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Miller Electric OM-220 390F manual

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Table of contents for the manual

  • Page 1

    Axcess W ire Feeder Processes Description Wire Feeder OM-220 390F 2006 − 08 MIG (GMA W) W elding Pulsed MIG (GMAW -P) Flux Cored (FCA W ) W elding ™ 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

    dec_wire_2/04 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Note Manufacturer : European Contact: Miller Electric Mg. Co. Mr . Danilo Fedolfi, 1635 W . Spencer St. Managing Director Appleton, WI 54914 USA MILLER Europe S.r .l. Phone: (920) 734-[...]

  • Page 5

    OM-220 390 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-220 390 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-220 390 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-220 390 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-220 390 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 ut ilisés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es ris ques possible[...]

  • Page 10

    OM-220 390 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-220 390 Page 7 2-3 . Da ngers s upplé mentai res en r ela tion avec l’insta llation, le fonctionneme nt et l a 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 surcharger [...]

  • Page 12

    OM-220 390 Page 8 2-5. Princi pales normes de sécur ité 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 eld[...]

  • Page 13

    OM-220 390 Page 9 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 W arning! 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[...]

  • Page 14

    OM-220 390 Page 10 3-2. Manufacturer ’ s Rating Label For CE Products 225 622-A For label location see Section 5-3. 3-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Output A Amperes V V olts Direct Current (DC) X Duty Cycle Wire Feed Percent IP Degree Of Protection Input Cold Jog (Inch) T owards W orkpiece Purge By Ga[...]

  • Page 15

    OM-220 390 Page 1 1 SECTION 4 − INTRODUCTION 4-1. 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 [...]

  • Page 16

    OM-220 390 Page 12 Ref. 801 915 / Ref. 803 501-B 1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 5 Network Feeder Cable 6 Negative ( − ) Weld Cable 7 W orkpiece 8 V oltage Sensing Lead Recommended for Accu-pulse a nd RMD (optional). . Positive (+) voltage sensing lead is contained in the motor cable. 9 Positive (+) Weld Cable 1 2 3[...]

  • Page 17

    OM-220 390 Page 13 5-3. Rear Panel Connections And Rotating Drive Assembly 802 825-A / 803 503-B 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 Locat[...]

  • Page 18

    OM-220 390 Page 14 5-4. 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 dc common I Motor voltage +40 volts dc 5-5. Gun Recommendation T able Process Gun GMA W − Hard or [...]

  • Page 19

    OM-220 390 Page 15 5-6. Installing And Threading W elding 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[...]

  • Page 20

    OM-220 390 Page 16 5-7. Feeder Display At Power Up 1 Upper Display 2 Lower Display 2 1 Power Source Upper Display Lower Display Axcess Axcs 300/450/675 10 44 V oltage Range Net W ait DTEC OFF Process  Setup Adj ust F eeder Setup V t A 219 71 1-A 5-8. Dual Schedule Switch Option 1 Maint 2P (Maintained-Contact 2-Pole Switch) DSS-9M Part# [...]

  • Page 21

    OM-220 390 Page 17 SECTION 6 − OPERA TION 6-1. 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 22

    OM-220 390 Page 18 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 with[...]

  • Page 23

    OM-220 390 Page 19 6-3. Front Panel Sections See Section 6-5 See Section 6-6 See Section 6-9 See Section 6-8 See Section 6-7 See Section 6-4 Process S etup Adjust Feeder Setup V t A 219 71 1-A[...]

  • Page 24

    OM-220 390 Page 20 6-4. Program Push Button 1 3 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 ress butt on to illuminate LED. T o change the program number, r otate Adjus t k nob to selec [...]

  • Page 25

    OM-220 390 Page 21 6-6. Lower Display 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 when the T ime LED is illuminated. 2 W[...]

  • Page 26

    OM-220 390 Page 22 6-7. Feeder Set Up Push Button 1 Feeder Set Up Push Button LED 2 Feeder Set Up Push Button • Press button to choose Sequence. Feeder Set Up push-button LED will illuminate. 3 Sequence LED • When the Feeder Set Up button is pressed once, the Sequence LED will illuminate and the upper display will show sequence options. Use the[...]

  • Page 27

    OM-220 390 Page 23 6-9. Process Set Up Push Button • Press the Process Set Up push button the first time will illuminate the button LED and the Process LED. The upper and lower displays will be used for Accu-pulse and only the lower display for MIG, Pulse and RM D (optional) to show the current process installed in this program. T o change proces[...]

  • Page 28

    OM-220 390 Page 24 6-10. Jog/Purge The Jog/Purge switch provides the following functions: • Pressing left side of the Jog/Purge switch allows the operator to feed wire without energizing the weld power or gas valve circuit. The wire will feed at a 50 ipm rate for 3 seconds, then the rate ramps up to 700 ipm until the Jog switch is released. • T[...]

  • Page 29

    OM-220 390 Page 25 6-1 1. Reset Mode 198 993 / 803 504-B . 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 30

    OM-220 390 Page 26 SECTION 7 − SETTING SEQUENCE P ARAMETERS 7-1. Sequence Parameters In A Program . For more information on Sequence mode, see Feeder Set Up Push Button in Section 6-7 . We ld Time can only be set by using an o ptional PD A w ith File Management/WaveWriter soft ware. If time is set to zero in any time d sequenc e, the sequenc e is[...]

  • Page 31

    OM-220 390 Page 27 SECTION 8 − MAINTENANCE 8-1. 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 [...]

  • Page 32

    OM-220 390 Page 28 8-2. 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 reme[...]

  • Page 33

    OM-220 390 Page 29 8-2. 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 err[...]

  • Page 34

    OM-220 390 Page 30 8-3. 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 5-2). Electrode wire feeding stops or feeds erratically during welding Check gun trigger connection. See gun Owner’s Manual. e[...]

  • Page 35

    OM-220 390 Page 31 Notes[...]

  • Page 36

    OM-220 390 Page 32 SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram[...]

  • Page 37

    OM-220 390 Page 33 21 1 005-E[...]

  • Page 38

    OM-220 390 Page 34 SECTION 10 − 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 − Fi g 10-3 21 − Fig 10-2 Figure 10-1. Main Assembly[...]

  • Page 39

    OM-220 390 Page 35 Description Part No. Item No. Figure 10-1. Main Assembly Quantity 1 159 647 INSULA TOR, motor clamp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 CLAMP , motor base 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 40

    OM-220 390 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 10-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 10-2. Control Box (Fig 10-1 Item 21) Quantity 1 178 936 LABEL, warning general precautionary wordless CE WF 1 . . . . . . . . . [...]

  • Page 41

    OM-220 390 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 10-2 . Control Box (Fig 10-1 Item 21) (Continued) Quantity 22 21 1 073 NAMEPLA TE, lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 210 998 SWITCH ASSY , jog/purge (including) 1 . . . . . . . .[...]

  • Page 42

    OM-220 390 Page 38 See T able 10-1 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 10-3. Drive Assembly , Wire Description Part No. Dia. Mkgs. Item No. Figure 10-3. Drive Assem[...]

  • Page 43

    OM-220 390 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 10-3. Drive Assembly , Wire (Fig 10-1 Item 4) (continued) Quantity 24 134 834 HOSE, SAE .187 ID x .410 OD (order by ft) 2ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 685 ADAPTER ASSY , gun/feeder LH (including) 1 . . . . . . . . . . . [...]

  • Page 44

    Notes[...]

  • 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 or ks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − USA USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 920-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − [...]