Professional Documents
Culture Documents
March 2002
Processes
MIG (GMAW) Welding Flux Cored (FCAW) Welding
Description
Wire Feeder
SuitCase 8VS
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.)
SuitCase 8VS
Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
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
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.
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.
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.
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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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S/N:
Hz DC IP 23
U2 100 V =
I2= 500 A
X 100 %
ST-181 678
NOTE
Output
Amperes
Duty Cycle
Percent
V IP
Input
Purge By Gas
Fast
Constant Current
Constant Voltage
Slow
Trigger Hold On
Read Instructions
U1
Primary Voltage
I2 U2
Increase
Hz
Hertz
I1
Primary Current
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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)
IP Rating
Overall Dimensions
Weight
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)
Gun
M25 Or M40 FC-1260
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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
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.
Cleaning Drive Rolls: Remove drive rolls, and clean grooves using a wire brush.
Correct 8 7 6 10 9
Incorrect
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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
4 Rear View
2 3 4
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Push female connector over male connector, and turn 1/4 turn clockwise.
3
Ref. 132 808-F / Ref. 802 706
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.
Tighten Clockwise
WOOD
802 706-A / Ref. ST-159 048-A / S-0627-A
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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
V
4
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
10
11
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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
Ref. 802 768 / Ref. 802 706-A / Ref. 203 745 / Ref. 203 749
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Notes
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voltage meter and High/Low 8 Meter Board Wire Feed Speed/ Voltage Meter Motor Control/ Arc Voltage
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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
10 Sense Lead
12
Arc Voltage
AC Or DC Control Circuits
Optional
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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.
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
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
GS1 OR WS1
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
TP1
TP1
CONTACTOR
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
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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
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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
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
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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).
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).
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).
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.
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).
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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.
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).
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See Section 7-7 for meter board data and Section 8-3 for meter calibration
V5
V6
V7
V4 V1
V2
V3
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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
203 029-B
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D5 C6
D12
R29 R28
C12 R47
R17 R16
R1
C27 R13 R80
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
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
C37 C13
C50 R91
U2 R84
R75 C34
D3 +
C10
A4
C9
R23
G D S Q1
HS2
D4
D8
R31
D1 D2 D9
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
C40
HS3
10 11 12
RC50
RC51
RC52
RC53
RC55
RC54
TM-1599 Page 22
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
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
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
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
Q3
OC1 R11 C6
5 6 7 8
2
10% unless
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
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
10% unless
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.
3 Months
Replace Damaged Or Unreadable Labels Replace Damaged Gas Hose
6 Months
Clean Drive Rolls Blow Out Or Vacuum Inside
CB1
Unit has internal thermostat protection and will not feed wire if overheating occurs (see Section 7-1).
TM-1599 Page 28
SuitCase 8VS
PURGE
POWER
Reinstall front panel. Turn off power. Close and latch door. 6
Front Panel
C B
0 15
49
Ref. 802 706-A
SuitCase 8VS
TM-1599 Page 29
Model
SuitCase 8VS
Circuit Diagram
200 620 203 029-B
Wiring Diagram
200 621-B 200 621-B
200 906
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
RC54 1
Q2
GND
C42
R67 R96
D21 GND POS RC50 1 RC51 4 RC52 1 RC53 D4 1 RC52 2 RC53 2 R20 R6
GND
GND
+15V
D16
2 3 A3 + 1 R85
R51
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
TRIGGER
GND 1 D1 D9 5 OC1 C3 D3 2 6 4
WORK POTENTIAL
RC50 13
R30
R31
Figure 9-4. Circuit Diagram For Motor Control Board PC1 Effective With Serial No. LA305132 Thru LB031536
TM-1599 Page 34 SuitCase 8VS
CV MOT CC
6 RC50 R26
7 RC50 R35
3 RC50 RC51
RC51
RC56
R58
R95 16 12 11 R83
C25
Q14
Q9 R56
GND
D17 R102
C38
D20 D19
R70
C21
R38
A2 +
GND 2 Q8 3 R90 1
R69
R41 R43
R73
C43 C31
C17
C34 R68
C12
R45
GND
R89
R55
GND R50
SuitCase 8VS
R49
GND
Q6
R53
Q7
R72
R71
R47
R52
R88
C24
GND D15
+15V
GND R24
D12
C5
C20
C23
C30
C27 GND
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
RC54 1
Q2
GND
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
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
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
R64
D7
TRIGGER
WORK POTENTIAL
RC50 13
R30
R31
Figure 9-5. Circuit Diagram For Motor Control Board PC1 Effective With Serial No. LB031537 Thru LB243978
TM-1599 Page 36 SuitCase 8VS
CV MOT CC
RC50
RC50
RC51
RC50
RC51
R26 R35
RC56
R58
C25
Q14
Q9 R56
GND
D17 R102
C38
D20 D19
R70
C21
R38
A2 +
R103 2 Q8 3 R90
GND
R69
13 14 10
R41 R43
R73
C43 C31
D11
+15V R40
C17
C34 R68
C12
R45
GND
R89
R55
GND R50
GND
R71
R47
R88
C24 D15
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
205 990
SuitCase 8VS
TM-1599 Page 37
RC54 1
Q2
GND
C42
R67 R96
D21 GND POS RC50 1 RC51 4 RC52 1 RC53 1 RC52 2 RC53 2 R20 D4 R6
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
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
R64
D7
R21
R78
C1 R80
TRIGGER
WORK POTENTIAL
RC50 13
R30
R31
Figure 9-6. Circuit Diagram For Motor Control Board PC1 Effective With Serial No. LB243979 and Following
TM-1599 Page 38 SuitCase 8VS
CV MOT CC
RC50
RC50
RC51
RC50
RC51
R26 R35
RC56
R58
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
R33
R73
C43 C31
R43
C17
C34 R68
C12
R45
GND
R55
R89
GND R50
GND
R71
R47
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
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
COM
COM
POS
MOTOR VOLTS
VSENSE
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
COM
R21
INLO
+V
INHI HOLD
C5 COM
D3
COM
COM
13
D2
D1
D2
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
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
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
TM-1599 Page 42
SuitCase 8VS
TM-1599 Processes
March 2002
Description
Wire Feeder
SuitCase 8VS
www.MillerWelds.com
27
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
802 675-A
Item No.
Dia. Mkgs.
Part No.
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.
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
PRINTED IN USA