Miller | JD23 | Owner Manual | Miller RDC-IW-1 User manual

Miller RDC-IW-1 User manual
Millerfi
October 1990
FORM: OM-871
E ffective With
No. JD-23
Style
MODEL: RDC-IW-1
RDC-IW-2
OWNERS
IMPORTANT:
MANUAL
Read and understand the entire contents of both this manual
and the power source manual used with this unit, with special emphasis on
the safety material throughout both manuals, before installing, operating, or
maintaining this equipment. This unit and these instructions are for use only
by persons trained and experienced
in the safe
operation
of
welding equip
MILLER ELECTRIC
A Miller
Mfg.
Co.
Group U~., Company
P.O. Box 1079
Appleton,
WI
54912 USA
Tel. 414-734.9821
ment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor if you do not fully understand these instructions.
SA-094 539
PRINTED IN U.S.A.
I
J
LIMITED WARRANTY
EFFECTIVE: AUGUST 6, 1990
This warranty supersedes all
previous MILLER
warranties and is exclusive with no other
LIMITED WARRANTY Subject to the terms and conditions
hereof. MILLER Electric Mfg. Co.. Appleton. Wisconsin war
rants 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 accessories or other items manufactured by
others. Such engines, trade accessories and other items are
sold subject to the warranties of their respective manumacturers,
if any. All engines are warrantied by their manufacturer for two
years from date of original purchase. except Deutz engines
which have a one year. 2000 hour warranty.
Except as specified below. MILLERs warranty does not apply
having normal useful life ot less man one II)
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.
guarantees
or warranties
expressed
or
implied.
In the case of MILLERs breach of warranty or any other duty
with respect to the quality of any goods. the exclusive remedies
therefore shall be. at MILLERs option li) repair or 12) replace
ment or. where authorized in writing by MILLER in appropriate
(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 expense. MILLERs option of repair or replacement will be
FOB.. Factory at Appleton. Wisconsin. or FOB. at a MILLER
cases.
authorized service facility. therefore. no compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apoarent defect or ?ajlure. MILLER shall instruct the
ciaimant on the warranty ciairn oroceaures to oe followed.
to components
MILLER shall be
required
warranty claims on war
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of
Equipment
1.
to the
to honor
original
Arc welders, power
user:
sources.
1 year
robots, and
components
2.
Load banks
main power rectifiers
1 year
3 years
3.
Original
4.
All
5.
All other MILLERMATIC Feeders
(labor
1 year
Replacement
7.
Batteries
provided
or
and torches
repair parts. exclusive of
.
.
tabor
90
days
1
year
60
days
6 months
that MILLER is notified in writing within thirty 30)
days
at the date of such failure.
As
a matter
submitted
UI:
by
of
general policy only. MILLER may honor claims
original user within the foregoing periods.
the
SENTATION 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 COURSE OF DEALING.
INCLUDING ANY IMPLIED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE.
ANY
EQUIPMENT
TO
AND
WITH
ALL
RESPECT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
only)
welding guns. feeder/guns
6.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY. GUARANTY OR REPRE
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING. MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE SY COMMERCIAL INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
WARRANTIES DO NOT
CONSUMER USE. MILLERS
EXTEND TO. AND NO RESELLER IS AUTHORIZED TO
EXTEND MILLERS WARRANTIES TO. ANY CONSUMER.
ERRATA SHEET
After this manual
to data
was
appearing
printed,
refinements In
equipment design occurred.
This sheet lists
exceptions
later In this manual.
AMENDMENT TO SECTION 2- INSTALLATION
Amend
Figure
2-2. RDC-IW-1 Installation With Wire Feeder
INTELLIWELD POWER SOURCE
115 VAC/Contactor
Rear
RDC4W-1
View
Digital
Wire Feeder
Connected To
Motor
RDC-IW-1
Front
View
TA-093 977-A
Figure
2-2. RDC-IW-1 Installation With Wire Feeder
Amend
Figure
2-3. RDC-IW-2 Installation With Wire Feeder
INTELLIWELD POWER SOURCE
115 VAC/Conlactor
Feeder
115 VAC
Digital Wire Feeder
TA-093 978-A
Figure
Amend heading numbers for
Figure
AMENDMENT TO SECTION 4
Add the
a
following WARNING
at
3-3 and
Figure
3-4 to read
Figure
2-4 and
Figure
2-5.
SEQUENCE OF OPERATION
beginnings
of Sections 4-1, 4-2, 4-3, 4-4, and 4-5:
WARNING: USING BOTH POSITIVE (+) WELD OUTPUT TERMINALS at same time can cause seri
electric shock and arcing hazards.
ous
Do not use both
Read
OM-871
2-3. RDC-IW-2 Installation With Wire Feeder
Page
2
positive (+) weld output terminals
welding power source
Owners
at the same time.
Manual for additional in formation.
OU.871
.
l~l9O
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufactur-
Use the following spaces to record the Model Designa
tion and Serial or Style Number of your unit. The infor
mation is located on the data card or the nameplate.
