Miller Axcess 450 HM Owner's Manual
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Miller Axcess 450 HM Owner's Manual

Miller Axcess 450 HM Owner's Manual

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Axcess 450 HM
OM-240 195C
Processes
Description
Arc Welding Power Source
R
Î
Î
File: Advanced Manufacturing Systems
2009−12
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding

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  • Page 1 OM-240 195C 2009−12 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Description Arc Welding Power Source Axcess 450 HM Î Î 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 8-5. Diagnostic LED’s On Process Control Module PC4 ......... 8-6.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009−08 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

  • Page 6: Noise Can Damage Hearing

    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. 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 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2009−08 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans D Porter des vêtements confectionnés avec des matières résistan- tes et ignifuges (cuir, coton lourd ou laine) et des bottes de les sources de soudage onduleur UNE FOIS protection. l’alimentation coupée. LE SOUDAGE peut provoquer un D Arrêter les convertisseurs, débrancher le courant électrique et incendie ou une explosion.

  • 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. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, 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- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...

  • Page 14: Sección 3 − Precauciones De Seguridad − Lea Antes De Usar

    SECCIÓN 3 − PRECAUCIONES DE SEGURIDAD − LEA ANTES DE USAR spa_som_2009−08 Protéjase usted mismo y a otros contra lesiones — lea y siga estas precauciones. 3-1. Uso de símbolos ¡PELIGRO! − Indica una situación peligrosa que, si no Indica instrucciones especiales. se la evita, resultará...
  • Page 15 Aun DESPUÉS de haber apagado el motor, puede EL SOLDAR puede causar fuego o quedar un VOLTAJE IMPORTANTE DE CC en las explosión. fuentes de poder con convertidor CA/CC. Soldando en un envase cerrado, como tanques, tambores o tubos, puede causar explosión. Las D Apague la inversora, desconecte la potencia de entrada y descar- chispas pueden volar de un arco de soldar.

  • Page 16: Símbolos Adicionales Para Instalación, Operación Y Mantenimiento

    D Proteja cilindros de gas comprimido del calor excesivo, golpes Los CAMPOS ELÉCTRICOS Y MAGNÉTICOS mecánicos, daño físico, escoria, llamas, chispas y arcos. (EMF) pueden afectar el funcionamiento de los dispositivos médicos implantados. D Instale y asegure los cilindros en una posición vertical asegurán- dolos a un soporte estacionario o un sostén de cilindros para D Las personas que utilicen marcapasos u otros prevenir que se caigan o se desplomen.

  • Page 17: Radiación De Alta Frecuencia

    D Asegure que solamente personas calificadas, familiarizadas con PIEZAS MÓVILES pueden equipos electrónicas instala el equipo. provocar lesiones. D El usuario se responsabiliza de tener un electricista capacitado que pronto corrija cualquier problema causado por la instalación. D Aléjese de toda parte en movimiento, tal como los ventiladores.

  • Page 18: Información Sobre Los Campos Electromagnéticos (Emf)

    3-6. Información sobre los campos electromagnéticos (EMF) La corriente que fluye a través de un conductor genera campos 3. No enrolle ni cuelgue los cables sobre su cuerpo. eléctricos y magnéticos (EMF) localizados. La corriente de la soldadura 4. Mantenga la cabeza y el tronco tan apartados del equipo del genera un campo EMF alrededor del circuito y los equipos de circuito de soldadura como le sea posible.

  • Page 19: Section 4 − Installation

    SECTION 4 − INSTALLATION Appearance of actual unit may vary from unit shown in manual. 4-1. Specifications Amperes Input At Rated Load Output 60 Wire Max Open Input Rated Welding Out- Voltage Input Input Diameter Circuit Voltage Power Range Three-Phase Range 460 V Three...

  • Page 20: Duty Cycle And Overheating

    4-3. 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 21: Serial Number And Rating Label Location

    4-5. 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. 4-6.

  • Page 22: Rear Panel Receptacle And Supplementary Protector

    4-7. Rear Panel Receptacle And Supplementary Protector 120 V 20 A AC Receptacle RC2 Receptacle supplies single-phase power. Maximum output from RC2 is limited by supplementary protector CB1 to 20 amps. Supplementary Protector CB1 CB1 protects 120 volt receptacle RC2 from overload.

