Miller RDC PS-1 Owner's Manual
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Miller JD23
The Miller JD23 is a remote control with digital readout, designed to control a PULSTAR 450 welding power source and provide the capability of presetting background voltage and peak pulse current parameters for a single digital wire feeder or one side of a dual digital wire feeder. It provides the digital wire feeder with the nearest tenth of a volt and nearest amp. The RDC-PS displays the actual value of the selected parameter upon arc initiation.
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May 1983 FORM: OM-869 Effective With Style No. JD-23 01 MODEL RDC PS-i RDC PS-2 OWN ERS MANUAL AuHER MILLER ELECTRIC MFG. CO. SI, P.O. Box 1079 APPLETON, WI 54912 USA 718 S. BOUNDS NWSA CODE NO. 4579 PRINTED IN U.S.A. T~& ~ LIMITED WARRANTY EFFECTIVE: JUNE 1. 1979 This warranty supersedes all previous MILL ER warranties arid is ex clusive with no othe.r guarantees or wrirranlies expressed oi implied. LIMITED WARRANTY Subject to the terms and conditions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its Distributor! Dealer that all new and unused Equipment furnished by Miller is free from detect 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 ~c As - ~ ( cessories ~ or other items manufactured trade accessories and other items engines, by ore sublcct qurreral policy oriiy, Miller may honor claims original usur within the foregoing penods. . breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be, ai Millers option (11 repair or 121 replacement, In the Such others sold of mOtter a submitr,ed by Ure where authorized in or, the to of Millers case reasonable cost of All the warranties of their respective manufacturers, if any are warranted by their manufacturer for one year from Miller service station or price less date of return of the . engines Original purchase. r~asonable goods at Miller in appropriate Æases, 131 replacement at an ~uthorized (4) payment of or credit for the purchase writing by repair de~reciation Customers of notice of apparent defect specified below Millers warranty does not apply having normal usetul life of less than one Ill year, such as spot welder tips, relay and contactor posits, 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. Except as mant on or or based upon actual usel upon risk and expense. failure, Miller shalT the warranty claim procedures Upon receipt instruct the clai- be followed. to - to ~ ~ Miller shall be ranted ~ - components required honor warranty claims to on in ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY . GUARANTY OR REPRESENTA- IMPLIED WARRANTY, . PERFORMANCE, ,AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF. TION , war the event of failure.resultingfrom a defect within the following periods frOm the date of delivery of Equipment to the original user: Equipment . AS FITNESS TO FOR PARl WITH PURPOSE,, ICULAR ~, RESPECT TO , ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX. - CLUDED AND DISCLAIMED BY MILLER. . . , . 1. 2. Arc welders, power sources and components - . 1 year main power rectifiers 1 year only) (labor 3 years welding gunsand feeder/guns 90 days Original - 3. All 4. All other Millermatic Feeders 5. Replacement 6. Battenie~ or repair partr~, . 1 yea~ exclusive of labor 60 days 6months EXCEPT AS PRODUCTS MILLER WRITING, ULTIMATE~ is notified in writinj within thirty (30) days of the date of such failure INTENDED IN FOR USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED WELDING IN USE THE EQUIPMENT TO, ,AND NO AND AND, NOT CONSUMER USE. MILLER provided,that Miller ARE MILLER COMMERCIAL/INDUSTRIAL BY PURCHASE BY PROVIDED EXPRESSLY MAINTENANCE FOR CONSUMERS OF OR WARRANTIES 30 NOT EXTEN.D IS RESELLER MILLER S WARRANTIES TO AUTHORIZED ANY TO EXTEND CONSUMER i ~ -~ ~.r ~ ~r , jr -~ ~ -~, j~ ~ J 1January 9, ~ ERRATA SHEET After this manual was printed, refinements appearing later in this manual. in equipment design occurred. This sheet lists exceptions to data - ~ f :~ ~~ . Amend Seciion 3 CAU1 ION : When the faceplateiof Exceec/wg .. - B~CKGRO1) 1 - us~r~g. a~kg round the RD backgrou~id~voltag i~. . age we/ding power source violent and damaging conditions at