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Miller KB20, RCDW-4 Owner's manual

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Millerfi
February
1991
FORM:
OM-862A
Eff
ective
W
ith
Style
No.
KB-20
MODEL:
RCDW-4
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
M~IIer
Grouo
UO
Comoa~y
P.O.
Box
~O79
Appleton.
WI
54912
USA
Tel.
414-734-9821
P~INTEO
IN
U
S.A.
LIMITED
WARRANTY
EFFECTIVE:.
AUGUST
6,
1990
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclus;ve
with
no
other
guarantees
or
warranties
expressed
or
irnpliea.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
nereof.
MILLER
Electric
Mfg.
Co..
Appleton.
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others,
Such
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers.
if
any.
All
engines
are
warrant;ed
by
their
manufacturer
for
two
years
from
date
of
original
purchase.
except
Deutz
engines
which
have
a
one
year.
2000
hour
warranty.
Except
as
spec~tied
below.
M1LLER
s
warranty
does
not
apply
to
components
having
normal
userul
life
of
less
tnan
one
Ii)
year.
such
as
spot
welder
tips.
relay
and
contactor
points.
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
aefect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders.
power
sources.
robots.
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
oower
rectifiers
3
years
(labor
1
year
only)
4
All
welding
guns.
feederguns
and
torches
.
90
days
5.
All
other
MILLERMATIC
Feeders
~
1
year
6.
Replacement
or
repair
parts.
exclusive
of
labor
60
days
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
sucn
failure.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
tne
quality
of
any
goods.
the
exclusive
remedies
therefore
shall
be.
at
MILLERs
option
11)
repair
or
(2)
replace
ment
or.
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
131
the
reasonable
cost
o~
reoair
or
replacement
at
an
authorized
MILLER
ser.ce
s~n~c~
oavm~~
1or
the
purcna~a
.
. ,.
es~
uoon
actual
use:
upon
return
~t
~
goocs
at
U~:oir..:.
and
expense.
MILLERs
option
of
reoair
or
replacement
will
be
FOB..
Factory
at
Appleton.
Wisconsin.
or
FOB.
at
a
MILLER
authorizeo
service
facility.
therecore,
no
compensation
for
transportation
costs
ot
any
Kind
will
ce
allowed.
Upon
receipt
of
notice
of
apoarent
defect
or
failure.
MILLER
shall
instruct
the
claimant
on
tne
wairanty
cla;m
proceoures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY.
GUARANTY OR
REPRE
SENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH.
BUT
FOR
THIS
PROVISION.
MiGHT
ARISE
BY
IMPLICATION.
OPERATION
OF
LAW.
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING.
I.IILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMEROIAL.INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES DO
NOT
EXTEND
TO.
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO.
ANY
CONSUMER.
As
a
matter
of
general
policy
only.
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
OM-862A
2191
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delivering
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_________________________________________
ers
Transportation
Department.
Serial
or
Style
No.
______________________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
______________________________
N
umber.
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
3-1.
Installation
2
Diagram
3-1.
DVC-2
Connections
. .
. .
2
SECTION
4
OPERATOR
CONTROLS
4-1.
RCDW-4
Voltage
Controls
3
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Gas
Metal
Arc
Welding
(GMAW)
3
5-2.
Shutting
Down
3
SECTION
6
MAINTENANCE
6-1.
Routine
Maintenance
4
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
4
SECTION
8
PARTS
LIST
Figure
8-1.
Front
&
Rear
View
5
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.
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
iden
tify
different
levels
of
hazard
and
special
instructions.
a
a
a
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
practice&which
must
be
followed
to
avoid
seri
ou~
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
2-1.
DESCRIPTION
The
RCDW-4
provides
remote
voltage
control
on
each
of
two
welding
wires
when
using
a
dual wire
feeder
and
one
welding
power
source.
SECTION
3INSTALLATION
Figure
3-1.
Rear
Panel
View
TA.047
979
Voltage
Schedule
Control
Receptacle
Voltage
Control
Plug
OM-862
Page
1
3-1.