  • Page 23: Remote 14 Receptacle Information

    4-8. Remote 14 Receptacle Information Socket* Socket Information Output contactor input signal. Closure to socket B enables output. Output contactor reference. Contact closure to socket A enables output. Output to remote control; +10 volts DC referenced to socket D. REMOTE Remote control circuit common.

  • Page 24: Connecting To Weld Terminals

    4-9. Connecting To Weld Terminals If using an electrode negative (straight polarity) process, the volt sense lead must be connected to the work. Î Î Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in (19mm) Correct Installation Incorrect Installation Ref.

  • Page 25: 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 26: Electrical Service Guide

    4-11. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. NOTICE −...

  • Page 27: Connecting Input Power

    4-12. Connecting Input Power = GND/PE Earth Ground Route input power cable through tubing inside unit. Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Route ground conductor through current transducer to ground terminal. 219 842-A Tools Needed: 5/16 in Ref. 805 340-A / Ref. 805 341-A / 218 005-A applicable, use lugs of proper amperage Disconnect Device...

  • Page 28: 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: 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 29 5-1 . 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 30: Front Panel Controls

    5-2. Front Panel Controls When an LED is lit, it means the related function is active. 200 410-A Program Display Wire Type LED In order for selections to be retained in When this LED is lit, turn the Adjust knob to Displays the number of the active program.
  • Page 31 Table 4-1. Welding Wire And Gas Abbreviations* Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation Steel E70, E100, E120 100% CO 90% Argon/10% CO 85% Argon/15% CO 75% Argon/25% CO 95% Argon/5% CO 95% Argon /5% O 98% Argon/2% O Stainless Steel 308, 309, 312, 316 98% Argon, 2% O...

  • Page 32: Front Panel Switches

    5-3. Front Panel Switches Ref. 805 341-A Power Switch The next message is : Contactor LED (Nonfunctional) Turns unit On or Off. Gas LED (Nonfunctional) AUTO The power-up sequence may last up to 30 seconds before the unit is ready to weld. Wirefeed LED (Nonfunctional) During power-up, the front panel will display AUTO CAL is an abbreviation for “automatic...

  • Page 33: Reset Mode

    5-4. 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 34: 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 35: Section 7 − Safety Precautions For Servicing

    SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read and follow these precautions. 7-1. Symbol Usage OM-240 195C 2009−12, safety_stm 2009−08 DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

  • Page 36: 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 37: Section 8 − Troubleshooting

    SECTION 8 − TROUBLESHOOTING 8-1. Set Value Mode 200 410-A The Set Value mode is a troubleshooting tool Adjust Knob Accu-pulse, or RMD (optional)] can be that allows the Axcess HM to control voltage/ changed in the top display. Wire speed can be Wire Feed Speed/Amps Display Push Arc Adjust and wire feed speed command val- changed in the bottom display.

  • Page 38: Diagnostics

    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 39 8-2. Diagnostics (Continued) WELD MOTR DEMO WAIT WAIT STOP DONE Indicates a UIM Indicates an Indicates a weld Indicates a motor Indicates a low WFS Indicates RMD/Ac- communication error. emergency stop error. cycle wait error. communication error. command error. cuspeed demo is expired.

  • Page 40: Removing Side Panel And Measuring Input Capacitor Voltage

    8-3. Removing Side Panel and Measuring Input Capacitor Voltage Turn Off welding power source, and 900 Volts DC can be present on the capacitor bus disconnect input power. and significant DC voltage can remain on Remove cover capacitors after unit is Off. Always check the voltage on both inverter assemblies as shown to be Power Interconnect Board Tools Needed:...

  • Page 41: Process Control Module Pc4 Diagnostic Led's

    8-4. 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 8-5 for information on diagnostic LED’s. Reinstall cover after checking diagnostic LED’s. LED1 LED2 LED3...

