Download OWN ERS MANUAL - Miller Electric

June 1986
IMPORTANT
Read
and
understand
the
entire
FORM: OM-533
Effective With Style No. JG-11
contents of both this manual and the power source
manual used with this unit, with special emphasis
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 equipment. Do not allow
untrained persons to install, operate, or maintain
this unit. Contact your distributor if you do not fully
understand these instructions.
on
MODEL
RPC-lP
FIJLE copy
.RETURN TO FOLDER
OWN ERS
MANUAL
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON, WI 54912 USA
ADDITIONAL COPY PRICE 35 CENTS
NWSA CODE NO. 4579
PRINTED IN U.S.A.
~
LIMITED WARRANTY
EFFECTIVE: JANUARY 2, 1986
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY
tions
warrants
\d
-
Subject
to the terms and condi-
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
to
its Distributor/Dealer 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
All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh and Onan engines
.
Œ~
which have
a two
year warranty,
as specified below, Millers warranty does not apply
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.
Except
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 (1) repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
?
the reasonable
~J
cost
of repair
replacement
or
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 F.O.B., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized service
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the warranty
claim procedures to be followed.
D
j~
?
to
Miller shall be required to honor warranty claims on warranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip-
~J
ment to the
1. Arc
3.
:t1
original
welders,
user:
power sources and components
feedeuandp~smatorches
AJlwaIdfr~ggu
4. All other Millermatic Feeders
5.
Replacement
or
repair parts:
6. Batteries
provided that Miller is notified
of the date of such failure.
....
1 year
90 days
1 year
exclusive of labor.. 60 days
6 months
in
writing within thirty (30) days
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED
WARRANTY, GUARANTY OR REPRESENTA
TION 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 MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT
AS
EXPRESSLY PROVIDED BY MILLER IN
MILLER
PRODUCTS ARE
INTENDED
FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS WARRANTIES DO NOT EXTEND
WRITING,
~
A
NYsA.
~
ERRATA SHEET
After this manual was
to data
appearing
printed,
refinements In
equipment design occurred.
This sheet lists
exceptions
later in this manual.
AMENDMENT TO SECTION 2- INSTALLATION
Add Section 2-3. 650/1000
a
An~ere Model Selector Switch
WARNING: ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
Shut down welding power source and disconnect the Remote Pendant Cont rol before
tion of dip switches.
ELECTROSTATIC DISCHARGE (ESD)
changing posi
damage circuit board components.
handling circuit boards.
properly grounded
Transport all static-sensitive components in proper static-shielding carriers or packages.
Put
Perform work
can
wrist strap BEFORE
on
only at
a
static-safe work
area.
This Remote Pendant Control is designed to be used with either a 650 or 1000 ampere intellipuise welding power
source. A dip switch is located on circuit board PC5 to set up the Remote Pendant Control for operation with 650 or
1000 ampere models. The unit is shipped from the factory set up for operation with the 650 ampere models. Proceed
as
follows to set up the Remote Pendant Control for
1.
2.
Remove
operation
with 1000 ampere models:
cover.
Place both dip switches in the down position for operation with 1000 ampere models. Place both
position for operation with 650 ampere models (see Figure 2-2 on this Errata Sheet).
dip switches in
up
3.
Add
Reinstall
Figure
2-2.
cover.
Dip Switch Positions
And Locations
Both dip switches down for
1000 amp.r. model operation
Both dip switches up for
050 amp.r. model operation
/~ >
Front Panel
8.113 509
FIgure
2-2.
