Miller Electric RHC-3GD25B Owner`s manual

May 1993
Form: OM-823H
Effective With Serial No. KB055102
OWNER’S
MANUAL
RHC-3, RHC-3-2, RHC-3GD25B,
RHCS-3, RHC-3-GD34A, RHC-14,
And RHC-23
Remote Hand Controls
For Remote Amperage Or Voltage Control
RHC-14 And RHC-23 Models Add Output (Contactor) Control
Primarily For SMAW Welding
20 ft (6 m) Interconnecting Cord
Read and follow these instructions and all
safety blocks carefully.
Give this manual to the operator.
Have only trained and qualified persons
install, operate, or service this unit.
For help, call your distributor
Call your distributor if you do not understand
the directions.
or: MILLER ELECTRIC Mfg. Co., P.O. Box
1079, Appleton, WI 54912
414-734-9821
cover 8/92 − Ref. ST-141 127-A
PRINTED IN USA
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION 2 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SECTION 3 − INSTALLATION
3-1.
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2.
Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
SECTION 4 − OPERATION
4-1.
Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1.
5-2.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
SECTION 6 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
SECTION 7 − PARTS LIST
Figure 7-1. Complete Assembly (RHC-3 Illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
OM-823H − 5/93
SECTION 1 − SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1
2
2
WARNING
MOVING PARTS can injure.
• Do not touch live electrical parts.
• Disconnect input power before
• Keep away from moving parts.
• Keep all panels and covers closed
4
installing or servicing.
when operating.
5
6
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
Safety Alert Symbol
2
Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION
3
ELECTRIC SHOCK can kill.
1
CAUTION means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And Result
4
Safety Instructions To Avoid
Hazard
5
Hazard Symbol (If Available)
6
Safety Banner
Read safety blocks for each symbol shown.
7
7
NOTE
NOTE
Special instructions for best operation − not related to safety.
Turn Off switch when using high frequency.
Figure 1-1. Safety Information
SECTION 2 − SPECIFICATIONS
Table 2-1. Remote Hand Control
Specification
Description
Model Description
RHC: Remote Hand Control; GD: For Use With Welding Generators Only; Suffix Of −2: Used To Control
Two Identical Welding Power Sources Or Welding Generators At The Same Time.
Interconnecting Cord
20 ft (6 m)
Overall Dimensions
See Figure 3-1
SECTION 3 − INSTALLATION
3-1. Location
C
1
B
1
Remote Hand Control
Install RHC onto wall, or place on
bench or other convenient location.
Inches
Millimeters
A
7-1/2
191
B
9-1/2
241
C
8-3/4
222
A
Ref. ST-141 127-A
Figure 3-1. Overall Dimensions
OM-823 Page 1
3-2. Interconnections
Turn Off welding power source, or
stop engine on welding generator.
1
1
Remote Hand Control
2
Interconnecting Cord
Units are equipped with a 20 ft (6
m) multiconductor cord (unless
otherwise specified). If a longer
cord is required, see Table 3-1.
2
3
Twistlock Plug
Make connection to matching receptacle on welding power source
or welding generator by inserting
plug, and turning cap in a clockwise
direction as far as it will go.
4
14- Or 5-Pin Amphenol Plug
Make connection to matching receptacle on welding power source
or welding generator by aligning
keyway, inserting plug, and rotating
threaded collar fully clockwise.
4
3
ST-141 127-A
Figure 3-2. Interconnections
Table 3-1. Interconnecting Cord Conductor Length And Size
Amperage Or Voltage Control
Cord Length
Conductor Size*
Up to 20 ft (6 m)
No. 16
Up to 20 ft (6 m) (GD Models)
No. 14
21 to 100 ft (6 to 30 m) (GD Models)
No. 12
21 to 50 ft (6 to 15 m)
No. 14
51 to 100 ft (16 to 31 m)
No. 12
101 to 200 ft (31 to 61 m)
No. 10
*AWG − American Wire Gauge
SECTION 4 − OPERATION
WARNING
ELECTRIC SHOCK can kill.
•
•
•
•
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrical parts.
Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
•
•
•
Keep your head out of the fumes.
Ventilate area, or use breathing device.
Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING can cause fire or explosion.
