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Miller Electric SuitCase 8VS manual

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Table of contents for the manual

  • Page 1

    SuitCase 8VS OM-1599 20 0 624M 2005 − 11 Processes Description MIG (GMAW) W elding Flux Cored (FCA W ) W elding Wire Feeder File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    dec_wire_6/05 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW W elding Products Italy S.r .l. Pho[...]

  • Page 5

    OM-1599 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols. Y Marks a special safety mess[...]

  • Page 6

    OM-1599 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (s[...]

  • Page 7

    OM-1599 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F [...]

  • Page 8

    OM-1599 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F[...]

  • Page 9

    OM-1599 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les utili sés Sy mbole graphique d’av ertis s ement ! At tention ! Cette pro - cédur e c ompor te d es risques possibles[...]

  • Page 10

    OM-1599 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau.[...]

  • Page 11

    OM-1599 Page 7 2-3 . Da ngers supplémenta ires en r e lation avec l’insta llation, le f onc tionneme nt et l a maintena nce Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l?[...]

  • Page 12

    OM-1599 Page 8 2-5. Princi pales nor mes de sécurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W eldin[...]

  • Page 13

    OM-1599 Page 9 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 W arning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects cl[...]

  • Page 14

    OM-1599 Page 10 3-2. Manufacturer ’ s Rating Label For CE Products ST-181 678 For label location see Section 5-1. S/N: Hz IP 23 VA X % V U 1 = A I 1 = U 2 = I 2 = 100 7.0 DC 100 500 100 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Output Input A Amperes V V olts X Duty Cycle Wire Feed Percent IP Degree Of Protec- [...]

  • Page 15

    OM-1599 Page 1 1 SECTION 4 − INST ALLA TION 4-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire T ype And Diameter Input W elding Circuit Rating IP Rating Max. Wire Spool Capacity Overall Dimensions W eight Open-Circuit/ Arc V oltage, 15 − 100 V olts DC Constant V oltage (CV) Or Constant Current (CC) [...]

  • Page 16

    OM-1599 Page 12 4-4. Installing And Aligning Wire Guide And Drive Rolls 802 706-A / Ref. 132 808-F / Ref. 162 079-A / Ref. 180 967 Installing Wire Guide And Drive Rolls: 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier . 3 Drive Roll Slide dr ive rol l onto drive roll carrier . T u[...]

  • Page 17

    OM-1599 Page 13 4-5. Connecting W elding Gun And V oltage Sensing Clamp Ref. 802 706-A / 802 768-A / Ref. S-0621-C Y T urn Off wire feeder and welding power source. Stop engine on welding generator . 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob, insert gun end into block. Position outlet wire guide as close a s possible to dr[...]

  • Page 18

    OM-1599 Page 14 4-7. Connecting Weld Cable Ref. 132 808-F / Ref. 802 706 Y T urn Off wire feeder and welding power source. Stop engine on welding generator . 1 User-Suppled W eld Cable Follow wire manufacturer’s recom- mendations for weld cable polarity . 2 User-Suppled Male Connector 3 User-Suppled Female Connector Push female connector over mal[...]

  • Page 19

    OM-1599 Page 15 SECTION 5 − OPERA TION 5-1. Controls For Non-CE Models Ref. 803 626-A / Ref. 802 706-A / Ref. 803 124 1 Power Control Switch 2 Trigger Hold Switch (Optional) This unit offers an optional trigger hold function, which is turned On or Of f with a front panel toggle switch. Depress the upper part of the switch (turns trigger hold On) [...]

  • Page 20

    OM-1599 Page 16 5-2. Controls For CE Models Ref. 803 626-A / Ref. 802 706-A / Ref. 203 745 / Ref. 203 749 1 Power Control Switch 2 Trigger Hold Switch Depress the upper part of the switch (turns trigger hold On) to weld without holding gun trigger throughout the weld cycle. T o start weld, press and release gun trigger . T o end weld, press and rel[...]

  • Page 21

    OM-1599 Page 17 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace Damaged Or Unreadable Labels Replace Damaged Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Clean Drive Rolls Blow Out Or V acuum Inside 6-2. O[...]

  • Page 22

    OM-1599 Page 18 6-3. T roubleshooting T rouble Remedy Wire does not feed; open-circuit voltage 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 . See gun Owner ’s Manual. Wire feeds erratically . Readjust hub tension. Readjust [...]

  • Page 23

    OM-1599 Page 19 SECTION 7 − ELECTRICAL DIAGRAMS 203 029 − C Figure 7-1. Circuit Diagram For Wire Feeder[...]

  • Page 24

    OM-1599 Page 20 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. Figure 8-1. Complete Assembly 802 675-E 1 2 4 5 7 8 5 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 48 68[...]

  • Page 25

    OM-1599 Page 21 Figure 8-1. Complete Assembly Description Quantity Part No. Dia. Mkgs. Item No. 1 202 695 Nut, Hub 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 919 Knob, Brake Adjust 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 26

    OM-1599 Page 22 Figure 8-1. Complete Assembly (Continued) Description Quantity Part No. Dia. Mkgs. Item No. 37 081 895 Nut, 010 − 32 Rubber .75dia .81l Insert In .38hole 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 200 604 Chassis, Control Box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 27

    OM-1599 Page 23 Figure 8-2. 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. V -Knurled rolls for hard [...]

  • Page 28

    OM-1599 Page 24 Notes[...]

  • Page 29

    OM-1599 Page 25 Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.weldin g .or g Star t Y our Professional W eldin g Career Now![...]

  • Page 30

    OM-1599 Page 26 Notes[...]

  • Page 31

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise o[...]

  • Page 32

    PRINTED IN USA © 2005 Miller Electric Mfg. Co. 10/05 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West Spenc er S treet Applet on, W I 54914 USA International He adquarters − US A USA P hone: 920-735-4505 Aut o-At t ended USA & C anada F A X: 920-735-4134 Int ernat ional FAX: 920-735-4125 European Headqua rters − United[...]