Miller Electric Welder RHC 3 User Manual

February 1992  
FORM: OM-823G  
Effective With Serial No. KB055102  
MODEL: RHC-3  
RHC-3-2  
RHC-3GD9A  
RHC-3GD25B  
RHCS-3  
RHC-3-GD34A  
RHC-14  
RHC-23  
OWNER’S MANUAL  
IMPORTANT: Read and understand the entire contents of both this manual  
MILLER ELECTRIC Mfg. Co.  
and the power source manual used with this unit, with special emphasis on  
A Miller Group Ltd., Company  
the safety material throughout both manuals, before installing, operating, or  
P.O. Box 1079  
maintaining this equipment. This unit and these instructions are for use only  
by persons trained and experienced in the safe operation of welding equip-  
ment. Do not allow untrained persons to install, operate, or maintain this unit.  
Contact your distributor if you do not fully understand these instructions.  
Appleton, WI 54912 USA  
Tel. 414-734-9821  
SA-141 127  
PRINTED IN U.S.A.  
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OM-823G - 2/92  
RECEIVING-HANDLING  
Before unpacking equipment, check carton for any Use the following spaces to record the Model Designa-  
damage that may have occurred during shipment. File tion and Serial or Style Number of your unit. The infor-  
any claims for loss or damage with the delivering car- mation is located on the rating label or nameplate.  
rier. Assistance for filing or settling claims may be ob-  
tained from the distributor and/or the equipment manu-  
facturer’s Transportation Department.  
Model  
Serial or Style No.  
Date of Purchase  
When requesting information about this equipment, al-  
ways provide the Model Description and Serial or Style  
Number.  
TABLE OF CONTENTS  
Section No.  
SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS  
Page No.  
1-1.  
1-2.  
1-3.  
General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .  
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
1
SECTION 2 INSTALLATION  
2-1.  
2-2.  
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
SECTION 3 OPERATOR CONTROLS  
3-1.  
3-2.  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2
2
SECTION 4 MAINTENANCE  
SECTION 5 ELECTRICAL DIAGRAMS  
Diagram 5-1. Circuit Diagram For Remote Hand Control Used With  
Transformer Arc Welding Power Source . . . . . . . . . . . . . . . .  
Diagram 5-2. Circuit Diagram For RHCS-3 . . . . . . . . . . . . . . . . . . . . . . . . . .  
Diagram 5-3. Circuit Diagram For RHC-3-GD9A And RHC-3-GD34A . . . .  
Diagram 5-4. Circuit Diagram For RHC-3-GD25B . . . . . . . . . . . . . . . . . . . .  
Diagram 5-5. Circuit Diagram For RHC-14 And RHC-23 . . . . . . . . . . . . . . .  
3
3
3
4
4
SECTION 6 PARTS LIST  
Figure 6-1. Complete Assembly (RHC-3 Illustrated) . . . . . . . . . . . . . . . . . . . . .  
LIST OF CHARTS AND TABLES  
6
1
Table 2-1. Cord Conductor Length And Size . . . . . . . . . . . . . . . . . . . . . . . . . . .  
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SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS  
1-1.  
GENERAL INFORMATION AND SAFETY  
identify different levels of hazard and special instruc-  
tions.  
A. General  
This safety alert symbol is used with the signal  
words WARNING and CAUTION to call atten-  
tion to the safety statements.  
Information presented in this manual and on various la-  
bels, tags, and plates on the unit pertains to equipment  
design, installation, operation, maintenance, and  
troubleshooting which should be read, understood, and  
followed for the safe and effective use of this equipment.  
WARNING statements identify procedures or  
practices which must be followed to avoid seri-  
ous personal injury or loss of life.  
The nameplate of this unit uses international symbols  
for labeling the front panel controls. The symbols also  
appear at the appropriate section in the text.  
CAUTION statements identify procedures or  
practices which must be followed to avoid minor  
personal injury or damage to this equipment.  