the weld. T controls ron-b ~ shown on~e shown ~oi~ actual welding power potentiometers which ~ on 4c~e RDC9PS mode) actual rating un the thepreset background votage is yv~lc~jng ~ol~tage will be the ~tting ¶t, - * ~ ___ 5-1. Circuit pre~~t~e. increase~e ~minimum a~?i~b4j4~i tl~ethewekjing. povyer~soUrce If out~u~v~I rir~j~ rat~~~4 ~i soui~ce RDCPS are ten-turn the A DC-PS. Clockwise control rotation - FigUre ~ ~. ~ ~~~eter t~se~ij~. th AMENDMENT TO SECTION 5 ~.A~Øpd th~p . lfthe.preset bac~kground v~lta~e~or tI~e weding ~4Jit~ge~parameters 1) - ~i.se ~V.QLI~S aici ~ backgroi~ndvoltage and r~eak purrent~~ci~r~p pararne~er ~nd co~inter clockwise above (Figure 3 welding powel-Is The BACKGROUND remote mode) ~ CU9~~CONTROLS Exceedin~g background voftage.par ~ ~..~I:L D~iagram~Fer ROC~PS1-~odels AC ~ - A2 AC OUT ~i. PLC I 7/44 00 TEIOO IN AC IN AC our - v DI 0 C 4~4P 4 F RC3riA~\A. AG CDL F Cir~it~i~r~ P ~~Fi~ure5~2. C~r~~ * ~ F Quantity Item Part RepIa~ed No. No. Witft~ 25 08275 25 .089 875 ~9 875 ~O89~876 Model PS-i Description CASE SECTION, front/bottom/rear CASE SECTION, front/bottom/rear .. !. .1 BESURE~rO PROVID~MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS 1 PS-2 SECTION 1 - INTRODUCTION and the be safety of others. Therefore, this equipment is to installed, operated, and maintained only be qualified persons in accordance with this manual and all ap plicable codes such as, but not limited to, those listed at the end of Section 1 Arc Welding Owners Safety - Rules For Power Source in the welding Operation Of power source Manual. Safety instructions specifically pertaining to this unit appear throughout this manual_highlighted by the signal words Ii1–t.h~Ih~cI and CAUTION which identify ___________ different levels of hazard. WARNING ____________statements include installation, operating, or practices which if not carefully followed could result in serious personal injury or loss of life. and maintenance Iq~~1lS~I procedures include installation, operating, or practices which if not carefully followed could result in minor personal injury or damage to this equipment. statements and maintenance procedures A third signal word, IMPORTANT highlights instruc special emphasis to obtain the most efficient operation of this equipment. _______________ tions which need 4-3/4 in. (121 mm) 1 2. RECEIVING HANDLING Prior to installing 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 will furnished by the manufacturer on request - - - this 11-3/4 in. (298mm) *PS2 model illustrated. Overall dimensions same for PS-i models Figure 1 - 1. A. if occasion to file claim arises. 1 - 1. Specifications When GENERAL INFORMATION AND SAFETY 1 General requesting information concerning this equip ment, it is essential that Model Description and Serial (or Style) Numbers of the equipment be supplied. - trol 3. DESCRIPTION The RDC-PS is a remote con with digital readout, designed to control a - PULSTAR 450 presented in this manual, and on various labels, tags, and plates on the unit pertains to equip~ ment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equip Information welding power provides the Background voltage to the peak pulse current to the feeder. It source and capability nearest a of tenth of nearest amp. digital wire presetting a volt and The RDC-PS displays the actual value of the selected parameter arc upon initiation. ment. B. The Safety installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices and procedures which ensure personal safety RDC-PS1 models can be used to preset background voltage and pea pulse current parameters for a single digital wire feeder or one side of a dual digital wire feeder. RDC-PS2 models preset background voltage and peak pulse current parameters for both sides of a dual wire feeder. OM-869 Page 1 SECTION 2 Output Control Receptacle INSTALLATION Receptacle 115 VAC/Contactor I Switching~cord Feeder 115 VAC Cord PS-2 models only Figure 2 - 1. Rear Panel View PULSTAR 450 Rear View RDC-PS1 I I 0 Digital Figure 2 Page 2 - 2. RDC-PS1 Installation Wire Feeder PULSTAR 450 Digital Dual Figure 2 - 3. RDC-PS2 Installation IMPORTANT Loosen the screws along the top of the wire feeder control box and set the RDC-PS on top of the wire feeder. Tighten securing screws. 