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TM-1599

Eff. w/Serial LA305132

March 2002

Processes
MIG (GMAW) Welding Flux Cored (FCAW) Welding

Description

Wire Feeder

SuitCase 8VS

Visit our website at

www.MillerWelds.com

TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Manufacturers Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Installing And Aligning Wire Guide And Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Connecting Welding Gun And Voltage Sensing Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Connecting Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Connecting Weld Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls For Non-CE Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Controls For CE Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 EXPLANATION OF ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Troubleshooting Circuit Diagram For Wire Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Motor Control Board PC1 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Motor Control Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Optional Trigger Hold Board PC30 Testing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Optional Trigger Hold Board PC30 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Optional Meter Board Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. Optional Meter Board Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Overload Protection And Thermostat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Calibrating Optional Inches Per Minute (IPM) Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 3 3 4 4 5 5 5 6 7 7 8 8 9 9 10 12 14 18 18 20 22 23 25 25 26 27 28 28 28 29 30 43

WARNING
This product, when used for welding or cutting, 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.)

Declaration of Conformity for European Community (CE) Products


NOTE
Manufacturers Name: Manufacturers Address: This information is provided for units with CE certification (see rating label on unit).

Miller Electric Mfg. Co.


1635 W. Spencer Street Appleton, WI 54914 USA

Declares that the product:

SuitCase 8VS
Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC

conforms to the following Directives and Standards:

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Standards Arc Welding Equipment Part I: Welding Power Sources: IEC 974-1 (April 1995 Draft Revision) Arc Welding Equipment: Wirefeed Systems: IEC 974-4 (May 1995 Draft Revision) Degrees of Protection Provided By Enclosures (IP Code): IEC 529:1989 Insulation Coordination For Equipment With Low-Voltage Systems: Part I: Principles, Requirements and Tests: IEC 664-1: 1992 Electromagnetic Compatibility, (EMC): EN 50199

European Contact:

Mr. Danilo Fedolfi, Managing Director MILLER Europe S.r.l. Via Privata Iseo 20098 San Giuliano Milanese, Italy 39(02)98290-1 39(02)98281-552

Telephone: Fax:
dec_con1 1/96

SECTION 1 SAFETY PRECAUTIONS FOR SERVICING


1-1. Symbol Usage
OM-1599-D - 2/02, safety_stm 7/98

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

. Means Note; not safety related. 1-2. Servicing Hazards


Y 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. Y Only qualified persons should service, test, maintain, and repair this unit. Y During servicing, keep everybody, especially children, away.

FLYING METAL can injure eyes.


D Wear safety glasses with side shields or face shield during servicing. D Be careful not to short metal tools, parts, or wires together during testing and servicing.

HOT PARTS can cause severe burns. ELECTRIC SHOCK can kill.
D Do not touch live electrical parts. D Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit. D D D D D Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground. Do not leave live unit unattended. If this procedure requires an energized unit, have only personnel familiar with and following standard safety practices do the job. When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free. Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source. D Do not touch hot parts bare handed. D Allow cooling period before working on welding gun or torch.

EXPLODING PARTS can cause injury.


D Failed parts can explode or cause other parts to explode when power is applied to inverters. D Always wear a face shield and long sleeves when servicing inverters.

SHOCK HAZARD from testing.


D Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections. D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip. D Read instructions for test equipment.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.


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

FALLING UNIT can cause injury.


STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

FIRE OR EXPLOSION hazard.


D Do not place unit on, over, or near combustible surfaces. D Do not service unit near flammables. SuitCase 8VS

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. TM-1599 Page 1

MOVING PARTS can cause injury.


D Keep away from moving parts. D Keep away from pinch points such as drive rolls.

H.F. RADIATION can cause interference.


D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment install, test, and service H.F. producing units. D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. D If notified by the FCC about interference, stop using the equipment at once. D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

MAGNETIC FIELDS can affect pacemakers.


D Pacemaker wearers keep away from servicing areas until consulting your doctor.

OVERUSE HEATING.

can

cause

OVER-

READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when servicing this unit. D Consult the Owners Manual for welding safety precautions. D Use only genuine replacement parts.

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit.

1-3. EMF Information


Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: The body of evidence, in the committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

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SECTION 2 DEFINITIONS
2-1. 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 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Disconnect input plug or power before working on machine. 2 Breathing welding fumes can be hazardous to your health. 2.1 Keep your head out of the fumes. 2.2 Use forced ventilation or local exhaust to remove the fumes. 2.3 Use ventilating fan to remove fumes. 3 Welding sparks can cause explosion or fire. 3.1 Keep flammables away from welding. Dont weld near flammables. 3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it. 3.3 Do not weld on drums or any closed containers. 4 Arc rays can burn eyes and injure skin. 4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working on the machine or welding. 6 Do not remove or paint over (cover) the label.

1.1

1.2

1.3

2.1

2.2

2.3

3.1

3.2

3.3

4.1

+
5

+
6

+
S-178 936

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TM-1599 Page 3

2-2. Manufacturers Rating Label For CE Products


For label location see Section 4-1.

S/N:

U1 100 V =1= 7.0 A I

Hz DC IP 23

U2 100 V =

I2= 500 A

X 100 %

ST-181 678

2-3. Symbols And Definitions

NOTE
Output

Some symbols are found only on CE products.


Input

Amperes

Duty Cycle

Wire Feed Cold Jog (Inch) Towards Workpiece Circuit Breaker

Percent

V IP

Volts Degree Of Protection

Input

Purge By Gas

Fast

Constant Current

Constant Voltage

Slow

Trigger Hold Off

Trigger Hold On

Read Instructions

U1

Primary Voltage

I2 U2

Rated Welding Current Conventional Load Voltage

Increase

Hz

Hertz

I1

Primary Current

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SuitCase 8VS

SECTION 3 INSTALLATION
3-1. Specifications
Type of Input Power Welding Power Source Type Wire Feed Speed Range Wire Type And Diameter
Solid Steel: .023 .062 in (0.6 1.6 mm); Stainless Steel: .023 .052 in (0.6 1.3 mm); Flux Cored: .030 .052 in (0.8 1.3 mm)

Input Welding Circuit Rating

IP Rating

Max. Wire Spool Capacity

Overall Dimensions

Weight

Open-Circuit/ Arc Voltage, 15 100 Volts DC

Constant Voltage (CV) Or Constant Current (CC) DC

50 700 ipm (1.3 18 mpm) Depending On Arc Voltage

Length: 15-5/8 in (397 mm) 330 Amperes At 60% Duty Cycle 23 14 lb (6.4 kg), 8 in (203 mm) Width: 6-1/2 in (165 mm) Height: 14-1/2 in (368 mm) 25 lb (11 kg)

3-2. Gun Recommendation Table


Process
GMAW Hard or Corded Wires FCAW Self-Shielding Wires

Gun
M25 Or M40 FC-1260

SuitCase 8VS

TM-1599 Page 5

3-3. 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

Installing Wire Guide And Drive Rolls

Loosen securing screw. Install inlet guide so inlet guide screw is centered in groove in guide, or so tip is as close to drive rolls as possible without touching. Tighten screw. Aligning Wire Guide And Drive Rolls:

5 4

View is from top of drive rolls looking down with pressure assembly open. 6 7 8 9 10 1 2 Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear

Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide. Close pressure roll assembly. Only top drive roll alignment is adjustable. Turn adjustment screw in or out until groove in drive roll lines up with wire guide as shown.

Aligning Wire Guide And Drive Rolls

Cleaning Drive Rolls: Remove drive rolls, and clean grooves using a wire brush.

Correct 8 7 6 10 9

Incorrect

Tools Needed: 3/16 in 3/8 in


802 706-A / Ref. 132 808-F / Ref. 162 079-A / Ref. 180 967

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SuitCase 8VS

3-4. Connecting Welding Gun And Voltage Sensing Lead


1 2 3 2 1 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. 4 5 6 Gun Trigger Plug Gun Trigger Receptacle Voltage Sensing Clamp Connection

Connect voltage sensing clamp, and connect clamp to workpiece. Internal Side View

4 6 5

Ref. 802 706-A / 802 768 / Ref. S-0621-C

3-5. Connecting Shielding Gas


1 Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) Shielding Gas Cylinder Valve Flowmeter

4 Rear View

2 3 4

Close valve on cylinder when finished welding.

