Miller Electric Axcess manual

Axcess W ire Feeder Processes Description MIG (GMA W) W elding Wire Feeder OM-211 076H 2006 − 08 File: Advanced Manufacturing Systems V isit our website at www.MillerWelds.com/ams ™[...]

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

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

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OM-21 1 076 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety m[...]

OM-21 1 076 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watchin[...]

OM-21 1 076 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit[...]

OM-21 1 076 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A [...]

OM-21 1 076 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les u tilisés Sy m bole graphique d’av ertiss ement ! Attention ! Cette pr o- cédur e c omport e des risques poss ib[...]

OM-21 1 076 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la p[...]

OM-21 1 076 Page 7 2-3 . Dangers s upplé mentaire s en r ela tion a v ec l’installa tion, l e fonctionnem ent e t la maintenanc e Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharg[...]

OM-21 1 076 Page 8 2-5. Princi pales normes de s écurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W e[...]

OM-21 1 076 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating Overall Dimensions W eight 40 V olts DC 10 Amperes Axcess Series Standard: 40 T o 1400 ipm (1.0 T o 35.6 mpm) .030 T o 1/8 in (0.8 T o 3.2 mm) Max Spool W eight: 60 lb ([...]

OM-21 1 076 Page 10 Ref. 801 915 / Ref. 803 501-A 1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 5 Network Feeder Cable 6 Negative ( − ) W eld Cable 7 W orkpiece 8 V oltage Sensing Lead (Optional) . Positive (+) voltage sensing lead is contained in the motor cable. 9 Positive (+) Weld Cable 1 2 3 4 5 7 8 9 4-2. Connection Diagram [...]

OM-21 1 076 Page 1 1 4-3. Rear Panel Connections And Rotating Drive Assembly 802 825-A / 803 503-A 2 3 4 1 9-Pin Network Receptacle 2 Shielding Gas V alve Fitting Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. 3 Weld Cable T erminal 4 Weld Cable 5 Drive Assembly 6 Drive Assembly Rotation Knob 7 Rating Label L[...]

OM-21 1 076 Page 12 4-4. 9-Pin Network Receptacle Information 9 Pin Pin Information A Capacitor C1 to ground B Shield G F C V olt sense H G E F D Can low I H D E E Can high A B I C D F +24 volts dc common B C G + 24 volts dc H Motor voltage − 40 volts I Motor voltage +40 volts 4-5. Gun Recommendation T able Process Gun GMA W − Hard or Cored Wir[...]

OM-21 1 076 Page 13 4-6. Installing And Threading Welding Wire Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A T ools Needed: . Be sure that outlet cable has proper size liner for the welding wire size. When installing gun, position liner extending from outlet wire guide as close a s possible to drive rolls without touching. Insta[...]

OM-21 1 076 Page 14 4-7. Feeder Display At Power Up 1 Upper Display 2 Lower Display Program Process Wire T ype Gas T ype T rigger Control Adjust V olts Time WFS Amps Process Set Up Feeder Set Up T rigger Hold 2 1 Power Source Upper Display Lower Display Axcess Axcs 300/450/675 10 44 V oltage Range Arc Adjust Arc Ctl Sequence 4-8. Dual Schedule Swit[...]

OM-21 1 076 Page 15 SECTION 5 − OPERA TION 5-1. Operational T erms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder: General T erms: Arc Adjust T erm used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual arc length. Likewise, decreasing a[...]

OM-21 1 076 Page 16 General T erms: Sequence Selecting Sequence will allow setting of preflow , start, crater , and postflow times and parameters. Preflow Setting a time value for gas flow prior to arc start. Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only adjustable with the optional PDA wit[...]

OM-21 1 076 Page 17 5-3. Front Panel Controls See Section 5-5 See Section 5-6 See Section 5-9 See Section 5-8 See Section 5-7 See Section 5-4 Program Process Wire T ype Gas T ype T rigger Control Adjust V olts T ime WFS Amps Process Set Up Feeder Set Up T rigger Hold Arc Adjust Arc Ctl Sequence[...]

OM-21 1 076 Page 18 5-4. Program Push Button 1 3 Program 2 1 Program Display The number of the active program is displayed. 2 Program Push Button 3 Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob. Momentarily pres s button to illuminate LED. T o c hange the program number , rotate Adjust k nob t[...]

OM-21 1 076 Page 19 5-6. Lower Display 2 1 5 4 3 WFS Amps Arc Ctl 6 T ime 7 1 Lower Display The lower display shows WFS (wire feed speed), AMPS (amperage), ARC CTL (arc control), or Time. The feeder displays only preset wire speed at idle (not welding). While welding, the average amperage is displayed. The lower display shows welding sequence time [...]