1. 115 VOLT AC CONNECTION TO WIRE Connect the fourFEEDER (Figures 2-1, 2-2 82-3) socket plug from the RDC-PS to the four-pin receptacle on the rear of the wire feeder. 2 - - volt/contactor cord (supplied with the wire feeder) to the four-pin receptacle on the rear of RDC-PS. Connect the three-pole twistlock plug on the 115 volts/contactor cord to the 115 VOLTS AC twistlock receptacle on the PULSTAR 450. Connect the two-pole twistlock plug on the 115 volts/contactor cord to the REMOTE CONTAC TOR CONTROL receptacle on the PULSTAR 450. 2 -4. SWITCHING 2 -2. OUTPUT CONTROL CONNECTION (Figures Connect the ten-socket connector on 2-1 2-2 8 2-3) - the supplied output control cord to the ten-pin recep tacle on the RDC-PS. Connect the ten-pin connector on the output control cord to the REMOTE OUTPUT CON TROL receptacle on the PULSTAR 450. 2-3. 115 VAC/CONTACTOR CONNECTION TO WELDING POWER SOURCE (Figures 2-1, 2-2 & Connect the four-socket plug on the 115 2-3) - Wire Feeder PS2 Models RELAY CONNECTION (RDC & 2-3) Connect the Only) (Figures 2-1 - four-contact connector from the RDC-PS to the fourcontact connector on the rear of the dual wire feeder. 2 - 5. REMOTE CONTROL RECEPTACLE(S) (Figures 2-1, 2-2 & 2-3) The REMOTE CONTROL receptacle(s) is provided for connecting an optional digital dual schedule control. Connect the six-pin plug cord from the Digital Dual on the output control - Schedule Control to the REMOTE CONTROL recep tacle. OM-869 Page 3 SECTION 3 - OPERATOR CONTROLS Peak Pulse Current Peak Pulse Current Control Display Remote Control, Switch Background Volts Control Receptacle Remote Control Receptacle I Background )lsplay Select Volts Control Switch PS-2 Model Illustrated Figure 3 - 1. Front Panel View* 1. BACKGROUND VOLTAGE & PEAK PULSE 3 CURRENT CONTROLS The (Figure 3-1) BACKGROUND VOLTS and PEAK PULSE CURRENT controls are ten-turn potentiometers which preset the background voltage and peak current welding parameters from the RDC-PS. Clockwise control rota tion increases the parameter. - - and peak pulse selects which welding. current to be parameter preset in turn and also will be displayed during The appropriate Indicator lamp lights to show which parameter is shown on the Digital Display. The Digital Display shows background voltage peak pulse current nearest tenth of a volt and to the to the nearest amp. If the preset backbround voltage or peak pulse current is the welding power source minimum, actual welding output will be the welding power source below minimum regardless of the preset value. If the preset background voltage is above the welding power source maximum, actual welding voltage will be the welding power 3 source maximum. 2. DIGITAL DISPLAY, DISPLAY SELECT SWITCH & INDICATOR LAMP (Figure 3-1) The DISPLAY SELECT switch enables background voltage - - SECTION 4 WARNING ARC RAYS, SPARKS, - can - 3. REMOTE CONTROL SWITCH(es) (Figure The Remote Control switch(es) is provided for selecting single scheduling via the RDC-PS or dual scheduling via an optional Digital Dual Schedule Con - trol. The Remote Control switch must be in the STAN DARD position to preset welding parameters at the RDC-PS. The Remote Control switch must be in the REMOTE position to preset welding parameters from the Digital Dual Schedule control and welding to dual schedule conditions. SEQUENCE OF OPERATION AND HOT _________ SURFACES 3 3-1) burn eyes and skin; NOISE can 1. GAS METAL ARC & FLUX WELDING With RDC-PS1 MODELS 4 - CORED-ARC damage hearing. Wear correct eye, ear, and body protection. AND GASES can seriously harm your health. 1. Use enough ventilation to keep fumes and gases from the breathing zone. 2. FUMES See Section 1 Safety Welding Power Sources - Owners Page 4 Manual for basic Rules For Operation Of Arc in the welding power source welding safety information. Be sure the unit has been installed as instructed source and wire in Section 2. Energize the welding power feeder. 3. Place the REMOTE OUTPUT CONTROL switch the welding position. on power source in the REMOTE 4. Place the Remote Control switch the STANDARD position. 