Miller SUITCASE 12RC Bedienungsanleitung

SuitCase 12RC

TM-1500-15D 2006−06

Eff. w/Serial LC323926

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Wire Feeder

File: MIG (GMAW)

Visit our website at

www.MillerWelds.com

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR SERVICING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Servicing Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. California Proposition 65 Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. EMF Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 −DEFINITIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Warning Label Definitions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. WEEE Label 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Manufacturer’s Rating Label For CE Products 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Symbols And Definitions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 −INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. 14-Pin Plug Information 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Gun Recommendation Table 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Equipment Connection Diagram 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing And Aligning Wire Guide And Drive Rolls 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Connecting Welding Gun 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting Shielding Gas 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Connecting Weld Cable 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Installing And Threading Welding Wire 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 −OPERATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Setting Digital Meter Board PC4 DIP Switches 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Gun Consumables Information 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 −THEORY OF OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 −TROUBLESHOOTING 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Table 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Troubleshooting Circuit Diagram For Wire Feeder 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Motor Control Board PC1 Testing Information 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Motor Control Board PC1 Test Point Values 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Optional Trigger Hold Board PC30 Testing Information 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Optional Trigger Hold Board PC30 Test Point Values 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Optional Meter Board PC4 Testing 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Optional Meter Board PC4 Test Point Values 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 −MAINTENANCE 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Overload Protection And Thermostat Protection 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 −ELECTRICAL DIAGRAMS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 −PARTS LIST FOR LC323926 THRU LC569569 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 −PARTS LIST FOR LC569570 THRU LF232631 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 −PARTS LIST FOR LF232632 AND FOLLOWING 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dec_wire_6/05

Declaration of Conformity for

European Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).

NOTE

Manufacturer:European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,

1635 W. Spencer St. Managing Director

Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.

Phone: (920) 734-9821 Via Privata Iseo 6/E

20098 San Giuliano

Milanese, Italy

Phone: 39(02)98290-1

Fax: 39(02)98290203

European Contact Signature:

Declares that the product: SuitCase 12RC

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic Compatibility (EMC) Directive: 89/336/EEC

Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC

Standards

Arc Welding Equipment −Part 5: Wire Feeders. IEC 60974-5 Ed. 1

Arc Welding Equipment −Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002

Arc Welding Equipment −Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1

Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1

Insulation Coordination For Equipment Within Low-Voltage Systems −

Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1

The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

TM-1500-15 Page 1SuitCase 12RC

SECTION 1 −SAFETY PRECAUTIONS FOR SERVICING

YWarning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

OM-1500-15Q, safety_stm 3/06

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

YMarks a special safety message.

.Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Servicing Hazards

YThe symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard.

YOnly qualified persons should service, test, maintain, and re-

pair this unit.

YDuring servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

DDo not touch live electrical parts.

DTurn Off welding power source and wire feeder

and disconnect and lockout input power using

line disconnect switch, circuit breakers, or by removing plug from re-

ceptacle, or stop engine before servicing unless the procedure spe-

cifically requires an energized unit.

DInsulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

DDo not leave live unit unattended.

DIf this procedure requires an energized unit, have only personnel

familiar with and following standard safety practices do the job.

DWhen testing a live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

DDisconnect input power conductors from deenergized supply line

BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

DTurn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Troubleshooting Section be-

fore touching any parts.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

DUse proper static-proof bags and boxes to

store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

DDo not place unit on, over, or near combustible

surfaces.

DDo not service unit near flammables.

FLYING METAL or DIRT can injure eyes.

DWear safety glasses with side shields or face

shield during servicing.

DBe careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllow cooling period before working on

equipment.

DTo handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

EXPLODING PARTS can cause injury.

DFailed parts can explode or cause other parts to

explode when power is applied to inverters.

DAlways wear a face shield and long sleeves

when servicing inverters.

SHOCK HAZARD from testing.

DTurn Off welding power source and wire feeder

or stop engine before making or changing me-

ter lead connections.

DUse at least one meter lead that has a self-

retaining spring clip such as an alligator clip.

DRead instructions for test equipment.

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

DUse equipment of adequate capacity to lift and

support unit.

DIf using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

TM-1500-15 Page 2 SuitCase 12RC

MOVING PARTS can cause injury.

DKeep away from moving parts such as fans.

DKeep away from pinch points such as drive

rolls.

DHave only qualified persons remove doors,

panels, covers, or guards for maintenance as

necessary.

DKeep hands, hair, loose clothing, and tools

away from moving parts.

DReinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

MAGNETIC FIELDS can affect pacemakers.

DPacemaker wearers keep away from servicing

areas until consulting your doctor.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before

starting to weld again.

DDo not block or filter airflow to unit.

H.F. RADIATION can cause interference.

DHigh-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

DHave only qualified persons familiar with

electronic equipment install, test, and service

H.F. producing units.

DThe user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

DIf notified by the FCC about interference, stop using the

equipmentat once.

DHave the installation regularly checked and maintained.

DKeep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

READ INSTRUCTIONS.

DUse Testing Booklet (Part No. 150 853) when

servicing this unit.

DConsult the Owner’s Manual for welding safety

precautions.

