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HK000000

Miller HK000000, RCDW-3A Owner's manual

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May
1988
FORM:
OM-858
/T~
Millerfi
MODEL
RCDW-3A
F~LE
COPY
~~gTUR~
~
FO~
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entirs
contents
of
both
this
MN1&
Electric
Mfg.Co.
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
In-
pa.
Box
1079
stalling,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
Appleton.
WI
54912
USA
Tel.
414-7349821
safe
operation
of
weldIng
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
PffiNTEO
IN
U.S.A.
*acmo.~Pt
mmci
~
wire
EFFECTIVE:
FEBRUARY
19,
1985
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi-
In
the
ca
of
MMs
breech
of
warranty
or
any
other
duty
dons
hereof.
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
with
respect
to
the
quakty
of
any
goods,
the
exclusive
rTbediu
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
the
ureshal
be.
at
Miers
option
(1)
repesror
(2)
replacement
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
or,
where
authorized
ii
writing
by
MM
ri
approp.~sto
ceses,
(3)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
the
reasonable
cost
of
repw
or
replacement
at
an
authorized
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
MM
service
sestion
or
(4)
peyetent
of
or
credit
for
the
purcl~e
accessories
or
other
items
manufactured
by
others.
Such
price
(lees
.
de1jrec~edon
besed
upon
actuef.use)
upon
engine.,
trade
accessories
and
other items
are
sold
subject
to
return
of
the
goods
at
Customers
risk
and
~
MILLER.
the
warranties
of
their
respective
manufacturers,
it
any.
All
option
of
reps,
or
replecuwuid
wlU
be
FOB..
Factory,
at
engines
are
warranted
by
their
manufacturer
for
one
year
from
Appleton,
Wlscor~in,
or
F.O.B.,
at
a
MILLER
authorized
service
date
of
original
purchase,
except
Tecumseh
engines
which
fa~ty,
therefore
no
conp~i~..Iion
for
Iransportation
cost.
of
have
a
two
year
warranty,
any
kind
wB
be
allowed.
Upon
rece~t
of
notice
of
~p&D,it
defect
or
failure,
MM
shell
instiuct
the
claimant
on
the
warranty
Except
as
specified
below,
Millers
warranty
does
not
apply
claim
procedures
to
be
fdllowed,~
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
wire
including
nozzles
and
nozzle
insulators
where
failure
does
ANY
IMPUED
WARRANTY,
GUARANTY
OR
REPRESBITA
not
result
from
defect
in
workmanship
or
materiel.
liON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
MIGHT
ARISE
BY
IMPUCA11ON,
OPERA11ON
OF
LAW,
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
within
the
following
periods
from
the
date
of
delIvery
of
Equip-
ANY
IMPUED
WARRANTY
OF
MERCHANTABILITY
OR
OF
~
merit
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE
WITH
RESPECT
TO
7j
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
1.
A,cwaldem,
p~rsouives,
rcbc~
and
~
.
1
~
CWDED
AND
DISCLAIMED
BY
MILLER.
2.
Loedbanks
lyeer
3.
Original
main
power
rectifiers
3
years
flebor
-1
year
only)
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
4.
All
welding
guns,
feeder/guns
and
torches
90
days
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
5.
All
other
Millermatic
Feeders
1
yesr
ULTIMATE
PURCHASE
BY
COMMERCIALIINDUSTRIAL
6.
Replacement
or
repair
part.,
exclusive
of
labor
..
60
days
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
7.
Batteries
6
months
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
provided
that
Miller
is
notified
In
writing
within
thirty
(30)
days
CONSUMER
USE.
MILLERS
WARRANTiES
00
NOT
~C1ThD
of
the
date
of
such
failure.
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
9CTEND
As
a
msttsr
of
~
p~y
~rtiy,
P.jM
may
~no~
dabse
MILLERS
WARRANTiES
TO,
ANY
CONSUMER.
a~,.uiu~d
by
the
original
ussr
within
the
fwe~u~kig
periods
SECTION
1
INTRODUCTION
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
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
RCDW-3A
is
a
remote
control
which
provides
a
separate
welding
condition
on
each
of
two
electrode
wires
using
a
dual
control/feeder
or
two
single
control/feeders
and
a
DELTAWELD
power
source.
