May
1977
FORM:
OM-824
~LE
CO~
w
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
20
CENTS
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
qIN
MODEL
RHC-3VR
RHC-4VR
RHC-6VR
RHC-7VR
STOCK
NO.
006 386
006
387
006
388
006 389
NWSA
CODE
NO.
4579
t~P
5~~%~
q
L~P
%~~iP
~
I
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
cx
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co.,
Apple-
3.
All
welding
guns
and
feeder/guns
90
days
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
4.
All
other
Millermatic
Feeders
.
.
.
I
year
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
(30)
days
of the
date
of
such
failure.
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
warran-
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
AND ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
replace-
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
WARRANTY
OF
MERCHANTABILITY
OR
OF
FiTNESS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLEk
IS
the
purchase
price
(less
reasonable
depreciation
based
upon
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
actual
use)
upon
return
of the
goods
at
Customers
risk
and
ex
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
dures
to
be
followed.
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
TRIAL
USERS
AND
FOR
OPERATiON
BY
PERSONS
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
of
failure
resulting
from
a
defect
within
the
following
periods
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
from
the
date
of
delivery
of
Equipment
to
the
original
user:
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RE-
I.
Arc
welders,
power
sources,
and
components
...
I
year
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR
2.
Original
main
power
rectifiers
3
years
RANTIES
TO,
ANY
CONSUMER.
t,
4
December
13,
1982
FORM:
OM-824
ERRATA
SHEET
After
this
manUal
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
Item
Or
Dia.
Part
Replaced
Page
No.
Mkgs.
No.
With
Description
Quantity
32
C50
031
728
084
087
CAPACITOR,
electrolytic
9000
uf
40
volts
dc
Pg
2
C51
031
751
031
721
CAPACITOR,
mylar
0.22
uf
200
volts
dc
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
ALE
Copy
RETUF~
TO
FCQ;~)~:~
SECTION
1
-
INTRODUCTION
1-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design.
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
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
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-3.
DESCRIPTION
CAUTION
Under
this
heading,
installation,
oper~g,
and
main
tenance
procedures
or
practices
will
be
found
that
it
not
carefully
followed
may
create
a
hazard
to
per-
sonnel.
I
A
N
I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip.
ment.
This
remote
hand
control
enables
the
operator
to
control
the
output
voltage
of
the
welding
power
source
from
the
work
site.
The
remote
hand
control
also
contains
a
voltage
regula
tor
circuit
which
compensates
for
line
or
load
variations
on
the
welding
power
source
to
provide
a
constant
voltage
1-4.
SAFETY
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
The
remote
hand
control
is
equipped
with
an
interconnect
ing
multi.conductor
cord
which
enables
the
remote
hand
control
to
be
remotely
located
from
the
welding
power
source
or
welding
generator.
The
remote
hand
control
can
be
wall
mounted
or
placed
on
a
stand
at
the
work
area.
If
it
is
necessary
to
install
a
multi-conductor
cord
of
longer
length,
refer
to
Table
2-1
for
cord
conductor
size
according
to
the
desired
length.
Refer
to
the
circuit
diagram
for
proper
connections.
Table
2-1.
Cord
Conductor
Length
&
Size
Cord
Length
Conductor
Size
(AWG)
UpTo
20
Feet
No.16
21
To
50
Feet
No.
14
5lTolOOFeet
No.12
101
To
200
Feet
No.
10
CAUTION
that
the
POWER
switch
on
the
welding
power
source
is
in
the
OFF
position
prior
to
connecting
the
remote
hand
control
or
replacing
the
fuse.
.1
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
Fully
insert
the
locking
cap
(PLG1)
that
is
attached
to
the
remote
hand
control
cord
into
the
voltage
control
receptacle
on
the
welding
power
source.
Turn
the
cap
in
a
clockwise
direction,
as
far
as
it
will
turn,
to
lock
the
cap.
Connect
the
feedback
terminal
on
the
black
lead
to
the
nega
tive
secondary
output
terminal.
Connect
the
feedback
terminal
on
the
remaining
lead
to
the
positive
secondary
output
terminal.
(On
welding
power
sources
with
two
positive
secondary
output
terminals
this
connection
must
be
made
to
the
high
or
main
positive
secondary
output
terminal).
2-3.
30
VOLTS
CONTROL
CIRCUIT
FUSE
REPLACEMENT
(Figure
2-2)
Replace
the
30
volts
control
circuit
fuse,
Fl
in
the
650
and
750
ampere
models;
F2
in
the
300
and
450
ampere
models,
with
the
supplied
15
ampere
fuse.
