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Miller Electric Axcess 300 manual

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Table of contents for the manual

  • Page 1

    OM-230 032C 2007−10 Axcess 300 Processes Description MIG (GMA W) W elding Pulsed MIG (GMAW -P) Flux Cored (FCA W ) W elding Automatic W elding Automatic Welding Interface And Arc Welding Power Source ™ File: Advanced Manufacturing Systems V isit our website at www.MillerWelds.com/ams[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

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

  • Page 4

    T ABLE OF CONTENTS SECTION 9 − TROUBLESHOOTING 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Removing Cover and Measuring Input Capacitor V oltage 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. W eld Process Board PC4 Diagnostic LED?[...]

  • Page 5

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

  • Page 6

    [...]

  • Page 7

    OM-230 032 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols o[...]

  • Page 8

    OM-230 032 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Page 9

    OM-230 032 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 10

    OM-230 032 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and [...]

  • Page 11

    OM-230 032 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures grave[...]

  • Page 12

    OM-230 032 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

  • Page 13

    OM-230 032 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 14

    OM-230 032 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de t o ucher[...]

  • Page 15

    OM-230 032 Page 9 2-5. P ri nc ipa le s nor me s de s éc ur ité Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American [...]

  • Page 16

    OM-230 032 Page 10[...]

  • Page 17

    OM-230 032 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Manufacturer ’ s W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect y[...]

  • Page 18

    OM-230 032 Page 12 1 Warning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 5 Always wait 5 minutes after power is turn[...]

  • Page 19

    OM-230 032 Page 13 3-3. Symbols And Definitions A Amperage Direct Current (DC) Alternating Current (AC) V V oltage Output Circuit Breaker Remote On Of f Positive Negative V oltage Input Arc Force Constant V oltage Inductance Protective Earth (Ground) Increase Line Connection Gas Metal Arc W elding (GMA W) Three Phase Static Frequency Con- verter- T[...]

  • Page 20

    OM-230 032 Page 14 SECTION 4 − INST ALLA TION . Appearance of actual unit may vary from unit shown in manual. 4-1. Specifications Input Power Rated W elding Output V oltage Range Wire Feed Speed Range** Wire Diameter Range Max Open Circuit V olt- age DC Amperes In- put At Rated Load Output 60 Hz, Three-Phase Input kV A Input KW DC 400V Three Phas[...]

  • Page 21

    OM-230 032 Page 15 4-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle ca n damage u[...]

  • Page 22

    OM-230 032 Page 16 4-5. Selecting A Location loc_2 3/96 -Ref. 803 667-A ! Do not stack units. Beware of tipping. 1 Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit. 2 Hand Cart Use cart or similar device to move unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Loca[...]

  • Page 23

    OM-230 032 Page 17 Ref. 803 668-A 1 1 15 V 10 A AC Receptacle RC2 Receptacle supplies 60 Hz single-phase power . Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps. 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects 1 15 volt receptacle RC2 from o v e r l oad. If CB1 opens, RC2 does not work. CB2 prot[...]

  • Page 24

    OM-230 032 Page 18 4-8. Connecting T o W eld T erminals 1 2 Ref. 803 667-A / 803 778-A ! T urn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Determine total cable length in weld circuit (both positive and negative cables com- bined) [...]

  • Page 25

    OM-230 032 Page 19 4-9. Network Wire Feeder Receptacle Functions 9 Pin* Pin Information A Not used. G E F B Shield. I H D G C V olt sense. A B I C H D Can low . A B E Can high. F +24 volts dc common. G + 24 volts dc H Motor voltage +40 volts dc common Ref. 803 668-A I Motor voltage +40 volts dc *The remaining pins are not used.[...]

  • Page 26

    OM-230 032 Page 20 4-10. Electrical Service Guide Failure to fo llow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. NOTICE − INCORRECT INPUT POWER can damage this welding [...]

  • Page 27

    OM-230 032 Page 21 4-1 1. Connecting Input Power 804 650-A / Ref. 803 855-A / Ref. 803 766-A / 219 842-A T ools Needed: 5/16 in Route ground conductor through tubing and cur- rent transducer to ground terminal. Route input conductors to filter board. 219842−A A s l g k d s ; lg k s ;l d f g k s ;d g l k A s l d h f s g k d s ; lg k s ; ld f g [...]

