Miller KB000000 Owner's manual

October

1991

FORM:

OM-096

983

MODEL:

RHC-3CBI

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

CHICAGO

BRIDGE

&

IRON

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.

SA-141

127

PPINTED

N

Li

SA.

OM-096

983

091

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

rating

label

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

1-3.

Description

1

SECTION

2INSTALLATION

2-1.

Location

1

2-2.

Interconnections

1

SECTION

3OPERATOR

CONTROLS

2

SECTION

4

MAINTENANCE

2

SECTION

5-

ELECTRICAL

DIAGRAMS

Diagram

5-1.

Circuit

Diagram

For

RHC-3CBI

2

LIST

OF

CHARTS

AND

TABLES

Table

2-1.

Cord

Conductor

Length

And

Size

1

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.

1-2.

SAFETY

ALERT

SYMBOL

AND

SIGNAL

WORDS

The

following

safety

alert

symbol

and

signal

words

are

used

throughoutthis

manual

to

call

attention

to

and

iden

tify

different

levels

of

hazard

and

special

instructions.

a

This

safety

alert

symbol

is

used

with

the

signal

words

WARNING

and

CAUTION

to

call

atten

tion

to

the

safety

statements.

a

WARNING

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

seri

ous

personal

injury

or

loss

of

life.

a

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.

1-3.

DESCRIPTION

This

Remote

Hand

Control

is

designed

for

use

as

a

re

mote

amperage

control

in

conjunction

with

a

welding

power

source.

SECTION

2

INSTALLATION

2-1.

LOCATION

A.

For

Models

Supplied

With

2

ft.

(.6

m)

Intercon

necting

Cord

The

Remote

Hand

Control

may

be

equipped

with

a

2

ft.

(.6

m)

interconnecting

cord

to

connectthe

Remote

Hand

Control

to

the

welding

power

source.

B.

For

Models

Not

Supplied

With

Interconnecting

Cord

(Table

2-1)

If

Remote

Hand

Control

is

shipped

without

an

intercon

necting

cord,

obtain

a

multi-conductor

(3

leads

mini

mum),

interconnecting

cord

to

connect

the

Remote

Hand

Control

to

the

welding

power

source.

See

Table

2-1

for

cord

conductor

size

according

to

the

desired

length.

The

Remote

Hand

Control

can

be

wall

mounted

or

placed

on

a

stand

at

the

work

area.

Table

2-1.

Cord

Conductor

Length

And

Size

Cord

Length

Conductor

Size*

Up

to

20ft

(6

m)

2lto5Oft(6tol5m)

51

to

lOOft(16to31

m)

101

to

200ft

(31

to

61

m)

No.

16

No.14

No.12

No.

10

*AwGAmerican

Wire

Guage

2-2.

INTERCONNECTIONS

1.

For

models

equipped

with

an

interconnecting

cord,

fully

insert

twistlock

plug

attached

to

cord

into

Remote

Amperage

Control

receptacle

on

the

welding

power

source.

Turn

plug

fully

clockwise

to

secure

connection.

2.

For

models

shipped

without

interconnecting

cord,

proceed

with

Steps

3

thru

7.

3.

Remove

wrapper

from

control.

4.

Route

3-conductor

cord

through

the

strain

relief

on

the

control

base.

5.

See

Diagram

5-1

for

proper

lead

connections

to

the

rheostat

and

supplied

3-prong

twistlock

plug.

6.

Tighten

the

strain

relief,

and

reinstall

wrapper.

7.

To

connect

control

to

power

source,

fully

insert

twistlock

plug

attached

to

cord

into

Remote

Am

perage

Control

Receptacle

on

the

welding

power

source.

Turn

plug

fully

clockwise

to

secure

con

nection.

OM-096

983

Page

1

SECTION

3

OPERATOR

CONTROLS

The

welding

power

source-Amperage

Adjustment

Con-

control

from

the

minimum

to

the

maximum

output

of

the

trot

is

inoperative

when

this

Remote

Hand

Control

is

welding

power

source.

