Miller ArcReach SuitCase 12 Owner's Manual
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Miller ArcReach SuitCase 12 Owner's Manual

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ArcReach
SuitCase 12
CE And Non-CE Models
OM-278792H
2019−12
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
R
R
File: MIG (GMAW)

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Summary of Contents for Miller ArcReach SuitCase 12

  • Page 1 OM-278792H 2019−12 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder ArcReach SuitCase 12 CE And Non-CE Models File: MIG (GMAW) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2017−04 Protect yourself from electric shock by insulating yourself from work and ground.

  • Page 14: Miscellaneous Symbols And Definitions

    Do not weld on drums or any closed containers. Safe16 2017−04 Do not remove or paint over (cover) the label. Safe20 2017−04 Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. Safe33 2017−04 Wire Feed wire between guide pins into drive rolls.

  • Page 15: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located inside the door. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 16: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Equipment Connection Diagram Turn Off wire feeder and welding power source. Stop engine on welding generator. Do not move or operate equipment where it could tip. Use only with CC/CV DC power sources. Welding Power Source Gas Hose Weld Cable To Feeder Work Cable To Workpiece...

  • Page 17: Equipment Setup

    Associating wire feeder to an ArcReach compatible welding power source or ArcReach Control when the wire feeder is triggered The welding power source must be in an Output On mode. See instructions in the welding power source Owner’s Manual. On feeder, set CC/CV switch to CV mode. The feeder will not associate with another piece of equipment if the feeder is set to CC mode. Turn on the welding power source and wire feeder.

  • Page 18: Installing Drive Rolls

    5-5. Installing Drive Rolls Installing Drive Rolls: Drive Securing Roll Nut Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier. Drive Roll Slide drive roll onto drive roll carrier. Turn nut one click. Repeat procedure for top drive roll.

  • Page 19: Connecting Welding Gun And Voltage Sensing Clamp

    5-6. Connecting Welding Gun And Voltage Sensing Clamp Turn Off wire feeder and welding power source. Stop engine on welding generator. Weld voltage is present at voltage sensing clamp when wire feeder and welding power source are on. This condition exists even if wire feeder light and meters are off.

  • Page 20: Connecting Shielding Gas

    5-7. Connecting Shielding Gas NOTICE − This feeder has a shield- ing gas filter that requires special attention when cleaning. See Sec- tion 7-3 for proper cleaning instruc- tions. Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) Tighten gas hose fitting to a maximum of 100 in.

  • Page 21: Selecting Cable Sizes

    5-9. Selecting Cable Sizes* Turn off power before connecting to weld output terminals. Do not use worn, damaged, undersized, or repaired cables. NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft).

  • Page 22: Installing And Threading Welding Wire

    5-10. Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension: Retaining Nut Hub Tension Adjustment Knob Hold wire tightly Remove retaining nut, and install spool to keep it from so hub pin fits spool hole. Reinstall re- unraveling. taining nut.
  • Page 23 Notes OM-278792 Page 19...

  • Page 24: Meter Board (Pc22) Dip Switch Settings

    5-12. Meter Board (PC22) DIP Switch Settings Accessing DIP Switch Lens DIP switch is located under the lens next to the displays. Lens Screws Remove three screws. Loosen upper right hand screw to rotate lens enough to access DIP switch. Replace three screws removed earlier.
  • Page 25 DIP Switch Settings (continued): Display Amperage − Set switch 2 so the depressed section is toward OPEN as labeled on the switch. Wire Speed / Amps Display will display Amps while welding and Wire Speed while not welding. If the hold func- tion is enabled, Amps will be displayed during hold also.

  • Page 26: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Internal Control Panel Front Panel With Meters Internal Side View Ref. 278794-A Voltmeter approximate. Refer to power source for ac- CC/CV Switch tual amperage. When not welding and the wire feeder is not Use switch to match feeder with the output associated with the ArcReach compatible of the power source.

  • Page 27: Cable Length Compensation (Clc)

    6-2. Cable Length Compensation (CLC) CLC will only work with a compatible power source. Having a good clean connection with the v-sense clamp will ensure CLC works properly. Cable Length Compensation (CLC) Indicator Cable Length Compensation (ON) After the feeder associates (see Section 5-3) to the power source, CLC will appear in the voltage display on the feeder.

  • Page 28: Wire Speed Dual Schedule

    6-3. Wire Speed Dual Schedule Wire Speed Dual Schedule allows the oper- ator to switch between standard wire speed and a reduced wire speed. When activated, the reduced wire speed will be 87.5% of the standard wire speed. Wire Speed Dual Schedule may be activated any time before or during the weld by using a gun with an in- Weld Gun With Internal Mounted...

