Miller Auto-Axcess 300 CE Owner'S Manual Download Page 38

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OM-231185 Page 32

SECTION 7

−

MAINTENANCE

7-1. Routine Maintenance

Disconnect power

before maintaining.

Maintain more often
during severe conditions.

= Check

= Change

= Clean

= Replace

* To be done by Factory Authorized Service Agent

Reference

Every

Months

Unreadable Labels

Weld Terminals

Damaged Gas Hose

Weld Cables

Cords

Gun Cables

Every

Months

Drive Rolls

Inside Unit

7-2. Blowing Out Inside Of Unit

Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow

through front and back louvers as

shown.

Ref. 803 675-B

Summary of Contents for Auto-Axcess 300 CE

Page 1: ...Processes Description MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding Automatic Welding Automatic Welding Interface And Arc Welding Power Source File Advanced Manufacturing Systems Visit o...

Page 2: ...ntinue 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: ...rial Number And Rating Label Location 12 4 2 Unit Specifications 12 4 3 Dimensions And Weight 12 4 4 Duty Cycle And Overheating 13 4 5 Volt Ampere Curves 13 4 6 Environmental Specifications 14 SECTION...

Page 4: ...ut Capacitor Voltage 43 9 4 Process Control Module PC4 Diagnostic LEDs 44 9 5 Diagnostic LEDs On Process Control Module PC4 44 9 6 Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings 45 9 7 D...

Page 5: ...ess 300 CE Auto Line Analog w Insight Core 907349006 Council Directives 2014 35 EU Low Voltage 2014 30 EU Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain Hazardous Substance...

Page 6: ...ttings programs only valid until setting options welding programs are changed Occupational exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations...

Page 7: ...neeling 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 order presented 1 a semiautomaticDC...

Page 8: ...ared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as clo...

Page 9: ...S can injure D Keep away from moving parts such as fans 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 ma...

Page 10: ...PA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of...

Page 11: ...s dans un environnement humideou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y...

Page 12: ...br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage v rifier et s assur...

Page 13: ...areil D Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur D Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e P...

Page 14: ...ational Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cy...

Page 15: ...ck by insulating yourself from work and ground Safe3 2012 05 Disconnect input plug or power before working on machine Safe5 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation...

Page 16: ...ated collection facility Contact your local recycling office or your local distributor for further information Safe37 2012 05 Wear hat and safety glasses Use ear protection and button shirt collar Use...

Page 17: ...ine Connection Gas Metal Arc Welding GMAW Three Phase Static Frequency Con verter Transformer Rectifier U0 Rated No Load Voltage OCV U1 Primary Voltage U2 Conventional Load Voltage X Duty Cycle Hz Her...

Page 18: ...Feed Speed Range Wire Diameter Range Max Open Circuit Volt age DC Amperes In put At Rated Load Output 60 Hz Three Phase Input kVA Input KW 400V Three Phase 225 A 25 V DC 100 Duty Cycle 10 44 Standard...

Page 19: ...cle Minutes duty1 4 95 230 226 B Continuous Welding 100 Duty Cycle At 225 Amperes 60 Duty Cycle At 300 Amperes 6 Minutes Welding 4 Minutes Resting 3 PHASE OPERATION WELD AMPERES DUTY CYCLE 10 15 20 25...

Page 20: ...suring electromagnetic compatibility in those locations due to con ducted as well as radiated disturbances This equipment complies with IEC61000 3 11 and IEC 61000 3 12 and can be connected to public...

Page 21: ...A Location 4 18 in 460 mm 18 in 460 mm OR 2 Movement Location And Airflow 3 Do not move or operate unit where it could tip loc_axcess 2015 04 OR 1 Ref 803 675 B Ref 801 915 A The proper interface kit...

Page 22: ...rk Press button to reset breaker If breaker continue to open contact a Factory Authorized Service Agent 4 Wirefeed Gas Receptacle RC8 Use receptacle to connect gas and motor control cable to power sou...

Page 23: ...nal and negative cable to Negative weld terminal 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output terminal Slide weld...

Page 24: ...120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x4 0 3x120 3x4 0 3x120 700 4 0 120 2x2 0 2x70 2x3 0 2x95 2x4 0 2x120 3x3 0 3x95 3x4 0 3x120 3x4 0 3x120 4x4 0 4x120 800 4 0 120 2x2 0 2x70 2x3 0 2x95...

Page 25: ...wire drive assembly Touch Sensor ON And Output Signal K Contact closure to L energizes Touch Sensor circuitry L Circuit common M Part touched 24 volts DC output signal referenced to circuit common Cir...

Page 26: ...ut 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 Three Phase Input Voltage V 400 Input Amperes...