  • Page 42: User Interface Module Pc7 Diagnostic Led's

    8-6. User Interface Module PC7 Diagnostic LED’s LED1 LED2 218 559-A / Ref. 805 342-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 43: Automation Interface Module Pc9 Diagnostic Led's

    8-8. Automation Interface Module PC9 Diagnostic LED’s LED11 LED13 LED25 LED28 LED12 LED14 LED27 LED31 LED30 LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10 LED32 LED33 LED15 LED20 LED19 LED18 LED16 LED21 LED22 LED23 LED24 LED26 LED29 LED17 216 958-A / Ref.

  • Page 44: Diagnostic Led's On Automation Interface Module Pc9

    8-9. Diagnostic LED’s On Automation Interface Module PC9 Status Diagnosis Input signal On from robot for jog advance Input signal Off from robot for no jog advance Input signal On from robot to energize contactor Input signal Off from robot to not energize contactor Input signal On remote program A selected Input signal Off remote program A not selected Input signal On remote program C selected...
  • Page 45 Status Diagnosis Input signal On from relay K4 to indicated wire stuck in weld joint Input signal Off from relay K4 to indicate wire is not stuck in weld joint Indicates +5 volts DC is present on automation module PC9 Indicates +5 volts DC is not present on automation module PC9 Input signal on from relay K5 for flow (shielding gas or coolant) present Input signal off from relay K5 for flow (shielding gas or coolant) not present...

  • Page 46: Network And Module Status Led's

    8-10. Network And Module Status LED’s Network Status LED’s The following are network status LED’s: LED1 on the UIM circuit board LED4 on the 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 47: Troubleshooting

    8-11. Troubleshooting Trouble Remedy No weld output; completely inoperative Place line disconnect in On position (see Section 4-12). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-12). Check for proper input power connections (see Section 4-12). No weld output;...

  • Page 48: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Power Source (Part 1 Of 2) OM-240 195 Page 44...
  • Page 49 240 189-A (Part 1 Of 2) OM-240 195 Page 45...
  • Page 50 Figure 9-2. Circuit Diagram For Welding Power Source (Part 2 Of 2) OM-240 195 Page 46...
  • Page 51 240 189-A (Part 2 Of 2) OM-240 195 Page 47...
  • Page 52 72 PIN HARTING CONNECTOR RC70−21 RC70−71 14 SOCKET CONNECTOR RC70−33 RC70−70 RC70−69 RC70−44 RC70−22 RC70−20 RC70−9 RC70−7 RC70−6 RC70−3 RC70−59 RC70−5 RC70−68 RC70−72 RC70−8 RC79−16 RC70−4 RC70−34 241 070-A Figure 9-3. 72 Pin To 14 Socket Adapter Schematic OM-240 195 Page 48...
  • Page 53 Notes OM-240 195 Page 49...

  • Page 54: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and 20 Fig.10-6 not available unless listed. 4 Fig. 10-3 7 Fig.10-4 16 Fig. 10-5 Ì Ref. 803 247-D Figure 10-1. Main Assembly OM-240 195 Page 50...
  • Page 55 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly ....212543 . . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz ....
  • Page 56 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 57 Hardware is common and not available unless listed. Ref. 802 916-B Figure 10-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-3. Top Tray Assembly (Fig 10-1 Item 4) ..PC12 ..209676 .
  • Page 58 Hardware is common and not available unless listed. 805 345-B Figure 10-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-4. Rear Panel Assembly (Fig 10-1 Item 8) ... . . 221279 .
  • Page 59 Hardware is common and not available unless listed. 805 346-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 60 Item Dia. Part Mkgs. Description Quantity Figure 10-5. Front Panel Assembly (Fig 10-1 Item 14) (Continued) ..LED1 ..202156 . . . LED, Amber 28.0V 50 MA 8000 MCD .
  • Page 61 Hardware is common and not available unless listed. 805 347-A Figure 10-6. Transformer Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-6. Transformer Assembly (Fig 10-1 Item 20) ....240275 .
  • Page 62 Notes...
  • Page 63 Effective January 1, 2009 (Equipment with a serial number preface of LK 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 64: Owner's Record

    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 2009 Miller Electric Mfg. Co. 2009−01...

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