Remote Control Welding With ArcReach®: Elevating Productivity, Quality and Safety

Remote control technology provides welders with the ability to set welding parameters at the joint, increasing safety by reducing trips to and from the power source and increasing arc-on time for greater productivity. This technology also helps improve quality by eliminating the need to settle for less-than-optimal settings.

Stay competitive, productive and profitable

Companies are always looking for ways to become more competitive, productive and profitable. Accurately bidding on jobs, having qualified welders, using the right welding equipment and completing projects on deadline are all imperative to reaching those goals. Also critical is workplace safety, and companies should take steps to minimize hazards that could lead to employee injury.

One way to do that is to use remote control technology, like Miller® ArcReach technology. It provides control of the welding power source at the weld joint, eliminating the need to walk back to the power source to make parameter adjustments, saving hours each day and reducing slips, trips and falls. ArcReach technology allows you to dial in your optimal arc without leaving the weld joint, resulting in higher-quality welds and less rework.

This technology is beneficial for industries where a welding operator is not welding next to the power source. These include large jobsites found in construction and shipbuilding, where welding can take place hundreds of feet away from the power sources or in tight, hard-to-reach places that aren’t ideal for operators to maneuver in and out of.

Available remote technology

There are two main types of remote control welding technologies available in the marketplace, but they are not all equal.

1. Remote control or RC feeder: This option requires weld cables and an additional control cord, providing full wire feed speed and voltage control at the weld joint.
2. Voltage sensing or VS feeder: This is the most advanced option available for MIG welding and includes complete remote control technology, offering wire feed speed, voltage control and process control via the existing weld cables — no additional cord required. For TIG and stick welding, amperage, arc control and process control are available via a remote. The control cord is not required.

Eliminating the control cord, which can contain more than 14 wires wrapped in a bundle, reduces cable management by 33% while giving the welding operator complete control at the weld joint and reducing the need to purchase or maintain expensive cords. These reduced costs can add up on jobsites that have dozens or even hundreds of welding machines. In addition, reducing unplanned downtime for the repair and maintenance of older corded options can also eliminate unnecessary costs.

Another benefit is that there are no line-of-sight limitations, as the weld cables provide the remote control capability rather than radio waves, which can be disrupted by obstructions or distance. As long as the cables are properly sized for the job, they will have the ability to communicate with the power source.

Explore the advantages of Miller® ArcReach® technology

ArcReach technology improves upon the voltage sensing remote technology mentioned earlier by enabling welders to control the power source remotely without the need for a control cord. There are numerous advantages to integrating ArcReach technology into your fleet.

• Control and productivity gains: Cable Length Compensation, or CLC™, automatically adjusts for voltage drop in weld cables — even hundreds of feet away from the power source. This allows greater accuracy and easier control of weld quality for the operator. It also saves time the operator would spend walking back and forth to the power source to dial in the voltage to meet welding specifications.
• Safety benefits: Reducing trips to and from a power source minimizes exposure to hazards and operator fatigue. A 100-foot control cable weighs, on average, 45-50 pounds; eliminating this extra weight and bulkiness allows for more agility and comfort.
• Reduced maintenance and costs: Remote control technology that does not require the extra control cord can reduce time-consuming and costly repairs or replacements, including addressing broken connectors or splicing crushed cables. The more machines a company has, the more savings it will see in this regard since there are fewer control cords to purchase or repair. Additionally, this saves time and effort rolling and unrolling extra cords at the start and end of each shift, which is crucial when moving between weld joints or project areas.
• Fleet management benefits: This technology is also advantageous for fleet management, as some remote control capabilities can be gradually integrated into a fleet without needing to replace all welding machines at once. Equipment with and without remote control technology is compatible, allowing for a seamless integration of new technology over time as budget permits. Many remote control technologies are available in multiprocess welding machines, offering versatility for MIG, stick or TIG welding to meet various jobsite needs. These remotes facilitate easy amperage adjustment, arc control and precision settings, maximizing equipment investments and meeting diverse welding requirements.

Discover Miller® ArcReach® welding systems

Designed to meet the varied needs of the construction industry, select Miller multiprocess welders, engine-driven welders and accessories feature ArcReach technology to maximize output and productivity.

• Multiprocess welders: Multiprocess welders make it easy to tackle a variety of jobs in the shop or field without switching power sources, with the XMT lineup specifically made for construction and fabrication, providing portability, versatility and excellent arc performance. The latest addition, the XMT® 400 ArcReach, builds on the reliable XMT 350 FieldPro™. It is the smallest and lightest machine in its amperage class, improving jobsite mobility. For larger wire and carbon diameters, we offer the XMT 650 ArcReach models. Additionally, the XMT 350 FieldPro and XMT 650 ArcReach lineups include a polarity reversing model which allows for better control over penetration and arc stability, making it suitable for both thick and thin materials. It also enhances cleaning action and versatility, enabling high-quality welds across various applications.
• Engine-driven welders: The Bobcat™, Trailblazer® and Big Blue® engine-driven welders feature ArcReach technology, available as both optional and standard, depending on the model. These welders use gasoline, diesel or propane engines to power stick, TIG, MIG and flux-cored welding, making them ideal for any jobsite your work truck encounters.
• Accessories: ArcReach feeders and ArcReach stick/TIG remotes are also compatible with a wide variety of Miller multiprocess and engine-driven welders, so companies can expand the use of the technology with their existing fleet. Miller is the only welding equipment manufacturer to offer this type of remote control technology without a control cable in an engine-driven power source.
• Heaters and tools: Miller induction heating solutions are designed for jobsite weld preheating in construction and pipe applications and are compatible for select ArcReach welding power sources. They are faster, safer and less expensive than open-flame or resistance methods. These solutions run off existing welding power sources, improving productivity and profitability on the jobsite. Contractors can see a return on investment by the 11th joint they preheat.

The ArcReach family of products provides maximum fleet compatibility and greater flexibility, allowing companies to fully utilize their existing accessories and power sources until they are ready to replace or upgrade. ArcReach-equipped power sources and wire feeders work with non-ArcReach equipment; however, the complete ArcReach benefit is only realized with the ArcReach system.

Upgrade to ArcReach

The integration of remote control welding technology and induction heating solutions presents numerous advantages for companies striving to enhance efficiency, reduce costs and improve safety in their welding operations. By adopting these advanced technologies, companies can achieve substantial financial savings, optimize their welding processes and stay competitive in the industry. The seamless compatibility with existing equipment and the versatile applications offered by these solutions further underscores their value, making them indispensable tools for modern welding operations.