Download
Share
Print this page
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

Miller Auto-Axcess 300 DI Owner's Manual

Hide thumbs Also See for Auto-Axcess 300 DI:

Advertisement

Quick Links

Download this manual
Visit our website at
www.MillerWelds.com
Auto-Axcess 300 DI
OM-228 874B
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
2006−04

Advertisement

loading
Need help?

Need help?

Do you have a question about the Auto-Axcess 300 DI and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Miller Auto-Axcess 300 DI

Summary of Contents for Miller Auto-Axcess 300 DI

  • Page 1 OM-228 874B 2006−04 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...
  • 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 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 7 − TROUBLESHOOTING ............7-1.
  • Page 5 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 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 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 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 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 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 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 Single-Phase/Three-Phase Welding Welding Speed Speed Diameter Diameter Circuit...
  • Page 14 3-3. 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 unit to cool. Reduce amperage or duty cycle before welding.
  • Page 15 3-5. Selecting A Location Y Do not move or operate Tipping Movement 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 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 CB2 to 10 amps. Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload.
  • Page 17 3-8. Connecting To Weld Terminals Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in (19 mm) Correct Installation Incorrect Installation 803 675-A / 803 778-A Y Turn off power before connecting to Positive (+) Weld Output Terminal Copper Bar weld output terminals.
  • Page 18 3-9. 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 19 3-10. 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 3-11. Motor Control Receptacle Functions Socket Socket Information Not used. Motor negative (−). Tach A, 0 volts = low and 3.5 volts = high.
  • Page 20 3-13. Electrical Service Guide CAUTION: INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. NOTE Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table.
  • Page 21 3-14. 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 22 3-15. Connecting 1-Phase Input Power = GND/PE Earth Ground Tools Needed: Route input power cable 5/16 in through tubing inside unit. Route ground conductor through current transducer to ground terminal. Ref. 144 221 / Ref. 070 399-F / 803 676-A / Ref. 218 005-A Y Turn Off welding power source, and national, state, and local electrical codes.
  • Page 23 3-16. Remote Program Select NOTE Remote Program Select is factory set to “On”. WaveWriter software is required to turn this function “Off”. When Remote Program Select is On, a robot pendant may be used to select programs. When Off, program selection must be done from the robot pendant.
  • Page 24 SECTION 4 − OPERATION 4-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: Synergic Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual pulse settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed speed setting.
  • Page 25 4-1 . Operational Terms (Continued) Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (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 optional PDA with File Management software).
  • Page 26 4-2. Front Panel Controls (See Section 4-3) 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 PDA with File Management/WaveWriter Gas Type LED software.
  • Page 27 4-3. Front Panel Controls - Continued (See Section 4-2) Arc Control LED 11 Wire Speed And Amps LED’s ”Display Command Values” mode. In the Display Command Values mode, The lit LED indicates whether wire speed or The LED lights to indicate the Arc Control command values are displayed while amps are being displayed.
  • Page 28 4-4. Front Panel Switches Ref. 803 677-A Power Switch AUTO Wirefeed LED Turns unit On or Off. Wirefeed LED illuminates when wire feeds or AUTO 300 indicates the software being retracts. The power-up sequence may last up to 30 loaded. seconds before the unit is ready to weld.
  • Page 29 4-5. 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 30 SECTION 5 − MAINTENANCE 5-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Clean And Replace Tighten Damaged Or Replace Damaged Weld Unreadable Gas Hose Terminals Labels Repair Or Replace Cracked Cables And Cords 6 Months Clean Blow Out Or...
  • Page 31 SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING 6-1. Symbol Usage safety_stm 8/03 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 32 MOVING PARTS can cause injury. H.F. RADIATION can cause interference. D Keep away from moving parts. 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. D Have only qualified persons familiar with electronic equipment install, test, and service H.F.
  • Page 33 SECTION 7 − TROUBLESHOOTING 7-1. 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 LED’s under the display windows...
  • Page 34 7-2. 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 STUK Indicates a Indicates a motor Indicates a wire Indicates an arc Indicates a ground Indicates a wire tachometer error.
  • Page 35 7-2. Diagnostics (Continued) OVER OVER WAIT CRNT STOP DONE Indicates an over Indicates RMD Indicates an Indicates a UIM Indicates a low WFS Indicates an average current error. emergency stop error. demo is done. communication error. command error. overcurrent error. UNIT TRIG COMM...
  • Page 36 7-3. 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 Remove cover after unit is Off. Always check the voltage on the inverter assembly as shown to be sure the input Power Interconnect Board Tools Needed:...
  • Page 37 7-4. 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 7-5 for information on diagnostic LED’s. Reinstall cover after checking diagnostic LED’s. LED1 LED2 LED3...
  • Page 38 7-6. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings Wire Feed Module PC6 Diagnostic LED’s are visible inside unit, located on PC6 mounted on the top tray assembly. Refer to Section 7-7 for information on diagnostic LED’s. Reinstall top cover after checking diagnostic LED’s.
  • Page 39 7-8. User Interface Module PC7 Diagnostic LED’s 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 LED’s. Diagnostic LED’s are visible inside unit, switch settings are different for each circuit located on PC7 mounted behind the front board.
  • Page 40 7-10. Network Status Table Circuit boards PC4, PC6, PC7, and PC9 have two bi-color (green/red) LED’s to give information about communication between circuit boards. See the table below for an explanation of what the LED’s indicate. Status Diagnosis There is no power applied to the circuit board or the board software is not executing. Green The circuit board is operating normally.
  • Page 41 SECTION 8 − ELECTRICAL DIAGRAMS 228 875-B (Part 1 Of 2) Figure 8-1. Circuit Diagram For Welding Power Source (Part 1 Of 2) OM-228 874 Page 37...
  • Page 42 Figure 8-2. Circuit Diagram For Welding Power Source (Part 2 Of 2) OM-228 874 Page 38...
  • Page 43 228 875-B (Part 2 Of 2) OM-228 874 Page 39...
  • Page 44 Ref. 219 267-B Figure 8-3. Circuit Diagram For Peripheral/Motor Interface OM-228 874 Page 40...
  • Page 45 Notes OM-228 874 Page 41...
  • Page 46 SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 4 − Fig 9-3 6 − Fig 9-4 5 − Fig 9-2 14 − Fig 9-5 804 576-A Figure 9-1. Main Assembly OM-228 874 Page 42...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....210492 . . . Cover, Top ........... .
  • Page 48 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Windtunnel Assembly LH And RH (Fig 9-1 Item 6) ....214597 . . . Windtunnel, LH w/Components (including).
  • Page 49 Hardware is common and not available unless listed. 802 916-C Figure 9-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-3. Top Tray Assembly (Fig 9-1 Item 4) ..PC12 ..209676 .
  • Page 50 Hardware is common and not available unless listed. 804 577-A Figure 9-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-4. Rear Panel Assembly (Fig 9-1 Item 8) ....175282 .
  • Page 51 Hardware is common and not available unless listed. 803 682-A Figure 9-5. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-5. Front Panel Assembly (Fig 9-1 Item 14) ....207456 .
  • Page 52 Item Dia. Part Mkgs. Description Quantity Figure 9-5. Front Panel Assembly (Fig 9-1 Item 14) (Continued) ....216966 . . . Cover, Connector D-sub 9 pin Male w/Chain .
  • Page 53 Item Dia. Part Description Quantity Mkgs. Figure 9-6. Drive Assembly, Wire ....010 668 SCREW, cap stl sch .250-20 x 1.500 ....... .
  • Page 54 Item Dia. Part Description Quantity Mkgs. Figure 9-6. Drive Assembly, Wire ....200 221 CABLE, gas ........... . .
  • Page 55 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 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. © PRINTED IN USA 2006 Miller Electric Mfg. Co. 2006−01...