1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. Axcess E Dual
  6. Owner's manual

Miller Axcess E Dual Owner's Manual

Wire feeder
Hide thumbs
Table of Contents

Advertisement

Quick Links

Visit our website at
www.MillerWelds.com/ams
Axcess E Dual

Wire Feeder

OM-248965G
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
R
File: Advanced Manufacturing Systems
2016−05

Advertisement

Table of Contents
loading

Related Manuals for Miller Axcess E Dual

Summary of Contents for Miller Axcess E Dual

  • Page 1: Wire Feeder

    OM-248965G 2016−05 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder Axcess E Dual Wire Feeder Visit our website at File: Advanced Manufacturing Systems www.MillerWelds.com/ams...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
  • Page 3 TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 12: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...
  • Page 13 Notes OM-248965 Page 9...

  • Page 14: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 15 Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation −...

  • Page 16: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Direct Current Output Amperes Volts (DC) Degree Of Duty Cycle Wire Feed Percent Protection Cold Jog (Inch) Towards Input Purge By Gas Fast Workpiece Constant Current Circuit Breaker Constant Voltage Slow Rated Welding...

  • Page 17: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. 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. 4-2.

  • Page 18: Connection Diagram

    5-2. Connection Diagram 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. Positive (+) Weld Cable 248 966-A OM-248965 Page 14...

  • Page 19: Rear Panel Connections And Rotating Drive Assembly

    5-3. Rear Panel Connections And Rotating Drive Assembly 9-Pin Network Receptacle Power Switch Shielding Gas Valve Fitting (Left And Right) Tools Needed: Requires fitting with 5/8-18 right- hand threads. Connect customer- 9/16, 5/8 in. supplied gas hose. Weld Cable Terminal Jumper Cable Weld Cable Drive Assembly...

  • Page 20: Installing Welding Gun

    5-5. Installing Welding Gun Gun Locking Tab Power Clamp Knob Gun Connection End Power Pin Groove Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. Push power pin into power clamp as far as possible to align the groove in the power pin of the gun with the gun locking tab.

  • Page 21: Installing And Threading Welding Wire

    5-6. Installing And Threading Welding Wire Install wire guides and Install wire spool. Adjust tension nut so anti-wear guide. wire is taut when wire feed stops. Install drive rolls. Pressure Indicator Scale Pressure Adjust Rear Pressure Rolls Adjust Front Rolls No Wire Slip Wire Slips NONCONDUCTIVE...

  • Page 22: Feeder Display At Power Up

    5-7. Feeder Display At Power Up Upper Display Lower Display While the system is initializing, the display will alternate between “Net Wait” and counting up dashes before the power source is fully operational. Program Volts Time Arc Adjust Amps Arc Ctl Sequence Process Trigger Control...

  • Page 23: Dual Schedule Switch Option

    5-8. Dual Schedule Switch Option Maint 2P (Maintained-Contact 2-Pole Switch) DSS-9M Part# 041793 DSS-9M Adapter Part# 157364 needed for Bernard and Tregaskiss dual schedule torches. Adapter Notes OM-248965 Page 19...

  • Page 24: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual arc length.

  • Page 25: Power Switch

    General Terms: Slope Slope refers to the shape of a volt-amp curve. Varying the amount of slope in the welding circuit will change the amount of short-circuit current and rate of response from the welding power source. Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts. TDS (Trigger Dual Schedule) TDS allows the operator to select between a pair of weld programs by using the gun trigger.

  • Page 26: Left/Right Select Switch

    6-3. Left/Right Select Switch 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 27: Front Panel Sections

    6-5. Front Panel Sections Section Section Program Volts Time Arc Adjust Section Amps Arc Ctl Sequence Process Trigger Control Wire Type Gas Type Trigger Hold Process Set Up Adjust Feeder Set Up Section Section Section 6-10 6-11 OM-248965 Page 23...

  • Page 28: Program Push Button

    6-6. Program Push Button Program Display The number of the active program is displayed. Program Push Button Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob. Momentarily press button illuminate LED. To change the program number, rotate Adjust knob to select one of eight programs.

  • Page 29: Lower Display

    6-8. Lower Display Time Amps Arc Ctl Lower Display Arc Ctl (Arc Control) LED When the lower display push-button LED and the WFS LED are both illuminated, it is LED illuminates to indicate that inductance The lower display shows WFS (wire feed possible to change WFS while welding by (MIG) or ARC [Pulse, Accu-pulse, or RMD speed), AMPS (amperage), ARC CTL (arc...