Model
________________________________________
ers
Transportation Department.
Senal
or
Style
No.
____________________
When
requesting information about this equipment, al
ways provide the Model Description and Serial or Style
Date of Purchase
_____________________
Number.
TABLE OF CONTENTS
Section No.
SECTION 1
-
Page No.
SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1.
General Information And
1-2.
Safety
SECTION 2
2-1.
Alert
Symbol
And
Safety
Signal Words
1
1
SPECIFICATIONS
Description
1
SECTION 3-INSTALLATiON OR RELOCATION
Diagram
Diagram
Diagram
3-1.
RDC-lW-1 Installation With Wire Feeder
2
3-2.
RDC-lW-2 Installation With Dual Wire Feeder
3
3-3.
Diagram
3-4.
Output Connections For Shielded Metal Arc Welding
(SMAW) (Reverse Polarity) Without Wire Feeder
Output Connections For Gas Tungsten Arc Welding
(GTAW) (Straight Polarity) Without Wire Feeder
3
3
3-1.
Installation Of Remote Control
4
3-2.
115 Volt AC Connection To The Wire Feeder
4
3-3.
Output Control Connection
4
3-4.
115 VAC Contactor Connection To
3-5.
3-6.
Welding Power Source
Switching Relay Connection (RDC-IW-2 Models Only)
Remote Control Receptacles
4
4
4
SECTION 4- OPERATOR CONTROLS
4-1.
Volts Control
4-2.
5
4-4.
Amps Control
Volts/Amps Display Select Switch
Remote Control Switch(es)
4-5.
CC/CP Selector Switch
5
4-6.
Arc Control
5
4-7.
Contactor Switch
6
4-8.
Digital Display
6
4-3.
5
And
Indicating Lights
5
5
Page No.
Section No.
SECTION 5- SEQUENCE OF OPERATION
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
SECTION 6
Gas Metal Arc And Flux Cored Arc Welding
Shielded Metal Arc Welding (SMAW)
(GMAW
Welding (SAW)
Submerged
Gas Tungsten Arc Welding (GTAW)
Air Carbon Arc Cutting And Gouging (AAC)
Shutting Down
Arc
And
FCAW)
6
7
7
8
8
8
MAINTENANCE AND TROUBLESHOOTING
6-1.
Routine Maintenance
9
6-2.
Troubleshooting
9
SECTION 7- ELECTRICAL DIAGRAMS
Diagram
Diagram
Diagram
Diagram
SECTION 8
Figure
Figure
7-1. Circuit
For RDC-IW-1 Models
11
7-2.
For RDC-IW-2 Models
12
For RDC-IW-1 Models
13
For RDC-lW-2 Models
14
7-3.
7-4.
Diagram
Circuit Diagram
Wiring Diagram
Wiring Diagram
PARTS LIST
8-1. Main
Assembly
Card, Relay
8-2. Circuit
16
18
LIST OF CHARTS AND TABLES
Table 6-1. Maintenance Schedule
Table 6-2.
Troubleshooting
9
10
SECTION 1
SAFETY PRECAUTIONS AND SIGNAL WORDS
ing Power Source in the welding power sources Owners
GENERAL INFORMATION AND SAFETY
1.1.
Manual.
A.
General
SAFETY
1-2.
Information presented in this manual and
on
various la
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective
use
of this
equipment.
The nameplate of this unit uses international symbols for
labeling the front panel controls. The symbols also ap
pear at the
B.
appropriate section
Safety
procedures which
personal safety and the
ensure
The
AND
SIGNAL
following safety alert symbol and signal words are
throughout this manual to call attention to and iden
used
tify different
a
This
levels of hazard and
safety
alert
symbol
special instructions.
is used with the
safety
statements.
a
WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
accordance with this manual and all applicable
IMPORTANT
statements
identify special
instructions
codes such as, but not limited to, those listed at the end
necessary for the most efficient operation of this
of Section 1
ment.
Safety
Rules For
signal
words WARNING and CAUTION to call atten
tion to the
safety
sons in
SYMBOL
in the text.
The installation, operation, maintenance, and trouble
shooting of arc welding equipment requires practices
and
ALERT
WORDS
Operation
Of Arc Weld-
SECTION 2
equip
SPECIFICATIONS
11-3/4 in.
(298 mm>
10-1/2 in.
(267 mm)
IMPORTANT: RDC-IW-2 mode/illustrated. Overall dimen
sions
same
for ROC-! W- I models.
SB.094 539
Figure
2-1.
2-1. Dimensions
The RDC-IW-1 models allow
DESCRIPTION
current
This unit is
WELD
a
remote
digital
control for the INTELLI
When
properly connected
to the welding power source, this unit provides arc con
trol, contactor control, voltage/amperage control, and
CC/CP (constant currentlconstant potential or voltage)
welding
selection.
power
source.
side of
parameters for
a
dual
digital
a
presetting
single digital
of
voltage
wire feeder
or
or one
wire feeder. RDC-lW-2 models pro
vide preset voltage or current parameters for both sides
of a dual wire feeder. The RDC-lW displays the actual
value of the selected parameter upon arc initiation.
