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Miller Electric 75 manual

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Table of contents for the manual

  • Page 1

    Axcess AlumaF eed 75 Processes Description MIG (GMA W) W elding Wire Feeder OM-228 956B 2006 − 08 File: Advanced Manufacturing Systems V isit our website at www.MillerWelds.com[...]

  • 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

    [...]

  • Page 5

    OM-228 956 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 me[...]

  • Page 6

    OM-228 956 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 watching[...]

  • Page 7

    OM-228 956 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 8

    OM-228 956 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 W elding Society Standard A [...]

  • Page 9

    OM-228 956 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 uti lisés Sy mbole graphique d’aver tis sement ! Attention ! Cette pro - cédur e c omporte des risques poss ibles[...]

  • Page 10

    OM-228 956 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 pe[...]

  • Page 11

    OM-228 956 Page 7 2-3 . Da ngers supplémentai res en r el ation avec l’installa tion, le f onc tionneme nt et l a maintena nce 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 surcharger [...]

  • Page 12

    OM-228 956 Page 8 2-5. Princi pales no rmes de sécu rité 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 el[...]

  • Page 13

    OM-228 956 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) .045 T o .062 in (1.1 T o 1.6 mm) Max Spool W eight: 60 lb ([...]

  • Page 14

    OM-228 956 Page 10 Ref. 801 915 / Ref. 804 584-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 3 4 5 7 8 9 4-2. Connection Diagram 6 2[...]

  • Page 15

    OM-228 956 Page 1 1 4-3. Rear Panel Connections And Rotating Drive Assembly 804 586-A 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 4 W eld Cable Screw - Screw Size (.375 - 16 x 1.50) 5 Drive Assembly 6 Drive Assembly Rotation Knob 7 [...]

  • Page 16

    OM-228 956 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. Installing Drive Rolls 804 187-A 1 Pressure Assembly Door 2 Drive [...]

  • Page 17

    OM-228 956 Page 13 4-6. Installing PD Continuous Wire Guides Ref. 804 192 / 804 188-A . PD Continuous Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for opti- mal performance. Should be used with PD drive rolls and cannot be used with non-PD (old-style) drive rolls. . 70 series wire guides are not compatible with 7[...]

  • Page 18

    OM-228 956 Page 14 4-7. Installing Non-PD (Old Style) Wire Guides Ref. 804 192-B / 804 188-A Installing wire guides with non- PD (old-style) drive rolls . Non-PD (old-style) wire guides and drive rolls should be used with 5/64 in (2.0 mm) and larger diameter wire. 1 Pressure Assembly Door 2 PD Inlet Guide 3 Intermediate Guide 4 Set Screw 5 Guide Ho[...]

  • Page 19

    OM-228 956 Page 15 4-8. Installing W elding Gun 804 189-A 1 Power Clamp Knob 2 Gun Locking T ab 3 Power Pin Groove 4 Gun Connection End Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. When installing gun, the liner should extend into the PD continu- ous guide (or exit guide if[...]

  • Page 20

    OM-228 956 Page 16 4-9. Installing Welding Wire And Adjusting Pressure Drive Setting Ref. 804 190-A T ools Needed: 1 Drive Roll Pressure Adjustment Lever 2 Notch In Lever (Indicates Pressure Settings) Pressure drive settings range from 1 to 8 with 8 being the maximum setting. . For aluminum (soft) wire set pressure drive setting at 4 or below . . B[...]

  • Page 21

    OM-228 956 Page 17 4-10. 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 4-1 1. Dual Schedule Sw[...]

  • Page 22

    OM-228 956 Page 18 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 ar[...]

  • Page 23

    OM-228 956 Page 19 General T erms: Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends. Postflow Setting a time value for gas flow after arc end. Feeder Set Up Allow selection of Sequence and trigger functions. Auto Thread Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract sim[...]

  • Page 24

    OM-228 956 Page 20 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[...]

  • Page 25

    OM-228 956 Page 21 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 p res s b utton to illuminate LED. T o change the program number, r otate Adjus t knob t[...]

  • Page 26

    OM-228 956 Page 22 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 w[...]