This
unit
is
equipped
with
contactors
to
provide
cold
wire
(electrically
deenergized)
conditions
on
the
inactive
gun
when
both
guns
are
connected
for
the
same
polarity.
Interconnecting
terminals
on
the
remote
control
allow
different
polarity
connections.
It
is
designed
specifically
for
use
with
the
Gas
Metal-Arc
Welding
(GMAW)
and
Flux
Cored-Arc
Welding
(FCAW)
processes.
IMPORTANT
____________
This
unit
is
designed
to
be used
with
one
gun
active
at
a
time.
1
-
4.
SAFETY
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front
of
the
welding
powe~source
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,
IMPOR
TANT,
and
NOTE
blocks
found
throughout
this
manual:
CAUTION
___________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
personnel.
IMPORTANT:
Under
this
heading,
installation,
operating,,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equipment.
S
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2
INSTALLATION
___________
Before
making
electrical
connections
necessary
for
the
proper
operation
of
the
remote
con
trol,
ensure
that
the
welding
power
source
and
con
trol/feeder
are
both
deenergized.
IMPORTANT
Duel
control/feeders
are
shipped
from
the
factory
wired
for
use
with
one
welding
power
source.
In
order
for
the
remote
control
to
function
pro
perly,
the
dual
control/feeder
must
be
modified
to
operate
as
if
two
we/ding
power
sources
are
in
use.
See
the
control/feeder
Owners
Manual
for
contactor
con
trol
modification
instructions.
Damage
to
equipment
will
result
if
the
dual
con-
trol/feeder
is
wired
for
use
with
one
we/ding
power
wurce
and
used
when
the
system
is
connected
with
one
gun
straight
polarity
and
the
other
gun
reverse
polarity.
S
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
remote
control
front
panel.
S
If
using
two
single
control/feeders
in
p/ace
of
the
duel,
control/feeder
models,
rep/ace
all
reference
to
Left
gun
and
Left
control/feeder
with
control/feeder
A,
and
Right
gun
and
Right
control/feeder
with
con
trol/feeder
8.
2-
1.
SECONDARY
CONNECTIONS
(FIgure
3-1)
Condition
A
and B
interconnecting
terminals
are
CAUTION
located
on
the
left
side
panel
of
the
remote
control.
These
terminals
provide
a
connection
point
between
the
welding
power
source
and
the
control/feeder(s).
Before
making
connection
to
the
remote
control
interconnec
ting
terminals
select
the
welding
condition
desired
on
each
electrode
wire.
Refer
to
the
welding
power
source
Owners
Manual
for
proper
secondary
cable
sizes.
S
Interconnecting
weld
cab/es
are
supplied
with
boom
mounted
dual
control/feeders
only.
These
cables
extend
out
the
back
of
the
boom.
The
cable
connecting
the
Left
gun
is
labeled
LEFT;
the
cable
connecting
the
Right
gun
is
not
labeled.
All
bench
mounted
control/feeders
require
customer
supplied
interconnecting
cables.
On
dual
control/feeder
models
these cables
must
be
connected
to
the
ap
propriate
gun
weld
cable
at
the
drive
assembly.
On
single
control/feeder
models
the
interconnecting
cables
must
be
connected
to
the
weld
cable
terminals
on
the
control/feeder
bases.
(See
the
appropriate
con
trol/feeder
Owners
Manual.)
When
using
two
single
control/feeders,
the
con
trol/feeder
connected
to
remote
control
Condition
A
Contactor
Control
receptacle
is
designated
con
trol/feeder
A.
The
control/feeder
connected
to
remote
control
Condition
B
Contactor
Control
receptacle
is
designated
control/feeder
B.
OM-858
Peg.
