OM-286308A Wireless Remote Controls For product information, Owner’s Manual translations, and more, visit www.MillerWelds.
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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D Ventilate the work area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.
CYLINDERS can explode if damaged. Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. D If notified by the FCC about interference, stop using the equipment at once.
SECTION 2 − BATTERY SAFETY PRECAUTIONS READ BEFORE USING Small Batt _2020-02 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 2-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
2-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI Standard Z49.1. Website: www.aws.org. Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www.csagroup.org. OM-286308 Page 6 Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1 from American National Standards Institute. Website: www.ansi.org.
SECTION 3 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020−02_fre 7 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 3-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement. D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé. D Eloigner votre tête des fumées.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction. LE BRUIT peut endommager l’ouïe.
LIRE LES INSTRUCTIONS. D Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. D Effectuer régulièrement le contrôle et l’entretien de l’installation.
SECTION 4 − CONSIGNES DE SÉCURITÉ RELATIVES AUX BATTERIES − LIRE AVANT UTILISATION Small Batt_2020-02_fre Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 4−1. Symboles utilisés DANGER! - Indique une situation dangereuse qui, si elle n’est pas évitée, entraînera la mort ou des blessures graves.
4−4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI Standard Z49.1. Website: www.aws.org. Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Standards Association. Website: www.csagroup.org. OM-286308 Page 12 Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1 from American National Standards Institute. Website: www.ansi.org.
SECTION 5 − INSTALLATION AND OPERATION 5-1. FCC Compliance This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with instructions, may cause harmful interference to radio communications.
5-4. WEEE Label (For Products Sold Within The EU) Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information.
5-5. Introduction A wireless remote-control system consists of a control and transceiver. 1 1 2 3 Wireless Foot Control Wireless Hand Control 14-Pin Transceiver The Wireless Foot Control, Wireless Hand Control, and 14−Pin Transceiver are capable of remotely turning on the output contactor and adjusting the output level of a welding power source.
5-7. Connecting 14-Pin Transceiver To Remote 14 Receptacle ! Unexpected weld output can cause electrical shock. Remote controls can turn on weld output from distant locations. Disconnect 14-Pin Transceiver from remote 14 receptacle and remove the batteries from the wireless foot control and/or wireless hand control before servicing equipment. Turn Off welding power source. 1 2 1 14-Pin Transceiver Hand Threaded Nut Insert the 14-Pin Transceiver into the remote 14 receptacle on the welding power source.
5-9. Wireless Hand Control Operation 2 ! Unexpected weld output can cause electrical shock. Wireless remote controls can turn weld output on from distant locations. Disconnect 14-pin transceiver from remote 14 receptacle and remove the batteries from the wireless foot control and/or wireless hand control before servicing equipment. 1 2 3 Wireless Hand Control Pairing Button Wireless Status Light Indication: Wireless status light indication: Solid Red = Not paired and/or lost communication.
5-10. Remote Amperage Or Voltage Control For Welding Power Source With Output Always On Wireless hand control operation for welding power sources with output contactor always on (Stick, TIG, and voltage sensing wire feed welding). ! Unexpected weld output can cause electrical shock. Wireless remote controls can turn weld output on from distant locations.
5-11. Remote Amperage Or Voltage Control For Welding Power Source With Output Contactor Wireless hand control operation for welding power sources with output contactor always on (Stick, TIG and voltage sensing wire feed welding). ! Unexpected weld output can cause electrical shock. Wireless remote control can turn weld output on from distant locations.
5-12. Pairing A Wireless Hand Control With A 14-Pin Transceiver 1 ! Unexpected weld output can cause electric shock. Remote controls can turn weld output on from distant locations. Disconnect 14-pin transceiver from remote 14 receptacle and remove the batteries from the wireless foot control and/or wireless hand control before servicing equipment. ! Turn off welding power source before pairing a wireless hand control or wireless foot control to another 14-pin transceiver.
5-13. Pairing A Wireless Foot Control With A 14-Pin Transceiver ! Unexpected weld output can cause electrical shock. Wireless Remote Control can turn weld output on from distant locations. Disconnect receiver from remote 14 receptacle and remove battery from remote control before servicing equipment. ! Turn off welding power source before pairing a Wireless Hand Control or Wireless Foot Control to another 14−Pin Transceiver.
5-14. Enabling Wireless Operation In Big 40 C, Big Blue 400/500/Air Pak/Turbo ! Stop engine. Disconnect negative (−) battery cable. Remove right side generator panel. 1 Electrical Box Remove white cover from electrical box. 2 Diagnostic Board PC9 PC9 is a small board (2x2) with 5 red LEDs, located in the upper left corner. Unplug receptacle connecting board. Reinstall electrical box cover. Reinstall right side generator panel. 1 2 Tools Needed: 3/8, 1/2 in. Ref. 803835-C / Ref.
5-15. Transceiver 14-Pin Information J I A K N H G OUTPUT ENABLE B Pin Information A Contactor control +15 volts DC / 24 volts AC, referenced to G. B Contact closure to A completes and enables output. C Output command voltage; 0-10 volts DC D Remote control circuit common. E Command percentage of Pin C with respect to Pin D F Current feedback; +1 volt DC per 100 amperes. H Voltage feedback; +1 volt DC per 10 volts output. G Return for all output signals: F, H and A.
SECTION 7 − PARTS LIST 1 2 3 4 Ref. 805625-A Figure 7-1. Wireless Foot Control Item No. Dia. Mkgs. Part No. Description 285008 Wireless Foot Control Quantity . . . 1 . . . . . . . . . . . . . 288128 . . Kit, Wireless Pedal Repair (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedal, Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ref. 805627-A Item No. Dia. Mkgs. Figure 7-2. Wireless Receiver w/Labels Part No. Description 284867 Wireless Receiver w/Labels Quantity 2 3 1 Ref. 805626-A Figure 7-3. Wireless Hand Control Item No. Dia. Mkgs. Part No. Description 285358 Wireless Hand Control Quantity . . . 1 . . . . . . . . . . . . . 285341 . . Strap, Clip Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.
Notes
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
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