The

Remote

Hand

Control

dial

is

connected

to

the

welding

power

source

control

circuitry.

calibrated

in

percentage

in

increments

often

from

0

to

The

Remote

Hand

Control

provides

complete

amperage

100

percent.

SECTION

4-

MAINTENANCE

a

WARNING:

ELECTRIC

SHOCK

can

kill;

HOT

SURFACES

can

cause

severe

burns,



Do

not

touch

live

electrical

parts.

strain

relief

connector

on

the

Remote

Hand

Control

base.

Repair

or

replace

the

cord

if

insulation

breaks

are

present.



Disconnect

plugs

from

power

source

before

Daily

rotate

the

Remote

Hand

Control

knob

from

the

0

to

inspecting

or

servicing.

100

percent

position.

This

procedure

will

prevent

oxida



Allow

unit

to

cool

before

servicing.

tion

from

forming

on

the

contacts,

which

could

insulate

the

contacts

from

the

brush,

causing

the

control

to

be

comeinoperative.

RefertoTable2-1

forpropercordcon

Once

a

month

inspect

the

Remote

Hand

Control

cord

for

ductor

size

and

to

Diagram

5-1

for

proper

cord

conductor

breaks

in

insulation

particularly

at

the

plug

and

at

the

connections.

SECTION

5-

ELE

CTRICAL

DIAGRAMS

No.

3

Black

Diagram

5-1.

Circuit

Diagram

For

RHC-3CBI

No.

3

C

x

Black

S

0633

Remote

Control

Rheostat

Back

View

OM-096

983

Page

2

Part

No.

Description

Quantity

RHC-3CBI

Control,

Hand

Remote

BE

SURE

TO

PROVIDE

MODEL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

040574

041

550

.030666

RHEOSTAT,

WW300Wl5ohm

1

.605797

. .

PLUG,

twlk3P3W2OA

125V

1

148

723

.

KNOB,

pointer

1 1

148

719

.

PLATE,

indicator

amperage

1 1

021

474

. .

CASE

SECTION,

base/front/rear

1 1



.

021

475



.

WRAPPER,

(consisting

of)

1



.

019 677



..

HANDLE,

door

pull

1

010

659

. .

CONNECTOR,

clamp

cable

.375

1

600

795

.

CORD,

port

No.

12

3/c

(order

by

ft)

2ft

OM~096

983

Page

3

October

1991

FORM:

OM-096

983

MODEL:

RHC-3CBI

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

CHICAGO

B

RIDGE

&

IRON

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.

SA-141

127

PRINTED

IN

U.S.A.

OM.096

983~

10/91

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

rating

label

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

1-3.

Description

1

SECTION

2INSTALLATION

2-1.

Location

1

2-2.

Interconnections

1

SECTION

3OPERATOR

CONTROLS

2

SECTION

4

MAINTENANCE

2

SECTION

5-

ELECTRICAL

DIAGRAMS

Diagram

5-1.

Circuit

Diagram

For

RHC-3CBI

2

LIST

OF

CHARTS

AND

TABLES

Table

2-1.

Cord

Conductor

Length

And

Size

1

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.

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

hazard

and

special

instructions.

a

This

safety

alert

symbol

is

used

with

the

signal

words

WARNING

and

CAUTION

to

call

atten

tion

to

the

safety

statements.

a

WARNING

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

seri

ous

personal

injury

or

loss

of

life.

4~

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.

1-3.

DESCRIPTION

This

Remote

Hand

Control

is

designed

for

use

as

a

re

mote

amperage

control

in

conjunction

with

a

welding

power

source.

SECTION

2

INSTALLATION

2-1.

LOCATION

A.

For

Models

Supplied

With

2

ft.

(.6

m)

Intercon

necting

Cord

The

Remote

Hand

Control

may

be

equipped

with

a

2

ft.

