Miller SuitCase X-TREME 8VS CE Page 1 Owner'S Manual Download

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SuitCase

X-TREME 8VS

OM-226 288G

2009

−

Processes

Description

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Wire Feeder

™

File: MIG (GMAW)

Visit our website at

www.MillerWelds.com

CE And Non-CE Models

Summary of Contents for SuitCase X-TREME 8VS CE

Page 1: ...SuitCase X TREME 8VS OM 226 288G 2009 08 Processes Description MIG GMAW Welding Flux Cored FCAW Welding Wire Feeder File MIG GMAW Visit our website at www MillerWelds com CE And Non CE Models ...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation...

Page 3: ...e EU 11 2 9 Symbols And Definitions 11 SECTION 3 INSTALLATION 12 3 1 Important Information Regarding CE Products Sold Within The EU 12 3 2 Specifications 12 3 3 Gun Recommendation Table 12 3 4 Equipment Connection Diagram 13 3 5 Installing And Aligning Wire Guide And Drive Rolls 14 3 6 Connecting Welding Gun And Voltage Sensing Clamp 15 3 7 Connecting Shielding Gas 15 3 8 Connecting Weld Cable 16 ...

Page 4: ... Low Voltage S 2004 108 EC Electromagnetic Compatibility Standards S IEC 60974 1 2005 Arc welding equipment Part 1 Welding power sources S IEC 60974 5 2007 Arc welding equipment Part 5 Wire feeders S IEC 60974 10 2007 Arc welding equipment Part 10 Electromagnetic compatibility EMC requirements S EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc...

Page 5: ...olds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant vo...

Page 6: ...nless they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw ...

Page 7: ... panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing u...

Page 8: ...Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 86...

Page 9: ...urant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou ...

Page 10: ... ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le co...

Page 11: ...ur D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonction...

Page 12: ...sement fermés les portes et les panneaux des sources de haute fréquence maintenir les éclateurs à une distan ce correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipe...

Page 13: ...n 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov N...

Page 14: ...OM 226 288 Page 10 ...

Page 15: ... or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collec tion facility Contact your local recycling office or your local distributor for further information 2 9 Symbols And Definitions Some symbols are found only on CE products Output Input A Amperes V Volts X Duty Cycle Wire Feed Percent IP Degree Of Protec tion Input Cold Jog Inch To wards Workpiece Purge By...

Page 16: ...ional EMF exposure information S The EMF assessment on this equipment was conducted at 0 5 meter S At a distance of 1 meter the EMF exposure values were less than 20 of the permissible values 3 2 Specifications Type of Input Power Welding Power Source Type Wire Feed Speed Range Wire Diameter Range Input Welding Circuit Rating IP Rating Max Wire Spool Capacity Overall Dimensions Weight Open Circuit...

Page 17: ...ork Cable To Workpiece Weld cable and work cable connec tions to power source DCEN DCEP are dependant on wire type Since feeder is not polarity sen sitive there is no need for an electrode polarity switch 4 Workpiece 5 Voltage Sensing Clamp Connect voltage sensing clamp to workpiece 6 Gun 7 Gun Trigger Receptacle 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on wire ty...

Page 18: ...p is as close to drive rolls as possible without touching Tighten screw Aligning Wire Guide And Drive Rolls View is from top of drive rolls look ing down with pressure assembly open 6 Drive Roll Securing Nut 7 Drive Roll 8 Inlet Wire Guide 9 Welding Wire 10 Drive Gear Turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Only bottom drive roll alignment...

Page 19: ...s possible to drive rolls without touching Tighten knob 4 Gun Trigger Plug 5 Gun Trigger Receptacle 6 Voltage Sensing Clamp Connect voltage sensing clamp to workpiece 1 3 4 5 Internal Side View 6 2 3 7 Connecting Shielding Gas Ref 804 420 A 1 Gas Hose With 5 8 18 Right hand Thread Fittings Customer Supplied 2 Shielding Gas Cylinder Shielding gas pressure not to exceed 100 psi 689 kPa 3 Valve 4 Flo...

Page 20: ... 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Welding Amperes 10 60 Duty Cycle AWG mm2 60 100 Duty Cycle AWG mm2 10 100 Duty Cycle AWG mm2 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0...

Page 21: ...through guides into gun Close and tighten pressure assem bly Press jog switch until wire comes out gun To set the proper drive roll tension release the tension on the drive rolls Position gun at about a 45 de gree angle with nozzle about two inches from a wooden surface In crease the tension while feeding the wire against the wooden sur face to one half turn past the point where the wire stops sli...

Page 22: ...nches Per Minute Displays Wire Speed in Inches per Minute Wire Speed Meters Per Minute Displays Wire Speed in Meters per Minute Information OFF Information is not displayed Information ON With switch in ON position at feeder power up feeder will display various sets of information Each set of infor mation will be displayed for three sec onds Display Board PC20 Software Part Number Top display will...

Page 23: ...set gas flow rate at the flowmeter 5 Trigger Hold Switch Optional 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 Welding will contin ue when trigger is released To stop welding press and release ...

Page 24: ...nger than 6 sec onds before releasing it Welding will contin ue when trigger is released To stop welding press and release the trig ger 4 Power Control Switch 5 Soft Start Switch The Soft Start feature provides a smooth start during most weld conditions When the trigger is pulled the wire speed is approxi mately 50 of the weld wire speed as set by the wire speed control knob After an arc is establ...

Page 25: ...OM 226 288 Page 21 4 3 Gun Consumables Information 235 264 A Notes ...

