Miller SuitCase 12RC Technical Manual
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Miller SuitCase 12RC Technical Manual

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SuitCase 12RC
TM-1500-15D
2006−06
Eff. w/Serial LC323926
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
File: MIG (GMAW)

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  • Page 1 TM-1500-15D 2006−06 Eff. w/Serial LC323926 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase 12RC File: MIG (GMAW) Visit our website at www.MillerWelds.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ......... . 1-1.
  • Page 3 European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). 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.

  • Page 5: Section 1 − Safety Precautions For Servicing

    D Do not place unit on, over, or near combustible D If using lift forks to move unit, be sure forks are surfaces. long enough to extend beyond opposite side of unit. D Do not service unit near flammables. SuitCase 12RC TM-1500-15 Page 1...

  • Page 6: California Proposition 65 Warnings

    Pacemaker wearers consult your doctor before welding or going near To reduce magnetic fields in the workplace, use the following welding operations. If cleared by your doctor, then following the above procedures: procedures is recommended. TM-1500-15 Page 2 SuitCase 12RC...

  • Page 7: Section 2 − Definitions

    Use welding helmet with correct shade of S-178 936 filter. Wear complete body protection. Become trained and read the instructions before working on the machine or welding. Do not remove or paint over (cover) the label. SuitCase 12RC TM-1500-15 Page 3...

  • Page 8: Weee Label

    Cold Jog (Inch) To- Input Purge By Gas Fast wards Workpiece Constant Current Circuit Breaker Constant Voltage Slow Rated Welding Trigger Hold Off Trigger Hold On Increase Current Conventional Load Read Instructions Primary Voltage Hertz Voltage Primary Current TM-1500-15 Page 4 SuitCase 12RC...

  • Page 9: Section 3 − Installation

    Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes. *The remaining pins are not used. 3-3. Gun Recommendation Table Process 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 5...

  • Page 10: Equipment Connection Diagram

    Positive (+) Weld Cable Workpiece Interconnecting Cord (Customer Supplied) 14-Pin Plug And Cord Wire Feeder Gun Trigger Receptacle 10 Gas Hose 11 Gas Cylinder Shielding gas pressure not to exceed 100 psi (689 kPa). 804 207-A TM-1500-15 Page 6 SuitCase 12RC...

  • Page 11: Installing And Aligning Wire Guide And Drive Rolls

    Cleaning Drive Rolls: Aligning Wire Guide And Drive Rolls Remove drive rolls, and clean grooves using a wire brush. Correct Incorrect Tools Needed: 3/16 in 3/8 in 804 210-A SuitCase 12RC TM-1500-15 Page 7...

  • Page 12: Connecting Welding Gun

    (Customer Supplied) Shielding Gas Cylinder Shielding gas pressure not to exceed 100 psi (689 kPa). Valve Rear View Flowmeter 14-Pin Plug Close valve on cylinder when fin- ished welding. Tools Needed: 5/8 in 804 208-A TM-1500-15 Page 8 SuitCase 12RC...

  • Page 13: Connecting Weld Cable

    Feed wire against wooden surface, and tighten knob so wire does not slip. Cut off wire, and close door. 6 in (150 mm) Pull and hold wire; cut off end. Tools Needed: Tighten Clockwise 9/16 in WOOD 804 212-A SuitCase 12RC TM-1500-15 Page 9...

  • Page 14: Section 4 − Operation

    Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve. Close and latch door. Internal Control Panel Internal Side View 804 213-A TM-1500-15 Page 10 SuitCase 12RC...

  • Page 15: Setting Digital Meter Board Pc4 Dip Switches

    14 Pin Voltage/Current 14 Pin Voltage/Current Voltage Sense Kit Voltage Sense Kit Feedback (195194) Feedback (195194) Meter Hold (ON) (OFF) Amps Display 14 Pin Voltage/Current Current Sense Kit Feedback (195194) 803 141/ Ref. 803 124 SuitCase 12RC TM-1500-15 Page 11...

  • Page 16: Gun Consumables Information

    4-3. Gun Consumables Information 200 007-B Notes TM-1500-15 Page 12 SuitCase 12RC...
  • Page 17 Notes SuitCase 12RC TM-1500-15 Page 13...

  • Page 18: Section 5 − Theory Of Operation

    14 Trigger Hold Board PC30 Feedback 15 Trigger Hold Switch S31 Provides ability to weld without holding gun trigger throughout weld cycle. 16 Meter Board PC4 Displays voltage and wire speed or voltage and amps. TM-1500-15 Page 14 SuitCase 12RC...
  • Page 19 Board PC30 Switch S31 ♦ Current Sensing (HD1) Input Signal Meter Board Arc Voltage Sensing Lead Input Signal To Wire Drive Housing ♦ ♦ Wire Voltage Speed Control Control AC Or DC Control Circuits ♦ Optional SuitCase 12RC TM-1500-15 Page 15...

