Miller | LE15 | Owner Manual | Miller RFCS-5 User manual

Miller RFCS-5 User manual
OM-844
183 973F
5/2004
Foot Controls
RFCS-5, RFCS-5HD, RFCS-6M,
RFCS-14, And RFCS-14HD
Visit our website at
www.MillerWelds.com
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.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − INSTALLATION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Typical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Remote Amperage Control For Welding Power Source Without
Remote Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Remote Amperage Control For Welding Power Source With Remote Control Switch
But Without Output (Contactor) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Remote Amperage Control For Welding Power Source With Remote Control Switch
And Output (Contactor) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Adjusting Potentiometer Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Changing Cord Location On RFCS-5HD, And RFCS-14HD Models . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
2
3
4
4
5
6
SECTION 1 − INSTALLATION AND OPERATION
READ SAFETY BLOCKS in welding power
source Owner’s Manual before proceeding.
WARNING
1-1. Typical Connection
Turn Off welding power source.
1
2
Foot Control
Remote 14, Remote 5, Or
Remote 6 Receptacle
Insert plug into matching 14-socket, 5-socket, or 6-socket receptacle, as applicable, on welding
power source. Tighten collar.
1
2
Ref. 801 736
1-2. Remote Amperage Control For Welding Power Source Without
Remote Control Switch
Off
0 A DC
On
Approximately
33 A DC
Combination Front Panel
And
Remote Control
Select Weld Process
Select Range And Polarity
Select Maximum
Amperage Percentage.
50% = Approx. 33 A DC
Press pedal lightly to turn
weld output and gas flow
on. Press pedal further to
increase weld output.
Release pedal to turn off
weld output and gas flow.
Ref. 155 790-E
OM-844 Page 1
1-3. Remote Amperage Control For Welding Power Source With Remote Control Switch
But Without Output (Contactor) Control
Example Of Combination Front Panel
And Remote Amperage Control
. See
welding power source
Owner’s Manual to determine
if Remote Foot Control works
as a combination or as full Amperage control.
In Example:
Min = 30 A In Range A or 40 A In
Range B (Unit Minimum)
Max = 95 A In Range A or 200 A In
Range B (Control Setting)
Unit Minimum
Control Setting
Set Switch
Set Desired Maximum
Amperage For Application
Press pedal to increase weld
output. Release pedal to
decrease weld output.
OR
EXAMPLE Of Full Remote Amperage Control
In Example:
Min = 30 A In Range A or 40 A
In Range B (Unit Minimum)
Max = 225 A In Range A or 375 A In
Range B (Unit Maximum)
Unit Minimum
Unit Maximum
Set Switch
Control Setting
Does Not Matter
Press pedal to increase weld
output. Release pedal to
decrease weld output.
Ref. 122 023-A / Ref. 141 127-A / 039 411-D
OM-844 Page 2
1-4. Remote Amperage Control For Welding Power Source With Remote Control Switch
And Output (Contactor) Control
Example Of Combination Front Panel
And Remote Amperage Control
. See
welding power source
Owner’s Manual to determine
if Remote Foot Control works
as a combination or as full Amperage control.
Off
0
On
Control
Setting
(150 A)
Combination Front Panel
And
Remote Control
Set Switch
Set Switch
Set Control
Press pedal lightly to turn weld
output and gas flow on. Press
pedal further to increase weld
output. Release pedal to turn
off weld output and gas flow.
EXAMPLE Of Full Remote Amperage Control
Off
0
On
Unit
Maximum
Set Switch
Set Switch
Control Setting
Does Not Matter
Press pedal lightly to turn weld
output and gas flow on. Press
pedal further to increase weld
output. Release pedal to turn
off weld output and gas flow.
Ref. 114 018 / Ref. 801 736
OM-844 Page 3
1-5. Adjusting Potentiometer Timing
Disconnect foot control from welding power source/generator.
2
1
BEFORERE−INSTALLINGBELT,TURNGEARALL
THEWAYTOTHESTOP.
AVANTDEREPOSERLACOURROIE,FAIRE
PIVOTERL’AXEJUSQU’ÀLABUTÉE.
