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OM-228 956B 2006 −08
Processes
MIG (GMAW) Welding
Description
Wire Feeder
Axcess AlumaFeed 75
Visit our website at
File: Advanced Manufacturing Systems
www.MillerWelds.com
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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 Installation,
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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 .045 To .062 in 100 Volts, Length: 27 in (686 70.5 lb 10 Amperes To 35.6 mpm) (1.1 To 1.6 mm) 750 Amperes, mm) (32.0 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
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4-2. Connection Diagram 1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 3 4 Gas Hose 5 Network Feeder Cable 4 6 Negative ( −) Weld Cable 7 Workpiece 8 Voltage Sensing Lead (Optional) Positive (+) voltage sensing lead is contained in the motor 2 5 cable. 1 9 Positive (+) Weld Cable 7 8 9 6 Ref. 801 915 / Ref. 804 584-A OM-228 956 Page 10
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4-3. Rear Panel Connections And Rotating Drive Assembly 1 9-Pin Network Receptacle 2 Shielding Gas Valve Fitting Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. 3 Weld Cable 4 Weld Cable Screw - Screw Size (.375 - 16 x 1.50) 5 Drive Assembly 7 6 Drive Assembly Rotation 1 Knob 2 7 Rating Label Location To rotate the drive assembly, loos- en drive assembly rotation knob, rotate drive assembly, and tighten knob. 350 Amps and above weld connection 3 4 0 to 350
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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 I Motor voltage +40 volts 4-5. Installing Drive Rolls 1 Pressure Assembly Door 2 Drive Roll 3 Ejector Button 4 Drive Roll Carrier Installation 4 Open pressure assembly door. 3 Align drive roll slots with three lobes on drive roll carrier. Insert drive roll onto carrier.
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4-6. Installing PD Continuous Wire Guides PD Continuous Wire Guides: Should be used with .068/.072 in (1.8 mm) and smaller diameter wire for opti- mal performance. Should be used with PD drive rolls and cannot be used with non-PD (old-style) drive rolls. 70 series wire guides are not compatible with 75 series wire 3 feeders. 1 Pressure Assembly Door 2 PD Inlet Guide 3 PD Wire Guide (Hard Wire) 4 PD Wire Guide (Two Pieces interlocked for Aluminum 4 Wire) Installing PD continuous wire guides w
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4-7. Installing Non-PD (Old Style) Wire Guides Installing wire guides with non- PD (old-style) drive rolls Non-PD (old-style) wire guides and drive rolls should be used with 5/64 in (2.0 mm) and larger diameter wire. 1 Pressure Assembly Door 2 PD Inlet Guide 3 Intermediate Guide 5 4 Set Screw 2 5 Guide Holder 6 Exit Guide 6 3 Open pressure assembly door. Lift up drive roll swing arms. 4 Install PD inlet guide. Do not tighten set screw to se- cure inlet guide. Set screw may be used to se- c
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4-8. Installing Welding Gun 1 Power Clamp Knob 2 Gun Locking Tab 3 Power Pin Groove 4 Gun Connection End Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab. When installing gun, the liner should extend into the PD continu- ous guide (or exit guide if used) as far as possible without interfering with the guide. Align the groove in the power pin of the gun with the gun locking tab. Secure gun by tightening power 4 clamp knob. Ins
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4-9. Installing Welding Wire And Adjusting Pressure Drive Setting Install wire spool. Adjust tension nut so wire is taut when wire feed stops. Thread wire. Adjust tension. 2 1 Drive Rolls Pressure assembly door not shown. Back Of Gun End Of Liner Ref. 804 190-A Tools Needed: No Wire Slip Wire Slips NONCONDUCTIVE NONCONDUCTIVE SURFACE SURFACE 15/16 in 1 Drive Roll Pressure Adjustment Lever When installing gun, the liner should extend surface and press gun trigger to feed wire into the PD contin
