCAW)

WARNING:

Read and follow safety informa

tion at beginning of entire Section 4 before

proceeding.

1. Install

and prepare welding power source according

to its Owner’s Manual.

2. Install Remote Control as instructed in Section 2.

3. Install

and prepare wire feeder according to its Own

er’s Manual.

4. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

5. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select and obtain proper welding wire, and

thread as instructed in wire feeder Owner’s

Manual.

6. Depress

welding power source POWER switch

button.

7. Place Mode Selector switch in CV position (see

Section 3-1).

8. Place CONTACTOR switch in OFF position (see

Section 3-3).

9. Place

AMMETER switch in A

VG (A

verage) position

(see Section 3-4).

10. Preset VOLTS/PEAK control to desired weld volt-

age setting (see Section 3-6). Pilot light should be

on.

11. Make adjustments to wire feeder.

12. Turn on shielding gas supply if applicable.

13. Begin welding.

4-3. SHIELDED METAL ARC WELDING (SMAW)

WARNING:

Read and follow safety informa

tion at beginning of entire Section 4 before

proceeding.

1. Install

and prepare welding power source according

to its Owner’s Manual.

2. Install Remote Control as instructed in Section 2.

3. Depress

welding power source POWER switch

button.

4. Place Mode Selector switch in CC position (see

Section 3-1).

5. Place

ARC CONTROL to desired position (see

Sec

tion 3-2). Pilot light should be on.

6. Place CONTACTOR switch in ON position (see

Section 3-3).

7. Place

AMMETER switch in A

VG (A

verage) position

(see Section 3-4).

8. Preset

AMPS/BKGD

control to desired weld amper

age setting (see Section 3-5). Pilot light should be

on.

9. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

10. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select and obtain proper electrode, and insert

into electrode holder.

11. Begin welding.

4-4.

SUBMERGED ARC WELDING (SA

WARNING:

Read and follow safety informa

tion at beginning of entire Section 4 before

proceeding.

1. Install

and prepare welding power source according

to its Owner’s Manual.

2. Install Remote Control as instructed in Section 2.

3. Install

flux system according to its Owner

’

s Manual.

4. Install

and prepare wire feeder according to its Own

er’s Manual.

5. Wear dry insulating gloves and clothing, and wear

safety

goggles with correct filter shade according to

ANSI Z49.1.

6. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select and obtain proper welding wire, and

thread as instructed in wire feeder Owner’s

Manual.

c. Select and obtain proper flux, and put into flux

system.

7. Depress

welding power source POWER switch

button.

8. Place Mode Selector switch in CV position (see

Section 3-1).

9. Place CONTACTOR switch in OFF position (see

Section 3-3).

10. Place

AMMETER switch in A

VG (A

verage) position

(see Section 3-4).

11. Preset VOLTS/PEAK control to desired weld volt-

age setting (see Section 3-6). Pilot light should be

on.

OM-533 Page 7

12. Make adjustments to wire feeder.

13. Turn on flux supply system.

14. Begin welding.

4-5. GAS TUNGSTEN ARC WELDING (GTAW)

WARNING:

Read and follow safety informa

tion at beginning of entire Section 4 before

proceeding.

1. Install

and prepare welding power source according

to its Owner’s Manual.

2. Install Remote Control as instructed in Section 2.

3. Install

and prepare High-Frequency unit according

to its Owner’s Manual if applicable. Scratch start

GTAW

does not require the use of external high fre

quency.

4. Depress

welding power source POWER switch

button.

5. Place Mode Selector switch in CC position (see

Section 3-1).

6. Set

ARC

CONTROL to MIN. (see Section 3-2). Pilot

light should be on.

7. Place CONTACTOR switch in ON position (see

Section 3-3).

8. Place

AMMETER switch in A

VG (A

verage) position

(see Section 3-4).

9. Preset

AMPS/BKGD

control to desired weld amper

age setting (see Section 3-5). Pilot light should be

on.

10. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

11. 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.

12. Turn on shielding gas and water supplies as appli-

cable.

13. Turn on and adjust High-Frequency unit if applica-

ble.

14. Begin welding.

4-6. AIR CARBON ARC CUTTING AND GOUGING

(CAC-A)

WARNING:

Read and follow safety informa

tion at beginning of entire Section 4 before

proceeding.

