Miller AUTO-AXCESS E ANALOG WELDING POWER SOURCES CE User manual

OM-251440K
2016−07
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Scan this tag with your mobile
device to learn more about this
product. Individual carrier rates
may apply.
Automatic Welding Interface And
Arc Welding Power Source
Start by downloading the free
mobile app at http://gettag.mobi
Auto-Axcess E Analog
Welding Power
Sources
™
CE
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com/ams
File: Advanced Manufacturing Systems
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 build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS FOR AUTO-AXCESS E 300 ANALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − SPECIFICATIONS FOR AUTO-AXCESS E 450 ANALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − LICENSE AGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − GENERAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Upper Front Panel Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Upper Rear Panel Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Lower Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Motor Control Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-12. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − RECOMMENDED SETUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
8
9
9
11
13
13
13
13
14
14
15
16
17
17
17
17
18
18
19
20
21
21
21
22
22
23
23
24
24
25
26
28
28
28
29
29
29
TABLE OF CONTENTS
8-3. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
8-4. Automated Welding Equipment Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
8-5. Process Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
8-6. Welding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
8-7. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
8-8. Using Multiple Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
8-9. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs . . . . . . . . . . . . . . . . .
35
8-10. Earth Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
8-11. 30 Points Of Mechanics In MIG Welding 30 Pts MIG − 2014-09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
8-12. Typical Robot Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
8-13. Weld Cycle Timing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
8-14. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
8-15. Stick Check Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
8-16. Arc Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
8-17. Basic Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
8-18. Electrical Functions Of Automated Welding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
SECTION 9 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
9-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
9-2. Pulse Welding Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
9-3. Front Panel Controls (See Section 9-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
9-4. Front Panel Controls - Continued (See Section 9-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
9-5. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
9-6. Front Panel Display At Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
9-7. User Interface Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
9-8. Robot Auto-Calibration Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
SECTION 10 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
10-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
SECTION 11 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
11-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
11-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
11-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
11-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
12-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
12-2. Error Code Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
12-3. E Module Board Stack Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76
12-4. Diagnostic LEDs On E Module Board Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
12-5. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
12-6. Diagnostic LEDs On Wire Feed Module PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79
12-7. User Interface Module PC7 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
12-8. Diagnostic LEDs On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
80
12-9. Automation Interface Module PC9 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
12-10. Diagnostic LEDs On Automation Interface Module PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
12-11. Network And Module Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
12-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
12-13. Check Web Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
12-14. Software Error Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86
SECTION 13 − WEB PAGES SITE TREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
SECTION 14 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
SECTION 15 − PARTS LIST FOR AUTO-AXCESS E 300 ANALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
SECTION 16 − PARTS LIST FOR AUTO-AXCESS E 450 ANALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
AUTO-AXCESS E 450 CE
AUTO-AXCESS E 300 CE
Stock Number
907443002
907442002
Council Directives:
• 2014/35/EU Low Voltage
• 2014/30/EU Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment
Standards:
• IEC 60974-1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974-10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
May 12, 2015
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
251450C
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
AXCESS E 450 W/CE
AXCESS E 300 W/CE
AUTO-AXCESS E 300 ANALOG W/CE
AUTO-AXCESS E 450 ANALOG W/CE
AUTO-AXCESS E 450 DIGITAL W/CE
AUTO-AXCESS E 300 DIGITAL W/CE
Stock Number
907439002
907440002
907442002
907443002
907496002
907497002
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822-1:2016, IEC 62822-2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non-thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
EMF Data for Non-thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory Ef­
fects
10 cm
0.17
Health Ef­
fects
10 cm
0.14
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.23
3 cm
0.13
3 cm
0.30
1 cm
1 cm
1 cm
1 cm
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
13 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
275656-A
Tony Samimi
Date tested:
2016-02-15
237 cm
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
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
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-251440 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
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 an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks 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.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-251440 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
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.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-251440 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-251440 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
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 donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
OM-251440 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surOM-251440 Page 6
chauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
OM-251440 Page 7
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-251440 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols and Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe6 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2012−05
OM-251440 Page 9
Do not remove or paint over (cover) the label.
Safe20 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
Do not use one eye bolt to lift or support unit.
Safe31 2012−05
Do not discard product with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Environmental Protection Use Period (China)
Safe123 2016−06
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
OM-251440 Page 10
V
V
>5min
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
V
Safe43 2012−05
= < 60°
Always lift and support unit using both eye bolts. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.
Safe44 2012−05
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
Direct Current
(DC)
Alternating
Current (AC)
Output
Circuit Breaker
Remote
On
Off
Positive
Negative
Voltage Input
Arc Force
Constant Voltage
Inductance
Protective Earth
(Ground)
Gas Metal Arc
Welding (GMAW)
Three Phase Static
Frequency ConverterTransformerRectifier
Increase
U0
Rated No Load
Voltage (OCV)
Hz
Hertz
I1max
V
Amperage
Line Connection
U1
IP
Primary Voltage
Degree Of
Protection
Pulsed
S
Suitable for Some
Hazardous
Locations
Rated Maximum
Supply Current
I1eff
Maximum Effective
Supply Current
U2
I2
Conventional
Load Voltage
Rated Welding
Current
Single Phase
X
%
Voltage
Duty Cycle
Percent
Three Phase
OM-251440 Page 11
Notes
OM-251440 Page 12
4-1. 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.
4-2. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Section 4-6 and 7-9 for information on connecting input power.
Input
Power
Rated
Welding
Output
Three
Phase
225 A @
25 V DC,
100%
Duty
Cycle
Wire Feed
Speed
Range**
Voltage
Range
Standard:
50-1400
ipm
(1.3-35.6 mpm)
10-44
Wire
Diameter
Range
Amperes Input At
Rated Load Output 50/60 Hz,
Three-Phase
Max
Open
Circuit Voltage
DC
Input
KW
7.2
(0.2*)
6.9
(0.04*)
400V
10.4
.030-.062 in.
(0.8-1.6 mm)
Input
kVA
80
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.
4-3. Dimensions And Weight
Hole Layout Dimensions
A
A
17-3/32 in. (434 mm)
B
17-3/8 in. (441 mm)
C
19-3/32 in. (485 mm)
D
16-3/32 in. (409 mm)
E
1/2 in. (13 mm)
21-3/4 in.
(553 mm)
C
26-1/2 in.
(673 mm)
B
Weight
117 lb (53 kg) Net
139 lb (63 kg) Ship
E
17-3/32 in.
(434 mm)
D
Ref. 250 016-D
OM-251440 Page 13
E300 Spec
SECTION 4 − SPECIFICATIONS FOR
AUTO-AXCESS E 300 ANALOG
4-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes 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.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 225 Amperes
60% Duty Cycle At 300 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 230 226-B
4-5. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
CV MODE
80
70
. This
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
VOLTGE
60
50
40
30
20
10
0
0
100
200
300
AMPERAGE
400
500
600
va_curve1 4/95
OM-251440 Page 14
Elec Serv 2014−01
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
50/60 Hz
Three
Phase
Input Voltage (V)
400
Input Amperes (A) At Rated Output
10.4
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2
10
Normal Operating Fuses 3
15
Min Input Conductor Size In AWG (mm2) 4
14
(2)
Max Recommended Input Conductor Length In Feet (Meters)
223
(68)
Min Grounding Conductor Size In AWG (mm2) 4
14
(2)
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-251440 Page 15
E300 Spec
4-6. Electrical Service Guide
4-7. Environmental Specifications
A. IP Rating
IP Rating
IP21S
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21S 2014−06
B. Information On Electromagnetic Compatibility (EMC) For Auto-Axcess E 300
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 22.51 mW (or the short−circuit power Ssc is greater than
7,106,792 VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator
if necessary, that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
C. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
D. Temperature Specifications
Operating Temperature Range
Storage Temperature Range
14 to 104 °F (−10 to 40°C)
−4 to 131 °F (−20 to 55°C)
Temp_2016- 07
OM-251440 Page 16
SECTION 5 − SPECIFICATIONS FOR
AUTO-AXCESS E 450 ANALOG
5-1. Serial Number And Rating Label Location
5-2. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Section 5-6 and 7-9 for information on connecting input power.
Input
Power
Three
Phase
Rated
Welding
Output
Wire Feed
Speed
Range**
Voltage
Range
10-44
Wire
Diameter
Range
Standard:
50-1400
ipm
(1.3-35.6 mpm)
400 V
Input: 450 A @
36.5 V DC,
100%
Duty
Cycle
.030-.062 in.
(0.8-1.6 mm)
Max
Open
Circuit Voltage
DC
Amperes Input
At Rated Load
Output 50/60 ,
Three-Phase
80
Input
kVA
Input
KW
19.46
(0.8*)
18.68
(0.17*)
400V
27.9
(0-1A*)
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.
5-3. Dimensions And Weight
Hole Layout Dimensions
A
A
17-3/32 in. (434 mm)
B
17-3/8 in. (441 mm)
C
19-3/32 in. (485 mm)
D
16-3/32 in. (409 mm)
E
1/2 in. (13 mm)
E
21-3/4 in.
(553 mm)
34-1/2 in.
(876 mm)
C
B
Weight
17-3/32 in.
(434 mm)
168 lb (76 kg) Net
185 lb (84 kg) Ship
D
Ref. 249 889-C
OM-251440 Page 17
E450 Spec
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.
5-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes 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.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
100% Duty Cycle At 450 Amperes
60% Duty Cycle At 580 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 220 485-A
5-5. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
CV MODE
80
70
. This
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
VOLTAGE
60
50
40
30
20
10
0
0
100
OM-251440 Page 18
200
300
400
AMPERAGE
500
600
700
va_curve1 4/95 − 220 486-A
5-6. Electrical Service Guide
Elec Serv 2014−01
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
be available.
50/60 Hz
Three
Phase
400
Input Voltage (V)
28
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes
1
Time-Delay Fuses 2
35
Normal Operating Fuses 3
40
Min Input Conductor Size In AWG (mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG (mm2) 4
10
(5.26)
211
(64)
10
(5.26)
Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-251440 Page 19
E450 Spec
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
5-7. Environmental Specifications
A. IP Rating
IP Rating
IP21S
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21S 2014−06
B. Information On Electromagnetic Compatibility (EMC) For Auto-Axcess E 450
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 33.41 mW (or the short−circuit power Ssc is greater than
4,789,675 VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator
if necessary, that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07
C. China EEP Hazardous Substance Information
质
量
China EEP Hazardous Substance Information
质
Hazardous Substance
部 Component Name
(适)
(if applicable)
铅
Pb
Hg
镉
Cd
铬
Cr6
苯
PBB
苯醚
PBDE
黄铜铜部
Brass and Copper Parts
X
O
O
O
O
O
装
Coupling Devices
X
O
O
O
O
O
!装
Switching Devices
O
O
X
O
O
O
"#"#配
Cable and Cable
Accessories
X
O
O
O
O
O
$
Batteries
X
O
O
O
O
O
%表&'*SJ/T 11364 规,-..
This table is prepared in accordance with China SJ/T 11364.
O:
表2该
质5该部7 8质9: 量85GB/T26572规, 限量要>?@.
Indicates that the concentration of the Hazardous Substance in all homogeneous materials of the part is below the relevant threshold of China
GB/T 26572.
X:
表2该
质AC5该部 DE8质9: 量超FGB/T26572规, 限量要>.
Indicates that the concentration of the Hazardous Substance in at least one homogeneous material of the part is above the relevant threshold of
China GB/T 26572.
HIKL限'*SJ/Z11388 规,N,.
The EFUP value of this EEP is defined in accordance with China SJ/Z 11388.
EEP_2016−06
D. Temperature Specifications
Operating Temperature Range
Storage Temperature Range
14 to 104 °F (−10 to 40°C)
−4 to 131 °F (−20 to 55°C)
Temp_2016- 07
OM-251440 Page 20
SECTION 6 − LICENSE AGREEMENT
You have acquired a device (Auto-Axcess E) which includes software licensed by Miller Electric Mfg. Co. from one or more software licensors
(EUROTECH, Inc. software suppliers). Such software products, as well as associated media, printed materials, and “online” or electronic
documentation for such software are protected by international intellectual property laws and treaties. The software is licensed, not sold. All rights
reserved.
SECTION 7 − GENERAL INSTALLATION
. Appearance of actual unit may vary from unit shown in manual.
7-1. Selecting A Location
Movement
Tipping
!
Do not move or operate
unit where it could tip.
1
OR
3
OR
Location And Airflow
4
!
Special installation may
be required where gasoline or volatile liquids are
present − see NEC Article
511 or CEC Section 20.
!
Do not stack units.
Beware of tipping.
8
9
Lifting Eyes
Lifting Forks
Use lifting eyes or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.
10 Hand Cart
18 in.
(460 mm)
Use cart or similar device to
move unit.
11 Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
loc_axcess 2015-04
OM-251440 Page 21
General
2
7-2. Connection Diagram
. The proper interface kit must
be installed in the welding
power source/interface unit to
allow it to be connected to the
robot.
1
Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
6 Robot Input/Output Cable
7 Gas And Motor Control Cable
8 Welding Power
Source/Interface Unit
9 Negative (−) Weld Cable
10 Workpiece
11 Voltage Sensing Lead
3
2
5
4
1
7
6
12
Recommended for Accu-pulse and
RMD.
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
8
12 Positive (+) Weld Cable
10
9
11
249 924-C
7-3. Upper Front Panel Receptacles
1
1
USB Host Receptacle A
USB receptacle provides connections
for various USB host devices.
Ref. 249 889-C
OM-251440 Page 22
7-4. Upper Rear Panel Receptacles
3
4
5
6
1
1
2
2
Ethernet Receptacle Port A
Ethernet Receptacle Port B
Port A and Port B are identified by the IP
address from the network server.
Ethernet
receptacles
provide
connections for either a network cable
or a laptop PC or both.
3
4
5
6
Optional MWCI Receptacle
Optional WFS (Wire Feed Sensor)
Optional GFS (Gas Flow Sensor)
Receptacle
Optional DeviceNet Receptacle
DeviceNet option provides hardware
and software that allows the welding
power source to be connected into a
DeviceNet network. Contact factory for
option details.
Ref. 249 889-C
7-5. Lower Rear Panel Receptacles And Supplementary Protectors
1
115 V 10 A AC Receptacle RC2
2
3
CB1 protects 115 volt receptacle RC2
from overload. If CB1 opens, RC2 does
not work.
6
5
1
2
Supplementary Protector CB1
Supplementary Protector CB2
CB2 protects the wirefeed motor from
overload. If CB2 opens, the wirefeeder
does not work.
. Press
button to reset breaker. If
breaker continue to open, contact a
Factory Authorized Service Agent.
4
Wirefeed/Gas Receptacle RC8
Use receptacle to connect gas and
motor control cable to power source
(see Sections 7-2 and 8 for additional
information).
3
5
4
Peripheral Receptacle RC25
Receptacle provides connection to
touch sensor, water flow switch, jog +/−,
and I/O relay contacts circuitry (see
Section 7-6).
6
Robot Interface Receptacle RC72
Use receptacle to connect robot
input/output cable (see Sections 7-2
and 8 for additional information).
Ref. 249 889-C
OM-251440 Page 23
General
Receptacle
supplies
60
Hz
single-phase power. Maximum output
from RC2 is limited by supplementary
protector CB1 to 10 amps.
7-6. Peripheral Receptacle Functions
Function
C B
D
L
E
F
M
J
H
Socket
A
Not used.
B
Not used.
C*
Circuit common.
D
Contact closure to C completes 40 volts DC
solenoid circuit to purge shielding gas line.
E
Contact closure to F indicates coolant flow switch is
closed and recirculating coolant system is
operational.
F*
Circuit common.
Jog
H**
Contact closure to circuit common advances
welding wire at wire drive assembly.
Retract
J**
Contact closure to circuit common retracts welding
wire at wire drive assembly.
K
Contact closure to L energizes Touch Sensor
circuitry.
L*
Circuit common.
M
Part touched +24 volts DC output signal referenced
to circuit common.