B. Safety  
The installation, operation, maintenance, and trouble-  
shooting of arc welding equipment requires practices  
and procedures which ensure personal safety and the  
safety of others. Therefore, this equipment is to be in-  
stalled, operated, and maintained only by qualified per-  
sons in accordance with this manual and all applicable  
codes such as, but not limited to, those listed at the end  
of Section 1 Safety Rules For Operation Of Arc Weld-  
ing Power Source.  
IMPORTANT statements identify special instructions  
necessary for the most efficient operation of this equip-  
ment.  
1-3.  
DESCRIPTION  
Remote Hand Controls are designed for use as remote  
amperage or voltage controls in conjunction with a weld-  
ing power source or welding generator having electric  
control facilities. Remote Hand Controls with the letters  
GD displayed in the model description are designed for  
use with welding generators only.  
1-2.  
SAFETY ALERT SYMBOL AND SIGNAL  
WORDS  
The following safety alert symbol and signal words are  
used throughout this manual to call attention to and  
SECTION 2 INSTALLATION  
Table 2-1. Cord Conductor Length And Size  
Amperage or Voltage Control  
source or welding generator. The Remote Hand Control  
can be wall mounted or placed on a stand at the work  
area.  
If it is necessary to install a muti-conductor cord of long-  
er length, refer to Table 2-1 for cord conductor size ac-  
cording to the desired length. Refer to Section 5 - Elec-  
trical Diagrams for connections  
Conductor  
Cord Length  
Size*  
Up to 20ft (6 m)  
Up to 20ft (6 m) (GD Models)  
21 to 100ft (6 to 30 m) (GD Models)  
21 to 50ft (6 to 15 m)  
No. 16  
No. 14  
No. 12  
No. 14  
No. 12  
No. 10  
2-2.  
INTERCONNECTIONS  
1. To make connections on models equipped with  
the twistlock plug, fully insert the twistlock plug  
that is attached to the Remote Hand Control cord  
into Remote Amperage or Voltage Control Re-  
ceptacle on the welding power source or welding  
generator. Turn the cap in a clockwise direction,  
as far as it will turn, to lock the connection.  
51 to 100ft (16 to 31 m)  
101 to 200ft (31 to 61 m)  
*AWG-American Wire Guage  
2-1.  
LOCATION  
The Remote Hand Controls is equipped with a twenty  
foot (6 m) interconnecting multi-conductor cord (unless  
otherwise specified) which enables the Remote Hand  
Control to be remotely located from the welding power  
2. To make connections on models equipped with  
the 14-pin or 5-pin Amphenol plug, align keyway,  
insert plug, and rotate threaded collar fully clock-  
wise.  
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SECTION 3 OPERATOR CONTROLS  
3-1.  
OPERATION  
B. Remote Hand Control Of Two Welding Power  
Sources  
A. General  
Remote amperage or voltage control of two welding  
power sources from one Remote Hand Control is made  
possible through the use of Remote Hand Control hav-  
ing two rheostats. These Remote Hand Controls are  
identified by a model suffix of -2, and are designed to si-  
multaneously control two identical welding power  
sources. These Remote Hand Controls have two rheo-  
stats coupled on a common control shaft. Rotating the  
knob on the Remote Hand Control simultaneously ad-  
justs each rheostat in the control to the same value,  
thus making possible remote control of two welding  
power sources from a single Remote Hand Control.  
When a Remote Hand Control is being used, it should  
be noted that on most welding power sources or welding  
generators, the Remote Hand Control functions as a  
fine amperage or voltage adjustment of the Amperage  
or Voltage Adjustment Control setting on the welding  
power source or welding generator. For example, if the  
Amperage or Voltage Adjustment Control on the weld-  
ing power source or welding generator is set at the mid-  
point position, the Remote Hand Control will provide  
(from its minimum to maximum positions) fine adjust-  
ment of one half of the welding power source or welding  
generator output. If full adjustment of the maximum out-  
put of the welding power source or welding generator  
from the Remote Hand Control is desired, it will be nec-  
essary to rotate the Amperage or Voltage Adjustment  
Control on the welding generator to the maximum posi-  
tion. The Remote Hand Control dial is calibrated in per-  
centage in increments of ten from 0 to 100 percent.  
