o854 mil - miller - welding equipment(! furnished by miller is free from defect in workmanship and...

16
July 1981 FORM: OM-854 OWN ERS MANUAL hullER MILLER ELECTRIC MFG. CO. 718 S. BOUNDS ST. P.O. Box 1079 APPLETON, WI 54912 USA ADDITIONAL COPY PRICE 35 CENTS NWSA CODE NO. 4579 PRINTED IN U.S.A. MODEL RCMP-3A

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Page 1: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

July 1981 FORM: OM-854

OWNER�SMANUAL

hullER

MILLER ELECTRIC MFG. CO.

718 S. BOUNDS ST. P.O. Box 1079

APPLETON, WI 54912 USA

ADDITIONAL COPY PRICE 35 CENTS

NWSA CODE NO. 4579

PRINTED IN U.S.A.

MODEL

RCMP-3A

Page 2: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

�L� ~

LIMITED WARRANTYEFFECTIVE: 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, Millet 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 Miller�s 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 Miller�s option Ill repair or (2) replacementcessories or other items manufactured by others. Such or, where authorized in writing by Miller in appropriate cases, 131

engines, trade accessories and other items are sold subject to the reasonable cost of repair or replacement at an authorized

~.dthe warranties of their respective manufacturers, if any .

All Miller service station or (4) payment of or credit for the purchase

engines are warranted by their manufacturer for one year from price (less reasonable depreciation based upon actual use) upon

date of original purchase. return of the goods at Customer�s risk and expense. Upon receipt

of notice of apparent defect or failure, Miller shall instruct the clai-

Except as specified below, Miller�s warranty does not apply mant on the warranty claim procedures to be followed.

to components having normal useful life of less than one Ii)

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 TION AS TO PERFORMANCE, AND ANY REMEDY FOR

not result from defect in workmanship or material. BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, k~MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,

Miller shall be required to honor warranty claims on war- CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING

ranted Equipment in the event of failure resulting from a defect ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF

within the following periods from the date of delivery of Equip- FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO

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

(labor - 1 year only) WRITING, MILLER PRODUCTS ARE INTENDED FOR

3. All welding guns and feeder/guns 90 days 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 130) days TO, AND NO RESELLER IS AUTHORIZED TO EXTEND

of the date of such failure. MILLER�S WARRANTIES TO, ANY CONSUMER.

~,i.

~1., ~ ~t, JY ~ �ji~ :~t, ~ �t, ~

Page 3: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

ERRATA SHEET

After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to dataappearing later in this manual.

AMENDMENT TO SECTION 4 - SEQUENCE OF OPERATION

Amend Figure 4 - 1. Circuit Diagram

rç�~Lr

TO REMOTE CONTROL

RECEPTACLE ON

WELDING MACHINE

Figure 4-1. Circuit Diagram

April 20, 1983 FORM: OM-854

CR.

TO FEEDER TO FEEDER

RC3 ~RC4

54

:c~1~

56

�ISV.

-'-

53

~CR24$

48

115 V.

-fi-

IIW1 W2

C

a

PLC i

TO FEEDER

A�MOVE JUMPER FROM

USING 2 SEPERATE

� ��

BJ A&9 TO B&C WHEN

WIRE FEEDERSCR1

11 � � I 1

TO CONTACTOR 4R~~RECEPTACLE ON

WELDING MAC~IINE FM

PLC3

.CRi

7 l15V FROM

> WELDING MACI-tINE

PLC29

~\

TO FEEDER

a..

Circuit Diagram No. A-081400-B

OM-854 Page A.

Page 4: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY
Page 5: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

SECTION 1 -

1-1. GENERAL - This manual has been preparedespecially for use in familiarizing personnel with the

design, installation, operation, maintenance, and

troubleshooting of this equipment. All information

presented herein and on various labels, tags, and plateson the unit 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 claims 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 - This unit is a multi-purposeremote control which provides a separate welding con

dition on each of two electrode wires using one or two

control/feeders and one welding power source. This

unit is equipped with contactors to provide cold wire

(electrically deenergized) conditions on the inactive gun

when both guns are connected for the same polarity. In-

CAUTION

SECTION 2 -

Before making electrical connections

necessary for the proper operation of the remote con

trol, ensure that the we/ding power source and con

trol/feeder are both deenergized.

