Miller Electric 75 Owner'S Manual Download Page 36 | Manualshive

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OM-228 956 Page 32

SECTION 8

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ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram

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Summary of Contents for 75

Page 1: ...Axcess AlumaFeed 75 Processes Description MIG GMAW Welding Wire Feeder OM 228 956B 2006 08 File Advanced Manufacturing Systems Visit our website at www MillerWelds com ...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation...

Page 3: ... 10 4 3 Rear Panel Connections And Rotating Drive Assembly 11 4 4 9 Pin Network Receptacle Information 12 4 5 Installing Drive Rolls 12 4 6 Installing PD Continuous Wire Guides 13 4 7 Installing Non PD Old Style Wire Guides 14 4 8 Installing Welding Gun 15 4 9 Installing Welding Wire And Adjusting Pressure Drive Setting 16 4 10 Feeder Display At Power Up 17 4 11 Dual Schedule Switch Options 17 SEC...

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Page 5: ...10 147 see Safety Standards D Properly install and ground this equipment according to its Owner s Manual and national state and local codes D Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach prop...

Page 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag D Wear approved safety glasses with side shield...

Page 7: ...es computers and communicationsequipment D Have only qualified persons familiar with electronic equipment perform this installation D The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintaine...

Page 8: ...A Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The...

Page 9: ...n selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales D Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du sectionne...

Page 10: ...ble de ses poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité DES PARTICULES VOLANTES peuvent blesser les yeux D Le soudage l écaillement le passage de la pièce à la brosse en fil de fer et le meulage génèrent des étincelles et des particules ...

Page 11: ...s interférences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation D L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation D Si le FCC sig...

Page 12: ... Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans le...

Page 13: ...70 5 lb 32 0 kg SECTION 4 INSTALLATION 4 1 Selecting A Location loc_2 3 96 Ref 804 585 A Y 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 Locate unit near correct input power supply...

Page 14: ... Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 5 Network Feeder Cable 6 Negative Weld Cable 7 Workpiece 8 Voltage 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: ... threads Connect customer supplied gas hose 3 Weld Cable 4 Weld Cable Screw Screw Size 375 16 x 1 50 5 Drive Assembly 6 Drive Assembly Rotation Knob 7 Rating Label Location To rotate the drive assembly loos en drive assembly rotation knob rotate drive assembly and tighten knob 9 16 5 8 in Tools Needed 3 16 in 5 6 2 1 7 0 to 350 Amps weld connection 350 Amps and above weld connection ...

Page 16: ... Pressure Assembly Door 2 Drive Roll 3 Ejector Button 4 Drive Roll Carrier Installation Open pressure assembly door Align drive roll slots with three lobes on drive roll carrier Insert drive roll onto carrier Drive roll will snap into place Removal Remove PD wire guide before removing lower drive rolls Lift up drive roll swing arm and press ejector button in middle of drive roll carrier If ejector...

Page 17: ... Guide 3 PD Wire Guide Hard Wire 4 PD Wire Guide Two Pieces interlocked for Aluminum Wire Installing PD continuous wire guides with PD drive rolls Drive rolls are identified by the initials PD and a part number on the drive roll Open pressure assembly door Lift up drive roll swing arms Remove PD inlet guide Insert wire guide gun end indi cated with arrow into block near brass power pin gun connect...

Page 18: ... cure inlet guide Set screw may be used to se cure PD inlet guide replace ments such as wire straighten ers or conduit adapters Remove screw securing intermedi ate guide holder Guide holder is located between the lower front and rear drive roll carriers Rotate guide holder 180 degrees and reinstall Install intermediate guide into guide holder and tighten set screw Loosen set screw insert exit guid...

Page 19: ... the power pin of the gun with the gun locking tab Secure gun by tightening power clamp knob Installing gun without Accu Mate connection When using a gun without the groove in the power pin loosen power clamp knob and rotate gun locking tab 180 degrees This pre vents the locking tab from extend ing into the power pin gun connec tion When installing gun the liner should extend into the PD continu o...

Page 20: ...the guide Install gun Lay gun cable out straight Cut off end of wire Push wire through guide up to drive rolls continue to hold wire Press Jog button to feed wire out gun To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Adjust pressure drive lever so wire does not slip Do not overtighten If contact tip is compl...