Dip Switch
Positions And Locations
AMENDMENT TO SECTION 5- MAiNTENANCE & TROUBLESHOOTING
Amend
Figure
5-1. Circuit
Diagram
A
II
B
C
97
97
For Pendant Control
C
A
L
F
J
E
M
P
~
C
H
I
C
S
N
R
B
0
/54
1/60
J_LED
I
~
/64
Figure
Amend
Figure
5-2. Circuit
Diagram
5-1. Circuit
/65
1/6/
J/69
J_LSD2
J_LED~
97~~7
97~,7
Circuit Diagram No. B-107 993-B
Diagram For Pendant Controi
For Circuit Board PC5
AM
AK
0
A-H
AAAP
Circuit
Figure
OM-533
Page
2
5-2. Circuit
Diagram
For Circuit Board PC5 Effective
Diagram
Through Serial
To
PLG2I
To P1022
No. B-107 994-A
No: JJ487350
AM
AK
A-N
AAAP
Circuit
Diagram
TO P~G2I
10
P1.022
No. B-124 223
Figure 5-2A. Circuit Diagram For Circuit Board PC5 Effective With Serial No. JJ487350
Add
Figure
5-3.
Wiring Diagram
For Pendant Control
(See Page
4 on this
Supplement)
AMENDMENT TO PARTS LIST
Amend the Parts List
Dia.
**
1-10
22-
Mkgs.
S6
as
follows:
Part
No.
108 944
108 198
R13,28 108 051
R32,33
Replaced
Description
With
108 945
124 002
095 828
052 145
Quantity
SWITCH, rotary
CIRCUIT CARD, pendant (Eff w/JJ487350)
RESISTOR, metal film 0.25 watt 26.7K ohm (Elf
RESISTOR, carbon film 0.25 watt 170K ohm
1
1
w/JJ487350)
.
1
2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-533
Page
3
a a. -n Cu C - CD U
-
2 -AH) 2 -AG 2 -AJ)
)A(RC3-)
_
90
I
160
WIP~
120
-~
wIp~
0
60
20
S6A
II
97B)IT-C 90A)RC3-G
2)-B)
159A)PLUG 158A(PLUG 157A)PLUG 129A)RC3-N 468(RC)-H 46C(PLUG
30A)RCS6B~
21-0)
I56A(PL~
2 -AK)
60
49A)P6-CW
IXW
A()HSI)32A(S6-0) 16A(PLOU 142A(S7-PEK) 13A(S6-90) (
WXPE )
~ ~:_ 16A
PLUG
rl29A)S6IBO
RB
13A(RC-S) 2-AL) 916I.)
132A(RC-T 169A(PLUG 1/
21-H)
GRD
46A
A(RC3-L
&
90A(R8-CW
~…,IA)S6-20
GRD
538A
C12
No.
CHASI GRD Diagr m
:
Wiring
)
2 -AB)
22
2 -API
60A(PLUG ~IA(S6-C) 32A(PLlJ~ 48A(S-0l4) 48B(PLUG IOA(S7-VG) 197A(IT-C)
3
LED
I
-
3-Co~ji 21-C)
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I
3~2~
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IRPD TMLH
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312
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21-A
MET R
For
0
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VOLT ~IET R
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97F(LED 97B)R8-CW 97A)RC3-F
I
2
J54C(AM-13) . 97K(AM-
IT
Diagram
U Q~
Wiring
AJ AH AG AF AE AD AC AB
2~L
211
PLC
PLC
120,8)
OUT)
16A(RC3-K) 15A(N-7) 152A(S7-WIPER)
48RIP(~3-fl 32A(RC-P 169A(LED ~IA(RC3-N) 157A(S6B-C) 159A(S6B-&02p.
3-k
:
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2 -AC) 2-C014}
160A(PLUG
~ ,~97EL D
2 -AF) I-CON) IT-C)
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)
~LR7C WI
Iei~
0
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LED
49A(RC3-) 49B(R7-CWI
~
16A(PLUG 97E(LO
2 -AD)
2
LED
(DA-rWC
2)-F)
IOA(RC3-E) I52A(PL.~ 142A(RC3-J)
I
-.~46A(RC3H)
10r~9-n
&6
I
/
57
SB
53.
Figure
SECTION 1
-
INTRODUCTION
Safety
B.
installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
The
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
-
Safety Rules For Operation Of
welding power source
Power Source in the
Manual.
Owners
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
___________
different levels of hazard.
ifl
: I~IcI statements include
and maintenance
carefully
or
procedures
or
installation, operation,
practices which if not
personal injury
followed could result in serious
loss of life.
operation,
practices which if not
could result in minor personal injury
equipment.