  • Page 20: Section 6 − Troubleshooting

    Wire feeds, but gas does not flow with Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary. gun trigger pressed. Check motor control board PC1 and connections, and replace if necessary (see Section 6-3). TM-1500-15 Page 16 SuitCase 12RC...
  • Page 21 Voltage/wire speed meter does not op- Check optional wire speed and voltage meter board PC4 and connections, and replace if necessary erate properly. (see Section 6-7). SuitCase 12RC TM-1500-15 Page 17...

  • Page 22: Troubleshooting Circuit Diagram For Wire Feeder

    6-2. Troubleshooting Circuit Diagram For Wire Feeder See Section 6-3 for PC1 data See Section 6-5 for PC30 data TM-1500-15 Page 18 SuitCase 12RC...
  • Page 23 Wire Speed control R1 +7 volts dc 0 to +7 volts dc from min to max of Wire Speed control R1 +24 volts dc See Section 6-7 for Test Equipment Needed: meter board data 223 794-B SuitCase 12RC TM-1500-15 Page 19...

  • Page 24: Motor Control Board Pc1 Testing Information

    6-3. Motor Control Board PC1 Testing Information Be sure plugs are secure before testing. See Section 6-4 for specific values during testing. Motor Control Board PC1 Receptacle RC1 Receptacle RC3 Test Equipment Needed: Receptacle RC4 218 491-A / 804 297-A TM-1500-15 Page 20 SuitCase 12RC...

  • Page 25: Motor Control Board Pc1 Test Point Values

    0 to +7 volts dc input from min to max of Wire Speed control R1 DC circuit common +7 volts dc output +7 volts dc output Not used DC circuit common +19 volts dc output with gun trigger pressed SuitCase 12RC TM-1500-15 Page 21...

  • Page 26: Optional Trigger Hold Board Pc30 Testing Information

    +24 volts dc with gun trigger switch closed +24 volts dc with gun trigger switch closed +24 volts dc with gun trigger switch closed Unused RC33 DC circuit common +13 volts dc with trigger hold switch S31 on TM-1500-15 Page 22 SuitCase 12RC...

  • Page 27: Optional Meter Board Pc4 Testing

    6-7. Optional Meter Board PC4 Testing Be sure plug is secure before test- ing. See Section 6-8 for specific val- ues during testing. Meter Board PC4 Receptacle RC15 Receptacle RC16 Test Equipment Needed: 210 769-B / 804 298-A SuitCase 12RC TM-1500-15 Page 23...

  • Page 28: Optional Meter Board Pc4 Test Point Values

    0−10 volts dc voltage command signal from remote control with respect to pin 2 0 to +7.12 volts dc wire speed command from PC1 +7.12 volts dc RC16 +15 volts dc −15 volts dc +5 volts dc DC circuit common 1 volt = 100 amps TM-1500-15 Page 24 SuitCase 12RC...

  • Page 29: Section 7 − Maintenance

    Correct problem and reset CB1. Close and latch door. Thermostat Protection Unit has internal thermostat protec- tion and will not feed wire if over- heating occurs (see Section 6-1). Internal Side View 804 213-A SuitCase 12RC TM-1500-15 Page 25...

  • Page 30: Section 8 − Electrical Diagrams

    The following is a list of all diagrams for models covered by this manual. Model Serial Or Style Number Circuit Diagram Wiring Diagram LC323926 thru LC569569 210 787-A 210 788-C♦♦ SuitCase 12RC LC569570 thru LF066951 215 341-B 210 788-C♦♦ LF066952 and following 223 794-B 223 796-B ♦♦...
  • Page 31 210 787-A Figure 8-1. Circuit Diagram For SuitCase 12RC Effective With Serial No. LC323926 Thru LC569569 SuitCase 12RC TM-1500-15 Page 27...
  • Page 32 215 341-B Figure 8-2. Circuit Diagram For SuitCase 12RC Effective With Serial No. LC569570 Thru LF066951 TM-1500-15 Page 28 SuitCase 12RC...
  • Page 33 223 794-B Figure 8-3. Circuit Diagram For SuitCase 12RC Effective With Serial No. LF066952 And Following SuitCase 12RC TM-1500-15 Page 29...
  • Page 34 223 796-B Figure 8-4. Wiring Diagram For SuitCase 12RC Effective With Serial No. LF066952 And Following TM-1500-15 Page 30 SuitCase 12RC...
  • Page 35 Notes SuitCase 12RC TM-1500-15 Page 31...
  • Page 36 Figure 8-5. Circuit Diagram For Motor Control Board PC1 Effective With Serial No. LE184521 And Following TM-1500-15 Page 32 SuitCase 12RC...
  • Page 37 218 492-B SuitCase 12RC TM-1500-15 Page 33...
  • Page 38 211 446-A Figure 8-6. Circuit Diagram For Optional Trigger Hold Board PC30 Effective With Serial No. LC323926 And Following TM-1500-15 Page 34 SuitCase 12RC...
  • Page 39 Notes SuitCase 12RC TM-1500-15 Page 35...
  • Page 40 Figure 8-7. Circuit Diagram For Meter Board Effective With Serial No. LC323926 and Following TM-1500-15 Page 36 SuitCase 12RC...
  • Page 41 210 770-B SuitCase 12RC TM-1500-15 Page 37...
  • Page 42 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. TM-1500-15 Page 38 SuitCase 12RC...
  • Page 43 TM-1500-15D 2006−06 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase 12RC ™ Eff w/LC323926 THRU LC569569 For OM-1500-15 (210 177) Revision A Visit our website at www.MillerWelds.com...