Tools Needed: 5/8 in 1

801 155-A / Ref. 802 770

SuitCase 8VS

TM-1599 Page 7

3-6. Connecting Weld Cable


1 Internal Side View User-Suppled Weld Cable Follow wire manufacturers recommendations for weld cable polarity. 2 3 User-Suppled Male Connector User-Suppled Female Connector

From Wire Feeder

Push female connector over male connector, and turn 1/4 turn clockwise.

3
Ref. 132 808-F / Ref. 802 706

3-7. 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 Nut

Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining nut. Adjust tension nut 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. Push wire through guides into gun. 3 Close and tighten pressure assembly. Press gun trigger until wire comes out gun. Feed wire against wooden surface, and tighten knob so wire does not slip. Cut off wire, and close door.

6 in (150 mm) Pull and hold wire; cut off end.

Tighten Clockwise

Tools Needed: 9/16 in

WOOD
802 706-A / Ref. ST-159 048-A / S-0627-A

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SuitCase 8VS

SECTION 4 OPERATION
4-1. Controls For Non-CE Models
1 2 3 2 1 Power Control Switch Trigger Hold Switch (Optional)

This unit offers an optional trigger hold function, which is turned On or Off with a front panel toggle switch. Depress the upper part of the switch (turns trigger hold On) to weld without holding gun trigger throughout the weld cycle. To start weld, press and release gun trigger. To end weld, press and release gun trigger. Depress the lower part of the trigger hold switch to turn trigger hold Off. 3 Purge Switch Press switch to momentarily energize gas solenoid and purge air from gun, and to adjust shielding gas regulator. 4 Wire Speed Control Use control to adjust wire speed within range selected by switch. 5 Jog Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve. 6 HI/LO Range Switch

PURGE TRIGGER POWER HOLD


8

V
4

WIRE SPEED (PERCENT)

Front Panel

Use switch to select high or low wire speed range. High range is 100 to 700 ipm. Low range is 50 to 350 ipm. 7 CC/CV Switch Use switch to match wire feeder with welding power source output.

Close and latch door. 8 Optional Voltage/Wire Speed Meter 9 Optional Voltage/Wire Speed Switch 10 Front Panel 11 Meter Hold Dip Switch If the switch is set to the HOLD position, the value will be held when you have welded for 8 seconds or more. The meter will display the last weld value for 15 seconds after trigger is released or until retriggered, whichever comes first.

LO

CC

JOG

HI

CV

Internal Control Panel

10

Meter Hold (OFF) Inches/ Minute

Meter Hold (OFF) Meter/ Minute

Meter Hold (ON) Inches/ Minute

Meter Hold (ON) Meter/ Minute

Internal Side View

11

Dip Switch Position

Ref. 802 768 / Ref. 802 706-A / Ref. 803 124

SuitCase 8VS

TM-1599 Page 9

4-2. Controls For CE Models


1 2 3 2 1 Power Control Switch Trigger Hold Switch

Depress the upper part of the switch (turns trigger hold On) to weld without holding gun trigger throughout the weld cycle. To start weld, press and release gun trigger. To end weld, press and release gun trigger. Depress the lower part of the trigger hold switch to turn trigger hold Off. 3 Purge Switch Press switch to momentarily energize gas solenoid and purge air from gun, and to adjust shielding gas regulator. 4 Wire Speed Control Use control to adjust wire speed within range selected by switch. 5 Jog Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve. 6 HI/LO Range Switch Use switch to select high or low wire speed range. High range is 100 to 700 ipm. Low range is 50 to 350 ipm. 7 CC/CV Switch Use switch to match wire feeder with welding power source output. Close and latch door.

Front Panel

Internal Control Panel

Internal Side View

Ref. 802 768 / Ref. 802 706-A / Ref. 203 745 / Ref. 203 749

TM-1599 Page 10

SuitCase 8VS

Notes

Work like a Pro!


Pros weld and cut safely. Read the safety rules at the beginning of this manual.

SuitCase 8VS

TM-1599 Page 11

SECTION 5 THEORY OF OPERATION


1 Gun Trigger Receptacle RC2 Connects gun trigger circuit to wire feeder. 2 Thermostat TP1 Provides overtemperature protection for welding circuit. 3 Motor Control Board PC1 Controls wire speed by changing the pulse width modulation signal (wider or narrower pulses meaning more or less voltage to motor) after comparing motor speed feedback voltage signal to selected voltage signal from R1. 4 Wire Drive Motor M1 Feeds wire at a speed set by wire speed control R1. 5 6 Wire Speed Control R1 CC/CV Switch S3 4 Wire Drive Motor M1 5 Wire Speed Control R1 6 CC/CV Switch S3 7 Wire Speed Range Switch S5 High/Low CC/CV Motor Command Motor Control Board PC1 Motor Command Selects wire feed speed. Matches wire feeder to welding power source output. 7 Wire Speed Range Switch S5 Selects high or low range wire feed speed. 8 Meter Board (Optional) Provides meter calibration for wire speed meter. Wire Speed Meter - Displays actual wire feed speed. Voltage Meter - Displays arc voltage at the wire feeder. 9 Power Control Switch S1 S1 provides on/off control of the wire feeder control circuitry. 10 Circuit Breaker CB1 Provides overload protection for wire feeder. 3

1 Gun Trigger Receptacle RC2

2 Thermostat TP1 Trigger Signal

voltage meter and High/Low 8 Meter Board Wire Feed Speed/ Voltage Meter Motor Control/ Arc Voltage

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SuitCase 8VS

11 Capacitors C1, C2 Smooths out open-circuit or arc voltage supplied to PC1. 12 Integrated Rectifier SR1 Changes open-circuit voltage to dc. 13 Contactor W1 Provides means to turn on and off open-circuit and weld voltage to welding gun. 14 Purge Switch S2 Energizes gas valve GS1 without energizing the weld circuit. 15 Gas Valve GS1 Provides shielding gas during the weld cycle. Circuit Breaker CB1 16 Optional Trigger Hold Board PC30/Trigger Hold Switch S31 Provides ability to weld without holding gun trigger throughout weld cycle. 17 Jog Switch S4 Integrated Rectifier SR1 Provides means to momentarily feed welding wire at speed set on Wire Speed control R1 without energizing welding circuit or shielding gas valve GS1. Weld Cable 13 Contactor W1 14 Purge Switch S2 15 Gas Valve GS1 16 Trigger Signal Trigger Hold Board PC30 Trigger Signal 17 Jog Switch S4 16 Trigger Hold Switch S31 Drive Housing or arc

9 Arc Voltage Power Control Switch S1

10 Sense Lead

11 DC Voltage Capacitors C1, C2

12

Arc Voltage

AC Or DC Control Circuits

Optional

SuitCase 8VS

TM-1599 Page 13

SECTION 6 EXPLANATION OF ELECTRICAL PARTS


elect_parts 2/02

6-1. Safety Precautions Read Before Using This Guide

Y WARNING: ELECTRIC SHOCK can kill. D Disconnect input power or stop engine before servicing. D Do not touch live electrical parts. D Do not operate machines with covers removed. D Have only qualified persons install, use, or service equipment.

6-2. Explanation Of Electrical Parts


PART NAME CAPACITOR FUNCTION A device that stores electrical energy. Large capacitors or a bank of capacitors can be used to smooth out the DC welding arc in a MIG welding power source. Smaller disk capacitors can be used for HF protection. PICTURE CIRCUIT SYMBOL
POLARIZED C1 NON-POL. C1

CIRCUIT BREAKER A protection device that breaks a circuit when current levels exceed its rating. Unlike a fuse that needs to be replaced when blown, a circuit breaker can be reset. DIODE A device that allows current to flow in one direction only. Most common use is to change AC to DC.

CB1

D1

FUSE

A protection device, usually an enclosed piece of wire that melts and breaks the circuit when the current exceeds the fuse rating. Produces a small DC voltage proportional to the current it is sensing (usually welding current). This feedback signal can be used to regulate the welding output (line voltage compensation). It may even be used to drive an ammeter. A device which resists the flow of electric current. Uses include limiting the current for a motor brake circuit in a wire feeder and for discharging a capacitor. Both devices have a moveable brush that makes contact along a resistor, allowing you to easily change the resistance measured at the brush (sometimes referred to as a wiper). Their primary purpose is to give the operator a way to adjust welding parameters such as wire speed, preflow time, voltage, inductance, etc.
FIXED

F1

HALL DEVICE

HD1

RESISTOR

R1

FIXED TAPPED

R1

POTENTIOMETER OR RHEOSTAT

VARIABLE

R1

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SuitCase 8VS

PART NAME PILOT LIGHT

FUNCTION A light located on the front panel which indicates if the machine is on or off. This device provides cooling of the internal parts of a welding power source.

