April1988
FORM:
OM-862
Millerfi
RCDW-4
OWNERS
MANUAL
IMPORTANT
MODEL
Read
and
understand
the
entire
contents
of
both
this
Miller
Electric
Mfg.Co.
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
in-
~.o.
Box
1079
stalling,
operating,
or
maintaining
this
equipment.
This
unit
and
these
Appleton,
WI
54912
USA
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
Tel.
414-734-9821
safe
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
PRINTED
IN
U.S.A.
LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
16.
1988
.
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi-
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
tions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
Miller
service
station
or
(4)
payment
of
or
credit for
the
purchase
accessories
or
other
items
manufactured
by
others.
Such
price
(less
reasonable
depredation
based
upon
actualuse)
upon
engines,
trade
accessories
and
other
items
are
sold
subject
to
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
the
warranties
of
their
respective
manufacturers,
if
any
.
All
option
of
repair
or
replacement
will
be
F.O.B.,
Factory,
at
~
engines
are
warranted
by
their
manufacturer
for
one
year
from
Appleton.
Wisconsin,
or
F.O.B.,
at
a
MILLER
authorized
service
date
of
original
purchase,
except
Tecumseh
engines
which
fadlity,
therefore,
no
compensation
for
transportation
costs
of
have
a
two
year
warranty,
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
*
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
warranty
Except
as
specified
below,
Millers
warranty
does
not
apply
claim
procedures
to
be
followed.
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
~f
wire
including
nozzles
and
nozzle
insulators
where
failure
does
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA.
~
not
result
from
defect
in
workmanship
or
material.
T1ON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
Miller
shall
be
required
to
honorwarranty
claims
on
war-
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
~
within
the
following
periods
from
the
date
of
delivery
of
Equip-
ANY
IMPLIED
WARRANTY
OF
MERCHANTABIUTY
OR
OF
ment
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
j~
1.
Arc
welders,
pc~esources,
robots,
and
components
.
1
year
CLUDED
AND
DISCLAIMED
BY
MILLER.
2.
Load
banks
1
year
j
3.
Original
main
power
rectifiers
3
years
(labor
-
1
year
only)
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
4.
All
welding
guns,
feeder/guns
and
torches
90
days
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
~&~/
5.
All
other
Millermatic
Feeders
1
year
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
6.
Replacement
or
repair
parts,
exclusive
of
labor
..
60
days
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
a~j~
7.
Batteries
6
months
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
~4
of
the
date
of
such
failure.
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
,~
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
C1
submitted
by
the
original
user
within
the
foregoing
periods.
...~
.
. .
.
ERRATA
SHEET
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
~
~py
After
this
manual
was
printed,
refinements
In
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
PARTS
LIST
Amend
Parts
List
as
follows:
Eff
With
Style
No.
KB-20
Dia.
Part
**
Mkgs.
No.
Replaced
With
Description
Quantity
4-
070
634
134
327
LABEL,
warning
general
precautionary
1
4-3
047
391
141
893
CASE
SECTION,
front/bottom/back
1
4-4
RC3
039
634
141
840
RECEPTACLE,
twik
fig
2P3W
20A
250V
1
~~flEfl
SECTION
1
-
INTRODUCTION
1
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
pertains
to
equip
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owners
Manual.
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
word
ITiT~~1~hilI~cI
which
identifies
the
level
of
hazard.
WARNING
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
IMPORTANT
An
additional
signal
word,
_______________,
highlights
instructions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
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
and
Serial
(or
Style)
Number
of
the
equipment
be
supplied.
1
-
3.
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
2
-
INSTALLATION
2
-
1.
LOCATION
-
The
RCDW-4
unit
is
designed
to
mount
on
top
of
a
dual
wire
feeder.
To
install
the
RCDW-4
unit,
proceed
as
follows:
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
procedures
before
beginning
this
installation.
Lockout/tagging
procedures
Consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
1.
Loosen
the
screws
along
the
top
of
the
wire
feeder
control.
Set
the
RCDW-4
on
top
of
the
control
and
secure
with
control
screws.
Welding
Power
Source
115
Volts/Contactor
Drive
Assembly
Voltage
Schedule
Control
Receptacle
Figure
2-1.
RCDW-4
Connections
Figure
2-2.
Rear
Panel
View
Voltage
Control
Plug
A047
979
OM-862
Page
1
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
receptacle.
SECTION
3-
FUNCTION
OF
CONTROLS
Figure
3-1.
Front
Panel
View
3
-
1.
RCDW-4
VOLTAGE
CONTROLS
(Figure
3-1)
-
The
RCDW-4
Voltage
controls
provide
remote
voltage
control
within
the
welding
power
source
load
voltage
range.