L~ statements include installation,
and maintenance
carefully followed
or damage to this
procedures
or
signal word, II~I~e1;If~1i~Ii highlights instruc
special emphasis to obtain the most
efficient operation of this equipment.
A third
tions which need
Prior to installing
RECEIVING-HANDLING
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 be furnished by the manufacturer on re
1
-
2.
-
this
TB109 521
Figure
1
-
1.
Dimensions
quest if occasion
1
-
1.
A.
GENERAL INFORMATION AND SAFETY
General
Information
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
ment.
to
file claim arises.
requesting information concerning this equip
ment, it is essential that Model Description and Style
Number of the equipment be supplied.
When
1
-
3.
DESCRIPTION
dant Control for the
-
This unit is
a
Intellipulse welding
Remote Pen
power
source.
properly connected to the welding power source
this unit provides arc control, contactor control,
voltage/amperage control, CV/CC selection, and pulse
frequency selection.
When
OM-533 Page 1
SECTION 2
INSTALLATION
Welding Power Source
Remote Control
Receptacle
IL
TA109
RPC-IP
Figure 2
WARNING: ELECTRIC SHOCK
-
kill.
can
remote Pendant
before
sure
it
making
2
Control connections.
-
1. WELDING POWER SOURCE REMOTE CON
(Figure 2-1)
TROL RECEPTACLE CONNECTIONS
-
A
17-socket
power
source
Amphenol receptacle on the welding
front panel (see OM-286) provides a con-
SECTION 3
3
-
1. MODE SELECTOR SWITCH
-
welding
power
(Figure 3-1)
position provides
a
constant
voltage output
feeding applications
Metal Arc (GMAW), Flux Cored
Submerged Arc (SAW) Welding.
OM-533 Page 2
the
plug
on
the remote control
point for the interconnecting
welding power source. Insert
interconnecting cable fully
from the
the
into
the receptacle and rotate collar clockwise.
pulsed output is desired for Gas Metal Arc
Welding-Pulsed Arc (GMAW-P), place switch at the
desired number of pulses per second: 60, 90, 120 or
180.
3
designed
from
17-socket
connection
source.
position provides a constant current output
specifically designed for Shielded Metal Arc (SMAW)
and Gas Tungsten Arc (GTAW) Welding processes.
The CC position is also normally used for Air Carbon
Arc Cutting (AAC) and gouging processes.
for wire
a
When
The CC
The CV
CONNECTIONS
OPERATOR CONTROLS
The Mode Selector switch allows selection of CC (cons
tant current), CV (constant voltage), or pulsed output
from the
RECEPTACLE
17-pin Amphenol receptacle
provides
cable
A
RPC-IP
2.
(Figure 2-1)
Place CONTACTOR switch in OFF position.
2
point for the Remote Pendant Control. Insert
17-pin Amphenol plug from the interconnecting cable
fully into the receptacle and rotate collar clockwise.
nection
_____
accidentally energized
Receptacle
Power Source/Remote Control Connections
1.
Do not touch live electrical parts.
Shut down welding power source and be
cannot be
782-A
Arc
such
as
(FCAW),
Gas
or
-
2. ARC CONTROL AND PILOT LIGHT
(Figure
3-1)
IMPORTANT
The ARC CONTROL potentiometer
pilot light are disabled in the CV (Constant Voltage)
and pulsed modes.
____________
and
The ARC CONTROL potentiometer provides variable
of short-circuit current to suit individual
selection
welding
causes
conditions.
Rotating
the current to increase
this
as
control
clockwise
the short-circuit condi
TB-i09 521
Figure3
-1.
Front Panel View
tion is
If the Remote Control CONTACTOR switch is in the ON
value above
position, open-circuit voltage will be present at the out
put terminals whenever the welding power source
POWER switch ON button is depressed.
approached. When this control is set at some
0, the current begins to increase when arc
voltage drops below 20 volts.
