Miller Axcess E 300 Owner'S Manual Download Page 100

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OM-244 814 Page 96

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 17-2. Windtunnel Assembly LH And RH
(Fig 17-1 Item 6) (Continued)

Quantity

030170

Bushing, Snap

−

in Nyl .750 Id X 1.000 Mtg Hole Cent

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . .

196259

Plugs, w/Leads & Current Xfmr (including)

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . .

115092

Housing, Plug & Skts

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115091

Housing, Plug & Skts

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT1

196231

Xfmr, Current Sensing 200/1

. . . . . . . . . .

. . . . . .

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201695

Clamp, Capacitor (Bottom)

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C1, C2

226081

Capacitor,Elctlt 2400 Uf 500 VDC Can 2.50 Dia

. . .

. . . . .

. . . .

. . . . . . . . . . . . . . . .

210507

Clamp, Capacitor (Top) Machined

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

261556

Kit, Input/Pre

−

regulator And Inverter Module

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . .

24 RT1,RT2,RT3

214015

Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead

. . .

. .

. . . .

. . . . . . . . . . . .

PC2

259491

Circuit Card Assy, Power Interconnect

. . .

. . . .

. . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

196143

Capacitor, Polyp Met Film 16. Uf 400 VAC 10%

. . .

. . . . .

. . . . . . .

. . . .

. . . . . . . . . . . . . . . . . .

196378

Bracket, Mtg Current Xfmr

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HD1

182918

Transducer, Current 400A Module Supply V +/

−

15v

. . .

. . . .

. . . . . .

. . . .

. . . . . . . . . . . . . .

196384

Cable, Transducer 20in

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R1, R2

196343

Resistors, W/Leads & Plug

. . .

. . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196840

Insulator, Resistors/Interface Board

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

109056

Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . .

196345

Coil, Inductor (Pre

−

regulator)

. . .

. . . . .

. . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196514

Gasket, Inductor Mounting

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196512

Bracket, Inductor Mounting

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196330

Heat Sink, Power Module

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196588

Baffle, Foam Rubber (Lower)

. . .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196365

Plugs, w/Leads (Fan)

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199136

Plugs, w/Leads (PC2 To PC1)

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC1

239612

Circuit Card Assy, Control (Inverter 300A)

. . .

. . . .

. . . . . .

. . .

. . . . . . . . . . . . . . . . . . . . . . . .

204846

Insulator, Screw

. . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

083147

Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High

. . .

. . . . . . . . . . . . . . . .

. . .

. . . . . . . . . . . . . .

*Recommended Spare Parts.

+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 ordering parts from your local distributor.

Summary of Contents for Axcess E 300

Page 1: ...rc Welding Power Source File Advanced Manufacturing Systems R Flux Cored FCAW Welding Gas And Self Shielded Air Carbon Arc CAC A Cutting and Gouging Scan this tag with your mobile device to learn more about this product Individual carrier rates may apply Start by downloading the free mobile app at http gettag mobi Visit our website at www MillerWelds com ams ...

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: ...ght 15 4 4 Duty Cycle And Overheating 16 4 5 Volt Ampere Curves 16 4 6 Electrical Service Guide 17 SECTION 5 SPECIFICATIONS FOR AXCESS E 450 19 5 1 Specifications 19 5 2 Environmental Specifications 19 5 3 Dimensions And Weight 19 5 4 Duty Cycle And Overheating 20 5 5 Volt Ampere Curves 20 5 6 Electrical Service Guide 21 SECTION 6 SPECIFICATIONS FOR AXCESS E 675 23 6 1 Specifications 23 6 2 Dimens...

Page 4: ...ON 10 OPERATION 49 10 1 Operational Terms 49 10 2 Pulse Welding Terms 50 10 3 Front Panel Switches 50 SECTION 11 MAINTENANCE 51 11 1 Routine Maintenance 51 11 2 Blowing Out Inside Of Unit 51 SECTION 12 TROUBLESHOOTING 53 12 1 Troubleshooting 53 12 2 Check Web Message Display 53 12 3 Software Error Message Display 55 12 4 E Module Board Stack Diagnostic LEDs 56 12 5 Diagnostic LEDs On E Module Boar...

Page 5: ...lds 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 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 vol...

