Miller | HH000000 | Owner Manual | Miller RCMP-11 User manual

Miller RCMP-11 User manual
March 1977
FORM:
OM-853
MODEL
STOCK NO.
RCMP-1 1
000 461
HLE COPY
RETURN TO FOL1~R
MODEL/STOCK NO.
SERIAL/STYLE NO.
OWNERS
DATE PURCHASED
MANUAL
MILLER ELECTRIC MFG. CO.
APPLETON, WISCONSIN, USA 54911
ADDITIONAL COPY
Ito
PRICE 25 CENTS
NWSA CODE NO. 4579
I) S
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LIMITED WARRANTY
EFFECTIVE: NOVEMBER 1,
1976
MILLER warranties and is
This warranty supersedes all previous
clusive with no other guarantees or warranties
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d
LIMITED WAR.RANTYMifler Electric Mfg. Co., Appleton, Wisconsin warrants to Customer that all new and unused
Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such engines,
trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any. At the present time,
the manufacturers warranty on the Mag-Diesel engine on DEL
200 is limited to sj.x months and on all other engines to one year.
MILLER warranty does not apply 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 wire including nozzles and
nozzle insulators where failure does not result from defect in
workmanship or material.
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefor shall be, at Millers option, (1) repair or (2) replacement or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station or (4) payment of or credit for
the purchase price (less reasonable depreciation based upon
actual use) upon return of the goods at Customers risk and CXpense. Upon receipt of notice of apparent defect or failure,
Miller shall instruct the claimant on the warranty claim procedures to be followed.
As a matter of general policy only, Miller may honor an original users warranty claims on warranted Equipment in the event
of failure resulting from a defect within the following periods
from the date of delivery of Equipment to the original user:
~b
d~-.
expressed
or
ex
implied.
I. Arc welders, power sources, and components
2. Original main power rectifiers
(Labor
3. All
welding
guns and
1 year
.
..
or
repair parts
*
years
90
other Millermatic Feeders
provided that the user so notifies Miller in
(30) days of the date of such failure.
Replacement
year
only)
feeder/guns
1
4. All
5.
1
3
writing
within
exclusive of labor
.
60
days
year
thirty
)
days
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT WHICH, BUT
FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW CUSTOM OF TRADE OR
ANY IMPLIED
COURSE OF DEALING,
WARRANTY OF MERCHANTABILITY OR OF FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY
AND ALL EQUIPMENT FURNISHED BY MILLER IS
~
IN~LUDING
EXCLUDED AND DISCLAIMED BY MILLER.
)
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR
PURCHASE
BY
ULTIMATE
COMMERCIAL/INDUS
TRIAL USERS AND FOR OPERATION BY PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT AND NOT
MILLER
FOR CONSUMERS OR CONSUMER USE.
WARRANTIES DO NOT EXTEND TO, AND NO RESELLER IS AUTHORIZED TO EXTEND MILLERS WAR-
RANTIES
...Jt.
TO,
.~
ANY CONSUMER.
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SECTION 1
1-1.
-
INTRODUCTION
1-4.
GENERAL
The
following definitions apply to CAUTION, IMPORTANT,
and NOTE blocks found throughout this manual:
This manual has been prepared especially for use in familiar
izing personnel with the design, installation, operation, main
tenance, and troubleshooting of this equipment. All informa
tion presented herein should be
assure
1-2.
given careful consideration
optimum performance of this equipment.
SAFETY
to
~(EiUIl1
RECEIVING-HANDLING
Under this heading, installation,
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
freight
and
occasion
to
bill will be furnished
file claim arises.
by the carrier
procedures
carefully followed
tenance
not
or
I
create
a
hazard to per-
I
E~TA~I
1~
DESCRIPTION
heading, installation, operating, and main
procedures or practices will be found that if
carefully followed may result in damage to equip
this
tenance
not
multi-purpose
ment.
remote control which is
designed
specifically for use with the Gas Metal-Arc (GMAW) Welding
process. This unit will provide two welding conditions on one
wire using one control/feeder and one welding power source.
a
and main
request if
on
Under
This unit is
may
operating,
will be found that if
sonnel.
When requesting information concerning this equipment, it is
essential that Model Description and/or Stock Number and
Serial (or Style) Numbers of the equipment be supplied.
1-3.
practices
NOTE
~lt i-pu
referred
to
rpose
rem o~
in this manual
as
co
ntrol
w
ill
he reaf tar
Under this heading, explanatory statements will be
found that need special emphasis to obtain the most
efficient operation of the equipment.
be
the Remote Control
SECTION 2- INSTALLATION
2-1.
REMOTE
VOLTAGE
CONTROL
CONNECTIONS
2-2.