Page 27: ...OM 231185 Page 21 Notes...

Page 28: ...er Input5 2013 04 Ref 803 766 C 804 750 B Ref 803 855 B Tools Needed 5 16 in Route ground conductor through tubing and current transducer to ground terminal Route input conductors to filter board 2 GN...

Page 29: ...connect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals...

Page 30: ...he welding puddle more fluid MIG CV weld process with individual settings of voltage and wire speed Postflow Setting a time value for gas flow after arc end only available on Auto Axcess models in the...

Page 31: ...e function that allows for a timed weld operation 0 to 999 seconds only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes and can only be set with...

Page 32: ...include steel displayed as STL stainless steel SS metal core MCOR aluminum ALUM See Table 6 1 for all wire abbreviations Gas Type LED When this LED is lit turn the Adjust knob to select the desired w...

Page 33: ...rmation depending on the active function of the unit and the weld process being used When the display shows voltage for a MIG process the Volts LED lights When it shows arc adjust for a pulsed and RMD...

Page 34: ...Argon 2 O2 81Ar 18HE 1CO2 Accu pulse 90HE 7 1 2Ar 2 1 2CO2 MIG RMD Accu pulse OX2 Tri Gas Tri Gas Cored Tubular Wire MCOR 71 76 86R 409 439 90 Argon 10 CO2 C10 98 Argon 2 O2 OX2 Aluminum ALUM 4XXX 5X...

Page 35: ...ROBT CAL message stop being displayed however if it is performed incorrectly the message remains on the display To start the calibration procedure over again turn unit input power off and then on agai...

Page 36: ...e NO REF V MEASURE V Arcstart 44 0Volts 1000 0IPM 01 0 14 0 5 6 L P 4 10 0 sec Fine 02 7 00 25 0 Arc End 0 0Volts 0 0IPM 0 0Sec 03 14 00 50 0 7 Call Safehome 04 Sample Auto Calibration Routine For ABB...

Page 37: ...Steel 90 Argon 10 CO2 Program 5 MIG 1 1 Mild Steel 75 Argon 25 CO2 Program 6 Accu pulse 1 1 Mild Steel 90 Argon 10 CO2 Program 7 Pulse 1 3 Mild Steel 90 Argon 10 CO2 Program 8 MIG 1 3 Mild Steel 75 Ar...

Page 38: ...e To be done by Factory Authorized Service Agent Reference Every 3 Months l Unreadable Labels Weld Terminals l Damaged Gas Hose nl Weld Cables nl Cords nl Gun Cables Every 6 Months OR Drive Rolls Insi...

Page 39: ...wer source SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power D Turn Off inverter disconnect input power and discharge input capacitors according to instruct...

Page 40: ...ding safety precautions D Use only genuine replacement parts from the manufacturer D Read and follow all labels and the Technical Manual carefully be fore installing operating or servicing unit Read t...

Page 41: ...whether Volts Arc Adjust or Wire Speed can be changed turning the Adjust knob Depending on the defined weld process either volts MIG or arc adjust pulse Accu pulse or RMD optional can be changed in th...

Page 42: ...I Unknown Error ERR UNKN Section 9 2 J Motor Communications Error MOTR COMM Section 9 2 K Over Average Current OVER AVE Section 9 2 L Over Current OVER CRNT Section 9 2 M Release Trigger REL TRIG Sec...

Page 43: ...ERR GND Indicates that weld current is flowing through the primary ground This is a latching error and welding power source power must be cycled off and back on again E Line Error ERR LINE Indicates...

Page 44: ...n over temperature condition on the primary or secondary heatsink or on the boost inductor To determine which of the two locations is at fault check LED 1 and LED 2 on inverter control board PC1 S If...

Page 45: ...chassis lifting eye bolts or weld secondary common Measure impedance between chassis and both weld secondary commons Measure the impedance across motor isolation barrier on motor housing All measureme...

Page 46: ...tput diode will cause an over current error and no weld output will be available N Release Trigger Error REL TRIG Indicates a timed weld has expired but the trigger is still active Press Jog Purge but...

Page 47: ...or W Robot Memory Error ROBT MEM Indicates robot lost memory data Press Jog Purge button to clear error X Unit Communication Error UNIT COMM Indicates the data bus on the PCM board is not functioning...

Page 48: ...the communication error AE RIO Bus Communication Indicates no error message on the displays RIO DeviceNet is losing packets of data Turn welding power source off and back on again to clear the commun...

Page 49: ...zero volts Measure input capacitor voltage on inverter assembly before proceeding If the capacitor voltage does not drop to near zero after several minutes use a bleeder resistor of between 25 and 100...

