Miller Electric 12VS manual

SuitCase X-TREME 12VS OM-1500-19 219 185P 2007 − 09 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[...]

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[...]

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

dec_stat_1/07 Declaration of Conformity for European Community (CE) Products . This information is provided for units with CE certification (see rating label on unit). Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r .l. Phone: [...]

OM-1500-19 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 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[...]

OM-1500-19 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

OM-1500-19 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.[...]

OM-1500-19 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and l[...]

OM-1500-19 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bole s ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures grav[...]

OM-1500-19 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

OM-1500-19 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

OM-1500-19 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher d[...]

OM-1500-19 Page 9 2-5. P ri nci pal es n or me s de s écu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American [...]

OM-1500-19 Page 10[...]

OM-1500-19 Page 1 1 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 objec[...]

OM-1500-19 Page 12 3-2. Manufacturer ’ s Rating Label For CE Products Ref. 181 678 / 804 005-A S/N: Hz IP 23 VA X % V U 1 = A I 1 = U 2 =I 2 = 11 0 10.0 DC 1 10 425 60 3-3. WEEE Label (For Products Sold Within The EU) Do not discard product (where ap- plicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) [...]

OM-1500-19 Page 13 3-4. Symbols And Definitions . Some symbols are found only on CE products. Output Input A Amperes V V olts X Duty Cycle Wire Feed Percent IP Degree Of Protec- tion Input Cold Jog (Inch) T o- wards W orkpiece Purge By Gas Fast Constant Current Circuit Breaker Constant V oltage Slow Trigger Hold Of f Trigger Hold On I 2 Rated W eld[...]

OM-1500-19 Page 14 SECTION 4 − INST ALLA TION 4-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range Input W elding Circuit Rating IP Rating Max. Wire Spool Capacity Overall Dimensions W eight Open-Circuit/ Arc V oltage, 14 − 11 0 V olts DC Constant V oltage (CV) Or Constant Current (CC) D[...]

OM-1500-19 Page 15 4-3. Equipment Connection Diagram Ref. 804 000-C ! T urn Off wire feeder and welding power source. Stop engine on welding generator . ! Use only with CC/CV DC Power Sources. 1 Constant Current (CC) or Constant V oltage (CV) W elding Power Supply 2 Weld Cable T o Feeder 3 Ground Cable T o W orkpiece W eld cable and ground cable co[...]

OM-1500-19 Page 16 4-4. Installing And Aligning Wire Guide And Drive Rolls Ref. 804 001-B 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 urn nut one click. Repeat procedure for to[...]

OM-1500-19 Page 17 4-5. Connecting W elding Gun And V oltage Sensing Clamp Ref. 804 002-C ! 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 drive rolls with- out touch[...]

OM-1500-19 Page 18 4-7. Connecting Weld Cable ! T urn Off wire feeder and welding power source. Stop engine on welding generator . 1 User-Suppled Weld 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 male connector , and turn 1/4 t[...]

OM-1500-19 Page 19 4-9. Installing And Threading W elding Wire Ref. 804 005-B Installing Wire And Adjusting Hub T ension: 1 Retaining Nut 2 Hub T ension Adjustment Knob 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. Threading Welding[...]

OM-1500-19 Page 20 4-10. Display Board (PC20) DIP Switch Settings DIP Switch Factory Settings Ref. 804 006-A 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 V oltage Display will show open circuit voltage. If the Wire Speed / Amps Display is set[...]

OM-1500-19 Page 21 SECTION 5 − OPERA TION 5-1. Controls With Meters Ref. 804 006-B 1 Power Control Switch 2 Trigger Hold Switch Trigger hold allows operator to weld without holding gun trigger . T o use trigger hold function, place trigger hold switch in the ON position. Th e operator must hold the trigger for a mini- mum of 2 seconds, but no lon[...]

OM-1500-19 Page 22 5-2. Controls Without Meters Ref. 804 006-B 1 Power Control Switch 2 Jog/Purge Switch Pressing the Jog switch allows the operator to jog wire without energi zing the contactor or gas valve. Pressing the Purge switch allows the opera- tor to purge gas lines before welding and to preset gas flow rate at the flowmeter . 3 Wire Speed[...]

OM-1500-19 Page 23 5-3. Gun Consumables Information 200 007-B Notes[...]

OM-1500-19 Page 24 5-4. Wire Speed Control Settings Ref. 222 307A Notes[...]

OM-1500-19 Page 25 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance . Maintain more often during severe conditions. ! Disconnect power before maintaining. 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[...]

OM-1500-19 Page 26 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. Have Factory Authorized Service Agent check Control [...]

OM-1500-19 Page 27 T rouble Remedy Information on display board is not accu- Have Factory Authorized Service Agent check Control board PC1. Information on display board is not accu rate. yg Check transducer HD1 and connections, and replace if necessary . Display on display board does not light. Have Factory Authorized Service Agent check Control bo[...]

OM-1500-19 Page 28 Notes[...]

OM-1500-19 Page 29 SECTION 7 − ELECTRICAL DIAGRAM 218 763-E Figure 7-1. Circuit Diagram For Wire Feeder[...]

OM-1500-19 Page 30 SECTION 8 − P ARTS LIST Ref. 804 007-K 3 4 9 6 7 8 11 10 12 14 13 64 66 5 67 50 37 38 19 20 25 21 22 23 24 17 35 30 49 18 34 33 45 29 32 36 31 28 26 27 15 16 54 53 55 63 69 52 46 47 51 65 58 59 60 62 57 61 62 48 68 56 42 42 39 41 41 44 42 40 43 68 70 71 72 26 73 1 (Fig 8-2) 2 (Fig 8-3) Figure 8-1. Complete Assembly[...]

OM-1500-19 Page 31 Figure 8-1. Complete Assembly Diagram marking Item No. Part No. Description Quantity 1 Fig 8-2 Panel Assembly Front (Without Meters) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fig 8-3 Panel Assembly Front (With Meters) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-1500-19 Page 32 Figure 8-1. Complete Assembly (Continued) Diagram marking Item No. Part No. Description Quantit y 49 207 679 Insert, Corner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 GS1 226 819 V alve, 12VDC 1W ay .750 − 14 Thd 2mm Orf 100PSI 1[...]

OM-1500-19 Page 33 Ref. 804 007-K . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 Figure 8-2. Front Panel Assembly without Meters Item No. Part No. Quantity Description Figure 8-2. Front Panel Assembly without Meters (Figure 8-1 Item 1) Dia. Mkgs . 1 171 007 Knob, Pointer 1.670 Dia X .250 Id W/Set ScrewSplstc 1 . . . . . . . . .[...]

OM-1500-19 Page 34 Ref. 804 007-K . Hardware is common and not available unless listed. 1 2 3 4 5 7 6 Figure 8-3. Front Panel Assembly with Meters Item No. Part No. Quantity Description Figure 8-3. Front Panel Assembly with Meters (Figure 8-1 Item 2) Dia. Mkgs . 1 179 851 Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring 1 . . . . . . . . . . . . [...]

OM-1500-19 Page 35 T able 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. V-Knurled rolls for ha[...]

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 Pr ofessional W eldin g Career Now![...]

Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm 5/16 in .3125 in 1/2 in 9/16 in 8 mm [...]

Notes 229895 MA TERIAL THICKNESS GAUGE[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 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 expe[...]

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F AX: 920-735-4134 Int ernati onal F A X: 920-735-4125 European Headqua rters − U[...]