IMPORTANT: When a Remote Hand Control is used,  
refer to the Instruction Manual of the welding power  
source or welding generator for additional operational  
information.  
3-2.  
CONTACTOR SWITCH  
On some welding power source or welding generators  
the Amperage Voltage Adjustment Control on the Weld-  
ing power source or welding generator is inoperative  
when a Remote Hand Control is connected in the weld-  
ing power source or welding generator control circuitry.  
In this situation, the Remote Hand Control provides  
complete control from the minimum to the maximum  
output of the welding power source or welding generator  
rather than fine adjustment of the Amperage or Voltage  
Adjustment control setting on the welding power source  
or welding generator.  
WARNING: ELECTRIC SHOCK can kill.  
Do not touch live electrical parts  
Do not touch the weld output terminals when  
the contactor is energized.  
Do not touch electrode and work clamp at the  
same time.  
IMPORTANT: To use the RHC-14 or RHC-23 contactor  
switch, the OUTPUT (CONTACTOR) switch on the  
welding power source must be in the Remote position  
for proper remote control operation.  
To determine in which way the Remote Hand Control af-  
fects the operation of the welding power source or weld-  
ing generator, refer to the welding power source or weld-  
ing generator circuit diagram and/or instruction Manual.  
The RHC-14 or RHC-23 switch has two positions, ON  
and OFF. Placing this switch in the ON position provides  
open-circuit voltage. Placing this switch in the OFF posi-  
tion stops open-circuit voltage (ocv goes to zero).  
SECTION 4 MAINTENANCE  
WARNING: ELECTRIC SHOCK can kill; HOT  
SURFACES can cause severe burns.  
and at the strain relief connector on the Remote Hand  
Control base. Repair all breaks with electrical tape, or  
replace the cord if necessary.  
Do not touch live electrical parts.  
Disconnect plugs from power source before  
Daily, rotate the Remote Hand Control knob from the 0  
to 100 percent position. This procedure will prevent oxi-  
dation from forming on the contacts, which could insu-  
late the contacts from the brush, causing the control to  
become inoperative. Refer to Table 2-1 for proper cord  
conductor size and to Diagrams 5-1 through 5-5 for  
proper cord conductor connections.  
inspecting or servicing.  
Allow unit to cool before servicing.  
Once a month inspect the Remote Hand Control cord for  
breaks in the insulating jacket particularly at the plug  
OM-823 Page 2  
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SECTION 5 ELECTRICAL DIAGRAMS  
Circuit Diagram No. SA-150 670  
Diagram 5-1. Circuit Diagram For Remote Hand Control Used With  
Transformer Arc Welding Power Source  
Circuit Diagram No. SA-150 671  
Diagram 5-2. Circuit Diagram For RHCS-3  
Circuit Diagram No. SA-094 231-A  
Diagram 5-3. Circuit Diagram For RHC-3-GD9A And RHC-3-GD34A  
OM-823 Page 3  
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Circuit Diagram No. SA-094 232-A  
Diagram 5-4. Circuit Diagram For RHC-3-GD25B  
Circuit Diagram No. SA-053 656-A  
Diagram 5-5. Circuit Diagram For RHC-14 And RHC-23  
OM-823 Page 4  
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SECTION 6 PARTS LIST  
OM-823 Page 5  
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Quantity  
Model  
Item Dia.  
No. Mkgs.  
Part  
No.  
