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OWNER’S
MANUAL
RC-4
Remote Voltage Control
Used With Dual Wire Feeder And A Welding Power Source
Read and follow these instructions and all Give this manual to the operator.
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit. For help, call your distributor
Call your distributor if you do not understand or: MILLER Electric Mfg. Co., P.O. Box 1079,
the directions. Appleton, WI 54912 414-734-9821
cover 7/93 – Ref. ST-128 782-A 1993 MILLER Electric Mfg. Co. PRINTED IN USA
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
Working as hard as you do
This Owner’s Manual is designed to help you get the most out of your – every power source from
Miller is backed by the most
Miller products. Please take time to read the Safety precautions. They will hassle-free warranty in the
help you protect yourself against potential hazards on the worksite. We’ve business.
SECTION 2 – SPECIFICATIONS
2-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-895A - 11/93
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY The following safety alert symbol and signal words are
used throughout this manual to call attention to and
A. General identify different levels of hazard and special instruc-
Information presented in this manual and on various la- tions.
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and This safety alert symbol is used with the signal
troubleshooting which should be read, understood, and words WARNING and CAUTION to call atten-
followed for the safe and effective use of this equipment. tion to the safety statements.
B. Safety
The installation, operation, maintenance, and trouble- WARNING statements identify procedures or
practices which must be followed to avoid seri-
shooting of arc welding equipment requires practices ous personal injury or loss of life.
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
stalled, operated, and maintained only by qualified per- CAUTION statements identify procedures or
sons in accordance with this manual and all applicable practices which must be followed to avoid minor
codes such as, but not limited to, those listed at the end personal injury or damage to this equipment.
of Arc Welding Safety Precautions in the welding power
source Owner’s Manual.
IMPORTANT statements identify special instructions
1-2. SAFETY ALERT SYMBOL AND SIGNAL necessary for the most efficient operation of this equip-
WORDS ment.
SECTION 2 – SPECIFICATIONS
11-1/2 in.
(292 mm)
3-7/8 in.
(98 mm)
10-1/4 in.
(260 mm)
ST-128 782-A
WARNING: ELECTRIC SHOCK can kill. 3. Slide remote control unit down onto screws.
• Do not touch live electrical parts. 4. Tighten the wire feeder wrapper screws.
• Shut down welding power source and wire
feeder, and disconnect input power employ- 3-2. CONNECTIONS TO WIRE FEEDER (Figure 3-1
ing lockout/tagging procedures before in- And Figure 3-2)
specting or installing.
1. Connect 4-socket Amp 115 Volts AC/Contactor
Lockout/tagging procedures consist of pad- Control plug to 115 Volts/Contactor receptacle on
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off rear of wire feeder control as follows: align keyway,
and red-tagging circuit breaker or other discon- insert plug, and rotate threaded collar fully clock-
necting device. wise.
2. Connect 4-pin Amp Right Contactor Control plug to
Right Contactor Control receptacle on rear of wire
3-1. INSTALLATION feeder control as follows: align keyway, insert plug,
The remote control unit is designed to mount on top of and rotate threaded collar fully clockwise.
the dual wire feeder. To install the unit, proceed as fol-
lows: 3-3. CO NNE CT I O NS TO WE L DI NG PO W E R
SOURCE (Figure 3-1 And Figure 3-2)
1. Place unit on top of wire feeder with front panels fac-
Connect 14-pin Amp 115 Volts AC/Contactor/Remote
ing same direction.
Voltage Control plug to Control receptacle on front of
2. Loosen wire feeder wrapper screws (4) that match welding power source as follows: align keyway, insert
the remote control unit wrapper screw slots. plug, and rotate threaded collar fully clockwise.