Page 6: ...rums 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 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 ...

Page 7: ...ING 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 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 la...

Page 8: ...ention 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 Super intendentof Documents P O Box 371954 P...

Page 9: ...électrique à courant 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...

Page 10: ...aine 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 contact...

Page 11: ...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 fonctionnem...

Page 12: ...à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l installa tion D L utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l installation D Si le FCC signale des interférences arrêter immédiatement l ap pareil D Effectuer régulièrement le contrôle et l entretien de l installation D Maintenir soig...

Page 13: ... 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 Region 5 Chicago is 312 353 2220 website www osha gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 3033...

Page 14: ...OM 244 814 Page 10 ...

Page 15: ...tric shock 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 or local exhaust to remove the fumes Safe8 2012 05 Use ventilating fan to remove fumes Safe10 2012 05 Keep flammables away from welding Do not weld near flammables Safe12 2012 05 Welding spar...

Page 16: ...nated 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 welding helmet with correct shade of filter Wear complete body protection Safe38 2012 05 Become trained and read the instructions before working on the machine or welding Safe40 2012 05 5min V V V H...

Page 17: ...nput Current I2 Maximum Effective Supply Current Gas Metal Arc Welding GMAW Percent S Suitable For Welding In An Environment With Increased Risk Of Electric Shock Constant Voltage Power Connection IP Degree Of Protection X Duty Cycle I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current U0 Rated No Load Voltage Average U1 Input Voltage Direct Current DC Alternating Current AC P...

Page 18: ...OM 244 814 Page 14 Notes ...

Page 19: ... 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 and is always less than one Ampere Use one Ampere for power efficiency calculations Wire feed speed ranges are for GMAW welding While pulse welding wire feed speed ranges may be more limited 4 2 Environmental Specifications IP Rating IP 23C This e...

Page 20: ...duty1 4 95 178 651 Continuous Welding 100 Duty Cycle At 225 Amperes 60 Duty Cycle At 300 Amperes 6 Minutes Welding 4 Minutes Resting 3 PHASE OPERATION SINGLE PHASE OPERATION DUTY CYCLE 10 15 20 25 30 40 50 60 70 80 90100 100 150 200 225 250 300 400 500 WELDING AMPERES 4 5 Volt Ampere Curves va_curve1 4 95 Volt amperecurves show minimum and maximum voltage and amperage output capabilities of unit C...

Page 21: ...tional Electrical 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 RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section...

Page 22: ...OM 244 814 Page 18 Notes ...

Page 23: ...24 0 0 1A 19 0 0 1A 19 9 0 8 19 2 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 GMAW welding While pulse welding wire feed speed ranges may be more limited 5 2 Environmental Specifications IP Rating IP 23C This equipment is designed for outdoor use It may be stored but is n...

Page 24: ...tes 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 3 PHASE OPERATION DUTY CYCLE 10 15 20 25 30 40 50 60 70 80 90 100 200 400 500 WELDING AMPERES 100 150 300 0 500 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...

Page 25: ...quired input voltage If actual input voltage is outside of this range output may not be available 50 60 Hz Three Phase Input Voltage V 200 208 230 380 400 460 575 Input Amperes A At Rated Output 54 49 29 28 24 19 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 70 60 35 35 30 25 Normal Operating Fuses 3 90 70 45 45 35 30 Min Input Conductor Size In AWG 4 6 8 8 10 10 12 Max Reco...

Page 26: ...OM 244 814 Page 22 Notes ...

Page 27: ... Standard 50 1400 ipm 1 3 35 6 mpm 035 062 in 0 8 1 6 mm 75 89 0 1A 50 0 1A 44 0 1A 35 0 1A 35 5 0 8 34 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 GMAW welding While pulse welding wire feed speed ranges may be more limited 6 2 Dimensions And Weight Hole Layout Dimensions...

Page 28: ...0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 206 789 A Continuous Welding 100 Duty Cycle At 675 Amperes DUTY CYCLE 10 20 30 40 50 60 70 80 90 100 100 200 300 400 500 600 700 800 900 1000 WELD AMPERES 6 4 Volt Ampere Curves va_curve1 4 95 221 502 A Volt amperecurves show minimum and maximum voltage and amperage output capabilities of unit Curves of other settings fall between curves shown This ...

