Miller Auto-Axcess 300 DI Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SAFETY PRECAUTIONS - READ BEFORE USING

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1-2. Arc Welding Hazards

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Symboles utilisés

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4. Proposition californienne 65 Avertissements

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2-5. Principales normes de sécurité

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2-6. Informations relatives aux CEM

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SECTION 3

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DEFINITIONS

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3-1. Manufacturer’s Warning Label Definitions

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3-2. Miscellaneous Symbols And Definitions

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SECTION 4

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INSTALLATION

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4-1. Specifications

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4-2. Dimensions And Weight

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4-3. Duty Cycle And Overheating

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4-4. Volt-Ampere Curves

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4-5. Serial Number And Rating Label Location

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4-6. Selecting A Location

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4-7. Connection Diagram

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4-8. Rear Panel Receptacles And Supplementary Protectors

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4-9. Connecting To Weld Terminals

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4-10. Selecting Weld Cable Sizes*

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4-11. Devicenet Receptacle Functions

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4-12. Motor Control Receptacle Functions

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4-13. E-Stop Receptacle Functions

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4-14. Electrical Service Guide

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4-15. Connecting 3-Phase Input Power

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4-16. Connecting 1-Phase Input Power

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4-17. Remote Program Select

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4-18. Remote Program Setting

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4-19. Touch Sensor Operation

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SECTION 5

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OPERATION

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5-1. Operational Terms

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5-2. Front Panel Controls (See Section 5-3)

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5-3. Front Panel Controls - Continued (See Section 5-2)

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5-4. Front Panel Switches

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5-5. Reset Mode

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SECTION 6

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MAINTENANCE

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6-1. Routine Maintenance

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6-2. Blowing Out Inside Of Unit

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Summary of Contents for Auto-Axcess 300 DI

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: ...LATION 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 Serial Number And Rating Label Location 15 4 6 Selecting A Location 16 4 7...

Page 4: ...Input Capacitor Voltage 37 8 4 Process Control Module PC4 Diagnostic LEDs 38 8 5 Diagnostic LEDs On Process Control Module PC4 38 8 6 Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings 39 8...

Page 5: ...ds when in 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 eq...

Page 6: ...ums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoli...

Page 7: ...NG PARTS 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...

Page 8: ...ntion During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Healt...

Page 9: ...utilisation d une 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 con...

Page 10: ...ne et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur...

Page 11: ...eur 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 bouteilles de gaz comprim...

Page 12: ...der seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion D L utilisateur est tenu de faire corriger rapidement par un lectricien quali...

Page 13: ...t Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Re...

Page 14: ...OM 228 874 Page 10...

Page 15: ...self 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 or local exhaust to...

Page 16: ...a designated 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 c...

Page 17: ...Earth Ground Increase Line 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...

Page 18: ...A 8 6 0 1A 5 3 0 2 4 9 0 04 Three Phase 225 A 25 3 V DC 100 Duty Cycle 19 9 0 1A 17 8 0 1A 10 9 0 1A 10 3 0 1A 9 0 0 1A 7 3 0 1A 7 1 0 2 6 8 0 04 While idling Input amperage fluctuates while idling an...

Page 19: ...TION SINGLE PHASE OPERATION DUTY CYCLE WELDING AMPERES 10 15 20 25 30 40 50 60 70 80 90 100 100 150 200 225 250 300 400 500 4 4 Volt Ampere Curves va_curve1 4 95 Volt amperecurves show minimum and max...

Page 20: ...tile liquids are present see NEC Article 511 or CEC Section 20 Ref 803 675 A Ref 801 915 A The proper interface kit must be installed in the welding power source interface unit to allow it to be conne...

Page 21: ...rminals 1 2 Ref 803 675 A 803 778 A Turn off power before connecting to weld output terminals Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine D...

Page 22: ...5 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 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0...

Page 23: ...574 A Socket Socket Information A Not used B Motor negative C Tach A 0 volts low and 3 5 volts high D Motor positive E Tach common F Gas valve 40 volts DC when valve is on with respect to socket K G E...

Page 24: ...Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class R...

Page 25: ...OM 228 874 Page 21 Notes...

Page 26: ...ble through tubing inside unit 2 218005 C ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE exists after removal of input power S Always wait 5 minutes after power is turned off before working on unit S...

Page 27: ...mperage 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 Route conductors cord through str...

Page 28: ...ut7 2012 05 Ref 803 766 C 803 676 A Ref 218 005 A Tools Needed 5 16 in Route ground conductor through current transducer to ground terminal Route input power cable through tubing inside unit 7 2 1 6 4...

Page 29: ...ing conductor through current transducer and connect to welding power source grounding terminal first Then connect input conductors L1 and L2 to welding power source line terminals Reinstall side pane...

