March
1982
FORM:
OM-856
OWN
ERS
MANUAL
HilliER
)ER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON
WI
54912
USA
Effective
With
Style
No.
JB22
MODEL
RCMP-4
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
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the
foregoing
periods.
to
its
Distributor/Dealer
that
all
new
and unused
Equipment
(
furnished
by
Miller
is
free
from
defect
in
workmanship
and
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac-
therefore
shall
be,
at
Millers
option
(1
repair
or
(2)
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
engines,
trade
accessories
and
other
items
are
sold
sublect
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
(41
payment
of
or
credit for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clai-
Except
as
specified
below,
Millers
warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
(ii
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA
wire
including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
(
ment
to
the
original
user:
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
components
.
.
1
year
2.
Original
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
(labor
-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
Allweldinggunsandfeeder/guns
9odays
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
r
4.
All
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
5.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
6.
Batteries
6
months
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
¶
provided
that
Miller
is
notified
in
writing
within
thirty
30)
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
:?t,
j~
SECTION
1
-
INTRODUCTION
1i.
GENERAL
-
This
manual
has
been
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.
1-2.
RECEIVING-HANDLING
-
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
lading
will
be
furnished
by
the
manufacturer
on
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip~
ment,
it
is
essential
that
Model
Description
of
the
equip
ment
be
supplied.
1-3.
DESCRIPTION
-
The
RCMP-4
is
a
multi
purpose
remote
control
unit
which
will
provide
a
separate
welding
condition
on
each
of
two
welding
wires
when
using
a
Dual
Wire
Feeder
model
capable
of
feeding
two
welding
wires
with
one
welding
power
source.
It
is
designed
specifically
for
use
with
the
Gas
Metal-Arc
(GMAW)
and
Flux
Cored-Arc
(FCAW)
welding
processes.
1-4.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front
of
the
welding
power
source
Owners
Manual
should
be
read
com
pletely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,
and
NOTE
blocks
found
throughout
this
manual:
t.q.iuiii.i~r
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
personnel.
~
~
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2-
INSTALLATION
CAUTION:
Before
making
electrical
connections
necessary
for
the
proper
operation
of
the
RCMP-4,
en
sure
that
the
welding
power
source
and
wire
feeder
are
both
deenergized.
2-1.
RCMP-4
VOLTAGE
CONTROL
CONNEC
TIONS
(Figures
2-1
&
3-1)
-
The
Voltage
Control
plug
provides
a
connection
point
between
the
RCMP-4
and
the
welding
power
source
voltage
adjustment
circuitry.
Insert
the
three-pole
twistlock
plug
from
~he
remote
control
fully
into
the
welding
power
source
VOLTAGE
CONTROL
receptacle
and
rotate
the
plug
clockwise.
I~sII~
Place
the
welding
power
source
VOL
TAGE
CONTROL
switch
in
the
REMOTE
position.
2-2.
RCMP-4
VOLTAGE
SCHEDULE
¶~ONTROL
CONNECTIONS
(Right
Contactor
Control
Connec
tion)
(Figures
2-1
&
3-1)
-
Insert
the
connector
on
the
Right
Contactor
Control
cable
fully
into
the
RCMP-4
Voltage
Control
receptacle
and
rotate
connector
clockwise.
The
remaining
end
of
the
cable
must
be
con
nected
to
the
Dual
Wire
Feeder
Right
Contactor
Control
receptacle.
OM-856Pagel
Welding
Power
Source
Wire
Work
Left
Trigger
Control
TA-086
587
Figure
2-1.
Gas
Metal-Arc
And
Flux
Cored-Arc
Welding
Processes
3-1.
RCMP-4
VOLTAGE
CONTROLS
(Figure
3-1)
The
RCMP-4
VOLTAGE
CONTROLS
provide
voltage
selection
within
the
welding
power
source
load
voltage
range
being
used.
When
the
Dual
Wire
Feeder
Left
control
is
active,
the
RCMP-4
LEFT
VOLTAGE
CONTROL
will
be
active.
When
the
Dual
Wire
Feeder
Right
control
is
active
the
RCMP-4
RIGHT
VOLTAGE
CONTROL
will
be
active.
Rotating
the
VOLTAGE
CON
TROLS
in
a
clockwise
direction
increases
the
load
voltage.
The
scale
surrounding
the
VOLTAGE
CONTROLS
is
calibrated
in
percentage
and
should
not
be
misconstrued
as
an
amperage
or
voltage
read~ng.
It
is
recommended
that
the
meters
be
read
whenever
it
is
necessary
to
know
the
amperage
and
voltage
putput.
I~~I~
The
contacts
of
the
VOLTAGE
CONTROLS
are
of
the
continuous
type,
thereby
making
it
possible
to
adjust
these
controls
while
welding.
3-2.
RCMP-4
PILOT
LAMPS
(Figure
3-1)
-
When
the
welding
power
source
is
energized,
the
remote
con
trol
LEFT
or
RIGHT
pilot
lamp
will,
when
illuminated,
in
dicate
which
VOLTAGE
CONTROL
is
active.
SECTION
4
-
SEQUENCE
OF
OPERATION
4-1.
GAS
METAL-ARC
AND
FLUX
CORED-ARC
WELDING
(Figure
2-1)
1.
Make
necessary
electrical
and
mechanical
con
nections
to
the
welding
power
source,
the
Dual
Wire
Feeder,
and
gun
as
outlined
in
the
welding
power
source
manual
the
Dual
Wire
Feeder
manual,
and
gun
manual,
respectively.
