August
1974
FORM:
OM-850
MODEL
RCDS-
1
RCDS-2
RCDS-3
~LE
COPY
RETURN
TO
FOLOER
STOCK
NO.
040 810
040
907
041
012
ADDITIONAL
COPY
PRICE
25
CENTS
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
us
5.
q
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WARRANTY
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
all
new
equipment
to
be
free
from
defects
in
C
I
material
and
factory
workmanship
for
the
periods
indicated
below,
provided
the
equipment
is
installed
and
C
D
C
I
CD
operated
according
to
manufacturers
instructions.
C
C)
C
p
C D
C)
MILLER
Electric
Mfg.
Co.s
obligation,
under
this
warranty,
is
limited
to
replacing
or
repairing
any
defective
~
part
or
correcting
any
manufacturing
defect
without
charge
during
the
warranty
period
if
MILLERS
inspec-
C
C)
tion
confirms
the
existence
of
such
defects.
MILLERS
option
of
repair
or
replacement
will
be
f.o.b.
factory
at
C
C
p
C)
Appleton,
Wisconsin
or
f.o.b.
a
MILLER
authorized
service
facility,
and
therefore
no
compensation
for
trans
portation
costs
of
any
kind
will
be
allowed.
C
p
C)
C
p
C)
The
warranty
period,
beginning
on
the
date
of
sale
to
the
original
purchaser-user
of
the
equipment,
will
be
as
c
C
C
P
follows:
c
1.
Arc
welders,
power
sources,
and
components
1
year
C
p
C
P
2.
Original
main
power
rectifiers
3
years
(unconditionally)
3.
MHFC-L1
Feeder,
MHG35C1,
20E,
20K,
CD
C
P
D
and
all
guns
and
torches
90
days
CD
4.
All
other
Millermatic
Feeders
1
year
5.
Mag-Diesel
engine
on
DEL-200
6
months
D
6.
All
other
engines
1
year
c
CD
c
~
Engine
Warranties
are
covered
by
the
engine
manufacturers,
subject
to
their
procedures
and
to
be
handled
CD
C
P
through
their
authorized
local
Service
Stations
or
agencies.
No
warranty
will
be
made
in
respect
to
trade
CD
D
accessories,
such
being
subject
to
the
warranties
of
their
respective
manufacturers.
C
CD
C)
CD
C)
C)
MILLER
Electric
Mfg.
Co.
will
not
be
liable
for
any
loss
or
consequential
damage
or
expense
accruing
c
~
directly
or
indirectly
from
the
use
of
equipment
covered
in
this
warranty.
CD
CD
C)
C)
C
)
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
C
C)
CD
C
D
warranties
expressed
or
implied.
c
~
C)
CD
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OPTIONAL
EQUIPMENT
DSS-1
Two
Position
Switch
This
switch
replaces
the
standard
switch
and
attaches
to
the
torch
handle.
It
provides
both
wire
feed
on-off
control
and
switching
from
schedule
A
to
schedule
B
or
vice
versa.
Includes
15
foot
lead
and
plug..
RFM-2
Remote
Foot.
Switch
Provides
for
switching
from
one
weld
schedule
to
another.
When
using
the
RFM-2
switch,
wire
feed
on-off
control
is
accomplished
with
the
standard
torch
switch.
Includes
20
foot
lead
and
plug.
1-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
maintenance,
and
troubleshooting
of
this
equipment.
All
information
presented
herein
should
be
given
careful
consid
eration
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
equipment,
it
is
essential
that
Model
Designation
and/or
Stock
Number
and
Serial
(or
Style)
Number
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
The
design
concept
of
this
remote
control
unit
is
to
be
able
to
use
one
welding
power
source
and
one
wire
feeder
for
dual
schedule
welding
by
connecting
to
a
third
module,
the
Re
mote
Control
Dual
Schedule.
The
dual
schedule
set-up
is
accomplished
by
using
the
existing
remote
control
recep
tacles
on
the
welding
power
source
and
wire
feeder.
No
tools
of
any
kind
are
required
for
installation
of
the
remote
con
trol
and
the
operation
of
it is
very
simple.
The
control
is
basically
a
combination
of
remote
voltage
con
trols
and
remote
wire
feed
speed
controls
brought
together
in
one
box.
The
circuit
is
arranged
in
such
a
way
that
the
operator
can
select
either
one
of
two
pairs
of
controls.
The
operator
can
use
one
voltage
control
with
its
corresponding
wire
feed
speed
control
or
by
merely
changing
the
position
of
the
schedule
selector
switch
on
the
gun
handle,
the
operator
can
use
the
other
set
of
controls.
