cover 7/93 − ST−128 782 PRINTED IN USA
© 1993 MILLER Electric Mfg. Co.
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
July 1993 Form: OM-895
Effective With Serial No. JK607490
RC-4
OM-895 - 6/90
Before unpacking equipment, check carton for any
damage that may have occurred during shipment. File
any claims for loss or damage with the delivering car-
rier. Assistance for filing or settling claims may be ob-
tained from the distributor and/or the equipment manu-
facturer’s Transportation Department.
When requesting information about this equipment, al-
ways provide the Model Description and Serial or Style
Number.
Use the following spaces to record the Model Designa-
tion and Serial or Style Number of your unit. The infor-
mation is located on the data card or the nameplate.
Model
Serial or Style No.
Date of Purchase
RECEIVING-HANDLING
TABLE OF CONTENTS
Section No. Page No.
SECTION 1 − SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS
2-1. Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION OR RELOCATION
3-1. Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Connections To Wire Feeder 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connections To Welding Power Source 3. . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATOR CONTROLS
4-1. Voltage Controls 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − SEQUENCE OF OPERATION
5-1. Gas Metal Arc And Flux Cored Arc Welding (GMAW And FCAW) 4. .
5-2. Shutting Down 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS
Diagram 7-1. Circuit Diagram 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST
Complete Assembly 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF CHARTS AND TABLES
Table 2-1. Specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-1. Maintenance Schedule 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-895 Page 1
SECTION 1 − SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various la-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
The nameplate of this unit uses international symbols
for labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
stalled, operated, and maintained only by qualified per-
sons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1 − Safety Rules For Operation Of Arc Weld-
ing Power Source in the welding power source Owner’s
Manual.
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instruc-
tions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
SECTION 2 − SPECIFICATIONS
11-1/2 in.
(292.1 mm)
10-1/4 in.
(260.4 mm)
3-7/8 in.
(98.4 mm)
ST-128 782
Figure 2-1. Dimensions
Table 2-1. Specifications
Weight
Net Ship
8 lbs.
(3.6 kg)
9 lbs.
(4.1 kg)
2-1. DESCRIPTION
This unit is designed to be used with a dual wire feeder
and one welding power source for Gas Metal Arc
(GMAW) and Flux Cored Arc Welding (FCAW) pro-
cesses. When properly connected in such a system, the
unit provides remote voltage control on each of the two
welding wires in the dual wire feeder.
OM-895 Page 2
SECTION 3 − INSTALLATION OR RELOCATION
ST-128 716
Right Contactor
Control Plug
115 Volts AC/Contactor
Control Plug
115 Volts AC/Contactor/
Remote Voltage
Control Plug
Figure 3-1. Rear Panel View
SA-128 780
Welding Power
Source
REAR VIEW
115 VAC/Contactor/
Remote Voltage
Control
Right Contactor
Control
RC-4
115 Volts AC
Contactor Control
Dual Wire
Feeder
Motor Control
RC-4
Dual Wire Feeder
FRONT VIEW
Right Trigger
Control
Left Trigger
Control
Work
Drive Assembly
Figure 3-2. Wiring Connections
OM-895 Page 3
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding power source and wire
feeder, and disconnect input power employing
lockout/tagging procedures before inspecting or
installing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
3-1. INSTALLATION
The remote control unit is designed to mount on top of
the dual wire feeder. To install the unit, proceed as fol-
lows:
1. Place unit on top of wire feeder with front panels fac-
ing same direction.
2. Loosen wire feeder wrapper screws (4) that match
the remote control unit wrapper screw slots.
3. Slide remote control unit down onto screws.
4. Tighten the wire feeder wrapper screws.
3-2. CONNECTIONS TO WIRE FEEDER (Figure 3-1
And Figure 3-2)
1. Connect 4-socket Amp 115 Volts AC/Contactor
Control plug to 115 Volts/Contactor receptacle on
rear of wire feeder control as follows: align keyway,
insert plug, and rotate threaded collar fully clock-
wise.
2. Connect 4-pin Amp Right Contactor Control plug to
Right Contactor Control receptacle on rear of wire
feeder control as follows: align keyway, insert plug,
and rotate threaded collar fully clockwise.
3-3. CONNECTIONS TO WELDING POWER
SOURCE (Figure 3-1 And Figure 3-2)
Connect 14-pin Amphenol 115 Volts AC/Contactor/Re-
mote Voltage Control plug to Control receptacle on front
of welding power source as follows: align keyway, insert
plug, and rotate threaded collar fully clockwise.
SECTION 4 − OPERATOR CONTROLS
SA-047 978-B
Left Voltage
Control
Right Voltage
Control
Figure 4-1. Front Panel View
4-1. VOLTAGE CONTROLS (Figure 4-1)
The VOLTAGE controls provide remote voltage control
within the welding power source load voltage range.
When the wire feeder Left control is active, the remote
control LEFT VOLTAGE control is active. When the wire
feeder Right control is active, the remote control RIGHT
VOLTAGE control is active. Rotating the VOLTAGE
controls in a clockwise direction increases the load volt-
age.
The scale surrounding the VOLTAGE controls is cali-
brated in percent and does not indicate an actual volt-
age value. The 0 (zero) setting represents welding pow-
er source minimum voltage, and 100 represents welding
power source maximum voltage.