Page 26: ...OM 226 288 Page 22 4 4 Wire Speed Control Settings Ref 222 307A Notes ...

Page 27: ...nd Cords 6 Months Clean Drive Rolls Blow Out Or Vacuum Inside 5 2 Overload Protection And Thermostat Protection Ref 804 855 A Turn Off wire feeder and welding power source Stop engine on welding generator 1 Circuit Breaker CB1 CB1 protects wire feeder from over load Correct problem and reset CB1 Close and latch door Thermostat Protection Unit has internal thermostat protec tion and will not feed w...

Page 28: ...s not on motor will switch to slower speed if current is not sensed by HD1 When soft start is on motor will run slow until weld current is sensed by HD1 Hub tension set too high see Section 3 10 Unit does not switch out of Soft Start Check transducer HD1 and connections and replace if necessary Wire feeds when Jog switch is pressed but not when gun trigger is pressed Check gun trigger connection a...

Page 29: ... switch settings on Display board PC20 see Section 3 11 Check Motor Control PC1 and connections replace if necessary 5 4 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 Constant Blinking Motor Overload Error HLP 15 3 Blinks Bus Bar Overheat Error Error Indications Error conditions are in...

Page 30: ...OM 226 288 Page 26 SECTION 6 ELECTRICAL DIAGRAM 226 637 E Figure 6 1 Circuit Diagram For Wire Feeder ...

Page 31: ...OM 226 288 Page 27 Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now ...

Page 32: ...ECTION 7 PARTS LIST Hardware is common and not available unless listed 8 5 6 3 4 2 1 Fig 7 2 Fig 7 3 7 21 10 11 9 12 13 17 15 18 19 20 16 22 14 59 60 61 65 64 20 66 62 67 63 Figure 7 1 Exploded View Of SuitCase X TREME 8VS ...

Page 33: ...11 Cable Sensing Includes 1 600 848 Wire Strd 12Ga Blk 600v 105C 65x30 Hyp 199Od 16 ft 208 820 Clamp Work 1 4 221 998 Cable Trigger 25 In Includes 1 PLG6 115 094 Housing Plug Skts Service Kit 1 049 445 Cable Port No 18 2 C Type Sjo Nprn Jkt 3 ft RC2 080 328 Rcpt W Skts Free Hanging 1 048 834 Conn Circ Cpc Clamp Str Rlf Size 11 329 Od 1 5 230 228 Bushing Strain Relief 120 150 Id X 500 Mtg Hole 1 6 ...

Page 34: ...X 1 835 Lg 500 Hex Stl Fem 3 28 226 285 Insulator Motor 1 29 200 814 Hose Assy Sae 187 Id X 410 Od X 17 000 W Clamps 1 30 149 332 Clamp Hose 405 485 Clp Dia Slfttng Olive Dra 2 31 GS1 226 819 Valve 12VDC 1Way 750 14 Thd 2mm Orf 100PSI 1 32 226 284 Insulator Capacitors 2 33 C1 C2 200 606 Capacitor Elctlt 1200 Uf 300 VDC Can 1 39 Dia 2 34 226 283 Bracket Capacitor 2 35 226 287 Chassis Control Box 1 ...

Page 35: ...bel Warning General Precautionary Static Vert 2 223 034 Label Warning General Precautionary Static Vert CE Only 2 PLG3 130 203 Housing Plug Skts Service Kit 1 PLG4 131 054 Housing Rcpt Skts Service Kit 1 PLG5 201 665 Housing Plug Skts Service Kit 1 PLG7 130 203 Housing Plug Skts Service Kit 1 PLG8 115 091 Housing Plug Skts Service Kit 1 PLG9 21 131 055 Housing Rcpt Skts Service Kit 2 PLG10 131 052...

Page 36: ... 2 S1 111 997 Switch Rocker SPST 10A 250VAC On Off Visi Red Rock 1 3 222 797 Blank Snap In Nyl Rect Mtg Hole Black 1 4 S2 216 295 Switch Rocker SPDT 4VA 28VDC On Off On 187T 1 5 Nameplate Without Meters Order By Model And Serial Number 1 6 225 989 Panel Front 1 7 R1 208 399 Pot Cp Std Slot 1T 2 W 10K Linear W Frict Tabs 1 To maintain the factory original performance of your equipment use only Manu...

Page 37: ... Rect Mtg Hole Black Standard For Units Not Equipped With Trigger Hold 1 4 S4 217 932 Switch Rocker SPST 4VA 28VDC On None Off 187 Ter Optional 1 5 S2 216 295 Switch Rocker SPDT 4VA 28VDC On Off On 187T 1 6 Nameplate W Meters Order By Model And Serial Number 1 7 225 989 Panel Front 1 8 PC20 226 373 Circuit Card Assy Meter Suitcase W Program 1 8 PC20 233 837 Circuit Card Assy Meter Suitcase W Progr...

Page 38: ...9 mm 1 2 mm 1 3 mm 1 6 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 2 0 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 2 0 mm 1 2 mm 1 3 mm 1 6 mm 2 0 mm 087 131 079 594 079 595 079 596 079 597 079 598 044 749 079 599 079 600 079 601 079 602 079 606 079 607 079 608 079 609 079 610 083 318 083 317 079 614 079 615 087 130 053 695 053 700 053 697 053 698 053 699 072 000 053 701 053 702 053 706 053 704 083 489 083 490 053 708 053 ...

Page 39: ...ts MIG Guns and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that ...

Page 40: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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