Page 21: ...igger Control Adjust Volts Time WFS Amps Process Set Up Feeder Set Up Trigger Hold 2 1 Power Source Upper Display Lower Display Axcess Axcs 300 450 675 10 44 Voltage Range Arc Adjust Arc Ctl Sequence 4 11 Dual Schedule Switch Options 1 Maint 2P Maintained Contact 2 Pole Switch DSS 9M Part 041 793 1 1 1 2 2 3 A 4 B DSS 9M ...

Page 22: ... is controlled by peak and minimum current levels Benefits are shorter arc lengths better puddle control more tolerant of tip to work variation less audible noise no arc wandering allows weld to fill in at toes increasing travel speed and deposition and more tolerant to poor fit up and gaps RMD optional RMD refers to Regulated Metal Deposition A precisely controlled short circuit transfer Benefits...

Page 23: ...e and trigger functions Auto Thread Method of jogging wire without holding jog or trigger switch Pressing Jog and Retract simultaneously will automatically feed wire Default setting is 192 at a feed rate of 700 ipm these values can be changed using a PDA with File Management WaveWriter software Pressing jog purge or trigger switch will terminate the auto threading feature 5 2 Power Switch 1 Power ...

Page 24: ... 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 Type Gas Type Trigger Control Adjust Volts Time WFS Amps Process Set Up Feeder Set Up Trigger Hold Arc Adjust Arc Ctl Sequence ...

Page 25: ...play The upper display shows voltage or arc length The unit displays both preset voltage or arc length and actual voltage When welding actual arc voltage is displayed 2 Upper Display Push Button Press the button to illuminate the LED and allow changing information in the display Release button to display voltage 3 Upper Display Push Button LED The upper display push button LED illuminates to indic...

Page 26: ...t knob 5 Time LED LED illuminates to indicate that a time value is being displayed for a sequence function and can be adjusted using the Adjust knob 6 Lower Display Push Button 7 Lower Display Push Button LED Pressing the button illuminates the LED and selects either WFS or Arc Ctl value for changing using the Adjust knob To select Arc Ctl press and hold lower display button for 2 seconds The top ...

Page 27: ...Use the Adjust control to set wire speed parameter Press the lower display push button a fourth time will cycle the display back to time Press the Feeder Set Up button a second time to go to Trigger Control mode and allow the top display to become active Use the Adjust control to cycle through trigger control methods as follows dual schedule trigger hold trigger dual schedule program select 4T see...

Page 28: ...setup items no program will be loaded and unit will return to standby mode If a custom program is loaded using an optionalPDA with File Management software the upper display will show CUST and the lower display will show PROG The Adjust control remains active to allow loading a standard program in place of the custom program Pressing and holding the Process Set Up push button in on power up allows...

Page 29: ...ted Jog speed can be adjusted by the Adjust control when the unit is jogging wire The unit displays jog speed when the unit is being jogged Jogging can also be accomplished by pressing the Jog Purge button Pressing the Jog Purge button also allows the operator to purge gas lines before welding and to preset gas pressure at the regulator This unit is equipped with Auto Thread capability By rocking ...

Page 30: ...utton to confirm the reset The reset message is displayed for 2 seconds while factory program settings are being reloaded During the reset mode the following factory default programs are loaded into the unit Cycl Pwr message appears on the display when programs complete loading Turn power off wait 10 seconds and turn power back on again to complete the reset operation After Reset is complete be su...

Page 31: ...set to zero in any timed sequence except Weld the sequence is skipped Maximum IPM may actually be lower depending on wire size and gas combination Trigger Pressed Trigger Released Time Start Time Preflow Weld Crater Time Postflow Start Time Time Postflow Crater Weld Preflow Sequence End Volts Trim IPM Seconds 2 Postflow Off 5 0 X Setting available 1 Preflow Off 5 0 Sequence Parameters 3 Start 4 Cr...

Page 32: ...e maintaining n Check Z Change Clean l Replace To be done by Factory Authorized Service Agent Reference Every Every 3 M th l Unreadable Labels Weld Terminals nl Weld Cables l Cracked Parts Months n 14 Pin Cord n Gas Hose And Fittings n Gun Cable Every 6 Months Or Inside Of Unit Drive Rolls ...

Page 33: ...n pressing the Jog Purge button ERR COOL The cool error indicates no coolant flow in water flow switch option The error may be reset by reestablishing coolant flow to the gun and then pressing the Jog Purge button ERR FTP The file transfer error occurs if data does not transfer to the feeder correctly Press Jog Purge button to clear error and transfer data to feeder again ERR GND The ground curren...