RHC- RHC- RHC- RHC- RHCS-  
Description  
3
3-2  
14  
23  
3
Figure 6-1. Complete Assembly  
. . 1 . R1 . . 030 653 . . RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . . . . . . . . . . . . 1  
. . 1 . R1 . . 107 363 . . RHEOSTAT, WW 150W 15 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 1 . R1 . . 035 897 . . POTENTIOMETER, C sltd sft 1/T 2W 1000 ohm . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . 1 . R1 . . 039 272 . . RHEOSTAT, WW 150W 1250 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 2 . . . . . . +021 475 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . . . . . . . . . . 1  
. . 2 . . . . . . +014 417 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . . . . . . . . . . 085 220 . . LABEL, caution electric circuit . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . 1 . . . 1 . . 1  
. . 3 . . . . . . . 021 474 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 1  
. . 3 . . . . . . . 106 952 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 3 . . . . . . . 109 974 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . 4 PLG1 605 797 . . PLUG, twlk 3P3W 20A 125V . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2  
. . 4 PLG1 144 310 . . HOUSING PLUG & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . 134 732 . . . . TERMINAL, male 1 pin 24-20 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
. . . . . . . . . . . 143 922 . . CLAMP, cable strain relief sz 17 & 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 4 PLG1 039 273 . . PLUG, 5 pin MS-3106A-16S-8P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . 1  
. . . . . . . . . . . 039 685 . . CLAMP, cable AN-3057-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . 1  
. . 5 . . . . . . . 600 733 . . CORD SET, pwr 115V 16ga 3/c 20ft . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . 1  
. . 5 . . . . . . . 052 246 . . CABLE, pwr 20ga 5/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20ft . 20ft  
. . 6 . . . . . . . 010 659 . . CONNECTOR, clamp cable .375 90deg . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . 1  
. . 6 . . . . . . . 070 654 . . BUSHING, strain relief .300 ID x .550mtg hole . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . 7 . . . . . . . 097 926 . . KNOB, pointer 2.375dia x .250 ID . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . . . . . . . . . . 1  
. . 7 . . . . . . . 097 922 . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . 8 . . . . . . . 039 411 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 8 . . . . . . . 148 720 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 8 . . . . . . . 130 214 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 8 . . . . . . . 053 574 . . PLATE, ind current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 8 . . . . . . . 148 716 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . S1 . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1  
. . . . . . . . . . . 604 311 . . GROMMET, rbr .250 ID x .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
1
2
8
3
7
4
5
6
SA-141 128  
Figure 6-1. Complete Assembly (RHC-3 Illustrated)  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.  
OM-823 Page 6  
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Quantity  
Model  
RHC-3-GD  
Item Dia.  
No. Mkgs.  
Part  
No.  
9A  
25B 34A  
Description  
Complete Assembly (Use Fig 6-1 View)  
. . 1 . . . R1 . 005 355 . . RHEOSTAT, WW 50W 9 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 1 . . . R1 . 605 049 . . RHEOSTAT, WW 300W 25 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 1 . . . R1 . 605 960 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 2 . . . R1 +021 475 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . 1  
. . . . . . . . . . . . 085 220 . . LABEL, caution electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . 1  
. . 3 . . . . . . . . 021 474 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . .  
1
. . 4 . PLG1 032 898 . . PLUG, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . 1  
. . 4 . PLG1 039 621 . . PLUG, twlk armd 4P4W 20A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 5 . . . . . . . . 600 349 . . CABLE, port No.14 3/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . 20ft . . . . . . . 20ft  
. . 5 . . . . . . . . 604 834 . . CABLE, port No.14 4/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20ft  
. . 6 . . . . . . . . 010 659 . . CONNECTOR, clamp .375 90deg . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 1 . . . . . 1  
. . 7 . . . . . . . . 097 926 . . KNOB, pointer 2.375dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 7 . . . . . . . . 148 723 . . KNOB, pointer 2.375dia x .379 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1  
. . 8 . . . . . . . . 006 101 . . PLATE, ind amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 8 . . . . . . . . 013 615 . . PLATE, ind amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . 8 . . . . . . . . 148 717 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.  
OM-823 Page 7  
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