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OM-535B August 1992

Eff. w/Style Number KB-49

Processes

Multiprocess Welding

Description
Remote Control Pendant

RCAP-1

Visit our website at


www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
Working as hard as you do
This Owner’s Manual is designed to help you get the most out of your – every power source from
Miller is backed by the most
Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the
help you protect yourself against potential hazards on the worksite. We’ve business.

made installation and operation quick and easy.


With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help you to decide which exact part
the U.S.A. to be registered to
the ISO 9001 Quality System you may need to fix the problem. Warranty and
Standard. service information for your particular model
are also provided. Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
SECTION 1 – SAFETY SIGNAL WORDS
mod1.1 9/91

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

Table 2-1. Pendant

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)

Input Power Cord With Plug 15 ft. (4.6 m)

Additional Required Equipment Welding Power Source With Suitable Remote 17 Receptacle

Welding Power Source Type Needed Constant Current/Constant Voltage (CC/CV) DC

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.

swarn3.1* 10/91

Turn OFF welding power source.


1 Welding Power Source
2 17-Socket Receptacle
3 Plug PLG1 From Pendant
Insert plug into matching 17-socket
receptacle on welding power
1 source, and tighten threaded collar.
4 Mounting Bracket
5 User-Supplied Mounting
Hardware
5
4

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.

• Do not locate unit over combustible surfaces.


• Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
• Do not weld on closed containers. tions.
• Allow work and equipment to cool before handling.
See Safety Precautions at beginning of welding power
source Owner’s Manual for basic welding safety infor-
ARC RAYS can burn eyes and skin; mation.
NOISE can damage hearing.
• Wear welding helmet with correct shade of filter.
• Wear correct eye, ear, and body protection.
swarn6.1* 10/91

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

Figure 4-1. Controls

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

Figure 4-2. Safety Equipment


OM-535 Page 3
1 CC/CV Switch
Use switch to select type of weld
output. Use constant current (CC)
1 for GTAW, SMAW, GMAW-P, and
CAC-A. Use constant voltage (CV)
for GMAW and FCAW.

Ref. TC-109 369-B

Figure 4-3. CC/CV Switch

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.

Figure 4-4. Output Control

1 Arc Control/Inductance Con-


trol
Use CC/CV Switch (see
Figure 4-3) to select weld amper-
age (CC) or voltage (CV). If CC po-
sition is selected, adjust Arc Force
(Dig). If CV, adjust Inductance.
Numbers around control are for ref-
erence only.
Arc Control
1
For SMAW (Stick Electrode) weld-
ing, use control to help start an arc
or make vertical or overhead welds
(control increases short-circuit am-
perage).
When set at 0, short-circuit amper-
age is the same as normal welding
amperage.
When setting increases, short-cir-
cuit amperage increases to help arc
starting.
Set at 0 for GTAW welding.
Inductance Control
Use this control to change weld out-
put inductance for GMAW and
FCAW. Inductance determines the
“wetness” of the weld puddle.

Figure 4-5. Arc Control/Inductance Control


OM-535 Page 4
1 Contactor Switch
Use this switch to select way of
controlling welding power source
1 output.
If open-circuit voltage is desired
whenever the welding power
source is energized, place switch in
ON position. Use this position for
SMAW and CAC-A.
If contactor control by means of a
wire feeder or remote device is de-
sired, place switch in OFF position.
Use this position for GMAW, FCAW
and GTAW.

Figure 4-6. Contactor Switch

1 Welding Power Source


For ARC PAK 350:
Set 14/17 switch to 17 position.
For MAXTRON 450:
1 Set Amperage/Voltage Control
switch to REMOTE 17 position.
Set Output/Contactor switch to RE-
MOTE 14/17 position.
Set Arc Force/Inductance And CC/
CV Control Switch to REMOTE 17
position.

