Miller AXCESS 450 CE Owner's Manual
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Miller AXCESS 450 CE Owner's Manual

Miller AXCESS 450 CE Owner's Manual

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Axcess 450
CE
File: Advanced Manufacturing Systems
OM-220 389R
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
R
2010−11

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  • Page 1 OM-220 389R 2010−11 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Description Arc Welding Power Source Axcess 450 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − SAFETY PRECAUTIONS FOR SERVICING ........9-1.

  • Page 5: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 8 D Keep your head out of the fumes. Do not breathe the fumes. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.

  • Page 9: 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 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 12 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.

  • Page 14: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 15: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 16 OM-220 389 Page 10...

  • Page 17: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding 2.2 Use forced ventilation or local Arc rays can burn eyes and injure electrode or wiring can kill. exhaust to remove the fumes.

  • Page 18: Weee Label

    > 5 min 219 844-A Warning! Watch Out! There are Do not touch fully charged can explode or cause other parts to possible hazards as shown by the capacitors. explode. symbols. Flying pieces of parts can cause Always wait 5 minutes after power is injury.

  • Page 19: Symbols And Definitions

    3-3. Symbols And Definitions Direct Current Alternating Amperage Voltage (DC) Current (AC) Output Circuit Breaker Remote Positive Negative Voltage Input Protective Earth Arc Force Constant Voltage Inductance (Ground) Three Phase Static Frequency Con- Gas Metal Arc Increase Line Connection verter- Welding (GMAW) Transformer- Rectifier...

  • Page 20: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 21: Section 5 − Installation

    SECTION 5 − INSTALLATION Appearance of actual unit may vary from unit shown in manual. 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front panel. Use rating label to determine input power requirements and/or rated output.

  • Page 22: Duty Cycle And Overheating

    5-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

  • Page 23: Selecting A Location

    5-6. Selecting A Location Movement Tipping Do not move or operate unit where it could tip. Location Do not stack units. Beware of tipping. Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Lifting Forks Use lifting forks to move unit.

  • Page 24: Rear Panel Receptacles And Supplementary Protectors

    5-8. Rear Panel Receptacles And Supplementary Protectors 115 V 10 A AC Receptacle RC2 Receptacle supplies single-phase power. Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps. Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload.

  • Page 25: Electrical Service Guide

    5-10. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. NOTICE −...

  • Page 26: Connecting Input Power

    5-11. Connecting Input Power = GND/PE Earth Ground Route input conductors to filter board. Route ground conductor Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk through tubing and cur- rent transducer to ground terminal. 219 842-A Tools Needed: 803 855-A / Ref. 803 766-A / 219 842-A 5/16 in.

  • Page 27: Section 6 − Recommended Setup Procedures

    ( ) = mm for metric use ****For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart) Ref. S-0007-G 2009−08 In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding characteristics with undersized cables.

  • Page 28: Connecting To Weld Terminals

    6-2. Connecting To Weld Terminals If using an electrode negative (straight polarity) process, the volt sense lead must be connected to the work. Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) Correct Installation Incorrect Installation Ref.

  • Page 29: Welding Circuit

    6-3. Welding Circuit Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics. Welding Power Source Electrode Cable Feeder Cable Work Cable Standard Welding Circuit Voltage Sensing Lead Wire Feeder Workpiece In pulse welding applications using inverter power sources,...

  • Page 30: Arranging Welding Cables To Reduce Welding Circuit Inductance

    6-4. Arranging Welding Cables To Reduce Welding Circuit Inductance Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder Workpiece The method used to arrange cables has significant affect welding properties. As an example, Accupulse and RMD welding processes can produce high welding circuit inductance depending on cable...

  • Page 31: Using Multiple Welding Power Sources

    Welding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensify. 6-5. Using Multiple Welding Power Sources Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sensing Lead Wire Feeder Workpiece Each welding power source should have a separate work cable connection...