A
K
Purge
Coolant Flow
Switch Input
Signal
Ref. 249 889-C
Socket Information
Touch Sensor ON
And Output Signal
*Circuit common is same electrical reference point.
**Speed of Jog + (advance) and Jog − (retract) is 60 ipm for 3 seconds, then it automatically changes to 700 ipm.
Note: A customer supplied matching amphenol plug, factory Part No. 194847, [Amphenol Part No. 97-3106A-20-33P(B)(621) and strain relief
clamp 97-3057-12(0621)] is required to use peripheral receptacle.
7-7. Motor Control Receptacle Functions
Socket
G
J
K
Socket Information
C
A
F
E
H
D
B
Ref. 249 889-C
OM-251440 Page 24
A
Not used.
B
Motor negative (−).
C
Tach A.
D
Motor positive (+).
E
Tach common.
F
Gas valve.
G
Electrode sense.
H
Tach +5 volts DC.
J
Tach B.
K
Gas valve.
7-8. Measuring Input Capacitor Voltage
Tools Needed:
1
5/16 in.
!
Turn Off welding power
source, and disconnect
input power.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
discharged before working
on unit.
2
Remove cover
+ lead to left bus terminal, − lead to right bus terminal
1
2
1
Power Interconnect Board
PC2
2
Voltmeter
Measure the DC voltage across the
+ bus terminal and − bus terminal on
PC2 as shown until voltage drops to
near 0 (zero) volts. Measure input
capacitor voltage on both inverter
assemblies before proceeding.
. If the capacitor voltage does
not drop to near zero after
several minutes, use a bleeder
resistor of between 25 and
1000 ohms, at least 5 watts,
#16 AWG 1000 volts DC
insulating rating wire
to
discharge the capacitor(s).
3
+ lead to left bus terminal, − lead to right bus terminal
Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
General
Proceed with job inside unit.
Reinstall cover when finished.
3
Typical Bleeder
Resistor
25 to 1000 ohm, 5 watt resistor
#16 AWG 1000 volts DC
insulation rating, approx 3 in
(76 mm) leads
802 985 / Ref. 249 744-B
OM-251440 Page 25
7-9. Connecting 3-Phase Input Power
3
= GND/PE Earth Ground
9
11
8
L1
5
L2
10
7
L3
1
6
7
Route input conductors to filter board.
Route ground conductor through tubing and
current transducer to ground terminal.
3
5
4
2
Tools Needed:
5/16 in.
Input5 2016-06 − 249 889-C / Ref.803 855-B / Ref. 803 766-C / 219 842-A / 251 184-C
OM-251440 Page 26
7-9. Connecting 3-Phase Input Power (Continued)
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 7-8 before
proceeding.
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input
conductors from unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
!
Make input power connections to the
welding power source first.
!
Always connect green or green/yellow
conductor to supply grounding
terminal first, and never to a line
terminal.
See rating label on unit and check input voltage available at site.
1 Input Power Conductors (Customer
Supplied Cord)
Select size and length of conductors using
Section 4-6 or 5-6. Conductors must comply
with national, state, and local electrical codes.
If applicable, use lugs of proper amperage
capacity and correct hole size.
Welding Power Source Input Power
Connections
2 Strain Relief (Customer Supplied)
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief. Tighten strain relief.
S Use large strain relief for input conductor
size 8 and larger.
S Use small strain relief with reducing washers for input conductor size 10.
3 Current Transducer
4 Welding Power Source Grounding
Terminal
5 Green Or Green/Yellow Grounding
Conductor
Route green or green/yellow grounding
conductor through current transducer and
connect to machine grounding terminal first.
6 Welding Power Source Line Terminals
7 Input Conductors (L1, L2 And L3)
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Reinstall side panel onto welding power
source.
Disconnect
Device
Input
Power
Connections
8 Disconnect Device (switch shown in the
OFF position)
9 Disconnect Device Grounding Terminal
10 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding terminal first.
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
11 Over-Current Protection
Select type and size of over-current protection using Section 4-6 or 5-6 (fused disconnect switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
Input5 2016−06
General
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-251440 Page 27
7-10. Touch Sensor Operation
The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source. The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle. Turning on touch sensor causes a DC voltage to be
present on the welding wire. When welding wire touches the weldment, the voltage sensing circuit closes, and a +24 volts DC output signal is sent to the
robot control indicating weldment detection. Touch sensor DC voltage on the welding wire is 80 volts DC. As soon as touch sensor turns on, WIRE LIVE
appears on the front panel display.
7-11. Remote Program Select
. Remote Program Select is factory set to “On”. Use the web pages to turn this function “Off”.
When Remote Program Select is On, a remote device or robot pendant may be used to select programs. When Off, program selection must be done
from the welding power source front panel.
7-12. Remote Program Setting
. When Remote Program Select is “On”, program selection will be determined by remote input once a weld is initiated. Prior to welding, program
selection can be done in a normal manner from the welding power source front control panel.
See the following table for the remote program select binary code.
Program No.
Output A
Output B
Output C
1
Off
Off
Off
2
On
Off
Off
3
Off
On
Off
4
On
On
Off
5
Off
Off
On
6
On
Off
On
7
Off
On
On
8
On
On
On
Notes
OM-251440 Page 28
SECTION 8 − RECOMMENDED SETUP PROCEDURES
8-1. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
. For welding output terminal connections see Sections 7-2 and 8-3 for
typical connection processes.
2
1
output term1 2015−02 / Ref. 249 889-C
8-2. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
150 ft
(45 m)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
500
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x3/0 (3x95)
600
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
700
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
800
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x4/0 (3x120)
3x4/0 (3x120)
4x4/0 (4x120)
4x4/0 (4x120)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 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-L 2015−02
. In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding characteris-
tics with undersized cables. A recommendation for weld cable size is a minimum of 2/0 for 300 ampere welding power sources and 4/0 for 450
ampere welding power sources when total cable length is less than 100 ft (30m).
OM-251440 Page 29
General
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
8-3. Connecting To Weld Terminals
. If using an electrode negative (straight polarity)
process, the volt sense lead must be connected
to the work.
1
4
Do not place
anything between
weld cable terminal
and copper bar.
2
3
Correct Installation
Incorrect Installation
Tools Needed:
3/4 in. (19 mm)
!
Turn off power before connecting to
weld output terminals.
!
Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your
machine.
Determine total cable length in weld circuit
(both positive and negative cables
OM-251440 Page 30
249 889-C
combined) and maximum welding
amperes. See Section 8-2 to select proper
cable size.
1
Weld Output Terminal
2
Supplied Weld Output Terminal Nut
3
Weld Cable Terminal
4
Copper Bar
Remove supplied nut from weld output
terminal. Slide weld cable terminal onto
weld output terminal and secure with nut so
that weld cable terminal is tight against
copper bar. Do not place anything
between weld cable terminal and copper
bar. Make sure that the surfaces of the
weld cable terminal and copper bar are
clean.
8-4. Automated Welding Equipment Recommendations
Planning proper layout and routing of welding cables and control cables should be considered when setting up automated equipment.
1
Whenever possible all cables should be routed out of the path of moving equipment.
2
Cable installation in a stationary position will decrease the likelihood of wires breaking down in the cable.
3
Cables that are moving will breakdown over time. This time can be increased by making sure there are no stress points when installing cables,
and deciding how and where to tie cables down.
4
If at all possible, do not route weld cables and control cables together. Leave as much space as reasonable between the weld cables and any
other control cables. Welding generates electrical noise which is present on the weld cables (see 8-3 for grounding information).
8-5. Process Considerations
To obtain the most performance from the welding equipment, it is important to use the right transfer mode for the application. There are no hard and fast
rules, but there are general guidelines to follow when making a selection. The transfer modes available depend the power source being used. The
possible transfer modes are as follows: Short Arc, Spray, Pulsed Spray, Accu-pulse, and RMD (Regulated Metal Deposition).
Process
Weld Puddle
Control
Standard
Spray
Pulsed
Spray
Flat/Horizontal
Accu-pulset
Standard
Short Circuit
All Position Performance
RMDt Regulate Metal
Deposition
Thin Material/Gap Filling
Note: To achieve optimum performance, 4/0 welding secondary cable is recommended and the supplied work sense lead
must be connected as close to the arc as possible.
General
Notes
OM-251440 Page 31
8-6. Welding Circuit
. Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics.
1
2
3
4
5
6
7
Standard Welding Circuit
ECL
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
Robot
Workpiece
In pulse welding applications using
inverter power
sources,
cable
resistance can result in less than
satisfactory performance. In most
cases, a welding circuit length of 50 ft
(15 m) or less will provide satisfactory
performance with a standard welding
circuit connection.
Gun
Travel
The length of a welding circuit is
determined as follows:
WCL
Welding Circuit = Electrode Cable
Length (ECL) + Work Cable Length
(WCL) + Workpiece Length (WL)
See Section 8-2 for weld cable size.
Variations in welding processes and
welding circuit resistance can affect
apparent voltage at the welding arc.
Voltage sensing can improve welding
performance by providing accurate
feedback to the welding power source.
WL
Current Flow Path
It is important to connect the voltage
sensing lead as near to the weld as
possible, but not in the return current
path.
Large Weld Structure
ECL
WCL
WL
Current Flow Path
250 489-C
OM-251440 Page 32
8-7. Arranging Welding Cables To Reduce Welding Circuit Inductance
Bad
1
2
3
4
5
6
7
1
6
2
The arrangement of the cables has an
effect that is significant to the welding
properties. As an example, Accupulse
and RMD welding processes can
produce high welding circuit inductance
depending on cable length and
arrangement. This can result in limited
current rise during droplet transfer into
the welding puddle.
3
5
The electrode sense lead is contained
in the feeder control cable and
automatically becomes enabled for all
semi-automatic processes. The work
sense lead connects to the Axcess
welding power source 4-pin connector
located above the negative output
terminal. This work sense lead
automatically compensates for work
cable voltage drop when connected to
the welding power source.
4
7
Better
Do not coil excess cables. Use cables
that are the appropriate length for the
application. Whenever using long weld
cables [longer than 50 ft (15 m)] try to
arrange positive and negative weld
cables together to reduce the magnetic
field surrounding the cables. Avoid
coupling the feeder and work sense
leads with the weld cables.
1
6
2
General
3
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
Robot
Workpiece
4
5
7
Best
1
6
3
2
4
5
7
250 503-C
OM-251440 Page 33
. Welding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensify.
8-8. Using Multiple Welding Power Sources
1
1
3
3
2
2
4
5
5
4
6
6
Gun
Travel
Current Flow Path
250 504-C
1
Welding Power Source
possible, but not in the return current path.
2
Electrode Cable
3
Feeder Cable
Connect voltage sensing lead at the end of
the weld joint.
4
Work Cable
5
Voltage Sensing Lead
6
Robot
7
Workpiece
Each welding power source should have a
separate work cable connection to the
workpiece. Do not stack or join work
cables together at the workpiece. This is
very important for pulse welding applications.
It is important to connect the voltage
sensing lead as near to the weld as
OM-251440 Page 34
The direction of the welding path should be
away from the work cable connections.
Connect work clamp at the beginning of the
weld joint.
Each welding gun should have its own
source of shielding gas. Use a separate
shielding gas regulator and shielding gas
connection for each welding gun.
Arc blow is the deflection of a welding arc
from its normal path due to magnetic
forces. It will adversely affect the
appearance of a weld, cause excessive
spatter, and impair the quality of a weld.
Arc blow occurs primarily during the
welding of steel or ferromagnetic metals.
Weld current will take the path of least
resistance, but not always the most direct
path through the workpiece to the work
lead connection. The most intense magnet
force will be around the arc due to a
difference in resistance for the magnetic
path in the base metal. The work clamp
connection is important and should be
placed at the starting point of a weld. It is
recommended to have as short of an arc as
possible so that there is less of an arc for
the magnetic forces to control. Conditions
affecting the magnetic force acting on the
arc vary so widely that the reference here
is only about cabling connections and arc
preferences.
8-9. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs
A. Bad Setup
1
1
3
3
2
4
2
5
4
5
General
6
6
Current Flow Path
250 512-C
1
2
3
4
5
6
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
Robot
7
Workpiece
This arrangement is a bad setup due to
sensing leads being directly in the current
flow path of the welding arc. Interaction
between welding circuits will affect voltage
drop in the workpiece. The voltage drop
across the workpiece will not be measured
correctly for the voltage feedback signal.
Voltage feedback to the welding power
sources will not be correct at either sense
lead and result in poor arc starts and arc
quality.
OM-251440 Page 35
B. Better Setup
1
2
3
1
4
6
5
3
7
2
6
4
5
Current Flow Path
250 513-C
1
2
3
4
5
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
OM-251440 Page 36
6
Robot
7
Workpiece
This arrangement is a better setup for
supporting separate voltage feedback to
the welding power sources. The most
accurate voltage sensing may not be
achieved due to voltage drops in the
workpiece.
This
may
require
compensation in the welding parameters.
C. Best Setup
1
2
3
1
6
3
4
7
5
5
2
4
General
6
Current Flow Path
250 515-C
1
2
3
4
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
5
Voltage Sensing Lead
6
Robot
7
Workpiece
This arrangement is the best setup for
proper voltage sensing at the workpiece.
Voltage feedback to the welding power
sources will more accurate and result in
reliable arc starts and better arc quality.
OM-251440 Page 37
8-10. Earth Grounding
When using a robot or any programmable controls, it is necessary to connect equipment to a good earth ground. Grounding helps eliminate electrically
generated noise from corrupting processing data or the potential damage to sensitive electrical components. Electrical noise is an issue anytime high
frequency TIG equipment or inverter type power supplies are used in the area. A method for checking for a good earth ground is shown below. Also, be
sure to a good connection to the earth ground.
110 Volts AC
100W Light Bulb
Neutral
V
1 Volt 1 W
Earth Ground Being Measured
Measuring Facility (Earth) Ground Resistance
The resistance of an earth ground can be measured using a 100W light bulb, an ac voltmeter and a 110 volts AC electrical drop. As shown in the circuit,
the 110 volts AC (hot) supply and the 100W light bulb approximate a 1 ampere current source when the light bulb circuit is completed by connecting to
the earth ground. The AC voltmeter, referenced to the AC neutral line, can then be used to measure the voltage rise due to the 1 ampere current source
through earth ground. Each volt of rise on the earth ground represents 1 ohm of resistance. A resistance of less than 10 ohms at the earth ground should
be adequate.
OM-251440 Page 38
OM-251440 Page 39
Line
Disconnect
Switch Box
5 ft.
(1.5 m)
Welding
Power
Source
Work Weld
Cable
15 ft.
(4.5 m)
Customer Supplied Driven Ground Rod
Or Separate Earth Ground Connection
Less Than 100 Ohms To Building Ground
10 ft. (3 m)
Minimum
Worktable
Insulating
Plate
Under Robot
Make Separate Equipment
Earth Ground Using A Minimum
Of No. 3 Gauge Copper Braided
Cable That Provides A Resistance
Value Less Than 100 Ohms Between
The Component Connection And
The Ground Wire
5 ft.
(1.5 m)
Insulating Liner
Strips Under Both
Support Channels
Robot
Control
General
If Using
Conduit,
Isolate It
From Robot
Control
Cabinet
Existing
Input Power
Supply Ground
Line
Disconnect
Switch Box
Existing
Input Power
Supply Ground
SB-136 221-A
Use Proper Size Input And Ground
Conductors For The Input Power
Supply Line Voltage
Input Power
Supply Line
Make Ground
Lead 5 ft. (1.5 m)
To 10 ft. (3 m) Longer
And Coil It Inside
Robot Control
Line Disconnect Switch Box
For Input Power To Fixture
Positioning And Peripheral
Equipment
Input Power
Supply Line
Figure 8-1. Earth Ground Connections To Stationary Robot System Components
Use Proper Size Input And Ground
Conductors For The Input Power
Supply Line Voltage
Existing
Input Power
Supply
Ground
Input Power
Supply Line
IMPORTANT: DO NOT mount anything to robot control cabinet.