IMPORTANT Dual control/feeders are shippedfrom the factory wired for use with one welding powersource. In order for the remote control to function pro

perly, the dual control/feeder must be modified to

operate as if two welding power sources are in use. See

the control/feeder Owner�s Manual for contactor con

trol modification instructions.

Damage to equipment will result if the dual con

trol/feeder is wired for use with one welding power

source and used when the system is connected with

one gun straight polarity and the other gun reverse

polarity.

I~I�II~ All directions, such as left or right, are with

respect to the operator facing the remote control front

panel.

2-1. SECONDARY CONNECTIONS (Figure3-1) - Condition A and B interconnecting terminals are

located on the left side panel of the remote control.

These terminals provide a connection point between the

welding power source and the control/feeder(s). Before

making connection to the remote control interconnec

ting terminals select the welding condition desired on

each electrode wire. Refer to the welding power source

Owner�s Manual for proper secondary cable sizes.

INTRODUCTION

terconnecting terminals on the remote control allow dif

ferent polarity connections. It is designed specificallyfor use with the Gas Metal-Arc Welding (GMAW) and

Flux Cored-Arc Welding (FCAW) processes.

I Wi I ~I�~ ~I V~ I~ 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 weldingpower source or welding generator manual should be

read completely. This will help avoid possible injury dueto misuse or improper welding applications.

The following definitions apply to CAUTION, IMPOR

TANT, and NOTE blocks found throughout this

manual:

1.4.1111 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.

I~ ~ Under this heading, explanatory statements

will be found that need special emphasis to obtain the

most efficient operation of the equipment.

INSTALLATION a

� ~ ~ A jumper cable must be used between remote

control Condition A and B input power terminals if both

guns are connected for the same polarity and both draw

weld current from the same welding power source out

put terminal. No jumper cable connection at the remote

control input power terminals is required if one gun is

connected for straight polarity and the other gunreverse polarity from the same welding power source

output terminaL

All cable carrying weld current must be of adequatecapacity for the anticipated maximum load.

I i~ I ~ Periodically inspect the labels on this unit for

legibility. All labels must be maintained in a c/earlyreadable state and replaced when necessary. See the

Parts List for part number of labels.

A. Dual Control/Feeder Feeding Two ElectrodeWires

I~I�1 I~ Interconnecting weld cables are supplied with

boom mounted dual control/feeders only. These cables

extend out the back of the boom. The cable connectingthe Left Gun is labeled LEFT; the cable connecting the

Right Gun is not labeled. Bench mounted dual con

trol/feeders require customer supplied interconnectingweld cab/es. See the control/feeder Owner�s Manual

for instructions on making proper connections to the

drive assembly.

1. High/Low Output Reverse Polarity (Figure 2-1).

I~I.Il~ When both guns are connected for the same

polarity, the electrode wire from the inactive gun will

not be electrically energized.

OM-854 Page 1

Page 6: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

a. Connect secondary cables from the weldingpower source POSITIVE output terminals to

the respective remote control input terminals

to obtain the desired output for each condi

tion.

b. Connect the interconnecting cables from the

guns to the appropriate output terminals on

the remote control.

See Note

Low Positive

NOTE 1: Weld Output

Secondary connections at the welding power source

positive output terminals can be reversed to obtain low

output reverse polarity on the Right Gun and high out

put reverse polarity on the Left Gun. The broken lines

indicate the reversed secondary cables.

NOTE 2:

It the welding power source has only one positive out

put terminal or if only one of the positive output ter

minals is used, a jumper cable must be connected

across remote control Condition A and B input power

terminals. All cable carrying weld current must be of

adequate capacity for the anticipated maximum load.

Note:

Welding Power Source

Low Positive

Weld OutputCable

Secondary connections at welding power source

positive output terminals can be reversed to obtain low

output straight polarity on the Right Gun and high out

put reverse polarity on the Left Gun. The broken lines

indicate the reversed secondary cables.

c. Connect the work cable to the NEGATIVE

output terminal on the welding power

source.