PICTURE

CIRCUIT SYMBOL
1 PL

FAN MOTOR

FM

VARISTOR

A protection device whose resistance is dependent on the voltage applied to it. In normal operation it has a high resistance; however, a surge of voltage (voltage spike) will cause its resistance to go way down and absorb the spike. These devices are most often found in rectifying circuits, where they are used to protect the diodes. These are electromechanical devices used to start or stop the flow of shielding gas or water.

VR1

GAS OR WATER SOLENOID (VALVE)

GS1 OR WS1

RELAYCOIL AND CONTACTS, NORMALLY OPEN AND NORMALLY CLOSED

This is an electromechanical device whose contacts change state (the normally open points close and the normally closed points open) when proper voltage is applied to the coil. These contact points in turn may control a fan motor, gas solenoid, contactor, etc. Circuit diagrams (schematics) always show the contact points in the power off state. This is a switch that closes its normally open contacts (or opens its normally closed contacts) when a preset temperature is reached. When the temperature goes back down, it will reset itself. Uses of these devices include turning on a fan motor when needed and shutting off the output of a welding power source if it is overheating. A heavy duty relay. Usually used to make and break the welding arc or primary power.

COIL

CR1

CR1

NRM OPEN NRM CLOSED POINTS POINTS

THERMOSTAT, NORMALLY OPEN AND NORMALLY CLOSED

TP1

TP1

NRM OPEN NRM CLOSED

CONTACTOR

W NRM OPEN POINTS

COIL W

STABILIZER/ REACTOR

When placed in a DC circuit, the inductor or stabilizer as it is usually called, will oppose any change in existing current. It is therefore widely used to stabilize the welding arc. When the inductor is placed in an AC circuit it is referred to as a reactor where it now acts to restrict the flow of current. A tapped reactor is used to create current ranges for welding.

Z1

L1

SuitCase 8VS

TM-1599 Page 15

PART NAME MOTOR

FUNCTION A device that is typically used to feed wire in a MIG welding system.

PICTURE

CIRCUIT SYMBOL

B1

SHUNT

A precision low-value resistor typically used to supply a small voltage to drive an ammeter.

SHUNT

MOSFET

A device that is used as an electronic switch. When a signal is applied to the gate (G), current is allowed to flow from the source (S) to the drain (D). This device can be used to control a relay, the speed of a motor, or even the output of a welding machine. A device that is used as an electronic switch. When a signal is applied to the gate (G), current is allowed to flow from the emitter (E) to the collector (C). This device is typically used in Inverter designed welding machines to control the welding output. Components that allow electrical connections between stationary and rotating contacts.

G AS S C1 G1 (B1) E1

IGBT

BRUSHES/SLIP RINGS

SLIP RINGS

BRUSHES

TERMINAL STRIP

An insulated connection point for wires. They are used for the ease of making multiple connections and can be a convenient point for making electrical checks when troubleshooting. (Notice the jumper link connecting terminals A and B together.) A mechanical device that completes or breaks the path of the current or sends it over a different path.

1T

42 42 104 105 74 A B C D E

SWITCH

SPST

SPDT

DPST

DPDT

TM-1599 Page 16

SuitCase 8VS

PART NAME SCR

FUNCTION A Silicon Controlled Rectifier (SCR) is an electrical device with three connections, anode, cathode, and gate. It will allow current to flow in only one direction and will only do so after receiving a signal on the gate lead. SCRs are used to change AC to DC and to control the output to a load such as a welding arc. A thermally sensitive resistor. The resistance of a thermistor changes with a change in temperature. Primarily used for Fan on Demand and Thermal Shutdown circuits. A device that changes AC voltage from one magnitude to another. Typically used to reduce high primary voltages to lower welding voltages.

PICTURE

CIRCUIT SYMBOL

K G

THERMISTOR

RT1 OR TH1

TRANSFORMER

T1

INTEGRATED BRIDGE RECTIFIER

An arrangement of four diodes used to change AC to DC.

AC AC

+
AC

SPARK GAP The arrangement of two electrodes between which a discharge of electricity will occur. Typically used to produce high frequency which can be used for arc starting when TIG welding. A transformer that produces an AC voltage used for measuring purposes. The primary winding is in series with the circuit carrying the current to be measured. Its main use in engine-driven equipment is to activate the Automatic Idle circuit by sensing welding current or auxiliary power current.

AC

CURRENT TRANSFORMER

CT1

OR CT1

SuitCase 8VS

TM-1599 Page 17

SECTION 7 TROUBLESHOOTING
7-1. Troubleshooting Table . See Section 7-2 for test points and values and
Section 10 for parts location.

Trouble
Unit completely inoperative.

Remedy
Check power source (see power source Owners Manual). Check weld cable and sensing lead connections. Check circuit breaker CB1, and reset if necessary (see Section 8-2). Check continuity of gun trigger switch and circuit. Repair or replace if necessary. Check continuity of power control switch S1, and replace if necessary. Check motor control board PC1 and connections, and replace if necessary (see Section 7-3). Check voltage and connections of wire drive motor M1. Check continuity of armature. Replace M if necessary (see Section 7-3).

Wire does not feed; open-circuit voltage available.

Check circuit breaker CB1, and reset if necessary (see Section 8-2). Unit overheated. Allow unit to cool. Check weld cable and sensing lead connection. Check gun trigger receptacle RC2 connection. Check continuity of gun trigger switch and circuit. Repair or replace if necessary. Check motor control board PC1 and connections, and replace if necessary (see Section 7-3). Check voltage and connections of wire drive motor M1. Check continuity of armature. Replace M1 if necessary (see Section 7-3).

Wire feeds erratically.

Remove weld spatter around nozzle opening. Readjust hub tension. Readjust drive roll pressure. Change to correct size drive roll. Clean or replace dirty or worn drive roll. Replace contact tip or liner. See gun Owners Manual. Check weld cable and sensing lead connection. Check resistance and connections of Wire Speed control R1; R1 is 0 to 10 k ohms 10%. Replace R1 if necessary. Check motor control board PC1 and connections, and replace if necessary (see Section 7-3). Check voltage and connections of wire drive motor M1. Check continuity of armature. Replace M1 if necessary (see Section 7-3).

Wire feeds as soon as power is applied.

Check continuity of gun trigger switch. Repair or replace if necessary. Check motor control board PC1 and connections, and replace if necessary (see Section 7-3).

Wire feeds when Jog switch is pressed but not when gun trigger is pressed. Wire stubbing on low end using a constant current power source.

Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch, and replace if necessary. Make sure CC/CV switch S3 is in CC position (se Section 4-1). Increase output setting of power source.

Optional meter not working.

Check optional meter board and connections, and replace if necessary (see Section 7-7). Check motor control board PC1 and connections, and replace if necessary (see Section 7-3).

TM-1599 Page 18

SuitCase 8VS

Trouble
Readings on accurate. optional meter not

Remedy
Calibrate meter board (see Section 7-7 and Section 8-3). Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary. Check motor control board PC1 and connections, and replace if necessary (see Section 7-3).

Gas does not flow with gas valve GS1; wire feeds.

Gas does not flow when Purge switch S2 is pressed.

Purge switch S2 does not work. Check and replace if necessary. Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.

Gas does not stop flowing with gas valve GS1; wire feeds.

Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary. Check motor control board PC1 and connections, and replace if necessary (see Section 7-3).

