Miller OWNER S MANUAL

Transcription

1 YY ~??? Miller U MODEL \!ERNIER RNGE CONTROL FILE COPY RETURN TO FOLDER q OWNER S MNUL IMPORTNT: Read and understand the entire contents of both this Miller Electric Mfg. Co. manual and the power source manual used with this unit, with special emphasis on the safety material throughout both manuals, before in- ~o Box 079 stalling, operating, or maintaining this equipment. This unit and these ppleton, WI 5492 u~-~ instructions are for use only by persons trained and experienced in the Tel 44~ 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. PRINTED IN U.S.. DDITIONL COPY PRICE 20 CENTS

2 LIMITED WRRNTY EFFECTIVE FEBRURY 6, ieee This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WRRNTY - Subject to the terms and condi- In the case of Miller s breach of warranty or any other duty tions hereof, Miller Electric Mfg. Co., ppleton, Wisconsin with respect to the quality of any goods, the exclusive remedies warrants to its Distributor/Dealer that all new and unused therefore shall be, at Miller s option () repair or 2) replacement Equipment furnished by Miller is free from defect in workman- or, where authorized in writing by Miller in appropriate cases, (3) ship and material as of the time and place of delivery by Miller. the reasonable cost of repair or replacement at an authorized No warranty is made by Miller with respect to engines, trade Miller service station or 4) payment of or credit for the purchase accessories or other items manufactured by others. Such price (less reasonable depreciation based upon actualumel upon engines, trade accessories and other items are sold subject to return of the goods at Customer s risk and expense. MILLER s the warranties of their respective manufacturers, if any. ll option of repair or replacement win be FOB., Factory, at engines are warranted by their manufacturer for one year from ppleton, Wisconsin. or FOB., at a MILLER authorized service date of original purchase, except Tecumseh engines which facility, therefore, no compensation for transportation costs of have a two year warranty, any kind will be allowed. Upon receipt of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty Except as specified below, Miller s warranty does not apply claim procedures to be followed. to components having normal useful life of less than one ( year, such as spot welder tips, relay and contactor points. MILLERMTIC parts that come in contact with the welding NY EXPRESS WRRNTY NOT PROVIDED HEREIN ND wire including nozzles and nozzle insulatorswhere failure does NY IMPLIED WRRNTY, GURNTY OR REPRESENTnot result from defect in workmanship or material. TiON S TO PERFORMNCE, ND NY REMEDY FOR BRECH OF CONTRCT WHICH, BUT FOR THIS PROVISION, Miller shall be required to honor warranty claims on war- MIGHT RISE BY IMPLICTION, OPERTION OF LW, ranted Equipment in the event of failure resulting from a defect CUSTOM OF TRDE OR COURSE OF DEUNG, INCLUDING within the following periods from the date of delivery of Equip- NY IMPUED WRRNTY OF MERCHNTBIUTY OR OF ment to the original user: FITNESS FOR PRTICULR PURPOSE, WITH RESPECT TO NY ND LL EQUIPMENT FURNISHED BY MILLER IS EX-. rc weldms, pcw~er sourt~, robots, and components. year CLUDED ND DISCLIMED BY MILLER. 2 Load banks.. year 3. Original main power rectifiers 3 years (labor - year only) EXCEPT S EXPRESSLY PROVIDED BY MILLER IN 4. ll welding guns, feeder/guns and torches 90 days WRITING, MILLER PRODUCTS RE INTENDED FOR 5. ll other Millermatic Feeders year ULTIMTE PURCHSE BY COMMERCIL/INDUSTRIL 6. Replacement or repair parts, exclusive of labor.. 60 days USERS ND FOR OPERTION BY PERSONS TRINED ND 7. Batteries 6 months EXPERIENCED IN THE USE ND MINTENNCE OF WELDING EQUIPMENT ND NOT FOR CONSUMERS OR provided that Miller is notified in writing within thirty 30 days CONSUMER USE. MILLER S WRRNTIES DO NOT EXTEND of the date of such failure. TO, ND NO RESELLER IS UTHORIZED TO EXTEND q~ s a matter of general policy only, Miller may honor claims MILLER S WRRNTIES TO, NY CONSUMER. submitted by the original user within the foregoing periods ,,~. -~...-.-

3 FIgure -. DimensIons -. GENERL INFORMTION ND SFETY. General Information presented in this manual and on various labels, tags, and plates on the unit pertain to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment. 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 in accordance with this manual and all applicable SECTION INTRODUCTION Codes such as, but not limited to, those listed at the end of Section - Safety Rules For Operation Of rc Welding Power Source in the welding power source Owner s Manual. Safety instructions specifically pertaining to this unit appear throughout this manual highlighted by the Signal words WRNING and CUTION which identify different levels of hazard. WRN ING statements include installation, operation, and maintenance procedures or practices which if not carefully followed could result in serious personal injury or loss of life. CUTION statements include installation, operation, and maintenance procedures or practices which if not carefully followed could result in serious personal injury or damage to this equipment. third signal word, IMPORTNT, highlights instructions which need special emphasis to obtain the most efficient operation of this equipment. T RECEIVING-HNDLING Before installing this equipment, clean all packing material from around the unit, and carefully inspect for any damage that may have occurred during shipment. ny claim for loss or damage that may have occurred in transit must be filed by the purchaser with the carrier. copy of the bill of lading will be furnished by the manufacturer on request if occasion to file claim arises. When requesting information concerning this equipment, it is essential that Model Description and Style Number of the equipment be supplied. -3. DESCRIPTION This unit is a Vernier Range Control potentiometer for the RC PK welding power source. When properly connected, it functions as a maximum amperage selection control, and thereby limits the maximum amperage output of the welding power source. OM-54 Page

