July
1981
FORM:
OM-865
OWN
ERS
MANUAL
mIHER
~.
~
~
~
~...
~
~
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.
MODEL
RCDW-2
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
12)
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
(41
payment
of
or
credit for
the
purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price
lless
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
and
contactor
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
lION
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,
r~
Miller
shall
be
required
to
honor
warranty
claims
on
war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
k~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
X
within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
1
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
only)
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
3.
Allweldinggunsandfeederiguns
9odays
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
of
the
date
of
such
failure.
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
*
,
. .
.
.
~t.
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
Serial
(or
Style)
Number
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
a
DELTAWELD
welding
power
source.
It
is
design
ed
specifically
for
use
with
the
Gas
Metal-Arc
(GMAW)
and
Flux
Cored
Arc
(FCAW)
Welding
processes.
IMPORTANT
_____________
This
unit
is
designed
to
be
used
with
one
gun
active
at
a
time.
1
-
4.
SAFETY
-
Before
the
equipment
is
put
into
operation,
the
safety
section
at
the
front of
the
welding
power
source
or
welding
generator
manual
should
be
read
completely.
This
will
help
avoid
possible
injury
due
to
misuse
or
improper
welding
applications.
The
following
definitions
apply
to
CAUTION,
IMPOR
TANT,
and
NOTE
blocks
found
throughout
this
manual:
LsfAUULs1j~iE
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.
II~I~
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2
-
INSTALLATION
Feeder
B
115
VAC
(If
Two
Control
Feeders
Used)
Third
Output
Terminal
Optional
On
450
Ampere
Model
NOTE:
RCDW-2
terminal
strip
iT
must
be
linked
across
terminals
A
and
B
when
using
a
Dual
Control/Feeder
Model.
8-045
175
Positive
Weld
Output
Positive
With
Slope
Weld
Output
Figure
2-1.
Gas
Metal-Arc
And
Flux
Cored
Arc
Welding
Connections
OM-865
Page
1
2
-
1.
REMOTE
VOLTAGE
CONTROL
CONNEC
TIONS
(Figures
2-1
&
3-1)
-
The
5-pin
Voltage
Con
trol
plug
provides
a
connection
point
between
the
RCDW-2
and
the
welding
power
source
voltage
adjust
ment
circuitry.
Align
plug
keyway
with
VOLTAGE
CON
TROL
receptacle
key;
insert
plug;
and
rotate
threaded
collar
clockwise.
I~II~
Place
the
welding
power
source
VOLTAGE
CONTROL
switch
in
the
REMOTE
position.
2
-2.
REMOTE
CONTACTOR
CONTROL
CON
NECTIONS
(Figures
2-1
&
3-1)
-
The
two-pole
twistlock
Contactor
Control
plug
provides
a
connection
point
between
the
RCDW-2
and
the
welding
power
source
contactor
control
circuitry.
Insert
plug
fully
into
the
CONTACTOR
CONTROL
receptacle
and
rotate
the
plug
clockwise.
2
-
3.
REMOTE
CONTROL
115
VAC
CONNEC
TIONS
CAUTION
____________
The
control
will
be
electrically
hot
inter
nally
and
ready
to
operate
as
soon
as
the
115
volts
ac
plug
is
connected
to
the
115
volts
ac
source.
The
115
VAC
plug
provides
a
connection
point
to
sUp
ply
the
RCDW-2
with
115
volts
ac
power.
Connect
the
115
VAC
plug
to
the
115
VOLTS
AC
duplex
receptacle
on
the
welding
power
source
or
to
a
115
volts
ac,
60
Hertz
power
supply.
A.
Left
Control/Feeder
(Or
Control/Feeder
A)
Insert
the
two-pole
twistlock
contactor
control
plug
from
the
Left
control
(or
control/feeder
A)
fully
into
the
RCDW-2
FEEDER
A
Contactor
Control
receptacle
and
rotate
the
plug
clockwise.
B.
Right
Control/Feeder
(Or
Control/Feeder
B)
Insert
the
two-pole
twistlock,
contactor
control
plug
from
the
Right
control
(or
control/feeder
B)
fully
into
the
RCDW-2
FEEDER
B
Contactor
Control
receptacle
and
rotate
the
plug
clockwise.
2
-
5.
CONTROL/FEEDER
115
VAC
CONNEC
TIONS
I~ISII~
The 115
VAC
receptacles
on
the
remote
con
trol
suppy
115
volts
ac
for
the
operation
of
two
con
trol/feeders.
When
using
one
control/feeder
(Dual
Control!