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: ...eed In MIG mode wire feed setting is independent of voltage setting In pulse Accu pulse and RMD optional adjusting wire feed speed also increases power level on wire electrode one knob control Wire Ty...

Page 32: ...When this LED is lit turn the Adjust knob to select the desired wire type wire alloy and size Wire type and size choices vary according to the selected weld process Choices may include steel displaye...

Page 33: ...d or actual save the changes and then turn the power to the unit off and then on again for the changes to be carried out by the unit 14 Volts And Arc Adjust LEDs The lit LED indicates whether voltage...

Page 34: ...3 Accu pulse 035 Mild Steel 90 Argon 10 O2 Program 4 Pulse 045 Mild Steel 90 Argon 10 CO2 Program 5 MIG 045 Mild Steel 75 Argon 25 CO2 Program 6 Accu pulse 045 Mild Steel 90 Argon 10 O2 Program 7 Pul...

Page 35: ...ce 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 Ins...

Page 36: ...ve unit use the one hand method Do not put both hands inside unit Keep one hand free D Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT D...

Page 37: ...abels and the Technical Manual carefully be fore installing operating or servicing unit Read the safety in formationat the beginning of the manual and in each section 7 3 California Proposition 65 War...

Page 38: ...r arc adjust pulse Accu pulse or RMD optional can be changed in the top display Wire speed can be changed in the bottom display Press the Wire Feed Speed Amps push button to toggle between selecting i...

Page 39: ...error occurs if weld current is detected in the earth ground connection May be caused by a conductor making contact with unit chassis Check and repair feeder weld connections Turn power off and back...

Page 40: ...ters Check and correct program parameters Press Jog Purge button to clear error TRIG STUK The trigger stuck error indicates the user held the gun trigger during power up Release trigger and turn power...

Page 41: ...n until voltage drops to near 0 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 bleede...

Page 42: ...Diagnostic LEDs 1 LED2 LED1 LED4 LED3 8 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 volts...

Page 43: ...d For proper operation do not change dip settings from those shown 8 6 Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings 217 333 B 804 575 A 2 1 LED1 LED2 LED3 LED4 8 7 Diagnostic LEDs On W...

Page 44: ...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 45: ...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 Replace...

Page 46: ...ed Check supplementary protector 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 wor...

Page 47: ...OM 228 874 Page 43 SECTION 9 ELECTRICAL DIAGRAMS 228 875 F Part 1 Of 2 Figure 9 1 Circuit Diagram For Welding Power Source Part 1 Of 2...

Page 48: ...OM 228 874 Page 44 Figure 9 2 Circuit Diagram For Welding Power Source Part 2 Of 2...

Page 49: ...OM 228 874 Page 45 228 875 F Part 2 Of 2...

Page 50: ...OM 228 874 Page 46 Ref 219 267 B Figure 9 3 Circuit Diagram For Peripheral Motor Interface...

Page 51: ...OM 228 874 Page 47 Notes...

Page 52: ...OM 228 874 Page 48 SECTION 10 PARTS LIST Hardware is common and not available unless listed 804 576 D 1 2 3 7 8 9 10 11 12 13 14 Fig 10 5 4 Fig 10 3 5 Fig 10 2 6 Fig 10 4 7 Figure 10 1 Main Assembly...

Page 53: ...lator 2 8 210482 Base 1 9 213386 Assembly Filter Primary 1 10 HD2 182918 Transducer Current 400A Module Supply V 15V 1 11 198951 Block Terminal 3 Pole 1 12 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 St...

Page 54: ...1 11 Z1 220496 Output Inductor Assy 1 12 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 2 13 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole Cent 4 14 196355 Insulator Screw 6 15 010546 Bu...

Page 55: ...196840 Insulator Resistors Interface Board 1 30 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 1 31 196514 Gasket Inductor Mounting 2 32 196512 Bracket Inductor Mounting 2 33 196330 Heat Sink...

Page 56: ...Panel Hole 312 Sq 500 High 24 6 PC4 221277 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 Po...

Page 57: ...9 CB2 093995 Supplementary Protector Man Reset 1P 15A 250VAC Frict 1 10 PC11 239631 Circuit Card Assy Motor Filter HF 1 11 216596 Strap Grounding 4 50 in long 1 12 225955 Plate Mounting E Stop 1 13 RC...

Page 58: ...Mode Choke 1 9 216965 Cover Connector D sub 9 skt Female w Chain 1 10 216966 Cover Connector D sub 9 pin Male w Chain 1 11 213102 Choke Common Mode w Leads 2 12 210866 Terminal pwr output black 1 13...

Page 59: ...lies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard...

Page 60: ...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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