  • Page 28

    OM-230 032 Page 22 SECTION 5 − RECOMMENDED SETUP PROCEDURES 5-1. Selecting Weld Cable Sizes* ! ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor . Locate welding operation 100 meters from any sensitive electronic equipme[...]

  • Page 29

    OM-230 032 Page 23 5-2. W elding Circuit . Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics. Ref. 804 525-A 1 W elding Power Source 2 Electrode Cable 3 Feeder Cable 4 Work Cable 5 V oltage Sensing Lead 6 Wire Feeder 7 W orkpiece In pulse welding applications using inverter power sources[...]

  • Page 30

    OM-230 032 Page 24 Ref. 804 526-A 1 W elding Power Source 2 Electrode Cable 3 Feeder Cable 4 Work Cable 5 V oltage Sensing Lead 6 Wire Feeder 7 W orkpiece Th e method used to arrange cables has a significant af fect on welding properties. As an example, Accupulse and RMD welding processes can produce high welding circuit inductance depending on cab[...]

  • Page 31

    OM-230 032 Page 25 . W elding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensify . Ref. 804 527-A 1 W elding Power Source 2 Electrode Cable 3 Feeder Cable 4 Work Cable 5 V oltage Sensing Lead 6 Wire Feeder 7 W orkpiece Each welding power source should have a separate work cable co[...]

  • Page 32

    OM-230 032 Page 26 5-5. V oltage Sensing Lead And Work Cable Connections For Multiple W elding Arcs A. Bad Setup Ref. 804 528-A 1 W elding Power Source 2 Electrode Cable 3 Feeder Cable 4 Work Cable 5 V oltage Sensing Lead 6 Wire Feeder 7 W orkpiece This arrangement is a bad setup due to sensing leads being directly in the current flow path of the w[...]

  • Page 33

    OM-230 032 Page 27 B. Better Setup Ref. 804 529-A 1 W elding Power Source 2 Electrode Cable 3 Feeder Cable 4 Work Cable 5 V oltage Sensing Lead 6 Wire Feeder 7 W orkpiece This arrangement is a better setup for supporting separate voltage feedback to the welding power sources. The most accurate voltage sensing may not be achieved due to voltage drop[...]

  • Page 34

    OM-230 032 Page 28 C. Best Setup Ref. 804 530-A 1 W elding Power Source 2 Electrode Cable 3 Feeder Cable 4 Work Cable 5 V oltage Sensing Lead 6 Wire Feeder 7 W orkpiece This arrangement is the best setup for proper voltage sensing at the workpiece. V oltage feedback to the welding power sources will more accurate and result in reliable arc starts a[...]

  • Page 35

    OM-230 032 Page 29 SECTION 6 − OPERA TION 6-1. Front Panel Switches 1 2 Ref. 803 669-A 1 Power Switch T urns unit On or Of f. 2 Pilot Light Light indicates status of welding power source, o n when unit is on and of f when unit is of f. 3 PDA Port 4 PC Port 3 4 6-2. Options A. E-Stop Option Th e E-Stop option comes with a 2-pin amphenol receptacle[...]

  • Page 36

    OM-230 032 Page 30 SECTION 7 − MAINTENANCE 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every Every 3 Months l Unreadable Labels ~ W eld T erminals l Damaged Gas Hose nl Weld Cab[...]

  • Page 37

    OM-230 032 Page 31 SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read and follow these precautions. 8-1. Symbol Usage OM-230 032C - 2007−10, safety_stm 2007−04 DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in[...]

  • Page 38

    OM-230 032 Page 32 F ALLING UNIT can cause injury . 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. MOVING P ARTS can cause injury [...]

  • Page 39

    OM-230 032 Page 33 SECTION 9 − TROUBLESHOOTING 9-1. Removing Cover and Measuring Input Capacitor V oltage Turn Of f welding power source, a n d disconnect input power . Remove cover 1 Interconnect Board PC2 2 V oltmeter Measure the dc voltage across th e + bus terminal and − bus terminal on PC2 as shown until voltage drops to near 0 (zero) volt[...]