  • Page 27

    OM-228 956 Page 23 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 bu[...]

  • Page 28

    OM-228 956 Page 24 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. •[...]

  • Page 29

    OM-228 956 Page 25 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, [...]

  • Page 30

    OM-228 956 Page 26 5-1 1. Reset Mode 198 993 / 804 587-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 the[...]

  • Page 31

    OM-228 956 Page 27 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 i[...]

  • Page 32

    OM-228 956 Page 28 SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every E very 3 Mt h l Unreadable Labels ~ W eld T erminals nl W eld Cables l Cracked Parts Months n 14-Pin Cord n Gas Hose And Fittings n [...]

  • Page 33

    OM-228 956 Page 29 7-2. Diagnostics ERR SENS • The voltage sense error indicates no voltage sensing feedback signal. Check connections at feeder and welding power source. Press Jog/Purge button to clear error . ERR T ACH • The tach error occurs 2 seconds after the loss of tachometer feedback. The motor speed is reg ul a ted through the monitori[...]

  • Page 34

    OM-228 956 Page 30 7-2. Diagnostics (Continued) ERR TEMP • The temperature error indicates welding power source has overheated and shutdown. The error may be cleared by allowing unit to cool down, and pressing the Jog/Purge button. ERR LINE • The line error indicates input power is outside of unit operating range. Check and correct input power [...]

  • Page 35

    OM-228 956 Page 31 7-2. Diagnostics (Continued) RMD DONE • The RMD done message indicates the RMD demo is completed. Pressing Jog/Purge button will change the screen to CYCL PWR on the display . T urn unit power of f and back on again. OVER A VER • The over average error indicates that current is outside the average range for the se t program p[...]

  • Page 36

    OM-228 956 Page 32 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram[...]

  • Page 37

    OM-228 956 Page 33 21 1 005-D[...]

  • Page 38

    OM-228 956 Page 34 SECTION 9 − P ARTS LIST 804 588-A . 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 − Fi g 9-3 , 9-4 21 − Fig 9-2 Figure 9-1. Main Assembly[...]

  • Page 39

    OM-228 956 Page 35 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    OM-228 956 Page 36 803 507-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 . . . . . . . . . . . . . . . . . .[...]

  • Page 41

    OM-228 956 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 9-2. Control Box (Fig 9-1 Item 21) (Continued) Quantity 22 228 270 NAMEPLA TE, lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 210 998 SWITCH ASSY , jog/purge (including) 1 . . . . . . . . . .[...]

  • Page 42

    OM-228 956 Page 38 See T able 9-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 804 186-A 4 5 6 7 8 3 2 1 9 10 2 11 12 13 14 15 16 17 18 19 20 21 22 Figure 9-3. Drive Assembly , Wire Item No. Diagram marking Part No. Description Quantity 9-3. Drive Assembly , Wire (9-1 Item 4) 1 224 772 Drive Assy , Mech[...]

  • Page 43

    OM-228 956 Page 39 . Hardware is common and not available unless listed. 804 589-A 1 2 3 4 Figure 9-4. Drive Assembly , Wire Description Part No. Dia. Mkgs. Item No. Figure 9-4. Drive Assembly , Wire (Fig 9-1 Item 4) Quantity 1 220 012 SCREW, 250-28x.62 button soc-hd zinc 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 44

    OM-228 956 Page 40 UC Groove 083 489 083 490 053 708 ve Rolls r ed) UC Groove 132 957 132 956 132 955 Standard Dri v (4 requir e U Groove 053 701 053 702 053 706 G uides V Groove 053 697 053 698 053 699 olls and G S tyle Drive r equired) Exit Guide 223 517 223 517 223 517 S tyle) Drive R o Guides for Old S t Rolls (1 each r e Intermediate Guide 223[...]

  • Page 45

    Notes[...]

  • Page 46

    Notes[...]

  • Page 47

    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[...]

  • Page 48

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West Spencer Street Applet on, WI 54914 US A International He adquarters − US A USA Phone: 9 20-735-4505 Auto-A tt ended USA & C anada F AX : 920-735-4134 Int ernati onal F A X: 9 20-735-4125 European Headqua rters − [...]