Miller RCMP-2 User Owner's Manual

July 1983
FORM: OM-852A
0~
MODEL
RCMP-2
OWN ERS
MANUAL
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST. P.O. Box 1079
APPLETON,
WI
54912 USA
ADDITIONAL COPY PRICE ZO CENTS
NWSA CODE NO. 4579
PRINTED IN U.S.A.
LIMITED WARRANTY
EFFECTIVE: JUNE 1, 1979
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
(~
LIMITED WARRANTY-Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that all new and unused Equipment
furnished by Miller is free from defect in workmanship and
material as of the time and place of delivery by Miller. No warranty is made by Miller with respect to engines, trade accessories
engines,
other
or
items
manufactured
by
trade accessories and other items
are
others.
sold
As
writing by Miller in appropriate cases, 131
repair or replacement at an authorized
Miller service station or 14) payment of or credit for the purchase
price Iless reasonable depreciation based upon actual usel upon
risk and expense. Upon receipt
return of the goods at Customers
the reasonable cost of
All
the warranties of their respective manufacturers, if any
are warranted by their manufacturer for one year from
.
original purchase.
Except
as
of notice of apparent defect or failure, Miller shall instruct the claimant on the warranty claim procedures to be followed.
specified below. Millers
warranty does not apply
normal useful life of less than one Ill
components having
such as spot welder tips, relay arid coritactor points,
MILLERMATIC
parts that come in contact with the welding
ANY
nozzles and nozzle insulators where failure does
TION
to
wire
not
including
result from defect in
workmanship
or
~
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
year,
~
general policy Only, Miller may honor claims
original user within the foregoing periods.
or, where authorized in
to
engines
date of
matter of
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option Ill repair or 121 replacement
Such
subject
a
submitted by the
GUARANTY OR REPRESENTA-
IMPLIED WARRANTY,
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
material.
Miller shall be
required to honor warranty claims on warEquipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip.
ment to the original user:
ranted
ANY
AS
TO
~
IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX~
CLUDED AND DISCLAIMED BY MILLER.
1.
2.
Arc welders, power sources and components
Original main power rectifiers
.
Ilabor- 1 year onlyl
guns and feeder/guns
3.
All
4.
All other Millermatic Feeders
welding
.
5.
Replacement
6.
Batteries
or
1 year
3 years
EXCEPT
AS
90 days
ULTIMATE
.
PRODUCTS
PURCHASE
that Miller is notified in
60 days
6months
writing
within
BY
MILLER
INTENDED
IN
FOR
COMMERCIAL/INDUSTRIAL
BY
WELDING
EQUIPMENT
thirty 1301 days
TO,
AND
the date of such fa~ure
NO
~
~
FOR
CONSUMERS
OR
~
WARRANTIES DO NOT EXTEND
RESELLER
WARRANT~S TO
~ ~f
NOT
AND
CONSUMER USE. MILLER
provided
ARE
USERS AND FOR OPERATION BY PERSONS TRAINED AND
AND
USE
MAINTENANCE
OF
IN
THE
EXPERIENCED
1 year
repair parts, exclusive of labor
PROVIDED
EXPRESSLY
MILLER
WRITING,
IS
AUTHORIZED
ANY CONSUMER
TO
EXTEND
~
ERRATASHEET
After this manual
to data
FILE COPY
RETURN TO FOLDER
was
appearing
printed,
refinements in
equipment design occurred. This
sheet lists
exceptions
later in this manual.
AMEND MENT TO PARTS LIST
Amend Parts List
as
follows:
Eftective With
Dia.
--
5-3
5-9
~First
Mkgs.
RC3,4
Part
No.
Replaced
039 634
082 700
141 840
digit represents page
no
No. KB-20
Quantity
Description
With
141 895
Style
RECEPTACLE, twlk fig 2P2W 20A 250V
PANEL, control
digits following
dash represent item
no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
1
1
SECTION 1
-
INTRODUCTION
1
prepared
especially for use in familiarizing personnel with the
design, installation, operation, maintenance, and
troubleshooting of this equipment. All information
presented herein should be given careful consideration
to assure optimum performance of this equipment.
-
1. GENERAL
This
-
has
manual
been
IMPORTANT
This unit is
gun active at
one
I~
panel
a
designed
to be used with
time.
This remote control
mu/ti-purpose we/ding
will hereafter be referred to in this manual
the
as
REMOTE CONTROL.