1
NOTE:
Both
guns
can
be
connected
for
straight
polarity
by
reversing
the
secondary
cables
at
the
welding
power
source
Output
terminals.
Right
Gun
Interconnecting
Cable
TB-047
911
FIgure
2-1.
Both
Guns
Reverse
Polarity
1.
Both
Guns
Reverse
Polarity
(Figure
2-1)
S
Both
guns
can
be
connected
for
straight
polarity
by
reversing
the
secondaiy
cables
at
the
welding
power
source
output
terminals
(see
Figure
2-1).
a.
Connect
a
secondary
cable
from
welding
power
source
POSITIVE
(or
POSITIVE
With
Slope,
if
applicable)
output
terminal
to
remote
control
Condition
A
input
terminal.
b.
Connect
a
jumper
cable
between
remote
control
Condition
A
and
B
input
terminals.
c.
Connect
the
interconnecting
cable
from
the
Left
gun
(or
control/feeder
A)
to
remote
control
Con
dition
A
output
terminal.
d.
Connect
the
interconnecting
cable
from
the
Right
gun
(or
control/feeder
B)
to
remote
con
trol
Condition
B
output
terminal.
e.
Connect
the
work
cable
to
welding
power
source
NEGATIVE
output
terminal.
2.
Both
Guns
Reverse
Polarity
Using
Two
Positive
Output
Terminals
(If
Applicable)
(Figure
2-2)
S
The
secondary
cables
can
be
reversed
at
the
welding
power
source
POSITIVE
WITH
SLOPE
and
POSITIVE
output
terminals
to
obtain
reverse
polarity
positive
output
with
slope
on
the
Right
gun
and
reverse
polarity
positive
output
on
the
Left
gun
(see
Figure
2-2)
a.
Connect
a
secondary
cable
from
welding
power
source
POSITIVE
WITH
SLOPE
output
terminal
to
remote
control
Condition
A
input
terminal.
S
b.
Connect
a
secondary
cable
from
welding
power
source
POSITIVE
output
terminal
to
remote
con
trol
Condition
B
input
terminal.
c.
Connect
the
interconnecting
cable
from
the
Left
gun
(or
control/feeder
A)
to
remote
control
Con
dition
A
output
terminal.
d.
Connect
the
interconnecting
cable
from
the
Right
gun
(or
control/feeder
B)
to
remote
con
trol
Condition
B
output
terminal.
e.
Connect
the
workcable
to
welding
power
source
NEGATIVE
output
terminal.
3.
Left
Gun
Reverse/Right
Gun
Straight
Polarity
(Figure
2-3).
CAUTION:
Both
electrode
wires
will
be
electrically
energized
when
either
gun
trigger
is
depressed.
The
electrode
wire
in
the
Left
gun
is
positive
while
the
elec
trode
wire
in
the
Right
gun
is
negative;
therefore
a
potential
path
exists
between
the
electrode
wires
if
the
guns
are
brought
into
close
proximity.
0n
units
with
two
positive
output
terminals,
both
guns
can
be
con.
Deltaweld
Power
Source
nected
for
reverse
polarity
from
either
positive
output
terminal.
RCDw-3A
Positive
Weld
Output
Cable
Work
Drive
Assembly
OM-858
Page
2
Diltawild
Power
Source
NOTE:
Secondary
cables
can
be
reversed
at
the
welding
power
source
POSITIVE
WITH
SLOPE
and
POSITIVE
output
terminals
to
obtain
reverse
polarity
positive
output
with
slope
on
the
Right
gun
and
reverse
polarity
positive
out
put
on
the
Left
gun.
RIght
Gun
Intsrconn.ctlng
CabIs
Drive
Au.mbly
B)
TB-047911
FIgure
2-2.
Both
Guns
Reverse
Polarity
Using
Two
Positive
Output
Terminals
NOTE:
Secondary
cables
can
be
reversed
at
the
wilding
power
source
output
terminals
to
obtain
straight
polarity
on
the
Left
gun
and
reverse
polarity
on
the
Right
gun.