5. Place on RDC-PS1 in Place the DISPLAY SELECT switch in the PEAK position and rotate the Right PEAK PULSE CUR RENT control to the desired setting for peak cur 6. the DISPLAY SELECT switch in the BACKGROUND position and rotate the BACKGROUND VOLTS control to the desiring rent on the Set desired wire feed speed for right side 7. 7. on wire feeder. setting. 6. right side. Place the DISPLAY SELECT switch in the PEAK position and rotate the PEAK PULSE CURRENT control to the desired setting. Place the DISPLAY SELECT switch in position display desired parameter while welding. IMPORTANT If an optional Digital Dual Schedule Control is used on the right side, place the Remote Con trol switch in the REMOTE position and set the welding parameters for the second schedule on the Dual Schedule Control. ______________ to 8. Set desired wire feed speed on 8. Depress the Left JOG switch (switches control and display to Left side). 9. Place the DISPLAY SELECT switch in the BACKGROUND position and rotate the Left BACKGROUND VOLTS control to the desired setting for background voltage on the left side. wire feeder. IMPORTANT If an optional Digital Dual Schedule control is used, p/ace the Remote Control switch in the REMOTE position and set the welding parameters for the second schedule on the Dual Schedule Control. _____________ 9. Turn shielding on gas supply. 10. Place the DISPLAY SELECT switch in the PEAK rotate the left PEAK PULSE CUR RENT control to the desired setting for peak cur position and 10. Begin welding. rent on the & FLUX METAL-ARC WELDING RDC-PS2 USING CORED-ARC WELDING MOD ELS 11. instructed in Sec 12. left side. 4 -2. GAS 1. Be sure the unit is installed as Place the DISPLAY SELECT switch in position display the desired parameter while welding. to Set desired wire feed speed for left side on wire feeder. tion 2. I h~ I ~. : V.t~I ~ If an 2. Energize the welding power source and the wire feeder. 3. Place the REMOTE OUTPUT CONTROL switch on the welding power source in the REMOTE optional Digital Dual Schedule control is used on the left side, place the Remote con trol switch in the REMOTE position and set the welding parameters for the second schedule on the Dual Schedule Control. position. IMPORTANT When power is wfre feeder, the right side controls the RDC-PS are energized. applied to the dual shielding 13. Turn 14. Begin welding. on gas supply. _____________ 4. the feeder and on 4 -3. SHUTFING DOWN Place the Remote Control switch the STANDARD 5. on on Turn off 1. RDC-PS2 in position. Shut 2. Place the DISPLAY SELECT switch in the BACKGROUND position and rotate the Right BACKGROUND VOLTS control to the desired setting for background voltage on the right side. SECTION 5 - shielding down wire gas supply feeder and welding power source. can harm health or kill. Shut off gas supply when not in use. ~ Gases MAINTENANCE & TROUBLESHOOTING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Disconnect unit from input power before internal WARNING 5 - 1. INSPECTION AND UPKEEP __________ IMPORTANT Periodically inspect the labels on this _______________ ly inspecting or servicing. Troubleshooting of internal parts by qualified persons. legibility. All precautionary labels must be main tained in c/early readable state and rep/aced when necessary. See the Parts List for part number of precau unit for to be performed only tionary labels. OM-869 Page 5 Periodically inspect all interconnecting cords for damage to or breaks in the insulation jacket, particularly at the plug. Repair or replace the cord(s) as necessary. B. The Troubleshooting following chart is designed remedies for 5 -2. TROUBLESHOOTING some to diagnose and of the troubles that may provide develop in this unit. General A. Chart Use this chart in conjunction with the circuit diagram performing troubleshooting procedures. If the trouble is not remedied after performing these pro while It is assumed that proper installation has been made, ac to Section 2 of this manual, and that the unit cording has been properly functioning until this cedures, the nearest Factory Authorized Service Sta tion should be contacted. In all cases of equipment recommendations malfunction, the manufacturers should be strictly followed. trouble developed. IMPORTANT: Ensure that all connections at the wire _____ feeder and