FORM:
OM-851A
F
January1982
Effective
With
Serial
No.
JB3O
MODEL
RCMP-1
I.
OWN
ERS
MANUAL
fullER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON
WI
54912
USA
ADDITIONAL
COPY
PRICE
25
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
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
(21
replacement
~
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
13)
~
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
141
payment
of
or
credit
for
the
purchase
~
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
(less
reasonable
depreciation
based
upon
actual
usel
upon
~
date
of
original
purchase.
return
of
the
goods
at
Customers
risk
and
expense.
Upon
receipt
)~J
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.
~,
d
to
components
having
normal
useful
life
of
less
than
one
Ill
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
j
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,
/t
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
EOUIPMENT
FURNISHED
BY
MILLER
IS
EX-
V
CLUDED
AND
DISCLAIMED
BY
MILLER.
1.
Arc
welders,
power
sources
and
componehts
. .
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.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
J
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
6months
WELDING
EOUIPMENT
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.
~
....~,
~
~
,,~
1-1.
GENERAL
SECTION
1
-
INTRODUCTION
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
hereinshould
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
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
This
unit
is
a
remote
control
multi-purpose
welding
panel
which
is
designed
specifically
for
use
with
the
Gas
Metal-Arc
(MIG)
Welding
process.
This
unit
will
provide
two
welding
conditions
on
one
wire
using
one
control/feeder
and
one
welding
power
source.
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
L_CAUTION
r!..
Under
this
heading,
installation,
ope
tenance
procedures
or
practices
will
not
carefully
followed
may
create
sonnel.
--I
rating,
and
main
be
found
that
if
a
hazard
to
per
1TITI
I
.
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
SECTION
2-
INSTALLATION
2-1.
REMOTE
VOLTAGE
CONTROL
CONNECTIONS
(Figure
3-1)
The
Voltage
Control
Plug
provides
a
connection
point
be
tween
the
Remote
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
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.
-
NOTE
When
remote
control
of
the
voltage
is
desired,
it
is
essential
that
the
welding
power
source
Voltage
Con
trol
Switch
be
placed
in
the
Remote
position.
2-2.
REMOTE
WIRE
FEED
SPEED
CONNECTIONS
(Figure
3-1)
The
Wire
Feed
Speed
Plug
provides
a
connection
point
be-
tween
the
Remote
WIRE
SPEED
Control
and
-the
control/
feeder
wire
feed
speed
circuitry.
Insert
the
six-pin
plug
from
the
REMOTE
CONTROL
fully
into
the
control/feeder
Wire
Feed
Speed
Receptacle.
NOTE
I
When
remote
control
of
the
wire
feed
speed
is
desired,
it
is
essential
that
the
control/feeder
Wire
Feed
Speed
Switch
be
placed
in
the
Remote
position.
2-3.
REMOTE
CONDITION
SELECTOR
CONNECTIONS
(Figure
3-1)
The
Condition
Selector
Receptacle
provides
a
connection
point
between
the
Remote
Condition
Selector
(optional
equipment)
and
the
REMOTE
CONTROL
Circuitry.
Insert
the
two-pole,
twistlock
plug
from
the
Remote
Condition
Selector
fully
into
the
REMOTE
CONTROL
Condition
Selec
tor
Receptacle
and
rotate
the
plug
clockwise
as
far
as
possible.
This
rotating
action
will
secure
the
plug
in
the
re
ceptacle
and
prevent
the
plug
from
coming
out
if
tension
should
be
applied
to
the
Remote
Condition
Selector
cord.
SECTION
3-
FUNCTION
OF
CONTROLS
3-1.
CONDITION
A
AND
B
VOLTAGE
CONTROLS
(Figure
3-1)
The
CONDITION
A
and
B
VOLTAGE
CONTROLS
provide
voltage
selection
within
the
welding
power
source
load
volt-
age
range
being
used.
Depending
on
the
position
of
the
Con
dition
Selector,
either
CONDITION
A
or
CONDITION
B
VOLTAGE
CONTROL
will
be
active.
Rotating
the
VOLT
AGE
CONTROLS
in
a
clockwise
direction
will
increase
the
load
voltage.
1-4.
SAFETY
I
E~r1
U
The
remote
control
multi-purpose
welding
panel
will
hereafter
be
referred
to
in
this
manual
as
the
RE
MOTE
CONTROL.
I
NOTE
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
-U
I
OM-851
Page
1
Figure
3-1.
Front
Panel
View
I
U
The
contacts
of
both
VOLTAGE
CONTROLS
are
of
the
Continuous
type,
thereby
making
it
possible
to
adjust
this
control
while
welding.
The
scale
surrounding
both
VOLTAGE
CONTROLS
are
cali
brated
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
amper
age
and
voltage
output.
