Miller | HE000000 | Owner Manual | Miller RCDS-1 User manual

Miller RCDS-1 User manual
August 1974
FORM: OM-850
MODEL
STOCK NO.
RCDS- 1
040 810
RCDS-2
040 907
RCDS-3
041 012
~LE COPY
RETURN TO FOLOER
MODEL/STOCK NO.
SERIAL/STYLE NO.
OWNERS
DATE PURCHASED
MANUAL
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
ADDITIONAL COPY
PRICE 25 CENTS
NWSA CODE NO. 4579
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WARRANTY
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to be free from defects in
Mfg. Co., Appleton, Wisconsin, warrants all new equipment
factory workmanship for the periods indicated below, provided the equipment
operated according to manufacturers instructions.
MILLER Electric
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material and
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is installed and
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Mfg. Co.s obligation, under this warranty, is limited to replacing or repairing any defective
part or correcting any manufacturing defect without charge during the warranty period if MILLERS inspection confirms the existence of such defects. MILLERS option of repair or replacement will be f.o.b. factory at
Appleton, Wisconsin or f.o.b. a MILLER authorized service facility, and therefore no compensation for trans
portation costs of any kind will be allowed.
MILLER Electric
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on
the date of sale to the
original purchaser-user
of the
equipment,
will be
as
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period, beginning
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The warranty
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4.
Arc welders, power sources, and components
main power rectifiers
Original
MHFC-L1 Feeder, MHG35C1,
and all guns and torches
5.
All other Millermatic Feeders
Mag-Diesel engine on DEL-200
6.
All other
1 year
3 years
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(unconditionally)
20E, 20K,
90 days
1 year
6 months
1 year
engines
Engine Warranties are covered by the engine manufacturers, subject to their procedures and to be
through their authorized local Service Stations or agencies. No warranty will be made in respect
accessories, such being subject to the warranties of their respective manufacturers.
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Co. will not be liable for any loss or consequential
indirectly from the use of equipment covered in this warranty.
MILLER Electric
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directly
or
Mfg.
damage
or
expense
accruing
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This warranty supersedes all previous MILLER warranties and is exclusive with
warranties expressed or implied.
no
other guarantees
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OPTIONAL EQUIPMENT
DSS-1 Two Position Switch
This switch replaces the standard switch and attaches to the torch handle. It provides both wire feed on-off control and
Includes 15 foot lead and plug..
to schedule B
or vice versa.
switching from schedule A
RFM-2 Remote Foot. Switch
Provides for switching from one weld schedule to another. When using the RFM-2 switch, wire feed on-off
accomplished with the standard torch switch. Includes 20 foot lead and plug.
control is
SECTION 1
1-1.
INTRODUCTION
-
GENERAL
schedule
This manual has been prepared especially for use in familiar
izing personnel with the design, installation, operation,
maintenance, and troubleshooting of this equipment. All
information presented herein should be given careful consid
eration to assure optimum performance of this equipment.
1-2.
mote
welding by connecting
Control
Dual
Schedule.
to a third module, the Re
The dual schedule set-up is
accomplished by using the existing remote control recep
tacles on the welding power source and wire feeder. No tools
of any kind are required for installation of the remote con
trol and the operation of it is very simple.
RECEIVING-HANDLING
The control is basically a combination of remote voltage con
trols and remote wire feed speed controls brought together in
box. The circuit is arranged in such a way that the
one
operator can select either one of two pairs of controls. The
operator can use one voltage control with its corresponding
wire feed speed control or by merely changing the position of
the schedule selector switch on the gun handle, the operator
can use the other set of controls.
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 equipment, it is
essential that Model Designation and/or Stock Number and
Serial (or Style) Number of the equipment be supplied.
1-3.
1-4.
DESCRIPTION
SAFETY
Caution should be exercised in taking voltage measurements
troubleshooting the unit. Always avoid contact be
tween any part of the human body and any current
carrying
part of the remote control unit.
when
The design concept of this remote control unit is to be able
to use one welding power source and one wire feeder for dual
SECTION 2
-
INSTALLATION
2-3.
SCHEDULE SELECTOR SWITCH
(Figure 2-1)
IMPORTANT
The
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This
RCDS-3 is designed to be used in conjunction
with an electric amperage controlled welding power
source having a 24 volt dc control circuit. If the weld
ing power source being used has a RANGE Switch, the
RANGE Switch must be placed in the LOW or the
WIDE
2-1.
position.
REMOTEWIRE FEED SPEED
(Figure 2-1)
schedule selector switch, as shown in the OPTIONAL
EQUIPMENT Section can either bea gun mounted switch or
foot control.
The
mounted
Dual Schedule Switch (DSS-1) provides
and Schedule control. The contactor is en
gaged by depressing the DSS-1 half way down. Pressing the
switch all the way down will engage the contactor and change
schedules. To change back to the original schedule, merely
release the switch approximately half the way up.
gun
both
contactor
The Remote Foot
Connect the remote wire feed
speed plug into the wire feed
receptacle on the control/feeder. Place the
STANDARD-REMOTE Switch on the control/feeder in the
REMOTE position.
speed
Momentary Switch (RFM-2) does not have
contactor control capability, it is intended to be used only
for Schedule selection. Depressing the foot pedal will select
the other schedule and keep that schedule in the circuit as
long as the foot pedal is depressed.
VOLTAGE
CONTROLS
LEGEND
115 VOLTS
ac
~
CONTACTOR CONTROL
~
GAS IN
GAS OUT
SCHEDULE B
PILOT LIGHT
NEGATIVE
POSITIVE
SWITCH CONTROL
ElIS
CONDUIT ASSEMBLY
]1EL
REMOTE VOLTAGE CONTROL
WIRE FEED
SPEED CONTROLS
REMOTE WIRE FEED SPEED
lIE
SCHEDULE SELECTOR CONTROL
TD-040 810-2
Figure
2-1.