2. High Output Straight Polarity/Low OutputReverse Polarity (Figure 2-2).

Remote Control Unit

~?o~o~~ooIL~!J

Condition A

Output Cable

Welding Power Source

Low High+ +.

High Positive

Weld Output

VSee Note 2

Condition B

Output Cable

Drive

(Assembly

Negative Weld Output

Left ~-

Gun~Right

Gun

1 IFigure 2-1. Reverse Polarity Connections

Low High+ + �

Remote Control Unit

A A

Jumper Cable

Work Cable

\

�I

ii�

Figure 2-2. High Output Straight Polarity/Low Output Reverse Polarity Connections

Page 2

Page 7: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

I~�I.) 1~ High output straight polarity connections for

the Left Gun are provided as an example of straight

polarity secondary connections. If low output straight

polarity is desired for the Left Gun, the secondary

cables at the we/ding power source POSITIVE output

terminals would need to be reversed. To obtain the

same output and polarity conditions for the Right Gun,

reverse the procedures outlined in this Section.

a. Connect a secondary cable from welding

power source NEGATIVE output terminal

and the interconnecting cable for the Left

Gun to remote control Condition B output

terminal.

I~I�1l~ Connect the interconnecting cable for the

Right Gun to welding power source NEGATIVE output

terminal, if desired, and if cable length permits.

b. Connect a secondary cable from welding

power source High POSITIVE output ter

minal to remote control Condition A inputterminal.

c. Connect the interconnecting cable for the

Right Gun to welding power source Low

POSITIVE output terminal.

d. Connect the work cable to remote control

Condition A output terminal.

e. Connect a jumper cable between remote

control Condition A and B output terminals.

CAUTION: Both electrode wires will be electrically

energized when either gun trigger is depressed. The

electrode wire in the Left Gun is negative while the elec

trode wire in the Right Gun is positive; therefore a

potential path exists between the electrode wires if the

guns are brought into close proximity.

B. Two Control/Feeders Feeding Two Elec

trode Wires (bA, 1OE, 30A or 30E Models)

1. High/Low Output Reverse Polarity (Figure 2-1)

L~�I.~ I~ When both guns are connected for the same

polarity, the electrode wire from the inactive gun will

not be electrically energized.

a. Connect secondary cables from the welding

power source POSITIVE output terminals to

the respective remote control input terminals

so as to obtain the desired output for each

condition.

I~ I~ The control/feeder connected to remote con

trol Condition A Contactor Control receptacle is

designated Control/Feeder A. The control/feeder con

nected to remote control Condition B Contactor Control

receptacle is designated Control/Feeder B.

c. Connect a secondary cable from the weld

cable terminal on Control/Feeder B to the

remote control Condition B output terminal.

d. Connect the work cable to the NEGATIVE

output terminal on the welding power

source.

2. High Output Straight Polarity/Low OutputReverse Polarity (Figure 2-2).

I~�IsIl~ High output straight polarity connections for

Control/Feeder A are provided as an example of

straight polarity secondary connections. If Low output

straight polarity is desired for Control/Feeder A, the

secondary cables at the welding power source

POSITIVE output terminals would need to be reversed.

To obtain s/rn/liar output and polarity conditions for

Control/Feeder B, reverse the procedures outlined in

this Section.

a. Connect a secondary cable from welding

power source NEGATIVE output terminal

and the interconnecting cable from the weld

cable terminal on Control/Feeder A to

remote control Condition B output terminal.

t~�IS1l~ Connect the interconnecting cable for Con

trol/Feeder A to welding power source NEGATIVE out

put terminal, if desired, and if cable length permits.

b. Connect a secondary cable from welding

power source High POSITIVE output ter

minal to remote control Condition A inputterminal.

c. Connect an interconnecting cable from the

weld cable terminal on Control/Feeder B to

welding power source Low POSITIVE out

put terminal.

d. Connect the work cable to remote control

Condition A output terminal.

e. Connect a jumper cable between remote

control Condition A and B output terminal.

CAUTION____________

Both electrode wires will be electricallyenergized when either gun trigger is depressed. The

electrode wire from Control/Feeder A is negative while

the electrode wire from Control/Feeder B is positive;therefore a potential path exists between the electrode

wires if the guns are brought into close proximity.