Prior to installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of
1
-
2. RECEIVING-HANDLING
lading and freight bill
request if occasion
-
by the carrier
will be furnished
to
on
file claim arises.
requesting information concerning this equip
ment, it is essential that Model Description and/or
Stock Number and Serial (or Style) Numbers of the
When
1
-
4. SAFETY
CAUTION,
-
throughout
following
and
definitions apply to
NOTE blocks found
this manual:
t~Lu1I~i1~ Under
this heading,
installation,
operating, and maintenance procedures or practices will
be found that if not carefully followed may create a
hazard to
personnel.
IMPORTANT
equipment be supplied.
The
IMPORTANT,
this
Under
heading, installation,
procedures or practices will
be found that if not carefully followed may result in
damage to equipment.
______________
operating,
1
-
DESCRIPTION
3.
which
provides
a
-
This unit is
a
remote control
separate welding condition
on
each of
using one or two control/feeders
and an MP (Multi-Purpose) welding power source. It is
designed specifically for use with the Gas Metal-Arc
(GMAW) and Flux Cored Arc (FCAW) Welding pro
and maintenance
electrode wires
two
I~IsI I ~ Under this
most
cesses.
heading, explanatory statements
spec/al emphasis to obtain the
efficient operation of the equipment.
will be found that need
SECTION 2- INSTALLATION
1. REMOTE VOLTAGE CONTROL CONNEC
TIONS (Figure 3-1)
The Voltage Control Plug pro
vides a
connection
point between the Remote
control circuitry. Insert the two-pole twistlock plug from
the REMOTE CONTROL fully into the welding power
VOLTAGE CONTROL and the welding power source
voltage adjustment circuitry. Insert the three-pole
twistlock plug from the REMOTE CONTROL fully into
the welding power source Voltage Control Receptacle
plug
2
-
-
Contactor Control Receptacle and rotate the
as far as possible. This rotating action
source
clockwise
will
secure the plug in the receptacle and prevent the
plug from coming Out if tension should be applied to the
Remote Contactor Control cord.
and rotate the
plug clockwise as far as possible. This
rotating action will secure the plug in the receptacle and
prevent the plug from coming out if tension should be
applied to the Remote Voltage Control cord.
I~1t~
When
control of the
remote
is
contactor
desired, it is essential that the welding power source
Contactor Control Switch be placed in the Remote posi
tion.
LIsii~
When
remote
control
of
the
voltage is
desired, it is essential that the welding power
source
Voltage Control Switch be placed in the Remote posi
2 -4. CONTROL/FEEDER REMOTE CONTACTOR
CONTROL CONNECTIONS
tion.
I~s)1~
2
2.
115 VAC CONNECTIONS
Two 10 ft. contactor control cables
are
sup
making
con
(Figure 3-1) This
115 VAC Plug provides a connection point to supply 115
volts ac to the REMOTE CONTROL from the welding
power source. Insert the three-po~ twistlock plug from
the REMOTE CONTROL fully into the welding power
115 VAC Receptacle and rotate the plug
source
clockwise as far as possible. This rotating action will
secure the plug in the receptacle and prevent the plug
from coming out if tension should be applied to the 115
plied
VAC cord.
The REMOTE CONTROL LEFT FEEDER Contactor Con
-
-
with Dual Control/Feeder Models for
tactor control connections.
If two control/feeders
are
used, it is recommended that 16/2 conductor cable be
used for the contactor control cable with
plug. (These parts may
depending on the model.)
male
A.
trol
or
a
two-prong
may not be
supplied
Left Feeder
receptacle provides
-
a
connection
point between
the
REMOTE CONTACTOR CONTROL CON
NECTIONS (Figure 3-1)
The Contactor Control Plug
Left Feeder and the REMOTE CONTROL. Insert the
two-pole twistlock plug from the Left Feeder fully into
provides
the LEFT FEEDER Contactor Control
2
-
3.
-
a
connection
CONTROL and the
point between the REMOTE_.
welding
power source contactor
rotate the
plug
receptacle
and
clockwise.
OM-852
Page
1
B.
Right Feeder
A.
Left Feeder
The REMOTE CONTROL RIGHT FEEDER Contactor
Control receptacle provides a connection point between
The REMOTE CONTROL LEFT FEEDER 115 AC recep
tacle provides a connection point to supply 11 5 volts ac
the Right Feeder and the REMOTE CONTROL. Insert
the two-pole twistlock plug from the Right Feeder fully
into the RIGHT FEEDER Contactor Control receptacle
to the Left Feeder
plug clockwise.
and rotate the
2
5. CONTROL/FEEDER
-
the
VAC
from the REMOTE CONTROL. Insert
twistlock
plug
from the Left Feeder
into the LEFT FEEDER 11 5 VAC
the
115
three-pole
CONNEC
receptacle and
fully
rotate
plug clockwise.
B.