Page 29: ...not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available 60 Hz Three Phase Input Voltage V 230 400 460 575 Input Amperes A At Rated Output 89 50 44 35 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 110 60 50 40 Normal Operating Fuses 3 125 80 70 50 Min Input Conductor Size In AWG 4 3 6 8 8 Max Recommended I...

Page 30: ...OM 244 814 Page 26 Notes ...

Page 31: ...number and rating information for this product is located on the front Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 8 2 Selecting A Location loc_2 3 96 245 733 A Do not stack units Beware of tipping 1 Lifting Forks Use lifting forks to move unit Extend forks beyond opposite side of...

Page 32: ...oltage Sensing Lead Recommendedfor Accu pulse and required for RMD Positive voltage sensing lead is contained in the motor cable 9 Positive Weld Cable 8 3 Connection Diagram 1 2 3 4 5 7 8 9 6 245 746 A 1 USB Host Receptacle A 2 USB Device Receptacle B USB receptacles provide connections for various USB host devices 8 4 Upper Front Panel Receptacles 1 2 ...

Page 33: ...ils 8 5 Upper Rear Panel Receptacles 1 3 4 5 2 6 Ref 245 741 A 1 115 V 10 A AC Receptacle RC2 Receptacle supplies 60 Hz single phase power Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload If CB1 opens RC2 does not work CB2 protects the wirefeed motor from overl...

Page 34: ... to weld B A short to socket A allows unit to weld The E Stop option comes with a 2 pin amphenol receptacle matching plug and 30 ft 9 m of high density molded cord to allow connecting the welding power source into an E Stop circuit An integrator will need to supply a closure for the non E Stop condition When the E Stop input connection changes it state from closed to open the welding power source ...

Page 35: ...the bus terminal and bus terminal on PC2 as shown until voltage drops to near 0 zero volts Measure input capacitor voltage on both inverter assemblies before proceeding 3 Typical Bleeder Resistor An 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 245 768 A 1 2 lead to left bus terminal lead to r...

Page 36: ...45 742 A 218 005 A Tools Needed 5 16 in 8 10 Connecting 3 Phase Input Power GND PE Earth Ground L1 7 1 L2 L3 3 4 8 6 9 10 2 Route ground conductor through current transducer to ground terminal Route input power cable through tubing inside unit 4 3 5 6 ...

Page 37: ... 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 Route conductors cord through strain relief and tighten screws 3 Welding Power Source Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Route green or green yellow grounding con ductor through current transducer and co...

Page 38: ...012 05 Ref 803 766 C Ref 144 221 Ref 070 399 803 668 A 248 842 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 2 1 6 4 3 5 9 10 8 11 1 L1 L2 1 GND PE Earth Ground 5 2 12 13 14 7 ...

Page 39: ...Insulation Sleeving 5 Green Or Green Yellow Grounding Conductor 6 Electrical Tape Insulate and isolate red conductor as shown Welding Power Source Input Power Connections 7 Strain Relief Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief and tighten screws Connect input conductors as shown in illustration 8 Current Transducer 9 Welding Po...

Page 40: ...ing amperes See Section 9 2 to select proper cable size 1 Positive 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 outpu...

Page 41: ... 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 3x95 3 ea 4 0 3x120 3 ea 4 0 3x120 4 ea 4 0 4x120 800 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 4 0 3x120 3 ea...

Page 42: ...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 9 2 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 43: ...ically 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...

Page 44: ...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 45: ...ngement 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 ...

Page 46: ...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 47: ...le 4 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 48: ...dition is usually encountered in direct current welding of magnetic materials such as iron and nickel Arc blow can happen in alternating current welding under certain conditions but these cases are rare and the intensity of the arc blow is always less severe Direct current flowing through the electrode and base metal will set up a magnetic field around the electrode This magnetic field tends to de...

Page 49: ...liner dirty or restricted Remove gun liner and clean or replace Wrong type or size of liner Install proper size liner Broken or damaged gun or torch Replace faulty parts Contact tip opening restricted Replace contact tip Wrong size or type of contact tip Replace with proper size and type contact tip Sharp bends or kinks in gun cable or liner Straighten gun cable and or replace liner Inlet cable to...

