Table of Contents
Related Manuals for Miller 394F
Summary of Contents for Miller 394F
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Page 1: Wire Feeder
Visit our website at www.MillerWelds.com/ams Axcess Dual Wire Feeder File: Advanced Manufacturing Systems OM-222 394F 2006−08 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder... - Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2. -
Page 5: Section 1 − Safety Precautions - Read Before Using
DC 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 Disconnect input power or stop engine before installing or servicing this equipment. - Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. -
Page 8: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. - Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique −... -
Page 12: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). -
Page 13: Section 3 − Introduction
SECTION 3 − INTRODUCTION 3-1. Specifications Type of Input Welding Power Wire Feed Speed Range Power Source Type 40 Volts DC Axcess Series Standard: 40 To 1400 ipm (1.0 10 Amperes SECTION 4 − INSTALLATION 4-1. Selecting A Location Movement Location Y Special installation may be required where gasoline or volatile liquids are present −... -
Page 14: Connection Diagram
4-2. Connection Diagram OM-222 394 Page 10 Welding Power Source Wire Feeder Gas Cylinder Gas Hose Network Feeder Cable Negative (−) Weld Cable Workpiece Voltage Sensing Lead Recommended for Accu-pulse and RMD (optional). Positive (+) voltage sensing lead is contained in the motor cable. -
Page 15: Rear Panel Connections And Rotating Drive Assembly
4-3. Rear Panel Connections And Rotating Drive Assembly Tools Needed: 9/16, 5/8 in 9-Pin Network Receptacle Power Switch Shielding Gas Valve Fitting (Left And Right) Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. Weld Cable Terminal Jumper Cable Weld Cable Drive Assembly... -
Page 16: 9-Pin Network Receptacle Information
4-4. 9-Pin Network Receptacle Information Capacitor C1 to ground Shield Volt sense Can low Can high +24 volts dc common + 24 volts dc Motor voltage +40 volts dc common Motor voltage +40 volts dc 4-5. Gun Recommendation Table Process GMAW −... -
Page 17: Installing And Threading Welding Wire
4-6. Installing And Threading Welding Wire Install wire spool. Adjust tension nut so wire is taut when wire feed stops. Pressure Indicator Scale Pressure Adjust Rear Rolls Be sure that outlet cable has proper size liner for the welding wire size. When installing gun, position... -
Page 18: Power Source Display At Power Up
4-7. Power Source Display At Power Up Program Volts Process Wire Type Gas Type Process Set Up Adjust Power Source Upper Display DTEC Axcess Axcs 4-8. Dual Schedule Switch Option OM-222 394 Page 14 Time Arc Length Amps Arc Ctl Sequence Trigger Control Trigger Hold... -
Page 19: Section 5 − Operation
SECTION 5 − OPERATION 5-1. Operational Terms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder: General Terms: Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual arc length. - Page 20 General Terms: Sequence Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters. Preflow Setting a time value for gas flow prior to arc start. Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only adjustable with the optional PDA with File Management/WaveWriter software).