Interconnection Diagram
OM-850 Page 1
SECTION 3
3-1.
-
OPERATION
GAS METAL-ARC WELDING
1.
Make all
necessary connections to the
control/feeder and torch
as
welding machine,
5.
Place the STANDARD-REMOTE wire feed speed switch
the control/feeder to the REMOTE position.
outlined in their respective
on
manuals.
6.
2.
Connect the remote voltage control plug to the remote
voltage control receptacle on the welding power source.
3.
Place the STANDARD-REMOTE voltage control switch
on the welding machine in the REMOTE position.
3.
Place
on
4.
Connect
selector
STANDARD-REMOTE voltage control switch
the welding power source in the REMOTE position.
the
schedule
selector
receptacle (RC1)
7.
Set the
8.
Turn the
9.
Select
on
plug
to
the
schedule
the RCDS.
voltage controls and wire feed speed controls
the RCDS to the desired settings.
welding
power
source
on
and control/feeder on.
the
Connect the
remote wire
speed receptacle
on
the proper schedule
selector switch in the desired
feed speed plug to the wire feed
provided
being used.
are
the control/feeder.
on
by placing the schedule
position. Two pilot lights
the RCDS to indicate which schedule is
C
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PLG 1
AMPHENOL
CR1
PLUG
I
TO
WIRE
FEEDER
REMOTE CONTROL
RECEPTACLE
SHIELD
D
A
GR-GROUND
TO WELDING MACHINE
PLG2
REMOTE
CONTROL
RECEPTACLE
C-COPPER
B-BRASS
Circuit
Figure 3-1. Circuit Diagram
Page
2
For RCDS-1
Diagram No. CA-040 810-1
August
MODEL/STOCK NO.
SERIAL/STYLE NO.
1974
FORM: OM-850
MODEL
STOCK NO.
RCDS-1
040 810
RCDS-2
040 907
RCDS-3
041 012
DATE PURCHASED
PARTS LIST
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
NWSA CODE NO. 4579
U
S
A-
Quantity
Dia.
Factory
Mkgs.
Part No.
Models
Description
RCDS-1
~
RCDS-2
(
RCDS-3
Complete Assembly
Cl
031 608
601 375
CR1
034 691
CR1
025 560
CR1
034676
CR2
034 676
039664
104 045
01,2
PL1,2
PL1,2
026202
*027 632
*027 638
027 628
027 631
PLG1
039 827
039828
PLG2
039 693
PLG2
605 797
R1,4
R2,5
030940
030 943
019 609
R3,6
R7,8
R7,8
030 854
030 070
030653
019 627
R9,l0
030 783
Ri 1
604 178
R12
030778
RC1
039 855
038 785
057 056
023 605
057057
025515
010 610
025 903
020 527
019663
020 528
*
CAPACITOR,electrolytic250uf25voltac
RING, mtg capacitor
RELAY, 3PDT i2voltdc
RELAY, 3 POT 12 volt dc
-
RELAY,3PDT24voltdc
RELAY, 3PDT 24 volt dc
SOCKET,tubeilpin
BRACKET, mtg relay
DIODE, lamp 400volt straight polarity
BULB, slide base 24 volt
BULB, slide base 48 volt
LENS, red indicator lamp
HOUSING, indicator lamp
CONNECTOR, straight male 6 contact
STRAIN RELIEF, amphenol
CAP, twistlock 3P3W
CAP,twistlock 3P3W
RESISTOR,carbon0.5watt2000ohm
POTENTIOMETER, carbon 1 turn 2 watt 15K ohm
KNOB, pointer small
RESISTOR, carbon 0.5 watt 18K ohm
RHEOSTAT, WW 150 watt 75 ohm
RHEOSTAT,WW 150 watt 15 ohm
KNOB, pointer large
RESISTOR, carbon 1 watt 220 ohm
RESISTOR, carbon 2 watt 100 ohm
RESISTOR,carbon 1 watt 180 ohm
RECEPTACLE, twistlock 2 prong
STR IP, terminal 3 pole
BRACKET, mtg- terminal strip
CORD SET, 115 volt 16 ga 3 conductor 20 ft
CABLE,electrical No. 2OAWG 5 conductor l5ft
CABLE,electricalNo. l65conductor20ft
CONNECTOR, cable clamp 3/8
COVER, control box
CASE SECTION, base/side
MOUNT,rubber
HANDLE, control box
-
-
-
-
-
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
2
2
2
2
2
2
1
1
1
2
2
2
1
1
1
1
1
1
4
4
4
2
2
2
Recommended Spare Parts
BE SURE TO PROVIDE
OM-850 Page 1
1
STOCK, AND MODEL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
1%
BL/(
Di
2/
D2
.11
271
22
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141
26Y
24
CRi
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PL G
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AMPHENOL
TO
25
I
WIRE
I
REMOTE CONTROL
301
26
PLUG
CR
_______
2
I
FEEDER
RECEPTACLE
0
R
1;i
3
I
WHT
SHIELD
23
II
II
RED
4S
ND
TO WELDING
REMOTE
MACHINE
CONTROL
RECEPTACLE
Circuit
Figure 3-2. Circuit Diagram
No. CA-040 907-1A1
For RCDS-2
>C
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Diagram
2/
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24
Ck1
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25~
26
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P
PLG~
AMPIIF in
FFFDEP
RFI1OTF C)rJTkc I
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SHIFID
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Circuit Diagram No. CA-041 012-IA
Figure 3-3. Circuit Diagram For RCDS-3
OM-850 Page 3
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