N.gatIve
W.Id
Output
Cabi.
I.
On
units
with
two
posltlv.
output
t.rmln.Ie.
ths
reverse
polarity
con
n.ctlon
can
be
made
from
the
POSmVE
WITH
SLOPE
output
ter
minal.
r~\
~L...
Pave
Wild
Output
Cable
I?
\
Right
Gun
Lift
Gun
\~nterconn.ctlng
interconnectIng
Cable
Figure
2-3.
Left
Gun
Reverse/Right
Gun
Straight
Polarity
RCDW-3A
Positive
W.ld
Output
Cables
Work
Cabls
DeItaw.ld
Power
Sourci
Posltlvs
With
PosItIve
Slop.
Negative
__
Assembly
Left
(CondItion
A)
Gun
I
I
Right
r~~s
Gun
(Condition
B)
Work
Work
CabI.
15.047911
OM-858
Page
3
I
Secondary
cables
can
be
reversed
at
the
we/ding
power
source
output
terrnina/s
to
obtain
straight
polarity
on
the
Left
gun
and
reverse
polarity
on
the
Right
gun.
a.
Connect
a
secondary
cable
from
welding
power
source
NEGATIVE
output
terminal
to
remote
control
Condition
A
input
terminal.
b.
Connect
a
secondary
cable
from
welding
power
source
POSITIVE
WITH
SLOPE
(or
POSITIVE)
output
terminal
to
remote
control
Condition
B in
put
terminal.
c.
Connect
the
interconnecting
cable
from
the
Left
gun
(or
control/feeder
A)
to
remote
control
Con
dition
B
input
terminal.
d.
Connect
the
interconnecting
cable
from
the
Right
gun
(or
control/feeder
B)
to
remote
con
trol
Condition
A
input
terminal.
e.
Connect
the
work
cable
to
remote
control
Condi
tion
B
output
terminal.
f.
Connect
a
jumper
cable
between
Condition
A
and
B
output
terminals.
2
-2.
REMOTE
VOLTAGE
CONTROL
CONNEC
TIONS
(Figure
3-1)
The
Voltage
Control
plug
pro
vides
a
connection
point
between
the
Remote
VOLTAGE
INCREASE
Controls
and
the
welding
power
source
voltage
adjustment
circuitry.
Align
the
keyway
on
the
5-pin
plug
from
the
remote
control
with
the
key
on
the
welding
power
source
Voltage
Control
recep
tacle;
insert
plug
and
rotate
threaded
collar
clockwise.
I
Place
the
welding
power
source
Voltage
Con
trol
switch
in
the
REMOTE
position.
2-3.
REMOTE
CONTACTOR
CONTROL
CONNEC
TIONS
(Figure
3-11
The
Contactor
Control
plug
provides
a
connection
point
between
the
remote
control
and
the
welding
power
source
contactor
control
cir
cuitry.
Insert
the
two-pole
twistlock
plug
from
the
remote
control
fully
into
the
welding
power
source
Con
tactor
Control
receptacle
and
rotate
the
plug
clockwise.
IMPORTANT
____________
Place
the
welding
power
source
Con
tactor
Control
switch
in
the
REMOTE
position.
Arcing
will
occur
in
the
contactors
in
the
remote
control
k~
this
is
not
complied
with.
2-4.
115
VAC
CONNECTIONS
(FIgure
3-1)
The
115
VAC
plug
provides
a
connection
point
to
supply
115
volts
ac
to
the
remote
control
from
the
welding
power
source.
Insert
the
three-pole
twistlock
plug
from
the
remote
control
fully
into
the
welding
power
source
115
VAC
receptacle
and
rotate
the
plug
clockwise.
2-5.
CONTROL/FEEDER
REMOTE
CONTACTOR
CONTROL
CONNECTIONS
(Figure
3-1)
I
Two
10
ft.
contactor
control
cables
are
sup
plied
with
Dual
Control/Feeder
Models
for
making
con
tactor
control
connections,
If
two
control/feeders
are
used,
it
is
recommended
that
16/2
conductor
cable
be
used
for
the
contactor
control
cable
with
a
two-prong
male
plug.