8-11. 30 Points Of Mechanics In MIG Welding
30 Pts MIG − 2014-09
Primary Power
S
Check primary power connection at line disconnect switch or receptacle and/or cord plug.
S
Check primary power connection at welding power source.
Secondary Power
S
Check secondary weld output connections at welding power source.
S
Inspect condition and routing of positive weld cable to wire drive motor.
S
Check connection of positive weld cable to wire drive motor.
S
Inspect condition and routing of negative weld cable to fixture.
S
Check connection of negative weld cable to fixture.
S
Inspect condition of any rotary grounds, grounding shoes or other auxiliary grounds.
S
Check installation, routing and condition of welding gun.
Shielding Gas
S
Check gas hose connection to shielding gas supply regulator.
S
Check shielding gas flow rate.
S
Check gas hose routing.
S
Check gas hose connection at wire drive housing.
S
Check gun connection at wire drive and be sure O−rings seal at drive housing.
S
Check condition of gas diffuser.
S
Check condition of nozzle.
S
Check O-ring for proper sealing at nozzle.
Welding Wire
S
Inspect condition of de-reeler. Check for wear at quick-connect coupling and replace if necessary.
S
Check placement of payoff pack or drum for smooth feed path.
S
Inspect condition and routing of input conduit.
S
Check installation of quick-connect coupling at rear of wire drive so that it does not contact drive rolls. Check for wear and replace if necessary.
S
Check drive rolls and replace if worn.
S
Check for drive roll tension setting.
S
Check intermediate guide for proper size to match wire size and replace if worn.
S
Check for proper length of liner at both ends and be sure it is cut without burrs.
S
Check liner for proper size to match wire size.
S
Check liner for wear and clean out to prevent plugging.
S
Check contact tip for proper size to match wire size.
S
Check contact tip for wear and change at regular intervals.
S
Check contact tip for a tight fit and secure installation at gun.
OM-251440 Page 40
8-12. Typical Robot Signals
A. Signals Robot Must Have
1
Arc start (referred to as contactor on circuit diagram)
2
Arc detected (current detection)
B. Commonly Used Robot Signals
1
Purge (gas on)
2
Jog forward (motor start)
3
Jog reverse (retract)
4
Wire speed analog command (wire speed control)
5
Voltage/trim/arc adjust analog command (depends on selected mode of transfer) Voltage-MIG, Trim-M technology pulse, Arc adjust-Accupulse (basically arc length control)
C. Often Used Robot Signals
1
Standby signal (this means power source is ready to weld)
2
Remote program select (allows robot to change programs)
3
Wire stuck signal (relay closure)
4
Error signal (relay closure)
D. Seldom Used Robot Signals
1
Touch Sense
2
Water flow error (if using a water flow switch hooked to the power source)
3
Current feedback
4
Voltage feedback
General
Notes
OM-251440 Page 41
8-13. Weld Cycle Timing Charts
These charts illustrate the operation of gas valve, motor speed, voltage/arc length control, and arc detected.
1
Pressing the start button.
2
Preflow time begins if the programmed parameters in the Auto-Axcess are used.
3
Start wire feed begins at run-in speed until an arc is established. This is also the point that the arc detected signal pulls in when the current
reaches 50% of expected current and arc voltage is between 20 to 60 volts DC.
4
Start time begins if the programmed parameters in the Auto-Axcess are used.
5
Weld parameters from the program are used for the welding operation.
6
Crater time begins if the programmed parameters in the Auto-Axcess are used.
7
End routines that started at beginning of welding operation, including Sharp start routine and stick check routine (this operation runs for approximately 250 to 500 milliseconds)
8
End of the welding arc and the point that arc detected signal opens.
9
Postflow time begins if the programmed parameters in the Auto-Axcess are used.
4
1
5
3
6
2
7
8
Gas
On
1
9
Off
5
Representative Of
Possible Wire Feed
Speed Values
3
350 IPM
300 IPM
2
6
300 IPM
7
100 IPM
0 IPM
2
3
Representative Of
Possible MIG Arc
Voltages
Using
Start And Crater
27.5 VDC
5
24 VDC
0 VDC
3
6
20 VDC
7
7
On
Arc Detected
Off
OM-251440 Page 42
9
8
8-14. Touch Sensor Operation
The touch sensor feature allows the robot to locate a weldment using the wire feed system and the welding power source. The sense leads (weld output
terminals on some models) provide a path for touch sensor voltage. Touch sensor operation is turned on by a contact closure to the Peripheral
receptacle RC25 sockets K and L (see Section 7-6) or at the 72-socket receptacle RC70 sockets 17 and 28 (Auto-Axcess models). The closure is
provided by the robot controller. When touch sensor is turned on “LIVE WIRE” will appear on the power source displays. The voltage at the welding wire
is 80 volts DC. Generally, when the touch sensor is turned on, the robot is programmed to move slowly towards the workpiece. Once the workpiece is
touched, the voltage sensing circuit closes and sends a +24 volts DC signal to the robot controller. The touched signal will remain present until the touch
sensor operation is turned off by opening the contacts at the robot controller (see robot controller Owner’s Manual for specific touch sensor set-up
information).
Some uses for the touch sensor operation are as follows:
1
Locating welding seam
2
Identify which part is in the fixture
3
Identify what sized part is in the fixture
4
Identify what parts are installed on a weldment
5
Use for automatic tool point correction systems.
8-15. Stick Check Function
A stick check function removes welding wire that has stuck to the workpiece at the end of a weld. Automated systems should use this function to prevent
damaging automated equipment that could potentially move before the wire is released from a workpiece.
The welding power source performs a stop routine call sharp start at the end of a weld that usually prevents wire from sticking to the workpiece. If sharp
start does not remove the wire, the power source goes through a stick check routine. The stick check turns on the power source at a minimum amount of
output. If current flows, the welding wire must be shorted to the workpiece. The output rises to burn off the short and then current flow is checked again.
The stick check runs for approximately 250 ms and if it has not cleared the short during this time, ERR STUK will appears on the displays. The operator
must remove the welding wire from the workpiece manually and reset the power source (see Section 12-2).
Information to remember about stick check is the following:
1
Some robots have stick check as part of their functions and it can be turned on or off in the robot. Typically, the robot stick check works fine;
however, only one stick check routine should be active, either the robot function or the power source function, not both.
2
When programming the movement of the robot arm, be sure to leave enough time for the stick check to perform its function. The power source
stick check time is approximately 350 ms.
Arc blow is the deflection of the welding arc from its normal path due to magnetic forces. This condition is usually encountered in direct current welding of
magnetic materials, such as iron and nickel. Arc blow can happen in alternating current welding under certain conditions, but these cases are rare and
the intensity of the arc blow is always less severe. Direct current flowing through the electrode and base metal will set up a magnetic field around the
electrode. This magnetic field tends to deflect the arc to the side at times, but usually the arc deflects either forward or backwards along the joint.
Back blow is encountered when welding toward the work cable connection on a workpiece near the end of a joint or into a corner. Forward blow is
encountered when welding away from the work cable connection on a workpiece at the start of a joint. In general, arc blow is the result of two basic
conditions:
1
The change of current flow direction as it enters the work and is conducted toward the work cable.
2
The asymmetric arrangement of magnetic material around the arc, a condition that normally exists when welding is performed near the end of
ferromagnetic materials.
Although arc blow cannot always be completely eliminated, it can be controlled or reduced to an acceptable level through knowledge of the two conditions listed above.
Except in cases where arc blow is unusually severe, certain steps can be taken to eliminate or reduces its severity. Some or all of the following steps
may be necessary:
1
Place work cable connection as far as possible from joints to be welded.
2
If back blow is the problem, place the work cable connection at the start of the joint to be welded and weld toward a heavy tack weld.
3
If forward blow is the problem, place the work cable connection at the end of the joint to be welded.
4
Position electrode angle so that arc force counteracts arc blow.
5
Use the shortest possible arc that maintains good welding practices (this helps arc force to counteract arc blow).
6
Reduce welding current if possible.
7
Weld toward a heavy tack weld or runoff tab.
8
Use the back step sequence of welding.
9
Change to an AC welding operation which may require a change in electrode classification.
10
Wrap the work cable around the workpiece in the direction that sets up a magnetic field to counteract the magnetic field causing the arc blow.
OM-251440 Page 43
General
8-16. Arc Blow
8-17. Basic Welding Troubleshooting
Listed below are some problems, causes and remedies related to welding operations; however, this list does not contain every possible condition that
could be encountered in welding.
Trouble
No weld output; unit completely
inoperative.
Probable Cause
Remedy
Line disconnect switch in Off position.
Place switch in On position.
Power source switch in Off position.
Place switch in On position.
Primary power fuse blown or circuit breaker
tripped.
Replace fuse or reset circuit breaker and check input voltage.
Weld output is present, but wire stops Wire feeder protective fuse blown or circuit breaker
feeding while welding.
tripped.
Replace fuse or reset circuit breaker and find overload condition.
OM-251440 Page 44
No start input signal to weld control.
Check external start, PLC, or robot signal to weld
control.
Wire feeder drive rolls misaligned.
Align drive rolls.
Wrong size drive rolls.
Replace with proper size drive rolls.
Too much or too little drive roll pressure.
Adjust drive roll pressure.
Too much tension set at wire spool.
Reduce wire spool tension.
Restriction in unspooler or drum adapter.
Replace unspooler or repair restriction.
Feeder motor burnt out.
Test motor and replace if necessary.
Gun liner dirty or restricted.
Remove gun liner and clean or replace.
Wrong type or size of liner.
Install proper size liner.
Broken or damaged gun or torch.
Replace faulty parts.
Contact tip opening restricted.
Replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Sharp bends or kinks in gun cable or liner.
Straighten gun cable and/or replace liner.
Inlet cable too long.
Reduce distance to shorten inlet cable or use an intermediate drive.
Gun overheating.
Use gun with proper amperage rating.
Wrong size wire.
Match wire size to liner and contact tip.
Guides rubbing on drive rolls.
Adjust or position guides properly.
Drive rolls jammed.
Remove foreign object from gears.
Motor cable disconnected or damaged.
Connect, repair or replace motor cable.
Porosity in weld.
Excessive spatter.
Probable Cause
Remedy
Dirty base metal, heavy oxides, mill scale, oil, etc.
Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Regulator/flowmeter faulty.
Adjust or replace regulator/flowmeter.
Gas cylinder valve closed.
Open gas cylinder valve.
Gas regulator diaphragm defective.
Replace regulator.
Flowmeter cracked or broken.
Repair or replace flowmeter.
Gas hose disconnected or leaking.
Connect or replace gas hose.
Too much or too little gas flow.
Adjust for proper gas flow.
Moisture in shielding gas.
Replace gas cylinder or supply.
Wrong gas for wire type or transfer mode.
Use correct shielding gas.
Feeder gas solenoid faulty.
Replace solenoid.
Gun or outlet cable leaking.
Repair or replace faulty parts.
Wire feed speed setting too high.
Reduce wire feed speed.
Contact tip extends too far out of nozzle.
Adjust or replace parts (max distance should not
exceed 1/8 in (3.2 mm).
Nozzle to work distance too large.
Reduce nozzle to work distance.
Incorrect gun or torch angle.
Set proper gun angle (porosity or dirty welds mean
gun angle is too large).
Nozzle restriction.
Clean off spatter or remove restriction.
Breeze or drafts in weld zone.
Shield weld zone from drafts.
Low shielding gas cylinder pressure.
Replace gas cylinder.
Gas leak at gun to feeder connection.
Properly install gun or replace O-rings at gun
connector.
Voltage set too high.
Reduce voltage setting (reduce trim or arc adjust
for pulse welding).
Incorrect gun or torch angle.
Set proper gun angle.
Too much or too little gas flow.
Adjust for proper gas flow.
Wrong gas for wire type or transfer mode.
Use correct shielding gas.
Wrong electrode wire type or size.
Use proper electrode wire.
Wrong inductance setting.
Adjust inductance.
Electrode wire dirty or old.
Replace with new electrode wire.
Oily or dirty base metal.
Clean base metal by brushing, grinding or use
chemical cleansing before welding.
Excessive wire stick-out or nozzle to work distance Adjust wire stick-out or reduce nozzle to work
too great.
distance.
Wrong transfer mode.
Set proper transfer mode.
Travel speed too slow.
Increase travel speed so that arc is on leading edge
of weld puddle.
OM-251440 Page 45
General
Trouble
Trouble
Wandering, hunting or erratic arc.
Probable Cause
Restriction in unspooler or drum adapter.
Replace unspooler or repair restriction.
Dirty or worn gun liner or inlet cable.
Remove gun liner or inlet cable and clean or
replace.
Sharp bends or kinks in gun cable or liner.
Straighten gun cable and/or replace liner.
Loose or worn contact tip.
Tighten or replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Gun overheating.
Use gun with proper amperage rating.
Loose power cables or other electrical
connections.
Tighten, repair or replace connections or cables,
also check all rotary or brush type connections.
Incorrect gun or torch angle.
Set proper gun angle.
Too much or too little gas flow.
Adjust for proper gas flow.
Moisture in shielding gas.
Replace gas cylinder or supply.
Wrong gas for wire type or transfer mode.
Use correct shielding gas.
Wrong program selection for pulse welding.
Make proper program selection.
Improper or unsteady analog command from robot
controller.
Check signal from robot controller (as a troubleshooting aid go to power source control of voltage
and wire speed).
Gun or outlet cable leaking.
Repair or replace faulty parts.
Incorrect nozzle to work distance.
Set proper distance [3/8 in to 5/8 in (9.5 to 15.9 mm)
for short arc, 5/8 in to 1 in (15.9 to 25.4 mm) for
pulse welding, and 3/4 in to 1-1/4 in (19.1 to 31.8
mm) for spray welding].
Voltage sensing leads open or shorted.
Repair or replace voltage sense leads.
High frequency noise in the area.
Be sure proper grounding methods are followed
when TIG or plasma equipment is used in the area.
Arc blow.
see Section 8-16.
Drive motor tachometer or motor cable open or
shorted.
Check drive motor tachometer and cables, and repair or replace.
Wrong size drive rolls.
Replace with proper size drive rolls.
Too much or too little drive roll pressure.
Adjust drive roll pressure.
Welding wire burns back to contact tip at Restriction in wire feed system.
the start of a weld.
Worn drive rolls.
Check inlet cable, gun liner and wire guides.
Replace drive rolls.
Wrong size drive rolls.
Replace with proper size drive rolls.
Improper start parameters.
Adjust start parameters.
Worn contact tip.
Replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Not enough cast in welding wire.
Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip Restriction in wire feed system.
during welding.
Worn drive rolls.
Check inlet cable, gun liner and wire guides.
Replace drive rolls.
Wrong size drive rolls.
Replace with proper size drive rolls.
Too much or too little drive roll pressure.
Adjust drive roll pressure.
Worn contact tip.
Replace contact tip.
Wrong size or type of contact tip.
Replace with proper size and type contact tip.
Not enough cast in welding wire.
Add a wire straightener to put cast in wire.
Welding wire burns back to contact tip at Welding power source output not shutting off.
the end of a weld.
Burnback setting too high or too long.
OM-251440 Page 46
Remedy
Make sure all switches are in correct position, repair power source if necessary.
Adjust burnback setting or turn off completely.
Trouble
Probable Cause
Remedy
Shutdown at arc initiation using power No voltage feedback signal.
source and feeder or interface.
Broken or disconnected voltage feedback lead, no
open circuit voltage, check power source.
No current feedback signal.
Poor parameters, open in weld circuit, faulty hall
device, check power source.
No tachometer sensing.
No wire speed command from robot, material
jammed in drive gears, faulty tachometer in drive
motor, wire feed drive circuit board, or motor cable,
check wire feed system.
Poor parameters preventing arc stability.
Check for proper pulse program, material, welding
wire, shielding gas, voltage setting, and wire speed
setting.
Arc start error.
Check contact tip, wire feed system and weld
circuit.
No start signal from robot.
Check robot setup and interconnect cable connection between robot controller and interface.
No wire feed with wire feed motor running.
