Miller RFCS-5 User manual

OM-844 183 973G

6/2004

Visit our website at

www.MillerWelds.com

RFCS-5, RFCS-5HD, RFCS-6M,

RFCS-14, And RFCS-14HD

Foot Controls

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor to receive the latest full

line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

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.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001:2000 Quality

System Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 7/03

TABLE OF CONTENTS

SECTION 1 − INSTALLATION AND OPERATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Typical Connection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Remote Amperage Control For Welding Power Source Without

Remote Control Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Remote Amperage Control For Welding Power Source With Remote Control Switch

But Without Output (Contactor) Control 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Remote Amperage Control For Welding Power Source With Remote Control Switch

And Output (Contactor) Control 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Adjusting Potentiometer Timing 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. Changing Cord Location On RFCS-5HD, And RFCS-14HD Models 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − ELECTRICAL DIAGRAMS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − PARTS LIST 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-844 Page 1

SECTION 1 − INSTALLATION AND OPERATION

READ SAFETY BLOCKS in welding power

source Owner’s Manual before proceeding.

WARNING

1-1. Typical Connection

Ref. 801 736

Turn Off welding power source.

1 Foot Control

2 Remote 14, Remote 5, Or

Remote 6 Receptacle

Insert plug into matching 14-sock-

et, 5-socket, or 6-socket recep-

tacle, as applicable, on welding

power source. Tighten collar.

1-2. Remote Amperage Control For Welding Power Source Without

Remote Control Switch

Ref. 155 790-E

0 A DC

Off

Select Maximum

Amperage Percentage.

Select Weld Process Select Range And Polarity

33 A DC

Combination Front Panel

And

Remote Control

Approximately

50% = Approx. 33 A DC

Press pedal lightly to turn

weld output and gas flow

on. Press pedal further to

increase weld output.

Release pedal to turn off

weld output and gas flow.

OM-844 Page 2

1-3. Remote Amperage Control For Welding Power Source With Remote Control Switch

But Without Output (Contactor) Control

.See welding power source

Owner’s Manual to determine

if Remote Foot Control works

as a combination or as full Am-

peragecontrol.

Ref. 122 023-A / Ref. 141 127-A / 039 411-D

EXAMPLE Of Full Remote Amperage Control

Set Switch

In Example:

Min = 30 A In Range A or 40 A In

Range B (Unit Minimum)

Max = 95 A In Range A or 200 A In

RangeB (Control Setting)

Control Setting

Does Not Matter

Unit Maximum

In Example:

Min = 30 A In Range A or 40 A

In Range B (Unit Minimum)

Max = 225 A In Range A or 375 A In

RangeB (Unit Maximum)

Unit Minimum

Control Setting

Set Desired Maximum

Amperage For Application

Set Switch

Press pedal to increase weld

output. Release pedal to

decreaseweld output.

Press pedal to increase weld

output. Release pedal to

decreaseweld output.

Example Of Combination Front Panel

And Remote Amperage Control

OM-844 Page 3

1-4. Remote Amperage Control For Welding Power Source With Remote Control Switch

And Output (Contactor) Control

.See welding power source

Owner’s Manual to determine

if Remote Foot Control works

as a combination or as full Am-

peragecontrol.

Ref. 114 018 / Ref. 801 736

0On

Off

0On

Off

EXAMPLE Of Full Remote Amperage Control

Control Setting

Does Not Matter

Set Switch Set Switch

Set Control

Set Switch Set Switch

Combination Front Panel

And

Remote Control

Control

Setting

(150 A)

Unit

Maximum

Press pedal lightly to turn weld

outputand gas flow on. Press

pedal further to increase weld

output. Release pedal to turn

off weld output and gas flow.

Press pedal lightly to turn weld

outputand gas flow on. Press

pedal further to increase weld

output. Release pedal to turn

off weld output and gas flow.

Example Of Combination Front Panel

And Remote Amperage Control

OM-844 Page 4

1-5. Adjusting Potentiometer Timing

Disconnect foot control from weld-

ing power source/generator.

Turn unit upside down, and remove

bottomplate.

1 Label

2 Gear

Turn gear on potentiometer shaft

counterclockwise as far as

possible.

Pull drive belt tight and mesh belt

teethwith gear teeth.

Connect free end of small spring

into end of drive belt.

Reinstall bottom plate

BEFORERE−INSTALLINGBELT,TURNGEARALL

THEWAYTOTHESTOP.

ANTESDEVOLVERAINSTALARLACORREADÉ

VUELTAALENGRANAJETODOLONECESARIO

HASTAQUESEDETENGA.

AVANTDEREPOSERLACOURROIE,FAIRE

PIVOTERL’AXEJUSQU’ÀLABUTÉE.

218006−A

1-6. Changing Cord Location On RFCS-5HD, And RFCS-14HD Models

Disconnect foot control from weld-

ing power source/generator.

1 Bottom Plate

Turn unit upside down, and remove

bottomplate.

Removescrew that holds cord in its

factory installed location.

2 Cord Slots

Position cord in desired slot.

Slide strain relief down cord and

into slot to protect cord. Secure

cord with screw in the same man-

ner in which it came from the

factory.

Reinstallbottom plate

OM-844 Page 5

SECTION 2 − ELECTRICAL DIAGRAMS

183 957-B

Circuit Diagram For RFCS-5, RFCS-5HD, RFCS-14, And RFCS-14HD Models

Circuit Diagram For RFCS-6M Models 208 615-B

OM-844 Page 6

SECTION 3 − PARTS LIST

ST-801 735-A

11 13 89

Quantity

Description

Part

No.

Dia.

Mkgs.

Item

No. 14 14HD

RFCS Models

6M5HD5

1 182 030 Belt 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 185 929 Pedal / housing / bottom 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 198 036 Bottom Plate 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 182 627 Spring 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 S1 183 629 Switch, limit 10A 125/250V 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 186 476 Cable Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 212 644 Cable Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 208 621 Cable Control 13’-3” (4 m) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 219993 Cable Control 20’ (6 m) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 182 628 Cable Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 199 405 Cable Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PGL1 131 204 Connector & Sockets 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 175 284 Cable 21’ 21’ 21’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 199 410 Cable 21’ 21’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 409 Strain Relief 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PLG2 039 273 Connector & Sockets 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 685 Connector, clamp str 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PLG2 144 310 Connector & Sockets 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143 922 Connector, clamp str 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 182 626 Spring 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 R1 183 956 Potentiometer 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 RC1 131 203 Connector & Sockets 1 1 1 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 C1, 2 028 291 Capacitor 2 2 2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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