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Miller Axcess 675 Owner's Manual

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Axcess 675
File: Advanced Manufacturing Systems
OM-217 751H
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
™
2006−05

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Summary of Contents for Miller Axcess 675

  • Page 1 OM-217 751H 2006−05 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 _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.

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

    D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.

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

    D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange suffisante pour lever l’appareil. Miller/Hobart. D En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org).

  • Page 13: Section 3 − Installation

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

  • Page 14: 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 15: Selecting A Location

    3-5. Selecting A Location Y Do not move or operate Movement Tipping unit where it could tip. Location Y Do not stack units. Beware of tipping. Y 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 16: Rear Panel Receptacles And Supplementary Protectors

    3-7. 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 17: Connecting To Weld Terminals

    3-8. 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 (19mm) Correct Installation Incorrect Installation 803 822-A / 803 778-A Y Turn off power before connecting to...

  • Page 18: Network Wire Feeder Receptacle Functions

    3-9. 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. OM-217 751 Page 14...

  • Page 19: Electrical Service Guide

    3-10. Electrical Service Guide CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of 50/60 Hz (+10%) power at +10% of rated input voltage. Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

  • Page 20: Connecting Input Power

    3-11. Connecting 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: Section 4 − Recommended Setup Procedures

    SECTION 4 − RECOMMENDED SETUP PROCEDURES 4-1. Selecting Weld Cable Sizes* Y ARC WELDING can cause Electromagnetic Interference. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual.

  • Page 22: Welding Circuit

    4-2. Welding Circuit NOTE 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 23: Arranging Welding Cables To Reduce Welding Circuit Inductance

    4-3. 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 24: Using Multiple Welding Power Sources

    NOTE Welding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensify. 4-4. 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...

  • Page 25: Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs

    4-5. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A. Bad Setup Current Flow Path 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 sensing leads being directly in the current...
  • Page 26 B. Better Setup Current Flow Path 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 compensation in the welding parameters.
  • Page 27 C. Best Setup Current Flow Path 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 reliable arc starts and better arc quality.

  • Page 28: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. 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 29: Section 6 − Maintenance

    SECTION 6 − MAINTENANCE 6-1. Routine Maintenance Y 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 Every l Unreadable Labels...

  • Page 30: Section 7 − Safety Precautions For Servicing

    SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING Y Warning: Protect yourself and others from injury — read and follow these precautions. 7-1. Symbol Usage OM-211 434M - 2006−05, safety_stm 3/06 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

  • Page 31: California Proposition 65 Warnings

    MOVING PARTS can cause injury. 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.

  • Page 32: Section 8 − Troubleshooting

    SECTION 8 − TROUBLESHOOTING 8-1. Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power source, and Y 900 Volts dc can be present on the capacitor bus and disconnect input power. significant DC voltage can remain on capacitors after Remove cover unit is Off.

  • Page 33: Process Control Module Pc4 Diagnostic Led's

    8-2. Process Control Module PC4 Diagnostic LED’s Process Control Module PC4 Diagnostic LED’s are visible inside unit, located on PC4 mounted on the top tray. Refer to Section 8-3 for information on diagnostic LED’s. Reinstall cover after checking diagnostic LED’s. LED1 LED2 LED3...

  • Page 34: Network And Module Status Led's

    8-4. Network And Module Status LED’s Network Status LED’s 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 35: Troubleshooting

    8-5. Troubleshooting Trouble Remedy No weld output; completely inoperative Place line disconnect in On position (see Section 3-11). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-11). Check for proper input power connections (see Section 3-11). No weld output;...

  • Page 36: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Power Source (1 Of 2) OM-217 751 Page 32...
  • Page 37 219 467-B (Part 1 Of 2) OM-217 751 Page 33...
  • Page 38 Figure 9-2. Circuit Diagram For Welding Power Source (2 Of 2) OM-217 751 Page 34...
  • Page 39 219 467-B (Part 2 Of 2) OM-217 751 Page 35...

  • Page 40: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 4 − Fig 10-3 5 − Fig 10-2 7 − Fig 10-4 16 − Fig 10-5 803 827-B Figure 10-1. Main Assembly OM-217 751 Page 36...
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly ....212543 . . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz ....
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 10-2. Windtunnel Assembly LH And RH (Fig 10-1 Item 6) ....214597 . . . Windtunnel, LH w/Components (including).
  • Page 43 Hardware is common and not available unless listed. 803 422-B Figure 10-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-3. Top Tray Assembly (Fig 10-1 Item 4) ... . . 221606 .
  • Page 44 Hardware is common and not available unless listed. 803 828-A Figure 10-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-4. Rear Panel Assembly (Fig 10-1 Item 7) ....198941 .
  • Page 45 Hardware is common and not available unless listed. 803 829-A Figure 10-5. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-5. Front Panel Assembly (Fig 10-1 Item 16) ....207456 .
  • Page 46 Item Dia. Part Mkgs. Description Quantity Figure 10-5. Front Panel Assembly (Fig 10-1 Item 16) (Continued) ....215467 . . . Label, Volt Sense .
  • Page 47 Effective January 1, 2006 (Equipment with a serial number preface of “LG” 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...
  • 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. © PRINTED IN USA 2006 Miller Electric Mfg. Co. 2006−01...

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