  • Page 32: Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs

    6-6. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A. Bad Setup Current Flow Path Ref. 804 460-A Welding Power Source Workpiece across the workpiece will not be measured correctly for the voltage feedback signal. Electrode Cable This arrangement is a bad setup due to Voltage feedback to the welding power Feeder Cable...
  • Page 33 B. Better Setup Current Flow Path Ref. 804 461-A Welding Power Source Wire Feeder the welding power sources. The most accurate voltage sensing may not be Electrode Cable Workpiece achieved due to voltage drops in the Feeder Cable workpiece. This require Work Cable This arrangement is a better setup for...
  • Page 34 C. Best Setup Current Flow Path Ref. 804 462-A Welding Power Source Voltage Sensing Lead This arrangement is the best setup for proper voltage sensing at the workpiece. Electrode Cable Wire Feeder Voltage feedback to the welding power Feeder Cable sources will more accurate and result in Work Cable Workpiece...

  • Page 35: Section 7 − Operation

    SECTION 7 − OPERATION 7-1. Front Panel Switches Ref. 803 418-B Power Switch Pilot Light PDA Port Light indicates status of welding power Turns unit On or Off. PC Port source, on when unit is on and off when unit is off.

  • Page 36: Section 8 − Maintenance

    SECTION 8 − MAINTENANCE 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 l Damaged Gas Hose...

  • Page 37: Section 9 − Safety Precautions For Servicing

    SECTION 9 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read and follow these precautions. 9-1. Symbol Usage OM-220 389R 2010−11 - Date, safety_stm 2010−03 DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.

  • Page 38: California Proposition 65 Warnings

    MOVING PARTS can injure. H.F. RADIATION can cause interference. D Keep away from moving parts such as fans. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and D Keep away from pinch points such as drive communications equipment. rolls.

  • Page 39: Section 10 − Troubleshooting

    SECTION 10 − TROUBLESHOOTING 10-1. Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power 900 Volts DC can be present on the capacitor bus source, and disconnect in- and significant DC voltage can remain on put power. capacitors after unit is Off. Always check the voltage on both inverter assemblies as shown to be Remove cover Tools Needed:...

  • Page 40: Process Control Module Pc4 Diagnostic Leds

    10-2. Process Control Module PC4 Diagnostic LEDs Process Control Module PC4 Diagnostic LEDs are visible inside unit, located on PC4 mounted on the top tray. Refer to Section 10-3 for information on diagnostic LEDs. Reinstall cover after checking diagnostic LEDs. LED1 LED2 LED3...

  • Page 41: Network And Module Status Leds

    10-4. Network And Module Status LEDs Network Status LEDs The following is a network status LED: LED4 on the PCM circuit board. Status Diagnosis The circuit board is not on-line with the network or there is no power applied to the circuit board. Green The circuit board is operating normally and the on-line connection is made with the network.

  • Page 42: Troubleshooting

    10-5. Troubleshooting Trouble Remedy No weld output; completely inoperative Place line disconnect in On position (see Section 5-11). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11). Check for proper input power connections (see Section 5-11). No weld output;...
  • Page 43 Notes OM-220 389 Page 37...

  • Page 44: Section 11 − Electrical Diagrams

    SECTION 11 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For Welding Power Source OM-220 389 Page 38...
  • Page 45 220 420-D OM-220 389 Page 39...

  • Page 46: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 4 − Fig 12-3 5 − Fig 12-2 8 − Fig 12-4 16 − Fig 12-5 Ref. 803 856-C Figure 12-1. Main Assembly OM-220 389 Page 40...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ....210492 . . . Cover, Top ........... .
  • Page 48 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Windtunnel Assembly LH And RH (Fig 12-1 Item 6) ....214597 . . . Windtunnel, LH w/Components (including).
  • Page 49 Hardware is common and not available unless listed. 803 422-B Figure 12-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-3. Top Tray Assembly (Fig 12-1 Item 4) ... . . 239598 .
  • Page 50 Hardware is common and not available unless listed. 803 423-C Figure 12-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-4. Rear Panel Assembly (Fig 12-1 Item 8) ....210474 .
  • Page 51 Hardware is common and not available unless listed. Ref. 803 424-B Figure 12-5. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-5. Front Panel Assembly (Fig 12-1 Item 14) ....207456 .
  • Page 52 Item Dia. Part Mkgs. Description Quantity Figure 12-5. Front Panel Assembly (Continued) ....207896 . . . Box, Louver ...........
  • Page 53 Notes...
  • Page 54 Notes...
  • Page 55 Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 56 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 2010 Miller Electric Mfg. Co. 2010−01...

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