2-2. REMOTE VOLTAGE CONTROL CONNEC

TIONS (Figure 3-1) - The Voltage Control plug pro

vides a connection point between the Remote

VOLTAGE INCREASE control and the welding power

source voltage adjustment circuitry. Insert the three-

pole twistlock plug from the remote control fully into

the welding power source VOLTAGE CONTROL recep

tacle and rotate the plug clockwise.

b. Connect a secondary cable from the weld

cable terminal on Control/Feeder A to the

remote control Condition A output terminal.

Ii�IsIl~ Place the welding source Voltage Control

switch in the REMOTE position and rotate the VoltageControl rheostat to 100.

OM-854 Page 3

Page 8: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

2-3. REMOTE CONTACTOR CONTROL CONNEC

TIONS (Figure 3-1) - The Contactor Control plug pro

vides a connection point between the remote control

and the welding power source contactor control cir

cuitry. Insert the two-pole twistlock plug from the

remote control fully into the welding power source Con

tactor Control receptacle and rotate the plug clockwise.

IMPORTANT P/ace the we/ding power source Con

tactor Contro/ switch in the REMOTE position. Arcingwil/ occur in the contactors in the remote control if this

is not complied with.

2-4. 115 VAC CONNECTIONS (Figure 3-1) - The 115

VAC plug provides a connection point to supply. 115

volts ac to the remote control from the welding power

source. Insert the three-pole twistlock plug from the

remote control fully into the welding power source 115

VAC receptacle and rotate the plug clockwise.

2-5. CONTROL/FEEDER REMOTE CONTACTOR

CONTROL CONNECTIONS (Figure 3-1)

I~Is1t~ Two 10 ft. contactor control cables are sup

plied with dual control/feeders for making contactor

control connections. If two control/feeders are used, it

is recommended that 16/2 conductor cable be used for

the contactor control cable with a two-prong male plug.(These parts may or may not be supplied depending on

the model.)When using two control/feeders, replace reference to

Left Control/Feeder with Control/Feeder A and RightControl/Feeder with Control/Feeder B.

A. Left Control/Feeder

The remote control Condition A Contactor Control

receptacle provides a connection point between theLeft Control/Feeder and the remote control. Insert the

two-pole twistlock plug from the Left control fully into

the Condition A Contactor Control receptacle and

rotate the plug clockwise.

B. Right Control/Feeder

The remote control Condition B Contactor Control

receptacle provides a connection point between the

Right Control/Feeder and the remote control. Insert the

two-pole twistlock plug from the Right control fully into

the Condition B Contactor Control receptacle and rotate

the plug clockwise.

2-6. CONTROL/FEEDER 115 VAC CONNECTIONS

A. Dual Control/Feeder A

The remote control Condition A 115 VAC receptacleprovides a connection point to supply 115 volts ac for

operation of a dual control/feeder. Insert the three-poletwistlock plug from the dual control/feeder fully into the

Condition A 115 VAC receptacle and rotate the plugclockwise.

B. Two Control/Feeders

tk~IIIl~ The remote control is shipped connected to

supply 115 volts ac for the operation of a dual con

trol/feeder. When using two control/feeders, connect

the jumper fink on terminal strip 1 T across terminals B

and C. Terminal strip 1 T is located on the upper leftportion of the back panel inside the remote control.

The remote control Condition A and B 115 VAC recep

tacles provide connection points to supply 115 volts ac

to Control/Feeder A and Control/Feeder B respectively.Insert the corresponding three-pole twistlock plug into

the appropriate receptacle and rotate the plugclockwise.

SECTION 3- FUNCTION OF CONTROLS

B-081 290-A

Condition A Contactor

Control Receptacle

Condition ACondition B contactor Condition B 115 Left Voltage Right Voltage

115 VAC ReceptacleControl Receptacle VAC Receptacle Increase Control Increase Control

Condition B

Input Terminal

Figure 3-1. Remote Control Components

Page 4

Page 9: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

3-1. REMOTE VOLTAGE INCREASE CONTROLS

(Figure 3-1)

�~�IsIl~ When using two control/feeders, replacereference to Left Control/Feeder with Control/Feeder A

and Right Control/Feeder with Control/Feeder B.

