OM-220 979B February 2005 Processes MIG (GMAW) Welding Description Wire Feeder ROI (Remote Operator Interface) Visit our website at www.MillerWelds.
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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (phone: 305-443-9353, website: www.aws.org). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie « NOTA » ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance.
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées. Le rayonnement de l’arc génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées. Des étincelles sont projetées pendant le soudage. D Porter un masque de soudage muni d’un filtre de la nuance adéquate pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLOSION LES ORGANES MOBILES peuvent causer des blessures. D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle. D Se tenir à l’écart des organes mobiles comme les ventilateurs. D Maintenir fermés et bien fixés les portes, panneaux, recouvrements et dispositifs de protection. D Ne pas installer l’appareil à proximité de produits inflammables.
2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 (téléphone : (305) 443−9353, site Web : www.aws.org). Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS F4.
SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear. 1 1.1 2 2.1 3 3.1 4 4.1 5 + 1.2 2.2 1.3 2.3 3.2 + 3.3 + + 6 S-178 936 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.
3-2. Manufacturer’s Rating Label For CE Products For label location see Section 5-4. S/N: U1 = 40 V I1 = 5.5 A IP 21 MILLER ELECTRIC MFG. CO., APPLETON, WI USA 220 498-A 3-3. Symbols And Definitions NOTE Some symbols are found only on CE products.
SECTION 4 − INTRODUCTION 4-1. Specifications Type of Input Power Welding Power Source Type 40 Volts DC 10 Amperes Axcess Series Wire Feed Speed Range Wire Diameter Range Standard: 40 To 1400 ipm (1.0 To 35.6 mpm) .035 To 1/16 in (0.8 To 1.6 mm) Overall Dimensions Weight Length: 7 in (178 mm) 11 lb (5 kg) Width: 7 in (178 mm) Max Spool Weight: 60 lb (27 kg) Height: 12 in (305 mm) SECTION 5 − INSTALLATION 5-1. Mounting Plate Hole Layout 4 in (102 mm) 7/32 in (5.6 mm) Dia.
5-3. Connection Diagram 1 2 3 4 5 6 7 8 1 3 9 7 6 5 4 10 Welding Power Source Wire Feeder Gas Cylinder Gas Hose Network Feeder Cable Negative (−) Weld Cable Workpiece Voltage Sensing Lead (Optional) . Positive (+) voltage sensing lead is contained in the motor cable. 9 Positive (+) Weld Cable 10 Motor Cable 11 Trigger Cable 8 11 11 2 803 698-E 5-4. Rear Panel Connections 1 2 3 9-Pin Network Receptacle Motor Control/Shielding Gas Valve Receptacle Rating Label Location 2 3 1 Ref.
5-5. 9-Pin Network Receptacle Information 9 F E H I D C 5-6.
5-7. Power Source Display At Power Up 1 2 1 2 t V Upper Display Lower Display A Process Setup Adjust Feeder Setup Upper Display Power Source Axcess Lower Display Net Wait DTEC OFF Axcs 300/450/675 Voltage Range 10 44 219 711-A 5-8.
SECTION 6 − OPERATION 6-1. 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.
General Terms: Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends. Postflow Setting a time value for gas flow after arc end. Feeder Set Up Allow selection of Sequence and trigger functions. Auto Thread Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously will automatically feed wire. Default setting is 192 at a feed rate of 700 ipm (these values can be changed using a PDA with File Management/WaveWriter software).
6-3.
6-4. Program Push Button 1 Program Display The number of the active program is displayed. 2 3 Program Push Button Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob. 1 3 Momentarily press button to illuminate LED. To change the program number, rotate Adjust knob to select one of eight programs. Pressing and holding the push button will display current wire size, wire type and process.
6-6. Lower Display 5 7 t 1 6 2 A 3 1 Lower Display The lower display shows WFS (wire feed speed), AMPS (amperage), ARC CTL (arc control), or Time. The feeder displays only preset wire speed at idle (not welding). While welding, the average amperage is displayed. The lower display shows welding sequence time when the Time LED is illuminated. 2 WFS (Wire Feed Speed) LED LED illuminates to indicate the preset wire feed value is being displayed and can be adjusted using the Adjust knob.
