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.
12
1-2. Remote Amperage Control For Welding Power Source Without
Remote Control Switch
Ref. 155 790-E
On
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
OR
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
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
2
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
1
2

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
12
57
6
3
10
11 13 89
12
2
4
2
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .