Miller AXCESS 450 CE Owner'S Manual Download Page 1

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OM-220 389R

2010

−

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 CE

Page 1: ...R 2010 11 Axcess 450 CE 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 R ...

Page 2: ...ontinue 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 operati...

Page 3: ...portant Information Regarding CE Products Sold Within The EU 14 SECTION 5 INSTALLATION 15 5 1 Serial Number And Rating Label Location 15 5 2 Specifications 15 5 3 Dimensions And Weight 15 5 4 Duty Cycle And Overheating 16 5 5 Volt Ampere Curves 16 5 6 Selecting A Location 17 5 7 Connection Diagram 17 5 8 Rear Panel Receptacles And Supplementary Protectors 18 5 9 Network Wire Feeder Receptacle Func...

Page 4: ...2 9 4 EMF Information 32 SECTION 10 TROUBLESHOOTING 33 10 1 Removing Cover and Measuring Input Capacitor Voltage 33 10 2 Process Control Module PC4 Diagnostic LEDs 34 10 3 Diagnostic LEDs On Process Control Module PC4 34 10 4 Network And Module Status LEDs 35 10 5 Troubleshooting 36 SECTION 11 ELECTRICAL DIAGRAMS 38 SECTION 12 PARTS LIST 40 WARRANTY ...

Page 5: ...C Low Voltage 2004 108 EC Electromagnetic Compatibility Standards IEC 60974 1 2005 Arc Welding Equipment Welding Power Sources IEC 60974 10 2007 Arc Welding Equipment Electromagnetic Compatibility Requirements EN 50445 Product family standard to demonstrate compliance of equipment for resistance welding arc welding and allied processes with the basic restrictions related to human exposure to elect...

Page 6: ......

Page 7: ...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 constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone D Disconne...

Page 8: ... 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 work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw frozen pipes D Remove stick electrode from holder or cut off weld...

Page 9: ... panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing u...

Page 10: ... web site www ansi org Standard for Fire Prevention 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 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...

Page 11: ...urant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou ...

Page 12: ... ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le co...

Page 13: ...ur D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonction...

Page 14: ...ecte et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipement commandé par ordinateur tel que les robots D Veiller à ce que tout l équipement de la zone de soudage soit comp...

Page 15: ...n 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov N...

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

Page 17: ... 1 Keep your head out of the fumes 2 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 near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed conta...

Page 18: ...ays wear a face shield 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 1 2 3 4 5 6 7 8 9 10 S 179 309 A 60 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Falling equipment can cause injury and damage to unit 3 Always lift and support unit using both eye bolts K...

Page 19: ...rth 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 Voltage X Duty Cycle Hz Hertz IP Degree Of Protection I2 Rated Welding Current Percent Pulsed Single Phase Three Phase I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current S Suitabl...

Page 20: ...s equipment was conducted at 0 5 meter S At a distance of 1 meter the EMF exposure values were less than 20 of the permissible values ce emf 1 2010 10 B Information On Electromagnetic Compatibility EMC This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring...

Page 21: ... DC Amperes In put At Rated Load Output 50 60 Three Phase Input kVA Input KW 400V Three Phase 400 V Input 450 A 36 5 V DC 100 Duty Cycle 10 44 Standard 50 1400 ipm 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 calculations Wire feed speed ranges are for ...

Page 22: ... warranty 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 5 5 Volt Ampere Curves va_curve1 4 95 220 486 A Volt amperecurves show minimum and maximum voltage and amperage output capabilities of unit Curves of other settings fall between curves shown This volt ampe...

Page 23: ...8 in 460 mm 18 in 460 mm 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 see NEC Article 511 or CEC Section 20 Ref 803 410 B Ref 801 915 A 1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 5 Network Feeder Cable 6 Negative Weld Cable 7 Workpiece 8 Work Sense Lead Recommendedfor Accu pulse a...

Page 24: ...pens the wirefeeder does not work Press button to reset breaker If breaker continue to open contact a Factory Authorized Service Agent 4 Network Wire Feeder Receptacle RC1 Use receptacle to connect network feeder cable to power source see Section 5 7 2 3 5 8 Rear Panel Receptacles And Supplementary Protectors 1 4 5 9 Network Wire Feeder Receptacle Functions 9 Pin Pin Information Ref 803 417 A A B ...

Page 25: ...y not be available 50 60 Hz Three Phase Input Voltage V 400 Input Amperes A At Rated Output 28 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 35 Normal Operating Fuses 3 40 Min Input Conductor Size In AWG 4 10 Max Recommended Input Conductor Length In Feet Meters 211 64 Min Grounding Conductor Size In AWG 4 10 Reference 2008 National Electrical Code NEC including article 630 ...

Page 26: ...e small strain relief with reducing washers for input conductor size 10 Connect input conductors as shown in illustration Route green or green yellow grounding conductor through current transducer and connect to welding power source grounding terminal first Then connect input conductors L1 L2 and L3 to welding power source line terminals Reinstall side panel onto welding power source Disconnect De...

Page 27: ...a 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 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x95 3 ea 3 0 3x95 600 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 3x95 3 ea 4 0 3x120 3 ea 4 0 3x120 700 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x...

Page 28: ...Weld 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 Terminal Nut 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight...

