Miller Electric Axcess 450 Owner'S Manual Download Page 1

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OM-220 389J

2007−10

Axcess 450

Processes

Description

MIG (GMAW) Welding

Pulsed MIG (GMAW-P)

Flux Cored (FCAW) Welding

Arc Welding Power Source

™

File: Advanced Manufacturing Systems

Visit our website at

www.MillerWelds.com/ams

Summary of Contents for Axcess 450

Page 1: ...9J 2007 10 Axcess 450 Processes Description MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding Arc Welding Power Source File Advanced Manufacturing Systems Visit our website at www MillerWelds...

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...

Page 3: ...STALLATION 14 4 1 Specifications 14 4 2 Dimensions And Weight 14 4 3 Duty Cycle And Overheating 15 4 4 Volt Ampere Curves 15 4 5 Selecting A Location 16 4 6 Connection Diagram 16 4 7 Rear Panel Recept...

Page 4: ...easuring Input Capacitor Voltage 32 9 2 Process Control Module PC4 Diagnostic LED s 33 9 3 Diagnostic LED s On Process Control Module PC4 33 9 4 Network And Module Status LED s 34 9 5 Troubleshooting...

Page 5: ...this product AxcessE 450 conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility Directives 89 336 EEC 92 31 EEC 2004 108 EC Machin...

Page 6: ......

Page 7: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Page 8: ...s they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the...

Page 9: ...ans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels cove...

Page 10: ...York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 91...

Page 11: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivante...

Page 12: ...de protection LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peu provoquer leur clatement Des ti...

Page 13: ...e pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteil...

Page 14: ...de provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur t...

Page 15: ...O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid r...

Page 16: ...OM 220 389 Page 10...

Page 17: ...2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld nea...

Page 18: ...when servicing unit 9 Always wear long sleeves and button your collar when servicing unit 10 After taking proper precautions as shown connect power to unit 4 04 219 844 A 5 min V V V 1 2 3 4 5 6 7 8 9...

Page 19: ...Connection Gas Metal Arc Welding GMAW Three Phase Static Frequency Con verter Transformer Rectifier U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage X Duty Cycle Hz He...

Page 20: ...m 1 3 35 6 mpm 030 062 in 0 8 1 6 mm 80 27 9 0 1A 19 46 0 8 18 68 0 17 While idling Input amperage fluctuates while idling and is always less than one Ampere Use one Ampere for power efficiency calcul...

Page 21: ...y Overheating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 220 485 A Continuous Welding 100 Duty Cycle At 450 Amperes 60 Duty Cycle At 580 Amperes 6 Minutes Welding 4 Minutes Resting 4 4 Volt Ampe...

Page 22: ...supply Movement 2 Location 4 18 in 460 mm 18 in 460 mm 3 Do not move or operate unit where it could tip Tipping 1 OR Special installation may be required where gasoline or volatile liquids are present...

Page 23: ...1 protects 115 volt receptacle RC2 from overload If CB1 opens RC2 does not work CB2 protects the wirefeed motor from overload If CB2 opens the wirefeeder does not work Press button to reset breaker If...

Page 24: ...ld Output Terminal 2 Negative Weld Output Terminal Connect positive weld cable to Positive weld terminal and negative cable to Negative weld terminal 3 Weld Output Terminal 4 Supplied Weld Output Term...

Page 25: ...power to this welding power source Actual input voltage should not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available 50 60 Hz...

Page 26: ...pplicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Install strain relief of proper size for unit and input conductors Rou...

Page 27: ...60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120...

Page 28: ...ce with a standard welding circuit connection The length of a welding circuit is determinedas follows Welding Circuit Electrode Cable Length ECL Work Cable Length WCL Workpiece Length WL See Section 5...

Page 29: ...y becomes enabled for all semi automatic processes The work sense lead connects to the Axcess welding power source 4 pin connector located above the negative output terminal This work sense lead autom...

Page 30: ...elding gas regulator and shielding gas connection for each welding gun Arc blow is the deflection of a welding arc from its normal path due to magnetic forces It will adversely affect the appearanceof...

Page 31: ...ent is a bad setup due to sensing leads being directly in the current flow path of the welding arc Interaction between welding circuits will affect voltage drop in the workpiece The voltage drop acros...