SuitCase 8VS

TM-1599 Page 19

7-2. Troubleshooting Circuit Diagram For Wire Feeder

See Section 7-7 for meter board data and Section 8-3 for meter calibration

V5

V6

See Section 7-3 for PC1 data

V7

V4 V1

V2

V3

See Section 7-5 for PC30 data

TM-1599 Page 20

SuitCase 8VS

Voltage Readings a) b) c)
V1 V2 V3 V4

Tolerance specified

10%

unless

Reference to circuit common (lead 15) unless noted Wiring Diagram see Section 9
Rectified and filtered arc voltage +15 volts dc output when arc voltage is greater than 15 volts dc Open-circuit or arc voltage input Values dependent on arc voltage a. Typically 2 to 15 volts dc from min to max of R1 with S3 in CC position and S5 in Low position b. Typically 3 to 28 volts dc from min to max of R1 with S3 in CC position and S5 in High position c. Typically 2 to 13 volts dc from min to max of R1 with S3 in CV position and S5 in Low position d. Typically 3 to 25 volts dc from min to max of R1 with S3 in CV position and S5 in High position a. 0 to +3.5 volts dc from min to max of R1 with S3 in CC position and S5 in Low position, b. 0 to +7 volts dc from min to max of R1 with S3 in CC position and S5 in High position, c. 0 to +3 volts dc from min to max of R1 with S3 in CV position and S5 in Low position, d. 0 to +6 volts dc from min to max of R1 with S3 in CV position and S5 in High position 12 volts dc with gun trigger switch closed

V5

V6, V7

Test Equipment Needed:

203 029-B

SuitCase 8VS

TM-1599 Page 21

D5 C6

D12

R100 RC56 R101 C20

R29 R28

C12 R47

R48 R44 C24

R17 R16

R35 R40 R41 A2 R42 R45 Q11 D11

R1
C27 R13 R80

D15 R49 R53 R52

Q6 + R88 R72
R90

A1

+ C11

R3 R102 D14 R33 R4 R27 R38 R2 R18 R5 R104C21 R32 R6 R14 R99 3 2 1
R15

C2 C3 C8
C18 R12 R11 D10

C7 3 4

R39 R56 C17 R61 C5 R62 R77 R63

R103 R43 C38 R93 C30 R79 R81

OC1

R19

1 2

+ C14
R50 D13 D23

R22 TEST1

A3 +

R60 D S G Q7 D18 C32 C16 C29 R46 Q10 R85 R76 + + R34 D16 R96 R51 C26 C35

A5

C1

R9 R20 R7 C4 R8 U1

C42

R10 C36 R25

R58Q9 C25 R64 C23 R78

C37 C13

C50 R91

U2 R84

R75 C34

D3 +
C10

A4

C9
R23

G D S Q1
HS2

D4

D8
R31

R83 R86 R68 R69 R70

D17 R59 D22 D20K C31

D1 D2 D9

R36 D25 R98 D24 Q13

S Q8 D C43 U3
C46 R89

A R57
Q14 R94 R95 R111 D21

C33

R37 R26

R71

D7 S
C19 Q12

D6

B C E Q2
HS4

R24 R21 R109 13

C40

HS1 R73 R55

HS3

10 11 12

RC50

RC51

RC52

RC53

RC55

RC54

TM-1599 Page 22

7-3. Motor Control Board PC1 Testing Information

Test Equipment Needed:

1 2 3 4 5 6 7 8

Be sure plugs are secure before testing. See Section 7-4 for specific values during testing.

Motor Control Board PC1 Receptacle RC50 Receptacle RC51 Receptacle RC52 Receptacle RC53 Receptacle RC54 Receptacle RC55 Receptacle RC56

Ref. 803 143 / 206 061

SuitCase 8VS 6 5 4 + +
C22 R30

C28

R66 R65

C39 R97

D D

A
D19

R67

R82

1 2 3

1 2 3 4 5 6 7 8 9

1 2 3 4 5

1 2

1 2

1 2 3 4 5 6 7

7-4. Motor Control Board PC1 Test Point Values


10% unless

a) Tolerance specified PC1 Voltage Readings

b) Reference to circuit common (lead 15) unless noted Value

Receptacle
RC50

Pin
1 2

Positive (+) open-circuit or arc voltage input with respect to RC50-5 Negative () voltage output to wire drive motor M1, 0 volts dc output with gun trigger switch open, +0.1 volts dc output with gun trigger switch closed Positive (+) voltage output to wire drive motor M1 (value dependent on arc voltage) a. Typically +2 to +15 volts dc output with respect to RC50-2 from min to max of Wire Speed control R1 with CC/CV switch S3 in CC position and Wire Speed Range switch S5 in Low position b. Typically +3 to +28 volts dc output with respect to RC50-2 from min to max of Wire Speed control R1 with CC/CV switch S3 in CC position and Wire Speed Range switch S5 in High position c. Typically +2 to +13 volts dc output with respect to RC50-2 from min to max of Wire Speed control R1 with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in Low position d. Typically +3 to +25 volts dc output with respect to RC50-2 from min to max of Wire Speed control R1 with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in High position

4 5 6 7 8

+15 volts dc output to gun trigger switch when arc voltage is greater than 15 volts dc DC circuit common, negative () open-circuit or arc voltage input with respect to RC50-1 +7 volts dc output with CC/CV switch S3A in CC position, +3 volts dc output with S3A in CV position +7 volts dc input with CC/CV switch S3A in CC position, 0 volts dc input with S3A in CV position a. 0 to +3.5 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CC position and Wire Speed Range switch S5 in Low position b. 0 to +7 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CC position and Wire Speed Range switch S5 in High position c. 0 to +3 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in Low position d. 0 to +6 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in High position

9 10 11 12

+15 volts dc input with gun trigger switch closed Weld electrode potential, bus bar or contactor W1 input CCW position of Wire Speed control R1 CW position of Wire Speed control R1, 0 to +7 volts dc (value dependent on arc voltage and position of Wire Speed Range switch S5) Work potential, voltage sense lead input +3 volts dc input with CC/CV switch S3A in CV position, 0 volts dc input with S3A in CC position Positive (+) inches per minute output with respect to RC51-3 for optional meter board Negative () inches per minute output with respect to RC51-2 for optional meter board Positive (+) open-circuit or arc voltage output with respect to RC51-5 DC circuit common, negative () open-circuit or arc voltage output with respect to RC51-4 Positive (+) open-circuit or arc voltage output with respect to RC50-5 +12 volts dc output with respect to RC52-1 with gun trigger switch closed and gas valve GS1 installed TM-1599 Page 23

13 RC51 1 2 3 4 5 RC52 1 2 SuitCase 8VS

Receptacle
RC53

Pin
1 2

Value
Positive (+) open-circuit or arc voltage output with respect to RC50-5 +12 volts dc output with respect to RC53-1 with gun trigger switch closed and contactor W1 installed Not used Motor start/stop, +13 volts dc with gun trigger switch open, 0 volts dc with gun trigger switch closed Motor start/stop, +13 volts dc with gun trigger switch open, 0 volts dc with gun trigger switch closed Motor start/stop, +13 volts dc with gun trigger switch open, 0 volts dc with gun trigger switch closed Motor start/stop, +13 volts dc with gun trigger switch open, 0 volts dc with gun trigger switch closed DC circuit common, negative () open-circuit or arc voltage output with respect to RC50-1 Not used Gas valve control, +13 volts dc output with gun trigger switch open, 0 volts dc output with gun trigger switch closed Gas valve control, +13 volts dc input with gun trigger switch open, 0 volts dc input with gun trigger switch closed or optional Purge switch S4 closed DC circuit common, negative () open-circuit or arc voltage output with respect to RC50-1 +6 volts dc output to CC/CV switch S3B a. +6 volts dc with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in High position

RC54

1 2 3 4 5 6 7

RC55

3 RC56 1 2

b. Arc voltage dependent with S3 in CC position 3 a. +6 volts dc input with CC/CV switch S3 in CV position b. +7 volts dc max input with S3 in CC position (arc voltage dependent) 4 a. +3 volts dc with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in Low position, +6 volts dc with S3 in CV position and S5 in High position b. +3.7 volts dc with CC/CV switch S3 in CC position and Wire Speed Range switch S5 in Low position, +7 volts dc max with S3 in CC position and S5 in High position (arc voltage dependent) 5 6 RC57 1 2 Not used Not used Not used Not used

TM-1599 Page 24

SuitCase 8VS

7-5. Optional Trigger Hold Board PC30 Testing Information


1 Be sure plugs are secure before testing. See Section 7-6 for specific values during testing. 1 2 3 Trigger Hold Board PC30 Receptacle RC31 Receptacle RC35

ASSEMBLY NO. R7 R16 R6 C3 Q1 C5 R10 R2 U1 R3 C1 R14 Q2 2 3 4 R8 R9 C10

Q3

A1 C8 R5 R15 L3 R17 R18 L4

U2 C4 R13 L1 1 RC35 RC31 L2 C7 3 1 4 2

OC1 R11 C6

5 6 7 8
2

Test Equipment Needed:

Ref. 803 143 / 200 904 / 202 191

7-6. Optional Trigger Hold Board PC30 Test Point Values


a) Tolerance specified PC30 Voltage Readings

10% unless

b) Reference to circuit common (lead 15) unless noted Value

Receptacle
RC31

Pin
1 2 3 4 5 6 7 8 Not used

Motor start/stop, +13 volts dc with Jog switch open, 0 volts dc with gun trigger switch closed +15 volts dc output to optional trigger hold board PC30 Not used Motor start/stop, +13 volts dc with Jog switch open, 0 volts dc with switch closed Not used Motor start/stop, +13 volts dc with gun trigger switch open, 0 volts dc with switch closed DC circuit common, negative () open circuit or arc volt output with respect to receptacle RC50-1 Not used DC circuit common +13 volts dc with trigger hold switch S31 off. Not used TM-1599 Page 25

RC35

1 2 3 4

SuitCase 8VS

7-7. Optional Meter Board Testing


Be sure plug is secure before testing. See Section 7-8 for specific values during testing. 1 2 Meter Board Receptacle RC15 IPM meter.

