Miller SuitCase X-TREME 12VS Owner's Manual
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Miller SuitCase X-TREME 12VS Owner's Manual

Ce and non-ce models
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SuitCase
X-TREME 12VS
CE And Non-CE Models
OM-252203P
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
R
™
File: MIG (GMAW)
2018−02

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Summary of Contents for Miller SuitCase X-TREME 12VS

  • Page 1 OM-252203P 2018−02 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase ™ X-TREME 12VS 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 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 14 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe63 2012−06 Do not weld on drums or any closed containers. Safe16 2017−04 Do not remove or paint over (cover) the label. Safe20 2017−04 Drive rolls can injure fingers.

  • Page 15: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Gas IN Input Run-In Rated Welding Increase Input Current Current Constant Current Wire Feed Trigger Hold Off Percent Cold Jog (Inch) Read Instructions Toward Workpiece Purge By Gas Supplementary Filter Protector Constant Voltage Trigger Hold On Amperes Volts Input Voltage...

  • Page 16: 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 17 D. China EEP Hazardous Substance Information   ‡ China EEP Hazardous Substance Information Ö Hazardous Substance Component Name × (if applicable) PBDE Ö Brass and Copper Parts Coupling Devices Switching Devices Ö Cable and Cable Accessories Batteries SJ/T 11364 This table is prepared in accordance with China SJ/T 11364.

  • Page 18: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Equipment Connection Diagram Turn Off wire feeder and welding power source. Stop engine welding generator. Do not move or operate equipment where it could tip. Use only with CC/CV DC Power Sources. Constant Current (CC) or Constant Voltage (CV) Welding Power Supply Weld Cable To Feeder...

  • Page 19: Installing Drive Rolls

    5-2. Installing Drive Rolls Installing Drive Rolls: Drive Roll Securing Nut Drive Roll Carrier Turn nut one click until lobes of nut Installing Drive Rolls line up with lobes of drive roll carrier. Drive Roll Slide drive roll onto drive roll carrier. Turn nut one click.

  • Page 20: Connecting Welding Gun And Voltage Sensing Clamp

    5-3. 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 lights and meters are off.

  • Page 21: Connecting Shielding Gas

    5-4. 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 Rear View (User−Supplied) Tighten gas hose fitting to a maximum of 100 in.

  • Page 22: Selecting Cable Sizes

    5-6. 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 23: Installing And Threading Welding Wire

    5-7. Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension: Retaining Nut Hub Tension Adjustment Knob Remove retaining nut, and install spool so hub pin fits spool hole. Reinstall re- Hold wire tightly to keep it taining nut. from unraveling.

  • Page 24: Meter Board (Pc20) Dip Switch Settings

    5-9. Meter Board (PC20) DIP Switch Settings Display Hold On Displays will hold their last value for five seconds 1 2 3 4 5 after the trigger is released. After the hold times out, the Voltmeter will show open circuit voltage or weld voltage polarity.

  • Page 25: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls With Meters Power Control Switch Trigger Hold Switch Trigger hold allows operator to weld without hold- ing gun trigger. To use trigger hold function, place trigger hold switch in the ON position. The operator must hold the trigger for a minimum of 2 seconds, but no longer than 6 seconds be- fore releasing it.

  • Page 26: Controls Without Meters

    6-2. Controls Without Meters Power Control Switch Trigger Hold Switch Trigger hold allows operator to weld without holding gun trigger. To use trigger hold function, place trigger hold switch in the ON position. The operator must hold the trigger for a mini- mum of 2 seconds, but no longer than 6 sec- onds before releasing it.

  • Page 27: 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 28: Wire Speed Control Settings

    6-4. Wire Speed Control Settings Ref. 257 488-A Notes OM-252203 Page 24...

  • Page 29: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power Maintain more often during before maintaining. severe conditions. n = Check Z = Change ~ = Clean l = Replace Every Replace Replace Damaged Months Damaged Gas Hose Unreadable n Z l Labels Repair Or Replace...

  • Page 30: 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 31: Troubleshooting

    7-4. Troubleshooting Trouble Remedy Wire does not feed; open-circuit voltage Check power switch S1 and connections, and 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 32: Diagnostics

    Trouble Remedy 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. without energizing the contactor or gas valve. The unit will feed approximately 35 feet (10.7 meters) of wire, then stop feeding.

  • Page 33: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 252200-E Figure 8-1. Circuit Diagram For Wire Feeder OM-252203 Page 29...

  • Page 34: Section 9 − Parts List

    SECTION 9 − PARTS LIST 39,40 256 891-C Figure 9-1. Complete Assembly Item Diagram Part marking Description Quantity Figure 9-1. Complete Assembly ....Fig 9-2 Panel Assembly Front (Without Meters) .
  • Page 35 Item Dia. Part Description Mkgs Quantity Figure 9-1. Complete Assembly (Continued) ....252170 Case, Control Feeder Machined Blk Sc ......
  • Page 36 Hardware is common and not available unless listed. 257 057-B Figure 9-2. Front Panel Assembly without Meters Item Dia. Part Description Mkgs Quantity Figure 9-2. Front Panel Assembly without Meters (Figure 9-1 Item 1) ......Nameplate, Without Meters (Order By Model And Serial Number) .
  • Page 37 Hardware is common and not available unless listed. 257 055-A Figure 9-3. Front Panel Assembly with Meters Item Dia. Part Description Mkgs Quantity Figure 9-3. Front Panel Assembly with Meters (Figure 9-1 Item 2) ......Nameplate, With Meters (Order By Model And Serial Number) .
  • Page 38 Hardware is common and not available unless listed. 257 016-B Figure 9-4. Drive Assembly, Wire OM-252203 Page 34...
  • Page 39 Item Dia. Part Description Mkgs Quantity Figure 9-4. Drive Assembly, Wire (Figure 9-1 Item 3) ... . . 252214 Motor, Right Angle 24VDC .........
  • Page 40 Table 9-1. Drive Roll Guide 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 41 Notes...
  • Page 42 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 43 Effective January 1, 2018 (Equipment with a serial number preface of MJ or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 44 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 2018 Miller Electric Mfg. LLC. 2018−01...

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