Affix
the
supplied
15
AMP
FUSE
label
over
the
10
AMP
marking
directly
under
the
fuse
holder.
output.
2-1.
LOCATION
SECTION
2
-
INSTALLATION
2-2.
INTERCONNECTIONS
(Figure
2-1)
I
~F2
0
o~o
o~o
Ii
300
Ampere
Model
TA-901
500-4
Figure
2-2.
30
Volts
Control
Circuit
Fuse
Location
TB-007
241
Figure
2-1.
Interconnections
OM-824
Page
1
Fl
Fl
Figure
2-2.
30
Volts
Control
Circuit
Fuse
Location
(Contd.)
TB-901
742-3
TA-901
500-4
r~5i
650
Ampere
Model
TA-900
505-4
SECTION
3-
FUNCTION
OF
CONTROLS
3-1.
REMOTE
HAND
CONTROL
The
voltage
control
knob
on
the
remote
hand
control
is
con
nected
to
the
indicator
and
a
potentiometer
thru
a
planetary
gear
system.
This
system
decreases
the
sensitivity
of
the
con
trol
knob,
enabling
the
operator
to
make
fine
voltage
adjust
ments
while
welding.
Rotating
the
control
clockwise
increases
the
welding
power
source
output
voltage.
The
scale
surrounding
the
voltage
control
knob
is
calibrated
in
increments
of
two,
from
0-100
percent.
This
scale
repre
sents
a
percentage
of
the
load
voltage
range
and
should
not
be
misconstrued
as
a
voltage
reading.
If
it
is
necessary
to
know
the
output
voltage
it
is
recommended
that
the
voltage
meter
on
the
welding
power
source
be
read.
3-2.
WELDING
POWER
SOURCE
CONTROLS
The
STANDARD-REMOTE
VOLTAGE
CONTROL
switch
on
the
welding
power
source
must
be
placed
in
the
REMOTE
position
when
the
remote
hand
control
is
used.
If
the
welding
power
source
is
equipped
with
a
LOAD
VOLT
AGE
RANGE
switch,
the
switch
should
be
placed
in
the
SINGLE
WIDE
position
when
using
the
remote
hand
con
trol.
F2
450
Ampere
Model
'
~4o6
a
750
Ampere
Model
WH
r
5-ORAl
PLC
GRN
PRONG
VIEW
Circuit
Diagram
No.
CA-006
386.1A
Figure
3-1.
Circuit
Diagram
Page
2
May
1977
FORM:
OM-824
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
8
Figure
A
Complete
Assembly
TD-052
356
1
7
0
30
19
VT
2T
22
r;in
~
20
R6BII
R~=~jpC
N
P64
P61
QSJ~
U
~
9462
467
763U
~
OM-824
Page
1
Figure
A
*Recommended
Spare
Parts.
Complete
Assembly
Item
Dia.
Factory
RHC-RHC-RHC-RHC
No.
Mkgs.
Part
No.
Description
3VR
4VR
6VR
7VR
Quantity
Model
1
006
535
RECTIFIER,
silicon
diode
(consisting
of)
1
1
1
1
2
D50
037
952
.
DIODE,
rectifier
15
amp
200
volts
straight
polarity
1
1
1
1
3
006
428
.
BRACKET,
mounting
-
heat
sink
1
1
1 1
4
010
617
BUSHING,
brass
0.194
ID
x
1/4
OD
x
0.194
7
7
7
7
5
032
280
WHEEL,
reduction
.
friction
rheostat
1
1 1
1
6
038
592
BRACKET,
mounting
-
potentiometer
1
1
1 1
7
R54
006533
POTENTIOMETER,carbon
1
turn
2watt
l000ohm
1
1
1
1
8
006
534
AMPLIFIER,
power
(consisting
of)
1
1
1
1
9
053
007
716
.
TRANSISTOR,
30
amp
100
volts
PNP
1
1
1
1
10
054
007
715
.
TRANSISTOR,
30
amp
90
volts
NPN
1
1
1 1
11
006425
.HEATSINK,diode
1
1
1
1
12
D53
037
952
.DIODE,
rectifier
15
amp
200
volts
straight
polarity
1 1
1
1
13
R69
006429
.RESISTOR,5watt0.lohm
1
1
1 1
14
D52
037
451
.