When the control is set at 10 (MAX.), the short-circuit
current is considerably higher than normal welding cur
(see welding power source volt-ampere curve for
CC mode). This provides extra current for arc starting in
rent
out-of-position welds
as
well
as
for certain types of elec
trodes.
rent is the same
Gas
used
as
normal
(SOFT), short-circuit
welding
current.
The 0
cur
posi
with the
provides current characteristics associated
Tungsten Arc Welding (GTAW) process.
on
the
the term CONTACTOR is
this manual, the
Although
nameplate
throughout
and
weld output is not switched on or off by a physical
secondary contactor; rather, the weld output/s controll
ed
When the control is set at 0
tion
~
by solid-state circuitry in the welding power
source.
If contactor control by means of a wire feeder is desired,
place 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 clos
ed.
When the control is set at 5, short-circuit current is ap
proximately half that of the 10 (MAX.) position but still
higher
than normal
vides
a
moderate
welding
The 5 position pro
increase for arc starting
current.
current
necessary for certain types of electrodes and
tions.
Select
a
setting best suited
The Arc Control
pilot light
for the
applica
while
processes
Welding (SMAW) and the Air
ting and gouging processes.
turns on when the
Mode
The ARC CONTROL
can
be
adjusted
welding.
Lift end of
3
-
4.
-
change switch positions.
(Figure 3-1)
weld
on
provides selection of reading
or
Average (AVG) weld
amperage
the Remote Control digital ammeter.
(Figure 3-1)
Normally the AVG
WARNING ELECTRIC SHOCK
can
kill.
_________
Do not touch live electrical parts.
Do not touch the weld output terminals when the
contactor is
to
The AMMETER switch
PEAK
3. CONTACTOR SWITCH
toggle switch
AMMETER SWITCH
amperage
3
Carbon Arc (AAC) Cut
application.
Selector switch is in the CC position indicating that the
ARC CONTROL is active.
Il~l~];1f..UI~
position is normally used with all wire feeding
(GMAW, GMAW-P, FCAW, SAW) and the
Gas Tungsten Arc Welding (GTAW) process. The ON
position is normally used with the Shielded Metal Arc
The OFF
energized.
Do not touch electrode holder (or gun wire) and
work c/amp at the same time.
switch
position is used for reading
weld amperage during Gas Metal Arc (GMAW), Flux
Cored Arc (FCAW), Submerged Arc (SAW), Shielded
Metal Arc (SMAW), Gas Tungsten Arc (GTAW)
Welding and Air Carbon Arc (AAC) Cutting and goug
ing processes.
OM-533 Paqe3
While
welding using
the Gas Metal Arc
Welding-Pulsed
3
6. VOLTS/PEAK CONTROL AND PILOT LIGHT
-
Arc (GMAW-P) process, the AVG switch position is used when display of the average (background and peak)
(Figure 3-1)
weld amperage is desired. The AMMETER switch can
be placed in the PEAK position when display of peak
This control presets weld voltage for constant voltage
applications and peak voltage for GMAW-P applica
tions.
weld amperage is desired.
3
-
5. AMPS/BKGD CONTROL AND PILOT LIGHT
(Figure 3-1)
When the Mode Selector switch is in the CV position or
of
the
one
pulses per second positions, the
VOLTS/PEAK pilot
This control presets weld amperage for constant current
applications and background amperage for GMAW-P
applications,
When the Mode Selector switch is in the CC
position or
positions, the
the
pulses per second
AMPS/BKGD pilot light turns on.
one
of
light
turns on.
This control is disabled when the Mode Selector switch
is in the CC position.
Rotating the
control clockwise increases
voltage.
II~I~D1Ifii~l~ The VOLTS/PEAK control
while we/ding.
can
be ad
justed
This control is disabled when the Mode Selector switch
is in the CV position.
Rotating the
3
justed
The AMPS/BKGD control
can
be ad-
welding.
(Figure 3-1)
displays
weld voltage to the nearest tenth
welding and preset voltage when unit is
idling. When welding using the pulsed GMAW process,
the meter displays peak voltage.
of
while
METERS
The voltmeter
control clockwise increases amperage.