(.6

m)

interconnecting

cord

to

connect

the

Remote

Hand

Control

to

the

welding

power

source.

B.

For

Models

Not

Supplied

With

Interconnecting

Cord

(Table

2-1)

If

Remote Hand

Control

is

shipped

without

an

intercon

necting

cord,

obtain

a

multi-conductor

(3

leads

mini

mum),

interconnecting

cord

to

connect

the

Remote

Hand

Control

to

the

welding

power

source.

See

Table

2-1

for

cord

conductor

size

according

to

the

desired

length.

The

Remote

Hand

Control

can

be

wall

mounted

or

placed

on

a

stand

at

the

work

area.

Table

2-1.

Cord

Conductor

Length

And

Size

Cord

Length

Conductor

Size*

Upto2Oft(6m)

21

to

50ft

(6

to

15

m)

51

tolO0ft(16to31

m)

101

to

200ff

(31

to

61

m)

No.16

No.

14

No.12

No.

10

*AwGAmerican

Wire

Guage

2-2.

INTERCONNECTIONS

1.

For

models

equipped

with

an

interconnecting

cord,

fully

insert

twistlock

plug

attached

to

cord

into

Remote

Amperage

Control

receptacle

on

the

welding

power

source.

Turn

plug

fully

clockwise

to

secure

connection.

2.

For

models

shipped

without

interconnecting

cord,

proceed

with

Steps

3

thru

7.

3.

Remove

wrapper

from

control.

4.

Route

3-conductor

cord

through

the

strain

relief

on

the

control

base.

5.

See

Diagram

5-1

for

proper

lead

connections

to

the

rheostat

and

supplied

3-prong

twistlock

plug.

6.

Tighten

the

strain

relief,

and

reinstall

wrapper.

7.

To

connect

control

to

power

source,

fully

insert

twistlock

plug

attached

to

cord

into

Remote

Am

perage

Control

Receptacle

on

the

welding

power

source.

Turn

plug

fully

clockwise

to

secure

con

nection.

OM-096

983

Page

1

SECTION

3

OPERATOR

CONTROLS

The

welding

power

source

Amperage

Adjustment

Con-

control

from

the

minimum

to

the

maximum

output

of

the

trol

is

inoperative

when

this

Remote

Hand

Control

is

welding

power

source.

The

Remote

Hand

Control

dial

is

connected

to

the

welding

power

source

control

circuitry.

calibrated

in

percentage

in

increments

of

ten

from

0

to

The

Remote

Hand

Control

provides

complete

amperage

100

percent.

SECTION

4

MAINTENANCE

a

WARNING:

ELECTRIC

SHOCK

can

kill;

HOT

SURFACES

can

cause

severe

burns,



Do

not

touch

live

electrical

parts.

strain

relief

connector

on

the

Remote

Hand

Control

base.

Repair

or

replace

the

cord

if

insulation

breaks

are

present.



Disconnect

plugs

from

power

source

before

inspecting

or

servicing.

Daily

rotate

the

Remote

Hand

Control

knob

from

the

0

to

100

percent

position.

This

procedure

will

prevent

oxida



Allow

unit

to

cool

before

servicing.

tion

from

forming

on

the

contacts,

which

could

insulate

the

contacts

from

the

brush,

causing

the

control

to

be

come

inoperative.

Refer

to

Table

2-1

for

proper

cord

con-

Once

a

month

inspect

the

Remote

Hand

Control

cord

for

ductor

size

and

to

Diagram

5-1

for

proper

cord

conductor

breaks

in

insulation

particularly

at

the

plug

and

at

the

connections.

SECTION

5

ELE

CTRICAL

DIAGRAMS

No.

3

Black

Remote

control

Rheostat

Diagram

5-1.

Circuit

Diagram

For

RHC-3CBI

No.

3

C

x

Black

S0633

Rheostat

Back

View

OM-096

983

Page

2

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