Wire stuck in contact tip, worn or wrong size drive
rolls, improper drive roll pressure setting, or wire
not unspooling or restriction in drum adapter, check
wire feed system.
Shutdown at arc initiation using robot No arc detected.
controller.
Robot times out before arc detected.
Check for arc detect signal coming from interface.
Add more time for robot arc detect input, verify weld
parameters, and check weld circuit.
Robot command scaling not set properly.
Set proper robot command scaling.
Time between welds too short.
Adjust welding cycle time.
Welding sequence problems.
Power source should energize and welding wire
should start feeding at the same time.
No wire feed speed command.
Set wire feed speed.
No voltage command.
Set voltage.
Poor connection in weld circuit.
Check welding gun, torch, contact tip adapter, contact tip, weld cable connections and any rotary or
brush type connection.
Improper gas flow causing start and timeout
issues.
Check for correct shielding gas and flow
adjustment.
OM-251440 Page 47
General
Shutdown at arc initiation due to weld cir- Poor part fit up at weld joint, wire not making contact Check part consistency for fitup and/or position gun
cuit condition.
with workpiece.
so wire always contacts part.
8-18. Electrical Functions Of Automated Welding Systems
Several important items to know about any automated welding system are as follows:
1
To troubleshoot any system, determine the functions of the individual parts of the system.
2
Determine what inputs and outputs are needed to control the timing, amount of weld output, and the movements of the part or welding gun.
3
Determine where the previous mentioned signals come from e.g. PLC, robot, or from within an interface device.
4
Determine which functions ar not occurring properly and troubleshoot the appropriate circuit or replace the faulty component in the system.
A. Function Of Power Sources
1
Turns weld power on/off (commonly referred to as contactor).
2
Controls weld output (voltage in CV mode and amperage in CC mode).
B. Function Of Fixed Automation Interface
1
Signals the power source to turn on weld output.
2
Energizes the gas solenoid.
3
Energizes the wire drive motor.
4
Controls the wire speed.
5
Signals the power source as to how much output to deliver (voltage or amperage depending on weld process).
6
Controls the timing of the a weld sequence that is dictated by the interface or some of the weld sequence that is dictated by the interface or
some external remote device such as a PLC.
7
Typically sends an arc established signal through the use of a relay closure.
C. Function Of Programmable Logic Controller (PLC)
1
Receives inputs from external devices such as the relay closure from an automation interface to determine arc initiation or arc error, or any
safety features that may prevent the start of a weld cycle or shut down the system to prevent injuries.
2
Controls external devices with the use of electronic switches such as starting the motor that rotates the workpiece.
3
Controls the timing of the weld cycle and movement of the workpiece or the welding gun through the programming of the PLC.
D. Function Of Limit Switches/Proximity Switches
1
Limit switches are used to determine mechanical position of workpieces, positioners, guns, or for safety devices. These switches are either
open or closed.
E. Function Of Flexible Automation Interfaces
1
Signals the power source to turn on weld output.
2
Energizes the gas solenoid.
3
Energizes the wire drive motor.
4
Controls wire speed by using internal commands or analog commands from the robot controller.
5
Signals the power source for amount of weld output to deliver (voltage or amperage depending on weld process) using internal commands or
analog commands from the robot controller.
6
Accept or ignore wire speed and voltage analog signals from the robot controller.
7
Control weld sequence timing as directed by the interface or robot controller.
8
Send an arc established signal using a relay closure.
9
Accept an arc on signal from the robot controller.
10
Check current flow to determine if wire is stuck to the workpiece at the end of a weld.
11
Provides a remote E-Stop.
12
Accepts a remote purge signal.
13
Accepts a remote jog signal for forward or reverse.
14
Provides arc error output relays.
15
Receives remote program select signals to allow program changes while welding or at the start of any weld.
There are three modes of interface operations available depending on robot controller capabilities:
1
Arc On, No Analog (power source) mode uses the robot controller to send a signal to start the welding process and the interface controls the
timing of the weld sequence (preflow, run-in, start time, weld, crater, and postflow).
2
Arc On, Analog (shared control) mode uses the robot controller to send a signal to start the welding process and send analog commands to the
interface to control the amount of weld output and wire speed. The interface will still control preflow, run-in, start time, and postflow.
3
PS, Wire, Gas, & Analog (robot control) mode use the robot controller to send a signal to start gas flow, a signal to start the wire feed motor, and
a signal to energize the power source. The robot controller also sends analog commands to the interface to control the amount of weld output
and wire speed.
OM-251440 Page 48
. One of the three modes is selected to match the capabilities and intended use of the robot controller. The Arc On, No Analog mode is a good
selection for testing the interface and power source functions in a system.
The requirements for making a MIG weld are as follows:
1
The gas solenoid must be energized.
2
The power source must be energized.
3
The wire drive motor must be turned on.
4
A wire speed command must be present at the main control board in the power source.
5
A weld output command must be present at the main control board in the power source.
F. Function Of Gas Flow
The gas solenoid can be energized for a weld in one of two ways, either by a remote start signal from an external device or by a gas on signal from an
external device. The signal type will depend on system setup and is important to know when troubleshooting a shielding gas problem in the welding
operation. Severe porosity will occur if there is no signal to energize the gas solenoid or if the gas solenoid fails to energize. Even when the solenoid
energizes, proper gas flow and gas mixture are necessary to obtain a good quality weld.
G. Function Of Power Source Open Circuit Voltage
The power source requires two signals to start and control weld output. First, a start signal to energize the power source in an automated system is
provided by an input signal from an external device (normally referred to as arc on, start, or contactor). The actual turning on of the power source may
also be dependent on the sequencing information programmed into the interface or robot controller. The power source should energize at the same time
the drive motor turns on which will occur after preflow given there is preflow time programmed into the weld sequence. If there is no output start signal
from an external device or the power source fails to energize, there will not be any welding. Second, control of weld output is accomplished by an analog
signal (command signal) supplied to the main control board in the power source. This command signal is provided by an interface to the power source.
Control of the signal is established by settings in the interface or by analog signals from a robot controller. If the command signal is not present, the result
will be either an arc initiation error or noodle welding at the workpiece.
H. Function Of Drive Motor
The drive motor requires two signals to start wire feeding. First, a motor start signal is needed and this is supplied either internally after the remote start
signal is present and preflow times out if applicable, or a remote jog forward signal is supplied from a robot controller. Second, an analog wire speed
command signal is supplied through settings on the interface or an analog input from a robot controller. A quality weld is made when wire speed is
matched properly to the weld parameters. If either of the two previously described signals is missing, the result will be an arc initiation error or wire will
burn back to the contact tip depending on the proximity of the gun to the workpiece. These symptoms can also occur if the wire cannot be fed smoothly
from the source to the contact tip. Liners, contact tips, and unspooling devices should all be examined when there is inconsistent or erratic welding.
General
To achieve a good quality weld, the output must be set properly according to material size and type, joint configuration, gas mix, travel direction, speed,
design consideration, and desired weld appearance.
OM-251440 Page 49
SECTION 9 − OPERATION
9-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
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.
AccuCurve
CV Pulse process using a pulse waveform with modified curves at particular locations within the
waveform. Has a distinguished change in arc characteristics. Front panel display is ACCU − CURV.
Accu-pulse
Pulse process utilizing constant current ramps with constant voltage control of peaks and
backgrounds. Adaptive response is controlled by peak, background, and minimum current levels.
Benefits are shorter arc lengths, better puddle control, more tolerant of tip-to-work variation, less
audible noise, no arc wandering, allows weld to fill in at toes increasing travel speed and deposition,
and more tolerant to poor fit up and gaps.
Adjust
Control knob used to change or set parameters and functions.
Amps
Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Control
Allows setting of inductance and slope in MIG mode. In pulse and Accu-pulse mode, this adjustment
changes the arc characteristics by adjusting the preprogrammed factory pulse data.
Arc Length
Distance from end of wire electrode to weld pool.
Auto Thread
Method of jogging wire without holding jog or trigger switch. By rocking the switch from purge to jog
within 0.5 seconds will automatically feed wire for a factory default setting of 192 in (4877 mm) of wire
before stopping. Default setting is 192 at a feed rate of 700 ipm (these values can be changed using
the HTML pages). Pressing jog, purge, or trigger switch will terminate the auto-threading feature.
Crater
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends.
Feeder Set Up
Allow selection of Sequence and trigger functions.
Gas Type
Selection of shielding gas being used in application.
IGNR (Ignore)
Allows the use of a dual schedule switch between ignore welds and count welds when using Insight
Centerpoint.
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit
transfers per second (provided no other changes are made) and increase the arc-on time. The
increased arc-on time makes the welding puddle more fluid.
MIG
CV weld process with individual settings of voltage and wire speed.
MWCI
Manual Weld Control Interface. A separate remote user interface dedicated to providing arc data
monitoring near the operator’s location. This interface provides the operator with the ability to start a
new part, join welds, or ignore welds. The MWCI has a display for error read-outs and status LEDs.
Preflow
Setting a time value for gas flow prior to arc start.
Postflow
Setting a time value for gas flow after arc end.
Process
A selection made for MIG, Pulse, and Accu-pulse.
Process Set Up
Selection procedure for entering program.
Program
Eight active slots for selection of various processes, wire type, and parameters.
Program Load
Enters selected program information into program slot.
Pulse
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as
factory taught data. Adaptive method is controlled by frequency adjustment.
Retract
Sequence function that allows the wire to move back towards the contact tip when a welding
operation is completed. Setting is both speed (IPM) and time (sec).
RMD
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of
RMD are well suited to thin materials, improves gap filling and spatter reduction. Provides less heat
input into workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge
materials.
Sequence
Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters.
Slope
Slope refers to the shape of a volt-amp curve. Varying the amount of slope in the welding circuit will
change the amount of short-circuit current and rate of response from the welding power source.
OM-251440 Page 50
9-1 .
Operational Terms (Continued)
General Terms:
Start
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts.
Time
Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in
the Arc On and Analog input or the Arc On and No Analog input modes).
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of
weld.
Wire Type
Selection of wire type by alloys and classification.
WFS
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage
setting. In pulse and Accu-pulse adjusting wire feed speed also increases power level on wire electrode (one knob control).
9-2. Pulse Welding Terms
1
Apk = Peak Amperage
Increasing
penetration.
Apk
increases
Vpk = Peak Voltage
Arc voltage during peak current
phase of the pulse waveform. This
determines arc length during
adaptive pulse welding.
2
Abk = Background Amperage
Maintains arc between pulses.
Vbk = Background Voltage
Arc voltage during background
current phase of the pulse
waveform. Stabilizes weld puddle
until next peak pulse.
3
PPS = Pulses Per Second
4
PWms = Pulse Width In
Milliseconds
Increasing PWms increases bead
width.
3
Amps
1
2
4
Time
OM-251440 Page 51
General
Increasing PPS increases travel
speed.
9-3. Front Panel Controls (See Section 9-4)
15
14
13
1
4
12
V
A
A
3
11
10
8
5
9
6
7
16
Adjust
Setup
Arc Control
2
. When an LED is lit, it means the related function is active.
219 712-A
1 Program Display
Displays the number of the active program.
2 Adjust Knob
Turn the Adjust knob to change program
number, Setup, Arc Control, and weld
parameters.
3 Program Push Button LED
The LED lights when the Program Push
Button is active.
4 Program Push Button
Press push button (LED lights) and turn Adjust
knob to select active program.
The letter C is displayed with the program
number if the program has been changed from
the factory settings using the optional PDA
with File Management/WaveWriter software
(see File Management/WaveWriter Owner’s
Manual).
. The program cannot be changed through
the front panel while welding.
Press and hold button to see program name.
Custom programs are named using optional
OM-251440 Page 52
PDA with File Management/WaveWriter
software. Program name is shown in upper
and lower displays (items 13 and 15).
5
Setup Mode Indicators
Gas Type LED
When this LED is lit, turn the Adjust knob to
select the desired weld gas. Gas type choices
vary according to the selected weld process.
The lit LED indicates which setup mode is
active. Setup mode parameters are shown in
Display Windows (see Items 13 and 15).
See Table 9-1 for all gas abbreviations.
Process LED
The LED lights to indicate one of the setup
modes is active.
When this LED is lit, turn the Adjust knob to
select the desired weld process. Choices
include pulse welding (displayed as PULS),
Accu-pulse, MIG welding (MIG), and Accu
Puls/RMD [Regulated Metal Deposition
(optional)].
Wire Type LED
When this LED is lit, turn the Adjust knob to
select the desired wire type, wire alloy, and
size. Wire type and size choices vary
according to the selected weld process.
Choices may include steel (displayed as
STL), stainless steel (SS), metal core
(MCOR), aluminum (ALUM). See Table 9-1
for all wire abbreviations.
6
7
Setup Push Button LED
Setup Push Button
Press button to select Process, Wire Type,
Wire Diameter, or Gas Type parameters.
. In order for selections to be retained in
memory, the Setup push button must be
pressed six times before any other push
button is pressed: once to select Process,
again to select Wire Type, again to select
Wire Alloy, again to select Wire Size,
again to select Gas Type, and a sixth time
to store selections in memory. The
displays will temporarily show “PROG
LOAD” to indicate the data is being stored
in memory.
9-4. Front Panel Controls - Continued (See Section 9-3)
Arc Control LED
The LED lights to indicate the Arc Control
button is active. Light goes out when button is
inactive.
9
Arc Control Push Button
This push button allows fine tuning inductance
for MIG programs, and Arc Control for
programs other than MIG. When the push
button is pressed, the upper display (item 15)
shows INDU for inductance, or ARC for Arc
Control to indicate which parameter is
selected for change. The range of possible
values is 0-99 for inductance, and 0-50 for arc
control. Turn the Adjust knob to change the
parameter value. Press button to deactivate
arc control mode (LED goes out).
10 Wire Feed/Gas/Contactor LEDs
The Wirefeed LED lights when the wire feeder
is energized. For example, when the front
panel Jog or Retract button is pressed, the
Wirefeed LED lights.
12 Wire Feed Speed/Amps Display Push
Button
13 Lower Display
Press Wire Feed Speed/Amps Display button
to show weld amperage or wire feed speed in
lower display (the applicable LED under the
lower display lights to indicate which is
shown). When welding, actual value is shown.
If amperage was selected for display, the unit
will show actual welding amperage prior to
and while welding unless the the unit is in
Display Command Values mode. Only wire
speed command will be displayed while
welding if the unit is set in Display Command
Values mode, even if the Wire Feed
Speed/Amps Display button is pressed.
. Displays show actual or command values
as determined by configuration menu
when using a PDA with File Management/
WaveWriter software. Command values
are displayed prior to welding and actual
values are displayed while welding unless
a PDA with File Management software
was used to set the unit in the ”Display
Command Values” mode. In the Display
Command Values mode, command
values are displayed while welding.
The Gas LED lights when the gas valve is
energized.
The Contactor LED lights when the output
contactor is energized, making the weld
output terminals live.
11 Wire Speed And Amps LEDs
The lit LED indicates whether wire speed or
amps are being displayed.
. If a PDA with File Management/WaveWriter
software is used to change wire feed units
(IPM, MPM) or display welding information
(command or actual),save the changes and
then turn the power to the unit off and then
on again for the changes to be carried out
by the unit.
14 Volts And Arc Adjust LEDs
The lit LED indicates whether voltage or arc
length is being displayed.
15 Upper Display
The upper display shows different information
depending on the active function of the unit
and the weld process being used. When the
display shows voltage (for a MIG process),
the Volts LED lights. When it shows arc adjust
[for a pulsed and RMD (optional) weld
process], the Arc Adjust LED lights. However,
during any weld process (MIG and pulse), the
unit will display actual arc voltage unless a
PDA with File Management/WaveWriter
software has set the unit in the ”Display
Command Values” mode.
16 Lock LED
The lock LED is illuminated when one or more
programs have been locked using an optional
PDA with File Management/WaveWriter
software. This indicates that some programs
have been disabled. A disabled program will
not show up for selection.
Refer to the File Management/WaveWriter
Owner’s Manual for additional information.