II~I~.1;1V~I~
7.
-
a
volt while
The ammeter
displays weld amperage to the nearest
ampere while welding and preset amperage when unit is
idling. When welding using the pulsed GMAW process,
the meter
SECTION 4
WARNING ELECTRIC SHOCK
can
-
displays background
amperage.
SEQUENCE OF OPERATION
kill; MOVING
4
1.
-
GAS METAL ARC WELDING-PULSED ARC
_________
PARTS
can
cause
serious
injury; IMPROPER AIR
FLOW AND EXPOSURE TO ENVIRONMENT
(GMAW-P)
can
damage internal parts.
Keep all covers and panels in place while
operating.
Warranty is void if the welding power source is operated
with any portion of the outer enclosure removed.
I~1rJ;1~Il~Icf Read and follow safety information
beginning of entire Section 4 before proceeding.
1.
Install and prepare
to its Owners
ding
welding
power
Manual.
ARC RAYS. SPARKS, AND HOT SURFACES can
burn eyes and skin; NOISE can damage hearing.
2.
Install Remote Control
Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
3.
Install and prepare wire feeder
Owners Manual.
4.
Depress welding
health.
enough ventilation to keep
breathing zone.
Use
Do not
other
source accor
instructed in Section 2.
according
to
its
fumes and gases
from the
puncture wounds.
point gun toward any part of the body
WELDING WIRE
as
at
5.
can cause
source
POWER switch
or
personnel.
HOT METAL, SPATTER, AND SLAG
power
ON button.
can cause
fire
Place Mode Selector switch to desired pulses per
90, 120, or 180) position (see Sec
second (60,
tion 3-1).
and burns.
Watch for fire.
Have
a
extinguisher nearby
fire
and know how to
MAGNETIC FIELDS FROM HIGH CURRENTS
affect
6.
Place CONTACTOR switch in OFF
Section 3-3).
7.
Place AMMETER switch in the desired
it.
use
can
pacemaker operation.
Wearers should consult with their doctor before
going near
operations.
See Section
1
arc
-
welding, gouging,
spot welding
Power Source in the
Owners
Manual.
Operation Of Arc
welding power source
For
position
(see Section 3-4).
8.
Safety Rules
Welding
OM-533 Page 4
or
position (see
Preset
AMPS/BKGD
control
to
desired
background amperage setting (see Section 3-5).
Pilot light should be on.
9.
control
Preset VOLTS/PEAK
desired
to
voltage setting (see Section 3-6).
should be
10.
Make
11.
Turn
12.
peak
light
7.
Place
shielding
8.
supply.
gas
Begin welding.
9.
4
safety in formation
before proceeding.
WARNING Read and follow
beginning
of entire Section 4
welding
Install and prepare
ding to its Owners
AVG
the
AMPS/BKGD control to desired weld
setting (see Section 3-5). Pilot light
Preset
amperage
should be
____________
in
switch
AMMETER
the
(average) position (see Section 3-4).
-
1.
Place CONTACTOR switch in ON position (see
Section 3-3).
feeder.
to wire
2. GAS METAL ARC AND FLUX CORED ARC
WELDING (GMAW & FCAW)
4
6.
on.
adjustments
on
Pilot
4.
-
on.
Begin welding.
SUBMERGED ARC WELDING (SAW)
at
safety information
LLL~h1Ikcr
Read and follow
beginning
of entire Section 4 before
at
proceeding.
source accor
power
Manual.
1.
Install and prepare welding power
Manual.
to its Owners
source accor
ding
instructed in Section 2.
2.
Install Remote Control
3.
Install and prepare wire feeder
Owners Manual.
as
according
to
2.
Install Remote Control
3.
Install
as
instructed in Section 2.
its
flux
system
according
its
to
Owners
Manual.
4.
Depress welding
POWER switch
source
power
ON button.
4.
its
Install and prepare wire feeder
Manual.
according
Depress welding
POWER switch
to
Owners
5.
Place Mode Selector switch in CV
position (see
5.