4 SECTION 2- INSTLLTION RC PK WeldIng 7-PIn ConnectIon From Process Control To RC PK Remote Control Receptacle (see SectIon 2-2) High Frequency Range Control Remole Hand or Foot Control Switch 5-Socket ConnectIon From Process Control To High Frequency Unit Remote In Receptacle 2-. LOCTION Remove one of the wrapper screws, and install the Vernier Range Control directly onto left or right side of the power source with the face plate facing the same direction as the front panel of the welding power source INTERCONNECTIONS WRNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down high frequency unit and welding power source and disconnect input power employing lockout/tagging procedures before inspecting, installing, or adjusting. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. Figure 2-. InstallatIon T Connect the 7-pin twistlock plug from the Vernier Range Control into the Remote Control Receptacle on welding power source as follows: align keyway, insert plug, and rotate threaded collar fully clockwise. Connect the 5-pin twistlock plug from the Vernier Range Control into the REMOTE IN receptacle on the rear of the high frequency unit on welding power source as follows: align keyway, insert plug, and rotate threaded collar fully clockwise (see Figure 2-). OM-54 Page 2

5 SECTION 3 OPERTOR CONTROLS 3-. MPERGE CONTROL age output from minimum to maximum of power source This control provides the means of adjusting the ampercapability. Rotating this control clockwise increases weld output. SECTION 4-SEQUENCE OF OPERTION 4-. OPERTION adjustment of the mperage Control setting. For exam pie, an mperage Control setting of 200 amperes will Whenaremotehandorfootcontrolswitchandhighfre- provide a fine amperage adjustment of 0 to 200 am quency unit are used with the RC PK welding power peres (minimum to maximum position) on the hand or source, the control switch functions as a fine amperage foot control switch. SECTION 5 MINTENNCE & TROUBLESHOOTING 5-. MINTENNCE Usage and shop conditions will determine the frequency and type of maintenance. WRNING: ELECTRIC SHOCK Can kill.. Do not touch live electrical parts. Shut down high frequency unit and welding power source, and disconnect the Vernier Range Control before inspecting, maintaining, or servicing.. Every six months inspect the Vernier Range Control interconnecting cords for damage to or breaks in the insulation jacket, particularly at the plug. Repair or replace cords as necessary. 2. Remove grease and grime from components; moisture from electrical parts and cord TROUBLESHOOTING WRNING: ELECTRIC SHOCK can kill. 0 Do not touch live electrical parts. Shut down high frequency unit and welding powersource anddisconnect the Vernier Range Control before inspecting, maintaining, troubleshooting, or servicing. Troubleshooting to be performed only by qualified persons. It is assumed that the unit was properly installed according to Section 2 of this manual, the operator is familiar with the function of controls, the welding power source and high frequency unit were working properly, and the trouble is not related to the welding process. The following information is supplied to diagnose and provide remedies for some of the troubles that may develop in this unit. Check the welding power source and high frequency unit Owner s Manual for possible problems caused by welding power source malfunctions. Use this information in conjunction with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these procedures, the nearest Factory uthorized Service Station should be contacted. In all cases of equipment malfunction, the manufacturer s recommendations should be strictly followed. Problems with this unit fall into two categories: ) front panel Components, or 2) the interconnecting cord and plug. If the control does not function, the plug may be loose in the receptacle, or the cord may be damaged internally, thereby interrupting signals between the welding power source and this unit. Check plug connections, and tighten if applicable. Check continuity of cord, and replace, if necessary. OM-54 Page 3

6 SECTION 6- ELECTRICL DIGRMS + I OV. C P COMMND B H CONTCTOR PLG I Diagram 6-. CIrcuit Diagram D <B PLG2 Circuit Diagram No PRTS LIST Dia. Part Mkgs. No. Description Quantity Complete ssembly Ri PLG PLG POTENTIOMETER, carbon turn 2 watt 000 ohm PLUG, 7 pin M P CLMP, cable CBLE, No, 20 8/C (order by ft) RECEPTCLE, 5 socket M BS CLMP, cable N CBLE, No. 6 5/C (order by ft) KNOB 5 04 CONNECTOR, clamp-cable /2 inch NMEPLTE (order by model & serial number) 723 CSE SECTION, front/end CSE SECTION, back/sides/end 2 ft 5 ft 2 BE SURE TO PROVIDE MODEL ND SERIL NUMBER WHEN ORDERING REPLCEMENT PRTS. OM-54 Page 4