General
8
Table 9-1. Welding Wire And Gas Abbreviations*
Wire Description
Wire Abbreviation
Alloy Type
Gas Type
Gas Abbreviation
Steel
STL
E70, E100, E120
100% CO2,
90% Argon/10% CO2,
85% Argon/15% CO2,
80% Argon/20% CO2,
75% Argon/25% CO2,
95% Argon/5% CO2,
95% Argon /5% O2
CO2
C10
C15
C20
C25
C5
OX5
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O2,
(81Ar/18HE/1CO2
Accu-pulse),
90HE/7-1/2Ar/2-1/2CO2
(MIG/Accu-pulse),
98% Argon/2% CO2
OX2
Cored Tubular Wire
Tri Gas
HE90
C2
MCOR
71, 76, 86R, 409, 439,
MATRIX
90% Argon/10% CO2,
98% Argon/2% O,2
95% Argon/5% CO2,
95% Argon /5% O2,
100% CO2
C10
OX2
C5
OX5
CO2
Aluminum
ALUM
4XXX, 5XXX
100% Argon
ARGN
Flux Cored Tubular Wire
FCOR
E70T-0
E70T-1
100% CO2
75% Argon/25% CO2
CO2
C25
* Not all wire types may be available with your unit.
OM-251440 Page 53
Table 9-2. Robot Abbreviations
Manufacturer
Robot Abbreviation
ABB
ABB
Fanuc
FANU
Daihen
DAHN
Kawasaki
KAWA
Kuka
KUKA
Comau
COMU
Hitachi
HCHI
Nachi
NCHI
Panasonic
PANA
Motoman
MOTO
Robot Adapter
DTEC
Detect Disabled
OFF
None
Robt DTEC
9-5. Front Panel Switches
6
3
4
1
5
7
2
Ref. 250 016-C
1 Power Switch
Turns unit On or Off.
2 Contactor LED
Contactor LED illuminates when weld output is
energized.
3 Purge Push Button
Press button to purge gas line.
. The gas purge has a timer and can be
changed using the web pages. The default time is 5 seconds.
OM-251440 Page 54
4
Gas LED
Gas LED illuminates when Purge push button
is pressed.
5
Jog Push Button
Press button to jog wire.
6
Wirefeed LED
Wirefeed LED illuminates when wire feeds or
retracts.
7
Retract Push Button
Press button to retract wire. Wirefeed LED
illuminates when Retract push button is
pressed.
Auto-Threading feature is activated by
pressing the Jog and Retract buttons
simultaneously. Pressing the Jog, Purge, or
trigger switch will turn off the Auto-Threading
feature.
9-6. Front Panel Display At Power Up
1
2
Upper Display
Lower Display
While the system is initializing, the
display will alternate between “Net
Wait” and counting up dashes
before the power source is fully
operational.
1
V
A
2
A
Setup
Power Source
Adjust
Upper Display
Arc Control
Lower Display
Net
Wait
Net
Wait
Voltage Range
General
—
— —
Net
Wait
— — —
Net
Wait
— — — —
Net
— — — —
Net
— — — —
Net
— — — —
Net
— — — —
Axcess E
Wait
—
Wait
— —
Wait
— — —
Wait
— — — —
Net
Wait
DTEC
OFF
Auto
E300/E450
10
44
Depends On Welding
Power Source Model
OM-251440 Page 55
9-7. User Interface Menu
1
Welding Power Source
Turn on welding power source.
Wait for system to initialize (see
Section 9-6).
1
Example display shows
a model 450
AUTO
V
E450
A
Adjust
Arc Control
A
Setup
25
V
200
Setup
A
A
Adjust
Arc Control
To enter the user interface menu, momentarily
press the Program push button and wire feed/
amps push button at the same time.
SW
V
REV
Setup
Adjust
A
A
Arc Control
After entering the user interface menu,
the initial display will vary by the first
item that appears.
Ref. 250 016-C / 219 712-A
OM-251440 Page 56
A. System Reset Mode
. System Reset is not active when
Program Lock is enabled.
SW
SYS
V
. System configuration data will be
V
REV
Setup
System Reset allows the operator to
reload factory program settings for all
eight active programs in the unit.
RST
A
A
Adjust
Setup
Arc Control
A
lost during the Reset operation.
A
Adjust
Arc Control
Rotate Adjust knob until System Reset
(SYS RST) appears on the display.
SYS
RST
V
V
Setup
NO
A
Adjust
V
Setup
Arc Control
Press the Setup push button to
select the reset mode.
PLS
V
Setup
WAIT
A
A
Adjust
Arc Control
Rotate Adjust knob to select NO or YES.
V
YES
A
Adjust
RST
Arc Control
The Arc Control push button LED
flashes indicating the unit is ready to
perform the system reset operation.
Press the Arc Control push button.
CYCL
Setup
Adjust
Setup
A
Arc Control
Program 1
Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2
MIG
.035 Mild Steel
75% Argon, 25% CO2
Program 3
Accu-pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 4
Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5
MIG
.045 Mild Steel
75% Argon, 25% CO2
Program 6
Accu-pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 7
Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8
MIG
.052 Mild Steel
75% Argon, 25% CO2
Unit will go through a soft boot and then
begins initialization (see Section 9-6).
During system reset the display flashes
please wait (PLS WAIT) and the
following factory default programs are
loaded into the unit:
A
Setup
Adjust
Arc Control
When System Reset is finished, the display
will show CYCL PWR for cycle power. Turn
the power source off and back on again.
Arc Control
Rotate Adjust knob to select NO or YES.
Program push button LED flashes,press
to enter reset selection. If NO is entered,
unit returns to standby mode.
V
PWR
Adjust
A
A
A
A
LED
YES
A
OM-251440 Page 57
General
RST
A
RST
B. Software Revision Readout
The top display shows the board (AIM,
UIM, and WFCM) and the lower
display shows the last 3 digits of the
circuit board part number plus a letter
designator.
SYS
SW
V
V
RST
Setup
REV
A
A
Adjust
Arc Control
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Setup
V
REV
123A
A
A
Adjust
Arc Control
Setup
25
V
V
Adjust
200
A
Arc Control
The Program push button LED flashes
indicating that pressing this button will exit
the user interface menu. Press the Program
push button.
Arc Control
Rotate Adjust knob to scroll through the
software revision for each circuit board.
A
OM-251440 Page 58
Adjust
AIM
321B
A
A
Press the Setup push button to select
the software revision mode.
Setup
Arc Control
UIM
V
LED
Adjust
Rotate Adjust knob until Software
Revision (SW REV) appears on
the display.
SW
Setup
A
A
Setup
Adjust
A
A
Arc Control
Unit goes back to its standby status.
C. Voltage Feedback Method
Allows changing the voltage feedback
method from volt sense lead to stud
feedback.
SEC
VOLT
V
V
COMP
A
Adjust
Arc Control
A
A
Adjust
Arc Control
A
Setup
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Rotate Adjust knob until Voltage Feedback
(VOLT FDBK) appears on the display.
VOLT
FDBK
V
V
FDBK
A
Adjust
Arc Control
A
Setup
STUD
A
Adjust
Arc Control
A
Setup
Press the Setup push button to select
voltage feedback method.
Rotate Adjust knob to select
STUD or volt sense lead (VSNS).
FDBK
General
Setup
FDBK
FDBK
V
V
VSNS
A
A
VSNS
A
Adjust
Arc Control
A
LED
Setup
Adjust
Arc Control
The Arc Control push button LED flashes
indicating that pressing this button will
change the voltage feedback method.
Press the Arc Control push button.
Setup
To exit the user interface menu, press the
Program push button.
25
V
200
Setup
Adjust
A
A
Arc Control
Unit goes back to its standby status.
OM-251440 Page 59
D. Load Bank Operation
Allows setting the load bank feature
on or off.
. Load Bank is a diagnostic tool for
VOLT
LOAD
V
V
FDBK
A
Adjust
Arc Control
A
Setup
testing the power conversion
modules, not a welding process
selection.
BANK
A
Adjust
Arc Control
A
Setup
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Rotate Adjust knob until Load Bank
(LOAD BANK) appears on the display.
LOAD
LDBN
V
V
BANK
A
Adjust
Arc Control
OFF
A
Setup
Setup
Press the Setup push button to select
the Load Bank operation.
A
A
Adjust
Arc Control
Rotate Adjust knob to select OFF or ON.
LDBN
LDBN
V
V
ON
ON
A
A
A
A
LED
Setup
Adjust
Arc Control
The Arc Control push button LED flashes
indicating that pressing this button will
set the load bank feature on. Press the
Arc Control push button.
25
V
200
Setup
Adjust
A
A
Arc Control
Unit goes back to its standby status.
OM-251440 Page 60
Setup
Adjust
Arc Control
To exit the user interface menu, press the
Program push button.
E. Wire Reset Operation
Allows the operator to reset the
date/time when a new spool of wire is
installed to allow wire usage tracking.
LOAD
WIRE
V
V
BANK
A
Adjust
Arc Control
RST
A
Setup
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Arc Control
Rotate Adjust knob until Wire Reset (WIRE
RST) appears on the display.
WIRE
RST
V
V
RST
Setup
Adjust
NO
A
A
Adjust
Setup
Arc Control
Press the Setup push button to select
the wire reset operation.
A
A
Adjust
Arc Control
Rotate Adjust knob to select YES or NO.
RST
General
Setup
A
A
RST
V
V
YES
YES
A
A
A
A
LED
Setup
Adjust
Arc Control
The Arc Control push button LED flashes
indicating that pressing this button will
reset the wire spool weight and date.
Press the Arc Control push button.
Setup
Adjust
Arc Control
To exit the user interface menu, press the
Program push button.
25
V
200
Setup
Adjust
A
A
Arc Control
Unit goes back to its standby status.
OM-251440 Page 61
F. Robot Calibration Mode
Use the robot calibration mode to
custom-calibrate the power source to
the robot command signals. This
ensures the wire speed, voltage, and
arc adjust are the same on the robot
pendant as on the power source.
WIRE
ROBT
V
V
RST
Setup
CAL
A
A
Adjust
Arc Control
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Setup
A
A
Adjust
Arc Control
Rotate Adjust knob until Robot Calibration
(ROBT CAL) appears on the display.
ROBT
CAL
V
V
CAL
ON
A
A
A
A
IMPORTANT:
The
factory
recommendation is to perform the
calibration on all installations or
code updates.
Follow this procedure if the factory
settings are not as accurate as
desired. Synchronization of the robot
and power source signals makes
installation easier and improves the
operation of the system.
. The
robot pendant must have
Weld enabled, and there can be
no start/stop crater conditions set
in the robot.
The calibration mode will execute as a
”dry run” from the operator’s
perspective. The welding power
source provides the robot with
feedback so the robot thinks a weld is
underway, yet the robot torch need not
move during the calibration.
. If
you wish to stop the calibration
procedure, turn unit input power
off and then on again.
Setup
Adjust
Arc Control
Press the Setup push button to select
the robot calibration mode.
Setup
Adjust
Arc Control
Calibration On (CAL ON) appears on
the displays.
CIRCULER
Use robot pendant or other method to enter
two weld schedules into the robot. Maintain
schedule 1 for at least 10 to 20 seconds
minimum before moving on to schedule 2.
Maintain schedule 2 for 10 to 20 seconds
before ending the simulated weld. Schedule
data is shown next.
Schedule 1
Schedule 2
10.0 Volts
100 IPM
44.0 Volts
1000 IPM
Proceed to next page.
OM-251440 Page 62
Robot Calibration Mode (Continued)
. If
you wish to stop the calibration
procedure, turn unit input power
off and then on again.
CAL
CAL
V
V
DONE
DONE
A
A
Setup
If the calibration is performed correctly
the CAL ON message stops being displayed and goes to CAL DONE; however, if it is performed incorrectly, the
message remains on the display.
Adjust
A
A
Arc Control
When calibration ends the displays will read
calibration done (CAL DONE).
Setup
Adjust
To start the calibration procedure over
again, turn unit input power off and
then on again following the calibration
setup steps following the calibration
setup steps.
Arc Control
To exit the user interface menu, press
the Program push button.
25
V
200
Setup
Adjust
A
A
Arc Control
Unit goes back to its standby status.
General
F.
OM-251440 Page 63
9-8. Robot Auto-Calibration Sample Programs
. It is critical to make certain that NO start power, start conditions, run-in, or crater parameters of any kind are present in the robot program. The
welding power source is looking for 2 distinct welding conditions. If there is a “start power” condition, the welding power source will equate this
as the first condition and fail to execute Auto-Cal correctly. If there is a “crater fill” condition, the welding power source will equate this as the second
condition and fail to execute Auto-Cal correctly.
Actual Motoman Welder Condition File
<Welding Current Output Char.>
NO.
REF (V) MEASURE (A)
01
0.01
1
02
7.00
500
03
13.99
999
04
0.00
000
<Welding Voltage Output Char.>
NO.
REF (V) MEASURE (V)
01
0.14
0.5
02
7.00
25.0
03
14.00
50.0
04
Sample Auto-Calibration Routine For Motoman Robot
0000
NOP
0001
Mov J
0002
AWELD 1.40
(AWELD direct input of 1.40Volts = 100 ipm)
0003
VWELD 2.80
(VWELD direct input of 2.80Volts = 10.0 volts)
0004
Arcon
0005
Timer T=10.00
0006
Arcof
0007
AWELD 14.00
(AWELD direct input of 14.00Volts = 1000 ipm)
0008
VWELD 12.32
(VWELD direct input of 12.32Volts = 44.0 volts)
0009
Arcon
0010
Timer T=10.00
0011
Arcof
0012
End
OM-251440 Page 64
Sample Auto-Calibration Routine For Fanuc Robot
1:
Call Safehome
2:
J P[1] 40% Fine
Arcstart [10.0Volts, 100.0IPM]
3:
L P[2] 10.0 sec Fine
Arc End [0.0Volts, 0.0IPM, 0.0Sec]
4:
Wait 1.00 (Sec)
5:
J P[3] 40% Fine
Arcstart [44.0Volts, 1000.0IPM]
6:
L P[4] 10.0 sec Fine
Arc End [0.0Volts, 0.0IPM, 0.0Sec]
7:
Call Safehome
Sample Auto-Calibration Routine For ABB Robot
Move J home, v500, z50, tweldgun;
Arcl \ on, *, v500, sm1, wd1, wv0, z50, tweldgun;
Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;
WaitTime 5;
Arcl \ on, *, v500, sm1, wd2, wv0, z50, tweldgun;
Arcl \ off, *, v500, sm1, wd2, wv0, z50, tweldgun;
Move J home, v500, z50, tweldgun;
*Seam Data values must all be set at zero.
Weld Data 2:
weld_sched:=0
weld_sched:=0
weld_speed:=5
weld_speed:=5
weld_voltage:=10
weld_voltage:=44
weld_wfs:=100
weld_wfs:=1000
org_weldspeed:=0
org_weldspeed:=0
org_weldvoltage:=0
org_weldvoltage:=0
org_weldwfeed:=0
org_weldwfeed:=0
General
Weld Data 1:
OM-251440 Page 65
SECTION 10 − MAINTENANCE
10-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
l Unreadable Labels
~ Weld Terminals
nl Cords
nl Gun Cables
Every
6
Months
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
l = Replace
l Damaged Gas Hose
Reference
nl Weld Cables
OR
~ Drive Rolls
~ Inside Unit
10-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
249 889-C
OM-251440 Page 66
SECTION 11 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
11-1. Symbol Usage
safety_stm 2015-09
DANGER! − Indicates a hazardous situation which, if
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
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
11-2. Servicing Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard.
Only qualified persons should test, maintain, and repair this
unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
During servicing, keep everybody, especially children, away.
FIRE OR EXPLOSION hazard.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
D
D
D
D
D
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
Do not leave live unit unattended.
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Troubleshooting Section before touching any parts.
ARC FLASH can kill.