Feeder
Models),
the
115
volts
ac
required
for
control/feeder
operation
should
be
obtained
from
the
RCDW-2
FEEDER
A
115
VAC
receptacle.
It
would
then
be
necessary
to
connect
the
jumper
link
on
terminal
strip
1
T,
located
on
the
rear
of
the
front
panel
inside,
the
remote
control,
across
terminals
A
and
B.
The
remote
control
is
shipped
with
the
jumper
fink
connected
across
terminals
B
and
C
for
operation
of
two
control/feeders.
A.
Using
Two
Control/Feeders
1.
Control/Feeder
A
2
-
4.
CONTROL/FEEDER
REMOTE
CONTACTOR
CONTROL
CONNECTIONS
I~EII~
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/s
recommended
that
16/2
conductor
cable
be
used
for
the
con
tactor
control
cable
with
a
two-prong
male
plug.
(These
parts
may
or
may
not
be
supplied
depending
on
the
model.)
The
Remote
Contactor
Control
receptacles
provide
a
connection
point
between
the
RCDW-2
and
the
con
trol
/feeder(s)
contactor
control
circuitry.
Insert
the
three-pole
twistlock
plug
from
control/feeder
A
fully
into
the
RCDW-2
FEEDER
A
115
VAC
recep
tacle
and
rotate
the
plug
clockwise.
2.
Control/Feeder
B
Insert
the
three-pole
twistlock
plug
from
control/feeder
B
into
the
RCDW-2
FEEDER
B
115
VAC
receptacle
and
rotate
the
plug
clockwise.
B.
Using
A
Dual
Control/Feeder
Model
Insert
the
three-pole
twistlock
plug
from
the
con
trol/feeder
fully
into
the
RCDW-2
FEEDER
A
115
VAC
receptacle
and
rotate
the
plug
clockwise.
SECTION
3-
FUNCTION
OF
CONTROLS
3
-
1.
REMOTE
VOLTAGE
CONTROLS
(Figure
3-1)
-
The
RCDW-2
VOLTAGE
CONTROLS
provide
voltage
selection
within
the
welding
power
source
load
voltage
range.
When
the
Dual
Control/Feeder
Left
con
trol
(or
control/feeder
A)
is
active,
the
CONDITION
A
VOLTAGE
CONTROL
is
active.
When
the
Dual
Con
trol/Feeder
Right
control
(or
control/feeder
B)
is
active
the
CONDITION
B
VOLTAGE
CONTROL
is
active
Rotating
the
VOLTAGE
CONTROLS
clockwise
in
creases
the
load
voltage.
I~
I
~
The
contacts
of
the
VOL
TA
GE
CONTROL
S
are
of
the
continuous
type,
thereby
making
it
possible
to
adjust
these
controls
while
we/ding.
The
scale
surrounding
the
VOLTAGE 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.
REMOTE
CONTROL
PILOT
LAMPS
(Figure
3-1)
-
When
the
welding
power
source
is
energized,
the
RCDW-2
CONDITION
A
or
B
pilot
lamp,
when
il
luminated,
indicates
which
condition
is
active.
Page
2
Feeder
B
115
VAC
Receptacle
Contactor
Control
Plug
A
Pilot
Lamp
Condition
B
Voltage
Control
Condition
B
Pilot
Lamp
6.045
176
SECTION
4-
SEQUENCE
OF
OPERATION
CAUTION:
_____
Never,
under
any
circumstances,
operate
the
RCDW-2
with
the
outer
enclosure
removed.
In
addi
tion
to
the
safety
hazard,
warranty
is
void
if
the
RCDW-2
is
operated
with
the
outer
enclosure
open
or
removed.
4
-
1.
GAS
METAL-ARC
(GMAW)
AND
FLUX-
CORED
ARC
(FCAW)
WELDING
(Figure
2-1)
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
Remote
Contactor
Control
connections
as
outlined
in
Section
2-2.
4.
Make
115
VAC
connections
as
outlined
in
Sec
tion
2-3.
5.
Make
control/feeder
Remote
Contactor
Control
connections
as
outlined
in
Section
2-4.
6.
Make
control/feeder
115
VAC
connections
as
outlined
in
Section
2-5.
7.
Rotate
the
RCDW-2
VOLTAGE
CONTROLS
to
the
desired
setting.
8.
Rotate
the
Dual
Control/Feeder
(or
con
trol/feeder
A
and
B)
Wire
speed
controls
to
the
desired
setting.
9.
Turn
on
the
shielding
gas
supply.
L~
I
Prior
to
we/ding,
it
is
imperative
that
pro
per
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
per
manent
bodily
damage.
10.
Energize
the
welding
power
source
and
con
trol/feeder(s).