  • Page 30: Feeder Set Up Push Button

    6-9. Feeder Set Up Push Button Sequence Start Crater Trigger Control Time Time Retract Time Trigger Hold Preflow Postflow Time Time Sequence Diagram Feeder Set Up Feeder Set Up Push Button LED pushing the Lower Display push button a all trigger control methods are compatible second time, while STRT or CRTR appear with each other, therefore, turning on certain Feeder Set Up Push Button...

  • Page 31: Adjust Knob

    6-10. Adjust Knob Adjust Knob The Adjust knob is used to change functions and parameters. Refer to the front panel sections information regarding use of this control. Adjust 6-11. Process Set Up Push Button Process Set Up Push Button Process Set Up LED Program Selection LEDs Process Wire Type...
  • Page 32 Table 6-2. Welding Wire And Gas Abbreviations* Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation Steel E70, E100, E120 100% CO 90% Argon/10% CO 85% Argon/15% CO 75% Argon/25% CO 95% Argon/5% CO 95% Argon /5% O Stainless Steel 308, 309, 312, 316 98% Argon, 2% O (81Ar/18HE/1CO...

  • Page 33: User Interface Menu

    6-12. User Interface Menu Welding Power Source Dual Wire Feeder Turn on welding power source and dual wire feeder. Wait for system to initialize (see Section 5-7). Example display shows a model 450 AXCS Program Volts Time Arc Adjust Amps Arc Ctl Sequence Process...
  • Page 34 A. System Reset System Reset is not active when Program Lock is enabled. System Reset allows the operator to reload factory program settings for all eight active programs in the unit. System configuration data will be Program Program Volts Time Arc Adjust Volts Time...
  • Page 35 B. Software Revision The top display shows the board (PCM, UIM, and WFCM) and the lower display shows the last 3 digits of the circuit board part number plus a letter designator. Program Program Volts Time Arc Adjust Volts Time Arc Adjust Amps Arc Ctl...
  • Page 36 C. Carbon Arc Cutting (CAC) Allows carbon arc cutting to be enabled or disabled. CAC can be loaded on any of the eight programs by selecting the process using the Process Set up button. Program Program Volts Time Arc Adjust Volts Time Arc Adjust...
  • Page 37 D. Voltage Feedback Allows changing the voltage feedback method from volt sense lead to stud feedback. VOLT Program Program Volts Time Arc Adjust Volts Time Arc Adjust FDBK ENBL Amps Arc Ctl Amps Arc Ctl Sequence Sequence Process Process Wire Type Trigger Control Wire Type Trigger Control...
  • Page 38 E. Load Bank Allows setting the load bank feature on or off. Load Bank is a diagnostic tool for testing the power conversion modules, not a welding process VOLT LOAD selection. Program Program Volts Time Arc Adjust Volts Time Arc Adjust BANK FDBK Amps...
  • Page 39 F. Spool Reset Allows the operator to reset the date/time when a new spool of wire is installed to allow wire usage tracking. LOAD WIRE Program Program Volts Time Arc Adjust Volts Time Arc Adjust BANK Amps Arc Ctl Amps Arc Ctl Sequence Sequence...

  • Page 40: Section 7 − Setting Sequence Parameters

    SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program For more information on Sequence mode, see Feeder Set Up Push Button in Section 6-9. Weld Time can only be set by using Sequence Parameters the HTML pages. If time is set to Off in Weld sequence, welding continues until Volts/Trim...

  • Page 41: Section 8 − Maintenance And Troubleshooting

    SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every l Unreadable Labels ~ Weld Terminals...

