Miller Electric SuitCase X-TREME 8VS Owner's Manual
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Miller Electric SuitCase X-TREME 8VS Owner's Manual

Miller Electric SuitCase X-TREME 8VS Owner's Manual

Ce and non-ce models wire feeder
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www.MillerWelds.com
SuitCase
X-TREME 8VS
CE And Non-CE Models
OM-226 288T
2011−12
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
R
File: MIG (GMAW)

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Summary of Contents for Miller Electric SuitCase X-TREME 8VS

  • Page 1 OM-226 288T 2011−12 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase X-TREME 8VS CE And Non-CE Models 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.

  • Page 4: Declaration Of Conformity

    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 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.

  • 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.

  • 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-226 288 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. 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. 3-2.

  • Page 16: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 17: Equipment Connection Diagram

    4-4. Equipment Connection Diagram Turn Off wire feeder and welding power source. Stop engine welding generator. Use only with CC/CV DC Power Sources. Constant Current (CC) or Constant Voltage (CV) Welding Power Supply Weld Cable To Feeder Work Cable To Workpiece Weld cable and work cable connec- tions to power source (DCEN/ DCEP) are dependant on wire type.

  • Page 18: 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 19: 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 20: Connecting Shielding Gas

    4-7. Connecting Shielding Gas NOTICE − This feeder has a shield- ing gas filter that requires special attention when cleaning. See Sec- tion 6-3 for proper cleaning instruc- tions. Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) Rear View Shielding Gas Cylinder Shielding gas pressure not to exceed 100 psi (689 kPa).

  • Page 21: Weld Cable Sizes

    4-9. Weld 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 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 22: 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 23: 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 24: Motor Board (Pc1) Dip Switch Settings

    4-12. Motor Board (PC1) DIP Switch Settings Motor Control Board PC1 DIP Switch LED5 If protective coating is present, re- move before setting DIP switch. It is not necessary to reapply the protect- ive coating. Set switch position 1 so the depressed section of the tab is toward 1 as labeled on the switch.

  • Page 25: 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 26: 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. While welding in CC mode, actual wire speed is dependant on arc voltage. Maxim- um wire speed may be limited by arc voltage.

  • Page 27: Gun Consumables Information

    5-3. Gun Consumables Information 235 264-A Notes OM-226 288 Page 23...

  • Page 28: Wire Speed Control Settings

    5-4. Wire Speed Control Settings Ref. 222 307A Notes OM-226 288 Page 24...

  • Page 29: 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 30: Cleaning Debris From Shielding Gas Filter Fitting

    6-3. Cleaning Debris From Shielding Gas Filter Fitting Disconnect power before maintaining. Shielding Gas Filter Fitting Remove fitting from gas valve on Rear View of Feeder back panel of feeder. Blow compressed air through the threaded male end of fitting to dis- lodge debris from internal mesh screen.
  • Page 31 Trouble Remedy Motor runs slowly. Check and replace contact tip or liner if necessary. Have Factory Authorized Service Agent check Control board PC1. When soft start is on, motor will run slow until weld current is sensed by HD1. Hub tension set too high (see Section 4-10). Unit does not switch out of Soft Start.

  • Page 32: Diagnostics

    6-5. 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 14 4 Blinks Motor (Constant Blinking) Overload Error HLP 15 3 Blinks Bus Bar Overheat Error Error Indications Error conditions are indicated by a “HLP”...

  • Page 33: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM 226 637-F Figure 7-1. Circuit Diagram For Wire Feeder OM-226 288 Page 29...

  • Page 34: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. (Fig 8-3) 1 (Fig 8-2) Figure 8-1. Exploded View Of SuitCase X-TREME 8VS OM-226 288 Page 30...
  • Page 35 Ref. 246 724-B Item Diagram Part marking Description Quantity Figure 8-1. Complete Assembly ....Fig 8-2 Panel Assembly, Front (Without Meters) ......
  • Page 36 Item Diagram Part marking Description Quantity Figure 8-1. Complete Assembly (Continued) ....144 172 Ftg, Hose Brs Barbed M 3/16 Tbg X .250-20 ......
  • Page 37 Item Diagram Part marking Description Quantity Figure 8-1. Complete Assembly (Continued) ....244 552 Bracket, Spool Support ..........
  • Page 38 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 15) ... . . 171 007 Knob, Pointer 1.670 Dia X .250 Id W/Set ScrewSplstc .
  • Page 39 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 15) ... . . 174 991 Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 .
  • Page 40 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 41 Notes SOCKET/WRENCH SELECTION TABLE SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size U.S. Bolt Decimal Bolt Bolt Decimal Bolt Diameter Equivalent Diameter Equivalent 1/4 in. .250 in. 3/8 in. 7/16 in. 6 mm .2362 in.
  • 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 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 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 2011 Miller Electric Mfg. Co. 2011−01...

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