  • Page 29: Wire Speed Control Settings

    6-4. Wire Speed Control Settings Ref. 257 488-A Notes OM-278792 Page 25...

  • Page 30: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months l Damaged Or Unreadable Labels...

  • Page 31: Cleaning Debris From Shielding Gas Filter Fitting

    7-3. Cleaning Debris From Shielding Gas Filter Fitting Disconnect power before maintaining. Shielding Gas Filter Fitting Remove fitting from gas valve on back panel of feeder. Blow compressed air through the threaded male end of fitting to dis- lodge debris from internal mesh screen.

  • Page 32: Troubleshooting

    7-4. Troubleshooting Trouble Remedy Wire does not feed; open-circuit voltage Check power switch S1 and connections, replace if necessary. available. Check supplementary protector CB1. Reset CB1. Unit overheated. Allow unit to cool. Check sensing lead connection. Check gun trigger plug connection. Check gun trigger.
  • Page 33 Trouble Remedy Wire remains energized after trigger is Check setting of trigger hold switch. released. Check contactor W1 to see if contacts are frozen closed. Gun trigger is pressed, gas does not If a welding arc is not established in 3 seconds after the gun trigger is activated, the unit will feed wire flow, wire is not energized, wire feeds.

  • Page 34: Diagnostics

    7-5. Diagnostics Error Indicators Shown On Display RED LED on Motor Board PC1 Error HLP 11 1 Blink Communication Error HLP 12 2 Blinks Trigger Error HLP 13 3 Blinks Tach Error HLP 14 4 Blinks Motor Overload Error HLP 15 5 Blinks Bus Bar Overheat Error...

  • Page 35: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 278773-E Figure 8-1. Circuit Diagram For Wire Feeder OM-278792 Page 31...

  • Page 36: Section 9 − Parts List

    SECTION 9 − PARTS LIST 40,41 278813-B Figure 9-1. Complete Assembly OM-278792 Page 32...
  • Page 37 ....279633 Label, Warning/Miller ArcReach SuitCase 12 Side ....
  • Page 38 Item Diagram Part marking Description Quantity Figure 9-1. Complete Assembly (Continued) ..PLG3, 25 . . . 115093 Housing Plug+Skts, (Service Kit) ........
  • Page 39 Hardware is common and not available unless listed. 278817-B Figure 9-2. Front Panel Assembly with Meters Item Dia. Part Description Mkgs Quantity Figure 9-2. Front Panel Assembly with Meters (Figure 9-1 Item 1) ..267296 Switch, Rocker SPST 15A 250VAC On−Off Visi Red Rock .
  • Page 40 Hardware is common and not available unless listed. 257 016-B Figure 9-3. Drive Assembly, Wire OM-278792 Page 36...
  • Page 41 Item Dia. Part Description Mkgs Quantity Figure 9-3. Drive Assembly, Wire (Figure 9-1 Item 2) ... . . 252214 Motor, Right Angle 24VDC .........
  • Page 42 Table 9-1. Drive Roll Base Selection Of Drive Rolls Upon The Following Recommended Usages: 1. V-Grooved Rolls For Hard Wire. 2. U-Grooved Rolls For Soft And Soft Shelled Cored Wires. 3. U-Cogged Rolls For Extremely Soft Shelled Wires (Usually Hard Surfacing Types). 4.

  • Page 43: Section 10 − Open Source License Notices

    SECTION 10 − OPEN SOURCE LICENSE NOTICES KSDK CMSIS Peripheral Drivers –Open source – Apache 2.0 & BSD−3−Clause, by Freescale *BSD−3−Clause Copyright (c) 2015−2016, Freescale Semiconductor, Inc. All rights reserved. Redistribution and use in source and binary forms, with or without modification, are permitted provided that the following conditions are met: Redistributions of source code must retain the above copyright notice, this list of conditions and the following disclaimer.
  • Page 44 THIS SOFTWARE IS PROVIDED BY THE COPYRIGHT HOLDERS AND CONTRIBUTORS “AS IS” AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE COPYRIGHT HOLDER OR CONTRIBUTORS BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES;...
  • Page 45 Notes...
  • Page 46 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 47 Effective January 1, 2019 (Equipment with a serial number preface of MK or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Subarc Wire Drive Assemblies below, Miller Electric Mfg.
  • Page 48 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2019 Miller Electric Mfg. LLC 2019−01...

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