Section 3-1).
power
source
ON button.
6.
Place CONTACTOR switch in OFF position (see
Section 3-3).
6.
Place Mode Selector switch in CV
position (see
Section 3-1).
7.
Place AMMETER switch in AVG
(average) posi
tion (see Section 3-4).
7.
Place Contactor switch in the OFF
position (see
Section 3-3).
8.
control to desired weld
Preset VOLTS/PEAK
voltage setting (see Section 3-6). Pilot light
should be
9.
Make
8.
Place AMMETER switch in AVG
(average) posi
tion (see Section 3-4).
on.
adjustments
to
wire feeder.
9.
Preset VOLTS/PEAK
control
to
desired
weld
Pilot
light
voltage setting (see Section 3-6).
4
shielding
10.
Turn
11.
Begin welding.
-
on
gas
supply
if
applicable.
should be
3. SHIELDED METAL ARC WELDING (SMAW)
I1i%~1~II~eF Read and follow
beginning
safety information
proceeding.
at
10.
Make
11.
Turn
12.
Begin welding.
adjustments
on
flux
to wire
feeder.
supply system.
of entire Section 4 before
4
1.
on.
Install and prepare
ding to its Owners
welding
power
-
Manual.
ILI..~:1k~lIk~Ie~
the
2.
Install Remote Control
3.
Depress
as
5. GAS TUNGSTEN ARC WELDING (GTAW)
source accor
beginning
welding
safety
information at
proceeding.
instructed in Section 2.
1.
the
Read and follow
of entire Section 4 before
power
source
POWER
Install and prepare welding power
ding
to its Owners
source accor
Manual.
switch ON button.
2.
4.
Place Mode Selector switch in CC
Install Remote Control
Section 3-1).
3.
Install and prepare
ding
5.
Rotate ARC CONTROL to desired
Section 3-2). Pilot
light should
be
as
instructed in Section 2.
position (see
position (see
on.
High-Frequency
unit
accor
its Owners
Manual if applicable. Scratch
start GTAW does not require the use of external
to
high frequency.
OM.533
Page
5
Depress welding
4.
power
POWER switch
source
4.
Depress welding
5.
Place Mode Selector switch in CC position (see
Section 3-1).
5.
6.
Set ARC CONTROL to MIN. (see Section 3-2).
Pilot light should be on.
6.
Place CONTACTOR switch in the ON
position
7.
(average)
8.
7.
Place Mode Selector switch in the CC position
(see Section 3-1).
Set ARC CONTROL
tion 3-2). Pilot
Place AMMETER switch in the AVG.
Preset AMPS/BKGD
amperage
should be
10.
Turn
be
position (see Sec
on.
position (see
(average) posi
tion (see Section 3-4).
control
to
desired
setting (see Section 3-5).
9.
weld
Pilot
Preset
light
gas and water
supplies
as
AMPS/BKGD
amperage
should be
on.
shielding
on
desired
Place AMMETER switch in AVG
position (see Section 3-4).
9.
to
light should
Place CONTACTOR switch in ON
Section 3-3).
(see Section 3-3).
8.
power source POWER switch
ON button.
ON button.
ap
desired
to
on.
10.
Turn
11.
Begin cutting/gouging
on
control
setting (see Section 3-5). Pilot light
air
supply.
plicable.
11.
Turn
on
and
adjust High-Frequency
4
plicable.
12.
4
6.
-
process.
unit if ap
7. SHUTTING DOWN
-
Begin welding.
1.
AIR CARBON ARC CUTTING AND GOUG
2.
Stop welding.
Depress
ING (AAC)
the
welding
power
source
POWER
switch OFF button.
WARNING Read and follow
3.
in formation at
safety
Turn off the
shielding
gas and water
supplies if
____________
the
beginning
1.
of entire Section 4 before
Install and prepare
to its Owners
ding
welding
applicable.
proceeding.
power source
accor
Manual.
HIGH
CONCENTRATION
SHIELDING GASES can harm health or kill.
Shut off gas
2.
Install Remote Control
3.
Connect compressed air
as
1.