1. Install

and prepare welding power source according

to its Owner’s Manual.

2. Install Remote Control as instructed in Section 2.

3. Connect compressed air supply.

4. Depress

welding power source POWER switch

button.

5. Place Mode Selector switch in CC position (see

Section 3-1).

6. Set ARC CONTROL to desired position (see Sec-

tion 3-2). Pilot light should be on.

7. Place CONTACTOR switch in ON position (see

Section 3-3).

8. Place

AMMETER switch in A

VG (A

verage) position

(see Section 3-4).

9. Preset AMPS/BKGD control to desired amperage

setting (see Section 3-5). Pilot light should be on.

10. Wear dry insulating gloves and clothing, and wear

welding helmet with proper filter lens according to

ANSI Z49.1.

11. Prepare for welding as follows:

a. Connect work clamp to clean, bare metal at

workpiece.

b. Select

and obtain proper carbon electrode,

and

insert into torch.

12. Turn on air supply.

13. Begin cutting/gouging process.

4-7. SHUTTING DOWN

1. Stop welding.

2. Depress

the welding power source POWER switch

OFF button.

3. Turn

f the shielding gas and water supplies if appli

cable.

WARNING: HIGH CONCENTRATION OF

SHIELDING GASES can harm health or kill.

•

Shut off gas supply when not in use.

4. Turn

f flux

supply and compressed air supply if ap

plicable.

OM-533 Page 8

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1. MAINTENANCE

Usage

and shop conditions will determine the frequency

and

type of maintenance. Inspect equipment as follows:

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Shut down welding power source, and dis-

connect

remote control before inspecting, main

taining, or servicing unit. Power to the remote

control

should be disconnected before

attempt

ing repair or replacement of internal compo-

nents.

1. Inspect interconnecting cord for damage to or

breaks in the insulation jacket, particularly at the

plugs. Repair or replace cord as necessary.

2. Remove

grease

and grime from components; mois

ture from electrical parts and cable.

5-2. TROUBLESHOOTING

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Shut down welding power source, and dis-

connect

remote control before inspecting, main

taining, or servicing unit. Power to the remote

control

should be disconnected before

attempt

ing repair or replacement of internal compo-

nents.

CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

•

Put on properly grounded wrist strap BE-

FORE handling circuit boards.

•

Transport circuit boards in proper static-

shielding carriers or packages.

•

Perform

work only at a static-safe work area.

INCORRECT INSTALLATION 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.

A. General

It is assumed that proper installation has been made,

according

Section 2 of this manual, and that the unit

has been functioning properly until trouble developed.

B. Troubleshooting

Troubleshooting to be performed only by qualified per-

sons.

The following information is supplied to diagnose and

provide

remedies for some of the troubles that may

velop

this unit. Check welding power source Owner

’s

Manual

for possible problems caused

by welding power

source malfunctions.

Use this information in conjunction with the circuit dia-

gram while performing troubleshooting procedures. If

the trouble is not remedied after performing these pro-

cedures, the nearest Factory Authorized Service Sta-

tion/Service Distribuitor should be contacted. In all

cases of equipment malfunction, the manufacturer’s

recommendations should be strictly followed.

Problems with this unit fall into four categories:

1. Front panel components

2. Circuit board PC5

3. Interconnecting cable

4. Welding power source.

If everything on the remote control functions except a

particular

switch, meter

, or control, the problem can be

attributed to a broken component. Replace the broken

component.

the problem is still present,

replace PC5. If the remote

control

is entirely non-functional, replace

PC5. If erratic

conditions occur and the welding power source was

working properly, replace PC5.

break in the

interconnecting cable can interrupt power

command signal between welding power source

and

remote

control. Replace interconnecting cable

if lack of

continuity is suspected.

Printed circuit board PC1 in the welding power source

sends

and receives signals from the remote control. If

all

other components of the system are functioning, re-

place welding power source PC1 according to instruc-

tions in welding power source Owner’s Manual.

OM-533 Page 9

SECTION 6 – ELECTRICAL DIAGRAMS

Circuit Diagram No. SB-107 993-B

Diagram 6-1. Circuit Diagram For Pendant Control

Circuit Diagram No. SB-124 223

Diagram 6-2. Circuit Diagram For Circuit Board PC5

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