The remote
digital control operates
on
115
VAC, 50/60
Hertz and draws 0.5 amps.
OM.871
Page
1
SECTION 3
INSTALLATION OR RELOCATION
115 VAClContactor
Receptacle
~Feeder115VAC
*switching Relay
*flDC.1w2 Models
Cord
Cord
Only.
S0494
Figure
3-1. Rear Panel View
INTELLIWELD POWER SOURCE
115 VAC/Contactor
Output Control
Rear
View
Connected To
Motor
Feeder 115 VAC
Digital
Wire Feeder
RDC-IW.1
El
0
Front
View
Digital
Wire Feeder
S 0483
Diagram
OM.871
Page
2
3-1. RDC-IW-1 Installation With Wire Feeder
INTELLIWELD POWER SOURCE
115 VAC/Contactor
Output
Connected
Motor
Control
Feeder 115 VAC
Gun
Digital
Trigger
Dual Wire Feeder
S-0484
Diagram
3-2. RDC-IW-2 Installation With Dual Wire Feeder
115 VAC/Contactor
115 VAC/Contactor
INTELLIWELD POWER SOURCE
Output
Control
/
RDC.IW-1 Shown
RDC-IW-1 Shown
(Connections Same
For RDC.IW.2)
(Connections Same
For RDC.IW.2)
S .0486
S0485
Diagram
Output Connections For Shielded
Welding (SMAW) (Reverse Polarity)
3-3.
Metal Arc
Without Wire Feeder
Diagram 3-4. Output Connections For Gas
Tungsten Arc Welding (GTAW) (Straight Polarity)
Without Wire Feeder
OM.871
Page
3
a
WARNING:
ELECTRIC SHOCK
can
kill.
3-4.
115
Shut down welding power source and wire
feeder, and disconnect input power employ
ing lockout/tagging procedures before
specting or installing.
in
Diagrams
consist
in open
3-1 And
(Figure
3-2)
Make connections between remote control, wire feeder,
welding power source as follows:
of
pad
position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
3-1 And
and
Connect ten-socket plug
1.
Lockout/tagging procedures
locking line disconnect switch
CONNECTION TO
CONTACTOR
VAC
WELDING POWER SOURCE
Do not touch live electrical parts.
trol cord to
on
supplied output
ten-pin receptacle
mote control.
Rotate threaded collar
con
of the
on rear
fully
re
clock
wise.
2.
Locate 115 volts/contactor control cable
supplied
with wire feeder.
Connect 115 volts/contactor cord to matching re
ceptacle on rear of wire feeder as follows: align
3.
INSTALLATION OF REMOTE CONTROL
3-1.
keyways, insert plug, and
The remote control
can be mounted on top of a wire
feeder. To install remote control, proceed as follows:
Loosen the four wrapper
feeder control box.
1.
Place remote control
2.
box with front
on
screws on
the top of the
in the
same
4.
Slide control down onto
5.
Tighten
wrapper
remaining
fully
IMPORTANT:
plug,
and roate threaded
clockwise.
If the
supplied cords do
not match the
wire feeder and/or welding power source receptacles,
obtain the necessaiy adapter cord from your welding
equipment distributor.
screws.
screws.
SWITCHING
lW-2 Models
115 VOLT AC CONNECTION TO THE WIRE
FEEDER
insert
align keyways,
collar
3-5.
3-2.
end of 115 volts/contactor cord
REMOTE 14 receptacle on welding power
source. Connect plug to receptacle as follows:
to
direction.
Position control so that wrapper slots correspond
to feeder control box screws.
3.
Route
4.
top of wire feeder control
panels facing
roate threaded collar
fully clockwise.
(Figure
3-1 And
Diagrams
RELAY
(RDC
Diagram
CONNECTION
Only) (Figure
3-1 And
3-2)
3-1 And
Connect four-contact connector from
3-2)
control to four-contact connector
Connect four-socket plug from rear of remote control to
four pin receptacle on rear of wire feeder. Rotate collar
feeder.
clockwise.
3-6.
rear
on rear
of remote
of dual wire
REMOTE CONTROL RECEPTACLES
(Figure
4-1)
OUTPUT CONTROL CONNECTION
3-3.
3-1 And
Diagrams
3-1 And
(Figure
3-2)
The remote control receptacle(s) is provided on the re
mote control front panel for connecting an optional digi
tal dual schedule control. Use an
Connect ten-socket plug
to
ten-pin receptacle
tate threaded collar
Connect
cle
on
fully
welding
clockwise.
OM.871
Page
4
supplied output control
on rear
fully
cord
of the remote control. Ro
clockwise.
end of cord to REMOTE 10 recepta
power source. Rotate threaded collar
remaining
the
on
control to
interconnecting cord to
front of the remote
receptacle
the
on
Digital Dual Schedule
six-pin receptacle
connect six-socket
on
Control.
IMPORTANT: When
using a Digital Dual Schedule Con
trol, place appropriate STANDARD/REMOTE switch in
the REMOTE
position.