INSTALLATION
(Figure
3-1
And
Diagram
3-1)
Welding
Power
Source
115
Volts/Contactor
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
we/ding
power
source
and
wire
feeder,
and
disconnect
input
power
employ
ing
lockout/tagging
procedures
before
in
specting
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.
The
RCDW-4
unit
is
designed
to
mount
on
top
of
a
dual
wire
feeder.
To
install
the
RCDW-4
unit,
proceed
as
fol
lows:
1.
Loosen
the
screws
along
the
top
of
the
wire
feed
er
control.
Set
the
RCDW-4
on
top
of
the
control
with
front
panels
facing
same
direction
and
se
cure
with
control
screws.
2.
Connect
the
ground
lead
from
the
RCDW-4
to
the
115
volts/contactor
receptacle
on
the
rear
of
the
wire
feeder
control.
3.
Connect
the
Voltage
Control
plug
from
the
RCDW-4
to
the
Voltage
Control
receptacle
on
the
welding
power
source.
IMPORTANT:
Place
the
welding
power
source
Voltage
Control
switch
in
the
Remote
position.
4.
Connect
the
Right
Contactor
Control
cable
to
the
Voltage
Schedule
Control
receptacle
on
the
RCDW-4.
Connect
the
remaining
end
of
the
cable
to
the
wire
feeder
Right
Contactor
Control
recep
tacle.
Right
Voltage
Control
Figure
4-1.
Front
Panel
View
Drive
Assembly
Left
Trigger
Control
Diagram
3-1.
DVC-2
Connections
SECTION
4
OPERATOR
CONTROLS
Left
Voltage
Control
TA-047
978-A
OM-862
Page
2
4-1.
RCDW-4
VOLTAGE
CONTROLS
(Figure
4-1)
The
RCDW-4
Voltage
controls
provide
remote
voltage
control
within
the
welding
power
source
load
voltage
range.
When
the
wire
feeder
Left
control
is
active,
the
RCDW-4
Left
Voltage
control
will
be
active.
When
the
wire
feeder
Right
control
is
active,
the
RCDW-4
Right
Voltage
control
wilt
be
active.
Rotating
the
Voltage
con
trols
in
a
clockwise
direction
increases
the
load
voltage.
The
scale
surrounding
the
Voltage
controls
is
calibrated
in
percent
and
does
not
indicate
an
actual
voltage
value.
The
0
(zero)
setting
represents
welding
power
source
minimum
voltage,
and
100
represents
welding
power
source
maximum
voltage.
IMPORTANT:
The
Voltage
controls
can
be
adjusted
while
welding.
SECTION
5
SEQUENCE
OF
OPERATION
a
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.
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
arid
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
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consult
their
doctor
before
going
neararc
welding,
gouging,
or
spot
weld
ing
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Sources
in
the
welding
pow
er
source
Owners
Manual
for
basic
welding
safety
information.
5-1.
GAS
METAL
ARC
WELDING
(GMAW)
a
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of
entire
Section
5
before
proceeding.
1.
Be
sure
the
welding
power
source,
wire
feeder,
and
welding
gun
are
installed
as
instructed
in
their
respective
Owners
Manuals.
2.
Install
the
RCDW-4
as
instructed
in
Section
3.
3.
Wear
dry
insulating
gloves
and
clothing.
4.
Rotate
the
Wire
Speed
control
to
the
desired
posi
tions.
5.
Rotate
the
RCDW-4
Voltage
Controls
to
the
de
sired
positions.
6.
Turn
on
shielding
gas
supply.
7.
Wear
welding
helmet
with
proper
filter
lens
ac
cording
to
ANSI
Z49.1.
8.
Energize
the
welding
power
source
and
wire
feeder.
9.
Begin
welding.
5-2.
SHUTTING
DOWN
1.
Stopwelding.
2.
Shut
down
welding
power
source.
3.
Shut
down
wire
feeder.
4.
Turn
off
shielding
gas
supply
at
the
source.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
OM-862
Page
3
/