remote control unit are secure and that all switches are in the proper position for the welding ap plication before proceeding with troubleshooting. TROUBLE No PROBABLE CAUSE Display Unable to preset background voltage pulse current. either or peak SUGGESTED CHECK AND/OR REMEDY Wire feeder Power switch in OFF position Energize wire Defective Replace digital meter. REMOTE OUTPUT CONswitch on welding power source in STAN TROL feeder. meter Place REMOTE OUTPUT CONTROL switch in REMOTE. DARD. Remote Control switch RDC-PS without a on in REMOTE Remote control Place Remote Control switch in STANDARD connect a remote control. connected. Unable to preset background voltage; peak pulse current adjustment VOLTS BACKGROUND control Ri Replace Ri (or R3). (or R3) defec tive. available. DISPLAY SELECT switch Replace S2. S2 defective. Relays CR52 or CR53 Replay defective relay(s). defective. Unable to preset peak pulse current; voltage background adjustment PULSE CURRENT control R2 (or R4) defec tive. PEAK Replace R2 (or R4). available. DISPLAY SELECT switch Replace S2. S2 defective. Relays CR52 or CR53 Replace defective relay(s). defective. Does not display actual welding. parameters while 115 VAC feeder. Relays connection CR50 (RDC-PS1 or to CR54 models), or or CR56 (RDC-PS2 models) defective. CR50 Page 6 Check connection. Replace defective relay. or AC IN 2 14 S AC 12 OUT P 4 DIGITAL METER i~c F H 10 L A C E 77442 0 00 TE1OO Circuit Diagram No. A-089 852 Figure 5 - 1. Circuit Diagram For RDC-PS1 Models OM-869 Page 7 AC IN AC OUT 77442 TEl 00 00 0 Circuit Figure 5 Page 8 - 2. Circuit Diagram For RDC-PS2 Models Diagram No. B-089 888 May 1983 FORM: OM 869 Effective With Style No. JD-23 MODEL RDC PS-i RDC PS-2 PARTS LIST 129 10- 91 4 AsembJy 23 Main - A Figure 2. 31 23 27 30 Quantity Item Dia. Part No. Mkgs. No. Figure A 1 2 3 4 PLG51 PLG5O 5 6 RC1 7 R1,2 7 R1-4 8 9 10 11 Model Description 072 +048 047 079 073 048 079 669 HOUSING, terminal 9 position 586 WRAPPER 497 LABEL, general precautionary 748 756 283 535 1 1 HOUSING, terminal 18 position STAND-OFF, No. 6-32 x 5/8 x 1/4 RECEPTACLE W/ PINS (consisting of) PLG3 . HOUSING PLUG & SOCKETS TERMINAL, female 15 16 17 18 19 20 20 21 RC3 RC4 22 TEl 23 S1,2 23 24 S1-3 24 RC2,3 RC2 25 26 27 28 PL1,2 29 30 PLG2 31 31 CR5O-54 CR5O-56 R51 RC5O RC51 1 4 1 4 4 2 4 1 3ft 3ft 1 1 1 079 534 010 476 BUSHING, strain relief 5/8 x .570 hole 604 108 WIRE, l8gastranded(orderbyft) 056 264 CONNECTOR, male 4 contact 4 4 089 870 039716 073 332 073 140 089 647 089 646 089 646 601 219 038 839 011 770 011 770 039 825 039 825 089 875 1 024 366 027 645 081 028 089 089 048 048 079 048 R50 1 4 1 (consisting of) . 14 1 1 TERMINAL, male 603 856 POTENTIOMETER, WWi0turn2watt 10K ohm 603 856 POTENTIOMETER, WWl0turn2watt 10K ohm 020 577 BUSHING, strain relief 1/2 x 15/32 hole 604 571 CORD, No. 184/C (order by ft) 079531 CLAMP,cable 048 284 13 I PS-2 Main Assembly PLG1 12 PS-i 798 598 707 709 028 028 843 028 079 844 000 038 035827 072 670 079 749 CORD, interconnecting lOft (consisting of) .PLUG,iOpinMS-3106A-i8-1P CLAMP, cable .CORD,No. 18 10/C (orderbyft) PLUG, l0socketMS-3106A-i8-1S RECEPTACLE, 10 pin MS-3102A-18-1P RECEPTACLE, i0pinMS-3i02A-18-1P LINK,jumper-terminalblock20amp BLOCK, terminal 20 amp 5 pole . . SWITCH,toggleSPDT5ampi25volts SWITCH,toggleSPDT5ampl25volts RECEPTACLE,6socketMS-3i02A-i8-1P 1 4ft 1 1 2 2 1 lOft lOft 1 1 1 1 2 2 1 2 1 3 1 2 RECEPTACLE,6socketMS-3i02A-18-1P CASE SECTION, front/bottom/rear NAMEPLATE (order by model & serial no) 1 1 1 KNOB, pointer LIGHT, indicator-red lens 125 voltsac METER, digital CONNECTOR, 15 socket edge CIRCUIT CARD, relay (consisting of) CIRCUIT CARD, relay (consisting of) RELAY, enclosed 120 volts ac 4PDT RELAY, enclosed 120 volts ac4PDT SOCKET, mtg-relay SOCKET, mtg-relay SPRING, hoiddown-relay POTENTIOMETER, cermet25turnO.5watt2K ohm .RESISTOR,carbonfilm0.25wattl0Kohm TERMINAL, header 9 post TERMINAL, header 18 post 2 4 2 2 . 1 1 1 1 1 5 7 . 5 . 7 . . 5 7 1 1 1 1 . 1 . . 1 1 + When ordering a component originally displaying a precautionary label, the labe should also be ordered. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-869 Page 2 1- ~
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