IMPORTANT: The output voltage control on the weld-
ing power source must be in its maximum position when
used with the remote control unit in order for the remote
control to provide the full range of the welding power
source output voltage.
IMPORTANT: The VOLTAGE controls can be adjusted
while welding.
SECTION 5 − SEQUENCE OF OPERATION
WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
• Do not touch live electrical parts.
• Keep all covers and panels in place while
operating.
Warranty is void if the welding power source is
operated with any portion of the outer enclosure
removed.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
hearing.
• Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
• Keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
OM-895 Page 4
WELDING WIRE can cause puncture
wounds.
• Do not point gun toward any part of the body,
any conductive surface, or other personnel.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns.
• Watch for fire.
• Keep a fire extinguisher nearby, and know
how to use it.
• Do not use near flammable material.
• Allow work and equipment to cool before
handling.
MAGNETIC FIELDS FROM HIGH CUR-
RENTS can affect pacemaker operation.
• Wearers should consult their doctor before
going near arc welding, gouging, or spot welding
operations.
See Section 1 - Safety Rules For Operation Of
Arc Welding Power Source in the welding power
source Owner’s Manual.
5-1. GAS METAL ARC AND FLUX CORED ARC
WELDING (GMAW And FCAW)
WARNING: Read and follow safety informa-
tion at beginning of entire Section 5 before
proceeding.
1. Install and prepare welding power source according
to its Owner’s Manual.
2. Install and prepare wire feeder according to it Own-
er’s Manual.
3. Install remote control unit as instructed in Section 3.
4. Wear dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
ANSI Z49.1.
5. Prepare for welding as follows:
a. Connect work clamp to clean, bare metal at
workpiece.
b. Select and obtain proper welding wire, and
thread as instructed in wire feeder Owner’s
Manual.
6. Rotate the Wire Speed controls to the desired posi-
tions.
7. Rotate the remote control VOLTAGE controls to the
desired positions.
8. Place the output voltage control on the welding
power source in its maximum position.
9. Turn on shielding gas supply.
10. Energize the welding power source and wire feeder.
11. Begin welding.
5-2. SHUTTING DOWN
1. Stop welding.
2. Shut down welding power source.
3. Shut down wire feeder.
4. Turn off shielding gas supply at the source.
WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
• Shut off gas supply when not in use.
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. ROUTINE MAINTENANCE (Table 6-1)
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of
precautionary labels.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding power source and wire
feeder, and disconnect input power employing
lockout/tagging procedures before inspecting,
maintaining, or servicing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Maintenance to be performed only by qualified
persons.
Table 6-1. Maintenance Schedule
Frequency* Maintenance
Every month. Units in heavy service environ-
ments:
Check labels and interconnect-
ing cords.
Every 6 months. Check all labels (see IMPORT-
ANT block, Section 6-1) and inter-
connecting cords.
*Frequency of service is based on units operated
40 hours per week. Increase frequency of maint-
enance if usage exceeds 40 hours per week.
OM-895 Page 5
Every six months, inspect all interconnecting cords and
plugs for damage to the insulation jacket. Repair or re-
place the cord(s) as necessary.
6-2. TROUBLESHOOTING
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding power source and wire
feeder, and disconnect input power employing
lockout/tagging procedures before inspecting,
maintaining, or servicing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Maintenance to be performed only by qualified
persons.
If this remote control unit does not set the desired volt-
ages, check all interconnections and switch positions on
wire feeder and welding power source, and correct all
connection or position errors.
SECTION 7 − ELECTRICAL DIAGRAMS
Circuit Diagram No. SA-127 639
Diagram 7-1. Circuit Diagram
OM-895 Page 6
SECTION 8 − PARTS LIST
Description Quantity
Part
No.
Dia.
Mkgs.
Complete Assembly
CR1 093 558 RELAY, encl 120VAC 4PDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
049 970 BRACKET, mtg relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
027 811 SOCKET, relay 14 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
048 029 CLIP, retaining socket relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 844 SPRING, hold down relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG1 111 122 HOUSING PLUG & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . .
109 770 · TERMINAL, male 1 pin 22-16 wire sz45 14. . . . . . . . . . . . . . . . . . . . . . . . . .
116 964 · CLAMP, cable 97-3057-1012 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110 015 CABLE, No. 18 7/c (order by ft) 11ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 104 CONNECTOR, clamp cable .500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG2 048 284 HOUSING PLUG & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . .
079 534 · TERMINAL, female 1skt 18-14 wire 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 571 CABLE, port No. 18 4/c (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 531 CLAMP, cable strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
070 654 BUSHING, strain relief .300 ID x .550mtg hole 1. . . . . . . . . . . . . . . . . . . . . .
PLG3 079 878 HOUSING PLUG & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . .
079 535 · TERMINAL, male 1 pin sz16 18-14 wire 4. . . . . . . . . . . . . . . . . . . . . . . . . .
049 455 CABLE, port No. 18 2/c (order by ft) 3ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 476 BUSHING, strain relief .625 ID x .570 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 531 CLAMP, cable strain relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R1,2 072 462 POTENTIOMETER, C std sft 1/T 2W 1000 ohm (consisting of) 2. . . . . . .
072 590 · LOCK, shaft pot .375-32 x .250dia shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . .
097 922 KNOB, pointer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . .
127 588 CASE SECTION, front/bottom/rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+047 390 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
/