Miller 907275 Owner's Manual
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Miller 907275 Owner's Manual

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Axcess 450
CE
File: Advanced Manufacturing Systems
OM-220389AA
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
R
2016−04

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  • Page 1 OM-220389AA 2016−04 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 8 − SAFETY PRECAUTIONS FOR SERVICING ........8-1.
  • Page 5 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 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number AXCESS 450 CE VERSION 907275 AXCESS 450 CE VERSION W/INSIGHT CORE 907275003 AXCESS 450 CE WITH RMD 907275011 AXCESS 300 CE AUTO-LINE 907348 AXCESS 300 CE AUTO-LINE W/INSIGHT...

  • Page 7: 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 8 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 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 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 11: 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 12 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 13: 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 14: 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 15: 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 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 Some symbols are found only on CE products. 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...

  • Page 18: 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 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. 4-2.

  • Page 19: Duty Cycle And Overheating

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

  • Page 20: Environmental Specifications

    4-6. Environmental Specifications A. IP Rating IP Rating IP21S This equipment is designed for indoor use and is not intended to be used or stored outside. IP21S 2014−06 B. Information On Electromagnetic Compatibility (EMC) This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low− voltage supply system.

  • Page 21: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting A Location Do not move or operate unit where it could tip. Movement Special installation may be Location And Airflow required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 22: Rear Panel Receptacles And Supplementary Protectors

    5-3. 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 23: Electrical Service Guide

    5-5. Electrical Service Guide Elec Serv 2014−01 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 24: Connecting 3−Phase Input Power

    5-6. Connecting 3−Phase Input Power = GND/PE Earth Ground Route input conductors to filter board. Route ground conductor through tubing and current transducer to ground terminal. Tools Needed: 5/16 in. Input5 2013−04 − Ref. 803 766-C / 803 855-B OM-220389 Page 18...
  • Page 25 5-6. Connecting 3−Phase Input Power (Continued) Turn Off welding power source, and Select size and length of conductors using Connect input conductors L1, L2, and L3 to check voltage on input capacitors Section 5-5 Conductors must comply with welding power source line terminals. according to Section 10-1 before national, state, and local electrical codes.

  • Page 26: Section 6 − Recommended Setup Procedures

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = 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-L 2015−02 6-2. Weld Output Terminals Turn off power before connecting to weld output terminals.

  • Page 27: Connecting To Weld Output Terminals

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

  • Page 28: Welding Circuit

    6-4. 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 29: Arranging Welding Cables To Reduce Welding Circuit Inductance

    6-5. 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 30: 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. 6-6. 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 31: Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs

    6-7. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A. Bad Setup Current Flow Path Ref. 804 460-B 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 32 B. Better Setup Current Flow Path Ref. 804 461-B 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 33 C. Best Setup Current Flow Path Ref. 804 462-B 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 34: 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 35: Section 8 − Maintenance

    SECTION 8 − MAINTENANCE 8-1. Routine Maintenance Disconnect power Maintain more often 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 9 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 9-1. Symbol Usage safety_stm 2015-09 DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 37 OVERUSE can cause OVERHEATING. FALLING EQUIPMENT can injure. D Allow cooling period; follow rated duty cycle. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Reduce current or reduce duty cycle before starting to weld again.

  • Page 38: Section 10 − Troubleshooting

    SECTION 10 − TROUBLESHOOTING 10-1. Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power source, and disconnect in- put 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...

  • Page 39: 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 diagnos- tic LEDs. Reinstall cover after checking diagnostic LEDs. LED1 LED2 LED3...

  • Page 40: Diagnostic Leds On Process Control Module Pc4

    10-3. Diagnostic LEDs On Process Control Module PC4 Status Diagnosis Indicates −25 volts DC is present on process control module PC4. Indicates −25 volts DC is not present on process control module PC4. Indicates +25 volts DC is present on process control module PC4. Indicates +25 volts DC is not present on process control module PC4.

  • Page 41: Troubleshooting

    10-5. Troubleshooting Trouble Remedy No weld output; completely inoperative Place line disconnect in On position (see Section 5-6). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-6). Check for proper input power connections (see Section 5-6). No weld output;...

  • Page 42: Section 11 − Electrical Diagrams

    SECTION 11 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For Welding Power Source OM-220389 Page 36...
  • Page 43 263 488-A OM-220389 Page 37...

  • Page 44: Section 12 − Parts List

    SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 5 − Fig 12-3 6 − Fig 12-2 9 − Fig 12-4 6 − Fig 12-2 21 − Fig 12-5 23 24 Ref. 803 856-F Figure 12-1. Main Assembly OM-220389 Page 38...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ....+210492 . . . Cover, Top ........... .
  • Page 46 Hardware is common and not available unless listed. 20 21 802 955-C Figure 12-2. Windtunnel Assembly LH And RH Item Dia. Part Mkgs. Description Quantity Figure 12-2. Windtunnel Assembly LH And RH (Fig 12-1 Item 6) ....214597 .
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Windtunnel Assembly LH And RH (Continued) ....196231 ..Xfmr, Current Sensing 200/1 .
  • Page 48 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 5) ... . . 239598 .
  • Page 49 Hardware is common and not available unless listed. 803 423-D Figure 12-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-4. Rear Panel Assembly (Fig 12-1 Item 9) ....+210474 .
  • Page 50 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 20) ....207456 .
  • Page 51 Item Dia. Part Mkgs. Description Quantity Figure 12-5. Front Panel Assembly (Continued) ....207896 . . . Box, Louver ...........
  • Page 52 Notes...
  • Page 53 Notes...
  • Page 54 Notes...
  • Page 55 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 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 2016 Miller Electric Mfg. Co. 2016−01...

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Axcess 450 ce907275003907275011

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