Page 34: ...lear error WELD WAIT The weld wait error indicates unit was not ready for a weld sequence Press Jog Purge button to clear error MOTR COM The motor communication error indi cates motor board lost data communica tions Press Jog Purge button to clear error PLS WAIT The uim communication error indicates user interface board lost data communications Press Jog Purge button to clear error OVER CRNT The o...

Page 35: ... UNKN Indicates a CRC PCM bus error Indicates an unknown error RMD DONE OVER AVER Indicates RMD demo is done Indicates an over average current error REL TRIG Indicates a contactor on error TRIG STUK Indicates a trigger closed error 7 3 Troubleshooting Y Disconnect power before troubleshooting Trouble Remedy Wire feeds shielding gas flows but electrode wire is not energized Check and secure weld ca...

Page 36: ...OM 228 956 Page 32 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 37: ...OM 228 956 Page 33 211 005 D ...

Page 38: ...228 956 Page 34 SECTION 9 PARTS 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 Fig 9 3 9 4 21 Fig 9 2 Figure 9 1 Main Assembly ...

Page 39: ... 428 HUB spool 1 13 135 205 NUT stl slflkg hex reg 625 11 w nylon insert 1 14 200 556 SUPPORT spool 1 15 201 781 KNOB w extension clamp 1 16 228 131 CLAMP motor top 1 17 145 639 STRIP buna N compressed sheet 062 x 4 000 x 4 000 1 18 200 552 BASE 1 19 134 306 FOOT rubber 1 250 dia x 1 375 high no 10 screw 4 20 200 557 STIFFENER base 1 21 Figure 9 2 CONTROL BOX 1 22 216 695 CAPACITOR w terminals 027...

Page 40: ...6 209 681 CIRCUIT CARD ASSY motor control 1 8 211 003 ENCLOSURE motor 1 9 010 494 BUSHING snap in nyl 1 375 id x 1 750 mtg hole 1 10 057 357 BUSHING snap in nyl 937 id x 1 125 mtg hole 1 11 RC1 211 018 CONNECTOR circ 97 met 9 pin size 20 rcpt 1 PLG43 46 49 72 115 093 HOUSING PLUG SKTS service kit 1 12 605 227 NUT 750 14 knurled1 68dia 41h nyl 1 13 219 047 VALVE 40 VDC 2 way custom port 1 8 orf w f...

Page 41: ...15 094 HOUSING PLUG SKTS service kit 1 PLG48 202 592 HOUSING PLUG SKTS service kit 1 PLG4 136 810 HOUSING PLUG SKTS service kit 1 PLG81 115 092 HOUSING PLUG SKTS service kit 1 PLG10 130 203 HOUSING PLUG SKTS service kit 1 PLG50 136 810 HOUSING PLUG SKTS service kit 1 PLG44 131 058 HOUSING PLUG SKTS service kit 1 PLG45 188 352 HOUSING RCPT SKTS service kit 1 PLG42 131 054 HOUSING RCPT SKTS service ...

Page 42: ... 308 Ring Rtng Ext 500 Shaft X 035 Thk 1 9 601 941 Screw 250 20x1 75 Hexwhd 61D Gr5 Pld 1 10 219 132 Screw 375 16x2 00 Hexwhd 81D Pld 1 11 602 241 Washer Flat 281 Idx0 625 Odx 065t Stl Pld Ansi 250 1 12 181 221 Screw 250 20x 50 Button Hd Soc Stl Pld 1 13 092 865 Key Stl 1215 1230 X 750 1 14 219 084 Pressure Assy 1 15 144 172 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 1 16 219 093 Block Gas 1 17 219 0...

Page 43: ... 250 28x 62 button soc hd zinc 4 2 Figure 9 3 DRIVE ASSEMBLY 1 3 M1 227 024 MOTOR 1 4 229550 ENCODER quadrature 500PPR incremental 5V shaftless 1 Recommended Spare Parts Have nearest Factory Authorized Service Agent replace encoder To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts ...

Page 44: ... 108 219 108 219 108 ve and Non P um de required PD Continuous Guide 223 100 223 101 223 101 rolls sion Drive D for Aluminu rolls 1 guide PD Drive Roll 227 770 222 499 227 772 oove drive ro D Precis PD 1 kit or 4 ro PD Kit 300 040 300 041 PD U U Groo Table 9 1 PD ire de required PD Continuous Guide 223 097 223 097 223 098 00041 contain P Ta D for Hard Wir rolls 1 guide PD Drive Roll 222 498 222 49...

Page 45: ...Notes ...

Page 46: ...Notes ...

Page 47: ...n Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushe...

Page 48: ...d retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering...

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