Arc flash is the rapid and violent release of energy that
occurs when electric current leaves its intended path
and arcs to other conductors or to ground. Arc flash
can be caused by equipment failure (faulty insulation,
corrosion, dust) improper installation, human error (improper tool
placement), and other factors. Conductive vapors can sustain the
arc until over-current devices open the circuit. Individuals within
the arc flash boundary are at risk.
D Do not work on energized equipment unless an assessment of
arc flash risk from the electrical supply circuit has been conducted
by a qualified person and you have been trained in safe work practices by your employer.
D Follow requirements in NFPA 70E for safe work practices and
Personal Protective Equipment (PPE).
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
FLYING METAL or DIRT can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
EXPLODING PARTS can injure.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing meter lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
OM-251440 Page 67
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep away from pinch points such as drive
rolls.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance and
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools
away from moving parts.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away from servicing areas until consulting their doctor and the
device manufacturer.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150853) when
servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine replacement parts from the manufacturer.
D Read and follow all labels and the Technical Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
D Perform installation, maintenance, and service according to the
Technical Manual, industry standards, and national, state, and
local codes.
11-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
11-4. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
OM-251440 Page 68
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
Trouble
SECTION 12 − TROUBLESHOOTING
12-1. Set Value Mode
V
A
A
1
Setup
Adjust
4
Arc Control
2
3
219 712-A
The Set Value mode is a troubleshooting tool
that allows certain robot command values to
be manually over-ridden.
1
Setup Push Button
2
Arc Control Push Button
3
Adjust Knob
4
Wire Feed Speed/Amps Display Push
Button
Enter the Set Value mode by pressing the
Setup and Arc Control push buttons at the
same time. When in the Set Value mode the
display windows briefly shows SET VALU and
the blinking LEDs under the display windows
indicate whether Volts, Arc Adjust, or Wire
Speed can be changed turning the Adjust
knob.
Depending on the defined weld process,
either volts (MIG) or arc adjust [pulse,
Accu-pulse, or RMD (optional)] can be
changed in the top display. Wire speed can be
changed in the bottom display. Press the Wire
Feed Speed/Amps push button to toggle
between selecting information in the top
display or bottom display. The LED under the
active display will blink to indicate the value
that can be changed.
Rotate the Adjust knob to change values.
Exit the Set Value mode by pressing the Setup
and Arc Control push buttons at the same time
or turning power source off and then back on
again.
OM-251440 Page 69
12-2. Error Code Troubleshooting Tables
ERR
Display Example
TACH
. The following error codes may appear on the upper and lower displays of the User Interface Module
to indicate specific errors. Explanations of
the error codes are provided in the sections referenced.
Error Type
User Interface Module
Upper Display
User Interface Module
Lower Display
Reference
Emergency Stop
E
STOP
Section 12-2. A
Arc Error
ERR
ARC
Section 12-2. B
No Coolant Flow
ERR
COOL
Section 12-2. C
Ground Current
Detect Error
ERR
GND
Section 12-2. D
Line Error
ERR
LINE
Section 12-2. E
Motor Over Current
ERR
MOTR
Section 12-2. F
Arc Start Error
ERR
STRT
Section 12-2. G
No Tach Error
ERR
TACH
Section 12-2. H
Thermal Over
Temperature
ERR
TEMP
Section 12-2. I
Unknown Error
ERR
UNKN
Section 12-2. J
Motor Communications Error
MOTR
COMM
Section 12-2. K
Over Average Current
OVER
AVE
Section 12-2. L
Over Current
OVER
CRNT
Section 12-2. M
Release Trigger
REL
TRIG
Section 12-2. N
Trigger Stuck
TRIG
STUK
Section 12-2. O
Wire Feed Speed Error
ERR
WFS
Section 12-2. P
Stop Error
ERR
STOP
Section 12-2. Q
Flow Error
ERR
FLOW
Section 12-2. R
Stuck Error
ERR
STUK
Section 12-2. S
Weld Wait
WELD
WAIT
Section 12-2. T
Please Wait
PLS
WAIT
Section 12-2. U
Low Wire Feed Speed
LOW
WFS
Section 12-2. V
Demo Done
DEMO
DONE
Section 12-2. W
Net Wait
NET
WAIT
Section 12-2. X
Software Error
SW
ERR
Section 12-2. Y
Check Web
CHCK
WEB
Section 12-2. Z
OM-251440 Page 70
Indicates an emergency stop error.
Receptacle RC5-1 connects to receptacle RC1-4 and receptacle RC5-2 connects to receptacle RC4-2 on E-Stop board
PC12. A closure between RC4-1 and RC4-2 allows +24 volts DC to be supplied to the four relays on E-Stop board PC12.
In an E-Stop situation (relays open), all four relays on the E-Stop board de-energize and cut power to the control boards.
E
When relay CR1 on E-Stop board PC12 is de-energized, it drops out the 18 volts AC from transformer T1 that powers the
inverter control board(s).
STOP
When relay CR2 on E-Stop board PC12 is de-energized, it breaks the contactor signal being sent to the inverter engine
board(s) from the process control module PC4 (J2-9 to RC2-3) and causes a loss of signal to the AIM board (RC2-1 and
RC2-2) and to micro input (RC5-3 and RC5-4), signaling an E-Stop is active.
When relay CR3 on E-Stop board PC12 is de-energized, it breaks the secondary side output of the motor board before it
goes to the filter board.
Relay CR4 on E-Stop board PC12 is a soft start relay in parallel with the contacts of relay CR1.
B. Arc Error
ERR
ARC
Indicates voltage has exceeded the programmable limit of a valid arc for the programmed amount of time (default time is
500 ms). Check contact tip, weld conditions, and shielding gas.
Arc error can be enabled or disabled using an optional PDA with File Management/WaveWriter software.
C. No Coolant Flow Error
ERR
COOL
Indicates no coolant flow in water flow switch option. The error may be reset by reestablishing coolant flow to the gun, and
then pressing the Jog/Purge button.
D. Ground Current Detect Error
ERR
GND
Indicates that weld current is flowing through the primary ground. This is a latching error and welding power source power
must be cycled off and back on again.
E. Line Error
ERR
LINE
Indicates that primary power has dropped below the operating point of the welding power source. Signal is sent from inverter engine module(s) (RC6, Pin 9 on inverter control board PC1) to process control module PC4 (J2, Pin 1). Check for a
brown-out condition. The primary boost capacitors have dropped below an acceptable minimum voltage threshold.
This circuit monitors the 940 volts primary DC bus voltage across the electrolytic capacitors C1 and C2. Low line is displayed when this voltage drops below 858 volts DC. This could happen when attempting to draw near rated output power
with an input voltage below 190 volts AC, three phase. This causes the boost section to go into current limit trying to supply the output power. Once current limit is reached, the boost section can no longer hold the bus capacitors at 940 volts
DC. The inverter control will also go into an output current limit mode in an attempt to supply output power.
F. Motor Over Current Error
ERR
MOTR
Indicates that the motor has been drawing too much current for too long a time period. To remedy this fault, reduce the wire
feed speed or the wire feeder torque load/duty cycle. Press Jog/Purge button to clear error.
G. Arc Start Error
ERR
STRT
Indicates the contactor either is or was active, but the system failed to start an arc. Conditions for a valid arc start are at
least 50% of arc start current, voltage less than 60 volts, and voltage greater than min. valid arc voltage (default is 22.5
volts). This situation is usually attributed to a contact tip or feeder issue. The arc start error parameter can be disabled
using an optional PDA with File Management/Wave Writer software.
OM-251440 Page 71
Trouble
A. Emergency Stop Error
H. No Tach Error
Indicates loss of tachometer feedback. Determine cause of error as follows:
ERR
TACH
I.
S
Press JOG button on the front panel.
S
Does the motor run wide open immediately?
S
YES Replace Motor Board PC6.
S
Does the motor ramp up in speed?
S
YES Bad motor tach. Contact nearest Factory Authorized Service Agent.
S
Does the motor respond at all?
S
YES Contact nearest Factory Authorized Service Agent.
S
Check motor cable. Is it damaged?
S
YES Replace motor cable.
S
NO Contact factory service personnel.
Thermal Over Temperature Error
Indicates one or more of the inverter engines overheated. Sent from inverter engine module(s) (RC6, Pin 12, on inverter
control board PC1) to process control module PC4 (J2, Pin 7). Check fan on inverter engine(s) and weld currents.
This signal is the sum of two conditions: shutdown that comes from the temperature monitoring circuit on the inverter control board, and Pwr-Up-Cnt that generated by the boost section of the inverter control board. When either of these signals
is active, RC6-12 is pulled low (this is the not ready line out of the inverter control board).
Shutdown is active when there is an over-temperature condition on the primary or secondary heatsink or on the boost
inductor. To determine which of the two locations is at fault, check LED 1 and LED 2 on inverter control board PC1.
ERR
TEMP
S
If LED 1 is lit, this indicates an over-temperature condition on the primary heat sink.
S
If LED 2 is lit, this indicates an over-temperature condition on the secondary heat sink or on the boost inductor.
Pwr-Up-Cnt (power up control) monitors primary voltage start-up conditions when the power source is first turned on. This
signal is opto-isolated from the boost section of the inverter control board. The following conditions must be met for the
power source to power up:
S
Auxiliary power board PC3 must be powered up and operating to supply prepower of +15 volts DC to the boost section of inverter control board PC1.
S
The peak voltage of the input line power must be greater than 150 volts peak.
S
The DC bus voltage must be greater than 85% of the rectified line voltage. This bus voltage also turns on the
pre-charge relay.
S
The DC bus voltage must be boosted to greater than 858 volts DC.
If any of these conditions are not met, then receptacle RC6-12 is pulled low and weld output is locked out.
J. Unknown Error
ERR
UNKN
OM-251440 Page 72
Indicates error bit from process control module PC4 is set, but error value sent does not match anything defined with the
UIM board PC7.
The motor board has lost communication with the PCM board PC4. Check cabling and cable routing for boom system
motor cable and secondary cables. Separate cable as much as possible.
Check if WFM board PC6 code is installed and if microprocessor is running. Check LED3 and LED4 on WFM board PC6.
Depending on the wire feed speed, check for 0-40 volts DC on J17-3 to J17-1. If there is no voltage present there, check
for 40 volts DC at J16-1 to J16-2. If voltage is present there and neither LED is lit (Red or Green), try to download WFM
code to welding power source. If neither LED turns on after downloading code and cycling power, replace WFM board
PC6.
If LED3 and LED4 are flashing Red or Green or they are solid Red, this indicates the WFM board is still not communicating
with the PCM board PC4. Be sure that the UIM board PC7 is on-line (two green LEDs lit).
MOTR
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
S
Check process control module PC4 for +24 volts DC at 6-pin connector J6-2 (+) and J6-5 (−).
If +24 volts is not present at the connector, proceed as follows:
S
Disconnect connector J10 and J11 from WFM board PC6. Check for +24 volts DC at J10-2 (+) and J10-5 (−), and
J11-2 (+) and J11-5 (−). One of the two connectors must measure +24 volts DC to ensures that the Devicenet lines
are being sent from process control module PC4 to WFM board PC6. If +24 volts DC is present at either connector,
replace WFM board PC6.
S
If +24 volts DC is not present at either J10 or J11 connector, check process control module PC4 at connectors J6, J7,
and J8.Remove plugs from connectors and check for +24 volts DC at pin2 (+) and pin 5 (−). If +24 volts DC is not
present at any of the connectors, replace process control module PC4.
COMM
If LED3 and LED4 are both green this indicates that the WFM board went off-line and then recovered which is usually due
to noise interference.
S
Check wire drive motor isolation. Isolated portion of motor housing should not touch robot arm, welding power source
chassis, lifting eye bolts, or weld secondary common. Measure impedance between chassis and both weld secondary
commons. Measure the impedance across motor isolation barrier on motor housing. All measurements should read
high impedance.
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
L. Over Average Current Error
Output current is exceeding the thermal capabilities of the welding power source for approximately 25 seconds.
Default value is as follows:
Axcess 450 limit is 610 A average
This is a duty cycle error and requires 5 minutes with power on and NO welding to clear the error.
This error indicates that an excessive amount of current was drawn over a short period of time. Over-average current is
drawn for a period of approximately 25 seconds and can also be expressed as exceeding the power source duty cycle.
OVER
AVE
The current limit is as follows:
Axcess 450 is 610 amperes
This alarm cannot be reset. To clear the condition, the power source must be turned on and allowed to idle for approximately 5 minutes. This cooling period is determined by an internal timer, and turn off power will not reset the timer since it is
saved with the Configuration data. After the 5 minute cooling period, press the Jog or Purge button, or cycle power to clear
the alarm.
If this alarm was received by mistake, and the power source did not exceed the duty cycle, check the following:
Check current feedback signal either while welding or connecting to a load bank. Measure between test point TP8 and
grounding strap on process control module PC4. Test point TP8 is located on left-hand side of board, about 1 in. (25 mm)
to the right of connector J11. TP8 is scaled: 1 volt measured equals 100 amperes actual. This measurement should read 0
volts when not welding. If the measurement reads approximately 13 volts DC, disconnect LEM device from engine (one at
a time) to determine if either device is bad. If the voltage reading still does not change, unplug the lower inverter control
board; if the reading remains the same, replace the upper inverter control board. Voltage readings should be present while
welding. If voltage readings are not correct for current feedback scaling, check individual inverter engines.
OM-251440 Page 73
Trouble
K. Motor Communications Error
M. Over Current Error
Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6,
Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6).
OVER
The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip
this circuit, only a fault will cause an over-current condition. LED4 will be lit on the inverter control board, and power must
be cycled to clear this error.
S
The most likely fault to trip this circuit is an open 940 volts DC bus bleeder resistor, either R1 or R8 on the interconnect
board. An open resistor will cause the bus, which is split between two series capacitors, to become unbalanced. The
capacitor with the open resistor will go to approximately 340 volts DC. The other capacitor will go to approximately 600
volts DC. Normally, both capacitors are at approximately 470 volts DC. The unit will weld like this most of the time. A
16 uF balancing capacitor in series with the transformer can keep the transformer from saturating under these adverse
conditions. Occasionally, the inverter transformer will saturate, and when this happens, it draws a huge amount of
current and trips the over-current circuit. This condition locks off the inverter control board and eventually the bus capacitors will fail. A change to a different resistor eliminated this situation and the problem is no longer an issue.
S
A shorted output diode will cause an over-current error and no weld output will be available.
CRNT
N. Release Trigger Error
REL
TRIG
Indicates a timed weld has expired, but the trigger is still active. Press Jog/Purge button to clear error.
This error occurs after a timed weld expires and the trigger is not released. A PDA with File Management/WaveWriter
software can be used to set up timed welds. This is strictly an informational−type error.
O. Trigger Stuck Error
TRIG
STUK
Indicates the welding power source was turned on and the trigger signal attempted to weld. Turn welding power source off
and back on again to clear the error.
This error indicates a trigger source was activated while the power source was being powered up. If the trigger source is
removed, the error can be cleared.
S
Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the source of the contactor or
trigger command.
S
If LED2 is lit on RIO board PC10, a contactor signal is being sent from the robot.
P. Wire Feed Speed Error
ERR
WFS
Indicates a wire feed speed error. Press Jog/Purge button to clear error.
This error indicates actual wire feed speed does not match wire feed speed command.
Q. Stop Error
ERR
STOP
Indicates an arc stop error. Press Jog/Purge button to clear error.
This error occurs as a result of obstructions in the wire feed system or a faulty wire drive system. Check wire feed and
wire drive system.
R. Flow Error
ERR
FLOW
Indicates a gas flow error. Press Jog/Purge button to clear error.
This error occurs when there is no gas flow to the gun. Check shielding gas system and reestablish gas flow to the gun.
S. Stuck Error
ERR
STUK
OM-251440 Page 74
Indicates a wire stuck error. Press Jog/Purge button to clear error.
This error occurs if the welding wire sticks to the workpiece at the end of a weld. This fault may be caused by poor welding
conditions. Cut the welding wire from the workpiece.
WELD
WAIT
Trouble
T. Weld Wait
Indicates a weld cycle wait error. Press Jog/Purge button to clear error.
This error occurs when the unit is not ready for a weld sequence.