. See Section 8-3 for calibrating

R41

10

6 7 8 9
RC15
BACK VIEW

1 2 3 4 5
2 Test Equipment Needed:
Ref. 803 139 / 206 543-A

TM-1599 Page 26

SuitCase 8VS

7-8. Optional Meter Board Test Point Values


a) Tolerance specified Meter Board Voltage Readings

10% unless

b) Reference to circuit common (lead 15) unless noted

Receptacle
RC15

Pin
1 2 3 4 5 6 7 8 9 10

Value
DC circuit common, negative () open-circuit or arc voltage output with respect to RC51-4 Work potential, voltage sense lead input Weld electrode potential, bus bar or contactor W1 input Gas valve control, +13 volts dc output with gun trigger switch open, 0 volts dc output with gun trigger switch closed

Positive (+) open-circuit or arc voltage output with respect to RC51-5 Positive (+) inches per minute output with respect to RC51-3 for optional meter board Negative () inches per minute output with respect to RC51-2 for optional meter board CW position of Wire Speed control R1, 0 to +7 volts dc (value dependent on arc voltage and position of Wire Speed Range switch S5) a. 0 to +3.5 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CC position and Wire Speed Range switch S5 in Low position b. 0 to +7 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CC position and Wire Speed Range switch S5 in High position c. 0 to +3 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in Low position d. 0 to +6 volts dc input from min to max of Wire Speed control R1 with CC/CV switch S3 in CV position and Wire Speed Range switch S5 in High position

SuitCase 8VS

TM-1599 Page 27

SECTION 8 MAINTENANCE
8-1. 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 Vacuum Inside

8-2. Overload Protection And Thermostat Protection


Y Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 1 Circuit Breaker CB1 CB1 protects wire feeder from overload. Correct problem and reset CB1. Close and latch door. Thermostat Protection

CB1

Unit has internal thermostat protection and will not feed wire if overheating occurs (see Section 7-1).

Internal Side View

Ref. 802 706-A

TM-1599 Page 28

SuitCase 8VS

8-3. Calibrating Optional Inches Per Minute (IPM) Meter


Meter is factory calibrated, but may need recalibration after motor brushes are fully seated. To recalibrate, proceed as follows: Nonconductive 5 2 1 Front Panel Remove the four screws and remove but do not disconnect the front panel. 2 3 1 3 4 4 5 6 CV/CC Switch Meter Board Potentiometer P2 Adjustment Screw (High Range) Wire Speed Range Switch Wire Speed Control A Set control to about 50%. Turn wire feeder and welding power source On. Press trigger and feed wire for 15 seconds. Measure wire length, and multiply x 4 to get actual ipm. For example: If 49 inches feeds in 15 sec, 49 x 4 = 196 actual ipm. Press trigger again: Meter reading should match actual ipm value, 196 in example. If not, press trigger and carefully adjust P2 until meter reads 196. Set switch to CV.

Set switch to high range.

PURGE

POWER

Reinstall front panel. Turn off power. Close and latch door. 6

V WIRE SPEED (PERCENT)

Front Panel

C B

0 15

49
Ref. 802 706-A

SuitCase 8VS

TM-1599 Page 29

SECTION 9 ELECTRICAL DIAGRAMS


. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information. The following is a list of all diagrams for models covered by this manual.

Model
SuitCase 8VS

Serial Or Style Number


LA305132 thru LB031536 LB031537 and following

Circuit Diagram
200 620 203 029-B

Wiring Diagram
200 621-B 200 621-B

Circuit Board PC1

LA305132 thru LB031536 LB031537 thru LB243978 LB243979 and following

201 738 205 990 206 078

Circuit Board PC30

LA305132 and following

200 906

Meter Board Optional Not included in this manual

LA305132 and following

206 544-B

TM-1599 Page 30

SuitCase 8VS

200 620

Figure 9-1. Circuit Diagram For SuitCase 8VS Effective With Serial No. LA305132 Thru LB031536
SuitCase 8VS TM-1599 Page 31

203 029B

Figure 9-2. Circuit Diagram For SuitCase 8VS Effective With Serial No. LB031537 And Following

TM-1599 Page 32

SuitCase 8VS

200 621-B

Figure 9-3. Wiring Diagram For SuitCase 8VS Effective With Serial No. LA305132 And Following
SuitCase 8VS TM-1599 Page 33

+15V Q13 +15V R111 +15V R98 D24 D13

RC54 1

Q2

GND

U2 2 IN OUT 7 3 6 ERR CS 5 VS VB8

Q12 R36 D25 R99

C42

R67 R96

D21 GND POS RC50 1 RC51 4 RC52 1 RC53 D4 1 RC52 2 RC53 2 R20 R6

R82 R15 R18 2 3 A1 + 1 R5 R4 R2 R3 C7 C6

GND D23 C22 R63 C39 C46 C37

GND

GND

+15V

D16

2 3 A3 + 1 R85

R51

+15V R77 C32

C16

R17

R13

GND

6 5 A1 + 1 TEST1 7 R14

R97 C40 Q1 R25 R23 R10 R37 +15V 16 12 11 13 14 10 +5vREF C8 R22 RC50 5 RC51 5 RC54 6 RC55 3 RC55 2 RC54 5 RC54 2 RC54 3 RC55 1 RC54 4 RC50 9 RC50 4 R109 D7 D6 GND D22 R75 R8

TEST1 3

GND

R19

R1

R16

R11 U1 3 OSC 6 RT CA 7 CT 9 EA COMP 2 EB IN+ 1 IN EB 4 +SENSE SHUT 5 DOWN SENSE R9 C9 R12 C4 GND

D14 R7

NEG

6 GND 5 A4 + 7

R60 D18

R91 C26 GND C29 R65 1 R66 2 A5 + 3 R81 R21 R78

R64 +15V R79 C28 C1 R80

TRIGGER

GND 1 D1 D9 5 OC1 C3 D3 2 6 4

WORK POTENTIAL

RC50 13

R30

R31

WELD RC50 ELECTRODE 10 POTENTIAL

Figure 9-4. Circuit Diagram For Motor Control Board PC1 Effective With Serial No. LA305132 Thru LB031536
TM-1599 Page 34 SuitCase 8VS

