Miller Auto-Axcess 300 DI Owner's Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. Auto-Axcess 300 DI
  6. Owner's manual

Miller Auto-Axcess 300 DI Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Visit our website at
www.MillerWelds.com/ams
Auto-Axcess 300 DI
OM-228 874Q
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
File: Advanced Manufacturing Systems
2013−02

Advertisement

Table of Contents
loading

Related Manuals for Miller Auto-Axcess 300 DI

Summary of Contents for Miller Auto-Axcess 300 DI

  • Page 1 OM-228 874Q 2013−02 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Automatic Welding Description Automatic Welding Interface And Arc Welding Power Source Auto-Axcess 300 DI  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 7 − SAFETY PRECAUTIONS FOR SERVICING ........7-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose.

  • 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_2011−10 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 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 11: 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. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser.

  • Page 12: 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- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-228 874 Page 10...

  • Page 15: 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. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 16 Do not remove or paint over (cover) the label. Safe20 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Flying pieces of parts can cause injury. Always wear a face shield when servicing unit. Safe27 2012−05 Always wear long sleeves and button your collar when servicing unit.

  • Page 17: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous 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-...

  • Page 18: Section 4 − Installation

    SECTION 4 − INSTALLATION Appearance of actual unit may vary from unit shown in manual. 4-1. Specifications Wire Rated Wire Amperes Input At Rated Load Output 60 Hz, Feed Open Input Weld- Voltage Diam- Input Input Single-Phase/Three-Phase Speed Circuit Power Range Rating eter...

  • Page 19: Duty Cycle And Overheating

    4-3. 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 3−PHASE unit to cool. Reduce amperage or OPERATION duty cycle before welding.

  • Page 20: Selecting A Location

    4-6. Selecting A Location Do not move or operate Tipping Movement unit where it could tip. Location Do not stack units. Beware of tipping. Special installation may be required where gaso- Lifting Forks line or volatile liquids are Use lifting forks to move unit. present −...

  • Page 21: Rear Panel Receptacles And Supplementary Protectors

    4-8. Rear Panel Receptacles And Supplementary Protectors Ref. 804 574-A 115 V 10 A AC Receptacle RC2 CB2 protects the wirefeed motor from Sections 4-7 and additional overload. If CB2 opens, the wirefeeder information). Receptacle supplies 60 Hz single-phase does not work. Peripheral Receptacle RC25 power.

  • Page 22: Selecting Weld Cable Sizes

    ( ) = 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 23: Devicenet Receptacle Functions

    4-11. Devicenet Receptacle Functions Socket Socket Information Chassis ground. +24 volts DC; available current is 1 ampere. +24 volts DC common. CAN H. CAN L. Ref. 804 574-A 4-12. Motor Control Receptacle Functions Socket Socket Information Not used. Motor negative (−). Tach A, 0 volts = low and 3.5 volts = high.

  • Page 24: Electrical Service Guide

    4-14. Electrical Service Guide Elec Serv 2011−08 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device.
  • Page 25 Notes OM-228 874 Page 21...

  • Page 26: Connecting 3-Phase Input Power

    4-15. Connecting 3-Phase Input Power = GND/PE Earth Ground WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE exists after removal of input power. S Always wait 5 minutes after power is turned off before working on unit. S Check input capacitor voltage, and be sure it is near 0 before touching any parts.
  • Page 27 4-15. Connecting 3-Phase Input Power (Continued) See rating label on unit and check input Input Conductors L1 (U), L2 (V) And L3 Turn Off welding power source, and voltage available at site. check voltage on input capacitors according to Section 8-3 before Connect input conductors L1 (U), L2 (V) and Input Power Conductors (Customer proceeding.

  • Page 28: Connecting 1-Phase Input Power

    4-16. Connecting 1-Phase Input Power =GND/PE Earth Ground Route input power cable through tubing inside unit. Route ground conductor through current transducer to ground terminal. Tools Needed: 5/16 in. Input7 2012−05 − Ref. 803 766-C / 803 676-A / Ref. 218 005-A OM-228 874 Page 24...

  • Page 29: Remote Program Select

    4-16. Connecting 1-Phase Input Power (Continued) Input Power Conductors (Customer 10 Welding Power Source Line Terminals Turn Off welding power source, and Supplied Cord) check voltage on input capacitors Route green or green/yellow grounding according to Section 8-3 before Select size and length of conductors using conductor through current transducer and proceeding.

  • Page 30: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: AccuCurve CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform. Has a distinguished change in arc characteristics.
  • Page 31 5-1 . Operational Terms (Continued) Time Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in the Arc On and Analog input or the Arc On and No Analog input modes). Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld. Weld Sequence function that allows for a timed weld operation [(0 to 999 seconds) only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be set with the...

  • Page 32: Front Panel Controls (See Section 5-3)

    5-2. Front Panel Controls (See Section 5-3) Program Volts Arc Adjust Wire Speed Amps Process Wirefeed Wire Type Gas Type Contactor Setup Adjust Arc Control When an LED is lit, it means the related function is active. 198 993 Program Display The lit LED indicates which setup mode is Setup Push Button active.

