Miller Electric RPC-IP User Manual
Ef
f. w/Serial Number JJ487350
April 1993
Multiprocess W
Remote Pendant Control
RPC-IP
elding
V
isit our website at
SECTION 1 – INTRODUCTION
5-3/4 in.
(141 mm)
9-3/8 in.
(238 mm)
5 in.
(123 mm)
ST-109 521-A
Figure 1-1. Dimensions
1-1. GENERAL INFORMATION AND SAFETY A. General
Information
presented in this manual and on various
bels, tags, and plates provided on this unit pertains to
equipment
and
design,
troubleshooting which should be read,
installation, operation, maintenance,
understood,
la
and
followed for the safe and ef
fective use of this equip
ment.
B. Safety
The 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
persons
ble
Welding
in accordance with
codes such as, but not limited to, those listed in Arc
Safety Precautions Section in the welding pow
this manual and all applica
er source Owner’s Manual.
instructions specifically pertaining to this unit ap
Safety
pear throughout this manual highlighted by the signal
words
WARNING
and
CAUTION
which identify dif
levels of hazard.
WARNING
statements include installation, operation,
and maintenance procedures or practices which if not
carefully
followed could result in serious personal injury
or loss of life.
CAUTION
statements include installation, operation,
and maintenance procedures or practices which if not
carefully
followed could result in minor personal injury or
damage to this equipment.
A
third signal word,
which
need special emphasis to obtain the most ef
IMPORTANT
, highlights instructions
operation of this equipment.
1-2. RECEIVING-HANDLING
unpacking equipment,
Before
check carton for any dam
age 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 manufacturer’s Transportation Department.
When requesting information about this equipment, al-
provide the Model Description and Serial Number
ways
1-3.
DESCRIPTION
This
unit is a Remote Pendant Control for the Intellipulse
-
welding
welding
tactor
power source. When properly connected to
power source this unit provides arc control, con
control, voltage/amperage control, CV/CC selec
tion, and pulse frequency selection.
-
-
-
-
ferent
ficient
-
.
the
-
-
OM-533 Page 1
W
elding Power
Source Remote
Control Receptacle
SECTION 2 – INSTALLATION
RPC-IP
Receptacle
Figure 2-1. Power Source/Remote Control Connections
WARNING: ELECTRIC SHOCK can kill.
•
Do not touch live electrical parts.
•
Shut down welding power source, and be
sure it cannot be accidentally energized before
making remote Pendant Control connections.
•
Place CONTACTOR switch in OFF position.
2-1. WELDING POWER SOURCE REMOTE CONTROL
RECEPT
The Remote Pendant Control connects to a 17-socket
Amphenol
panel
(see OM-286). Insert 17-pin Amphenol plug
the interconnecting cable fully into the receptacle and
rotate collar clockwise.
2-2. RPC-IP RECEPTACLE CONNECTIONS (Figure 2-1)
The interconnecting cable from the welding power
source connects to a 17-pin Amphenol receptacle on
remote control. Insert the 17-socket plug from the
the
terconnecting
collar clockwise.
OM-533 Page 2
ACLE CONNECTIONS (Figure 2-1)
receptacle on the welding power source
cable fully into the receptacle, and rotate
front
from
in
2-3. 650/1000 AMPERE MODEL SELECTOR SWITCH
WARNING: ELECTRIC SHOCK can kill.
•
Do not touch live electrical parts.
•
Shut down welding power source, and dis-
connect the Remote Pendant Control before
changing position of dip switches.
ELECTROSTATIC DISCHARGE (ESD) can
damage circuit boards.
•
Put on properly grounded wrist strap BE-
FORE handling circuit boards.
•
Perform
This Remote Pendant Control is designed to be used
with either a 650 or 1000 ampere intellipulse welding
power source. A dip switch is located on circuit board
to set up the Remote Pendant Control for operation
PC5
with 650 or 1000 ampere models. The unit is shipped
the factory set up for
from
models.
dant Control for operation with 1000 ampere models:
1. Remove cover.
2. Place
-
3. Reinstall cover.
Proceed as follows to set up the Remote Pen
both dip switches in the down position for op
eration with 1000 ampere models. Place both dip
switches in up position for operation with 650 ampere models (see Figure 2-2).
work only at a static-safe work area.
operation with the 650 ampere
ST-109 782-B
-
-
Mounting
Screws (5)
Dip
Switch
Cover
Front
Panel
Figure 2-2. Dip Switch Positions And Locations
SECTION 3 – OPERATOR CONTROLS
3-1. MODE
The Mode Selector switch allows selection of CC
(constant
put from the welding power source.
The
CC position provides a constant current output spe
cifically designed for Shielded Metal Arc (SMAW) and
Gas
T
position
(CAC-A) and gouging processes.
The
CV position provides a constant voltage output de
signed
Arc (GMAW), Flux Cored Arc (FCAW), or Submerged
Arc
(SA
SELECT
current), CV (constant voltage),
ungsten Arc (GTAW) W
OR SWITCH (Figure 3-1)
or pulsed out
elding processes. The CC
is also normally used for Air Carbon Arc Cutting
for wire feeding applications such as Gas Metal
W) Welding.
Circuit
Board
PC5
Both dip switches down for
1000 ampere model operation
Both dip switches up for
650 ampere model operation
approached. When this control is set at some value
above 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
rent (see welding power source volt-ampere curve for
CC
out-of-position
is considerably
higher than normal welding cur
mode). This provides extra current for arc starting in
welds as well as for certain types of elec
trodes.
the control is set at 0 (SOFT), short-circuit current
When
is the same as normal welding current. The 0 position
provides
current characteristics associated
Tungsten Arc Welding (GTAW) process.
ST-113 509-A
-
-
with the Gas
When
pulsed output is desired for Gas Metal Arc W
ing
- Pulsed Arc (GMAW-P), place switch at the desired
eld-
number of pulses per second: 60, 90, 120 or 180.
3-2. ARC
IMPORTANT:
pilot
CONTROL AND PILOT LIGHT
The ARC CONTROL potentiometer and
light are disabled in the CV (Constant V
(Figure 3-1)
oltage) and
pulsed modes.
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
When the control is set at 5, short-circuit current is
approximately
higher
than normal welding current. The 5 position pro
half that of the 10 (MAX.) position but still
vides a moderate current increase for arc starting necessary
for certain types of electrodes and
applications.
Select a setting best suited for the application.
The Arc Control pilot light turns on when the Mode Se-
lector
switch is in the CC position indicating that the ARC
CONTROL is active.
IMPORTANT:
The ARC CONTROL can be adjusted
while welding.
OM-533 Page 3
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