Page 29: ...nce 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 6 1 for weld cable size Variations in welding processes and welding circuit resistance can affect apparent voltage at the welding arc Voltage sensing can improve welding performance by providing accur...

Page 30: ...ly 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 automatically compensates for work cable voltage drop when connected to the welding power source Do not coil excess cables Use cables that are the appropriate length for the application Whenever using lon...

Page 31: ...ielding 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 a weld cause excessive spatter and impair the quality of a weld Arc blow occurs primarily during the welding of steel or ferromagnetic metals Weld current will take the path of least resistance but ...

Page 32: ...ment 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 across the workpiece will not be measured correctly for the voltage feedback signal Voltage feedback to the welding power sources will not be correct at either sense lead and result in poor arc starts and...

Page 33: ...sing 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 voltage drops in the workpiece This may require compensationin the welding parameters Current Flow Path 1 2 3 6 3 2 1 6 4 5 7 4 5 ...

Page 34: ... 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 accurate and result in reliable arc starts and better arc quality Current Flow Path 1 2 3 6 3 2 1 6 4 7 5 5 4 ...

Page 35: ...er source on when unit is on and off when unit is off 3 PDA Port 4 PC Port 3 4 7 2 Options A Accuspeed Option Accuspeed is a CV Pulse process designed for high travel speeds typically used in Robotic applications Arc is de signed to be tight and fast The Accuspeed process is a software option that is loaded into a welding power source Contact factory for option details ...

Page 36: ...ace 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 Inside Unit 8 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 803 410 B ...

Page 37: ...and 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 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 instructions in Troubleshooting Section be fore touch...

Page 38: ... which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling This product contains chemicals...

Page 39: ...example 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 capacitor bus and significant DC voltage can remain on capacitors after unit is Off Always check the voltage on both inverter assemblies as shown to be sure the input capacitors have discharged before wo...

Page 40: ...PC4 Diagnostic LEDs 1 LED2 LED1 LED4 LED3 10 3 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 DC is not present on process control module PC4 2 On Indicates 25 volts DC is present on process control module PC4 Off Indicates 25 volts DC is not present on process control module PC4 3 4 On S...

Page 41: ...ith 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 circuit board if necessary B Module Status LEDs The following is a module status LED LED3 on the PCM circuit board Status Diagnosis Off There is no power applied to the circuit board or the board ...

Page 42: ... Wire does not feed 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 rolls Remove weld spatter around the nozzle opening Replace contact tip or liner See gun Owner s Manual Check motor control cable connections Wire feeds as soon as power is supplied C...

Page 43: ...OM 220 389 Page 37 Notes ...

Page 44: ...OM 220 389 Page 38 SECTION 11 ELECTRICAL DIAGRAMS Figure 11 1 Circuit Diagram For Welding Power Source ...

Page 45: ...OM 220 389 Page 39 220 420 D ...

Page 46: ...ge 40 SECTION 12 PARTS LIST Hardware is common and not available unless listed Ref 803 856 C 2 3 6 7 5 9 11 10 15 14 15 9 1 12 13 4 Fig 12 3 5 Fig 12 2 8 Fig 12 4 16 Fig 12 5 17 19 18 18 20 Figure 12 1 Main Assembly ...

Page 47: ...14 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 15 213372 Filter Assy Secondary 2 16 Fig 12 5 Front Panel Assembly 1 227855 Kit Connectors W Washer For Power Cables Includes 1 17 010467 Connector Clamp Cable 1 250 1 18 225840 Washer Reducer 1 25 in 0 75 in 2 19 010916 Connector Clamp Cable 0 750 1 20 247392 Insulator Input Filter 1 OPTIONAL When ordering a component originally displaying a pre...

Page 48: ...0 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 237370 Circuit Card Assy Power Interconnect 1 26 C3 196143 Capacitor Polyp Met Film 16 Uf 400 VAC 10 1 27 196378 Bracket Mtg Current Xfmr 1 28 HD1 182918 Transducer Current 400A Module Supply V 15v 1 196384 Cabl...

Page 49: ...12 Id X 1 500 Mtg Hole 1 4 PC4 239599 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 PC Card 250 w Post Lock 500 1 OPTIONAL When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equ...

Page 50: ...plementary 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 239623 Circuit Card Assy E Stop 1 10 115440 Stand off no 6 32 x 687 lg 250 hex al fem 4 11 212764 Plug Assy Rear 1 OPTIONAL When ordering a component originally displaying a precautionary label the label should also be ordere...

Page 51: ...lator Switch Power 1 3 211475 Plate front panel 1 4 PC13 239619 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 Choke Common Mode w Leads 2 8 216965 Cover Connector D sub 9 skt Female w Chain 1 9 216966 Cover Connector D sub 9 pin Male w Chain 1 10 RC5 214664 Receptacle Common Mode Choke 1 11 025248 Stand off ...

Page 52: ... Nameplate Front 1 21 210865 Terminal Pwr Output Red 1 22 210483 Bracket lift eye 1 23 210358 Bolt eye shld thd stem 500 13 X 1 500 1 OPTIONAL When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when o...

Page 53: ...Notes ...

Page 54: ...Notes ...

Page 55: ...ables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumabl...

Page 56: ...h 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 Carrier to ...

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