  • Page 33: Front Panel Controls - Continued (See Section 5-2)

    5-3. Front Panel Controls - Continued (See Section 5-2) 10 Wire Feed/Gas/Contactor LEDs shown). When welding, actual value is shown. If a PDA with File Management/WaveWriter software is used to change wire feed units The Wirefeed LED lights when the wire feeder If amperage was selected for display, the unit (IPM, MPM) or display welding information is energized.

  • Page 34: Reset Mode

    5-5. Reset Mode Reset mode is not active when Program Lock is enabled. The reset mode allows the operator to reload factory program settings for all eight active programs in the unit. System configuration data will be lost during the Reset operation. Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed.

  • Page 35: Section 6 − Maintenance

    SECTION 6 − MAINTENANCE 6-1. 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 36 SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 7-1. Symbol Usage OM-228 874Q - 2013−01, safety_stm 2011−10 DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 37 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 38 SECTION 8 − TROUBLESHOOTING 8-1. Set Value Mode Program Volts Arc Adjust Wire Speed Amps Process Wirefeed Wire Type Gas Type Contactor Setup Adjust Arc Control The Set Value mode is a troubleshooting tool display windows briefly shows SET VALU and active display will blink to indicate the value that allows certain robot command values to the blinking LEDs under the display windows...
  • Page 39 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 STRT STOP FLOW Indicates a Indicates a motor Indicates a wire Indicates an arc Indicates an arc Indicates a gas tachometer error.
  • Page 40 8-2. Diagnostics (Continued) WELD MOTR ROBT WAIT WAIT TRIG Indicates a UIM Indicates a CRC Indicates a weld Indicates a motor Indicates a low WFS Indicates a contactor communication error. robot memory error. cycle wait error. communication error. command error. on error.
  • Page 41 8-3. Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power source, disconnect input power. Significant DC voltage can Tools Needed: remain on capacitors after unit is Off. Always check the voltage as shown to be sure 5/16 in. the input capacitors have discharged before working on unit.
  • Page 42 8-4. 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 8-5 for information on diagnostic LEDs. Reinstall cover after checking diagnostic LEDs. LED1 LED2 LED3...
  • Page 43 8-6. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings Wire Feed Module PC6 Diagnostic LEDs are visible inside unit, located on PC6 mounted on the top tray assembly. Refer to Section 8-7 for information on diagnostic LEDs. Reinstall top cover after checking diagnostic LEDs.
  • Page 44 8-8. User Interface Module PC7 Diagnostic LEDs LED1 LED2 218 559-A / 804 575-A User Interface Module PC7 Reinstall cover after checking diagnostic Dip switches are used to identify each circuit board on the internal network. Dip LEDs. Diagnostic LEDs are visible inside unit, switch settings are different for each circuit located on PC7 mounted behind the front board.
  • Page 45 8-10. Network And Module Status LEDs Network Status LEDs The following are network status LEDs: LED1 on the UIM circuit board LED4 on the WFM and PCM circuit boards LED30 on the AIM 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 46 8-11. Troubleshooting Trouble Remedy No weld output; completely inoperative Place line disconnect in On position (see Section 4-15 or 4-16). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-15 or 4-16). Check for proper input power connections (see Section 4-15 or 4-16). Erratic or improper weld output with no Use proper size and type of weld cable (see Section 4-10).
  • Page 47 SECTION 9 − ELECTRICAL DIAGRAMS 228 875-F (Part 1 Of 2) Figure 9-1. Circuit Diagram For Welding Power Source (Part 1 Of 2) OM-228 874 Page 43...
  • Page 48 Figure 9-2. Circuit Diagram For Welding Power Source (Part 2 Of 2) OM-228 874 Page 44...
  • Page 49 228 875-F (Part 2 Of 2) OM-228 874 Page 45...
  • Page 50 Ref. 219 267-B Figure 9-3. Circuit Diagram For Peripheral/Motor Interface OM-228 874 Page 46...
  • Page 51 Notes OM-228 874 Page 47...
  • Page 52 SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 4 − Fig 10-3 6 − Fig 10-4 5 − Fig 10-2 14 − Fig 10-5 804 576-D Figure 10-1. Main Assembly OM-228 874 Page 48...
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly ....210492 . . . Cover, Top ........... .
  • Page 54 Hardware is common and not available unless listed. 20 21 802 955-A Figure 10-2. Windtunnel Assembly LH And RH Item Dia. Part Mkgs. Description Quantity Figure 10-2. Windtunnel Assembly LH And RH (Fig 10-1 Item ....214597 .
  • Page 55 Item Dia. Part Mkgs. Description Quantity Figure 10-2. Windtunnel Assembly LH And RH (Continued) ..C1, C2 ..226081 ..Capacitor,Elctlt 2400 Uf 500 VDC Can 2.50 Dia .
  • Page 56 Hardware is common and not available unless listed. 802 916-C Figure 10-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-3. Top Tray Assembly (Fig 10-1 Item 4) ..PC12 ..239623 .
  • Page 57 Hardware is common and not available unless listed. 804 577-B Figure 10-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-4. Rear Panel Assembly (Fig 10-1 Item 8) ....217297 .
  • Page 58 Hardware is common and not available unless listed. 803 682-B Figure 10-5. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-5. Front Panel Assembly (Fig 10-1 Item 14) ....207456 .
  • Page 59 Effective January 1, 2013 (Equipment with a serial number preface of MD 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 60 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 2013 Miller Electric Mfg. Co. 2013−01...

Table of Contents