Miller Axcess 675 Owner's Manual
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Miller Axcess 675 Owner's Manual

Miller Axcess 675 Owner's Manual

Automatic welding interface and arc welding power source
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Axcess 675
File: Advanced Manufacturing Systems
OM-217 751S
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
R
2012−06

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  • Page 1 OM-217 751S 2012−06 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Automatic Welding Description Automatic Welding Interface And Arc Welding Power Source Axcess 675 File: Advanced Manufacturing Systems Visit our website at 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 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-217 751 Page 10...

  • Page 15: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS Appearance of actual unit may vary from unit shown in manual. 3-1. Specifications Wire Amperes Input At Rated Load Output 60 Hz, Rated Wire Open Input Voltage Feed Input Input Three-Phase Welding Diameter Circuit IP Rating Power Range Speed...

  • Page 16: Duty Cycle And Overheating

    3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes 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 17: Section 4 − Installation

    SECTION 4 − INSTALLATION 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 18: Rear Panel Receptacles And Supplementary Protectors

    4-4. 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 19: Network Wire Feeder Receptacle Functions

    4-6. Network Wire Feeder Receptacle Functions Pin* Pin Information Not used. Shield. Volt sense. Can low. Can high. +24 volts DC common. + 24 volts DC Motor voltage −40 volts Motor voltage +40 volts Ref. 803 823-A *The remaining pins are not used. 4-7.

  • Page 20: Connecting 3-Phase Input Power

    4-8. 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 21 4-8. Connecting 3-Phase Input Power (Continued) See rating label on unit and check input volt- Welding Power Source Line Terminals Turn Off welding power source, and age available at site. check voltage on input capacitors Input Conductors L1, L2, L3 according to Section 9-1 before Input Power Conductors (Customer Connect input conductors L1, L2, and L3 to...

  • Page 22: Section 5 − Recommended Setup Procedures

    SECTION 5 − RECOMMENDED SETUP PROCEDURES 5-1. Selecting Weld Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 23: Welding Circuit

    5-2. 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 24: Arranging Welding Cables To Reduce Welding Circuit Inductance

    5-3. 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 25: 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. 5-4. 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 26: Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs

    5-5. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A. Bad Setup Current Flow Path Ref. 804 639-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 27 B. Better Setup Current Flow Path Ref. 804 640-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 28 C. Best Setup Current Flow Path Ref. 804 641-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 29: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Front Panel Switches Ref. 803 824-A 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 30: Section 7 − Maintenance

    SECTION 7 − MAINTENANCE 7-1. 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 31: Section 8 − Safety Precautions For Servicing

    SECTION 8 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 8-1. Symbol Usage OM-217 751S - 2012−06, safety_stm 2011−10 DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

  • Page 32: 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 33: Section 9 − Troubleshooting

    SECTION 9 − TROUBLESHOOTING 9-1. Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power source, and disconnect in- put power. Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.

  • Page 34: Process Control Module Pc4 Diagnostic Leds

    9-2. 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 9-3 for information on diagnostic LEDs. Reinstall cover after checking diagnostic LED1 LEDs.

  • Page 35: Network And Module Status Leds

    9-4. 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 36: Section 10 − Electrical Diagrams

    SECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Power Source (1 Of 2) OM-217 751 Page 32...
  • Page 37 219 467-D (Part 1 Of 2) OM-217 751 Page 33...
  • Page 38 Figure 10-2. Circuit Diagram For Welding Power Source (2 Of 2) OM-217 751 Page 34...
  • Page 39 219 467-D (Part 2 Of 2) OM-217 751 Page 35...

  • Page 40: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. 4 − Fig 11-3 5 − Fig 11-2 7 − Fig 11-4 16 − Fig 11-5 Ref. 803 827-C Figure 11-1. Main Assembly OM-217 751 Page 36...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 11-1. Main Assembly ....212543 . . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz ....
  • Page 42 Hardware is common and not available unless listed. 20 21 802 955-A Figure 11-2. Windtunnel Assembly LH And RH Item Dia. Part Mkgs. Description Quantity Figure 11-2. Windtunnel Assembly LH And RH (Fig 11-1 Item 6) ....214597 .
  • Page 43 Item Dia. Part Mkgs. Description Quantity Figure 11-2. Windtunnel Assembly LH And RH (Continued) ....217625 ..Kit, Input/Pre−regulator And Inverter Module .
  • Page 44 Hardware is common and not available unless listed. 803 422-B Figure 11-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-3. Top Tray Assembly (Fig 11-1 Item 4) ... . . 239598 .
  • Page 45 Hardware is common and not available unless listed. 803 828-B Figure 11-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-4. Rear Panel Assembly (Fig 11-1 Item 7) ....198941 .
  • Page 46 Hardware is common and not available unless listed. Ref. 803 829-A Figure 11-5. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-5. Front Panel Assembly (Fig 11-1 Item 16) ....207456 .
  • Page 47 Effective January 1, 2012 (Equipment with a serial number preface of MC 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 48 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 2012 Miller Electric Mfg. Co. 2012−01...

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