Related Manuals for Miller Electric SuitCase X-TREME 8 HD
Summary of Contents for Miller Electric SuitCase X-TREME 8 HD
- Page 1 OM-246 828H 2011−12 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase X-TREME 8 HD File: MIG (GMAW) Visit our website at www.MillerWelds.com...
- Page 2 ISO 9001 Quality System Standard. particular model are also provided. 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 specification sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1. -
Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 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 Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging D Do not install unit near flammables. -
Page 8: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer. -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 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 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz D Fermer l’alimentation du gaz comprimé en cas sous haute pression. Si une bouteille est endommagée, elle peut exploser. -
Page 12: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com). - Page 14 OM-246 828 Page 10...
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Page 15: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Some symbols are found only on CE products. Output Input Amperes Volts Degree Of Protec- Duty Cycle Wire Feed Percent tion Cold Jog (Inch) To- Input Purge By Gas Fast wards Workpiece Constant Current Circuit Breaker Constant Voltage... -
Page 16: Section 4 − Installation
SECTION 4 − INSTALLATION 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located inside the cover. 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: Installing And Aligning Wire Guide And Drive Rolls
4-5. Installing And Aligning Wire Guide And Drive Rolls Installing Wire Guide And Drive Rolls: Drive Roll Securing 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. -
Page 18: Connecting Welding Gun And Voltage Sensing Clamp
4-6. Connecting Welding Gun And Voltage Sensing Clamp Turn Off wire feeder and welding power source. Stop engine on welding generator. Gun Securing Knob Gun Block Gun Power Pin Power Pin Groove Gun Locking Tab Loosen knob, insert gun end into block. -
Page 19: Connecting Shielding Gas
4-7. Connecting Shielding Gas Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) Shielding Gas Cylinder Shielding gas pressure not to exceed 100 psi (689 kPa). Valve Rear View Flowmeter Close valve on cylinder when fin- ished welding. Tools Needed: 5/8 in. -
Page 20: Weld Output Terminals And Selecting Cable Sizes
4-9. Weld Output Terminals And Selecting Cable Sizes* 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 30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable size. -
Page 21: Installing And Threading Welding Wire
4-10. Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension: Hold wire tightly Retaining Nut to keep it from Hub Tension Adjustment Knob unraveling. Remove retaining ring, and install spool so hub pin fits spool hole. Re- install retaining nut. Adjust tension knob so only a slight force is needed to turn spool. -
Page 22: Display Board (Pc20) Dip Switch Settings
4-11. Display Board (PC20) DIP Switch Settings DIP Switch Settings: Display Hold ON Displays will hold their last value for five seconds after the trigger is re- leased. After the hold times out, the Voltage Display will show open circuit voltage. -
Page 23: Section 5 − Operation
SECTION 5 − OPERATION 5-1. Controls With Meters Voltmeter Displays actual arc voltage while welding or open circuit voltage while idle at the feeder. The voltage displayed while welding is an av- erage reading over a time span of 6 to 8 sec- onds. -
Page 24: Controls Without Meters
5-2. Controls Without Meters Wire Speed Control Use control to adjust wire speed within the speed range selected by the wire speed range switch, located on the inner control panel. Maximum wire speed may be limited by arc voltage. Jog/Purge Switch Pressing the Jog switch allows the operator to jog wire without energizing the contactor or gas valve. -
Page 25: Dual Schedule (If Applicable)
5-3. Dual Schedule (If Applicable) Feeder With Internal Mounted Dual Schedule Switch Feeder With External Mounted Dual Schedule Switch Ref. 804 875-A / 248 660-A A two position switch is attached to the gun Internal Mounted Dual Schedule Switch Trigger Receptacle handle and is used to select the desired Dual Schedule Plug Trigger Receptacle... -
Page 26: Gun Consumables Information
5-4. Gun Consumables Information 235 264-A OM-246 828 Page 22... -
Page 27: Section 6 − Maintenance & Troubleshooting
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Replace Damaged Or Replace Damaged Unreadable Gas Hose Labels Repair Or Replace Cracked Cables And Cords 6 Months Clean Blow Out Or Drive Vacuum Inside... -
Page 28: Troubleshooting
6-3. 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 29: 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. If the gun trigger is still activated after two minutes, the wire will stop feeding. -
Page 30: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM 249 007-C Figure 7-1. Circuit Diagram For Wire Feeder OM-246 828 Page 26... - Page 31 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 OM-246 828 Page 27...
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Page 32: Section 8 − Parts List
SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 2 (Fig 8-3) 1 (Fig 8-2) Figure 8-1. Exploded View Of SuitCase X-TREME 8 HD OM-246 828 Page 28... - Page 33 Ref. 251 943-A Item Diagram Part marking Description Quantity Figure 8-1. Complete Assembly ....Fig 8-2 Panel Assembly, Front (Without Meters) ......
- Page 34 Item Diagram Part marking Description Quantity Figure 8-1. Complete Assembly (Continued) ....248 481 Cable, Trigger 25 In. With Dual Schedule (Includes) ....
- Page 35 Item Diagram Part marking Description Quantity Figure 8-1. Complete Assembly (Continued) ....235 607 Nut, Hub ............
- Page 36 Hardware is common and not available unless listed. Ref. 804 854-A Figure 8-2. Front Panel Assembly without Meters Item Dia. Part Description Mkgs Quantity Figure 8-2. Front Panel Assembly without Meters (Figure 8-1 Item 1) ... . . 171 007 Knob, Pointer 1.670 Dia X .250 Id W/Set ScrewSplstc .
- Page 37 Hardware is common and not available unless listed. Ref. 804 854-A Figure 8-3. Front Panel Assembly with Meters Item Dia. Part Description Mkgs Quantity Figure 8-3. Front Panel Assembly with Meters (Figure 8-1 Item 2) ... . . 174 991 Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 .
- Page 38 Table 8-1. Drive Roll & Wire Guide Kits (2 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 39 LIMITED WARRANTY − Subject to the terms and conditions 90 Days — Parts Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its Accessory (Kits) 1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the...
- Page 40 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 2011 Miller Electric Mfg. Co. 2011−01...