(These
parts
may
or
may
not
be
supplied
depending
on
the
model.)
A.
.~Left
Control/Feeder
The
remote
control
Condition
A
Contactor
Con
trol
receptacle
provides
a
connection
point
be
tween
the
Left
control/feeder
(or
control/feeder
A)
and
the
remote
control.
Insert
the
two-pole
twistlock
plug
from
the
Left
control
fully
into
the
Condition
A
Contactor
Control
receptacle
and
rotate
the
plug
clockwise.
B.
Right
Control/Feeder
2
-
6.
TIONS
The
remote
conii~ol
Condition
B
Contactor
Con
trol
receptacle
provides
a
connection
point
bet
ween
the
Right
control/feeder
(or
control/feeder
B)
and
the
remote
control.
Insert
the
two-pole
twistlock
plug
from
the
Right
control
fully
into
the
Condition
B
Contactor
Control
receptacle
and
rotate
the
plug
clockwise.
CONTROL/FEEDER
115
VAC
CONNEC
~The
remote
control
is
shipped
connected
to
supply
115
volts
ac
for
the
operation
of
a
dual
con
trol/feeder.
When
using
two
control/feeders,
connect
the
jumper
link
on
terminal
strip
1
T
across
terminals
B
and
C.
Terminal
stnp
1
Tis
located
on
the
upper
left
por
tion
of
the
back
panel
inside
the
remote
control.
A.
Dual
Control/Feeder
A
The
remote
control
Condition
A
115
VAC
recep
tacle
provides
a
connection
point
to
supply
115
volts
ac
for
operation
of
a
dual
control/feeder.
Insert
the
three-pole
twistlock
plug
from
the
dual
control/feeder
fully
into
the
Condition
A
115
VAC
receptacle
and
rotate
the
plug
clockwise.
B.
Two
Control/Feeders
The
remote
control
Condition
A
and
B
115
VAC
receptacles
provide
connection
points
to
supply
115
volts
ac
to
Control/Feeder
A
and
Con-
troll
Feeder
B
respectively.
Insert
the
correspon
ding
three-pole
twistlock
plug
into
the
ap
propriate
receptacle
and
rotate
the
plug
clockwise.
OM-858
Pag.4
SECTION
3
FUNCTION
OF
CONTROLS
Figure
3-1.
Remote
Control
Components
B-047
473-A
3-
1.
REMOTE
VOLTAGE
INCREASE
CONTROLS
(Figure
3-1)
The
Remote
VOLTAGE
INCREASE
controls
provide
voltage
selection
within
the
welding
power
source
load
voltage
range
being
used.
When
the
Left
control/feeder
is
active,
the
remote
control
LEFT
VOLTAGE
INCREASE
control
will
be
active.
When
the
Right
control/feeder
is
active,
the
remote
control
RIGHT
VOLTAGE
INCREASE
control
will
be
active.
Rotating
the
VOLTAGE
INCREASE
controls
in
a
clockwise
direction
will
increase
the
load
voltage.
The
scale
surrounding
the
VOLTAGE
INCREASE
con
trols
is
calibrated
in
percentage
and
should
not
be
misconstrued
as
an
amperage
or
voltage
reading.
It
is
recommended
that
the
meters
be
read
whenever
it
is
necessary
to
know
the
amperage
and
voltage
output.
S
The
contacts
of
the
VOL
TAGE
INCREASE
controls
are
of
the
continuous
type,
thereby
making
it
possible
to
adjust
these
controls
while
welding.
3-2.
REMOTE
CONTROL
PILOT
LAMPS
(Figure
3-1)
When
the
welding
power
source
is
energized,
the
remote
control
Condition
A
or
B
pilot
lamp,
when
il
luminated,
will
indicate
which
condition
is
active.
SECTION
4
SEQUENCE
OF
OPERATION
CAUTION
__________
Never,
under
any
circumstances,
operate
the
remote
control
14*1,
the
outer
enclosure
removed.
