OWNER S MANUAL. RFC-14, RFC-23A, RFC-23AG, RFCS-23, And RFC-23GD25A

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1 March 1994 Form: OM-826H Effective With Style No. KD27 OWNER S MANUAL RFC-14, RFC-23A, RFC-23AG, RFCS-23, And RFC-23GD25A Remote Foot Controls For Remote Amperage, Voltage, And Output (Contactor) Control For SMAW And GTAW Welding 20 ft (6 m) Interconnecting Cord cover 1/94 Ref. ST A Read and follow these instructions and all safety blocks carefully. Have only trained and qualified persons install, operate, or service this unit. Call your distributor if you do not understand the directions MILLER Electric Mfg. Co. Give this manual to the operator. For help, call your distributor or: MILLER Electric Mfg. Co., P.O. Box 1079, Appleton, WI PRINTED IN USA

3 NOTE EMF INFORMATION Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989):... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks. To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around the body. 4. Keep welding power source and cables as far away as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information. mod10.1 4/93 TABLE OF CONTENTS SECTION 1 SAFETY INFORMATION SECTION 2 SPECIFICATIONS SECTION 3 INSTALLATION SECTION 4 OPERATION 4-1. Adjusting Amperage Or Voltage Without Output (Contactor) Control Adjusting Amperage Or Voltage With Output (Contactor) Control SECTION 5 MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Troubleshooting SECTION 6 ELECTRICAL DIAGRAMS SECTION 7 PARTS LIST Figure 7-1. Complete Assembly OM-826H 3/94

4 SECTION 1 SAFETY INFORMATION mod1.1 2/93 Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION WARNING NOTE ELECTRIC SHOCK can kill. Do not touch live electrical parts. Disconnect input power before installing or servicing. WARNING 3 4 CAUTION READ SAFETY BLOCKS at start of Section 3-1 before proceeding. Turn Off switch when using high frequency. MOVING PARTS can injure. Keep away from moving parts. Keep all panels and covers closed when operating. 1 Safety Alert Symbol 2 Signal Word WARNING means possible death or serious injury can happen. CAUTION means possible minor injury or equipment damage can happen. 3 Statement Of Hazard And Result 4 Safety Instructions To Avoid Hazard 5 Hazard Symbol (If Available) 6 Safety Banner Read safety blocks for each symbol shown. 7 NOTE Special instructions for best operation not related to safety. Figure 1-1. Safety Information SECTION 2 SPECIFICATIONS Table 2-1. Remote Foot Control Specification Description Model Description RFC: Remote Foot Control Interconnecting Cord 20 ft ( 6 m) Overall Dimensions See Figure 3-1 OM-826 Page 1

5 SECTION 3 INSTALLATION Inches Millimeters A 7-1/2 190 B 6-1/4 159 C A B C Ref ST A Figure 3-1. Overall Dimensions Turn Off welding power source, or stop engine on welding generator. 1 1 Welding Power Source Or Generator 2 Remote Foot Control 4 OR Interconnecting Cord(s) Units are equipped with a 20 ft (6 m) multiconductor cord(s) (unless otherwise specified). If a longer cord is required, see Table Or 5-Pin Amphenol Plug Insert plug into matching receptacle on welding power source or welding generator, and tighten threaded collar. 5 Twistlock Plugs Insert plugs into matching receptacles on welding power source or welding generator, and tighten cap clockwise as far as it will go ST OM-826 Page 2 Figure 3-2. Interconnections

6 Table 3-1. Interconnecting Cord Conductor Length And Size Amperage Or Voltage Control Contactor Control Cord Length Conductor Size* Cord Length Conductor Size* Up to 20 ft (6 m) No. 16 Up to 20 ft (6 m) (GD Models) No to 100 ft (6 to 30 m) (GD Models) No to 50 ft (6 to 15 m) No. 14 Up to 200 ft (61 m) No to 100 ft (16 to 31 m) No to 200 ft (31 to 61 m) No. 10 *AWG American Wire Gauge SECTION 4 OPERATION WARNING ELECTRIC SHOCK can kill. Always wear dry insulating gloves. Insulate yourself from work and ground. Do not touch live electrical parts. Keep all panels and covers securely in place. FUMES AND GASES can be hazardous to your health. Keep your head out of the fumes. Ventilate area, or use breathing device. Read Material Safety Data Sheets (MSDSs) and manufacturer s instructions for material used. WELDING can cause fire or explosion. Do not weld near flammable material. Watch for fire; keep extinguisher nearby. Do not locate unit over combustible surfaces. Do not weld on closed containers. Allow work and equipment to cool before handling. ARC RAYS can burn eyes and skin; NOISE can damage hearing. Wear welding helmet with correct shade of filter. Wear correct eye, ear, and body protection. MAGNETIC FIELDS FROM HIGH CUR- RENTS can affect pacemaker operation. Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. See Safety Precautions at beginning of welding power source or welding generator manual for basic welding safety information. swarn6.1* 10/91 NOTE See welding power source or welding generator Owner s Manual to determine if Remote Foot Control will act as a fine Amperage or Voltage control, or as a full range Amperage or Voltage control. OM-826 Page 3

