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

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

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SuitCase
X-TREME 8VS
CE And Non-CE Models
OM-226 288G
2009−08
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
™
™
File: MIG (GMAW)

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

  • Page 1 OM-226 288G 2009−08 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 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

    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 _2009−08 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • 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. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2009−08 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans D Porter des vêtements confectionnés avec des matières résistan- tes et ignifuges (cuir, coton lourd ou laine) et des bottes de les sources de soudage onduleur UNE FOIS protection. l’alimentation coupée. LE SOUDAGE peut provoquer un D Arrêter les convertisseurs, débrancher le courant électrique et incendie ou une explosion.

  • 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. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, 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- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-226 288 Page 10...

  • Page 15: Serial Number And Rating Label Location

    2-7. 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. 2-8.

  • Page 16: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Important Information Regarding CE Products (Sold Within The EU) 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

    3-4. 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

    3-5. 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

    3-6. Connecting Welding Gun And Voltage Sensing Clamp Turn Off wire feeder and welding power source. Stop engine on welding generator. Gun Block Gun Securing Knob Gun Power Pin Loosen knob, insert gun end into block. Position power pin as close as possible to drive rolls without touching.

  • Page 20: Connecting Weld Cable

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart) Ref. S-0007-G 2009−08 OM-226 288 Page 16...

  • Page 21: Installing And Threading Welding Wire

    3-10. 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

    3-11. 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 4 − Operation

    SECTION 4 − OPERATION 4-1. 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

    4-2. 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: Gun Consumables Information

    4-3. Gun Consumables Information 235 264-A Notes OM-226 288 Page 21...

  • Page 26: Wire Speed Control Settings

    4-4. Wire Speed Control Settings Ref. 222 307A Notes OM-226 288 Page 22...

  • Page 27: Section 5 − Maintenance & Troubleshooting

    SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. 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

    5-3. Troubleshooting Trouble Remedy Wire does not feed; open-circuit voltage Check power switch S1 and connections, and replace if necessary. available. Check circuit breaker 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 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 226 637-E Figure 6-1. Circuit Diagram For Wire Feeder OM-226 288 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-226 288 Page 27...

  • Page 32: Section 7 − Parts List

    SECTION 7 − PARTS LIST Hardware is common and not available unless listed. (Fig 7-3) 1 (Fig 7-2) Figure 7-1. Exploded View Of SuitCase X-TREME 8VS OM-226 288 Page 28...
  • Page 33 Ref. 804 854-D Item Diagram Part marking Description Quantity Figure 7-1. Complete Assembly ....Fig 7-2 Panel Assembly, Front (Without Meters) ......
  • Page 34 Item Diagram Part marking Description Quantity Figure 7-1. Complete Assembly (Continued) ....144 172 Ftg, Hose Brs Barbed M 3/16 Tbg X .250-20 ......
  • Page 35 Item Diagram Part marking Description Quantity Figure 7-1. Complete Assembly (Continued) ....226 752 Support, Spool ...........
  • Page 36 Hardware is common and not available unless listed. Ref. 804 854-A Figure 7-2. Front Panel Assembly without Meters Item Dia. Part Description Mkgs Quantity Figure 7-2. Front Panel Assembly without Meters (Figure 7-1 Item 15) ... . . 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 7-3. Front Panel Assembly with Meters Item Dia. Part Description Mkgs Quantity Figure 7-3. Front Panel Assembly with Meters (Figure 7-1 Item 15) ... . . 174 991 Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 .
  • Page 38 Table 7-1. 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 Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
  • 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 2009 Miller Electric Mfg. Co. 2009−01...

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