July
1983
FORM:
OM-852A
OWN
ERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
ZO
CENTS
MODEL
RCMP-2
0~
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
Ill
repair
or
121
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
131
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of
their
respective
manufacturers,
if
any
.
All
Miller
service
station
or
14)
payment
of
or
credit
for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
Iless
reasonable
depreciation
based
upon
actual
usel
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
Ill
year,
such
as
spot
welder
tips,
relay
arid
coritactor
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
Ilabor-
1
year
onlyl
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
All
welding
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
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
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
~
CONSUMER
USE.
MILLER
WARRANTIES
DO
NOT
EXTEND
provided
that
Miller
is
notified
in
writing
within
thirty
1301
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
~
~
~f
the
date
of
such
fa~ure
~
~
WARRANT~S
TO
ANY
CONSUMER
FILE
COPY
ERRATASHEET
RETURN
TO
FOLDER
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMEND
MENT
TO
PARTS
LIST
Amend
Parts
List
as
follows:
Eftective
With
Style
No.
KB-20
--
Dia.
Part
Mkgs.
No.
Replaced
With
Description
Quantity
5-3
RC3,4
039
634
141
840
RECEPTACLE,
twlk
fig
2P2W
20A
250V
5-9
082
700
141
895
PANEL,
control
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
1
1
SECTION
1
-
INTRODUCTION
1
-
1.
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
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
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
which
provides
a
separate
welding
condition
on
each
of
two
electrode
wires
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
cesses.
IMPORTANT
This
unit
is
designed
to
be
used
with
one
gun
active
at
a
time.
I
~
This
remote
control
mu/ti-purpose
we/ding
panel
will
hereafter
be
referred
to
in
this
manual
as
the
REMOTE
CONTROL.
1
-
4.
SAFETY
-
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
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
______________
Under
this
heading,
installation,
operating,
and
maintenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equipment.
I~IsI
I
~
Under
this
heading,
explanatory
statements
will
be
found
that
need
spec/al
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2-
INSTALLATION
2
-
1.
REMOTE
VOLTAGE
CONTROL
CONNEC
TIONS
(Figure
3-1)
-
The
Voltage
Control
Plug
pro
vides
a
connection
point
between
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.
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
tion.
2
-
2.
115
VAC
CONNECTIONS
(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
source
115
VAC
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
115
VAC
cord.
2
-
3.
REMOTE
CONTACTOR
CONTROL
CON
NECTIONS
(Figure
3-1)
-
The
Contactor
Control
Plug
provides
a
connection
point
between
the
REMOTE_.
CONTROL
and
the
welding
power
source
contactor
control
circuitry.
Insert
the
two-pole
twistlock
plug
from
the
REMOTE
CONTROL
fully
into
the
welding
power
source
Contactor
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
Contactor
Control
cord.
I~1t~
When
remote
control
of
the
contactor
is
desired,
it
is
essential
that
the
welding
power
source
Contactor
Control
Switch
be
placed
in
the
Remote
posi
tion.
2
-4.
CONTROL/FEEDER
REMOTE
CONTACTOR
CONTROL
CONNECTIONS
I~s)1~
Two
10
ft.
contactor
control
cables
are
sup
plied
with
Dual
Control/Feeder
Models
for
making
con
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
a
two-prong
male
plug.
(These
parts
may
or
may
not
be
supplied
depending
on
the
model.)
A.
Left
Feeder
-
The
REMOTE
CONTROL
LEFT
FEEDER
Contactor
Con
trol
receptacle
provides
a
connection
point
between
the
Left
Feeder
and
the
REMOTE
CONTROL.
Insert
the
two-pole
twistlock
plug
from
the
Left
Feeder
fully
into
the
LEFT
FEEDER
Contactor
Control
receptacle
and
rotate
the
plug
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
Right
Feeder
and
the
REMOTE
CONTROL.
Insert
the
two-pole
twistlock
plug
from
the
Right
Feeder
fully
into
the
RIGHT
FEEDER
Contactor
Control
receptacle
and
rotate
the
plug
clockwise.
2
-
5.