REMOTE
WIRE
SPEED
CONNECTIONS
(Figure
(Figure 3-1)
3-1)
Voltage Control plug connects the Remote VOLTAGE
to the welding power source voltage adjustment
circuitry. Insert the three-pole, twistlock plug from the
Remote Control into the welding power source Voltage
Control receptacle and rotate the plug clockwise as far as
possible.
The Wire Speed plug connects the Remote WIRE SPEED
control to the control/feeder wire speed circuitry. Insert the
six-pin plug from the Remote Control fully into the control/
The
CONTROL
feeder Wire Speed receptacle.
2-3.
REMOTE CONDITION SELECTOR CONNECTIONS
(Figure 3-1)
The two-pole twistlock plug originating at the control/feeder
must be connected to the Condition Selector receptacle on
the Remote Control to enable CONDITION A
ote Co nt rol of the vo Itage is d esired
it is
essential that the welding power source VOLTAGE
CONTROL switch be placed in the REMOTE position
or
B selection.
,
SECTION 3
3-1.
CONDITION
A
AND
B
VOLTAGE
-
Insert the plug into the receptacle and rotate it clockwise
far as possible.
FUNCTION
CONTROLS
3-2.
OF
as
CONTROLS
CONDITION A AND B PILOT LAMPS
(Figure 3-1)
(Figure 3-1)
the welding power source energized and with the
Condition Selector in a position corresponding to either
A
Condition
Condition
or
B, the CONDITION A or
CONDITION B pilot lamp, respectively, will be illuminated.
With
The CONDITION A and B VOLTAGE CONTROLS provide
voltage selection within the welding power source load
voltage range being used. Either the CONDITION A or
CONDITION B VOLTAGE CONTROL will be active depend
ing on the position of the Condition Selector switch.
Rotating
the controls clockwise increases the load
voltage.
NOTE
The VOLTAGE
CONTROLS may be adjusted while
3-3.
CONDITION A AND B WIRE SPEED CONTROLS
(Figure 3-1)
The CONDITION A and B WIRE SPEED controls adjust the
wire feed speed. Either the CONDITION A or CONDITION
B WIRE SPEED control will be active depending on the
position of the Condition Switch. Rotating the controls
clockwise increases the wire speed.
welding.
NOTE
the
VOLTAGE
CONTROLS are
calibrated in percentage and should not be misconstrued as
amperage or voltage readings. It is recommended that the
be read whenever it is necessary to know the
meters
amperage and voltage output.
The
scales
surrounding
The
i
WIRE
SPEED controls may
be
adjusted while
1
welding.
OM-853
Page
1
The
scales
the WIRE SPEED controls are
percentage and should not be misconstrued as
amperage or voltage readings. It is recommended that the
be read whenever it is necessary to know the
meters
amperage and voltage output.
calibrated
surrounding
in
Condition A
Voltage Control
Condition B
Voltage Control
Condition A
Pilot Lamp
Condition B
Wire Speed
Control
Ion A
Wire
Speed
Control
TB-009 496
Wire Speed Plug
Figure
SECTION 4
-
3-1. Connectors And Controls
SEQUENCE OF OPERATION
Condition Selector
Receptacle & Plug
CF-RC4
CF
Condition Selector
Receptacle & Plug
CF-RC3
S PIG1
:eeder/ PLG4/
_______________
Legend
W
Welding Power Source
R
Remote Control Unit
1
Condition Selector
Receptacle & Plug
RC1
R
PLG7
CF
-
-
S
Dual Schedule Switch
CF
Control/Feeder
Figure 4-1. Gas Metal-Arc Welding Connections
Page
2
______
-
Condition Selector
~Switch
(Mounted
On Gun)
4-1.
GAS METAL-ARC (GMAW) WELDING
(Figure 4-1)
NOTE
1.
Make necessary electrical and mechanical connections
to the welding power source, control/feeder, and gun
outlined in the welding power source manual,
as
If the
control/feeder manual, and gun manual, respectively.
al
2.
Make Remote VOLTAGE CONTROL connections
outlined in Section 2-1.
3.
Make Remote WIRE SPEED connections
in Section 2-2.
as
4.
Make Condition
Section 2-3.
outlined
gun-mounted Condition Selector switch (option
equipment) is employed, both contactor and weld
ing condition control are provided. This switch has
essentially three positions.
as
1.
In the first switch position, to which the switch
automatically returns if no switch lever pressure is
applied, the welding power source contactor is not
energized.
2.
In the second switch position, which is obtained by
depressing the switch lever about half way down,
the welding power source contactor is energized
and the Remote Control is placed in the CONDI
TION A position.
3.
may not be used in
In the third switch position, which is obtained by
depressing the switch lever all the way down, the
welding power source contactor is retained in an
energized state and the Remote Control is placed
in the CONDITION B position.