Right Contactor
Control Plug
ST-128 716-A
OM-895 Page 2
Right Contactor 115 VAC/Contactor/
Control Remote Voltage
Welding Power Control
Source
REAR VIEW
RC-4
115 Volts AC
Contactor Control
Dual Wire
Feeder
Motor Control
RC-4
FRONT VIEW
SA-128 780
WARNING: ELECTRIC SHOCK can kill; 5-1. GAS METAL ARC AND FLUX CORED ARC
MOVING PARTS can cause serious injury; WELDING (GMAW And FCAW)
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts. WARNING: Read and follow safety informa-
• Do not touch live electrical parts. tion at beginning of entire Section 5 before
proceeding.
• Keep all covers and panels in place while
operating. 1. Install and prepare welding power source according
Warranty is void if the unit is operated with any to its Owner’s Manual.
portion of the outer enclosure removed. 2. Install and prepare wire feeder according to it Own-
er’s Manual.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage 3. Install remote control unit as instructed in Section 3.
hearing.
• Wear correct eye, ear, and body protection. 4. Wear dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
FUMES AND GASES can seriously harm ANSI Z49.1.
your health.
5. Prepare for welding as follows:
• Keep your head out of the fumes.
• Ventilate to keep from breathing fumes and
a. Connect work clamp to clean, bare metal at
workpiece.
gases.
• If ventilation is inadequate, use approved b. Select and obtain proper welding wire, and
breathing device. thread as instructed in wire feeder Owner’s
Manual.
WELDING WIRE can cause puncture
wounds. 6. Rotate the Wire Speed controls to the desired posi-
• Do not point gun toward any part of the body, tions.
any conductive surface, or other personnel. 7. Rotate the remote control VOLTAGE controls to the
desired positions.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns. 8. Place the output voltage control on the welding
• Watch for fire. power source in its maximum position.
• Keep a fire extinguisher nearby, and know 9. Turn on shielding gas supply.
how to use it.
• Do not use near flammable material.
10. Energize the welding power source and wire feeder.
6-1. ROUTINE MAINTENANCE (Table 6-1) maintained in a clearly readable state and replaced
IMPORTANT: Every six months inspect the labels on when necessary. See Parts List for part number of
this unit for legibility. All precautionary labels must be precautionary labels.
OM-895 Page 4
WARNING: ELECTRIC SHOCK can kill. Every six months, inspect all interconnecting cords and
• Do not touch live electrical parts. plugs for damage to the insulation jacket. Repair or re-
• Shut down welding power source and wire place the cord(s) as necessary.
feeder, and disconnect input power employ-
ing lockout/tagging procedures before in-
specting, maintaining, or servicing. 6-2. TROUBLESHOOTING
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off WARNING: ELECTRIC SHOCK can kill.
and red-tagging circuit breaker or other discon-
necting device.
• Do not touch live electrical parts.
MOVING PARTS can cause serious injury. • Shut down welding power source and wire
• Keep away from moving parts. feeder, and disconnect input power employ-
ing lockout/tagging procedures before in-
HOT SURFACES can cause severe burns. specting, maintaining, or servicing.
• Allow cooling period before servicing. Lockout/tagging procedures consist of pad-
Maintenance to be performed only by qualified locking line disconnect switch in open position,
persons. removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
Table 6-1. Maintenance Schedule necting device.
Frequency* Maintenance MOVING PARTS can cause serious injury.
Every month. Units in heavy service environ-
• Keep away from moving parts.
ments: HOT SURFACES can cause severe burns.
Check labels and interconnect- • Allow cooling period before servicing.
ing cords.
Maintenance to be performed only by qualified
Every 6 months. Check all labels (see IMPORT- persons.
ANT block, Section 6-1) and inter-
connecting cords.
If this remote control unit does not set the desired volt-
*Frequency of service is based on units operated ages, check all interconnections and switch positions on
40 hours per week. Increase frequency of maint- wire feeder and welding power source, and correct all
enance if usage exceeds 40 hours per week. connection or position errors.
Dia. Part
Mkgs. No. Description Quantity
Complete Assembly
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-895 Page 6
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate 185 & Spoolmate 250
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.
miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier for: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.