SECTION 4- OPERATOR CONTROLS
Control
Digital Display
Amps Control
Arc Control
Contactor
CC/C P Switch
Remote Control
Switch
Volts/Amps 5witch
Volts Control
Ret. SA.094 539
Remote Control
Figure
4-1. Front Panel View
VOLTS CONTROL (Figure 4-1)
4-1.
The VOLTS control is
a
ten-turn
potentiometer which
the control clockwise increases
(RDC-IW-2
voltage.
This control is disabled when the CCICP Selector switch
is in the CC position.
IMPORTANT: The VOLTS control can be adjusted while
optional Digital Dual Schedule Control. The Remote
Control switch must be in the STANDARD position to
preset welding parameters at the RDC-IW. The Remote
Control switch must be in the REMOTE position to pre
set welding parameters from the Digital Dual Schedule
control and to dual schedule
AMPS CONTROL
The AMPS control is
(FIgure 4-1)
potentiometer which pre
weld amperage for constant current applications.
Rotating
ten-turn
a
the control clockwise increases amperage.
This control is disable when the CC/CP Selector switch
is in the CP position.
IMPORTANT: The AMPS control
can
be
adjusted while
VOLTS/AMPS
DISPLAY
SELECT
AND INDICATING LIGHTS
This switch is used to select either volts
on
the
digital display.
volts
indicating light comes
cating light
on.
displayed,
When the switch is in the
displayed,
while
The
VOLTS/AMPS
and the amps indi
Switch
Welding
processes. The CC
The CP position provides a constant voltage output de
signed for wire feeding applications such as Gas Metal
(GMAW), Flux Cored Arc (FCAW),
(SAW) Welding.
ARC CONTROL
4-6.
or
Submerged
(Figure 4-1)
The ARC CONTROL
disabled in the CP
potentiometer is
(Constant Potential) and pulsed
modes.
and the
comes on.
IMPORTANT:
changed
are
are
or
source.
position is also normally used for Air Carbon Arc Cutting
(AAC) and gouging processes.
IMPORTANT:
amps to be
When the switch is in the
VOLTS (down) position, volts
AMPS position, amps
SWITCH
(Figure 4-1)
welding power
Gas Tungsten Arc (GTAW)
Arc
shown
conditions.
The CC position provides a constant current output spe
cifically designed for Shielded Metal Arc (SMAW) and
Arc
welding.
4-3.
welding
CC/CP SELECTOR SWITCH (Figure 4-1)
4-5.
from the
sets
Illustrated)
The CC/CP selector switch allows selection of CC (con
stant current), CP (constant potential or voltage) output
welding.
4-2.
Model
an
presets weld voltage for constant voltage applications.
Rotating
Receptacle
can
be
The ARC CONTROL potentiometer provides variable
selection of short-circuit current to suit individual welding
conditions. Rotating this control clockwise causes the
current to increase as the short-circuit condition is ap
proached.
welding.
0, the
When this control is set at
current
begins
some
to increase when arc
value above
voltage drops
below 20 volts.
4-4.
REMOTE CONTROL
SWITCH(es) (Figure 4-1)
The Remote Control switch(es) is provided for selecting
single scheduling via the RDC-IW or dual scheduling via
When the control is set at 10, the short-circuit current is
considerably higher than normal welding current (see
welding power
source
volt-ampere
curve
for CC
mode).
OM-871
Page
5
This provides extra current for arc starting in out-of-posi
as well as for certain types of electrodes.
tion welds
When the control is set at 0, short-circuit current is the
same as normal welding current. The 0 position provides
current characteristics associated with the Gas
sten Arc
Tung
Welding (GTAW) process.
If the Remote Control CONTACTOR switch is in the ON
will be present at the out
put terminals whenever the welding power source
POWER switch ON button is pressed.
position, open-circuit voltage
IMPORTANT:
on
When the control is set at 5, short-circuit current is ap
proximately half that of the 1 0 position but still higher
than normal
welding
current. The 5
moderate current increase for
arc
certain types of electrodes and
Select
a
position provides
starting
a
indicating light
on or
off by
a
physical secondary
contactor; rather, the weld output is controlled by solidstate circuitry in the welding power source.
If contactor control
place
turns on when the
CP Selector switch is in the CC position
while
output is not switched
applications.
indicating
CC/
that
the ARC CONTROL is active.
IMPORTANT:
the term CONTACTOR is used
necessary for
setting best suited for the application.
The Arc Control
Although
nameplate and throughout this manual, the weld
the
by
means
of
a
wire feeder is desired,
the Remote Control CONTACTOR switch in the
OFF position. Open-circuit voltage will be present at the
weld output terminals whenever the gun switch is
closed.
The ARC CONTROL
be
can
adjusted
welding.
DIGITAL DISPLAY
4-8.
4-7.
CONTACTOR SWITCH
a
WARNING:
(Figure 4.1)
ELECTRIC SHOCK
functioning as a voltmeter, the digital display indi
voltage to the nearest tenth of a volt while welding
and preset voltage when unit is idling.