6-7. Feeder Set Up Push Button 3 Start Time 4 Crater Time Preflow Time 1 Postflow Time 2 Sequence Diagram Feeder Setup 1 2 Feeder Set Up Push Button LED Feeder Set Up Push Button • Press button to choose Sequence. Feeder Set Up push-button LED will illuminate. 3 Sequence LED • When the Feeder Set Up button is pressed once, the Sequence LED will illuminate and the upper display will show sequence options.
6-9. Process Set Up Push Button 1 2 3 3 Process Set Up Push Button Process Set Up LED Program Selection LEDs 2 1 Process Setup • Press the Process Set Up push button the first time will illuminate the button LED and the Process LED. The upper and lower displays will be used for Accu-pulse and only the lower display for MIG, Pulse and RMD (optional) to show the current process installed in this program. To change process, turn the adjust knob.
6-10. Reset Mode . Reset mode is not active when RST NO Program Lock is enabled. The reset mode allows the operator to reload factory program settings for all eight active programs in the unit. V A A . System configuration data will be lost during the Reset operation. Setup Adjust Arc Control Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed.
6-11. Jog/Purge 1 2 3 Jog/Purge Push Button Adjust Control Gun Trigger Receptacle 2 3 1 803 693-A The Jog/Purge switch provides the following functions: • Pressing left side of the Jog/Purge switch allows the operator to feed wire without energizing the weld power or gas valve circuit. The wire will feed at a 60 ipm rate for 3 seconds, then the rate ramps up to 700 ipm until the Jog switch is released. • The unit also provides the ability to jog the wire feeder by means of the gun trigger.
SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program . For more information on Sequence mode, see Feeder Set Up Push Button in Section 6-7. Sequence Weld Time can only be set by using an optional PDA with File Management/WaveWriter software. Parameters Volts/Arc Adjust Seconds If time is set to zero in any timed sequence, the sequence is skipped. 1. Preflow Off-5.0 . Maximum IPM may actually be 2. Postflow Off-5.0 IPM 3. Start 10.0-44.0/ 0-99 40-1400 Off-5.0 4.
SECTION 8 − MAINTENANCE 8-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Clean and tighten weld terminals. Replace unreadable labels. Replace cracked parts. Check control cord. Repair or replace cracked weld cable. Check gas hose and fittings. Check gun cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. Or Clean drive rolls.
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: ERR ERR ERR ERR ERR ERR SENS TACH MOTR WFS STRT STOP Indicates an arc start error. Indicates an arc stop error. Indicates a voltage sense error. Indicates a tachometer error. Indicates a motor error. Indicates a wire feed speed error. ERR ERR ERR ERR ERR ERR FLOW COOL FTP GND STUK PSF Indicates a gas flow error.
8-2. Diagnostics (Continued) ERR ERR ERR ERR UNIT UIM TEMP LINE ARC POL MEM MEM Indicates a temperature error. Indicates a line error. Indicates an arc error. Indicates a polarity error. Indicates a memory CRC PCM error. Indicates a memory CRC UIM error. MOTR WELD MOTR PLS OVER LOW MEM WAIT COM WAIT CRNT WFS Indicates a UIM communication error. Indicates an overcurrent error. Indicates a memory CRC motor error. Indicates a weld cycle wait error.
SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1.
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SECTION 10 − PARTS LIST . Hardware is common and 20 7 not available unless listed. 6 5 4 1 3 2 8 10 9 13 19 11 14 15 12 16 18 17 803 696-A Figure 10-1. Remote Operator Interface Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Remote Operator Interface ... 1 ............... ..................... ... 2 ............... ... 3 ............... . . . 4 . . . . PC7 . . . . . ... 5 ............... ... 6 ............... . . . 7 . . . . PC6 . . . . . ... 8 ............... . . . 9 . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Remote Operator Interface (Continued) . . . 14 . . . . PC1 . . . . . . . . 15 . . . . RC4 . . . . . . . . 16 . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . 18 . . . . . S2 . . . . . . ..................... ..................... ..................... . . . 19 . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . PLG47 . . . . . . . . . . . . . PLG48 . . . . . . . . . . . . . .
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Effective January 1, 2005 (Equipment with a serial number preface of “LF” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.