In
addition
to
a
safety
hazard,
improper
cooling
may
resuft
in
damage
to
the
remote
control
components.
Warranty
is
void
if
the
remote
control
is
operated
with
the
outer
enclosure
open
or
removed.
4-1.
GAS
METAL-ARC
WELDING
(GMAW)
AND
FLUX
CORED-ARC
WELDING
(FCAW)
1.
Make
necessary
electrical
and
mechanical
con
nections
to
the
welding
power
source,
con
trol/feeder,
and
gun
as
outlined
in
the
welding
power
source
manual,
control/feeder
manual,
end
gun
manual,
respectively.
3.
Make
remote
control
secondary
connections
as
outlined
in
Section
2-1.
3.
Make
Remote
Voltage
Control
connections
as
outlined
in
Section
2-2.
4.
Make
Remote
Contactor
Control
connections
as
outlined
in
Section
2-3.
5.
Make
115
VAC
connections
as
outlined
in
Sec
tion
2-4.
6.
Make
control/feeder
Remote
Contactor
Control
connections
as
outlined
in
Section
2-5.
7.
Make
control/feeder
115
VAC
connections
as
outlined
in
Section
2-6.
8.
Rotate
the
remote
control
LEFT
VOLTAGE
IN
CREASE
control
to
the
desired
position.
Contector
Control
Plug
To
Welding
Pow.r
Condition
B
input
Terminal
Condition
A
Condition
B
Output
Output
T.rmln.I
Terminal
CondltlOb8
Contactor
Control
Rsc.ptacis
OM-868
PageS
S
When
using
two
control/feeders,
replace
reference
to
control/fteder
LEFT
WIRE
SPEED
control
with
control/feeder
A
WIRE
SPEED
control
and
con
trol/feeder
RIGHT
WIRE
SPEED
control
with
con-
tm//feeder
B
WIRE
SPEED
control.
9.
Rotate
the
control/feeder
LEFT
WIRE
SPEED
control
to
the
desired
position.
10.
Rotate
the
remote
control
RIGHT
VOLTAGE
IN
CREASE
control
to
the
desired
position.
11.
Rotate
the
control/feeder
RIGHT
WIRE
SPEED
control
to
the
desired
position.
___________
Prior
to
welding,
it
is
imperative
that
pro
per
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and
welding
helmet)
be
put
on.
Failure
to
comply
may
result
in
serious
and/or
perma
nent
bodily
damage.
12.
Turn
on
the
shielding
gas
supply.
13.
Energize
the
welding
power
source
and
con
trol/feeder(s).
Commence
welding.
14.
CONDITION
A
or
B
will
automatically
be
selected
whenever
the
Left
Gun
or
the
Right
Gun
(Gun
A
or
Gun
B
if
using
two
control/feeders)
respectively,
is
activated.
Only
one
condition
and
one
gun
is
active
at
one
time.
S
The
Remote
VOL
TAGE
INCREASE
controls
and/or
the
WIRE
SPEED
controls
can
be
adjusted
while
welding;
4-2.
SHUTTING
DOWN
1.
Cease
welding.
2.
Allow
the
welding
power
source
to
idle
for
3
minutes
with
no
load
applied
to
permit
proper
cooling.
3.
Place
the
welding
power
source
POWER
switch
in
the
OFF
position.
Since
the
remote
control
derives
its
operating
power
from
the
welding
power
source,
the
remote
control
will
also
be
deenergized
when
the
welding
power
source
is
deenergized.
4.
If
the
control/feeder(s)
does
not
derive
its
operating
power
from
the
welding
power
source,
place
the
control/feeder(s)
POWER
switch
in
the
OFF
position.
~.
5.
Turn
off
the
shielding
gas.
CAUTION
___________
if
welding
is
performed
in
a
confined
area,
failure
to
turn
off
the
shielding
gas
supply
could
result
in
a
build
up
of
gas
fumes,
thereby
endangering
personnel
reentering
the
welding
area.