OM-21 1 076 Page 20 5-7. Feeder Set Up Push Button 1 Feeder Set Up Push Button 2 Feeder Set Up Push Button LED Press button to choose sequence, trigger control, or trigger hold. 3 Sequence LED 4 Trigger Control LED 5 Trigger Hold LED 6 Lock LED (Access Allowed Only By Using An Optional PDA With File Management Software) • When the Feeder Set Up b[...]

OM-21 1 076 Page 21 5-9. Process Set Up Push Button • Press the Process Set Up push button the first time will illuminate the button LED and Process LED above the button. Both displays will show the current process and, if desired, these displays will be active to allow selecting a new process. Default processes are MIG, PULSE, and ACCU PULSE. ?[...]

OM-21 1 076 Page 22 5-10. Jog/Purge Pressing the Jog/Purge switch allows the operator to jog wire without energizing the weld power or gas valve circuit. • The unit provides the ability to jog the wire feeder by means of the gun trigger or the Jog/Purge switch. If the welding arc does no t initiate in 3 seconds after the gun trigger is activated,[...]

OM-21 1 076 Page 23 5-1 1. Reset Mode 198 993 / 803 504-A . Reset mode is not active when Program Lock is enabled. Th e reset mode allows the operator to reload factory program settings for all eight active programs in the unit. . System configuration data will be lost during the Reset operation. Enter reset mode by turning power On and pressing th[...]

OM-21 1 076 Page 24 SECTION 6 − SETTING SEQUENCE P ARAMETERS 6-1. Sequence Parameters In A Program . For more information on Sequence mode, see Feeder Set Up Push Button in Section 5-7 . If time is set to Of f in Weld sequence, welding continues until gun trigger is released. If time is set to zero in any timed sequence except Weld, the sequence [...]

OM-21 1 076 Page 25 SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Y 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 3 l Unreadable Labels ~ W eld T erminals l Damaged Gas Hose nl Weld Cables 3 Months[...]

OM-21 1 076 Page 26 7-2. Diagnostics ERR T ACH • The tach error occurs 2 seconds after the loss of tachometer feedback. The motor speed is re gu la ted through the monitoring of voltage and current. Press Jog/Purge button to clear error . ERR MOTR • The motor error indicates that the motor has been drawing too much current for too long. T o rem[...]

OM-21 1 076 Page 27 7-2. Diagnostics (Continued) WELD W AIT • The weld wait erro r indicates unit was not ready for a weld sequence. Press Jog/ Purge button to clear error . MOTR COM • The motor communication erro r indi- cates motor board lost data communica- tions. Press Jog/Purge button to clear error . PLS W AIT • The uim communication er[...]

OM-21 1 076 Page 28 7-3. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check and secure weld cable connections (see Section 4-2). Electrode wire feeding stops or feeds erratically during welding Check gun trigger connection. See gun Owner’s Manual. [...]

OM-21 1 076 Page 29 Notes[...]

OM-21 1 076 Page 30 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram[...]

OM-21 1 076 Page 31 21 1 005-E[...]

OM-21 1 076 Page 32 SECTION 9 − P ARTS LIST 803 506-C . Hardware is common and not available unless listed. 12 18 20 2 1 3 16 17 7 15 8 11 9 10 6 19 14 11 10 13 5 22 4 − Fig 9-3 21 − Fig 9-2 Figure 9-1. Main Assembly[...]

OM-21 1 076 Page 33 Description Part No. Item No. Figure 9-1. Main Assembly Quantity 1 159 647 INSULA TOR, motor clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 CLAMP , motor base 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-21 1 076 Page 34 803 507-D . Hardware is common and not available unless listed. 2 3 4 5 6 7 9 10 11 8 12 13 14 16 17 16 19 20 21 22 23 24 25 1 15 Figure 9-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 9-2. Control Box (Fig 9-1 Item 21) Quantity 1 134 464 LABEL, W arning General Precautionary 1 . . . . . . . . . . . . . . . . . [...]

OM-21 1 076 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 9-2. Control Box (Fig 9-1 Item 21) (Continued) Quantity 22 21 1 073 NAMEPLA TE, lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 210 998 SWITCH ASSY , jog/purge (including) 1 . . . . . . . . .[...]

OM-21 1 076 Page 36 See T able 9-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 802 950-B 9 29 28 35 30 31 32 27 34 26 33 23 22 25 24 21 1 4 3 2 5 6 8 7 4 5 1 2 3 6 16 15 20 10 15 13 18 11 12 14 19 18 17 Figure 9-3. Drive Assembly , Wire Description Part No. Dia. Mkgs. Item No. Figure 9-3. Drive Assembl[...]

OM-21 1 076 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 9-3. Drive Assembly , Wire (Fig 9-1 Item 4) (continued) Quantity 184 685 ADAPTER ASSY , gun/feeder LH (including) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 149 959 FITTING, brs barbed M 3/16tbg x .312-24 1 . . . . . . . . . .[...]

Notes[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

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