C19 C2 D10 4 TEST1 C10 D2 D8 GND

CV MOT CC

1 RC51 +15V +15V TEST PT 2 6 RC50

6 RC50 R26

7 RC50 R35

3 RC50 RC51

RC51

RC56

R94 R59 2 3 R57 A4 + R61 GND 1 R62 Q11

Q10 R76 R46

R58

R95 16 12 11 R83

C25

Q14

Q9 R56

GND

D17 R102

R93 R101 6 CW R100 5 R42 6 7 A5 + GND R44 GND CW R103

C38

D20 D19

R70

C21

R38

A2 +

GND 2 Q8 3 R90 1

R69

U3 3 OSC 6 RT 7 CT 9 EA COMP 13 2 EB IN+ 1 14 IN EB 4 10 SHUT +SENSE 5 DOWN SENSE +5vREF CA

R33 6 R34 7 A3 + D11 +15V R40 5 R48 R32 1 A2 + 2 3

R41 R43

R73

C43 C31

C17

R86 TEST PT 1 5 RC56

C34 R68

C12

R45

GND

R89

R55

GND R50

SuitCase 8VS

R84 GND RC54 7 2 TEST1

R49

C35 R39 R29 R28 R104 GND D5

GND

Q6

R53

Q7

R72

R71

R47

R52

C11 GND R27

R88

C24

GND D15

+15V

GND R24

D12

C5

C20

C23

C30

C27 GND

2 RC56 HI LOW A1A5 U1,U3 U2 8=+15V,4=GND 15=+15V,8=GND 1=+15V,4=GND

POWER/GROUND NETS FOR CHIPS

1 RC56 CV CC

3 RC56 HI LOW

4 RC56

12 RC50

WFS C14

8 RC50

11 RC50

+15V

C18 GND

C33

TM-1599 Page 35

C13

C36

201 738

+15V Q13 +15V R111 +15V R98 D24 D13

RC54 1

Q2

GND

U2 2 7 IN OUT 3 ERR CS6 5 VS VB8

Q12 R36 D25 R99

C42

R67 R96

D21 GND POS RC50 1 RC51 4 RC52 1 RC53 D4 1 RC52 2 RC53 2 R20 R6

SA-148 024-A
GND D23 C39 C46 C22 C37 GND

R82 R15 R18 2 R4 3 A1 + 1 R5 R2 R3 C7 C6

GND

+15V

R63

D16

2 3 A3 + 1 R85

R51

+15V R77

C16

C32

R17

R13

GND

6 5 A1 + 7 R14

R97 RC50 5 RC51 5 RC54 6 RC55 3 RC55 2 RC54 5 RC54 2 RC54 3 RC55 1 RC54 4 RC50 9 RC50 4

TEST1 3

GND +15V

C40 Q1 R25 R23 R37 R10

R19

R1

R16

C50

R11 U1 16 12 11 13 14 10 3 OSC 6 RT CA 7 CT 9 EA COMP 2 EB IN+ 1 IN EB 4 +SENSE SHUT 5 DOWN SENSE +5vREF R9 C9 GND

D14 R7

C8

R22

R12

C4

NEG

6 GND 5 A4 + 7

R60 D18

R8 R91 GND D22 R75 C26 R65 1 R66

R64

C29 GND +15V 2 A5 + 3 R81 R79 C28

D7

D6 R21 R78 C1 R80 R109 GND 1 D1 D9 5 OC1 C3 D3 2 6 4

TRIGGER

WORK POTENTIAL

RC50 13

R30

R31

WELD RC50 ELECTRODE 10 POTENTIAL

Figure 9-5. Circuit Diagram For Motor Control Board PC1 Effective With Serial No. LB031537 Thru LB243978
TM-1599 Page 36 SuitCase 8VS

C19 C2 D10 4 TEST1 C10 D8 D2 GND

CV MOT CC

1 RC50 RC51 +15V +15V TEST PT 2 6

RC50

RC50

RC51

RC50

RC51

R26 R35

RC56

R94 R59 2 3 R57 A4 + 1 R62 Q11 R61 GND

Q10 R76 R46

R58

R95 11 R83 R84 GND

C25

Q14

Q9 R56

GND

D17 R102

R93 R101 6 CW R100 R42 6 A5 + GND R44 GND CW

C38

D20 D19

R70

C21

R38

A2 +

R103 2 Q8 3 R90

GND

R69

U3 16 12 3 OSC 6 RT 7 CT 9 EA COMP 2 EB IN+ 1 IN EB 4 +SENSE SHUT 5 DOWN SENSE +5vREF CA

R33 6 R34 7 A3 + 5 R48 R32 1 A2 + 2 3 7

13 14 10

R41 R43

R73

C43 C31

D11

+15V R40

C17

R86 TEST PT 1 5 RC56

C34 R68

C12

R45

GND

R89

R55

GND R50

C35 R39 R29 R28 R104 GND D5

R49 Q6 R53 Q7 R72

GND

R71

R47

C11 GND R27

R52 GND +15V GND R24

R88

C24 D15

D12 12 RC50 8 RC50 11 RC50

C5

C27 GND

C20

C23

C30

2 RC56 HI LOW

1 RC56 CV CC

3 RC56 HI LOW

4 RC56

+15V

WFS C14

C18 GND

C33

C13

C36

1 TEST1

RC54 7 2 TEST1

POWER/GROUND NETS FOR CHIPS A1A5 U1,U3 U2 8=+15V,4=GND 15=+15V,8=GND 1=+15V,4=GND

205 990

SuitCase 8VS

TM-1599 Page 37

+15V Q13 +15V R111 +15V R98 D24 D13

RC54 1

Q2

GND

U2 2 7 IN OUT 3 6 ERR CS 5 VS VB8

Q12 R36 D25 R99

C42

R67 R96

D21 GND POS RC50 1 RC51 4 RC52 1 RC53 1 RC52 2 RC53 2 R20 D4 R6

R82 R15 R18 2 3 R4 A1 + 1 R5 R3 R2 C7 C6

GND D23 C22 R63 C39 C46 C37

GND

SA-148 024-A
+15V

GND

D16

2 3 A3 + 1 R85

R51

+15V R77

C16

C32

R17

R13

GND

6 5 A1 + 7 R14

R97 RC50 5 RC51 5 RC54 6 RC55 3 RC55 2 RC54 5 RC54 2 RC54 3 RC55 1 RC54 4 RC50 9 RC50 4

TEST1 3

+15V

GND

C40 Q1 R25 R23 R10 R37

R19

R1

R16

C50

R11 U1 16 12 11 13 14 10 3 OSC 6 RT CA 7 CT 9 EA COMP 2 EB IN+ 1 IN EB 4 +SENSE SHUT 5 DOWN SENSE +5vREF R9 C9 GND

GND D14 R7

C8

R22

R12

C4

NEG

6 GND 5 R60 D18 R91 A4 + 7

R8 GND D22 R75 C26 R65 1 R66 D6

R64

C29 GND +15V 2 A5 + 3 R81 R79 C28

D7

R21

R78

C1 R80

R109 GND 1 D1 D9 5 OC1 C3 D3 2 6 4

TRIGGER

WORK POTENTIAL

RC50 13

R30

R31

WELD RC50 ELECTRODE 10 POTENTIAL

Figure 9-6. Circuit Diagram For Motor Control Board PC1 Effective With Serial No. LB243979 and Following
TM-1599 Page 38 SuitCase 8VS

C19 C2 D10 4 TEST1 C10 D8 D2 GND

CV MOT CC

1 RC50 RC51 +15V +15V TEST PT 2 6

RC50

RC50

RC51

RC50

RC51

R26 R35

RC56

R94 R59 2 3 R57 A4 + R61 GND 1 R62 Q11

Q10 R76 R46

R58

R95 16 12 11 13 14 10 R83 R84

C25

Q14

Q9 R56

GND

D17 R102

R93 R101 6 R38 7 A2 + R69 5 R42 6 6 R34 7 A3 + +15V R40 D11 5 R48 R32 1 A2 + 2 3 R41 7 A5 + 5 CW R100 GND R44 GND CW

C38

D20 D19

R70

C21

R103 2 Q8 3 R90

GND

U3 3 OSC 6 RT 7 CT 9 EA COMP 2 EB IN+ 1 IN EB 4 +SENSE 5 SHUT SENSE DOWN +5vREF CA

R33

R73

C43 C31

R43

C17

R86 TEST PT 1 5 RC56

C34 R68

C12

R45

GND

R55

R89

GND R50

C35 R39 R29 R28 R104 GND D5

R49 Q6 R53 Q7 R72 R52 R88

GND

R71

R47

C11 GND R27

C24

GND D15

+15V

GND R24

D12

C5

C20

C23

C30

C27 GND

2 RC56 HI LOW

1 RC56 CV CC

3 RC56 HI LOW

4 RC56

12 RC50

WFS C14

8 RC50

11 RC50

+15V

C36

C18 GND

C33

C13

1 TEST1

RC54 7 2 TEST1

POWER/GROUND NETS FOR CHIPS A1A5 U1,U3 U2 8=+15V,4=GND 15=+15V,8=GND 1=+15V,4=GND

206 078

SuitCase 8VS

TM-1599 Page 39

+V RC15 5 VIN VR1 CW VOUT S21 ON (CLOSE) FOR METER HOLD FUNCTION S22 ON (CLOSE) FOR METERS PER MINUTE S23 ON (CLOSE) FOR METERS PER MINUTE C16 C15 R40 R24 +5V