U. Please Wait
PLS
WAIT
Indicates a UIM communication error. Press Jog/Purge button to clear error.
This error occurs when the user interface circuit board loses data communications.
V. Low Wire Feed Speed
LOW
WFS
Indicates a low wire feed speed command error. Press Jog/Purge button to clear error.
This error occurs when actual wire feed speed is lower than the wire feed speed command. Check for obstructions in the
wire feed system or a faulty wire drive system.
W. Demo Done
DEMO
Indicates RMD/Accuspeed demo has expired. Press Jog/Purge button to clear error.
DONE
This message appears when RMD and Accuspeed demos are completed. Pressing the Jog/Purge button will change the
screen to CYCL PWR on the display. Turn unit power off and back on again. RMD and Accuspeed share the same demo
timer. If the time expires for one demo process, both demo processes are deactivated.
X. Net Wait
NET
WAIT
Indicates a communication problem. Press Jog/Purge button to clear error.
If the display remains in NET WAIT status, this indicates there is a communication problem between various circuit boards
in the wire feeder or ROI and welding power source.
Y. Software Error
SW
Indicates incompatible software code. Press Jog/Purge button to clear error.
ERR
This error occurs after a software download and the versions between circuit boards are not compatible or a feeder or ROI
that has not been updated is connected to a power source with incompatible code. This error can also occur if power is
cycled off and on with less than 10 seconds of off time.
Z. Check Web
CHCK
WEB
Indicates an E Module update error. Press Jog/Purge button to clear error.
This error occurs when performing an E Module update to an existing unit. This requires connecting to the web pages to
enter serial number information.
OM-251440 Page 75
12-3. E Module Board Stack Diagnostic LEDs
1
D103
D91
D10 D11 D7
D99
D96
D92
D101
D14
D4
D98
D108
D8
D1
LED2 LED1
D3
250 237-A / 250 294-C
1 E Module Board Stack
Diagnostic LEDs are visible inside unit, located on the E Module Board Stack.
OM-251440 Page 76
Refer to Section 12-4 for information on
diagnostic LEDs.
Reinstall cover after checking diagnostic
LEDs.
A. DeviceNet Communication LEDs
D7, D10, D11, D19, and D21 are off until communication is established. Once communication is established D7, D10,
D11, and D19 flash on and off, and D21 turns on steady. If any of these LEDs are off, there is a problem. Contact the
nearest factory Authorized Service Agent.
LED
LED1
LED2
D7
Function
——
——
DSP AWAKE
Status
——
——
——
ARM AWAKE
Flashing
Off
D11
D19
D21
ARM AUX
AD AUX
AD AWAKE
See Section 12-11.
——
Flashing
Off
D10
Diagnosis
Flashing
Indicates DSP communicating.
Indicates DSP not communicating.
Indicates ARM communicating.
Indicates ARM not communicating.
Indicates auxiliary in use.
Off
Indicates auxiliary not in use.
Flashing
Indicates normal operation .
Off
Indicates problem with AD micro.
On
Indicates normal operation.
Off
Indicates problem with AD micro.
B. DeviceNet Power Supply LEDs
D91
D92
D96
D99
D103
On
(Auto Units Only − DeviceNet ext) Indicates +24 VDC is present from external DeviceNet connection.
Off
(Auto Units Only − DeviceNet ext) Indicates +24 VDC is off from external DeviceNet connection.
On
Indicates +5 VDC for ISO-Int is present.
Off
Indicates +5 VDC for ISO-Int is not present.
On
Indicates +24 VDC DeviceNet is present.
Off
Indicates +24 VDC DeviceNet is not present.
On
(Auto Units Only − ISO ext) Indicates +5 VDC is present from external DeviceNet connection.
Off
(Auto Units Only − ISO ext) Indicates +5 VDC is not present from external DeviceNet connection.
On
Indicates +40 VDC is present.
Off
Indicates +40 VDC is not present.
OM-251440 Page 77
Trouble
12-4. Diagnostic LEDs On E Module Board Stack
C. General Purpose LEDs
D17
D25
D26
D28
On
Gnd Cnt − Indicates ground error. Contact nearest factory Authorized Service Agent.
Off
Indicates no error.
On
OVR CNT − Indicates an error. Contact nearest factory Authorized Service Agent.
Off
Indicates no error.
On
OVR PWR − Indicates unit is operating at max input current. Contact nearest factory Authorized Service
Agent.
Off
Indicates no error.
——
——
D30
Future use.
On
OVR TMP − Indicates unit is overheated. Turn unit off and allow to cool. If error continues, contact nearest
factory Authorized Service Agent.
Off
Indicates no error.
On
Contactor − Indicates unit is receiving a contactor On signal.
Off
Indicates contactor on signal is not being received. Check input connections.
D43
On
ARM/O − Indicates +10 VDC is present, should flash at same rate as ARM AWAKE.
Off
Indicates +10 VDC is not present.
D44
On
E-Stop − Indicates E-Stop is not present.
Off
Indicates E-Stop has been engaged, check external sources.
On
USB Host on − Indicates this function is operating properly.
Off
Indicates USB error. Cycle unit power, if error is still present contact nearest factory Authorized Service
Agent.
On
Indicates +2.5 VDC is present.
Off
Indicates +2.5 VDC is not present.
On
Indicates +25 VDC is present.
Off
Indicates +25 VDC is not present.
D33
D98
D101
D108
OM-251440 Page 78
1
Wire Feed Module PC6
Diagnostic LEDs are visible inside
unit, located on PC6 mounted on
the top tray assembly.
2
Refer to Section 12-6 for
information on diagnostic LEDs.
1
Reinstall top cover after checking
diagnostic LEDs.
LED1 LED2
2
Dip Switch S1
Dip switches are used to identify
each circuit board on the internal
network. Dip switch settings are
different for each circuit board. For
proper operation, do not change dip
settings from those shown.
LED3
LED4
249 748-A / 803 853-B
12-6. Diagnostic LEDs On Wire Feed Module PC6
LED
Status
1
On
Indicates +15 volts DC is present on wire feed module PC6.
Off
Indicates +15 volts DC is not present on wire feed module PC6.
On
Indicates +5 volts DC is present on wire feed module PC6.
Off
Indicates +5 volts DC is not present on wire feed module PC6.
On
See Network Status Table in Section 12-11.
Off
See Network Status Table in Section 12-11.
2
3,4
Diagnosis
OM-251440 Page 79
Trouble
12-5. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings
12-7. User Interface Module PC7 Diagnostic LEDs
LED1
LED2
1
227 542-C / 803 853-B
1 User Interface Module PC7
Diagnostic LEDs are visible inside unit,
located on PC7 mounted behind the front
panel.
Refer to Section 12-8 for information on
diagnostic LEDs.
12-8. Diagnostic LEDs On User Interface Module PC7
LED
Status
1, 2
On
See Network Status Table in Section 12-11.
Off
See Network Status Table in Section 12-11.
OM-251440 Page 80
Diagnosis
Reinstall cover after checking diagnostic
LEDs.
1
Trouble
12-9. Automation Interface Module PC9 Diagnostic LEDs
LED11
LED13 LED25
LED28
LED12
LED14
LED27
LED31
LED30
LED1
LED2
LED3
LED4
2
LED5
LED6
LED7
LED8
LED9
LED10
LED32
LED33
LED15
LED20 LED19 LED18 LED16
LED17
LED21 LED22 LED23 LED24 LED26 LED29
249 749-A / Ref. 249 744-B
1 Automation Interface Module PC9
Diagnostic LEDs are visible inside unit,
located on PC9 mounted on left side.
Refer to Section 12-8 for information on
diagnostic LEDs.
Reinstall cover after checking diagnostic
LEDs.
2
Dip Switch S4
Dip switches are used to identify each
circuit board on the internal network. Dip
switch settings are different for each circuit
board. For proper operation, do not change
dip settings from those shown.
OM-251440 Page 81
12-10. Diagnostic LEDs On Automation Interface Module PC9
LED
Status
1
On
Input signal On from robot for jog advance.
Off
Input signal Off from robot for no jog advance.
On
Input signal On from robot to energize contactor.
Off
Input signal Off from robot to not energize contactor.
On
Input signal On remote program A selected.
Off
Input signal Off remote program A not selected.
On
Input signal On remote program C selected.
Off
Input signal Off remote program C not selected.
On
Input signal On from E-stop board PC12 for no emergency stop.
Off
Input signal Off from E-stop board PC12 acknowledges E-stop is On from robot.
On
Spare 1 not assigned.
Off
Spare 1 not assigned.
7
On
Input signal On Autoset-C selected.
Off
Input signal Off Autoset-C not selected.
8
On
Input signal On Autoset-B selected.
Off
Input signal Off Autoset-B not selected.
On
Input signal On Remote Jog on from peripheral plug.
Off
Input signal Off Remote Jog off from peripheral plug.
10
On
Input signal On Remote Purge on from peripheral plug.
Off
Input signal Off Remote Purge off from peripheral plug.
11
On
Input signal On from robot for jog retract.
Off
Input signal Off from robot for no jog retract.
On
Input signal On from robot for purge.
Off
Input signal Off from robot for no purge.
13
On
Input signal On remote program B selected.
Off
Input signal Off remote program B not selected.
14
On
Input signal On Touch Sensor on from robot or peripheral plug.
Off
Input signal Off Touch Sensor off from robot or peripheral plug.
On
Spare 0 not assigned.
Off
Spare 0 not assigned.
16
On
Spare 2 not assigned.
Off
Spare 2 not assigned.
17
On
Input signal On Autoset-A selected.
Off
Input signal Off Autoset-A not selected.
On
Input signal On Autoset-D selected.
Off
Input signal Off Autoset-D not selected.
On
Input signal On Remote Retract on from peripheral plug.
Off
Input signal Off Remote Retract off from peripheral plug.
On
Input signal On Remote Water Flow on from peripheral plug.
Off
Input signal Off Remote Water Flow off from peripheral plug.
On
Input signal On from robot for no emergency stop.
Off
Input signal Off from robot for emergency stop.
On
Input signal On from relay K3 for welding power source ready and no detected errors present.
Off
Input signal Off from relay K3 for welding power source not ready, detected errors are present, or unit is
in operating mode preventing the weld ready signal from being enabled.
2
3
4
5
6
9
12
15
18
19
20
21
23
OM-251440 Page 82
Diagnosis
Status
24
On
Input signal On from relay K4 to indicated wire stuck in weld joint.
Off
Input signal Off from relay K4 to indicate wire is not stuck in weld joint.
25
On
Indicates +5 volts DC is present on automation module PC9.
Off
Indicates +5 volts DC is not present on automation module PC9.
26
On
Input signal on from relay K5 for flow (shielding gas or coolant) present.
Off
Input signal off from relay K5 for flow (shielding gas or coolant) not present.
On
Indicates −15 volts DC is present on automation interface module PC9.
Off
Indicates −15 volts DC is not present on automation interface module PC9.
28
On
Indicates +15 volts DC is present on automation interface module PC9.
Off
Indicates +15 volts DC is not present on automation interface module PC9.
29
On
Input signal on from relay K6 for arc detected.
Off
Input signal off from relay K6 for no arc detected.
On
See Network Status Table in Section 12-11.
Off
See Network Status Table in Section 12-11.
32
On
Input signal on for aux. relay energized.
Off
Input signal off for aux. relay energized.
33
On
Input signal on touch sensor touch detected.
Off
Input signal off touch sensor touch not detected.
27
30, 31
Trouble
LED
Diagnosis
12-11. Network And Module Status LEDs
A. Network Status LED
LED2 on the E Module board stack
Status
Off
Green
Flashing Green
Red
Diagnosis
The board stack is not on-line with the network or there is no power applied to the board stack.
The board stack is operating normally and the on-line connection is made with the network.
The board stack is waiting for an on-line connection to be made with the network.
The board stack has encountered a communication link failure with the network. Check DeviceNet cable connections. Replace
board stack if necessary.
B. Module Status LED
LED1 on the E Module board stack
Status
Off
Green
Flashing Red
Red
Diagnosis
There is no power applied to the board stack or the board stack software is not executing its functions.
The board stack is operating normally.
The board stack has encountered a recoverable fault. Wait or cycle power to clear fault.
The board stack has encountered an unrecoverable fault.
OM-251440 Page 83
12-12. Troubleshooting
Trouble
No weld output; completely inoperative
Remedy
Place line disconnect in On position (see Section 7-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 7-9).
Check for proper input power connections (see Section 7-9).
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.
error displayed.
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 8-2).
errors displayed.
Check that proper program for wire size, process, and shielding gas is loaded.
Clean and tighten all weld connections.
No 115 volts AC at the duplex receptacle. Reset supplementary protector CB1 (see Section 7-5).
Wire does not feed.
Check supplementary protector CB2 and reset if necessary (see Section 7-5).
Check motor control cable connections.
Wire feeds erratically.
Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.
Wire feeds as soon as power is supplied. Check gun trigger. See gun Owner’s Manual.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
Check voltage sense lead connection, clean and tighten if necessary.
Gas does not flow or does not stop flow- Check gas valve and flow meter.
ing; wire feeds.
Wire burns back to gun contact tip when Check to be sure that volt sense lead is connected to the work.
using electrode negative (straight
polarity) process.
12-13. Check Web Message Display
When an existing Auto-Axcess power source is upgraded to an Auto-Axcess E, the first time the unit is powered up the
message CHCK WEB will appear on the display (see Figure 12- 1).
CHCK
V
WEB
A
A
Setup
Adjust
Arc Control
Figure 12- 1. Welding Power Source Display On First Power Up After Upgrade
OM-251440 Page 84
Figure 12- 2. Web Site For Auto-Axcess E Information
OM-251440 Page 85
Trouble
Certain information must be entered on the web pages for the unit to function properly. The user will be prompted for
power source serial number, model and type (Semi-Auto, AROI, AUTO, etc.) as shown in Figure 12- 2.
12-14. Software Error Message Display
1.
During the initial power up sequence, the ARM checks the UIM, WFCM and RIO for software numbers or
revisions and compares them to what is stored to see if they are compatible. If these software versions are not
compatible, the ERR S W will appear on the display (see Figure 12- 3). Compatible software can be downloaded
from www.MillerWelds.com.
ERR
V
SW
A
A
Setup
Adjust
Arc Control
Figure 12- 3. Welding Power Source Display For Software Version Issues
2.
After supplying information on the web site and resolving any software issues, the unit as a system should now be
operational.
OM-251440 Page 86
Trouble
Notes
OM-251440 Page 87
SECTION 13 − WEB PAGES SITE TREE
The Axcess E machine IP address is required to open the web pages. If necessary, have the IT administrator provide
this address to allow opening the web pages. Port A on the power source is factory set to 169.254.0.2 as a static IP
address. Connect a PC to Port A and enter 169.254.0.2 in the web browser to access the web pages.
AXCESS E
Login Page
ITW Welding
Companies
Home Page
Welder
Configuration
Custom
Dashboard
Locks
Program Setup
Process
Setup
Robot
Configuration
Sequencer
Setup
Robot Options
Setup
Error Setup
OM-251440 Page 88
Welding Wire
Setup
Feed/Torch
Weld Cable
Setup
Secondary Data
Auto Cal
System Log
Logs/Reports
Trouble
Diagnostics
Errors
Short Term
Weld Data
Software
Communications
System Settings
Weld
Ethernet
Settings
More
Time Settings
Axcess Upgrade
Options
Welder
Information
Process Enables
Machine
Lifetime
Report
OM-251440 Page 89
TABLE OF CONTENTS
SECTION 14 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14-1. Circuit Diagram For Auto-Axcess E 300 Analog Welding Power Source (Part 1 Of 3) . . . . . . . .
91
91
Figure 14-2. Circuit Diagram For Auto-Axcess E 300 Analog Welding Power Source (Part 2 Of 3) . . . . . . . .
92
Figure 14-3. Circuit Diagram For Auto-Axcess E 300 Analog Welding Power Source (Part 3 Of 3) . . . . . . . .