DUse only genuine replacement parts from the

manufacturer.

1-3. California Proposition 65 Warnings

YWelding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

YBattery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductiveharm. Wash hands after handling.

For Gasoline Engines:

YEngine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

YDiesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

1-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

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 your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor before welding or going near

welding operations. If cleared by your doctor, then following the above

procedures is recommended.

TM-1500-15 Page 3SuitCase 12RC

SECTION 2 −DEFINITIONS

2-1. Warning Label Definitions

1 1.1 1.2 1.3

3 3.1 3.2 3.3

4 4.1 +

22.1 2.2

2.3

S-178 936

Warning! Watch Out! There are

possible hazards as shown by the

symbols.

Drive rolls can injure fingers

Welding wire and drive parts are at

welding voltage during operation −

keep hands and metal objects

clear.

1 Electric shock can kill.

1.1 Wear dry insulating gloves.

Do not touch electrode with

bare hand. Do not wear wet or

damaged gloves.

1.2 Protect yourself from electric

shock by insulating yourself

from work and ground.

1.3 Disconnect input plug or

power before working on

machine.

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the

fumes.

2.2 Use forced ventilation or local

exhaust to remove the fumes.

2.3 Use ventilating fan to remove

fumes.

3 Welding sparks can cause

explosion or fire.

3.1 Keep flammables away from

welding. Don’t weld near

flammables.

3.2 Welding sparks can cause

fires. Have a fire extinguisher

nearby and have a watch

person ready to use it.

3.3 Do not weld on drums or any

closed containers.

4 Arc rays can burn eyes and

injure skin.

4.1 Wear hat and safety glasses.

Use ear protection and button

shirt collar. Use welding

helmet with correct shade of

filter. Wear complete body

protection.

5 Become trained and read the

instructions before working on

the machine or welding.

6 Do not remove or paint over

(cover) the label.

TM-1500-15 Page 4 SuitCase 12RC

2-2. WEEE Label

Do not discard this product with

general waste.

Reuse or recycle Waste Electrical

and Electronic Equipment (WEEE)

by disposing at a designated collec-

tion facility.

Contact your local recycling office

or your local distributor for further

information.

2-3. Manufacturer’s Rating Label For CE Products

ST-181 678

For label location

see Section 4-1.

S/N:

IP 23

VAX%

I1=

=I2=

100

7.0

100 500 100

2-4. Symbols And Definitions

Some symbols are found only on CE products.

NOTE

Output Input AAmperes VVolts

XDuty Cycle Wire Feed Percent IP Degree Of Protec-

tion

Input Cold Jog (Inch) To-

wards Workpiece Purge By Gas Fast

Constant Current Circuit Breaker Constant Voltage Slow

Trigger Hold Off Trigger Hold On I2Rated Welding

Current Increase

Read Instructions U1Primary Voltage U2Conventional Load

Voltage Hz Hertz

I1Primary Current

TM-1500-15 Page 5SuitCase 12RC

SECTION 3 −INSTALLATION

3-1. Specifications

Type of

Input

Power

Welding

Power

Source

Type

Wire Feed

Speed

Range

Wire

Diameter

Range

Input

Welding

Circuit

Rating

Max. Wire

Spool

Capacity

Overall

Dimensions Weight

24 Volts AC

Single Phase

10 Amperes

50/60 Hz

Constant

Voltage (CV)

DC With

14-Pin And

Contactor

Control

50 to 700 ipm

(1.3 To 17.8

mpm)

.023 To 5/64 in

(0.6 To 2 mm)

100 Volts,

500

Amperes,

100%

Duty Cycle

30 lb (13.6

kg),

12 in (304

mm)

Length: 20 in

(508 mm)

Width: 8 in

(203 mm)

Height: 15-1/2 in

(394 mm)

25.5 lb

(11.6 kg)

3-2. 14-Pin Plug Information

Pin* Pin Information

A24 volts ac with respect to socket G.

AJ BContact closure to A completes 24 volts ac contactor control circuit.

IGCircuit common for 24 volts AC circuit.

C+10 volts dc input from power source to wire feeder with respect to socket D.

FDRemote control circuit common.

E0 to +10 volts dc output signal from wire feeder to power source with respect to socket D.

HVoltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.

FCurrent feedback; 0 to +10 volts dc, 1 volt per 100 amperes.

*The remaining pins are not used.

3-3. Gun Recommendation Table

Process Gun

GMAW −Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, And 600 Amp.

FCAW −Self-Shielding Wires FC-1260 Or FC-1150

SuitCase 12RC

TM-1500-15 Page 6

3-4. Equipment Connection Diagram

804 207-A

1 Constant Voltage (CV)

Welding Power Source

Supplying 24 VAC To Feeder

Use optional PSA-2 adapter for

power sources having only 115

VAC supply.

2 Negative (−) Weld Cable

3 Positive (+) Weld Cable

4 Workpiece

5 Interconnecting Cord

(Customer Supplied)

6 14-Pin Plug And Cord

7 Wire Feeder

8 Gun

9 Gun Trigger Receptacle

10 Gas Hose

11 Gas Cylinder

.Shielding gas pressure not to

exceed 100 psi (689 kPa).

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