Page 50: ...t wire stick out or reduce nozzle to work dis tance Wrong transfer mode Set proper transfer mode Travel speed too slow Increase travel speed so that arc is on leading edge of weld puddle Wandering hunting or erratic arc Restriction in unspooler or drum adapter Replace unspooler or repair restriction Dirty or worn gun liner or inlet cable Remove gun liner or inlet cable and clean or re place Sharp ...

Page 51: ...essure Adjust drive roll pressure Worn contact tip Replace contact tip Wrong size or type of contact tip Replace with proper size and type contact tip Not enough cast in welding wire Add a wire straightener to put cast in wire Welding wire burns back to contact tip at the end of a weld Welding power source output not shutting off Make sure all switches are in correct position re pair power source ...

Page 52: ...lems Power source should energize and welding wire should start feeding at the same time No wire feed speed command Set wire feed speed No voltage command Set voltage Shutdownat arc initiation due to weld cir cuit condition Poor part fit up at weld joint wire not making contact with workpiece Check part consistency for fitup and or position gun so wire always contacts part Poor connection in weld ...

Page 53: ... functions Gas Type Selection of shielding gas being used in application IGNR Ignore Allows the use of a dual schedule switch between ignore welds and count welds when using Insight Centerpoint Inductance In short circuit GMAW welding an increase in inductance will decrease the number of short circuit transfers per second provided no other changes are made and increase the arc on time The increase...

Page 54: ...tage setting In pulse and Accu pulse adjusting wire feed speed also increases power level on wire elec trode one knob control 4T 4T allows the operator to select between weld parameters and crater parameters using the gun trigger Crater time must be set for at least 0 2 seconds to make this function operational If gun trigger is released during welding unit goes into trigger hold then pressing and...

Page 55: ...n l Replace 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 11 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 245 733 A ...

Page 56: ...OM 244 814 Page 52 Notes ...

Page 57: ...ve 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 Check gun trigger See gun Owner s Manual Wire stubbing on low end using a constant current power source Increase output setting of the power source Check voltage se...

Page 58: ...mation must be entered on the web pages for the unit to function properly The user will be prompted for power source serial number model and type Semi Auto AROI AUTO etc as shown in Figure 2 Figure 2 Web Site For Axcess E Information ...

Page 59: ...not compatible the ERR S W will appear on the display see Figure 3 Compatiblesoftware can be downloaded from www MillerWelds com ERR S W Trigger Control Program Process Wire Type Gas Type Process Set up Volts Time Arc Adjust WFS Amps Arc Ctl Sequence Trigger Hold Adjust Feeder Set Up 1 Figure 3 Feeder Display For Software Version Issues 2 After supplying information on the web site and resolving a...

Page 60: ...t lo cated on the E Module Board Stack Refer to Section 12 5 for information on diagnostic LEDs Reinstall cover after checking diagnostic LEDs 250 237 A Ref 250 294 A 12 4 E Module Board Stack Diagnostic LEDs 1 D108 D101 D96 D1 D8 LED1 LED2 D3 D4 D14 D10D11 D7 D103 D98 D92 D91 D99 ...

Page 61: ...ates auxiliary not in use D19 AD AUX Flashing Indicates normal operation Off Indicates problem with AD micro D21 AD AWAKE On Indicates normal operation Off Indicates problem with AD micro B DeviceNet Power Supply LEDs D91 On Auto Units Only DeviceNet ext Indicates 24 VDC is present from external DeviceNet connection Off Auto Units Only DeviceNet ext Indicates 24 VDC is off from external DeviceNet ...

Page 62: ...g properly Off Indicates USB error Cycle unit power if error is still present contact nearest factory Authorized Service Agent D101 On Indicates 2 5 VDC is present Off Indicates 2 5 VDC is not present D108 On Indicates 25 VDC is present Off Indicates 25 VDC is not present 12 6 Network And Module Status LEDs A Network Status LED LED2 on the E Module board stack Status Diagnosis Off The board stack ...

Page 63: ...Trouble OM 244 814 Page 59 Notes ...

Page 64: ...ages Port A on the power source is factory set to 169 254 0 2 as a static IP address Connect a PC to Port A and enter 169 254 0 2 in the web browser to access the web pages AXCESS E Login Page ITW Welding Companies Welder Configuration Program Setup Logs Reports Advanced Errors Feed Torch Weld Cable Setup Welding Wire Setup Process Setup Locks System Log Secondary Data Weld Sequencer Trigger Funct...