3-2.
CONDITION
A
AND
B
PILOT
LAMPS
(Figure
3-1)
With
the
welding
power
source
energized
and
with
the
Condi
tion
Selector
in
a
position
corresponding
to
either
Condition
A
or
Condition
B,
the
CONDITION
A
or
CONDITION
B
Pilot
Lamp,
respectively.
will
be
illuminated.
Condition
B
Voltage
Control
Condition
B
Pilot
Lamp
Condition
B
Wire
Speed
Control
TB-040
810
3-3.
CONDITION
A
AND
B
WIRE
SPEED
CONTROLS
(Figure
3-1)
The
CONDITION
A
and
B
WIRE
SPEED
Controls
provide
wire
feed
speed
control.
Depending
on
the
position
of
the
Condition
Selector,
either
CONDITION
A
or
CONDITION
B
WIRE
SPEED
Control
will
be
active.
Rotating
the
WIRE
SPEED
Controls
in
a
clockwise
direction
will
increase
the
wire
feed
speed.
NOTE
The
contacts
of
the
WIRE
SPEED
Controls
Øre
of
the
continuous
type,
thereby
making
it
possible
to
adjust
this
control
while
welding.
The
scale
surrounding
both
WIRE
SPEED
Controls
are
cali
brated
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
amper
age
and
voltage
output.
SECTION
4
-
SEQUENCE
OF
OPERATION
Figure
4-1.
Gas
Metal-Arc
Welding
Connections
TA-041
125-1
Condition
A
Condition
A
Pilot
Lamp
Condition
A
Wire
Speed
Control
Voltage
Control
Plug
Wire
Feed
Speed
Plug
.
I
U
Welding
Power
Source
Page
2
U
CAUTION
Never,
under
any
circumstances,
operate
the
R~MOTE
CONTROL
with
the
outer
enclosure
removed.
In
addi
tion
to
a
safety
hazard,
improper
cooling
may
result
in
damage
to
the
REMOTE
CONTROL
components.
Warranty
is
void
if
the
REMOTE
CONTROL
is
operated
with
the
Outer
enclosure
open
or
removed.
10.
Welding
Condition
A
or
B
may
be
achieved
by
placing
the
Condition
Selector
in
the
position
corresponding
to
Condition
A
or
Condition
B.
respectively.
NOTE
If
the
gun-mounted
Condition
Selector
Switch
(optional
equipment)
is
employed,
both
r.ontactor
and
welding
condition
control
are
provided.
This
switch
has
essentially
three
positions.
4-1.
GAS METAL-ARC
(MIG)
WELDING
(Figure
4-1)
1.
Make
necessary
electrical
and
mechanical
connections
to
the
welding
power
source,
control/feeder,
and
gun
as
outlined
in
the
welding
power
source
manual,
control/feeder
manual,
and
gun
manual,
respectively.
2.
Make
Remote
Voltage
Control
Connections
as
out
lined
in
item
2-1
-
3.
Make
Remote
Wire
Feed
Speed
Connections
as
out
lined
in
item
2-2.
4.
Make
Condition
Selector
Connections
as
outlined
in
item
2-3.
5.
Place
the
welding
power
source
Load
Voltage
Range
Switch
in
the
desired
position.
NOTE
Due
to
the
circuitry
limitations
of
the
REMOTE
CON
TROL,
the
welding
power
source
may
not
be
used
in
the
Medium
Range
while
using
the
REMOTE
CON
TROL.
It
will
be
necessary,
therefore,
to
place
the
welding
power
source
Load
Voltage
Range
Switch
in
either
the
Low,
High,
or
Wide
Range
when
using
the
REMOTE
CONTROL.
6.
Rotate
the
CONDITION
A
VOLTAGE
CONTROL
and
WIRE
SPEED
Control
to
the
approximate
desiied
setting.
7.
Rotate
the
CONDITION
B
VOLTAGE
CONTROL
and
WIRE
SPEED
Control
to
the
approximate
desired
setting.
Prior
to
welding,
it
is
imperative
that
proper
protective
clothing
(welding
coat
and
gloves)
and
eye
protection
(glasses
and/or
welding
helmet)
be
put
on.
Failure
to
comply
may
result
in
serious
and/or
permanent
bodily
damage.
I
8.
Turn
on
the
shielding
gas
supply,
if
used.
9.
Energize
the
welding
power
source
and
control/feeder.
Commence
welding.
2.
Allow
the
welding
power
soutce
to
idle
for
3
minutes
with
no
load
applied.
3.
Place
the
welding
power
source
Power
Switch
in
the
OFF
position.
Since
the
REMOTE
CONTROL
derives
its
Oper
ating
power
from
the
welding
power
source,
the
REMOTE
CONTROL
will
also
be
de.energized
when
the
welding
power
source
is
de-energized.