7 4-1. Adjusting Amperage Or Voltage Without Output (Contactor) Control EXAMPLE Of Fine Remote Amperage Control Without Output (Contactor) Control Min (40 A) Max (Control Setting, 200 A) In Example: Min = 40 A In Range B Max = 200 A In Range B (Control Setting) Set Switch Set Desired Max. Amperage Press Control To Adjust Amperage For Application EXAMPLE Of Full Remote Amperage Control Without Output (Contactor) Control Or Min (40 A) Unit Maximum (375 A) In Example: Min = 40 A In Range B Max = 375 A In Range B Set Switch Control Setting Press Control To Adjust Amperage Does Not Matter Ref. ST A / Ref. ST A / ST D Figure 4-1. Examples Of Amperage Or Voltage Adjustment Without Output (Contactor) Control OM-826 Page 4

8 4-2. Adjusting Amperage Or Voltage With Output (Contactor) Control WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Do not touch weld output terminals when contactor is energized. Do not touch electrode and work clamp at the same time. swarn7.1 10/91 EXAMPLE Of Fine Remote Amperage/Voltage Control With Output (Contactor) Control Unit Minimum On Control Setting (200 A or 24 V) Off Set Switches Set Control Press control to turn weld output On. Release control to turn weld output Off. EXAMPLE Of Full Remote Amperage/Voltage Control With Output (Contactor) Control Or Unit Minimum On Unit Maximum (375 A or 36 V) Off Set Switches Control Setting Does Not Matter Press control to turn weld output On. Release control to turn weld output Off. Ref. ST Figure 4-2. Examples Of Amperage Or Voltage Adjustment With Output (Contactor) Control OM-826 Page 5

9 SECTION 5 MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn Off welding power source, and disconnect remote control before inspecting, maintaining, or servicing. Stop engine on welding generator. HOT PARTS can cause severe burns. Allow cooling period before maintaining or servicing. Maintenance to be performed only by qualified persons. swarn8.1* 2/ Routine Maintenance Turn Off all power before maintaining. 3 Months Everyday Move Control From Min To Max 14-Pin Cord Replace Cracked Parts Replace Unreadable Labels Figure 5-1. Maintenance Schedule 5-2. Troubleshooting Table 5-1. Welding Trouble Trouble Remedy Section No amperage or voltage control. Set switches and controls on welding power source or generator. 4-1, 4-2, * Be sure welding power source Power switch is On. Secure cord connections or replace cords, if necessary. Figure 3-2 No output (contactor) control. Set switch on welding power source or generator. 4-2, * Be sure welding power source Power switch is On. Secure cord connections or replace cords, if necessary. Figure 3-2 *See welding power source or generator Owner s Manual. OM-826 Page 6

10 SECTION 6 ELECTRICAL DIAGRAMS SA / SA Figure 6-1. Circuit And Wiring Diagram For RFC-14 SA Figure 6-2. Circuit Diagram For RFC-23A OM-826 Page 7

11 SA Figure 6-3. Circuit Diagram For RFC-23AG SA OM-826 Page 8 Figure 6-4. Circuit Diagram For RFCS-23

12 SA Figure 6-5. Circuit Diagram For RFC-23GD25A OM-826 Page 9

13 SECTION 7 PARTS LIST ST B Figure 7-1. Complete Assembly OM-826 Page 10

14 Item No. Dia. Mkgs. Part No. Description Quantity Model Figure 7-1. Complete Assembly RFC-23A RFC-23AG RFC-14 RFC-23GD25A RFCS SCREW, cap stl hex hd x PEDAL, foot PEDAL, foot SPRING, torsion CASE SECTION, cover/end LABEL, caution electric circuit etc CONNECTOR, clp - cable BLANK, snap-in nyl.875mtg hole CORD SET, pwr 115V 16ga 2/c 20ft CORD SET, pwr 115V 16ga 3/c 20ft CORD SET, pwr 115V 16ga 2/c PLUG, twlk 2P 2W 20A 250V PLUG, twlk grd 2P 3W 15A 250V CABLE, port No 16 5/c (order by ft) ft ft PLUG, 5 pin MS3106A-16S-8P HOUSING PLUG & PINS, (consisting of) TERMINAL, male 1 pin wire CLAMP, cable strain relief CLAMP, cable AN PLUG, twlk 3P 3W 20A 125V PLUG, twlk 4P 4W 20A 250V CORD SET, pwr 115V 16ga 3/c 20ft CORD, port No 14 4/c (order by ft) ft BUSHING, strian relief.455/.629 ID CASE SECTION, base/side MOUNT, nprn SWITCH, limit 15A 125V SWITCH, limit 10A 125V SCREW, shld stl sch x BAR,pedal - control foot ACTUATOR, switch - limit BRACKET, support - arm ARM, brush holder SCREW, cap stl sch 8-32 x HOLDER, brush * BRUSH, contact CAP, brush holder WASHER, spring stl.500 shakeproof SCREW, shld stl sch x BOLT, mach stl hexhd x RESISTOR, WW adj 130W 15 ohm RESISTOR, WW adj 130W 1000 ohm RESISTOR, WW adj 300W 25 ohm NUT, weld NUT, weld stl slflkg hex NAMEPLATE (order by model number) 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-826 Page 11

General Installation Instructions

General Installation Instructions WARNING To reduce the risk of death, injury or property damage from fire, electric shock, cuts, abrasions, falling parts and other hazards: Service of the equipment must