Page 50: ...4 Diagnostic LEDs 1 LED2 LED1 LED4 LED3 9 5 Diagnostic LEDs On Process Control Module PC4 LED Status Diagnosis 1 On Indicates 25 volts DC is present on process control module PC4 Off Indicates 25 volt...

Page 51: ...For proper operation do not change dip settings from those shown 9 6 Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings 217 333 B 804 756 B 2 1 LED1 LED2 LED3 LED4 9 7 Diagnostic LEDs On Wi...

Page 52: ...p Switch S2 Dip switches are used to identify each circuit board on the internal network Dip switch settings are different for each circuit board For proper operation do not change dip settings from t...

Page 53: ...switches are used to identify each circuit board on the internal network Dip switch settings are different for each circuit board For proper operation do not change dip settings from those shown 216...

Page 54: ...nal On from robot for jog retract Off Input signal Off from robot for no jog retract 12 On Input signal On from robot for purge Off Input signal Off from robot for no purge 13 On Input signal On remot...

Page 55: ...aux relay energized 33 On Input signal on touch sensor touch detected Off Input signal off touch sensor touch not detected 9 12 Network And Module Status LEDs A Network Status LEDs The following are n...

Page 56: ...le Reset supplementary protector CB1 Wire does not feed Check supplementary protector CB2 and reset if necessary Check motor control cable connections Wire feeds erratically Readjust hub tension Readj...

Page 57: ...OM 231185 Page 51 SECTION 10 ELECTRICAL DIAGRAMS 263 490 B Part 1 Of 2 Figure 10 1 Circuit Diagram For Welding Power Source Part 1 Of 2...

Page 58: ...OM 231185 Page 52 Figure 10 2 Circuit Diagram For Welding Power Source Part 2 Of 2...

Page 59: ...OM 231185 Page 53 263 490 B Part 2 Of 2 RC1 PLG...

Page 60: ...OM 231185 Page 54 Figure 10 3 Circuit Diagram For 72 Pin Robot Interface...

Page 61: ...OM 231185 Page 55 219 266 D...

Page 62: ...OM 231185 Page 56 Figure 10 4 Circuit Diagram For Peripheral Motor Interface...

Page 63: ...OM 231185 Page 57 219 267 B...

Page 64: ...8 SECTION 11 PARTS LIST Hardware is common and not available unless listed 804 751 E 1 23 Fig 11 5 5 Fig 11 3 6 Fig 11 2 7 Fig 11 4 2 2 3 4 8 10 8 10 11 13 12 12 14 15 16 17 18 19 20 21 22 9 Figure 11...

Page 65: ...hock Exploding Parts Wdles 2 13 219842 Label Warning Input Connections Electric Shock CE 1 14 213386 Assembly Filter Primary 1 15 HD2 182918 Transducer Current 400A Module Supply V 15V 1 16 220377 Bra...

Page 66: ...acer Windtunnel 3 10 T1 203408 Xfmr HF Litz Litz 1 11 Z1 220496 Output Inductor Assy 1 12 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 13 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole...

Page 67: ...31 196514 Gasket Inductor Mounting 1 32 196512 Bracket Inductor Mounting 1 33 196330 Heat Sink Power Module 1 34 L2 196345 Coil Inductor Pre regulator 1 35 196588 Baffle Foam Rubber Lower 1 196365 Plu...

Page 68: ...10 Panel Hole 312 Sq 500 High 4 6 PC4 239599 Process Control Module 1 7 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 8 210491 Panel Mtg Components Top 1 9 223439 Insulator circuit card Aux P...

Page 69: ...3 X 1 500 1 8 210505 Nameplate Rear 1 9 201058 Connector Rect 72 Pin Assy 1 10 210483 Bracket lift eye 1 11 CB1 083432 Supplementary Protector Man Reset 1P 10A 250VAC Frict 1 12 CB2 093995 Supplementa...

Page 70: ...11 1 Item 22 Quantity 1 S1 207456 Switch Assy Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg 1 2 207895 Insulator Switch Power 1 3 179851 Knob Pointer 1 670 Dia X 250 Id Push On W Spring 1 4 233576 Panel PC...

Page 71: ...PB3 199443 Switch Pb Mc No Spst 10A 115VAC w Blk Cap Panelmt 3 18 231056 Knob Black Electroswitch 1 19 212779 Nameplate Front 1 20 210865 Terminal pwr output red 1 21 210483 Bracket lift eye 1 22 2103...

Page 72: ...Notes...

Page 73: ...Notes...

Page 74: ...Notes...

Page 75: ...ns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components suc...

Page 76: ...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 Equip...

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