Page 65: ...ftware System Settings Machine Lifetime Report Short Term Weld Data Weld Communications Errors Time Settings Ethernet Settings More Subselect and type additional text here Welder Information Subselect and type additional text here Axcess Upgrade Options ...

Page 66: ... Figure 14 2 Circuit Diagram For Axcess E 300 2 Of 2 64 Figure 14 3 Circuit Diagram For Axcess E 450 1 Of 2 66 Figure 14 4 Circuit Diagram For Axcess E 450 2 Of 2 68 Figure 14 5 Circuit Diagram For Axcess E 675 1 Of 2 70 Figure 14 6 Circuit Diagram For Axcess E 675 2 Of 2 72 Figure 14 7 Circuit Diagram For Axcess E Module 74 ...

Page 67: ...Circuits OM 244 814 Page 63 SECTION 14 ELECTRICAL DIAGRAMS 248 763 E Part 1 Of 2 Figure 14 1 Circuit Diagram For Axcess E 300 1 Of 2 ...

Page 68: ...OM 244 814 Page 64 Figure 14 2 Circuit Diagram For Axcess E 300 2 Of 2 ...

Page 69: ...Circuits OM 244 814 Page 65 248 763 E Part 2 Of 2 ...

Page 70: ...OM 244 814 Page 66 Figure 14 3 Circuit Diagram For Axcess E 450 1 Of 2 ...

Page 71: ...Circuits OM 244 814 Page 67 245 131 F Part 1 Of 2 ...

Page 72: ...OM 244 814 Page 68 Figure 14 4 Circuit Diagram For Axcess E 450 2 Of 2 ...

Page 73: ...Circuits OM 244 814 Page 69 245 131 F Part 2 Of 2 ...

Page 74: ...OM 244 814 Page 70 Figure 14 5 Circuit Diagram For Axcess E 675 1 Of 2 ...

Page 75: ...Circuits OM 244 814 Page 71 250 570 C Part 1 Of 2 ...

Page 76: ...OM 244 814 Page 72 Figure 14 6 Circuit Diagram For Axcess E 675 2 Of 2 ...

Page 77: ...Circuits OM 244 814 Page 73 250 570 C Part 2 Of 2 ...

Page 78: ...OM 244 814 Page 74 Figure 14 7 Circuit Diagram For Axcess E Module ...

Page 79: ...Circuits OM 244 814 Page 75 250 571 C ...

Page 80: ...OM 244 814 Page 76 Notes ...

Page 81: ...e 77 SECTION 15 PARTS LIST FOR AXCESS E 300 Hardware is common and not available unless listed 248 813 D 5 Fig 15 4 6 Fig 15 2 7 Fig 15 5 15 Fig 15 6 2 Fig 15 3 1 3 4 8 8 9 10 11 12 13 14 Figure 15 1 Axcess E 300 Main Assembly ...

Page 82: ...ly 1 8 227792 Panel Side W Insulator 2 9 210482 Base 1 10 213386 Assembly Filter Primary 1 11 HD2 182918 Transducer Current 400A Module Supply V 15V 1 12 198951 Block Terminal 3 Pole 1 13 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 14 213372 Filter Assy Secondary 1 15 Fig 16 6 Front Panel Assembly 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label ...

Page 83: ...Rectifier 1 9 196349 Spacer 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 2 13 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole Cent 4 14 196355 Insulator Screw 6 15 010546 Bushing Snap in Nyl 375 Id X 500 Mtg Hole 1 16 242680 Windtunnel RH w Components including 1 17 196332 Windtunnel RH 1 18 030170 Bu...

Page 84: ... 1 196384 Cable Transducer 20in 1 29 R1 R2 196343 Resistors W Leads Plug 1 196840 Insulator Resistors Interface Board 1 30 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 1 31 L2 196345 Coil Inductor Pre regulator 1 32 196514 Gasket Inductor Mounting 2 33 196512 Bracket Inductor Mounting 2 34 196330 Heat Sink Power Module 1 35 196588 Baffle Foam Rubber Lower 1 196365 Plugs w Leads Fan 1 199...