Commence
welding.
11.
CONDITION
A
or
B
is
automatically
selected
whenever
the
Left
Gun
or
the
Right
Gun
(Gun
A
or
Gun
B
if
using
two
control/feeders)
respec
tively,
is
activated.
Only
one
condition
and
one
gun
is
active
at
one
time.
I~ISII~
The
RCDW-2
VOL
TAGE
CONTROLS
and
the
control/feeder
Wire
speed
controls
can
be
adjusted
while
we/ding.
4
-
2.
SHUTTING
DOWN
1.
Cease
welding.
2.
Allow
the
welding
power
source
to
idle
for
3
minutes
with
no
load
applied
to
permit
proper
cooling.
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.
4.
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
build
up
of
gas
fumes,
thereby
endangering
personnel
reentering
the
welding
~rea.
Feeder
A
Contactor
Control
Receptacle
FEEDER
A
115
VAC
Receptacle
Condition
A
Voltage
Control
Feeder
B
Contactor
Control
Receptacle
115
VAC
Plug
Figure
3-1.
Remote
Control
Components
OM-865
Page
3
TO
FEEDER
TO
FEEDER
,
TO
FEEDER
TO
REMOTE
CONTROL
RECEPTACLE
ON
WELDING
MACHINE
Figure
4-1.
Circuit
Diagram
+
P
C3
PLC
TO
FEEDER
iT
A~
INSTALL
JUMPER
8
9
ACROSSA&BWHEN
~CR2
USING
DUALSWINGARC
-
CR1
>
~
TO
CONTACTOR
L~~R1~~J
CR2
CR2~
RECEPTACLE
ON
Ts
16
WELDING
MACHINE
~_L~
~
(2)
(1)
4
1~
~
PC4
54
:CR1
~
$6
II5v
A-047
072
7
PLG3
CRI
115V
FROM
>
WELDING
MACHINE
9
PLG2
Page
4
July
1981
FORM:
OM-86
PARTS
LIST
MODEL
RCDW-2
3
~
E
0
U)
U,
C
0
4-
a
0.
E
0
U
h
0
0,
U-
Co
C
LL)
p
C
a,
C
I-
I-
C
I-
It,
I-
N
I-
en.
I-
0,
I-
en
N
N
N
(V)
I-
N
1%
I-
Co
I-
en
Co
N
N
0,
I-
C
N
OM-865
Page
1
Item
Dia.
No.
Mkgs.
Part
No.
Description
Quantity
Figure
A
Complete
Assembly
1
023606
CORDSET,ll5voltsl6ga2/c2oft
1
2
010
610
CONNECTOR,
clamp-cablel/2inch
3
3
RC3,4
039 634
RECEPTACLE,
twistlock
-
flanged
2P2W
20
amp
250
volts
2
4
RC1
,2
039
686
RECEPTACLE,
twistlock
-
grounded
2P3W
15
amp
277
volts
2
5
R1,2
072
462
POTENTIOMETER,
carbon
1
turn2
watt
1000
ohm
(consisting
of)
2
072
590
.
LOCK,
shaft
-
potentiometer
2
6
023
235
CASE
SECTION,
base/sides
1
7
019663
MOUNT,neoprenel5/16ODx3/8rec3/16x3/8
4
8
CR1
.3
034 674
RELAY,
enclosed
115
volts
ac
DPDT
2
9
CR2
034
677
RELAY,
enclosed
115
volts
ac
3PDT
1
10
039 663
SOCKET,
tube
8
pin
2
11
039
664
SOCKET,
tube
11
pin
1
12
025 088
BRACKET,
mounting
-
relay
1
13
047
121
WRAPPER
1
14
038 620
LINK,
jumper
-
terminal
block
30
amp
1
15
iT
038 602
BLOCK,
terminal
30
amp3
pole
1
16
NAMEPLATE
(order
by
model)
1
17
020 528
HANDLE,
control
box
2
18
027
631
HOUSING,
indicator-light
2
19
PL1
,2
*027
629
BULB,
incandescent
-
slide
base
120
volts
2
20
027
628
LENS,
red
-
indicator
light
2
21
019627
KNOB,
pointer
2
22
PLG3
039 635
CONNECTOR,
body-twistlock2P2W
3
23
PLG2
039
687
CAP,
twistlock
-
grounded
2P3W
3
24
600 733
CORD
SET,
li5voltsi6ga3/c2Oft
2
25
PLG1
039
273
PLUG,
5
pin
MS
3106A-16S-8P
1
26
039 685
CLAMP,
cable
1
*Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
MODEL
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-865
Page
2
/