-
MAINTENANCE
IAI~1~II~Ic~
-
as
remote
-
be
ELECTRIC SHOCK
5
-
can
can kill.
Do not touch live electrical parts.
Shut down welding power source and disconnect
kill.
replacement
1.
inspecting, maintaining,
before
remote control
attempting repair
or
replacement
A.
of internal components.
General
of internal components.
Inspect interconnecting cord for damage to or
breaks in the insulation jacket, particularly at the
plugs. Repair or replace cord as necessary.
Remove grease and grime from components;
moisture from electrical parts and cable.
It is assumed that proper installation has been made, ac
to Section 2 of this manual, and that the unit
cording
has been
functioning properly
until trouble
developed.
Troubleshooting
Troubleshooting
sons.
OM-533 Page 6
inspecting, maintaining,
Power to the remote control should
disconnected before attempting repair or
be
or
or
before
servicing unit.
B.
2.
if
2. TROUBLESHOOTING
Power to the remote control should
disconnected
supply
I~IJ:1~II~cf ELECTRIC SHOCK
follows:
control before
air
MAINTENANCE & TROUBLESHOOTING
Do not touch live electrical parts.
Shut down welding power source and disconnect
servicing unit.
supply and compressed
applicable.
Usage and shop conditions
frequency and type of maintenance.
Inspect equipment
Turn off flux
supply.
SECTION 5
5
not in use.
instructed in Section 2.
4.
will determine the
supply when
OF
to be
performed only by qualified
per
June 1986
Effective With
PARTS
LIST
FORM: OM-533
Style No. JG-11
Item
Dia.
Part
No.
Mkgs
No.
Description
Main Assembly
Figure A
2
3
R6,7
4
S7
5
S8
6
LED 1-3
7
RC3
8
9
R8
10
S6
108 056
109 779
CASE SECTION, front end
CASE
603 856
011 770
079 722
083 850
097 867
POTENTIOMETER, WW 10 turn 2 watt 10K ohm
SWITCH, toggle SPDT5 amp 125 volts
SWITCH, toggle SPDT 0.4 amp 2-4 volts dc
1
2
LIGHT, indicator-red lens 2 volts
RECEPTACLE, 17 pin MS-3102A-20-29P
NAMEPLATE (order by model & style number)
009 156 POTENTIOMETER, carbon 1 turn 2 watt 2.5K ohm.
108944 SWITCH, rotary-0.5 amp 115 volts ac
SHIELD, meter
108453 METER, DC 0-200 MV
108 904 ANCHOR, meter
108 198 CIRCUIT CARD, pendant (Fig
3
1
1
108 903
11
12
Quantity
A&V
PC5
038 785
1
2
B
Pg 2)
1
STRIP, terminal 3 pole
072 566
HOUSING, terminal header 8 pin
081 380 HOUSING, terminal header 14 pin
108 907 HOUSING, receptacle 13 socket
097 922 KNOB, pointer
1
2
4
2
019 663
MOUNT, 15/16ODx3/8
097 132 STAND-OFF, No. 6-32 x 3/8 inches
094 484 STAND-OFF, No. 6-32 x 1 inch
4
4
1
2
1:
4
TB109
Figure
A
-
Main Assembly
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-533
Page
1
521
Dia.
Part
Mkgs.
No.