Right Feeder
TIONS
The REMOTE CONTROL RIGHT FEEDER
115 VA C
I~IsI~ 1~ The
receptacles
CONTROL supply 115 volts
ac
for the
on
the REMOTE
operation of
two
receptacle provides
volts
ac to
TROL.
control/feeder operation should be obtained for the
REMOTE CONTROL LEFT FEEDER 115 VAC recep
receptacle and
Right
Insert the
Feeder
115 VAC
connection point to supply 115
Feeder from the REMOTE CON
Right
three-pole
the
control/feeders. When using one control/feeder (Dual
Control /Feeder Models), the 115 volts ac required for
a
fully into
twistlock
plug from
the
the RIGHT FEEDER 115 VAC
rotate the
plug clockwise.
tacle. It would then be necessary to connect the jumper
on terminal strip 1 T, located on the back of the con
trol panel, across terminals A and B. The REMOTE
link
CONTROL is shipped with the jumper link connected
terminals B and C for operation of two con
trol/feeder.
across
SECTION 3
-
FUNCTION OF CONTROLS
Left Feeder
Contactor Control
Right
Voltage Adjustment Control
Receptacle.
Left Feeder
115 VAC
Receptacle
Right
Right
Lamp
Feeder
Pilot
115 VAC
Receptacle
Left
Voltage Adjustment
Control
Left
Pilot Lamp
Voltage
Control
Control
Plug
Plug
115 VAC
Plug
TB-041 126-1
Figure 3-1. Front Panel View
3
-
1.
LEFT AND RIGHT VOLTAGE ADJUSTMENT
control will be active.
MENT controls in
load voltage.
CONTROLS (Figure 3-1)
V
a
Rotating the VOLTAGE ADJUST
clockwise direction will increase the
The scale
VOLTAGE ADJUSTMENT
I~sII~ The contacts of the VOL TA GEADJUSTMENT
of the continuous type, thereby making
adjust these controls while welding.
controls
are
possible
to
The LEFT AND RIGHT VOLTAGE ADJUSTMENT
it
con
provide voltage selection with the welding power
source bade voltage range being used. Depending on
whether the REMOTE CONTROL is in the LEFT OR
RIGHT mode, either the LEFT or RIGHT VOLTAGE
trols
OM-852 Page 2
surronding the VOLTAGE ADJUSTMENT
controls is calibrated in percentage and should not be
misconstrued as an amperage or voltage reading. It is
recommended that the meters be read whenever it is
necessary to know the amperage and voltage output.
3
-
3-1)
2.
-
LEFT AND
With the
RIGHT PILOT
welding
power
LAMPS
source
(Figure
energized and
with the REMOTE CONTROL in the LEFT or RIGHT
mode, the LEFT or RIGHT Pilot Lamp, respectively, will
be illuminated.
SECTION 4
-
SEQUENCE OF OPERATION
Voltage Control
Remote Control Unit
Welding
Power Source
TA.041 126-2A
Figure
1~..tUI I Is1~
Welding Connections
Never, under any circumstances, operate
REMOTE
the
4-1. Gas Metal-Arc
CONTROL
removed. In addition to the
with
the
outer
8.
enclosure
Rotate the LEFT VOLTAGE ADJUSTMENT
trol and Left Feeder Wire
safety hazard, the warranty
operated with the
desired
Speed Control
con
to the
setting.
is void if the REMOTE CONTROL is
outer enclosure open
or
removed.
9.
Rotate the
control and
4-1.
GAS
METAL-ARC
(GMAW)
WELDING
the desired
RIGHT VOLTAGE ADJUSTMENT
Wire Speed Control to
Right Feeder
setting.
(Figure 4-1)
10.
1.
Make necessary electrical and mechanical con
nections to the welding power source, con
trol/feeder, and gun as outlined in the welding
power source manual, control/feeder
and gun manual, respectively.
2.
Make Remote
manual,
Voltage Control Connections
Turn
on
the
shielding
gas
CAUTION Prior to
welding, it is imperative that pro
protective clothing (welding coat and gloves) and
eye protection (glasses and we/ding he/met) be put on.
Failure to comply may result in serious and/or perma
nent bodily damage.
_________
per
as
11.
outlined in Section 2-1.
Energize the welding
power
trol/Feeder. Commence
3.
Make 115 VAC Connections
as
12.
Con
The Left
as
Make Control/Feeder Remote Contactor Control
as outlined in Section 2-4.
gun and the Right Feeder are activated, the Left
Feeder will be rendered inactive.