The Remote VOLTAGE INCREASE controls provide

voltage selection within the welding power source load

voltage range being used. When the Left Con

trol/Feeder is active, the remote control LEFT

VOLTAGE INCREASE control will be active. When the

Right Control/Feeder is active, the remote control

RIGHT VOLTAGE INCREASE control will be active.

Rotating the VOLTAGE INCREASE controls in a

clockwise direction will increase the load voltage.

The scale surrounding the VOLTAGE INCREASE con

trols 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.

I~I�Il~ The contacts of the VOLTAGE INCREASE

controls are of the continuous type, thereby making it

possible to adjust these controls while welding.

3-2. REMOTE CONTROL PILOT LAMPS (Figure3-1) - When the welding power source is energized, the

remote control Condition A or B pilot lamp, when il

luminated, will indicate which condition is active.

SECTION 4 - SEQUENCE OF OPERATION

CAUTION____________

Never, under any circumstances, operatethe remote control with the outer enclosure removed. In

addition to a safety hazard, improper cooling may result

in damage to the remote control components. Warrantyis void if the remote control is operated with the outer

enclosure open or removed.

4-1. GAS METAL-ARC WELDING (GMAW) AND

FLUX CORED-ARC WELDING (FCAW)

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 control secondary connections as

outlined in Section 2-1.

3. Make Remote Voltage Control connections as

outlined in Section 2-2.

4. Make Remote Contactor Control connections as

outlined in Section 2-3.

9. Rotate the remote control LEFT VOLTAGE IN

CREASE control to the desired position.

k��II~ When using two control/feeders, replacereference to Control/Feeder LEFT WIRE SPEED control

with Control/Feeder A WIRE SPEED control and Con

trol/Feeder RIGHT WIRE SPEED control with Con

trol/Feeder B WIRE SPEED control.

10. Rotate the control/feeder LEFT WIRE SPEED

control to the desired position.

11. Rotate the remote control RIGHT VOLTAGE IN

CREASE control to the desired position.

12. Rotate the control/feeder RIGHT WIRE SPEED

control to the desired position.

CAUT~ON: Prior to welding, it is imperative that pro

per protective clothing (welding coat and gloves) and

eye protection (glasses and welding helmet) be put on.

Failure to comply may result in serious and/or perma

nent bodily damage.

13. Turn on the shielding gas supply.

5. Make 115 VAC connections as outlined in Sec

tion 2-4.

6. Make control/feeder Remote Contactor Control

connections as outlined in Section 2-5.

7. Make control/feeder 115 VAC connections as

outlined in Section 2-6.

8. Place the welding power source Load Voltage

Range switch, if applicable, in the desired position.

I~ ~ If the welding power source is equipped with

three output terminals and a Load Voltage Rangeswitch, the Load Voltage Range switch must be in the

Single Wide position when using the High and Low out

put terminals at the same time. If only one output ter

minal is used, the welding power source Load Voltage

Range switch may be in any position.

14. Energize the welding power source and con

trol/feeder(s). Commence welding.

15. CONDITION A or B will automatically be

selected whenever the Right Gun or the Left Gun

(Gun A or Gun B if using two control/feeders)

respectively, is activated. Only one condition and

one gun is active at one time.

I~sIl~ The Remote VOL TAGE INCREASE controls

and/or the WIRE SPEED controls can be adjusted while

welding.

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.

OM-854 Page 5

Page 10: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

3. Place the welding power source POWER switch

in the OFF position. Since the remote control

derives its operating power from the weldingpower source, the remote control will also be

deenergized when the welding power source is

deenergized.

4. If the control/feeder(s) does not derive its

operating power from the welding power source,

place the control/feeder(s) POWER switch in the

OFF position.

5. 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 endangeringpersonnel reentering the welding area.