  • Page 42: Error Code Troubleshooting Tables

    8-2. Error Code Troubleshooting Tables Display Example TACH The following error codes may appear on the upper and lower displays of the User Interface Module to indicate specific errors. Explanations of the error codes are provided in the sections referenced. User Interface Module User Interface Module Error Type...
  • Page 43 Emergency Stop Error Indicates an emergency stop error. Receptacle RC5-1 connects to receptacle RC1-4 and receptacle RC5-2 connects to receptacle RC4-2 on E-Stop board PC12. A closure between RC4-1 and RC4-2 allows +24 volts DC to be supplied to the four relays on E-Stop board PC12. In an E-Stop situation (relays open), all four relays on the E-Stop board de-energize and cut power to the control boards.
  • Page 44 Arc Start Error Indicates the contactor either is or was active, but the system failed to start an arc. Conditions for a valid arc start are at least 50% of arc start current, voltage less than 60 volts, and voltage greater than min. valid arc voltage (default is 22.5 volts).
  • Page 45 Motor Communications Error The motor board has lost communication with the PCM board PC4. Check cabling and cable routing for boom system motor cable and secondary cables. Separate cable as much as possible. Check if WFM board PC6 code is installed and if microprocessor is running. Check LED3 and LED4 on WFM board PC6. Depending on the wire feed speed, check for 0-40 volts DC on J17-3 to J17-1.
  • Page 46 Over Current Error Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6, Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6). The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip this circuit, only a fault will cause an over-current condition.
  • Page 47 Stuck Error Indicates the welding wire is stuck to the workpiece at the end of a weld. May be caused by poor weld conditions. The error may be cleared by cutting wire from workpiece, and pressing the Jog/Purge button. STUK Weld Wait Error WELD Indicates unit was not ready for a weld sequence.
  • Page 48 Gas Flow Error Indicates no gas flow to the gun. The error may be reset by re-establishing gas flow to the gun, and then pressing the Jog/ Purge button. AA. Robot Communication Error ROBT The robot I/O module has lost communication with the welding power source. Contact factory service department for assistance.

  • Page 49: Troubleshooting

    AG. UIM Bus Communication — — — — Indicates no error message on the displays. UIM board PC7 DeviceNet is losing packets of data. Turn welding pow- er source off and back on again to clear the communication error. — — 8-3.
  • Page 50 Certain information 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 8-2. Figure 8-2. Web Site For Axcess E Information OM-248965 Page 46...

  • Page 51: Software Error Message Display

    8-5. Software Error Message Display During the initial power up sequence, the ARM checks the UIM, WFCM and RIO for software numbers or revisions and compares them to what is stored to see if they are compatible. If these software versions are not compatible, the ERR S W will appear on the display (see Figure 8-3).

  • Page 52: Section 9 − Web Pages Site Tree

    SECTION 9 − WEB PAGES SITE TREE The Axcess E machine IP address is required to open the web pages. If necessary, have the IT administrator provide this address to allow opening the web pages. Port A on the power source is factory set to 169.254.0.2 as a static IP address.
  • Page 53 Home Page Diagnostics Software System Settings Weld Ethernet Errors Communications More Time Settings Settings Axcess Upgrade Welder Options Information Subselect and Subselect and type additional type additional text here text here Machine Short Term Lifetime Weld Data Report OM-248965 Page 49...

  • Page 54: Section 10 − Electrical Diagram

    SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram OM-248965 Page 50...
  • Page 55 218 564-F OM-248965 Page 51...

  • Page 56: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. 4 − Figure 11-3 21 − Figure 11-2 804 023-A Figure 11-1. Main Assembly OM-248965 Page 52...
  • Page 57 Item Part Description Quantity Figure 11-1. Main Assembly ....159647 Insulator, Motor Clamp ......... . .
  • Page 58 Hardware is common and not available unless listed. 804 024-D Figure 11-2. Control Box Item Dia. Part Mkgs. Description Quantity Figure 11-2. Control Box (Figure 11-1 Item 21) ....+220321 Wrapper, Feeder Dual Axcess .
  • Page 59 Item Dia. Part Mkgs. Description Quantity Figure 11-2. Control Box (Figure 11-1 Item 21) (Continued) ....030170 Bushing, Snap−In Nyl .750 ID x 1.000 Mtg Hole .
  • Page 60 Hardware is common and not available unless listed. See Table 11-1 For Drive Roll & Wire Guide Kits 802950−F Figure 11-3. Drive Assembly, Wire Item Dia. Part Mkgs. Description Quantity Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4) ..
  • Page 61 Item Dia. Part Mkgs. Description Quantity Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4) (continued) ....167387 Spacer, Locating ..........
  • Page 62 Table 11-1. Drive Roll And Wire Guide Kits OM-248965 Page 58...
  • Page 63 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 64 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

Table of Contents