  • Page 44: Section 9 − Parts List For Lc323926 Thru Lc569569

    SECTION 9 − PARTS LIST FOR LC323926 THRU LC569569 Hardware is common and not available unless listed. Figure 9-1. Complete Assembly 803 373-B TM-1500-15 Page 40 SuitCase 12RC...
  • Page 45 ... . . 085 243 Knob, Adjust Tension 1.250 Dia X .312−18 Thrd Stl ....SuitCase 12RC TM-1500-15 Page 41...
  • Page 46 +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. TM-1500-15 Page 42 SuitCase 12RC...
  • Page 47 1.3 mm 083 317 083 490 U-Cogged 056 193 1/16 in .062 in 1.6 mm 079 614 053 708 U-Cogged 056 195 5/64 in .079 in 2.0 mm 079 615 053 710 U-Cogged 056 195 S-0157-C SuitCase 12RC TM-1500-15 Page 43...
  • Page 48 Notes TM-1500-15 Page 44 SuitCase 12RC...
  • Page 49 TM-1500-15D 2006−06 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase 12RC ™ Eff w/LC569570 THRU LF232631 For OM-1500-15 (210 177) Revisions B Thru K Visit our website at www.MillerWelds.com...

  • Page 50: Section 10 − Parts List For Lc569570 Thru Lf232631

    SECTION 10 − PARTS LIST FOR LC569570 THRU LF232631 H ardw are is common and not available unless listed. Figure 10-1. Complete Assembly 803 373-F TM-1500-15 Page 46 SuitCase 12RC...
  • Page 51 ... . . 213 190 Nameplate, Miller SuitCase 12RC W/Meters, ......
  • Page 52 ....Nameplate, Miller Suitcase 12 RC W/Meters,Triggerhold ......
  • Page 53 1.3 mm 083 317 083 490 U-Cogged 056 193 1/16 in .062 in 1.6 mm 079 614 053 708 U-Cogged 056 195 5/64 in .079 in 2.0 mm 079 615 053 710 U-Cogged 056 195 S-0157-C SuitCase 12RC TM-1500-15 Page 49...
  • Page 54 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org TM-1500-15 Page 50 SuitCase 12RC...
  • Page 55 TM-1500-15D 2006−06 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase 12RC ™ Eff w/LF232632 AND FOLLOWING For OM-1500-15 (210 177) Revisions L Thru Q Visit our website at www.MillerWelds.com...

  • Page 56: Section 11 − Parts List For Lf232632 And Following

    SECTION 11 − PARTS LIST FOR LF232632 AND FOLLOWING Hardware is common and not available unless listed. Figure 11-1. Complete Assembly 804 214-E TM-1500-15 Page 52 SuitCase 12RC...
  • Page 57 Housing Plug+Skts, (Service Kit) ......As Rqd SuitCase 12RC TM-1500-15 Page 53...
  • Page 58 Housing Plug+Skts, (Service Kit) ........TM-1500-15 Page 54 SuitCase 12RC...
  • Page 59 +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Notes SuitCase 12RC TM-1500-15 Page 55...
  • Page 60 1.3 mm 083 317 083 490 U-Cogged 056 193 1/16 in .062 in 1.6 mm 079 614 053 708 U-Cogged 056 195 5/64 in .079 in 2.0 mm 079 615 053 710 U-Cogged 056 195 S-0157-C TM-1500-15 Page 56 SuitCase 12RC...
  • Page 61 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in)
  • Page 62 Notes...
  • Page 63 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 64 Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters − United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 © PRINTED IN USA 2006 Miller Electric Mfg. Co.

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