Professional Documents
Culture Documents
Processes
Multiprocess Welding
Description
Remote Control Pendant
RCAP-1
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify
different levels of hazard and special instructions.
WARNING
WARNING statements identify procedures or practices which must be followed to avoid serious personal
injury or loss of life.
CAUTION
CAUTION statements identify procedures or practices which must be followed to avoid minor personal
injury or damage to this equipment.
IMPORTANT: statements identify special instructions necessary for the most efficient operation of this equipment.
SECTION 2 – SPECIFICATIONS
Specification Description
Overall Dimensions Height: 5-1/2 in. (140 mm); Width: 2-3/4 in. (70 mm); Depth: 2-1/2 in. (64 mm)
Additional Required Equipment Welding Power Source With Suitable Remote 17 Receptacle
Welding Processes Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc (FCAW), Gas Tungsten Arc
(GTAW), Gas Metal Arc - Pulsed (GMAW-P) Welding, Air Carbon Arc Cutting And Gouging (CAC-A)
OM-535 Page 1
SECTION 3 – INSTALLATION
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn OFF welding power source, and place pendant CONTACTOR switch in OFF position before making connections.
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ST-156 635
Figure 3-1. Connections To Welding Power Source And Optional Wall-Mounting Procedure
OM-535 Page 2
SECTION 4 – OPERATION
WARNING
ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
• Always wear dry insulating gloves. • Keep away from moving parts.
• Insulate yourself from work and ground. • Keep all doors, panels, covers, and guards closed
• Do not touch live electrical parts. and securely in place.
• Keep all panels and covers securely in place.
WELDING WIRE can cause puncture
FUMES AND GASES can be hazardous wounds.
to your health. • Do not press gun trigger until instructed to do so.
• Keep your head out of the fumes. • Do not point gun toward any part of the body, other
• Ventilate area, or use breathing device. people, or any metal when threading welding wire.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
WELDING can cause fire or explosion. MAGNETIC FIELDS FROM HIGH CUR-
• Do not weld near flammable material. RENTS can affect pacemaker operation.
• Watch for fire; keep extinguisher nearby.
• Pacemaker wearers keep away.
1 Output Control
2 Arc Control/Inductance Con-
trol
1 3 Contactor Switch
4 CC/CV Switch
2
Every month check labels, cord,
and plug for damage.
3
SA-106 543-B
1 2 3 1 Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct shade
of filter (see ANSI Z49.1).
sb3.1 10/91
1 Output Control
Use CC/CV switch to select weld
1
amperage (CC) or voltage (CV). In
CC, adjust control according to am-
perage (A) scale. In CV, adjust con-
trol according to voltage (V) scale.
Begin Welding
ssb6.1 2/92
Turn On Feeder
And Welding Begin Welding
Power Source
Begin Welding
ssb7.1 2/92
Figure 4-13. Sequence Of Air Carbon Arc Cutting And Gouging (CAC-A)
SECTION 5 – TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn OFF welding power source, and disconnect pendant before inspecting, maintaining, or servicing.
No control of weld output. Check welding power source control settings. Figure 4-7
Be sure plug PLG1 is securely connected to REMOTE 17 recep- Figure 3-1
tacle on welding power source.
Check pendant cord and replace if necessary. ––
Erratic weld; incorrect weld characteris- Check pendant settings. Figure 4-2,
tics. Figure 4-3,
Figure 4-4,
Figure 4-5
Check wire feed speed at wire feeder if applicable. ––
OM-535 Page 6
SECTION 6 – ELECTRICAL DIAGRAMS
SA-099 207-A
OM-535 Page 7
SECTION 7 – TUNGSTEN ELECTRODE
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IMPORTANT: For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding
(GTAW) process.
Pure Tungsten
(Green Band)
.010” Up to 15 * Up to 15 Up to 10
.020” 5-20 * 5-20 10-20
.040” 15-80 * 10-60 20-30
1/16” 70-150 10-20 50-100 30-80
3/32” 125-225 15-30 100-160 60-130
1/8” 225-360 25-40 150-210 100-180
5/32” 360-450 40-55 200-275 160-240
3/16” 450-720 55-80 250-350 190-300
1/4” 720-950 80-125 325-450 250-400
2% Thorium Alloyed
Tungsten (Red Band)
.010” Up to 25 * Up to 20 Up to 15
.020” 15-40 * 15-35 5-20
.040” 25-85 * 20-80 20-60
1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32” 400-500 40-55 300-450 200-320
3/16” 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
Zirconium Alloyed Tung-
sten (Brown Band)
.010” * * Up to 20 Up to 15
.020” * * 15-35 5-20
.040” * * 20-80 20-60
1/16” * * 50-150 60-120
3/32” * * 130-250 100-180
1/8” * * 225-360 160-250
5/32” * * 300-450 200-320
3/16” * * 400-550 290-390
1/4” * * 600-800 340-525
♦Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
S-0009
OM-535 Page 8
7-2. Preparing Tungsten
1 Tungsten Electrode
1 2 Balled End
Ball end of tungsten before welding
by applying either an ac amperage
slightly higher than what is recom-
1-1/2 Times mended for a given electrode diam-
Electrode Diameter
eter (see Table 7-1), or a dc elec-
trode positive amperage.
2
Ref. S-0161
CAUTION
FLYING SPARKS AND HOT METAL can cause injury and start fires.
• Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
• Keep flammables away.
warn2.1 9/91
1 Tungsten Electrode
1 2
2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.
2-1/2 Times
Electrode Diameter
Ref. S-0161
1 1 Stable Arc
2 Flat
2
Diameter of this flat determines am-
perage capacity.
3 Grinding Wheel
3
4 Straight Ground
4
Ideal Tungsten Preparation – Stable Arc Ref. S-0162
1 1 Arc Wander
2 Point
2 3 Grinding Wheel
4 Radial Ground
OM-535 Page 9
SECTION 8 – PARTS LIST
1 2
8
3
4 SA-106 543-B
5
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-535 Page 10
Notes
Notes
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate 185 & Spoolmate 250
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.
miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier for: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.