Remote wire feeder using binary phase shift keying to modulate communications of command/control signals to be transmitted over a weld cable

A welding system comprising:

• a power source operable in a power delivery state wherein power for a welding process is delivered and operable in a stand-by state wherein the power source is itself powered but does not deliver power for the welding process;
• a wire feeder remotely located from the power source and connected to the wire feeder and designed to receive power for a welding process from the power source across a weld cable;
• a welding torch having a trigger and operably connected to the wire feeder and designed to deliver consumable wire to a workpiece during the welding process;
• a communications network between the power source and the wire feeder, the communications network designed to transmit control commands between the power source and the wire feeder across the weld cable;
• and
• wherein the communications network includes a sensor that detects when the trigger is shifted to a weld start position and upon said detection causes the communications network to transmit a power delivery signal to the power source that when received by the power source causes the power source to shift from the stand-by state to the power deliver state such that power for the welding process is delivered from the power source to the wire feeder.

A method of remotely controlling a power source for welding comprising the steps of:

• transmitting a first control message containing operational control information from a wire feeder to a power source remotely located from the wire feeder, the first control message transmitted across a weld cable connecting the wire feeder and the power source, and the first control message transmitted at a first frequency;
• determining if the power source received the first control message;
• and if not,
• transmitting a second control message different from the first control message but containing the operational control information of the first control message from the wire feeder to the power source, the second control message transmitted across the weld cable and at a second frequency different than the first frequency.