DIODE,
rectifier
22
amp
200
volts
reverse
polarity
1
1
1
1
15
073
756
.
STAND-OFF,
no.
6-32
x
5/8
long
1/4
hex
4
4
4
4
16
601
242
.
INSULATOR,
washer
-
heat
sink
4
4
4
4
17
019
677
HANDLE,
door
-
pull
1
1
1 1
18
021
475
WRAPPER
1
1
1
1
19
006
427
BRACKET,
mounting
-
circuit
card
assembly
1 1 1 1
20
007
155
CIRCUIT
CARD
ASSEMBLY
(consisting
of)
1
20
007
156
CIRCUIT
CARD
ASSEMBLY
(consisting
of)
1
20
006432
CIRCUITCARDASSEMBLY(consistingof)
1
20
007
157
CIRCUIT
CARD
ASSEMBLY
(consisting
of)
1
A50
000087
.
AMPLIFIER,
operational
iCtemp.
range
-55
to
125
1
1
1
1
C51
039
344
.
CAPACITOR,
mylar
0.47
uf
100
volts
dc
1 1
1 1
C52
031
693
.
CAPACITOR,
mylar
0.33
uf
75
volts
dc
1 1
1 1
D51
037
449
-
DIODE,
zener
15
volts
1
watt
straight
polarity
1
1
1
1
050,52
039
353
-
TRANSISTOR,
4
amp
40
volts
NPN
2 2
2
2
051
039
354
.
TRANSISTOR,
4
amp
40
volts
PNP
1
1
1
1
R51
000
039
.
RESISTOR,
carbon
2
watt
680
ohm
1 1
1 1
R52,58
605
979
.
RESISTOR,
metal
film
0.25
watt
15K
ohm
2
2
2
2
R53,55
006
424
.
POTENTIOMETER,
cermet
trimmer
1
turn
5
watt
2K
ohm
2
2
2
2
R56
035
825
.
RESISTOR,
carbon
film
0.25
watt
1
K
ohm
1 1
1
1
R57,60
605
978
.
RESISTOR,
metal
film
0.25
watt
2.74K
ohm
2 2
2
2
R59
000
035
.
RESISTOR,
metal
film
0.5
watt
6.8K
ohm
1 1
1
1
R61
039
335
.
RESISTOR,
carbon
film
0.25
watt
47K
ohm
1
1
1
1
R62
030
033
-
RESISTOR,
carbon
0.5
watt
470
ohm
1
1
1 1
R63
030
038
.
RESISTOR,
carbon
0.5
watt
220
ohm
1
1
1
1
R64,65
030
024
.
RESISTOR,
carbon
0.5
watt
1000
ohm
1
1
1
1
R66,67
030
839
.
RESISTOR,
WW
fixed
5
watt
220
ohm
1
1
1
1
R68
030
937
.
RESISTOR,
carbon
0.5
watt
10
ohm
1
1
1
1
1,2T
000
059
-
BLOCK,
terminal
5
amp
6
pole
2 2 2 2
21
R50
006
532
RESISTOR,
WW
adj
50
watt
5
ohm
w/leads
1 1
1
1
22
006430
CASE
SECTION,base/front/rear
1
1
1 1
23
010
659
CONNECTOR,
clamp
.
cable
3/8
inch
90
deg
1 1
1
1
24
006
530
CABLE
ASSEMBLY,
power
(consisting
of)
1
1
1
24
006
529
CABLE
ASSEMBLY,
power
(consisting
of)
1
25
006
531
.
CABLE.
power
1
1
1
1
26
PLG1
605
797
.
CAP,
twistlock
3P3W
20
amp
125
volts
1
1
1
1
27
600
340
.
CORD,
portable
no.
16
2/c
1
1
1
28
035
535
POINTER,
rheostat
-
voltage
control
1
1
1
1
29
007
1
58
KNOB,
indicator
1
1
1 1
30
006
502
PLATE,
indicator
-
amperage
1
1
1
1
31
006
426
BRACKET,
mounting
-
capacitor
1 1
1 1
32
C50
031
728
~027
419
013312
CAPACITOR,
electrolytic
9000
uf
35
volts
dc
FUSE,
ceramic
15
amp
250
volts
(loose
item)
LABEL,usel5ampfuse
1
1
1
1
1
1
1
1
1
1
1
1
BE
SURE
TO
PROVIDE
STOCK
AND
MODEL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-824
Page
2
-
1
-
2
-
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Miller RHC-4VR Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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