Miller Electric 394F manual

Axcess Dual W ire Feeder Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) Welding (Gas- And Self-Shielded) Wire Feeder OM-222 394F 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-222 394 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[...]

OM-222 394 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[...]

OM-222 394 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-222 394 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 W[...]

OM-222 394 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 m bole graphique d’avert issement ! Attent ion ! Cet te pro - cédur e c ompor te d es risques p os s[...]

OM-222 394 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[...]

OM-222 394 Page 7 2-3 . Dangers s uppléme ntaires e n rela t ion avec l’ins tallation, le fonctionnement et la m a intenance 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 l?[...]

OM-222 394 Page 8 2-5. Princi pales n ormes de sécu rit 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-222 394 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 (2[...]

OM-222 394 Page 10 804 019-A 1 W elding 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 (+) W eld Cable 4-2. Connection Diagram[...]

OM-222 394 Page 1 1 4-3. Rear Panel Connections And Rotating Drive Assembly 804 020-A / 802 825-A 1 9-Pin Network Receptacle 2 Power Switch 3 Shielding Gas V alve Fitting (Left And Right) Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. 4 Weld Cable T erminal 5 Jumper Cable 6 Weld Cable 7 Drive Assembly 8 Drive[...]

OM-222 394 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 dc common I Motor voltage +40 volts dc 4-5. Gun Recommendation T able Process Gun GMA W − Hard or [...]

OM-222 394 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 as possible to drive rolls without touching. Install[...]

OM-222 394 Page 14 4-7. Power Source 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 Length Arc Ctl Sequence Net W ait DTEC OFF[...]

OM-222 394 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 ar[...]

OM-222 394 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 with[...]

OM-222 394 Page 17 SECTION 6 − OPERA TION 6-1. Power Switch 1 Power Switch 804 021-A 1 1 Left/Right Select Switch Pressing the Left/Right Select switch allows the operator to choose which side of the units’ con- trols will operate. 6-2. Left/Right Select Switch 804 022-A . Depressing the Left or Right Gun T rigger also allows the operator to en[...]

OM-222 394 Page 18 6-3. 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 60 ipm rate for 3 seconds, then the rate ramps up to 700 ipm until the Jog switch is released. • Th[...]

OM-222 394 Page 19 6-4. Front Panel Sections See Section 6-6 See Section 6-7 See Section 6-10 See Section 6-9 See Section 6-8 See Section 6-5 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-222 394 Page 20 6-5. 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 , rotat e Adjust knob to[...]

OM-222 394 Page 21 6-7. 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[...]

OM-222 394 Page 22 6-8. 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[...]

OM-222 394 Page 23 6-10. 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 proce[...]

OM-222 394 Page 24 6-1 1. Reset Mode 198 993 / 803 246-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[...]

OM-222 394 Page 25 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 6-8 . We ld Time can only be set by using an o ptional PDA with File Management/WaveWriter softwar e. If time is set to zero in any tim ed sequenc e, t he sequenc e is [...]

OM-222 394 Page 26 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 [...]

OM-222 394 Page 27 8-2. Diagnostics ERR T ACH • The tach error occurs 2 seconds after the loss of tachometer feedback. The motor speed is reg ula 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 remed[...]

OM-222 394 Page 28 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[...]

OM-222 394 Page 29 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 4-2). Electrode wire feeding stops or feeds erratically during welding Check gun trigger connection. See gun Owner’s Manual. e[...]

OM-222 394 Page 30 SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram[...]

OM-222 394 Page 31 218 564-D[...]

OM-222 394 Page 32 SECTION 10 − P ARTS LIST 804 023-A . Hardware is common and not available unless listed. 12 19 2 1 3 17 18 7 16 8 11 9 10 6 20 15 11 10 14 5 22 4 − Figure 10-3 21 − Figure 10-2 9 13 Figure 10-1. Main Assembly[...]

OM-222 394 Page 33 Description Part No. Item No. Figure 10-1. Main Assembly Quantity 1 159 647 INSULA TOR, motor clamp 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 CLAMP , motor base 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-222 394 Page 34 804 024-C . Hardware is common and not available unless listed. 1 2 4 5 6 3 7 8 9 10 12 11 14 15 16 17 13 18 19 11 21 20 22 23 24 25 26 27 28 29 Figure 10-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 10-2. Control Box (Figure 10-1 Item 21) Quantity 1 +220 321 WRAPPER, feeder dual Axcess 1 . . . . . . . . . . . .[...]

OM-222 394 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 10-2. Control Box (Figure 10-1 Item 21) (Continued) Quantity 19 030 170 BUSHING, snap − in nyl .750 ID x 1.000 mtg hole 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 219 047 V AL VE, 40 VDC 2 way custom port 1/8 orf w/frict 2 . . . . . . . . . [...]

OM-222 394 Page 36 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[...]

OM-222 394 Page 37 Description Part No. Dia. Mkgs. Item No. Figure 10-3. Drive Assembly , Wire (Figure 10-1 Item 4) (continued) Quantity 22 168 825 DRIVE, pinion 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 133 308 RING, retaining ext .375 shaft x .0[...]

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[...]

PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wor k s Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F AX : 920-735-4134 Int ernational F A X: 9 20-735-4125 European Headqua rters −[...]