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OM-230 032C 2007−10
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
™
Axcess 300
Visit our website at
File: Advanced Manufacturing Systems
www.MillerWelds.com/ams
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. 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. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Insta
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TABLE OF CONTENTS SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 9-1. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 9-2. Weld Process Board PC4 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 9-3. Diagnostic LED’s On Process Board PC4 . . . . .
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Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). Manufacturer: European Contact: Miller Electric Mg. Co. Mr. Danilo Fedolfi, 1635 W. Spencer St. Managing Director Appleton, WI 54914 USA ITW Welding Products Italy S.r.l. Phone: (920) 734-9821 Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 European Contact Signature: Declares that this product
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 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. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible This grou
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Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap. health. Remove any combustibles, such as a butane lighter or matches, Keep your head out of the fumes. Do not breathe the
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is Have only qualified persons remove doors, panels, covers, or properly sized,
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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 & Safety Code Section 25249.5 et seq.) tive harm. For Diesel Engines: Battery posts, terminals and related accessories contain lead and lead
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 7 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. l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut
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Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in- les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tels Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement. Des étincelles peuven indiquées dans la partie Entretien avant de touche
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Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LES ACCUMULATIONS DE GAZ des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. Placer les bouteilles debout en les fixant dans un support station- Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation. de se renverser. Veiller toujours à bien
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LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. Le rayonnement haute fréquence (H.F.) peut Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica- geant le fil de soudage. tion, les services de sécurité et les ordinate
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for We
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OM-230 032 Page 10
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SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Disconnect input plug or power before working on machine. 2 Breathing welding fumes can be hazardous t
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2 3 4 1 5 6 V V > 5 min V 219844−A 7 8 9 10 4/04 1 Warning! Watch Out! There are Do not touch fully charged can explode or cause other parts to possible hazards as shown by the capacitors. explode. symbols. 8 Flying pieces of parts can cause 5 Always wait 5 minutes after power is injury. Always wear a face shield 2 Electric shock from wiring can kill. turned off before working on unit, OR when servicing unit. 3 Disconnect input plug or power 6 Check input capacitor voltage, and 9 Always wear lo
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3-3. Symbols And Definitions Direct Current Alternating Amperage Voltage (DC) Current (AC) V A Output Circuit Breaker Remote On Off Positive Negative Voltage Input Protective Earth Arc Force Constant Voltage Inductance (Ground) Three Phase Static Frequency Con- Gas Metal Arc Increase Line Connection verter- Welding (GMAW) Transformer- Rectifier Rated No Load Conventional Primary Voltage Duty Cycle U X Voltage (Average) U Load Voltage U 0 1 2 Degree Of Rated Welding Hertz Percent IP Protection I
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SECTION 4 − INSTALLATION Appearance of actual unit may vary from unit shown in manual. 4-1. Specifications Amperes In- Max put At Rated Open Rated Wire Feed Wire Load Output Input Voltage Input Input Welding Speed Diameter Circuit Volt- 60 Hz, Power Range kVA KW age Output Range** Range Three-Phase DC DC 400V 225 A @ 10.4 7.2 6.9 Standard: 25 V DC, (0.2*) (0.04*) Three 50-1400 .030-.062 in 10-44 100% 80 ipm (0.8-1.6 mm) Phase Duty (1.3-35.6 mpm) Cycle *While idling; Input amperage fluctuates w