Figure 4-7. Welding Power Source

Install & Install & Prepare Put On Turn On Turn On Feeder


Connect Wire Feeding Personal Safety Set Controls Shielding Gas And Welding
Equipment System Equipment Power Source

Begin Welding

ssb6.1 2/92

Figure 4-8. Sequence Of Gas Metal Arc Welding (GMAW)

Install & Install & Prepare Install Synergic Put On Turn On


Connect Wire Feeding Pulse Control Personal Safety Set Controls Shielding Gas
Equipment System Equipment

Turn On Feeder
And Welding Begin Welding
Power Source

Figure 4-9. Sequence Of Gas Metal Arc Welding - Pulsed (GMAW-P)

Install & Install & Prepare Put On Turn On Feeder


Connect Wire Feeding Personal Safety Set Controls And Welding Begin Welding
Equipment System Equipment Power Source

Figure 4-10. Sequence Of Flux Cored Arc Welding (FCAW)


OM-535 Page 5
Install & Install & Connect Select Insert Put On
Connect High-Frequency Tungsten Tungsten Personal Safety Set Controls
Equipment Unit (See Section 7) Into Torch Equipment

Turn On Turn On Turn On


Shielding Gas High-Frequency Welding Power Begin Welding
Unit Source
ssb8.1 2/92

Figure 4-11. Sequence Of Gas Tungsten Arc Welding (GTAW)

Install & Select Put On Insert Turn On


Connect Electrode Personal Safety Set Controls Electrode Welding Power
Equipment Equipment Into Holder Source

Begin Welding
ssb7.1 2/92

Figure 4-12. Sequence Of Shielded Metal Arc Welding (SMAW)

Install & Connect Select Put On Insert


Connect Compressed Electrode Personal Safety Set Controls Electrode
Equipment Air Supply Equipment Into Holder

Turn On Turn On Begin


Compressed Welding Power Cutting Or
Air Supply Source Gouging
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.

Troubleshooting to be performed only by qualified persons.

Table 5-1. Welding Trouble


Trouble Remedy Section
No weld output. Be sure welding power source POWER switch is ON. ––
Check welding gun and/or wire feeder if applicable. ––

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. ––

Pendant does not work. Check pendant potentiometers and switches. ––

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

Figure 6-1. Circuit Diagram

OM-535 Page 7
SECTION 7 – TUNGSTEN ELECTRODE
mod2.1 10/91

IMPORTANT: For additional information, see your distributor for a handbook on the Gas Tungsten Arc Welding
(GTAW) process.

7-1. Selecting Tungsten Electrode

Table 7-1. Tungsten Size

Amperage Range - Gas Type♦ - Polarity


Electrode Diameter DC – Argon – Electrode DC – Argon – Electrode AC – Argon – Using AC – Argon – Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.

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

Figure 7-1. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding

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

Wrong Tungsten Preparation – Wandering Arc Ref. S-0162

Figure 7-2. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

OM-535 Page 9
SECTION 8 – PARTS LIST

1 2

8
3

4 SA-106 543-B
5

Figure 8-1. RCAP-1

Item Dia. Part


No. Mkgs. No. Description Quantity

099 232 Figure 8-1. RCAP-1

. . . 1 . . . . . . . . . . . . . 134 429 . . CASE SECTION, front/end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


.............................. NAMEPLATE, (order by model and style number) . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 148 348 . . CASE SECTION, back/sides/end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 097 866 . . PLUG, 17 pin MS-3106A-20-29P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 073 296 . . CLAMP, cable 97-3057-12-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 135 304 . . CABLE, port No. 18 8/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ft
. . . 6 . . . . . . . . . . . . . 134 900 . . STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . S2 . . . . . 079 722 . . SWITCH, tgl SPDT .4A 2-4VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . S1 . . . . . . 011 770 . . SWITCH, tgl SPDT 5A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 097 922 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . R1,2 . . . . 035 897 . . POTENTIOMETER, C std slot 1/T 2W 1K ohm . . . . . . . . . . . . . . . . . . . . . . 2

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.

4. 6 Months — Batteries In Canada, legislation in some provinces provides for certain


additional warranties or remedies other than as stated herein,
5. 90 Days — Parts and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
* MIG Guns/TIG Torches Warranty provides specific legal rights, and other rights may
* Induction Heating Coils and Blankets be available, but may vary from province to province.

miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

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.

Always provide Model Name and Serial/Style Number.


Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters–USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters –
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com

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.

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00

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