4.
Place
the
Control/Feeder
Power
Switch
in
the
OFF
posi
tion
if
the
Control/Feeder
is
provided
with
operating
power
external
to
the
welding
power
source.
5.
Turn
off
the
shielding
gas,
if
used,
at
the
shielding
gas
source.
CAUTION
I
If
welding
is
performed
in
a
confined
area,
failure
to
tuin
off
the
shielding
gas
supply
could
result
in
a
build
up
of
gas
fumes,
thereby
endangering
personnel
re
enteringtheweldingarea.
1
.
In
the
first
switch
position,
to
which
the
switch
automatically
returns
if
no
switch
lever
pressure
is
applied,
the
welding
power
source
contactor
is
not
energized
2.
In
the
second
switch
position,
which
is
obtained
by
depressing
the
switch
lever
about
half
way
down,
the
welding
power
source
contactor
is
energized
and
the
REMOTE
CONTROL
is
placed
in
the
CONDITION
A
position.
3.
In
the
third
switch
position,
which
is
obtained
by
depressing
the
switch
lever
all
the
way
down,
the
welding
power
source
contactor
is
retained
in
an
energized
state
and
the
REMOTE
CONTROL
is
placed
in
the
CONDITION
B
position.
Switch
the
REMOTE
CONTROL
from
CONDITION
A
to
CONDITION
B
(or
from
CONDITION
B
to
CON
DITION
A)
can
be
accomplished
by
varying
the
amount
of
pressure
applied
to
the
switch
lever.
I
I
I
11.
CONDITION
A
and/or
BVOLTAGECONTROLand/
or
WIRE
SPEED
Control
may
be
adjusted
while
weld
ing
to
achieve
optimum
welding
conditions.
4-2.
SHUTTING
DOWN
1
Break
the
arc.
OM-851
Page
3
C
II
.
~JGRN.
>
E
SHIELD
GR-~ROUND
TO
WELDING
MACHINE
PLG2
REMOTE
C3NTRCL
RECEPTAC~
E
C-COPPER
B-
BRASS
Circuit
Diagram
No.
CA-041
012-lA
CR1
PLG
1
AMPHE
r~
L
PLUG
TO
VvIkE
FEEDER
REMOTE
CDNTRUL
RECFFTACLE
D
A
Figure
4-2.
Circuit
Diagram
January
1982
FORM:
OM-851A
PARTS
LIST
Effective
With
Style
No.
JB3O
MODEL
RCMP-1
OM-851
Page
1
Figure
A
-
Complete
Assembly
TD-007
806-A
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity
Figure
A
Complete
Assembly
1
PLG2
605 797
CAP,
twistlock3P3W20
amp
125
volts
1
2
600
733
CORD
SET,
ll5voltsl6ga3C2Oft
1
3
010 610
CONNECTOR,
clamp
-
cable
1/2
inch
2
4
RC1
039 855
RECEPTACLE,
twistlock
2P2W
20
amp
250
volts
2
5
601
375
RING,
mounting
-
capacitor
1
6
Cl
031
608
CAPACITOR,
electrolytic
250
uf
25
volts
ac
1
7
R7,8
030 653
RHEOSTAT,
WW
150
watt
15
ohm
2
8
+023
235
CASE
SECTION,
base/side
1
047 497
LABEL,
general
precautionary
1
9
019 663
MOUNT,
neoprene
4
10
R1,4
030 940
RESISTOR,
carbon0.5watt2000
ohm
2
11
Dl
,2
026
202
DIODE,
1
amp
400
volts
straight
polarity
2
12
R3,6
030
854
RESISTOR,
carbon0.5wattl8Kohm
2
13
038
785
STRIP,
terminal3
pole
2
14
R2,5
030
943
POTENTIOMETER,
carbon
1
turn2wattl5K
ohm
2
15
057
056
BRACKET,
mounting
-
terminal
2
16
082 699
PANEL,
control
1
17
CR1
000 770
RELAY,
enclosed
24
voltsdc3PDT
1
18
NAMEPLATE
(order
by
model
and
serial
numbers)
1
19
020528
HANDLE
2
20
027
631
HOUSING,
indicator
light
2
21
PL1
,2
*027
638
BULB,
slide
-
base
48
volts
2
22
027 628
LENS,
red
-
indicator
light
2
23
019
609
KNOB,
pointer-potentiometer
2
24
019 627
KNOB,
pointer
2
25
039 828
CLAMP,
cable
1
26
057
057
CABLE,
electrical
No.
20
5/c
15
ft
1
27
PLG1
039
827
PLUG,
6
pin
MS-3106A-14S-6P
1
*Recommended
Spare
Parts.
+
When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-851
Page
2
4
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