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OM-252 203 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som 2013−09

7

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
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.

NOTICE − Indicates statements not related to personal injury.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.

1-2.

Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks
or  severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.

Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present on
unit.

Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; 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
semiautomatic DC 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 voltage wire welder
is recommended. And, do not work alone!

Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.

Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

When making input connections, attach proper grounding conduc-
tor first − double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.

Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or repaired cables.

Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directly
with a separate cable.

Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.

Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.

Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.

Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.

Use GFCI protection when operating auxiliary equipment in damp
or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.

Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-
ment.

To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.

Содержание SuitCase X-TREME 12VS

Страница 1: ...SuitCase OM 252 203H 2015 09 Processes Description MIG GMAW Welding Flux Cored FCAW Welding Wire Feeder File MIG GMAW Visit our website at www MillerWelds com X TREME 12VS CE And Non CE Models...

Страница 2: ...ntinue 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...

Страница 3: ...Rating Label Location 13 4 2 Unit Specifications 13 4 3 Wire Type Size and Feed Speed Capability Table 13 4 4 Gun Recommendation Table 13 4 5 Environmental Specifications 13 SECTION 5 INSTALLATION 14...

Страница 4: ...e of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 2005 Arc welding equipment Part 1 Welding power sources IEC 60974 5 2007 Arc welding equipment Part 5 Wir...

Страница 5: ...uch 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...

Страница 6: ...perly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work...

Страница 7: ...PARTS can injure Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for mai...

Страница 8: ...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...

Страница 9: ...ant lectrique UNIQUE MENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est...

Страница 10: ...ssements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste lai...

Страница 11: ...associ s en bon tat Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne Le couvercle du d...

Страница 12: ...es de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QU...

Страница 13: ...l 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 Par...

Страница 14: ...OM 252 203 Page 10...

Страница 15: ...n Safe37 2012 05 Safe57 2012 05 Wear dry insulating gloves Do not touch electrode wire with bare hand Do not wear wet or damaged gloves Protect yourself from electric shock by insulating yourself from...

Страница 16: ...t shade of filter Wear complete body protection Safe66 2012 06 Become trained and read the instructions before working on the machine or welding Safe65 2012 06 3 2 Miscellaneous Symbols And Definition...

Страница 17: ...52 in 0 6 To 1 3 mm Flux Cored 030 5 64 in 0 8 To 2 mm 300 Amperes At 100 Duty Cycle 425 Amperes At 60 Duty Cycle 45 lb 20 4 kg 12 in 304 mm Length 21 in 533 mm Width 9 in 229 mm Height 15 1 2 in 394...

Страница 18: ...magnetic Compatibility EMC This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There can be potential...

Страница 19: ...Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier 3 Drive Roll Slide drive roll onto drive roll carrier Turn nut one click Repeat procedure for top drive roll...

Страница 20: ...to drive rolls without touch ing Align the gun power pin groove with the gun locking tab Tighten gun securing knob If the gun power pin does not have a groove loosen knob to ro tate the gun locking t...

Страница 21: ...a maximum of 100 in lbs 12 N m 2 Shielding Gas Cylinder Shielding gas pressure not to exceed 100 psi 689 kPa 3 Valve 4 Flowmeter Close valve on cylinder when fin ished welding 1 Rear View 2 3 4 5 5 Co...

Страница 22: ...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...

Страница 23: ...f the wire slips at maximum hand tight pressure there may be other problems Check the gun liner spool tension contact tip and drive roll wear as all these can cause wire feeding problems Cut off wire...

Страница 24: ...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 information will be displayed for...

Страница 25: ...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 When using wire speed d...

Страница 26: ...he reduced wire speed will be 87 5 of the standard wire speed See Section 6 3 5 CC CV Switch Use switch to match feeder with the output of the power source While welding in CC mode actual wire speed i...

Страница 27: ...it will display the active wire speed whether it is standard wire speed or reduced wire speed Weld Gun With Internal Mounted Dual Schedule Switch Comparable To PipePro Dura Flux Gun 1 Gun Trigger Rec...

Страница 28: ...OM 252 203 Page 24 6 4 Wire Speed Control Settings Ref 257 488 A Notes...

Страница 29: ...Cables And Cords Every 6 Months Clean Drive Rolls Blow Out Or Vacuum Inside 7 2 Overload Protection And Thermostat Protection Ref 256 618 A Turn Off wire feeder and welding power source Stop engine o...

Страница 30: ...ve 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 if blowing compressed air through fitting d...

Страница 31: ...t tip or liner if necessary See gun Owner s Manual Check that DIP switches on Motor Control Board PC1 are set correctly see Section 5 8 Have Factory Authorized Service Agent check Motor Control Board...

Страница 32: ...nication Error HLP 12 2 Blinks Trigger Error HLP 13 3 Blinks Tach Error HLP 14 4 Blinks Motor Overload Error HLP 15 5 Blinks Bus Bar Overheat Error Error Indications Error conditions are indicated by...

Страница 33: ...OM 252 203 Page 29 SECTION 8 ELECTRICAL DIAGRAM 252 200 D Figure 8 1 Circuit Diagram For Wire Feeder...

Страница 34: ...7 29 31 26 30 33 13 43 44 45 46 47 34 35 36 37 42 39 40 41 32 38 1 2 4 5 256 891 C 41 48 13 13 Figure 9 1 Complete Assembly Figure 9 1 Complete Assembly Diagram marking Item No Part No Description Qua...

Страница 35: ...38276 Circuit Card Assy Motor Control Board W Program 1 35 HD1 218339 Transducer Current 600A Module Supply V 5V 1 36 183387 Washer Cone 380idx 860odx 109T Stl Pld 4000Lbs 2 37 W1 255627 Contactor Ass...

Страница 36: ...one Off 187Ter 1 8 S1 267296 Switch Rocker SPST 15A 250VAC On Off Visi Red Rock 1 9 252262 Cable Trigger 25in W Strain Relief Includes 1 139042 Bushing Strain Relief 270 470 Id X 804 Mtg Hole 1 PLG6 1...

Страница 37: ...f 187 Ter 1 8 S1 267296 Switch Rocker SPST 15A 250VAC On Off Visi Red Rock 1 9 252262 Cable Trigger 25in W Strain Relief Includes 1 139042 Bushing Strain Relief 270 470 Id X 804 Mtg Hole 1 PLG6 115094...

Страница 38: ...ware is common and not available unless listed 5 1 2 3 9 10 11 14 13 12 15 16 17 18 19 20 29 30 31 32 33 24 13 25 42 45 44 46 43 37 38 40 39 34 35 36 23 6 7 21 22 8 27 4 28 257 016 B 41 10 26 Figure 9...

Страница 39: ...c Hd Hex Gr8 Pln 1 26 264611 O Ring 187 Id X 312 Od X 063 Cs 75 Duro Fluor 1 27 144172 Ftg Hose Brs Barbed M 3 16 TBG X 250 20 1 28 263877 Wire Drive Bus Bar Service Kit Includes 1 259857 Screw 375 16...

Страница 40: ...n 035 in 045 in 052 in 062 in 035 in 045 in 052 in 062 in 035 in 045 in 052 in 062 in 045 in 052 in 062 in 0 6 mm 0 8 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 0 9 mm 1 2 mm 1 3 mm 1...

Страница 41: ...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...

Страница 42: ...Notes...

Страница 43: ...ns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components suc...

Страница 44: ...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 Equip...

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