Make Remote Contactor Control Connections
connections
6.
and
or Right mode will automatically be
selected whenever the left or right gun, respec
tively, is activated. Whenever the left gun and
Left Feeder are activated, the Right feeder will be
rendered inactive. Likewise, whenever the right
outlined in Section 2-3.
5.
source
welding.
outlined in Sec
tion 2-2.
4.
supply.
Make Control/Feeder 115 VAC connections
as
CAUTION Despite the fact that one of the Con
trol/Feeders is inactive, this inactive Control/Feeder
Gun welding wire is still electrically energized.
___________
outlined in Section 2-5.
7.
welding power source Load Voltage
Range Switch in the desired position.
Place the
13.
The LEFT
or
RIGHT VOLTAGE ADJUSTMENT
control and/or Wire
Figure 4-1 illustrates a small diameter welding
wire used/n conjunction with the welding power source
Low Output Terminal and a large diameter we/ding wire
used in conjunction with the welding power source
High Output Terminal. With such an arrangement, the
welding power source Load Voltage Range Switch
must be in the Wide Range position. Conversely, if both.
Contro//Feeders~ are operated from the sarne~y~out
Terminal, the we/ding power source Load Voltage
Range Switch may be in any position.
Speed Control may be ad
justed while welding to achieve optimum
welding conditions.
I~I.Jt~
4
2. SHUTTING DOWN
-
1.
Breakthearc.
2.
Allow the
welding
minutes with
no
power source to idle for 3
load
applied.
OM-S52Page3
--9
Place the welding power source Power Switch in
the OFF position. Since the REMOTE CONTROL
derives its operating power from the welding
3.
5.
Turn off the
shielding
gas.
performed in a confined
shielding gas supply could
result in a buildup of gas fumes, thereby endangering
personnel reentering the we/ding area.
CAUTION If
welding
is
___________
power source, the REMOTE CONTROL will also
be deenergized when the welding power source
is
deenergized.
If the Control/Feeders do not derive
4.
area, failure to turn off the
power from the
operating
power source, place the
Control/Feeder Power Switches in the OFF posi
welding
tion.
TO
+
FEEDER
TO
FEEDER
54
I
RC ~
RC4
:CR1
TO
REMOTE
56
CONTROL
RECEPTACLE
~
15 V.
ON
WELDING MACHINE
PLG
TO FEEDER
I
iT
INSTALL
JUMPER
ACROSS A&B WHEN
USING
_
DUAL
SWINGARC
CR1
iij
TO
CONTACTOR
RECEPTACLE
I
Ti
:cRi
4R~_J
115V
7
ON
>
WELDING MACHINE
FROM
WELDING MACHINE
4
PLG3
PLG2
9
RC2
TO FEEDER
--B,
Figure 4-2. Circuit Diagram
OM-852Page4
Circuit Diagram No. A-047 998
Item
Dia.
No.
Mkgs.
Figure
Part No.
023 606
4
5
010 610
039
039
030
023
RC3,4
RC1,2
R1,2
7
CR 1-3
9
10
11
634
686
653
235
019 663
059 266
082 700
038 620
038602
6
8
iT
12
13
020 528
14
027 631
15
PL1,2
16
17
18
19
*027 638
027 628
019 627
PLG3
PLG2
20
21
Quantity
Complete Assembly
A
2
3
Description
PLG1
039
039
600
605
635
687
733
797
CORD SET, 115 volts 16 ga 2/conductor 20 ft
CONNECTOR, clamp -cable 1/2 inch
RECEPTACLE, twistlock flange inlet 2P2W 20 amp 250 volts
RECEPTACLE, twistlock grounded 2P3W 15 amp 277 volts
RHEOSTAT, WW15O watt 15 ohm
-
-
3
2
2
2
CASE SECTION, base/sides
1
MOUNT, neoprenel5/16ODx3/8 rec3/16x3/8
RELAY, enclosed 120 volts ac DPDT w/flange
PANEL, control
LINK, jumper -terminal block 30 amp
BLOCK, terminal 30 amp 3 pole
NAMEPLATE (order by model and serial numbers)
4
HANDLE, control box
HOUSING, indicator light
BULB, slide base 48 volts
LENS, red indicator light
KNOB, pointer
CONNECTOR, body twistlock 2P2W 20 amp 250 volts
CAP, twistlock grounded 2P3W 15 amp 277 volts
CORD SET, ii5voltsi6 ga 3/conductor 20 ft
CAP, twistlock 3P3W 20 amp 125 volts
2
-
-
-
3
2
2
2
2
3
3
2
1
7
10-007 753.C
Figure~A
*Recommended
-
Comllete A~ssembIy
Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBERS WHEN ORDERING REPLACEMENT PARTS.
OM-852
Page
5