When
can
kill.
cates
Do not touch live electrical parts.
Do not touch the weld output terminals when
the contactor is energized.
Do not touch electrode (or gun wire) and work
clamp
When
functioning as an ammeter, the digital display indi
cates weld amperage to the nearest ampere while weld
ing and preset amperage when unit is idling.
at the same time.
SEQUENCE OF OPERATION
SECTION 5
f~
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
Keep
all
covers
can
Wearers should consult with their doctor be
going near arc welding, gouging,
welding operations.
fore
and panels in place while op
erating.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
5-1.
hearing.
FUMES AND GASES
your health.
can
body protection.
seriously
harm
Use enough ventilation to keep fumes and
gases from the breathing zone.
WELDING
wounds.
WIRE
can
cause
puncture
Do not point gun toward any part of the
other personnel.
HOT
(GMAW
AND
FCAW)
AA
WARNING: Read and follow safety informa
tion at beginning of entire Section 5 before
a
USING BOTH POSITIVE (+)
WARNING:
WELD OUTPUT TERMINALS at same time
can cause serious electric shock and arcing
hazards.
proceeding.
Do not use both positive
nals at the same time.
body or
METAL, SPATTER, AND SLAG
spot
GAS METAL ARC AND FLUX CORED ARC
WELDING
Wear correct eye, ear, and
or
See Section 1
Safety Rules For Operation Of
Arc Welding Power Source in the welding power
Manual.
source Owners
void if the unit is operated with any
portion of the outer enclosure removed.
Warranty is
cause
(Figure 4-1)
(+) weld output termi
Read welding power source Owners
for additional information.
can
fire and burns.
Manual
Watch for fire.
Have
a
to use
fire
it.
Install and
extinguisher nearby and know how
ing
2.
OM.871
Page
6
connectwelding
to its Owners
power
source
accord
Manual.
Install Remote Control
as
instructed in Section 3.
Install and connect wire feeder
3.
Owners
Wear
4.
according
to its
workpiece.
dry insulating gloves
and
Select proper electrode.
6.
clothing.
Connect work clamp to clean, bare metal at
5.
Connect work clamp to clean, bare metal at
5.
Manual.
7.
Depress welding power
workpiece.
Place Remote
8.
6.
Select proper
7.
Depress welding power
welding
wire.
ing power
source
POWER switch
9.
Output Control
on
position.
11.
Place CONTACTOR switch in ON position.
the A DC-lW
12.
the weld
con
Place VOLTS/AMPS switch in the AMPS posi
tion.
13.
Place CC/CP Selector switch in CP position.
Place VOLTS/AMPS switch in the VOLTS
12.
Thread
Owners
15.
welding
wire
as
instructed in wire feeder
Manual.
Make ay required adjustments to wire feeder.
IMPORTANT: If an optional Digital Dual Schedule con
trol is used, place Remote Control switch in the RE
MOTE position and set the welding parameters for the
second schedule on the Dual Schedule Control.
16.
Turn
17.
Wear
18.
on
shielding gas supply,
welding helmet with
cording to ANSI Z49.1.
if
15.
Wear
16.
Insert electrode into electrode holder.
17.
Begin welding.
welding helmet with proper
cording to ANSI Z49.1.
proper filter lens
a
WARNING: Read and follow safety informa
tion at beginning of entire Section 5 before
a
USING BOTH POSITIVE (+)
WARNING:
WELD OUTPUT TERMINALS at same time
can cause serious electric shock and arcing
hazards.
Do not use both positive
same time.
WARNING: Read and follow safety informa
tion at beginning of entire Section 5 before
both
2.
Install Remote Control as instructed in Section 3.
3.
4.
Install and connect wire feeder
Install flux system
dry insulating gloves
as
Install and connect wire feeder
Owners Manual.
Depress welding power
4.
Wear
9.
and
clothing.
POWER switch
on
the RDC-IW con
position (see Section 4-4).
Place CC/CP Selector switch in CP position.
10.
Place CONTACTOR switch in OFF position.
11.
Place VOLTS/AMPS switch in the VOLTS
to its
posi
tion.
12.
dry insulating gloves
clothing.
source
Place remote control switch
accord
according
and
ON button.
instructed in Section 3.
3.
Man
workpiece.
trol in the desired
Install Remote Control
to its Owners
Connect work clamp to clean, bare metal at
8.
2.
according
Wear
Read we/ding power source Owners Manual
for additional information.
source
to its
6.
time.
Install and connect welding power
ing to its Owners Manual.
according
Manual.
5.
7.
1.
source
ual.
positive (.4.) weld output termi
same
accord
Install and connect welding power
ing to its Owners Manual.
Owners
WARNING:
USING BOTH POSITIVE (+)
WELD OUTPUT TERMINALS at same time
can cause serious electric shock and arcing
hazards.
Manual
1.
(SMAW)
proceeding.
use
(+) weld output termi
nals at the
Read welding power source Owners
for additional in formation.
a
Do not
(SAW)
proceeding.
ac
SHIELDED METAL ARC WELDING
ac
SUBMERGED ARC WELDING
Begin welding.
nals at the
filter lens
5-3.
applicable.