CONTROL/FEEDER
115
VAC
CONNEC
TIONS
I~IsI~
1~
The
115
VA
C
receptacles
on
the
REMOTE
CONTROL
supply
115
volts
ac
for
the
operation
of
two
control/feeders.
When
using
one
control/feeder
(Dual
Control
/Feeder
Models),
the
115
volts
ac
required
for
control/feeder
operation
should
be
obtained
for
the
REMOTE
CONTROL
LEFT
FEEDER
115
VAC
recep
tacle.
It
would
then
be
necessary
to
connect
the
jumper
link
on
terminal
strip
1
T,
located
on
the
back
of
the
con
trol
panel,
across
terminals
A
and
B.
The
REMOTE
CONTROL
is
shipped
with
the
jumper
link
connected
across
terminals
B
and
C
for
operation
of
two
con
trol/feeder.
The
REMOTE
CONTROL
LEFT
FEEDER
115
AC
recep
tacle
provides
a
connection
point
to
supply
11
5
volts
ac
to
the
Left
Feeder
from
the
REMOTE
CONTROL.
Insert
the
three-pole
twistlock
plug
from
the
Left
Feeder
fully
into
the
LEFT
FEEDER
11
5
VAC
receptacle
and
rotate
the
plug
clockwise.
B.
Right
Feeder
The
REMOTE
CONTROL
RIGHT
FEEDER
115
VAC
receptacle
provides
a
connection
point
to
supply
115
volts
ac
to
the
Right
Feeder
from
the
REMOTE
CON
TROL.
Insert
the
three-pole
twistlock
plug
from
the
Right
Feeder
fully
into
the
RIGHT
FEEDER
115
VAC
receptacle
and
rotate
the
plug
clockwise.
SECTION
3
-
FUNCTION
OF
CONTROLS
3
-
1.
LEFT
AND
RIGHT
VOLTAGE
ADJUSTMENT
CONTROLS
(Figure
3-1)
V
VOLTAGE
ADJUSTMENT
I~sII~
The
contacts
of
the
VOL
TA
GEADJUSTMENT
controls
are
of
the
continuous
type,
thereby
making
it
possible
to
adjust
these
controls
while
welding.
The
LEFT
AND
RIGHT
VOLTAGE
ADJUSTMENT
con
trols
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
control
will
be
active.
Rotating
the
VOLTAGE
ADJUST
MENT
controls
in
a
clockwise
direction
will
increase
the
load
voltage.
The
scale
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
-
2.
LEFT
AND
RIGHT
PILOT
LAMPS
(Figure
3-1)
-
With
the
welding
power
source
energized
and
with
the
REMOTE
CONTROL
in
the
LEFT
or
RIGHT
mode,
the
LEFT
or
RIGHT
Pilot
Lamp,
respectively,
will
be
illuminated.
Left
Feeder
Contactor
Control
Receptacle.
Left
Feeder
115
VAC
Receptacle
Right
Feeder
115
VAC
Receptacle
Right
Voltage
Adjustment
Control
Right
Pilot
Lamp
Control
Plug
Left
Pilot
Lamp
Left
Voltage
Adjustment
Control
Voltage
Control
Plug
115
VAC
Plug
Figure
3-1.
Front
Panel
View
TB-041
126-1
OM-852
Page
2
Welding
Power
Source
SECTION
4
-
SEQUENCE
OF
OPERATION
TA.041
126-2A
1~..tUI
I
Is1~
Never,
under
any
circumstances,
operate
the
REMOTE
CONTROL
with
the
outer
enclosure
removed.
In
addition
to
the
safety
hazard,
the
warranty
is
void
if
the
REMOTE
CONTROL
is
operated
with
the
outer
enclosure
open
or
removed.
4-1.
GAS
METAL-ARC
(GMAW)
WELDING
(Figure
4-1)
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
manual,
and
gun
manual,
respectively.
2.
Make
Remote
Voltage
Control
Connections
as
outlined
in
Section
2-1.
3.
Make
115
VAC
Connections
as
outlined
in
Sec
tion
2-2.
4.
Make
Remote
Contactor
Control
Connections
as
outlined
in
Section
2-3.
