Frequently Asked Questions (FAQ) about remote amperage controllers

I am changing machines.  Can I move my Pipeliner to my new machine?

• The Pipeliner is designed to operate on over 59 different machines.  In the Lincoln line, all SA, SAE and Classic machines are interchangeable as far as the Pipeliner is concerned.  Simply remove it from the old machine and install it to the new machine.  Our technical support section has the installation instructions contained for all machines.

What gauge wiring should I wire the Pipeliner system into my machine?

• We recommend 12 gauge stranded wiring since the heaviest load the wiring will feel is the electrical outlet current used to drive up to 20 amp loads for chop saws and other larger motor driven tools.  We recommend a 12 gauge extension cord be used for control too.  The Pipeliner hand control only uses .003 amps but the tools you drive will use up to 20 amps.

I already have a Miller, Lincoln factory (or Cable's) remote control installed and want to install the Pipeliner.  Do I have to remove or modify these other remote control systems in order to use the Pipeliner?

• When you install the Pipeliner remote control there are no other switches to install or other modifications to your existing wiring at all.  No changes need be made to any other remote units you have installed.  Installation is very simple and can be made by most individuals without assistance.  By leaving your original remote controls intact, you assure yourself of a "backup" in case the Pipeliner experiences a problem.

Why does rain ,or water, effect the Pipeliner remote control?

• Water is conductive.  The extension cord carrying power to the remote hand control has 120 volts AC or DC within it.  When an extension cord connection is immersed into mud or water, a conductive path is made throughout the whole plug or receptacle.  It's the same as taking a live extension cord at home and dropping it into a tub of water.  The ground terminal of the plug/receptacle is the return control signal from the hand control to the machine and if 120 volts is tracked over to it by a wet connector, the remote system will malfunction until the problem is corrected through cleaning or drying out.  The Pipeliner is designed so that no damage will occur to either the hand control or machine board by this type of problem.

• If your connections are kept dry (or out of mud and water) you should not experience any problems.

I lost control of my machine.  It runs hot all of the time and I can't control the machine amperage with the local fine control rheostat.

• There are several causes that will create this problem.  One is the Pipeliner machine board.  the second is the extension cord used for your remote cable and the other is the hand control itself.  In 95% of all cases it will end up being a damaged, contaminated or wet extension cord.  Troubleshooting is simple.  Follow these steps EXACTLY in the sequence shown.

1. Remove the extension cord and remote hand control from the machine.  If you still cannot control the machine by it's fine control rheostat the circuit board in the machine is at fault.  If this proves true you can verify the defective board by removing any one of the two wires from the machine rheostat connections to the Pipeliner machine board.  If the problem goes away, you have positively confirmed that the board is defective.
    

2. If step 1 is passed then plug the remote hand control directly into the remote receptacle.  DO NOT USE THE EXTENSION CORD!  Test the machine once again.  If you have control of the machine by the remote hand control THE EXTENSION CORD has a problem and has to be repaired or replaced.

In an emergency how can I disable the Pipeliner remote control from my machine so that I can weld until it is repaired?

• Very simple.  Remove one of the wires going from the Pipeliner machine board to your machine's rheostat.  On old model Pipeliner boards simply remove the wire from terminal #6 or on all newer models (Manufactured after 6/1/2002) simply remove the wires off terminals #1 or #2.  You will be able to weld normally.

I plugged my Pipeliner remote hand control into a standard electrical outlet.  Is it damaged?

• No.  The Pipeliner hand control is designed so that it will not be damaged by plugging it into the wrong electrical outlet.

Does the hand control unit for the Pipeliner get hot?

• No.  The Pipeliner hand control uses very little power and never gets hot.

Why does a GFI receptacle not work with a SA-200 or Classic-I machine?

• GFI (Ground Fault Interrupters) utilize a very small set of current transformers to determine if there is a difference between the current in one wire verses the return current in the other wire within an electrical circuit.  If there is a difference, the GFI will trip and prevent electrocution.  Transformers require AC to operate.  They will not operate on DC (the type of auxiliary power generated on these types of machine) and consequently do not provide protection.  They must be used on machine producing AC auxiliary power only.

Can I use the extension cord used for my remote control as a standard extension cord when the Pipeliner remote hand control is not being used?

• Yes you can as long as you use a standard 3-wire to 2-wire electrical plug adapter such as those found in hardware and grocery stores.  Failure to use the adapter mentioned could lead to a mild (but not lethal) electrical  shock while using tools with metal grounded casings or while in a wet location.  Maximum amperage possible from the grounding terminal is .003 amps (3 milliamps, 3 thousandths of an amp) and is incapable of producing physical harm.

Can my Pipeliner hand control be used on any machine that has a Pipeliner remote control installed.  For example, a Miller Big-40, a SA-200 and then a Classic III?

• Yes.  All Pipeliner hand control can be switched and used between any machine that has the Pipeliner system installed.  If problems arise in the field you can use someone else's hand control to test your machine.  The Pipeliner hand control is designed so that no damage can be done to it's electrical parts so you do not have to worry about damaging your fellow weldor's hand unit when switching units for testing.