1-4.
SAFETY
Caution
should
be
exercised
in
taking
voltage
measurements
when
troubleshooting
the
unit.
Always
avoid
contact
be
tween
any
part
of
the
human
body
and
any
current
carrying
part
of
the
remote
control
unit.
SECTION
2
-
INSTALLATION
IMPORTANT
This
RCDS-3
is
designed
to
be
used
in
conjunction
with
an
electric
amperage
controlled
welding
power
source
having
a
24
volt
dc
control
circuit.
If
the
weld
ing
power
source
being
used
has
a
RANGE
Switch,
the
RANGE
Switch
must
be
placed
in
the
LOW
or
the
WIDE
position.
Connect
the
remote
wire
feed
speed
plug
into
the
wire
feed
speed
receptacle
on
the
control/feeder.
Place
the
STANDARD-REMOTE
Switch
on
the
control/feeder
in
the
REMOTE
position.
The
schedule
selector
switch,
as
shown
in
the
OPTIONAL
EQUIPMENT
Section
can
either
bea
gun
mounted
switch
or
foot
control.
The
gun
mounted
Dual
Schedule
Switch
(DSS-1)
provides
both
contactor
and
Schedule
control.
The
contactor
is
en
gaged
by
depressing
the
DSS-1
half
way
down.
Pressing
the
switch
all
the
way
down
will
engage
the
contactor
and
change
schedules.
To
change
back
to
the
original
schedule,
merely
release
the
switch
approximately
half
the
way
up.
The
Remote
Foot
Momentary
Switch
(RFM-2)
does
not
have
contactor
control
capability,
it
is
intended
to
be
used
only
for
Schedule
selection.
Depressing
the
foot
pedal
will
select
the
other
schedule
and
keep
that
schedule
in
the
circuit
as
long
as
the
foot
pedal
is
depressed.
SECTION
1
-
INTRODUCTION
I
I
2-3.
SCHEDULE
SELECTOR
SWITCH
(Figure
2-1)
2-1.
REMOTEWIRE
FEED
SPEED
(Figure
2-1)
LEGEND
115
VOLTS
ac
~
CONTACTOR
CONTROL
GAS
OUT
~
GAS
IN
NEGATIVE
POSITIVE
SWITCH
CONTROL
ElIS
CONDUIT
ASSEMBLY
]1EL
REMOTE
VOLTAGE
CONTROL
REMOTE
WIRE
FEED
SPEED
lIE
SCHEDULE
SELECTOR
CONTROL
VOLTAGE
CONTROLS
SCHEDULE
B
PILOT
LIGHT
WIRE
FEED
SPEED
CONTROLS
Figure
2-1.
Interconnection
Diagram
TD-040
810-2
OM-850
Page
1
SECTION
3
-
OPERATION
3-1.
GAS
METAL-ARC
WELDING
1.
Make
all
necessary
connections
to
the
welding
machine,
control/feeder
and
torch
as
outlined
in
their
respective
manuals.
2.
Connect
the
remote
voltage
control
plug
to
the
remote
voltage
control
receptacle
on
the
welding
power
source.
3.
Place
the
STANDARD-REMOTE
voltage
control
switch
on
the
welding
machine
in
the
REMOTE
position.
3.
Place
the
STANDARD-REMOTE
voltage
control
switch
on
the
welding
power
source
in
the
REMOTE
position.
4.
Connect
the
remote
wire
feed
speed
plug
to
the
wire
feed
speed
receptacle
on
the
control/feeder.
5.
Place
the
STANDARD-REMOTE
wire
feed
speed
switch
on
the
control/feeder
to
the
REMOTE
position.
6.
Connect
the
schedule
selector
plug
to
the
schedule
selector
receptacle
(RC1)
on
the
RCDS.
7.
Set
the
voltage
controls
and
wire
feed
speed
controls
on
the
RCDS
to
the
desired
settings.
8.
Turn
the
welding
power
source
and
control/feeder
on.
9.
Select
the
proper
schedule
by
placing
the
schedule
selector
switch
in
the
desired
position.
Two
pilot
lights
are
provided
on
the
RCDS
to
indicate
which
schedule
is
being
used.
PLG
1
AMPHENOL
PLUG
TO
WIRE
FEEDER
REMOTE
CONTROL
RECEPTACLE
C
II
.
~/GRN.>E
CR1
I
SHIELD
D
A
GR-GROUND
TO
WELDING
MACHINE
PLG2
REMOTE
CONTROL
RECEPTACLE
C-COPPER
B-BRASS
Circuit
Diagram
No.