ANTESDEVOLVERAINSTALARLACORREADÉ
VUELTAALENGRANAJETODOLONECESARIO
HASTAQUESEDETENGA.
218006−A
Turn unit upside down, and remove
bottom plate.
1
Label
2
Gear
Turn gear on potentiometer shaft
counterclockwise as far as
possible.
Pull drive belt tight and mesh belt
teeth with gear teeth.
Connect free end of small spring
into end of drive belt.
Reinstall bottom plate
1-6. Changing Cord Location On RFCS-5HD, And RFCS-14HD Models
Disconnect foot control from welding power source/generator.
1
Bottom Plate
Turn unit upside down, and remove
bottom plate.
Remove screw that holds cord in its
factory installed location.
2
Cord Slots
Position cord in desired slot.
2
1
OM-844 Page 4
Slide strain relief down cord and
into slot to protect cord. Secure
cord with screw in the same manner in which it came from the
factory.
Reinstall bottom plate
SECTION 2 − ELECTRICAL DIAGRAMS
183 957-B
Circuit Diagram For RFCS-5, RFCS-5HD, RFCS-14, And RFCS-14HD Models
Circuit Diagram For RFCS-6M Models
208 615-A
OM-844 Page 5
SECTION 3 − PARTS LIST
1
2
2
6
4
5 7
11
9
8
13
12
10
2
3
ST-801 735-A
Quantity
RFCS Models
Item
No.
Dia.
Mkgs.
Part
No.
. . . 1 . . . . . . . . . . . . . 182 030
. . . 2 . . . . . . . . . . . . . 185 929
. . . 3 . . . . . . . . . . . . . 198 036
. . . 4 . . . . . . . . . . . . . 182 627
. . . 5 . . . . . S1 . . . . 183 629
. . . 6 . . . . . . . . . . . . . 186 476
. . . 6 . . . . . . . . . . . . . 212 644
. . . 6 . . . . . . . . . . . . . 208 621
. . . 6 . . . . . . . . . . . . . . 219993
. . . 6 . . . . . . . . . . . . . 182 628
. . . 6 . . . . . . . . . . . . . 199 405
. . . 7 . . . PGL1 . . . 131 204
. . . 8 . . . . . . . . . . . . . 175 284
. . . 8 . . . . . . . . . . . . . 199 410
. . . . . . . . . . . . . . . . . . . 199 409
. . . 9 . . . PLG2 . . . 039 273
. . . . . . . . . . . . . . . . . . . 039 685
. . . 9 . . . PLG2 . . . 144 310
. . . . . . . . . . . . . . . . . . . 143 922
. . . 10 . . . . . . . . . . . . . 182 626
. . . 11 . . . . . R1 . . . . 183 956
. . . 12 . . . . RC1 . . . . 131 203
. . . 13 . . . C1, 2 . . . 028 291
OM-844 Page 6
5
5HD
6M
14
14HD
Description
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Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1
Pedal / housing / bottom . . . . . . . . . . . . . . 1 . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1
Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 1
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1
Switch, limit 10A 125/250V . . . . . . . . . . . . 1 . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1
Cable Control . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Control 13’-3” (4 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Control 20’ (6 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cable Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets . . . . . . . . . . . . . . . . . 1 . . . . . . 1 . . . . . . . . . . . . 1 . . . . . 1
Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21’ . . . . . . . . . . . . 21’ . . . 21’
Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21’ . . . . . . . . . . . . . . . . . . 21’
Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . 1
Connector & Sockets . . . . . . . . . . . . . . . . . 1 . . . . . . 1
Connector, clamp str . . . . . . . . . . . . . . . . . 1 . . . . . . 1
Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
Connector, clamp str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1
Potentiometer . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1
Connector & Sockets . . . . . . . . . . . . . . . . . 1 . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1
Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . 2 . . . . . 2 . . . . . 2 . . . . . 2
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies (Unless Otherwise Stated)
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
*
*
*
Remote Controls
Accessory Kits
Replacement Parts (No labor)
*
*
Spoolmate Spoolguns
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 3/04
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
 2003 Miller Electric Mfg. Co.
1/03
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