  • Page 40

    OM-230 032 Page 34 1 Weld Process Board PC4 Diagnostic LED’ s are visible inside unit, located on PC4 mounted on the top tray . Refer to Section 9-3 for information on diagnostic LED’s. Reinstall cover after checking diagnostic LED’ s. 216 956-A / Ref. 803 670-A 9-2. W eld Process Board PC4 Diagnostic LED’ s 1 LED2 LED1 LED4 LED3 9-3. Diagn[...]

  • Page 41

    OM-230 032 Page 35 9-4. Network And Module Status LED’ s A. Network Status LED’ s The following is a network status LED: LED4 on the PCM circuit board. Status Diagnosis Of f T he circuit board is not on-line with the network or there is no power applied to the circuit board. Green The circuit board is operating normally and the on-line connecti[...]

  • Page 42

    OM-230 032 Page 36 9-5. T roubleshooting T rouble Remedy No weld output; completely inoperative Place line disconnect in On position (see Section 4-1 1). Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 4-1 1). Check for proper input power connections (see Section 4-1 1) . No weld output; meter display on with no[...]

  • Page 43

    OM-230 032 Page 37 Notes[...]

  • Page 44

    OM-230 032 Page 38 SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Power Source[...]

  • Page 45

    OM-230 032 Page 39 229 810-A[...]

  • Page 46

    OM-230 032 Page 40 SECTION 1 1 − P ARTS LIST . Hardware is common and not available unless listed. Ref. 804 651-A 1 2 3 18 20 19 19 7 8 16 7 14 13 9 10 17 − Fig 1 1-5 4 − Fig 1 1- 3 6 − Fig 1 1- 4 5 − Fig 1 1- 2 12 11 15 Figure 1 1-1. Main Assembly[...]

  • Page 47

    OM-230 032 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 1 1-1. Main Assembly Quanti ty 1 210492 Cover , T op 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 T2 212543 Xfmr, Control T oroidal 665 V AC Pri 1900 V A 60 Hz 1 . . . . . . . . [...]

  • Page 48

    OM-230 032 Page 42 802 955-A 3 4 5 6 7 8 33 34 35 17 18 20 21 23 24 25 23 36 29 26 13 27 28 30 31 10 11 15 14 2 9 19 37 38 23 22 32 12 . Hardware is common and not available unless listed. 7 6 13 1 16 Figure 1 1-2. Windtunnel Assembly LH And RH Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Windtunnel Assembly LH And RH (Fig 1 1-1 Item 6) Q[...]

  • Page 49

    OM-230 032 Page 43 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Windtunnel Assembly LH And RH (Continued) (Fig 1 1-1 Item 6) Quanti ty 20 201695 Clamp, Capacitor (Bottom) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 C1, C2 226081 Capacitor ,Elctlt 2400 Uf 500 Vd[...]

  • Page 50

    OM-230 032 Page 44 . Hardware is common and not available unless listed. 803 422-B 1 2 3 4 5 7 6 5 Figure 1 1-3. T op T ray Assembly Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. T op T ray Assembly (Fig 1 1-1 Item 4) Quanti ty 1 PC3 231928 Circuit Card Assy , Aux Power 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 51

    OM-230 032 Page 45 . Hardware is common and not available unless listed. 803 672-A 1 2 3 4 5 6 7 8 9 10 11 Figure 1 1-4. Rear Panel Assembly Description Part No. Dia. Mkgs. Item No. Figure 1 1-4. Rear Panel Assembly (Fig 1 1-1 Item 8) Quanti ty 1 210478 Panel, Rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 52

    OM-230 032 Page 46 . Hardware is common and not available unless listed. Ref. 804 676-A 1 2 3 5 6 7 4 8 9 10 11 12 6 13 14 15 15 16 17 18 7 6 19 20 21 Figure 1 1-5. Front Panel Assembly Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Front Panel Assembly (Fig 1 1-1 Item 14) Quanti ty 1 S1 207456 Switch, Rotary 2 Posn 1P 40A 600V AC PNLMTG 90[...]

  • Page 53

    OM-230 032 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 1 1-5. Front Panel Assembly (Continued) Quanti ty 14 207979 Box, Louver 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 186621 Boot, Generic 2 . . . . . . . . . . . . . . . . . . . .[...]

  • Page 54

    Notes[...]

  • Page 55

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expert[...]

  • Page 56

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 9 20-735-4134 Int ernational F AX : 9 20-735-4125 European Headquarters ?[...]