2.
Make
RCMP-4
Voltage
Control
connections
as
outlined
in
Section
2-1.
3.
Make
RCMP-4
Voltage
Schedule
Control
con
nections
as
outlined
in
Section
2-2.
4.
Place
the
welding
power
source
LOAD
VOLTAGE
RANGE
switch,
if
applicable,
in
the
desired
position.
I~
If
a
small
diameter
welding
wire
is
used
in
con
junction
with
the
Low
output
terminal
and
a
large
diameter
we/ding
wire
is
used
in
conjunction
with
the
High
output
terminal,
the
we/ding
power
source
LOAD
VOL
TA
GE
RANGE
switch,
if
applicable,
must
be
in
the
SINGLE
WIDE
position.
Conversely,
if
both
welding
wires
are
used
in
conjunction
with
the
same
output
ter
minal,
the
LOAD
VOL
TAGE
RANGE
switch
can
be
in
any
position.
5.
Rotate
the
RCMP-4
VOLTAGE
CONTROLS
to
the
desired
positions.
6.
Rotate
the
Dual
Wire
Feeder
WIRE
SPEED
con
trols
to
the
desired
positions.
CAUTION
____________
Prior
to
welding,
it/s
imperative
that
pro
per
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and
welding
helmet)
be
put
on.
Failure
to
comply
may
result
in
serious,
and/or
perma
nent
bodily
damage.
SECTION
3-
FUNCTION
OF
CONTROLS
Voltage
Control
Receptacle
Voltage
Control
Plug
Right
Voltage
Control
Right
Pilot
Light
£
Left
Voltage
Control
Left
Pilot
Light
Figure
3-1.
Front
Panel
View
TB-081
871
CAUTION
____________
Never,
under
any
circumstances,
operate
the
RCMP-4
with
the
outer
enclosure
removed.
In
addi
tion
to
a
safety
hazard,
warranty
is
void/f
the
RCMP-4
is
operated
with
the
outer
enclosure
open
or
removed.
7.
Turn
on
the
shielding
gas
supply.
Page
2
8.
Energize
the
welding
power
supply
and
the
Dual
Wire
Feeder.
Commence
welding.
9.
The
LEFT
or
RIGHT
VOLTAGE
CONTROL
will
be
active
whenever
the
Left
or
Right
Gun,
respectively,
is
activated.
Only
one
gun
can
be
active
at
one
time.
CAUTION:
______
_____
Despite
the
fact
that
one
of
the
guns
is
inactive,
this
inactive
gun
we/ding
wire
is
still
electrically
energized.
2.
Allow
the
welding
power
source
to
idle
for
three
minutes
with
no
load
applied
to
permit
proper
cooling.
3.
Place
the
welding
power
source
POWER
switch
in
the
OFF
position.
Since
the
Dual
Wire
Feeder
derives
its
power
from
the
welding
power
source,
it
will
also
be
deenergized
when
the
welding
power
source
is
deenergizec~.
4.
Turn
off
the
shielding
gas.
Ii~I.M~
The
VOL
TAGE
CONTROLS
and/or
the
WIRE
SPEED
controls
can
be
adjusted
while
welding.
4-2.
SHUTFING
DOWN
1.
Break
the
arc.
t.~...iuiii.i~r
If
we/ding
is
performed
in
a
confined
area,
failure
to
turn
off
the
shielding
gas
supply
could
result
in
a
build
up
of
gas
fumes,
thereby
endangering
personnel
reentering
the
welding
area.
SECTION
5
-
MAINTENANCE
IMPORTANT
_______________
Periodically
inspect
the
labels
on
this
unit
for
legibility.
All
precautionar,
labels
must
be
main
tained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
the
Parts
List
for
part
number
of
precau
tiona,y
labels.
Periodically
inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the
insulating
jacket,
particularly
at
the
plug.
Repair
or
replace
the
cord(s)
a~
necessary.
TO
FEEDER
G
R.
TO
REMOTE
CONTROL
RECEPTACLE
ON
WELDING
MACHINE
C
B
PLG
1
49
48
115
V.
~RC3
Circuit
Diagram
Circuit
Diagram
No.
A-081
297
+
OM-856
Page
3
2
3
4
5
6
7
8
9
10
11
12
13
14
15
605 797
039
635
039 634
082
701
030 653
019
663
023
235
059 266
020
528
027
631
*027
638
027
628
019 627
010 610
600
733
1
1
1
1
.2
4
1
.1
2
2
2
2
2
1
1
Item
Dia.
No.
Mkgs.
Part
No.
Complete
Parts
List
Description
Quantity
PLG1
RC3
R1,2
CR1
PL1,2
CAP,
twistlock3P3W2O
amp
125
volts
CONNECTOR
BODY,
twistlock2P2W20
amp
250
volts
RECEPTACLE,
twistlock
flange
2P2W
20
amp
250
volts
WRAPPER
RHEOSTAT,
WW15O
watt
15
ohm
MOUNT,
neoprene
15/16
OD
x3/8
CASE
SECTION,
base/sides
RELAY,
enclosed
120
voltsac
DPDT
HANDLE,
control
box
HOUSING,
indicator
light
BULB,
incandescant
slide
base
48
volts
LENS,
red
indicator
light
KNOB,
pointer
CONNECTOR,
clamp-cable
1/2
inch
CORD
SET,
115
volts
16
ga
3/c 20
feet
1
2
3
4
5
15
14
6
9
10
11
7
8
12
1
Figure
A
-
Complete
Assembly
TD-081
872
*Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Page4
/