When
the
wire
feeder
Left
control
is
ac
tive,
the
RCDW-4
Left
Voltage
control
will
be
active.
When
the
wire
feeder
Right
control
is
active
the
RCDW-4
Right
Voltage
control
will
be
active.
Rotating
the
Voltage
controls
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
A-047
978
source
maximum
voltage.
IMPORTANT
The
Voltage
controls
can
be
adjusted
SECTION
4-
SEQUENCE
OF
OPERATION
WARNING
_________
ELECTRIC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
injury;
IMPROPER
AIR
FLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
internal
parts.
Do
not
touch
five
electrical
parts.
Keep
c/ear
of
pinch
points.
Keep
all
covers
and
panels
in
p/ace
while
operating.
Warranty
is
void
if
wire feeder
is
operated
with
any
por
tion
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.
Ventilate
to
keep
from
breathing
fumes
and
gases.
/f
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
SLAT
can
cause
fire
and
burns.
Watch
for
fire.
Have
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
Allow
work
and
equipment
to
cool
before
hand/
ing.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consu/t
their
doctor
before
going
near
arc
we/ding
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Sources
in
the
welding
power
source
Owners
Manual
for
basic
welding
safety
information.
4
-
1.
GAS
METAL
ARC
(GMAW)
AND
FLUX
CORED
ARC
WELDING
(FCAW)
1.
Be
sure
the
welding
power
source,
wire
feeder
and
welding
gun
are
installed
as
instructed
in
their
respective
Owners
Manuals.
2.
Install
the
RCDW-4
as
instructed
in
Section
2.
3.
Rotate
the
Wire
Speed
control
to
the
desired
positions.
4.
Rotate
the
RCDW-4
Voltage
Controls
to
the
desired
positions.
5.
Turn
on
shielding
gas
supply.
6.
Energize
the
welding
power
source
and
wire
feeder.
7.
Begin
welding.
4
-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.
L~~U~U
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
Left
Voltage
Control
Right
Voltage
Control
while
we/ding.
OM-862
Page
2
SECTION
5
-
MAINTENANCE
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
the
Parts
List
for
part
number
of
precautionary
labels.
5
-
1.
INSPECTION
AND
UPKEEP
-
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
At
minimum,
inspect
equipment
every
three
months
as
follows:
WARNING
__________
ELECTRIC
SHOCK
can
kill.
Do
not
touch
ilve
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
internally
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
Maintenance
of
internal
parts
to
be
performed
only
by
qualified
persons.
Every
three
months
inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the
insulation
jacket,
particularly
at
the
plug.
Repair
or
replace
the
cord(s)
as
necessary.
Figure
4
-
1.
Circuit
Diagram
Circuit
Diagram
No.
A-119
138-A
II
B
0
E
TO
REMOTE
CONTROL
RECEPTACLE
ON
WELDING
MACHINE
C
PLG
I
TO
FEEDER
RC3~
18
19
OM-862
Page
3
Item
Dia.
No.
Mkgs
Figure
A
1
t047
390
070 634
2
R1,2
072462
072
590
097
992
3
047
391
4
RC3
039
634
5
115104
6
CR1
093
558
049
970
027
811
048 029
079
844
7
600 733
8
039
685
039
273
9
PLG1
039
273
112
051
049 455
079
878
079 535
079
531
039
635
Description
Figure
A
-
Front
&
Rear
View
Quantity
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Oft
1
4
1
1
tWhen
ordering
a
component
originally
displaying
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Part
No.
Front
&
Rear
View
WRAPPER
LABEL,
warning
electric
shock
can
etc
POTENTIOMETER,
carbon
1
turn
2
watt
1000
ohm
(consisting
of)
LOCK,
shaft
-
potentiometer
KNOB,
pointer
CASE
SECTION,
front/bottom!
back
NAMEPLATE
(order
by
model)
RECEPTACLE,
twistlock
-
flanged
2P2W
CONNECTOR,
clamp
-
cable
1/2
inch
RELAY,
enclosed
120
volts
ac4PDT
w/flange
BRACKET,
mtg-relay
SOCKET,
relay
CLIP,
retaining
SPRING,
holddown-relay
CORD
SET,
115
volts
16
ga
3/c
20
ft
CLAMP,
cable
PLUG,
5
pin
MS
3106A-16S-18P
RECEPTACLE,
5
socket
MS-31
02A-1
6S-8S
CABLE,
contactor
(consisting
of)
CABLE,
No.
182/c
(order
byft)
HOUSING
PLUG
&
PINS
(consisting
of)
TERMINAL,
male
CLAMP,
cable
29/64
CONNECTOR
BODY,
twistlock
2P2W
20
amp
250
volts
4
5
2
3
2
9
OM-862
Page
4
/