206 544-B

RC15 9

POWER AND GROUND COM COM C13 DEVICE A12 . VOUT CAP 5 4 OSC CAP+ 7 2 LV TEST 6 1 U1 C14 U1

RC15 10 Q3

+V (4=V,8=+V) . (3=COM,8=+V)

+V

R41

V D3 R25

NEG COM

RC15 1 RC15 6 R13 RC15 7 5 + R3 R8 R7 R6 CW R15 A1 R4 7 6

COM

COM

POS

MOTOR VOLTS

R5 3 S23 S2 R23 R22 R14 P2 C7 8

VSENSE

RC15 8 COM +V +V +5V

R1

COM Q2 R32 +V R28 R29 D6 6 A2 7 R38 Q4 D5 R30 R17 R27 Q1 C9 C4 R33 COM R16 D1 5 + D4 R31 3

2 A1 + 1

S21 1 S2 10

+5V

RC15 TRIGGER 4

RC18 LCD1 WF CASE VOLTS S1

COM

R21

INLO

+V

INHI HOLD

C5 COM

11 12 +5V COM S1 VOLTS

D3

COM

COM

13

D2

D1

D2

L1 SENSE+ RC15 3 R35 3 2 R10 C3 + A2

CASE

WF

S2 S22 R37

Figure 9-7. Circuit Diagram For Meter Board Effective With Serial No. LA305132 and Following
C2 R26 R39 D7 COM R11 C8 L2 RC15 2 R36 C17 COM

VOLTS SENSE

SENSE

TM-1599 Page 40

SuitCase 8VS

C1

C11

C6

C12

+15V +15V +15V POWER/GROUND NETS FOR CHIPS U1 U2 A1 R10 R16 12 TRIGGER IN 2 RC31 L1 GND C5 +15V GND OC1 +15V 4 RC35 2 +15V R8 R9 R14 R2 3 RC31 6 4 1 5 R13 Q1 13 U2 11 R11 GND GND C10 GND 7=GND,14=+15V 4=GND,8=+15V C8 C1 A1

U1

U2

U1 8 11 9 10 SET CLK D RESET Q Q 13 12

GND

+15V

RC31

L3

Q2

CONTACTOR

GND 2 8 1 3 U2 2 9 6 R6 C6 C3 U2 U2 10 5 4 R7 3 A1 + 1

GND 8 RC31

+15V

GND L2 GND

RC31 U1 6 3 5 2 RC35 3 RC35 SET CLK 4 D RESET OFF GND Q Q 1 2 6 A1 5 R3 + ON R5 GND 7 R15

GND 6 RC31 1 RC31

Q3

L4 MOTOR START/STOP

GND

Figure 9-8. Circuit Diagram For Optional Trigger Hold Board PC30 Effective With Serial No. LA305132 And Following

SuitCase 8VS

TM-1599 Page 41

200 906
C7

C4

R17

R18

Notes

Work like a Pro!


Pros weld and cut safely. Read the safety rules at the beginning of this manual.

TM-1599 Page 42

SuitCase 8VS

TM-1599 Processes

March 2002

Eff. w/Serial Number LB031537

MIG (GMAW) Welding Flux Cored (FCAW) Welding

Description

Wire Feeder

SuitCase 8VS

Visit our website at

www.MillerWelds.com

SECTION 10 PARTS LIST


29

. Hardware is common and

27

not available unless listed. 26

28

30 31

24

25

32

23

33

34

35

22

20 21

18

37

36

28

41

39 38

42 40 43 44 45 55 54 53 52 51 46

19

16

17

15

14

13

12

58

57 56

11

50

10

62

63

61

60

59

49

48

47

Figure 10-1. Complete Assembly


TM-1599 Page 44 SuitCase 8VS

802 675-A

Item No.

Dia. Mkgs.

Part No.

Description Figure 10-1. Complete Assembly

Quantity

. . 1 . . . . . . . . . . . . . . 202 695 . . 2 . . . . . . . . . . . . . . 172 919 . . 3 . . . . . . . . . . . . . . 010 910 . . 4 . . . . . . . . . . . . . . 172 918 . . 5 . . . . . . . . . . . . . . 201 309 . . 6 . . . . . . . . . . . . . . 058 424 . . 7 . . . . . . . . . . . . . . 202 696 . . 8 . . . . . . . . . . . . . . 058 424 . . 9 . . . . . . . . . . . . . . 200 618 . . 10 . . . . . . . . . . . . . 200 615 . . 10 . . . . . . . . . . . . 202 173 . . 11 . . . . . . . . . . . . . 201 302 . . 12 . . . . . . . . . . . . . 605 227 . . 13 . . . . . . . . . . . . . . 201 311 . . 14 . . . . . . . . . . . . . 139 041 . . 15 . . . . . . . . . . . . . 126 738 . . 16 . . . . GS1 . . . . 128 074 . . 17 . . . . SR1 . . . . 035 704 . . 18 . . . . S3,5 . . . . 200 633 . . 19 . . . . . . . . . . . . . 098 615 . . 20 . . . . . . . . . . . . . 200 632 . . 20 . . . . . . . . . . . . . 202 897 . . 20 . . . . . . . . . . . . . 203 748 . . 21 . . . . . . . . . . . . . 200 631 . . 21 . . . . . . . . . . . . . 202 854 . . 22 . . . . CB1 . . . . 180 912 . . 22 . . . . CB1 . . . . . 202 711 . . 23 . . . . . . . . . . . . . 200 617 . . 24 . . . . . . . . . . . . . 200 603 . . . . . . . . . . . . . . . . . . +134 327 . . . . . . . . . . . . . . . . . . +178 936 . . . . . . . . . . . . . . . . . . +178 937 . . 25 . . . . R1 . . . . . 073 562 . . 26 . . . . . . . . . . . . . 202 179 . . 26 . . . . . . . . . . . . . 203 746 . . 26 . . . . . . . . . . . . 202 177 . . 26 . . . . . . . . . . . . 206 962 . . 27 . . . . . . . . . . . . . 200 639 . . 27 . . . . . . . . . . . . 202 186 . . 27 . . . . . . . . . . . . . 203 743 . . 27 . . . . . . . . . . . . 206 902 . . 28 . . . . S2 . . . . . 200 640 . . 28 . . . S2,S4 . . . 200 640 . . 29 . . . . S1 . . . . . . 111 997 . . 30 . . . . . . . . . . . . . 193 920 . . 31 . . . . . . . . . . . . . 200 616 . . 32 . . . . . . . . . . . . . 081 895 . . 33 . . . . . . . . . . . . . 200 604 . . 34 . . . . . . . . . . . . . 200 608 . . . . . . . . . . . . . . . . . . . 600 399 . . . . . . . . . . . . . . . . . . . 187 194 . . 35 . . . . RC2 . . . . 200 609 . . . . . . . . . . . . . . . . . . . 049 455 . . . . . . . . . . . . . . . . . . . 048 834 . . . . . . . . . . . . . . . . . . . 080 328 . . 36 . . . . . . . . . . . . . 172 732 . . . . . . . . . . . . . . . . . . . 601 222
SuitCase 8VS