5-2.
a
Place ARC CONTROL to desired position (see
Section 4-6).
Preset VOLTS control to desired weld voltage
setting (see Section 4-1).
14.
14.
posi
tion.
13.
Preset AMPS Control to desired weld amperage
setting (see Section 4-2).
Place CONTACTOR switch in OFF position.
11.
con
4-4).
Place CC/CP Selector switch in CC position.
on
trol in the STANDARD position.
10.
the RDC-IW
10.
switch
power source in the REMOTE
Place remote control switch
9.
on
trol in the desired position (see Section
Place Remote
ing
Output Control switch on the weld
the REMOTE position.
source in
Place remote control switch
ON button.
8.
POWER switch
source
ON button.
Preset VOLTS control to desired weld
voltage
setting (see Section 4-1).
OM-871
Page
7
13.
Wear
14.
Make any required
15.
Turn
16.
Begin welding.
safety goggles with
cording to ANSI Z49.1.
on
correct filter shade ac
adjustments
to wire feeder.
flux system.
welding helmet with
cording to ANSI Z49.1.
18.
Wear
19.
Begin welding.
(AAC)
GAS TUNGSTEN ARC WELDING (GTAW)
a
WARNING: Read and follow safety informa
tion at beginning of entire Section 5 before
a
WARNING:
USING BOTH POSITIVE (+)
WELD OUTPUT TERMINALS at same time
can cause serious electric shock and arcing
proceeding.
a
WARNING: Read and follow safety informa
tion at beginning of entire Section 5 before
a
WARNING:
USING BOTH POSITIVE (+)
WELD OUTPUT TERMINALS at same time
can cause serious electric shock and arcing
hazards.
proceeding.
Do not use both positive (..) weld output termi
nals at the same time.
hazards.
Read welding power source Owners
for additional information.
Do not use both positive (.4.) weld output termi
na/s at the same time.
Read welding power source Owners
for additional in formation.
Install and connect
ing
to its Owners
Manual
1.
Manual.
Install Remote Control
3.
Install and connect wire feeder
as
2.
Install Remote Control
3.
Connect compressed air supply.
4.
Wear
instructed in Section 3.
5.
according
to its
accord
as
instructed in Section 3.
dry insulating gloves
and
clothing.
Connect work clamp to clean, bare metal at
Manual.
Install and connect
ing
source
workpiece.
6.
4.
Install and prepare welding power
to its Owners Manual.
Manual
ing
welding power source accord
2.
Owners
ac
AIR CARBON ARC CUTTING AND GOUGING
5-5.
5-4.
1.
proper filter lens
to its Owners
High-Frequency
unit accord
7.
Manual, if applicable. Scratch
start GTAW does not
require
the
5.
Wear
6.
Connect work clamp to clean, bare metal at
and
Depress welding power
source
POWER switch
ON button.
of external
use
high frequency.
dry insulating gloves
Select proper carbon electrode.
clothing.
8.
Place CC/CP Selector switch in CC position.
9.
Place CONTACTOR switch in ON position.
10.
Place VOLTS/AMPS switch in the AMPS posi
tion.
workpiece.
11.
7.
Select proper tungsten electrode.
8.
Depress welding power
source
POWER switch
12.
ON button.
Preset AM PS control to desired amperage
(see Section 4-2).
Set ARC CONTROL to desired
13.
Insert electrode into torch.
14.
Turn
10.
Place CC/CF Selector switch in CC
15.
Wear
11.
Place CONTACTOR switch in ON position.
16.
12.
Place VOLTS/AMPS switch in the AMPS posi
tion.
Begin cutting/gouging
5-6.
SHUTTING DOWN
Preset AMPS control to desired weld amperage
1.
setting (see Section 4-2).
2.
13.
position.
Set ARC CONTROL toO (zero).
15.
Prepare tungsten electrode according
16.
Turn
source
on
Owners
to
welding
3.
Turn
on
cable.
shielding gas and water supplies as appli
OM-871
Page 8
and
adjust High-Frequency
supply.
air
welding helmet with proper filter lens
cording to ANSI Z49.1.
Stop welding
or
ac
process.
cutting/gouging
Depress the welding power
process.
source
POWER
unit if
appli
Turn off the
shielding gas
and water
supplies
if ap
plicable.
Manual, and insert into
a
WARNING:
CONCENTRATION
HIGH
SHIELDING GASES
can
harm health
Shut off gas supply when not in
cable.
17.
on
switch OFF button.
14.
power
torch.
position (see Sec
tion 4-6).
Place remote control switch on the RDC-IW con
trol in the desired position (see Section 4-4).
9.
setting
4.
Turn off flux
applicable.
supply
and
or
OF
kill.
use.
compressed
air
supply
if
SECTION 6
6-1.