•
•
•
•
•
OM-823 Page 2
Do not weld near flammable material.
Watch for fire; keep extinguisher nearby.
Do not locate unit over combustible surfaces.
Do not weld on closed containers.
Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
•
•
Wear welding helmet with correct shade of filter.
Wear correct eye, ear, and body protection.
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
•
•
Pacemaker wearers keep away.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding operations.
See Safety Precautions at beginning of welding power
source or welding generator manual for basic welding
safety information.
swarn6.1* 10/91
4-1. Control Operation
NOTE
See welding power source or welding generator Owner’s Manual to determine if
Remote Hand Control will act as a fine Amperage or Voltage control, or as a full
range Amperage or Voltage control.
A. Adjusting Amperage Or Voltage Without Output (Contactor) Control
EXAMPLE Of Fine Remote Amperage Control Without Output (Contactor) Control
Min
(40 A)
Set Switch
Set Control
Max
(200 A)
Adjust Remote Amperage
Or
In Example: Min = 40 A In Range B
Percentage Of Output = 50%
Max = 200 A In Range B (100% of 200 A)
EXAMPLE Of Full Remote Amperage Control Without Output (Contactor) Control
Min
(40 A)
Set Switch
Control Setting
Does Not Matter
Max
(375 A)
Adjust Remote Amperage
In Example: Min = 40 A In Range B
Percentage Of Output = 50%
Max = 375 A In Range B (100% Of 375 A)
Ref. ST-122 023-A / Ref. ST-141 127-A / ST-039 411-D
Figure 4-1. Examples Of Amperage Or Voltage Adjustment Without Output (Contactor) Control
OM-823 Page 3
B. Adjusting Amperage Or Voltage With Output (Contactor) Control (RHC-14 And RHC-23 Models Only)
WARNING
ELECTRIC SHOCK can kill.
•
•
•
Do not touch live electrical parts.
Do not touch weld output terminals when contactor is energized.
Do not touch electrode and work clamp at the same time.
swarn7.1 10/91
EXAMPLE Of Fine Remote Amperage Control With Output (Contactor) Control
Min
(5 A)
Set Switches
Set Control
Max
(200 A)
In Example: Min = 5 A
Percentage of Output = 100%
Max = 200 A (100% of 200 A)
Place switch in On position for open-circuit
voltage. When switch is in Off position no
weld output voltage is present.
Or
EXAMPLE Of Full Remote Amperage Control With Output (Contactor) Control
Min
(5 A)
Max
(375 A)
In Example: Min = 5 A
Percentage of Output = 100%
Max = 375 A (100% of 375 A)
Set Switches
Control Setting
Does Not Matter
Place switch in On position for open-circuit
voltage. When switch is in Off position no
weld output voltage is present.
Ref. ST-159 059 / Ref. ST-130 214-A
Figure 4-2. Examples Of Amperage Or Voltage Adjustment With Output (Contactor) Control
OM-823 Page 4
C. Remote Hand Control Of Two Welding Power Sources Or Welding Generators
Models with the suffix -2, are designed to control two identical welding power sources or welding generators at the
same time. Turning the knob on the remote hand control adjusts the amperage or voltage on each welding power
source or welding generator to the same output setting. Refer to welding power source or welding generator Owner’s
Manual for additional information.
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
Turn Off welding power source, and disconnect
remote control before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
•
Allow cooling period before maintaining or servicing.
Maintenance and troubleshooting to be performed only
by qualified persons.
swarn8.1* 2/93
5-1. Routine Maintenance
3 Months
Turn Off all power before
maintaining.
Everyday
14-Pin Cord
Turn
Control
Replace
Cracked
Parts
Replace
Unreadable
Labels
ST-141 127-A
Figure 5-1. Maintenance Schedule
5-2. Troubleshooting
Table 5-1. Welding Trouble
Trouble
No amperage or voltage control.
Remedy
Section
Set switches and controls on welding power source or generator.
4, *
Check weld output on welding power source or generator.
Secure cord connections or replace cords, if necessary.
No Output (Contactor) control.
Switch in wrong position or control not so equipped.
*
−−
Figure 4-2
*See welding power source or generator Owner’s Manual.
