OM-1500-19 219 185P 2007−09 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder SuitCase X-TREME 12VS ™ ™ File: MIG (GMAW) Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
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. 1635 W. Spencer St. Appleton, WI 54914 USA Phone: (920) 734-9821 Mr. Danilo Fedolfi, Managing Director ITW Welding Products Italy S.r.l.
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 or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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 poor, wear an approved air-supplied respirator.
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. FALLING UNIT can cause injury. MOVING PARTS can cause injury. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-4. California Proposition 65 Warnings Welding 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 lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 7 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 l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
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 CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
LES FILS DE SOUDAGE peuvent provoquer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher des organes mobiles tels que des ventilateurs.
2-5. Principales normes de sécurité Safety in Welding, 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 Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
OM-1500-19 Page 10
SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Warning! 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 clear. 1 1.1 2 2.1 3 3.1 4 4.1 5 + 1.2 2.2 1.3 2.3 3.2 + 3.3 + + 6 S-178 936 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.
3-2. Manufacturer’s Rating Label For CE Products S/N: Hz DC IP 23 U1 110 V =I1= 10.0 A U2= 110 V I2= 425 A X 60 % Ref. 181 678 / 804 005-A 3-3. WEEE Label (For Products Sold Within The EU) Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information.
3-4. Symbols And Definitions . Some symbols are found only on CE products.
SECTION 4 − INSTALLATION 4-1. Specifications Welding Power Source Type Type of Input Power Open-Circuit/ Arc Voltage, 14 − 110 Volts DC Constant Voltage (CV) Or Constant Current (CC) DC Power Source Only Wire Feed Speed Range Wire Diameter Range 50 − 780 ipm (1.3 − 19.8 mpm) Depending On Arc Voltage *Solid Steel: .023 − .062 in (0.6 − 1.6 mm); Stainless Steel: .023 − .052 in (0.6 − 1.3 mm); Flux Cored: .030 − .062 in (0.8 − 1.6 mm) *Maximum gun length is 10 ft. for solid steel .062 in. wire. 4-2.
4-3. Equipment Connection Diagram 1 10 ! Turn 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 Voltage (CV) Welding Power Supply Weld Cable To Feeder Ground Cable To Workpiece 2 3 Weld cable and ground cable connections to power source (DCEN/ DCEP) are dependant on wire type. . Since feeder is not polarity sensitive, there is no need for an electrode polarity switch.
4-4. Installing And Aligning Wire Guide And Drive Rolls Installing Wire Guide And Drive Rolls: 1 2 Drive Roll Nut Drive 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. 4 5 Inlet Wire Guide Screw Inlet Wire Guide (One Piece Anti-wear) . The factory installed inlet wire guide is good for up to 5/64 inch diameter wire.
4-5. Connecting Welding Gun And Voltage Sensing Clamp 2 ! Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 2 3 Gun Securing Knob Gun Block Gun Outlet Wire Guide Loosen knob, insert gun end into block. Position outlet wire guide as close as possible to drive rolls without touching. Tighten knob. 1 4 5 6 Connect voltage sensing clamp to workpiece. 3 Internal Side View Gun Trigger Plug Gun Trigger Receptacle Voltage Sensing Clamp 4 6 5 Ref. 804 002-C 4-6.
4-7. Connecting Weld Cable Rear View ! Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 User-Suppled Weld Cable Follow wire manufacturer’s recommendations for weld cable polarity. From Wire Feeder 2 3 Push female connector over male connector, and turn 1/4 turn clockwise. 2 1 User-Suppled Male Connector User-Suppled Female Connector 3 804 004-A 4-8.
4-9. Installing And Threading Welding Wire . Hold wire tightly to keep it from unraveling. Installing Wire And Adjusting Hub Tension: 1 2 Retaining Nut Hub Tension Adjustment Knob Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining nut. Adjust tension knob so only a slight force is needed to turn spool. Threading Welding Wire: 3 Pressure Assembly Adjustment Knob Lay gun cable out straight. Open pressure assembly, hold wire tightly, and cut off end.
4-10. Display Board (PC20) DIP Switch Settings DIP Switch Settings: Display Hold ON 1 2 3 4 5 Displays will hold their last value for five seconds after the trigger is released. After the hold times out, the Voltage Display will show open circuit voltage. If the Wire Speed / Amps Display is set to display Amps, the amperage value will hold, after the hold times out, preset Wire Speed will be displayed. Display Hold OFF 1 2 3 4 5 Displays will not hold values.
SECTION 5 − OPERATION 5-1. Controls With Meters 1 2 2 OFF 3 1 Power Control Switch Trigger Hold Switch 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 minimum of 2 seconds, but no longer than 6 seconds before releasing it. Welding will continue when trigger is released. 4 To stop welding, press and release the trigger.