MAINTENANCE AND TROUBLESHOOTING
IMPORTANT:
Every six months, inspect all interconnecting cords and
plugs for damage to the insulation jacket. Repair or re
this unit for
place the cord(s)
ROUTINE MAINTENANCE
Every six months inspect the labels on
legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of
precautionary labels.
a
WARNING:
ELECTRIC SHOCK
can
kill.
TROUBLESHOOTING
a
WARNING: ELECTRIC SHOCK
Do not touch live electrical parts.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Lockout/tagging procedures Consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
MOVING PARTS
Allow
can cause severe
can cause
injury.
serious
Keep away from moving parts.
injury.
HOT SURFACES
Keep away from moving parts.
HOT SURFACES
kill.
can
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
servicing.
servicing.
serious
(Table 6-2)
Shutdown welding powersource, and discon
Shutdown welding power source, and discon
nect input power employing lockout/tagging
procedures before inspecting, maintaining, or
can cause
necessary.
6-2.
Do not touch live electrical parts.
MOVING PARTS
as
Allow
burns.
burns.
cooling period before servicing.
Troubleshooting
cooling period before servicing.
can cause severe
to be
performed only by quali
fied persons.
Table 6-1. Maintenance Schedule
It
Maintenance
Frequency*
Every
month.
Units in
heavy
service environ
ments:
assumed that the unit
~
was
properly installed
accord
manual, the operator is familiar
with the function of controls, the unit was working prop
ing
to Section 3 of this
erly,
and that the trouble is not related to the
welding
process.
Check labels and interconnecting
cords.
The
following table is designed
Every
6 months.
Check all labels (see IMPORTAN1
block, Section 6-1) and inter
connecting cords.
*Frequency of service is based on units operated 40
hours per week. Increase frequency of maintenance
if usage exceeds 40 hours per week.
to
diagnose
and
provide
of the troubles that may develop in
this unit. Use this table in conjunction with the circuit dia
gram while performing troubleshooting procedures. If
remedies for
some
the trouble is not remedied after
performing these
proce
dures, contact the nearest Factory Authorized Service
Station. In all cases of equipment malfunction, strictly
follow the manufacturers
procedures
and instructions.
OM-871
Page
9
Table 6-2.
TROUBLE
No
display.
Welding
power source
does not deliver preset
current and voltage.
Troubleshooting
REMEDY
CAUSE
Wire feeder Power switch in OFF position.
Energize
Digital
Replace
meter.
Remote Control switch on RDC-IW-2 in
REMOTE position without a digital Dual
Scheduling Control connected.
wire feeder.
meter.
Place Remote Control switch in
STANDARD position or connect
a
Digital
Dual
Scheduling
Control.
Remote Control switch
on
welding power
source.
Unable to preset
current
voltage;
adjustment available.
VOLTS control Ri.
Make sure Remote Control
switch is in REMOTE position.
Replace
Ri.
~______________________________
VOLTS/AMPS Switch S2.
Replace S2.
Relay CR52.
Replace CR52.
Switch S5.
Replace S5.
AMPS control R2 (or R4).
Replace R2 (or R4).
VOLTS/AM PS switch S2.
Replace S2.
Relay CR52.
Replace CR52.
Switch S5.
Replace S5.
Does not display actual
115 VAC connection to feeder improper
Check connection.
parameters while welding.
or
Unable to preset current;
voltage adlustment available.
not secure.
CR50 or CR54 (RDC-1W-1 models),
CR50 or CR56 (RDC-1W-2 models).
Relays
or
OM.871
Page
10
Replace relay(s).
SECTION 7- ELECTRICAL DIAGRAMS
AC
B
AC
DA
IN
B
C
E
H
C
D
I
Circuit
Diagram
7-1. Circuit
Diagram
Diagram
No. A-093 385
For RDC-IW-1 Models
OM-871
Page
11
AC
IN~
AC
OUT
A
~
C
CE
F
Circuit Diagram No. B-093 419-A
Diagram
OM-871
Page
12
7-2. Circuit
Diagram
For RDC-IW-2 Models
635
07
SC-i
No.
Diagram
P3
Wiring
Models
248
RDC-IW1
For
Diagram
PLG2
Wiring
I
PC
PL2
7-3.
Diagr m
I
PLG
GPOUN
SI
KEYWA
PCJ
PLG5O
SECTION 8
PARTS LIST
OM-871
Page
15
541-A
SC-094
24
25
26
(RDC-IW2)
1
27
8-2
Fig
7
Asembly
Main
6
28
8-1.
29
Figure
5
30
2
31
32
~
~
30
33
Quantity
Item
No.
Dia.
Part
No.
Mkgs.