OM-823 Page 5
SECTION 6 − ELECTRICAL DIAGRAMS
SA-150 670
Figure 6-1. Circuit Diagram For RHC-3
Ref. SA-150 671
Figure 6-2. Circuit Diagram For RHCS-3
OM-823 Page 6
SA-094 231-A
Figure 6-3. Circuit Diagram For RHC-3-GD34A
SA-094 232-A
Figure 6-4. Circuit Diagram For RHC-3-GD25B
SA-053 656-A
Figure 6-5. Circuit Diagram For RHC-14 And RHC-23
OM-823 Page 7
SECTION 7 − PARTS LIST
1
2
3
9
4
5
8
7
6
ST-141 128
Figure 7-1. Complete Assembly (RHC-3 Illustrated)
OM-823 Page 8
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
RHC- RHC- RHC- RHC- RHCS3-2
14
23
3
3
Figure 7-1. Complete Assembly
. . . 1 . . . . R1 . . . . . 030 653 . . RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . 1
. . . 1 . . . . R1 . . . . . 107 363 . . RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . R1 . . . . . 035 897 . . POTENTIOMETER, C sltd sft 1/T 2W
1000 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 1 . . . . R1 . . . . . 039 272 . . RHEOSTAT, WW 150W 1250 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 085 220 . . LABEL, caution electric circuit . . . . . . . . . . . . . 1 . . . 1 . . . . 1 . . . 1 . . .
. . . 3 . . . . . . . . . . . . +021 475 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . +014 417 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 4 . . . . . . . . . . . . . 021 474 . . CASE SECTION, base/front/rear . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 106 952 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 109 974 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 5 . . PLG1 . . . . 605 797 . . PLUG, twlk 3P3W 20A 125V . . . . . . . . . . . . . . 1 . . . 2
. . . 5 . . PLG1 . . . . 144 310 . . HOUSING PLUG & PINS, (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 134 732 . . . . TERMINAL, male 1 pin 24-20 wire . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . 143 922 . . . . CLAMP, cable strain relief sz 17 & 20 . . . . . . . . . . . . . . . . . 1
. . . 5 . . PLG1 . . . . 039 273 . . PLUG, 5 pin MS-3106A-16S-8P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . . . . . . . . . . . . . . . . . 039 685 . . CLAMP, cable AN-3057-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . .
. . . 6 . . . . . . . . . . . . . 600 733 . . CORD SET, pwr 115V 16ga 3/c 20ft . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 052 246 . . CABLE, pwr 20ga 5/c (order by ft) . . . . . . . . . . . . . . . . . . . . 20ft . 20ft
. . . 7 . . . . . . . . . . . . . 010 659 . . CONNECTOR, clamp cable .375 90deg . . . . 1 . . . 2 . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . 070 654 . . BUSHING, strain relief
.300 ID x .550mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 8 . . . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . 9 . . . . . . . . . . . . . . 039 411 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 148 720 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 130 214 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 053 574 . . PLATE, ind current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 148 716 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . S1 . . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1
. . . . . . . . . . . . . . . . . . . . 604 311 . . GROMMET, rbr .250 ID x .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . 1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
Model
RHC-3-GD
Item Dia.
Part
25B
34A
No. Mkgs.
No.
Description
605 960
..
..
..
..
..
..
..
..
..
..
..
..
..
1 . . . R1 . 605 960
1 . . . R1 . 605 049
2 . . . . . . . . 085 220
3 . . . R1 +021 475
4 . . . . . . . . 021 474
5 . PLG1 032 898
5 . PLG1 039 621
6 . . . . . . . . 600 349
6 . . . . . . . . 604 834
7 . . . . . . . . 010 659
8 . . . . . . . . 148 723
9 . . . . . . . . 148 717
9 . . . . . . . . 013 615
Complete Assembly (Use Fig 7-1 View)
..
..
..
..
..
..
..
..
..
..
..
..
..
RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RHEOSTAT, WW 300W 25 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LABEL, caution electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
PLUG, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PLUG, twlk armd 4P4W 20A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CABLE, port No.14 3/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20ft
CABLE, port No.14 4/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20ft
CONNECTOR, clamp .375 90deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
NAMEPLATE, RHC-3GD 34A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PLATE, ind amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-823 Page 9