ITCMOVE JUMPER FROM

RC1 B.. A&B TOB&C WHEN

�Th USING 2 SEPERATE

CR2 WIRE FEEDERS

115V. FROM

WELDING MAC i-fl NE

,� ,~

TO FEEDER

Circuit Diagram No. A-081 400-A

Figure 4-1. Circuit Diagram

+

TO FEEDER TO FEEDER

RC3

TO REMOTE CONTROL

RECEPTACLE ON

WELDING MACHINE

RC4

PLG i

54

CR1

56

115 V.

-fi-

-~-

-fi-

53

CR249

48

115 V.

-'-

IIWi

TO FEEDER

~1

CR1

F, � I 1

TO CONTACTOR LHCR~4RECEPTACLE ON

WELDING MACHINE FM

>-

PLG3

7

9PLG2

Page 6

Page 11: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

July 1981 FORM: OM-85

PARTSLIST

MODEL

RCM P-3A

Page 12: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

89

FigB

13

14

15

36

33

16

17

34

35

32

24 FigureA

-

Main

Assembly

2120

19

18 TD-081136-A

Page 13: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

Item Dia. FactoryNo. Mkgs. Part No. Description Quantity

Figure A Main Assembly

1 PLG1 605 797 CAP, twistlock3P3W20amp 125 volts 1

2 600 733 CORDSET,ll5voltsl6ga3/c20ft 2

3 010 610 CONNECTOR, clamp -cable 1/2inch 3

4 t048 938 CABINET (consisting of) 1

5 010 853. FASTENER, screw-slotted hd No.2 1

6 010855 .RETAINER,screwNo.2 1

7 010 854. NUT, speed No.2 clip - on type 1

047 497 LABEL, general precautionary 1

1 T 038 602 BLOCK, terminal 30 amp 3 pole 1

9 038 620 LINK, jumper - terminal block 30 amp 1

10 FM 007678 MOTOR,1/70hpl50voltsacl55Orpm 1

11 031 296 BRACKET, mounting - motor fan 1

12 032618 BLADE,fan6OHz6inch4wing 1

13 W1,2 048 597 CONTACTOR, 3P 110-120/208-240 volts (See Fig. B Page 3) 2

14 048 601 LINK, jumper - contactor 4

15 R1,2 030 653 RHEOSTAT, WW 150 watt 15 ohm 2

16 NAMEPLATE (order by model) 1

17 032 522 PLATE, indicator - voltage increase right 1

18 019 627 KNOB, pointer 2

19 032 521 PLATE, indicator - voltage increase left 1

20 027 628 LENS, light - indicator red clear 2

21 PL1,2 *027 638 BULB, incandescent-slide base 48 volts 2

22 027 631 HOUSING, light - indicator slide base 125 volts 2

23 CR1-3 059 266 RELAY, 120 volts ac DPDT 3

24 039 047 TERMINAL, power output - red (consisting of) 4

25 601976. SCREW, cap-steelhexhdl/2-13x1-1/2 1

26 039049 .TERMINALBOARD, red 1

27 053032 .CLIP,spring-busbar 1

28 601 880 .NUT,steel-hexjaml/2-13 1

29 039044 .BUSBAR 1

30 601879 .NUT,steel-hexfulll/2-13 1

31 RC1 ,2 039 686 RECEPTACLE, twistlock - grounded 2P3W 2

32 048 475 GUARD, stud - power 1

33 RC3,4 039 634 RECEPTACLE, twistlock - flanged INL 2P2W 2

34 PLG2 039 687 CAP, twistlock - grounded 2P3W 3

35 PLG3 039 635 CONNECTOR BODY, twistlock 2P2W 3

36 023 606 CORD SET, 115 volts 16 ga 2/c 600 volts 1

*Recommended Spare Parts.

tWhen ordering a component originally displaying a precautionary label, the label should also be ordered.

BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.

OM-854 Page 2

Page 14: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY

Figure B - Contactor

*Recommended Spare Parts.

BE SURE TO PROVIDE MODEL WHEN ORDERING REPLACEMENT PARTS.

Item

No.

FactoryPart No. Description

Figure B 048 597 Contactor (See Fig. A Page 2 Item 13)

Quantity

41

41-~

048 599 COIL contactor 120/240 volts 1

42 048 600 KIT, point - contactor 3

421

18-034 909

/I

42

Page 3

Page 15: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY
Page 16: o854 mil - Miller - Welding Equipment(! furnished by Miller is free from defect in workmanship and In the case of Miller™s breach of warranty or any other duty ... AND ANY REMEDY