MEDIUM range while using the Remote Control.
be necessary, therefore, to place the welding
power source LOAD VOLTAGE RANGE switch in
either LOW. HIGH, or WIDE RANGE when using the
Remote Control.
Switching the Remote Control from CONDITION A
B
(or from CONDITION B to
CONDITION
CONDITION A) can be accomplished by varying the
amount of pressure applied to the switch lever.
Selector connections
as
Place
the welding power source LOAD
RANGE switch in the desired position.
5.
Due
to
the
circuitry
Control, the welding
limitations
power
source
of
the
outlined
in
VOLTAGE
Remote
the
It will
I
6.
I
Rotate
the
CONDITION
A
VOLTAGE
and WIRE SPEED control to the desired
7.
to
Rotate
and
the
WIRE
CONDITION B
SPEED control
CONTROL
4-2.
setting.
VOLTAGE CONTROL
to the desired setting.
SHUTTING DOWN
1.
Break the
2.
Allow the welding power
with no load applied.
3.
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 de-energized when the welding power
source is de-energized.
4.
Place the control/feeder Power Switch in the OFF
position if the control/feeder is provided with operating
power external to the welding power source.
I
U
welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
(glasses and/or welding helmet) be put on. Failure to
comply may result in serious and/or permanent bodily
Prior to
damage.
I
5.
8.
9.
Turn
on
Energize
the
the
shielding
welding
gas
supply,
arc.
source
to
idle for 3 minutes
Place the
Turn
off
the
shielding gas, if used,
at
the
shielding gas
source.
if used.
power source and control/feeder.
CAUTION
Commence welding.
10.
I
or B may be achieved by placing
Condition Selector in the position corresponding
to Condition A or Condition B, respectively.
Welding Condition A
If welding is performed in a confined area, failure to
off the shielding gas supply could result in a build
the
turn
of gas
fumes, thereby
reentering the welding area.
up
NOTE
L
endangering
personnel
U
CONDITION A and/or B VOLTAGE CONTROL
and/or WIRE SPEED control may be adjusted while
welding to achieve optimum welding conditions.
OM-853 Page 3
TO
PLUG
CFEDR ONTRL
AMPHENOL WIRE REMOTE RECPTAL
C
A
>E
II Ii
1
II II ~
GR-OUND
MACHINE CONTRL
WELDING REMOTE RECPTAL
TO
PLG2
461-lA
CA-DO
No.
Diagram
C-OPER B-RAS
Circuit
I
~1
ELD
SHI
Diagram
Circuit
27
4-2.
1
~0 0) Co cv
Figure
FORM:
March 1977
MODEL/STOCK NO.
SERIAL/STYLE NO.
DATE PURCHASED
PARTS LIST
MILLER ELECTRIC MFG. CO.
APPLETON? WISCONSIN, USA 54911
NWSA CODE NO. 4579
OM-853
MODEL
STOCK NO.
RCMP-11
000461
2
Item
Dia.
Factory
No.
Mkgs.
Part No.
Figure
Description
A
PLG2
Complete Assembly
605797
CAP, twistlock 3P3W 20
2
600 733
CORD SET, 115 volts
3
010 610
4
019 663
4
030131
POTENTIOMETER,
2
034 338
PANEL, control
BRACKET, mounting socket relay
SOCKET, tube 11 pin
RELAY, enclosed 24 volts dc 3PDT
NAMEPLATE (order by stock, model, and serial numbers)
HANDLE, control box
HOUSING, light indicator slide base 125 volts
BULB, slide base 48 volts
LENS, light indicator red clear
KNOB, pointer
KNOB, pointer
STRAIN RELIEF, receptacle/plug
CABLE, electrical No. 20 5/c 15 ft
PLUG, 6 pin MS-3106A-14S-6P
039855
6
Cl
031 608
7
R7,8
R2,5
11
030 653
12
104 045
13
039 664
14
-
023 235
9
10
CR1
034676
020 528
17
027 631
18
PL1,2
19
027 628
019 609
21
019 627
22
039 828
23
24
19 18
2
2
2
2
-
057 057
PLG1
carbon I turn 2 watt 50K ohm
-
*027 638
20
2
-
15
16
1
-
601 375
8
amp 115 volts
l6ga 3/c 20 ft
CONNECTOR, clamp cable 1/2 inch
RECEPTACLE, twistlock 2P2W
RING, mounting capacitor 1-3/8x 1-7/16
CAPACITOR, electrolytic 250 uf 25 volts ac
RHEOSTAT,WW l50watt 15 ohm
CASE SECTION, base/sides
MOUNT, neoprene
RC1
5
Quantity
039827
17 20 21
2
2
TD-009 497
20
19
18
17 16
Figure
A
-
Complete Assembly
*Recommended Spare Parts.
BE SURE TO PROVIDE STOCK, MODEL, AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-853 Page 1
I
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