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Page 21: Section 6 − Operation
SECTION 6 − OPERATION 6-1. Power Switch 6-2. Left/Right Select Switch Power Switch 804 021-A Left/Right Select Switch Pressing the Left/Right Select switch allows the operator to choose which side of the units’ con- trols will operate. Depressing the Left or Right Gun Trigger also allows the operator to enable the con- trols on that side of the unit. -
Page 22: Jog/Purge
6-3. Jog/Purge The Jog/Purge switch provides the following functions: Pressing left side of the Jog/Purge switch allows the operator to feed wire without energizing the weld power or gas valve circuit. The wire will feed at a 60 ipm rate for 3 seconds, then the rate ramps up to 700 ipm until the Jog switch is released. -
Page 23: Front Panel Sections
6-4. Front Panel Sections Section Program Process Wire Type Gas Type Process Set Up Section 6-10 Volts Time Arc Adjust Amps Arc Ctl Sequence Trigger Control Trigger Hold Adjust Feeder Set Up Section Section Section Section OM-222 394 Page 19... -
Page 24: Program Push Button
6-5. Program Push Button 6-6. Upper Display Upper Display The upper display at idle (not welding) shows preset volts with process selection MIG or Arc Adjust for all other processes. When welding, the display shows actual voltage. The display will show actual voltage for approximately 3 seconds after welding stops before returning to preset value. -
Page 25: Lower Display
6-7. Lower Display Lower Display The lower display shows WFS (wire feed speed), AMPS (amperage), ARC CTL (arc control), or Time. The feeder displays only preset wire speed at idle (not welding). While welding, the average amperage is displayed. The lower display shows welding sequence time when the Time LED is illuminated. -
Page 26: Feeder Set Up Push Button
6-8. Feeder Set Up Push Button Sequence Trigger Control Trigger Hold Feeder Set Up Feeder Set Up Push Button LED Feeder Set Up Push Button Press button to choose Sequence. Feeder Set Up push-button LED will illuminate. Sequence LED When the Feeder Set Up button is pressed once, the Sequence LED will illuminate and the upper display will show sequence options. -
Page 27: Process Set Up Push Button
6-10. Process Set Up Push Button Press the Process Set Up push button the first time will illuminate the button LED and the Process LED. The upper and lower displays will be used for Accu-pulse and only the lower display for MIG, Pulse and RMD (optional) to show the current process installed in this program. -
Page 28: Reset Mode
6-11. Reset Mode Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed. RST NO message will not display until after the power-up sequence is completed (approximately 20 seconds). Rotate Adjust knob to change NO to YES. -
Page 29: Section 7 − Setting Sequence Parameters
SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program Sequence 1. Preflow 2. Postflow 3. Start 4. Crater Start Time Preflow Time Start Preflow Trigger Pressed Parameters Volts/Arc Seconds Adjust Off-5.0 Off-5.0 10.0-44.0/ 40-1400 Off-5.0 0-99 10.0-44.0/ 40-1400 Off-5.0 0-99... -
Page 30: Section 8 − Maintenance
SECTION 8 − MAINTENANCE 8-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every l Unreadable Labels ~ Weld Terminals Months nl Cords nl Gun Cables Every Months ~ Drive Rolls ~ Inside Unit OM-222 394 Page 26 Y Disconnect power... -
Page 31: Diagnostics
8-2. Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors. Explanations are in the text below: TACH MOTR Indicates a Indicates a motor tachometer error. error. COOL Indicates a coolant Indicates a ground flow error. - Page 32 8-2. Diagnostics (Continued) WELD MOTR WAIT Indicates a weld Indicates a motor cycle wait error. communication error. OVER DONE AVER Indicates an arc Indicates an over error. average current error. WELD WAIT The weld wait error indicates unit was not ready for a weld sequence.
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Page 33: Troubleshooting
8-3. Troubleshooting Trouble Wire feeds, shielding gas flows, but Check and secure weld cable connections (see Section 4-2). electrode wire is not energized. Electrode wire feeding stops or feeds Check gun trigger connection. See gun Owner’s Manual. erratically during welding. erratically during welding Check gun trigger. -
Page 34: Section 9 − Electrical Diagram
SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram OM-222 394 Page 30... - Page 35 218 564-D OM-222 394 Page 31...
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Page 36: Section 10 − Parts List
SECTION 10 − PARTS LIST 4 − Figure 10-3 21 − Figure 10-2 OM-222 394 Page 32 Figure 10-1. Main Assembly Hardware is common and not available unless listed. 804 023-A... - Page 37 Item Part ....159 647 ....159 646 .
- Page 38 Item Dia. Part Mkgs....+220 321 ....134 464 .
- Page 39 Item Dia. Part Mkgs....030 170 ....219 047 .
- Page 40 Hardware is common and not available unless listed. See Table 10-1 For Drive Roll & Wire Guide Kits Item Dia. Part Mkgs....010 668 .
- Page 41 Item Dia. Part Mkgs....168 825 ....133 308 .
- Page 42 Notes...
- Page 43 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.
- Page 44 File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2006 Miller Electric Mfg. Co. 2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...