CA-040
810-1
Figure
3-1.
Circuit
Diagram
For
RCDS-1
Page
2
August
1974
FORM:
OM-850
MODEL
RCDS-1
RCDS-2
RCDS-3
STOCK
NO.
040
810
040
907
041
012
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
U
S
A-
Quantity
Dia.
Factory
Models
Mkgs.
Part
No.
Description
RCDS-1
~
RCDS-2
(
RCDS-3
Complete
Assembly
Cl
031
608
CAPACITOR,electrolytic250uf25voltac
1 1 1
601
375
RING,
mtg
-
capacitor
1
1
1
CR1
034
691
RELAY,
3PDT
i2voltdc
1
CR1
025
560
RELAY,
3
POT
12
volt
dc
1
CR1
034676
RELAY,3PDT24voltdc
1
CR2
034
676
RELAY,
3PDT
24
volt
dc
1
039664
SOCKET,tubeilpin
1
2
1
104
045
BRACKET,
mtg
-
relay
1
2
1
01,2
026202
DIODE,
lamp
400volt
straight
polarity
2
2
2
PL1,2
*027
632
BULB,
slide
base
24
volt
2
2
PL1,2
*027
638
BULB,
slide
base
48
volt
2
027
628
LENS,
red
-
indicator
lamp
2
2
2
027
631
HOUSING,
indicator
lamp
2
2
2
PLG1
039
827
CONNECTOR,
straight
-
male
6
contact
1
1
1
039828
STRAIN
RELIEF,
amphenol
1
1
1
PLG2
039 693
CAP,
twistlock
3P3W
PLG2
605
797
CAP,twistlock
3P3W
1
1
R1,4
030940
RESISTOR,carbon0.5watt2000ohm
2
2
2
R2,5
030
943
POTENTIOMETER,
carbon
1
turn
2
watt
15K
ohm
2 2
2
019
609
KNOB,
pointer
-
small
2
2
2
R3,6
030
854
RESISTOR,
carbon
0.5
watt
18K
ohm
2
2
2
R7,8
030 070
RHEOSTAT,
WW
150
watt
75
ohm
2
R7,8
030653
RHEOSTAT,WW
150
watt
15
ohm
2
2
019
627
KNOB,
pointer
-
large
2 2
2
R9,l0
030 783
RESISTOR,
carbon
1
watt
220
ohm
2
Ri
1
604
178
RESISTOR,
carbon
2
watt
100
ohm
R12
030778
RESISTOR,carbon
1
watt
180
ohm
RC1
039
855
RECEPTACLE,
twistlock
2
prong
1 1
1
038
785
STR
IP,
terminal
3
pole
2
2
2
057
056
BRACKET,
mtg-
terminal
strip
2
2
2
023
605
CORD
SET,
115
volt
16
ga
3
conductor
20
ft
1
1
057057
CABLE,electrical
No.
2OAWG
5
conductor
l5ft
1
025515
CABLE,electricalNo.
l65conductor20ft
010 610
CONNECTOR,
cable
clamp
3/8
2 2
2
025
903
COVER,
control
box
1 1
1
020
527
CASE
SECTION,
base/side
1
1
1
019663
MOUNT,rubber
4 4
4
020
528
HANDLE,
control
box
2
2
2
*
Recommended
Spare
Parts
BE
SURE
TO
PROVIDE
STOCK,
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-850
Page
1
1%
Figure
3-2.
Circuit
Diagram
For
RCDS-2
Circuit
Diagram
No.
CA-040
907-1A1
Figure
3-3.
Circuit
Diagram
For
RCDS-3
Circuit
Diagram
No.
CA-041
012-IA
Di
22
P
24
CRi
-
R
_______
2
25
26
R
3
D2
BL/(
2/
.11
271
141
26Y
I
AMPHENOL
PLUG
o
CR
I
PL
G
TO
I
WIRE
FEEDER
I
REMOTE
CONTROL
301
RECEPTACLE
0
I
SHIELD
1;i
WHT
23
RED
4S
II
II
ND
TO
WELDING
MACHINE
REMOTE
CONTROL
RECEPTACLE
D1
22
P
24
Ck1
25~
26
P
3
I-
>C
St/C
2/
I
.
~1GRN
>E
27!
I
I
PLG~
I
AMPIIF
in
Il
t
C
Cl-Il
I
____________
Tfl
II~
~ikF
FFFDEP
~
I
RFI1OTF
C)rJTkc
I
30
-Ed-I-
T-\CI
E
P
I
6
I
SHIFID
WI-IT
.3
,Is(
bEj
-22
I
II
A
OM-850
Page
3
/