5-2. Controls Without Meters 1 2 OFF 2 1 Power Control Switch Jog/Purge Switch Pressing the Jog switch allows the operator to jog wire without energizing the contactor or gas valve. Pressing the Purge switch allows the operator to purge gas lines before welding and to preset gas flow rate at the flowmeter. 3 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.
5-3.
5-4. Wire Speed Control Settings Ref.
SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! . Maintain more often Disconnect power before maintaining. 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 Vacuum Inside 6-2. Overload Protection And Thermostat Protection 1 ! Turn Off wire feeder and welding power source. Stop engine on welding generator.
6-3. Troubleshooting Trouble Remedy Wire does not feed; open-circuit voltage Check circuit breaker CB1. Reset CB1. available. 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 board PC1. Wire feeds erratically. Readjust hub tension. Readjust drive roll pressure. Clean or replace dirty or worn drive roll (see Section 4-4).
Trouble Remedy y Authorized Service Agent g check Control board PC1. Information on display board is not accu accu- Have Factory rate. Check transducer HD1 and connections, and replace if necessary. Display on display board does not light. Have Factory Authorized Service Agent check Control board PC1. Replace display board. Segments on the display board are Replace display board. missing. 6-4.
Notes OM-1500-19 Page 28
SECTION 7 − ELECTRICAL DIAGRAM 218 763-E Figure 7-1.
SECTION 8 − PARTS LIST 58 59 34 18 73 26 72 60 33 71 32 31 36 29 62 45 54 39 42 42 61 53 44 49 27 62 55 28 26 30 57 16 24 23 41 22 21 40 17 43 42 41 15 63 69 70 52 68 37 35 47 65 19 20 25 51 50 38 46 48 68 56 14 11 67 13 5 66 10 64 12 7 8 1 (Fig 8-2) 6 3 4 2 (Fig 8-3) Ref. 804 007-K 9 Figure 8-1.
Item No. Diagram marking Part No. Description Quantity Figure 8-1. Complete Assembly 1 . . . . . . . . . . . . . . . . . . Fig 8-2 2 . . . . . . . . . . . . . . . . . . Fig 8-3 3 . . . . . . . . . . . . . . . . . 221 050 4 . . . . . . . . . . . . . . . . . 208 015 5 . . . . . . . . . . . . . . . . . 221 051 6 . . . . . . . . . . . . . . . . . 138 044 7 . . . . . . . . . . . . . . . . . . 214 011 . . . . . . . . . . . . . . . . . . . 600 848 . . . . . . . . . . . . . . . . . . . 208 820 8 . . . . . . .
Item No. Diagram marking Part No. Description Quantity Figure 8-1. Complete Assembly (Continued) 49 . . . . . . . . . . . . . . . . 207 679 . . Insert, Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 50 . . . . . . . GS1 . . . . 226 819 . . Valve, 12VDC 1Way .750−14 Thd 2mm Orf 100PSI . . . . . . . . . . . . . . . . . . 1 51 . . . . . . . . . . . . . . . . 222 067 . . Insulator, Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. 6 7 5 1 4 3 2 Ref. 804 007-K Figure 8-2. Front Panel Assembly without Meters Item No. .. .. .. .. .. .. .. 1 2 3 4 5 6 7 Dia. Mkgs . Part No. Description Quantity Figure 8-2. Front Panel Assembly without Meters (Figure 8-1 Item 1) . . . . . . . . . . . . . 171 007 . . . . . . . S1 . . . . 111 997 . . . . . . . . . . . . . . . 222 797 . . . . . . . S2 . . . . 216 295 . . ........................ . . . . . . . . . . . . . 220 442 . . . . . .
. Hardware is common and not available unless listed. 6 7 5 1 4 3 2 Ref. 804 007-K Figure 8-3. Front Panel Assembly with Meters Item No. .. .. .. .. .. .. .. 1 2 3 4 5 6 7 Dia. Mkgs . Part No. Description Quantity Figure 8-3. Front Panel Assembly with Meters (Figure 8-1 Item 2) . . . . . . . . . . . . . 179 851 . . . . . . . S1 . . . . 111 997 . . . . . . . S4 . . . . 217 932 . . . . . . . S2 . . . . 216 295 . . ........................ . . . . . . . . . . . . . 220 442 . . . . . PC20 . . .
Table 8-1. Drive Roll & Wire Guide Kits (2 Drive Roll) . Base selection of drive rolls upon the following recommended usages: 1. 2. 3. 4. 5. V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).
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Notes SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) Specifications Socket or Wrench Size SOCKET/WRENCH SELECTION TABLE (METRIC) 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 .3150 in 14 mm 14 mm 3/8 in .375 in 9/16 in 5/8 in 10 mm .3937 in 17 mm 17 mm 7/16 in .4375 in 5/8 in 3/4 in 12 mm .
229895 Notes MATERIAL THICKNESS GAUGE
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