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-141 294-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. 1994 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 54912 414-734-9821 PRINTED IN USA
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.................................................... 1 SECTION 2 SPECIFICATIONS.......................................................... 1 SECTION 3 INSTALLATION............................................................ 2 SECTION 4 OPERATION 4-1. Adjusting Amperage Or Voltage Without Output (Contactor) Control.................. 4 4-2. Adjusting Amperage Or Voltage With Output (Contactor) Control..................... 5 SECTION 5 MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance........................................................... 6 5-2. Troubleshooting............................................................... 6 SECTION 6 ELECTRICAL DIAGRAMS................................................... 7 SECTION 7 PARTS LIST Figure 7-1. Complete Assembly........................................................ 10 OM-826H 3/94
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. 5 6 7 1 2 2 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
SECTION 3 INSTALLATION Inches Millimeters A 7-1/2 190 B 6-1/4 159 C 11 279 A B C Ref ST-141 294-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 3 2 3 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 3-1. 4 14- 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. 1 2 5 3 ST-800 096 OM-826 Page 2 Figure 3-2. Interconnections
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. 14 21 to 100 ft (6 to 30 m) (GD Models) No. 12 21 to 50 ft (6 to 15 m) No. 14 Up to 200 ft (61 m) No. 16 51 to 100 ft (16 to 31 m) No. 12 101 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
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-122 023-A / Ref. ST-141 127-A / ST-039 411-D Figure 4-1. Examples Of Amperage Or Voltage Adjustment Without Output (Contactor) Control OM-826 Page 4
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-159 059 Figure 4-2. Examples Of Amperage Or Voltage Adjustment With Output (Contactor) Control OM-826 Page 5
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* 2/93 5-1. 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
SECTION 6 ELECTRICAL DIAGRAMS SA-130 542 / SA-130 512 Figure 6-1. Circuit And Wiring Diagram For RFC-14 SA-162 462 Figure 6-2. Circuit Diagram For RFC-23A OM-826 Page 7
SA-162 463 Figure 6-3. Circuit Diagram For RFC-23AG SA-162 464 OM-826 Page 8 Figure 6-4. Circuit Diagram For RFCS-23
SA-162 465 Figure 6-5. Circuit Diagram For RFC-23GD25A OM-826 Page 9
SECTION 7 PARTS LIST 8 10 9 1 2 7 6 3 4 5 11 12 13 14 31 17 30 27 26 17 18 19 16 15 29 25 24 23 20 21 28 22 ST-145 917-B Figure 7-1. Complete Assembly OM-826 Page 10
Item No. Dia. Mkgs. Part No. Description Quantity Model Figure 7-1. Complete Assembly RFC-23A RFC-23AG RFC-14 RFC-23GD25A RFCS-23... 1.... 601 970.. SCREW, cap stl hex hd.375-24 x 4.500........ 1...... 1..... 1..... 1.... 1... 2.... 019 662.. PEDAL, foot................................ 1...... 1..... 1............ 1... 2.... 009 490.. PEDAL, foot....................................................... 1... 3.... 010 789.. SPRING, torsion............................. 1...... 1..... 1..... 1.... 1... 4... +159 894.. CASE SECTION, cover/end................... 1...... 1..... 1..... 1.... 1.......... 085 220.. LABEL, caution electric circuit etc.............. 1...... 1..... 1..... 1.... 1... 5.... 115 104.. CONNECTOR, clp - cable.500................ 1...... 1............ 1.......... 000 527.. BLANK, snap-in nyl.875mtg hole.............................. 1............ 1... 6.... 053 786.. CORD SET, pwr 115V 16ga 2/c 20ft............ 1... 6.... 600 733.. CORD SET, pwr 115V 16ga 3/c 20ft..................... 1... 6.... 136 823.. CORD SET, pwr 115V 16ga 2/c....................................... 1... 7.... 039 618.. PLUG, twlk 2P 2W 20A 250V................. 1.................... 1... 7.... 035 494.. PLUG, twlk grd 2P 3W 15A 250V....................... 1... 8.... 600 343.. CABLE, port No 16 5/c (order by ft)........................... 20ft......... 21ft... 9.... 039 273.. PLUG, 5 pin MS3106A-16S-8P.............................................. 1... 9.... 141 162.. HOUSING PLUG & PINS, (consisting of)....................... 1.......... 134 731.... TERMINAL, male 1 pin 18-14 wire.......................... 14... 10.... 079 739.... CLAMP, cable strain relief................................... 1... 10.... 039 685.. CLAMP, cable AN-3057-8................................................... 1... 11.... 605 797.. PLUG, twlk 3P 3W 20A 125V................. 1...... 1... 11.... 039 621.. PLUG, twlk 4P 4W 20A 250V........................................ 1... 12.... 600 733.. CORD SET, pwr 115V 16ga 3/c 20ft............ 1...... 1... 12.... 604 834.. CORD, port No 14 4/c (order by ft)................................... 26ft... 13.... 139 041.. BUSHING, strian relief.455/.629 ID............ 1...... 1..... 1..... 1.... 1... 14.... 014 920.. CASE SECTION, base/side................... 1...... 1..... 1..... 1.... 1... 15.... 019 663.. MOUNT, nprn............................... 4...... 4..... 4..... 4.... 4... 16.... 011 628.. SWITCH, limit 15A 125V..................... 1...... 1..... 1............ 1... 16.... 603 947.. SWITCH, limit 10A 125V............................................ 1... 17.... 159 897.. SCREW, shld stl sch.250-20 x.437............ 1...... 1..... 1..... 2.... 1... 18.... 159 895.. BAR,pedal - control foot...................... 1...... 1..... 1..... 1.... 1... 19.... 010 795.. ACTUATOR, switch - limit.................... 1...... 1..... 1..... 1.... 1... 20.... 159 892.. BRACKET, support - arm..................... 1...... 1..... 1..... 1.... 1... 21.... 159 893.. ARM, brush holder........................... 1...... 1..... 1..... 1.... 1... 22.... 604 432.. SCREW, cap stl sch 8-32 x 1.000.............. 1...... 1..... 1..... 1.... 1... 23.... 018 639.. HOLDER, brush............................. 1...... 1..... 1..... 1.... 1... 24... *018 640.. BRUSH, contact............................. 1...... 1..... 1..... 1.... 1... 25.... 161 306.. CAP, brush holder........................... 1...... 1..... 1..... 1.... 1... 26.... 079 625.. WASHER, spring stl.500 shakeproof........... 2...... 2..... 2..... 2.... 2... 27.... 159 896.. SCREW, shld stl sch.312-18 x.375............ 1...... 1..... 1..... 1.... 1... 28.... 601 795.. BOLT, mach stl hexhd.250-20 x 4.500.......... 1...... 1..... 1..... 2.... 1... 29.... 030 631.. RESISTOR, WW adj 130W 15 ohm............ 1...... 1... 29.... 030 051.. RESISTOR, WW adj 130W 1000 ohm.......................... 1............ 1... 29.... 004 652.. RESISTOR, WW adj 300W 25 ohm................................... 1... 30.... 601 855.. NUT, weld.250-20........................... 1...... 1..... 1..... 1.... 1... 31.... 601 850.. NUT, weld stl slflkg hex.375-24................ 1...... 1..... 1..... 1.... 1..................... NAMEPLATE (order by model number)......... 1...... 1 +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