Page 85: ... 8 246591 Ground Strap 2 9 228008 Insulator 1 10 245350 Assembly Personality Board 1 11 240728 Nameplate Axcess E Top Front 1 12 244236 Cable USB Type B Sealed Panel Mount 1 13 244237 Dust Cap 2 14 244239 Cable USB Type A Sealed Panel Mount 1 15 203423 Bushing Strain Relief 300 360 ID X 689 Sq Mtg 3 16 246545 Bracket Axcess E Strain Relief 1 17 244980 Circuit Card Assy Ethernet LED 1 18 244257 Cab...

Page 86: ...t card Aux Power 1 3 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 4 210491 Panel Mtg Components Top 1 5 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 4 Recommended Spare Parts 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 Replac...

Page 87: ...entary 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 E stop Connector Factory Installed Option For Axcess includes 1 12 PC14 227901 E Stop Connector 1 13 228694 Jumper Connector W Cover 1 Recommended Spare Parts OPTIONAL When ordering a...

Page 88: ...Bus Bar Output 1 6 244989 Circuit Card Assy Vsense Filter 1 7 210866 Terminal Pwr Output Black 1 8 248552 Panel Front 1 9 219843 Label Work Sense 1 10 207979 Box Louver 1 11 186621 Boot Generic 2 12 PL1 163562 Light ind white lens 1 13 248553 Nameplate Front 1 14 210865 Terminal Pwr Output Red 1 15 210483 Bracket lift eye 1 16 245352 Bolt eye shld thd stem 500 13 X 1 500 1 Recommended Spare Parts ...

Page 89: ...SECTION 16 PARTS LIST FOR AXCESS E 450 Hardware is common and not available unless listed 245 791 D 3 4 7 8 6 10 12 11 16 15 14 13 16 9 1 17 Fig 16 6 5 Fig 16 4 6 Fig 16 2 9 Fig 16 5 2 Fig 16 3 Figure 16 1 Axcess E 450 Main Assembly ...

Page 90: ...6 5 Rear Panel Assembly 1 10 227793 Panel Side W Insulator 2 11 210482 Base 1 12 213386 Assembly Filter Primary 1 13 HD2 182918 Transducer Current 400A Module Supply V 15V 1 14 198951 Block Terminal 3 Pole 1 15 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 16 213372 Filter Assy Secondary 2 17 Fig 16 6 Front Panel Assembly 1 Recommended Spare Parts When ordering a component originally displaying...

Page 91: ...Rectifier 1 9 196349 Spacer 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 2 13 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole Cent 4 14 196355 Insulator Screw 6 15 010546 Bushing Snap in Nyl 375 Id X 500 Mtg Hole 1 16 242680 Windtunnel RH w Components including 1 17 196332 Windtunnel RH 1 18 030170 Bu...

Page 92: ... 1 196384 Cable Transducer 20in 1 29 R1 R2 196343 Resistors W Leads Plug 1 196840 Insulator Resistors Interface Board 1 30 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 1 31 L2 196345 Coil Inductor Pre regulator 1 32 196514 Gasket Inductor Mounting 2 33 196512 Bracket Inductor Mounting 2 34 196330 Heat Sink Power Module 1 35 196588 Baffle Foam Rubber Lower 1 196365 Plugs w Leads Fan 1 199...

Page 93: ... 8 246591 Ground Strap 2 9 228008 Insulator 1 10 245350 Assembly Personality Board 1 11 240728 Nameplate Axcess E Top Front 1 12 244236 Cable USB Type B Sealed Panel Mount 1 13 244237 Dust Cap 2 14 244239 Cable USB Type A Sealed Panel Mount 1 15 203423 Bushing Strain Relief 300 360 ID X 689 Sq Mtg 3 16 246545 Bracket Axcess E Strain Relief 1 17 244980 Circuit Card Assy Ethernet LED 1 18 244257 Cab...

Page 94: ...t card Aux Power 1 3 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 4 210491 Panel Mtg Components Top 1 5 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 4 Recommended Spare Parts 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 Replac...

Page 95: ...mentary 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 E Stop Connector Factory Installed Option For Axcess includes 1 12 PC14 227901 E Stop Connector 1 13 228694 Jumper Connector W Cover 1 Recommended Spare Parts OPTIONAL When ordering ...