. . Nut, Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knob, Brake Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer, Flat .406 ID x 0.812 OD x .065t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer, Anti-Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer, Fibre (Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer, Fibre (Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shroud, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support, Spool W/Trigger Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 75014 Knurled1.68 dia .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulator, Strain Relief/Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing, Strain Relief .481/.617 ID X 1.115 Mtg Hole . . . . . . . . . . . . . . . . . . . Guide, Mtg pc Card 8 In Deep Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve, 12VDC 2way Custom Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier, Integ Bridge 40. Amp 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch, Rocker Dpdt 8A 125VAC Onnoneon Black . . . . . . . . . . . . . . . . . . Hose, Sae .187 ID X .410 OD X 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Inner (prior to serial no. LB031537) (non-CE only) . . . . . . . . . . . Nameplate, Inner (effective with serial no. LB031537) (non-CE only) . . . . . Nameplate, inner (CE only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Inner (prior to serial no. LB031537) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Inner (effective with serial no. LB031537) . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker, Man Reset 1p 5A 250V Fric Snapin (prior to LA305160) . . Circuit Breaker, Man Reset 1p 7A 250V Fric Snapin (Eff w/LA305160) . . . . Insulator, Cover Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Case, Control Feeder Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Warning General Precautionary (non-CE only) . . . . . . . . . . . . . . . . . . . Label, Warning General Precautionary Wordless (CE only) . . . . . . . . . . . . . . Label, Warning Pinchless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pot, Cp Std Slot 1t 2. W 10k Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel, Front (non-CE only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Assy, Front (CE only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Assy, Front (non-CE only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Assy, Front (Meter Option) (eff w/LB031537) . . . . . . . . . . . . . . . . . . . . Nameplate (non-CE only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (non-CE only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (CE only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Meter Option) (eff w/LB031537) . . . . . . . . . . . . . . . . . . . . . . . . . . Switch, Rocker Dpdt 8A 125VAC Onnone(On) (prior to LB031537) . . . . Switch, Rocker Dpdt 8A 125VAC Onnone(On) (eff w/LB031537) . . . . . . Switch, Rocker Spst 10A 250VAC Onoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knob, Pointer .840 DiA X .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Mtg Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut, 01032 Rubber .75dia .81l Insert In .38hole . . . . . . . . . . . . . . . . . . . . . . . Chassis, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead, Sensing Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wire, Strd 14GA blk 600V 105C 41X30 Hyp .170OD . . . . . . . . . . . . . . . . . . . Plug, Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable, Extension Trigger 8.000 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable, Port No 18 2/C Type sjo nprn Jkt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conn, Circ cpc Clamp Str Rlf Size 11 .329OD . . . . . . . . . . . . . . . . . . . . . . . . . Rcpt W/Skts, Free Hanging (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable, Sensing 15 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamp, Univ 50 Amp Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 4 1 1 1 1 1 1 1 1 1 1

TM-1599 Page 45

Item No.

Dia. Mkgs.

Part No.

Description Figure 10-1. Complete Assembly (Continued)

Quantity

. . . . . . . . . . . . . . . . . . . 601 225 . . . . . . . . . . . . . . . . . . . 600 399 . . . . . . . . . . . . . . . . . . . 172 737 . . 37 . . . . . . . . . . . . . 200 613 . . 38 . . . . . . . . . . . . . 200 612 . . 39 . . . . TP1 . . . . 201 441 . . 40 . . . . . . . . . . . . . 200 628 . . . . . . . . . . . . . . . . . . . 600 322 . . 41 . . . . M1 . . . . 173 435 . . 42 . . . . . . . . . . . . . 079 624 . . 43 . . . . . . . . . . . . . 173 616 . . 44 . . . . . . . . . . . . . 144 712 . . 45 . . . . . . . . . . . . . 201 433 . . 46 . . . . . . . . . . . . . 182 788 . . 47 . . . . . . . . . . . . . 124 778 . . 48 . . . . . . . . . . . . . 173 619 . . 49 . . . . . . . . . . . . . 172 075 . . 50 . . . . . . . . . . . . . 173 620 . . 51 . . . . . . . . . . . . . 010 224 . . 52 . . . . . . . . . . . . . 089 562 . . 53 . . . . . . . . . . . . . 085 244 . . 54 . . . . . . . . . . . . . 089 477 . . 55 . . . . . . . . . . . . . 085 243 . . 56 . . . . . . . . . . . . . 200 626 . . 57 . . . . W1 . . . . 192 809 . . 58 . . . . . . . . . . . . . 200 625 . . 59 . . . . . . . . . . . . . 201 378 . . 60 . . . C1,2 . . . . 200 606 . . 61 . . . . . . . . . . . . . 201 313 . . 62 . . . . PC1 . . . . 200 607 . . 62 . . . . PC1 . . . . 205 989 . . 62 . . . . PC1 . . . . 206 058 . . 63 . . . . . . . . . . . . . 201 434 . . . . . . . . . . . . . . . . . . 200 903 . . . . . . . . . . . . . . . . . . 097 132 . . . . . . . . . . . . . . . . . . 098 691 . . . . . . . . . . . . . . . . . . 203 067 . . . . . . . . . . . . . . . . . . 206 542 . . . . . . . . . . . . . . . . . . 093 551

. . . . Insulator, Vinyl Clamp Univ 50 Amp Black . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Wire, Strd 14GA blk 600V 105C 41X30 Hyp .170OD . . . . . . . . . . . . . . 15 ft . . . . Plug, Jack 2/C Solder Terminals Male . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Standoff, No 1032 X 1.835 Lg .500 Hex Stl Fem . . . . . . . . . . . . . . . . . . . 3 . . Standoff, No 1032 X 1.710 Lg .438 Dia Stl Fem . . . . . . . . . . . . . . . . . . . 1 . . Cable Assy, W/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Lead List, Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . Cable, Weld Cop Strd No 2/0 Epdm Jkt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor, Gear 24VDC Right Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Screw, 37516 x 2.25 Hex Hdpln Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Cover, Right Angle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Ftg, Hose Brs Barbed M 3/16 Tbg X .25020 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Insert, Corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Housing, Adapter Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Knob, T 2.000 Bar W/.31218 Stud 1.000 Lg Plstc . . . . . . . . . . . . . . . . . . . 1 . . Carrier, Drive Roll W/Components 24 Pitch 10mm Shaft . . . . . . . . . . . . . 1 . . Carrier, Drive Roll W/Components 24 Pitch . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Bushing, Motor Mtg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . Pin, Spring Cs .187 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Fastener, Pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Washer, Cupped .328 ID x .812 OD x 16ga x .125 Li . . . . . . . . . . . . . . . . . 1 . . Spring, Cprsn .770 OD X .100 Wire X .715 Pld . . . . . . . . . . . . . . . . . . . . . . 1 . . Knob, Adjust Tension 1.250 Dia X .31218 Thrd Stl . . . . . . . . . . . . . . . . . . 1 . . Bracket, Mtg Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Contactor, 12VDC 1pst Onoff Magnetic Blow Out . . . . . . . . . . . . . . . . . . . 1 . . Bracket, Mtg Contactor/Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Insulator, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Capacitor, Elctlt 1200 uf 300 VDC Can 1.39 Dia . . . . . . . . . . . . . . . . . . . . . 2 . . Strip, Mtg. Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Circuit Card Assy, Motor Control (prior to LB031536) . . . . . . . . . . . . . . . . . 1 . . Circuit Card Assy, Motor Control (eff w/LB031537 thru LB243978) . . . . . 1 . . Circuit Card Assy, Motor Control (eff w/LB243979 and on) . . . . . . . . . . . . 1 . . Cover, Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Ckt Card Assy, Trigger Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Standoff, No 6-32 x .375 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Standoff, No 6-32 x .500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Plug Assy, Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . Circuit Card Assy, Meter (Meter Option) (eff w/LB031537) . . . . . . . . . . . . 1 . . Knob, Pointer (Meter Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Part of Trigger Hold feature (optional in non-CE models, standard in CE models) +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

TM-1599 Page 46

SuitCase 8VS

Table 10-1. Drive Roll & Wire Guide Kits (2 Drive Roll)

NOTE

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 shelled cored wires. 5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Kit No. 087 131 079 594 079 595 161 189 079 596 079 597 079 598 044 749 079 599 079 600 079 601 079 606 079 607 079 608 079 609 083 318 083 317 Drive Roll Part No. Type 087 130 053 695 053 700 053 696 053 697 053 698 053 699 072 000 053 701 053 702 053 706 132 958 132 957 132 956 132 955 083 489 083 490 V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved U-Grooved U-Grooved U-Grooved U-Grooved V-Knurled V-Knurled V-Knurled V-Knurled U-Cogged U-Cogged Inlet Wire Guide 056 192 056 192 056 192 056 192 056 193 056 193 056 195 056 192 056 193 056 193 056 195 056 192 056 193 056 193 056 195 056 193 056 193
Ref. S-0859

Fraction .030 in .035 in .040 in .045 in .052 in 1/16 in .035 in .045 in .052 in 1/16 in .035 in .045 in .052 in 1/16 in .045 in .052 in

Wire Diameter Decimal .023/.025 in .030 in .035 in .040 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

Metric 0.6 mm 0.8 mm 0.9 mm 1.0 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 1.6 mm 1.2 mm 1.3 mm

.023/.025 in

SuitCase 8VS

TM-1599 Page 47

Notes

TM-1599 Page 48

SuitCase 8VS

Notes

SuitCase 8VS

TM-1599 Page 49

Miller Electric Mfg. Co.


An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International HeadquartersUSA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066

PRINTED IN USA

2001 Miller Electric Mfg. Co.

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