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OM-222 394F 2006 −08
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
™
Axcess Dual
Wire Feeder
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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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 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. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessa
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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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. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (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 Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 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. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier d’É
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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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). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − INTRODUCTION 3-1. Specifications Type of Input Welding Power Wire Diameter Welding Circuit Overall Wire Feed Speed Range Weight Power Source Type Range Rating Dimensions 40 Volts DC Axcess Series Standard: 40 To 1400 ipm (1.0 .030 To 1/8 in 100 Volts, Length: 27 in (686 87 lb 10 Amperes To 35.6 mpm) (0.8 To 3.2 mm) 750 Amperes, mm) (39.5 kg) 100% Duty Width: 12-1/2 in Max Spool Cycle (318 mm) Weight: 60 lb (27 Height: 14-1/2 in kg) (368 mm) SECTION 4 − INSTALLATION 4-1. Selecting A L
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4-2. Connection Diagram 1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 3 5 Network Feeder Cable 6 Negative ( −) Weld Cable 7 Workpiece 8 Voltage Sensing Lead Recommended for Accu-pulse and RMD (optional). Positive (+) voltage sensing 4 lead is contained in the motor 5 cable. 9 Positive (+) Weld Cable 2 1 9 7 6 8 804 019-A OM-222 394 Page 10
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4-3. Rear Panel Connections And Rotating Drive Assembly 1 9-Pin Network Receptacle 2 Power Switch 3 Shielding Gas Valve Fitting (Left And Right) Requires fitting with 5/8-18 right- hand threads. Connect customer- 3 supplied gas hose. 4 Weld Cable Terminal 2 5 Jumper Cable 1 6 Weld Cable 7 Drive Assembly 9 8 Drive Assembly Rotation Knob (Left And Right) 9 Rating Label Location To rotate the drive assembly, loosen drive assembly rotation knob, rotate drive assembly, and tighten knob. 4 5 6 7 8 Too
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4-4. 9-Pin Network Receptacle Information Pin Pin Information 9 A Capacitor C1 to ground B Shield C Volt sense F F G G D Can low E E H H E Can high II D D A F +24 volts dc common C C B B G + 24 volts dc H Motor voltage +40 volts dc common I Motor voltage +40 volts dc 4-5. Gun Recommendation Table Process Gun GMAW − Hard or Cored Wires 400, 500, And 600 Amp Air-Cooled Guns GMAW − Pulse Water-Cooled Guns OM-222 394 Page 12
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4-6. Installing And Threading Welding Wire Install wire spool. Adjust tension nut so Install wire guides and anti-wear guide. wire is taut when wire feed stops. Install drive rolls. Pressure Indicator Scale Pressure Adjust Rear Pressure Rolls Adjust Front Rolls No Wire Slip Wire Slips NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE Drive Rolls Tools Needed: 3/16, 5/64 in Gun Cable 15/16, 3/8 in End Of Liner Be sure that outlet cable has proper size For soft wire or small diameter stainless To
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4-7. Power Source Display At Power Up 1 Upper Display 1 2 Lower Display Program Volts Time Arc Length WFS Amps Arc Ctl 2 Sequence Process Trigger Control Wire Type Gas Type Trigger Hold Process Set Up Adjust Feeder Set Up Power Source Upper Display Lower Display Voltage Range Net Wait DTEC OFF Axcess Axcs 300/450/675 10 44 4-8. Dual Schedule Switch Option 1 Maint 2P (Maintained-Contact 2-Pole Switch) DSS-9M Part# 041 793 11 DSS-9M 22 1 A 3 B 4 OM-222 394 Page 14
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SECTION 5 − OPERATION 5-1. Operational Terms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder: General Terms: Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by volts in MIG programs. Trigger Control Selecting Trigger Control allows activating trigger functions such as DS, TH, 4
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General Terms: Sequence Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters. Preflow Setting a time value for gas flow prior to arc start. Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only adjustable with the optional PDA with File Management/WaveWriter software). Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends. Postflow Setting a time value for gas flow