Page 96: ... 2 6 PC15 PC20 244993 Circuit Card Assy Stud Filter 2 7 207897 Bus Bar Output 2 8 210866 Terminal Pwr Output Black 1 9 247005 Panel Front 1 10 219843 Label Volt Sense 1 11 207896 Box Louver 1 12 186621 Boot Generic 2 13 PL1 163562 Light ind white lens 1 14 245604 Nameplate Front 1 15 210865 Terminal Pwr Output Red 1 16 210483 Bracket lift eye 1 17 245352 Lift Eye 4 1 Recommended Spare Parts When o...

Page 97: ...3 SECTION 17 PARTS LIST FOR AXCESS E 675 Hardware is common and not available unless listed 250 661 C 8 3 1 2 11 15 13 14 12 9 8 10 6 5 6 4 Fig 17 3 5 Fig 17 2 7 Fig 16 5 16 Fig 16 6 15 15 5 Figure 17 1 Axcess E 675 Main Assembly ...

Page 98: ...W1 254597 Contactor DEF PRP 60A 3P 24VAC Coil W Boxlug 1 11 213386 Assembly Filter Primary 1 12 HD2 182918 Transducer Current 400A Module Supply V 15V 1 13 198951 Block Terminal 3 Pole 1 14 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 15 218365 Filter Assy Secondary 3 16 Fig 16 6 Front Panel Assembly 1 Fig 17 4 Assembly E module W Ethernet USB 1 Recommended Spare Parts When ordering a componen...

Page 99: ... D2 201531 Kit Diode Power Module 2 8 196347 Heat Sink Rectifier 1 9 196349 Spacer 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 2 13 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole Cent 4 14 196355 Insulator Screw 6 15 010546 Bushing Snap in Nyl 375 Id X 500 Mtg Hole 1 16 242680 Windtunnel RH w Compon...

Page 100: ... HD1 182918 Transducer Current 400A Module Supply V 15v 1 196384 Cable Transducer 20in 1 29 R1 R2 196343 Resistors W Leads Plug 1 196840 Insulator Resistors Interface Board 1 30 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 1 31 L2 196345 Coil Inductor Pre regulator 1 32 196514 Gasket Inductor Mounting 2 33 196512 Bracket Inductor Mounting 2 34 196330 Heat Sink Power Module 1 35 196588 Ba...

Page 101: ...ircuit card Aux Power 1 3 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 4 210491 Panel Mtg Components Top 1 5 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 4 Recommended Spare Parts 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 R...

Page 102: ...6591 Ground Strap 2 9 228008 Insulator 1 10 245350 Assembly Personality Board 1 11 240728 Nameplate Axcess E Top Front 1 12 244236 Cable USB Type B Sealed Panel Mount 1 13 244237 Dust Cap 2 14 244239 Cable USB Type A Sealed Panel Mount 1 15 203423 Bushing Strain Relief 300 360 ID X 689 Sq Mtg 3 16 246545 Bracket Axcess E Strain Relief 1 17 244980 Circuit Card Assy Ethernet LED 1 18 244257 Cable As...

Page 103: ...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 12 PC14 227901 E Stop Connector 1 13 228694 Jumper Connector W Cover 1 Recommended Spare Parts When ordering a component originally...

Page 104: ...60 Hz 3000 Rpm 6 378 Mtg Holes 3 4 244989 Circuit Card Assy Vsense Filter 1 5 025248 Stand off Insul 250 20 X 1 250 Lg X 437 Thd 2 6 PC15 PC20 244993 Circuit Card Assy Stud Filter 2 7 220815 Bus Bar Output 1 8 210864 Bus Bar Output 1 9 210866 Terminal Pwr Output Black 1 10 210473 Panel Front 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label s...

Page 105: ... white lens 1 15 250292 Nameplate Front 1 16 210865 Terminal Pwr Output Red 1 17 210483 Bracket lift eye 1 18 245352 Lift Eye 4 1 Recommended Spare Parts 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 requ...

Page 106: ...Notes ...

Page 107: ...blies 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 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 ...

Page 108: ...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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Miller Axcess E 300, Owner'S Manual

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