Page 32: ...ing Lead 6 Wire Feeder 7 Workpiece This arrangement is a better setup for supporting separate voltage feedback to the welding power sources The most accurate voltage sensing may not be achieved due to...

Page 33: ...Work Cable 5 Voltage Sensing Lead 6 Wire Feeder 7 Workpiece This arrangement is the best setup for proper voltage sensing at the workpiece Voltage feedback to the welding power sources will more accur...

Page 34: ...ON 6 OPERATION 6 1 Front Panel Switches 1 2 Ref 803 418 B 1 Power Switch Turns unit On or Off 2 Pilot Light Light indicates status of welding power source on when unit is on and off when unit is off 3...

Page 35: ...done by Factory Authorized Service Agent Reference Every Every 3 Months l Unreadable Labels Weld Terminals l Damaged Gas Hose nl Weld Cables 3 Months nl Cords nl Gun Cables Every 6 Months OR Drive Ro...

Page 36: ...h the ground D Do not leave live unit unattended D If this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job D When testing a li...

Page 37: ...lding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health Safety Code Section 25249...

Page 38: ...ample of a typical bleeder resistor is shown on this page Proceed with job inside unit Reinstall cover when finished Tools Needed 5 16 in 802 985 Ref 803 419 B 900 Volts dc can be present on the capac...

Page 39: ...PC4 Diagnostic LED s 1 LED2 LED1 LED4 LED3 9 3 Diagnostic LED s On Process Control Module PC4 LED Status Diagnosis 1 On Indicates 25 volts dc is present on process control module PC4 Off Indicates 25...

Page 40: ...th the network Red The circuit board has encountered a communication link failure with the network Check DeviceNet cable connections Verify dip switch positions according to Sections 1 2 and 1 3 Repla...

Page 41: ...ed Check circuit breaker CB2 and reset if necessary Check motor control cable connections Wire feeds erratically Readjust hub tension Readjust drive roll pressure Clean or replace dirty or worn drive...

Page 42: ...OM 220 389 Page 36 SECTION 10 ELECTRICAL DIAGRAMS Figure 10 1 Circuit Diagram For Welding Power Source...

Page 43: ...OM 220 389 Page 37 220 420 B...

Page 44: ...ge 38 SECTION 11 PARTS LIST Hardware is common and not available unless listed Ref 803 856 B 2 3 6 7 5 9 11 10 15 14 15 9 1 12 13 4 Fig 11 3 5 Fig 11 2 8 Fig 11 4 16 Fig 11 5 17 19 18 18 Figure 11 1 M...

Page 45: ...Input Filter 1 14 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 15 213372 Filter Assy Secondary 2 16 Fig 11 5 Front Panel Assembly 1 227855 Kit Connectors W Washer For Power Cables Includes 1 17 0...

Page 46: ...Vdc Can 2 50 Dia 2 22 210507 Clamp Capacitor Top Machined 2 23 217625 Kit Input Pre regulator And Inverter Module 1 24 RT1 RT2 214015 Thermistor NTC 30K Ohm 25 Deg C 7 18in Lead 1 25 PC2 222661 Circu...

Page 47: ...2 Id X 1 500 Mtg Hole 1 4 PC4 204048 Circuit Card Assy Process Control Module 1 5 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 8 6 210491 Panel Mtg Components Top 1 7 198122 Stand Off Support...

Page 48: ...pplementary Protector Man Reset 1P 10A 250VAC Frict 1 7 CB2 093995 Supplementary Protector Man Reset 1P 15A 250VAC Frict 1 8 RC2 196814 Receptacle w Leads 115V Duplex 1 9 PC12 209676 Circuit Card Assy...

Page 49: ...or Switch Power 1 3 211475 Plate front panel 1 4 PC13 208071 Circuit Card Assy ISO COMM 1 5 FM 196313 Fan Muffin 115V 50 60 Hz 3000 Rpm 6 378 Mtg Holes 2 6 C6 C7 C8 206878 Capacitor Assy 3 7 213102 Ch...

Page 50: ...0 210865 Terminal Pwr Output Red 1 21 210483 Bracket lift eye 1 22 210358 Bolt eye shld thd stem 500 13 X 1 500 1 OPTIONAL When ordering a component originally displaying a precautionary label the lab...

Page 51: ...nduction 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...

Page 52: ...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...

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