TO
REMOTE
CONTROL
RECEPTACLE
ON
WELDING
MACHINE
t15V
FROM
WELDING
MACHINE
Figurs
4-1.
CircuIt
Diagram
TO
FEEDER
TO
FEEDER
0
5,
~CR~
49
4a
ISV.
-~-
-&-
RC3
CAUTION
+
TO
TO
FEEDER
IT
.~
MOVE
JUMPER
FROM
USING
2
SEPERATE
~
ALBTOB&C
WHEN
WIRE
FEEDERS
II
WI
W2
PLG3
iT
Ce
BO~
A0~
TO
FEEDER
PLG2
RCZ
04
oS
055
056
043
050
0
70
CircuIt
DIagram
No.
A-048
737-C
OM-858
Pag.6
May1988
FORM:
OM-858
PARTS
LIST
4
E
C
U.
OM-858
Page
1
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Main
Auembly
1
PLG1
039
273
PLUG,
5
pin
MS31O6A-16S-8P
1
2
039 685
CLAMP,
cable
1
3
600733
CORDSET,ll5voitsl6ga3/c2oft
2
4
010 610
CONNECTOR,ciamp-cabIe1/2inch.~
3
5
048
938
CABINET
(consisting
of)
1
6
010
853
.
FASTENER,screw-slottedhdNo.2
1
7
010 855
.
RETAINER,
screw
No.
2
1
8
010854
.NUT,speedNo.2clip-on
1
9
iT
038
646
BLOCK,
terminal
30
amp
10
pole
1
10
038 620
LINK,
jumper
-
terminal
block
30
amp
1
11
FM
007 678
MOTOR,
1/70
hpil5voltsac
1550
rpm
1
12
031
296
BRACKET,
mounting-motorfan
1
13
032
618
BLADE,
fan
60
Hz
6
inch
4
wing
1
14
Wi
,2
099
044
CONTACTOR,
3P
110-120/220-240
volts
(consisting
of)
2
048599
.COIL,1i5/23OvoIts
1
15
099 435
LINK,
connecting
-
contactor
4
16
Ri
,2
072 623
POTENTIOMETER,
carbon
1
turn
2
watt
1000
ohm
2
072
590
LOCK,
shaft
2
17
NAMEPLATE
(order
by
model)
1
18
047
630
PLATE,
indicator
-
voltage
increase
left
1
19
019
627
KNOB,
pointer
2
20
047
471
PLATE,
indicator
-
voltage
increase
right
1
21
027
628
LENS,
light
-
indicator
red
clear
2
22
PL1
,2
027
629
BULB,
incandescent
-
slide
base
120
volts
2
23
027
631
HOUSING,light-indicatorslidebasei25volts
2
24
CR1
,3
059
266
RELAY,
enclosed
120
volts
ac
DPDT
w/flange
2
25
CR2
039
498
RELAY,
enclosed
120
voltsac3PDl
1
26
039
047
TERMINAL,
power
output
-
red
(consisting
of)
4
27
601
976
.
SCREW,
cap
-
steel
hex
hd
1/2-13
x
1-1/2
1
28
039 049
.
TERMINAL
BOARD,
red
1
29
601
880
.
NUT,
hex-jam
1/2-13
1
30
039
044
.
BUS
BAR
1
31
601
879
.NUT,hexfulll/2-13
1
32
RC1
,2
039
686
RECEPTACLE,
twistlock
-
grounded
2P3W
15
amp
277
volts
2
33
048
475
GUARD,
stud
-
power
1
34
RC3,4
039
634
RECEPTACLE,
twistlock
-
grounded
2P3W
20
amp
250
volts
2
35
PLG2
039
687
CAP,
twisdock
-
grounded
2P3W
15
amp
277
volts
3
36
PLG3
039
635
CONNECTOR
BODY,
twistlock
2P2W
20
amp
250
volta
3
37
023606
CORDSET,llSvoItsl6ga2/c2Oft
1
Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
MODEL
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-858P.512
/