108 198
Circuit Card, Pendant
Ai,2
096 275
A3
009 159
Ci
039 482
000 348
IC, linear 324
IC, linear 358
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
Figure
B
C2,3
C4-8,il,12
Di-6
073 739
003 530
028 351
R4
009 172
R5
108 054
R6
072 677
R7,8
089 174
R9,10,29
097 110
All
052 142
Ri 2
095 246
R13,28
108 051
R14
095 823
Ri 5
089
108
052
035
039
C9,10
R16
R17
Ri8,20-22,30,31
R19
173
053
138
827
332
R23,24,27
044 633
RC21
072 564
081 382
092 367
052 149
092 648
RC22
51
U1,2
VR1
VR2
083 772
071 248
j
2
1
electrolyte 100 uf 35 voltsdc
1
tantalum 0.47 uf 35 volts
2
ceramic0.1 uf50voltsdc
7
ceramic 1 uf50volts
2
DIODE,signal0.O2Oamp75voltsSP
6
POTENTIOMETER, cermet 25 turn 0.5 watt 50K ohm
RESISTOR, metal film 0.25 watt 1.74K ohm
RESISTOR, carbon film 0.25 watt 33K ohm
RESISTOR,metalfilm0.25wattl00Kohm
RESISTOR,metalfilmO.25wattlKohm
AESISTOR,carbonfilm0.25watti20Kohm
POTENTIOMETER, cermet 20 turn 0.5 watt 500K ohm
RESISTOR, metalfilm0.25watt26.7Kohm
RESISTOR, metalfilmO.25watt44.8Kohm
RESISTOR, metal film 0.25 watt 4.99K ohm
RESISTOR, metal film 0.25 watt2lKohm
RESISTOR, carbon film 0.25 watt20K ohm
RESISTOR, carbon film 0.25 watt 10K ohm
RESISTOR, carbonfilm0.25watt l5Kohm
RESISTOR, carbon film 0.25 watt 1 .2K ohm
RESISTOR, carbon film 0.25 watt zero ohm
TERMINAL, header 8 pin
1
1
2
3
1
1
2
1
1
1
1
6
1
3
15
1
1
SWITCH, DIP SPST
IC, interface 4066
IC, linear 7815
IC, linear 78M05
1
2
1
1
R30
0
~A3
D6~
05
U
cu
U2
r~
~ R5~
~:,
213
rj
69
II
~m
~RI8
~Rl9
411>
~jj
V
5
0
6
~
78
LI
~
c~o~7
Li
~I
312
(,4fl
___
1
_
1!i~1
~8L
1~1
___
<
1
TERMINAL,headerl4pin
______
0
Quantity
Description
___
Al
E~7DlF9
0
£
LI
__
2
1n1
02
03
___
~
04
~
RIO
p7
P8
R I I
Li~
R2 I
P27
B
~oomm~I~~Exz0
0
COMPONENTS TO BE REPLACED BY
QUALIFIED PERSONNEL ONLY
Figure
B
-
Circuit Card, Pendant
Ref. C-108 199
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-533 Page 2
If
The following information is supplied to diagnose and
provide remedies for some of the troubles that may
in
develop
Owners
welding
this
for
attributed to
Check welding power source
possible problems caused by
unit.
Manual
everything
on
the remote control functions except a
or control, the problem can be
particular switch, meter,
a
broken component.
Replace the broken
component.
power source malfunctions.
If the
Use this information
problem is still present, replace PC5. If the remote
entirely non-functionl, replace PC5. If erratic
conditions occur and the welding power source was
working properly, replace PC5.
control is
in
conjunction with the circuit
diagram while performing troubleshooting procedures.
If the trouble is not remedied after
performing these
Factory Authorized Service
Station should be contacted. In all cases of equipment
procedures, the
malfunction,
nearest
the
manufacturers
A
power
should be strictly followed.
Problems
with
this
unit
fall
into
three
categories:
1.) front panel components, 2.) circuit board PC5, or
3.) the welding power source or interconnecting cable.
6
r
E
J
break
in
the
interconnecting cable can interrupt
signals between welding power
source and remote control.
Replace interconnecting
cable if lack of continuity is suspected. Printed Circuit
board PCi in the welding power source sends and
receives signals from the remote control. If all other
components of the system are functioning, replace
welding power source PCi according to instructions in
welding power source Owners Manual.
recommendations
N
P
K
command
or
0
I
H
Circuit
Figure 5
-
1.
S
Diagram
P
N
B
No. B-107 993
Circuit Diagram For Pendant Control
OM-533
Page?
HM
0<
Circuit
Figure
OM-533 Page 8
5
-
2. Circuit
Diagram
For Circuit Board PC5
Diagram
AH
TO
PLG2I
~APP
TO
PLG22
No. B-107 994