5.
Make
Control/Feeder
Remote
Contactor
Control
connections
as
outlined
in
Section
2-4.
8.
Rotate
the
LEFT
VOLTAGE
ADJUSTMENT
con
trol
and
Left
Feeder
Wire
Speed
Control
to
the
desired
setting.
9.
Rotate
the
RIGHT
VOLTAGE
ADJUSTMENT
control
and
Right
Feeder
Wire
Speed
Control
to
the
desired
setting.
10.
Turn
on
the
shielding
gas
supply.
CAUTION
_________
Prior
to
welding,
it
is
imperative
that
pro
per
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.
11.
Energize
the
welding
power
source
and
Con
trol/Feeder.
Commence
welding.
12.
The
Left
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
gun
and
the
Right
Feeder
are
activated,
the
Left
Feeder
will
be
rendered
inactive.
6.
Make
Control/Feeder
115
VAC
connections
as
outlined
in
Section
2-5.
7.
Place
the
welding
power
source
Load
Voltage
Range
Switch
in
the
desired
position.
I~I.Jt~
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.
CAUTION
___________
Despite
the
fact
that
one
of
the
Con
trol/Feeders
is
inactive,
this
inactive
Control/Feeder
Gun
welding
wire
is
still
electrically
energized.
13.
The
LEFT
or
RIGHT
VOLTAGE
ADJUSTMENT
control
and/or
Wire
Speed
Control
may
be
ad
justed
while
welding
to
achieve
optimum
welding
conditions.
4
-
2.
SHUTTING
DOWN
1.
Breakthearc.
2.
Allow
the
welding
power
source
to
idle
for
3
minutes
with
no
load
applied.
Voltage
Control
Remote
Control
Unit
Figure
4-1.
Gas
Metal-Arc
Welding
Connections
OM-S52Page3
--9
3.
Place
the
welding
power
source
Power
Switch
in
the
OFF
position.
Since
the
REMOTE
CONTROL
derives
its
operating
power
from
the
welding
power
source,
the
REMOTE
CONTROL
will
also
be
deenergized
when
the
welding
power
source
is
deenergized.
5.
Turn
off
the
shielding
gas.
CAUTION
___________
If
welding
is
performed
in
a
confined
area,
failure
to
turn
off
the
shielding
gas
supply
could
result
in
a
buildup
of
gas
fumes,
thereby
endangering
personnel
reentering
the
we/ding
area.
4.
If
the
Control/Feeders
do
not
derive
operating
power
from
the
welding
power
source,
place
the
Control/Feeder
Power
Switches
in
the
OFF
posi
tion.
TO
FEEDER
TO
FEEDER
iij
I
Ti
TO
CONTACTOR
4R~_J
RECEPTACLE
ON
WELDING
MACHINE
4
PLG3
TO
FEEDER
--B,
TO
REMOTE
CONTROL
RECEPTACLE
ON
WELDING
MACHINE
115V
FROM
>
WELDING
MACHINE
Circuit
Diagram
No.
A-047
998
OM-852Page4
Figure
4-2.
Circuit
Diagram
+
R
C
~
RC4
54
I
:CR1
~
56
15
V.
PLG
I
CR1
TO
FEEDER
iT
INSTALL
JUMPER
ACROSS
A&B
WHEN
_
USING
DUAL
SWINGARC
:cRi
7
PLG2
9
RC2
Item
Dia.
No.
Mkgs.
Part
No.
Description
Quantity
Figure
A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
023
606
010
610
039
634
039
686
030
653
023 235
019
663
059
266
082
700
038
620
iT
038602
020
528
027
631
PL1,2
*027
638
027
628
019
627
PLG3
039
635
PLG2
039
687
600
733
PLG1
605
797
Complete
Assembly
3
2
2
2
1
4
3
2
2
2
2
2
3
3
2
1
*Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
RC3,4
RC1,2
R1,2
CR
1-3
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
CASE
SECTION,
base/sides
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)
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
7
Figure~A
-
Comllete
A~ssembIy
10-007
753.C
OM-852
Page
5
/