Figure
I
S1,2
011 770
I
S1-3
011 770
2
R1,2
603856
2
R1-4
603856
3
R5
093 550
4
094026
4
S3,4
S4,5
5
PLG5O
6
PLG5O
PLG51
094026
135560
079 747
079748
Model
Description
8-1. Main
Assembly
~oc-~w-i
SWITCH, tgl SPOT 5A 125V
SWITCH, tgl SPOT 5A 125V
2
POTENTIOMETER, WW sltd sft biT 2W 10K ohm
POTENTIOMETER, WW sltd sft lOfT 2W 10K ohm
POTENTIOMETER, C sltd sft lIT .5W 2.5K ohm
SWITCH, tgl DPDT MC 5A 125VAC
SWITCH, tgl DPDT MC 5A 125VAC
HOUSING PLUG & SOCKETS, (consisting of)
2
TERMINAL,
HOUSING,
HOUSING,
RDCIW-2
3
4
I
I
2
2
9
contact hdr 24-18 wire
term hdr 18
pin posn
pin. posn
1
7
079748
079 747
093 723
094 036
8
+048 586
WRAPPER
I
9
134327
LABEL, warning general precautionary
1
1
10
073756
4
4
6
7
term hdr 18
TERMINAL, contact hdr 24-18 wire
CIRCUIT CARD, relay (Fig 8-2)
CIRCUIT CARD, relay (Fig 8-2)
12
010476
13
604571
14
079531
15
048284
STAND-OFF, No. 6-32 x .625 lg
RECEPTACLE w/PINS, (consisting of)
TERMINAL, male 1 pin sz 16 18-14 wire
BUSHING, strain relief .625 ID x .57Omtg hole
CABLE, port No. 184/c (order by ft)
CLAMP, cable strain releif sz 11
HOUSING PLUG & SOCKETS, (consisting of)
16
17
079 534
020 577
604 108
TERMINAL, female lskt 18-14 wire
BUSHING, strain relief .500 ID x .465mtg hole
WIRE, lead l8ga strd (order by ft)
18
056 264
CONNECTOR, male 4cont 1OA
CABLE, interconnecting 1 Oft (consisting of)
PLUG, 10 pin MS-3106A-18-1P
CLAMP, cable AN-3057-1 0
CABLE, port No. 18 10/c (order by ft)
PLUG, lOsktMS-3106A-18-1S
RECEPTACLE, 10 pin MS-3102A-18-1P
RECEPTACLE, 10 pin MS-3102A-18-1P
11
RCI
048283
079 535
19
089 870
20
039 716
21
22
073 332
073 140
23
089 647
24
24
RC3
RC4
089646
089646
25
601 219
26
TE 1
038 839
27
RC2
039 825
27
RC2,3
039 825
28
089 875
28
089 876
29
30
097 922
31
PL1,2
027 645
32
P LG2
028 598
33
081 798
34
093 551
+When
ordering
a
LINK, iumper term blk 20A
BLOCK, term 20A 5P
RECEPTACLE, 6skt MS-3102A-14S-6S
RECEPTACLE, 6skt MS-31 02A-1 4S-6S
CASE, section front/bottom/rear
CASE, section front/bottom/rear
NAMEPLATE, (order by model & serial number)
KNOB, pointer
LIGHT, md red lens 125VAC
TERMINAL, hdr l5skt
METER, digital
KNOB, pointer
component originally displaying
a
precautionary label, the label should
1
18
18
1
I
1
1
4
4
1
1
3ft
3ft
1
1
1
1
4
4
4ft
1
1
1
1
2
2
loft
lOft
1
1
2
2
1
1
2
1
1
1
2
4
2
2
1
1
1
1
1
1
also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-871
Page
17
Quantity
Dia.
Part
No.
Mkgs.
Model
Description
Figure
CR5O-54
093 558
CR5O,52,56
093 558
CR51 ,53,54
R50
048 028
R51
035 827
R52
094 028
R53,55
094 040
R54
094 027
R56
RC5O
RC5O
RC51
094 028
8-2. Circuit Card,
Relay (Fig 8-1 Item 7)
RELAY, end 12OVAC 4PDT
RELAY, end 12OVAC 4PDT
RELAY, end 1 2OVAC 4PDT
POTENTIOMETER, cermet
000 038
RDC-IW-1
4
3
3
2511 .5W 2K ohm
trmr
1
RESISTOR, CF .25W 10K ohm
RESISTOR, MF .25W 226K ohm
1
1
RESISTOR, MF .25W 1 meg ohm
RESISTOR, MF .25W 909K ohm
RESISTOR, MF .25W 226K ohm
TERMINAL, hdr 18 pin
TERMINAL, hdr 9 post
TERMINAL, hdr 18 pin
RESISTOR, WW fxd zero ohm
SPRING, holddown relay
SOCKET, relay
079 749
072 670
079 749
092 648
079 844
091 861
RDC-IW-2
2
2
1
1
0
11
1
4
6
4
6
0
CR54
A
0
B
0
C
0
D
0
£
0
F
0
G
0
1
I
1 1
I
I
I
j
I
I
I
I
I
I
j
r
I
I
CR51
H
r
c~c
1
0
0
RCSO
ASgY
.1
094036
10
0
K
0
0
0
LU
P1
PR
0
0
O~jRC5t
o
o
o
o
o
ST U
V
W
X
Y
ZJM4BB~CCJ00
0
o
o
0
0
0
8~094 035
RDC-IW-2 Card Illustrated
Figure
8-2. Circuit
Card, Relay
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-871 Page 18
I
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