94
Figure 14-4. Circuit Diagram For Auto-Axcess E 450 Analog Welding Power Source (Part 1 Of 3) . . . . . . . .
96
Figure 14-5. Circuit Diagram For Auto-Axcess E 450 Analog Welding Power Source (Part 2 Of 3) . . . . . . . .
98
Figure 14-6. Circuit Diagram For Auto-Axcess E 450 Analog Welding Power Source (Part 3 Of 3) . . . . . . . .
100
Figure 14-7. Circuit Diagram For Axcess E Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
Figure 14-8. Circuit Diagram For 72 Pin Robot Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Figure 14-9. Circuit Diagram For Peripheral/Motor Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
OM-251440 Page 90
Circuits
SECTION 14 − ELECTRICAL DIAGRAMS
263 492-C (Part 1 Of 3)
Figure 14-1. Circuit Diagram For Auto-Axcess E 300 Analog Welding Power Source (Part 1 Of 3)
OM-251440 Page 91
Figure 14-2. Circuit Diagram For Auto-Axcess E 300 Analog Welding Power Source (Part 2 Of 3)
OM-251440 Page 92
Circuits
263 492-C Part 2 Of 3)
OM-251440 Page 93
Figure 14-3. Circuit Diagram For Auto-Axcess E 300 Analog Welding Power Source (Part 3 Of 3)
OM-251440 Page 94
Circuits
263 492-C (Part 3 Of 3)
OM-251440 Page 95
Figure 14-4. Circuit Diagram For Auto-Axcess E 450 Analog Welding Power Source (Part 1 Of 3)
OM-251440 Page 96
Circuits
263 491-C (Part 1 Of 3)
OM-251440 Page 97
Figure 14-5. Circuit Diagram For Auto-Axcess E 450 Analog Welding Power Source (Part 2 Of 3)
OM-251440 Page 98
Circuits
263 491-C (Part 2 Of 3)
OM-251440 Page 99
Figure 14-6. Circuit Diagram For Auto-Axcess E 450 Analog Welding Power Source (Part 3 Of 3)
OM-251440 Page 100
Circuits
263 491-C (Part 3 Of 3)
OM-251440 Page 101
Figure 14-7. Circuit Diagram For Axcess E Module
OM-251440 Page 102
Circuits
250 369-D
OM-251440 Page 103
Figure 14-8. Circuit Diagram For 72 Pin Robot Interface
OM-251440 Page 104
Circuits
219 266-D
OM-251440 Page 105
Figure 14-9. Circuit Diagram For Peripheral/Motor Interface
OM-251440 Page 106
Circuits
219 267-B
OM-251440 Page 107
SECTION 15 − PARTS LIST FOR
AUTO-AXCESS E 300 ANALOG
. Hardware is
common and
not available unless listed.
2
1
2
3 − Fig 15-3
4
5
8 − Fig 15-5
6 − Fig 15-4
9
11
7 − Fig 15-2
19
20
15
17
23
16
10
22
18
21
14
12
9
24 − Fig 15-6
13
13
11
251 490-D
Figure 15-1. Auto-Axcess E 300 Analog Main Assembly
OM-251440 Page 108
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . +242008
. . . 2 . . . . . . . . . . . . . . . . 179309
. . . 3 . . . . . . . . . . . . . . . . 250287
. . . 3 . . . . . . . . . . . . . . . . 250286
. . . 4 . . . . . T2 . . . . . . . 212543
. . . 5 . . . . . . . . . . . . . . . . 210481
. . . 6 . . . . . . . . . . . . . . . Fig 15-4
. . . 7 . . . . IM-1 . . . . . . 214597
. . . . . . . . . . IM-1 . . . . . . 242680
. . . 8 . . . . . . . . . . . . . . . Fig 15-5
. . . 9 . . . . . . . . . . . . . . . +230260
. . . 10 . . . . . . . . . . . . . . . . 178551
. . . 11 . . . . . . . . . . . . . . . . 179310
. . . 12 . . . . . . . . . . . . . . . +210482
. . . 13 . . . . . . . . . . . . . . . . 219844
. . . 14 . . . . . . . . . . . . . . . . 219842
. . . 15 . . . . . . . . . . . . . . . . 213386
. . . 16 . . . . HD2 . . . . . . 182918
. . . 17 . . . . . . . . . . . . . . . . 220377
. . . 18 . . . . . . . . . . . . . . . . 204846
. . . 19 . . . . . . . . . . . . . . . . 247392
. . . 20 . . . . PC14 . . . . . . 229967
. . . 21 . . . . . . . . . . . . . . . . 148025
. . . 22 . . . . . . . . . . . . . . . . 220376
. . . 23 . . . . . . . . . . . . . . . . 213372
. . . 24 . . . . . . . . . . . . . . . Fig 15-6
. . . . . . . . . . . . . . . . . . . . . . 227855
. . . . . . . . . . . . . . . . . . . . . . 010467
. . . . . . . . . . . . . . . . . . . . . . 225840
. . . . . . . . . . . . . . . . . . . . . . 010916
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Falling Equipment Can Injure-Wordless . . . . . . . . . . . . .
. . . Assy, Auto-Axcess E Analog Module I100 (Fig 16-3) . . . . . . . . . . . . . . .
. . . Assy, Auto-Axcess E Analog Module I100 W/Sensor Bd (Fig 16-3) . . .
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, LH w/Components (Fig 15-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (Fig 15-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side W/Insulator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, General Precautionary Wordless Intl Small . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Electric Shock/Exploding Parts-Wdles . . . . . . . . . . . . . .
. . . Label, Warning Input Connections/Electric Shock CE . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Kit, Connectors W/Washer For Power Cables (Includes) . . . . . . . . . . . .
. . . . Connector, Clamp Cable 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Reducer 1.25 in − 0.75 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Connector, Clamp Cable 0.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
1
1
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 109
E300 Parts
Figure 15-1. Auto-Axcess E 300 Analog Main Assembly
14
. Hardware is
common and
not available unless listed.
15
2
1
3
4
5
6
7
12
13
11
8
9
33
10
6
34
35
7
17
16
18
19
32
31
20 21
30
29
23
24
25
23
27
13
36
28
26
22
23
38
37
802 955-C
Figure 15-2. Windtunnel Assembly LH And RH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-2. Windtunnel Assembly LH And RH
(Fig 15-1 Item 7)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
................
................
. . . . . L1 . . . . . . .
................
. . . R3, C4 . . . . .
................
. . . D1, D2 . . . . .
................
................
. . . . . T1 . . . . . . .
. . . . . Z1 . . . . . . .
................
................
................
................
................
................
................
................
214597
196351
213940
214519
233052
199840
201531
196347
196349
203408
220496
170647
179276
196355
010546
242680
196332
030170
196259
. . . Windtunnel, LH w/Components (including). . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Heat Sink Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Xfmr, HF Litz/Litz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Output Inductor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . .
. . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . .
. . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
2
1
3
1
1
2
4
6
1
1
1
2
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 110
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
......................
......................
. . . . . . . . . . CT1 . . . . . .
. . . 20 . . . . . . . . . . . . . . . .
. . . 21 . . . C1, C2 . . . . .
. . . 22 . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . . .
. . . 24 RT1,RT2,RT3 . .
. . . 25 . . . . PC2 . . . . . .
. . . 26 . . . . . C3 . . . . . . .
. . . 27 . . . . . . . . . . . . . . . .
. . . 28 . . . . HD1 . . . . . .
......................
. . . 29 . . . R1, R2 . . . . .
......................
. . . 30 . . . . . . . . . . . . . . . .
. . . 31 . . . . . L2 . . . . . . .
. . . 32 . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . . .
......................
......................
. . . 36 . . . . PC1 . . . . . .
. . . 37 . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . . .
115092
115091
196231
201695
203912
210507
261556
214015
270832
196143
196378
182918
196384
196343
196840
109056
196345
196514
196512
196330
196588
196365
199136
272259
204846
083147
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor,Elctlt 2400 Uf 500 VDC Can 2.50 Dia . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead . . . . . . . . . . . .
. . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Current Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Transducer, Current 400A Module Supply V +/− 15v . . . . . . . . . . . . . .
. . . . Cable, Transducer 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistors, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Resistors/Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . .
. . . . Coil, Inductor (Pre−regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (PC2 To PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Control (Inverter 400A) Analog Auto-Axcess E 300
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . .
1
1
1
2
2
2
1
3
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
4
4
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 111
E300 Parts
Figure 15-2. Windtunnel Assembly LH And RH
(Fig 15-1 Item 6) (Continued)
. Hardware is
common and
not available unless listed.
1
3
4
2
17
15
16
14
13
5
18
7
12
8
11
10
6
9
245 871-E
Figure 15-3. E-module w/Ethernet And USB Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-3. E-module w/Ethernet And USB Assembly
(Fig 15-1 Item 3)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . . . . . . . . . . . . . 250516
. . . . . . . . . . . . . . . . 115440
. . . . . . . . . . . . . . . ♦244985
. . . . . . . . . . . . . . . . 000527
. . . . . . . . . . . . . . . . 242645
. . . . . . . . . . . . . . . ♦242007
. . . . . . . . . . . . . . . . 241996
. . . . . . . . . . . . . . . . 246591
. . . . . . . . . . . . . . . . 222808
. . . . . . . . . . . . . . . . 245350
. . . . . . . . . . . . . . . . 250299
. . . . . . . . . . . . . . . . 244237
. . . . . . . . . . . . . . . . 244239
. . . . . . . . . . . . . . . . 203423
. . . . . . . . . . . . . . . . 246545
. . . . . . . . . . . . . . . . 244980
. . . . . . . . . . . . . . . . 244257
. . . . . . . . . . . . . . . . 170647
. . . Assy, Axcess E Circuit Card Board Stack . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, No 6−32 X .687 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Axcess E MWCI Interface . . . . . . . . . . . . . . . . . . . . . .
. . . Blank, Snap−in Nyl .875 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Axcess E Top Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Amp W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Chassis, Axcess E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Ground Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Tubing, GL Acryl .750- .786 ID 8.000 Yel FA1 . . . . . . . . . . . . . . . . . . . . .
. . . Assembly, Personality Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Auto−Axcess E Top Front . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cable, USB Type A, Sealed Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing,Strain Relief .300/.360 ID X .689 Sq Mtg . . . . . . . . . . . . . . . . . .
. . . Bracket,Axcess E Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Ethernet LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cable Assy, RJ45 Male/M12 Female .4m . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap-in Nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
1
4
1
1
1
1
1
2
1
1
1
1
1
3
1
1
2
1
*Recommended Spare Parts.
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 112
. Hardware is
1
common and
not available unless listed.
3
4
9
2
8
5
7
249 750-A
Figure 15-4. Top Tray Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-4. Top Tray Assembly (Fig 15-1 Item 6)
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
. . . . PC12 . . . . . .
. . . . PC3 . . . . . .
................
................
................
................
................
................
. . . . PC6 . . . . . .
239623
239598
210490
134201
170647
210491
223439
198122
245594
. . . Circuit Card Assy, E−stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off, PC Card .312/.375/Post&Lock .43 . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Circuit Card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . .
. . . Wire Feed Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 113
E300 Parts
6
. Hardware is
common and
not available unless listed.
12
10
1
6
2
11
9
3
14
7
13
8
15
5
4
250 056-B
Item
No.
Dia.
Mkgs.
Figure 15-5. Auto-Axcess E 300 Analog Rear Panel Assembly
Part
No.
Description
Quantity
Figure 16-5. Auto-Axcess E 300 Analog Rear Panel Assembly
(Fig 15-1 Item 8)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
. . . . PC9 . . . . . . 250456
. . . . . . . . . . . . . . . . 212628
. . . . PC10 . . . . . . 239627
. . . . . . . . . . . . . . . . 217297
. . . . . . . . . . . . . . . +210479
. . . . . . . . . . . . . . . . 245352
. . . . . . . . . . . . . . . . 210505
. . . . . . . . . . . . . . . . 201058
. . . . . . . . . . . . . . . . 210483
. . . . CB1 . . . . . . 083432
. . . . CB2 . . . . . . 093995
. . . . PC11 . . . . . . 239631
. . . . RC2 . . . . . . 604176
. . . . . . . . . . . . . . . . 216596
. . . . . . . . . . . . . . . . 219842
. . . Automation Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 6-32 x 1.000 lg .250 hex nyl fem . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Connector, Rect 72 Pin Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . .
. . . Circuit Card Assy, Motor Filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Input Connections/Electric Shock CE . . . . . . . . . . . . . . .
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 114
. Hardware is
common and
not available unless listed.
4
18
2
3
5
1
16
6
17
7
8
10
15
E300 Parts
6
9
11
14
12
13
12
250 021-A
Figure 15-6. Auto-Axcess E 300 Analog Front Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-6. Auto-Axcess E 300 Analog Front Panel Assembly
(Fig 15-1 Item 23)
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
. . . . . S1 . . . . . . .
................
................
................
. . . . . FM . . . . . . .
. PC15,PC20 . . .
................
................
................
................
207456
207895
179851
251414
196313
244993
210865
244989
207980
210866
. . . Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . .
. . . Panel, PC Card Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Circuit Card Assy, Stud Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Vsense Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
1
1
1
OM-251440 Page 115
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-6. Auto-Axcess E 300 Analog Front Panel Assembly
(Fig 15-1 Item 23) (Continued)
...
...
...
...
...
...
...
...
11
12
13
14
15
16
17
18
................
................
................
................
PB1, PB2, PB3 . .
................
................
................
250004
186621
207979
219843
199443
250005
210483
245352
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Work Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
3
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 116
E450 Parts
Notes
OM-251440 Page 117
SECTION 16 − PARTS LIST FOR
AUTO-AXCESS E 450 ANALOG
. Hardware is
common and
not available unless listed.
4
5
2
1
6 − Fig 16-4
7 − Fig 16-2
2
3 − Fig 16-3
10 − Fig 16-5
11
8
7 − Fig 16-2
13
9
22
21 20
12
25
19
18
16
23
26 − Fig 16-6
25
17
14
11
24
15
15
13
251 481-D
Figure 16-1. Auto-Axcess E 450 Analog Main Assembly
OM-251440 Page 118
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-1. Auto-Axcess E 450 Analog Main Assembly
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Falling Equipment Can Injure-Wordless . . . . . . . . . . . . .
. . . Assy, Auto-Axcess E Analog Module I100 (Fig 16-3) . . . . . . . . . . . . . . .
. . . Assy, Auto-Axcess E Analog Module I100 W/Sensor Bd (Fig 16-3) . . .
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, LH w/Components (Fig 16-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (Fig 16-2) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Module Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Contactor, Def Prp 40A 3P 24VAC Coil w/Boxlug . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side W/Insulator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Small Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, General Precautionary Wordless Intl Small . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Electric Shock/Exploding Parts-Wdles . . . . . . . . . . . . . .
. . . Label, Warning Input Connections/Electric Shock CE . . . . . . . . . . . . . . .
. . . Filter Assembly, Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, Input Filter Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
2
2
1
1
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
2
1
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 119
E450 Parts
. . . 1 . . . . . . . . . . . . . . . +242008
. . . 2 . . . . . . . . . . . . . . . . 179309
. . . 3 . . . . . . . . . . . . . . . . 250287
. . . 3 . . . . . . . . . . . . . . . . 250286
. . . 4 . . . . . T2 . . . . . . . 212543
. . . 5 . . . . . . . . . . . . . . . . 210481
. . . 6 . . . . . . . . . . . . . . . Fig 16-4
. . . 7 . . IM1, IM2 . . . . 214597
. . . . . . . . . . . . . . . . . . . . . . 242680
. . . 8 . . . . . . . . . . . . . . . . 198961
. . . 9 . . . . . W1 . . . . . . . 180270
. . . 10 . . . . . . . . . . . . . . . Fig 16-5
. . . 11 . . . . . . . . . . . . . . . +237360
. . . 12 . . . . . . . . . . . . . . . . 178551
. . . 13 . . . . . . . . . . . . . . . . 179310
. . . 14 . . . . . . . . . . . . . . . +210482
. . . 15 . . . . . . . . . . . . . . . . 219844
. . . 16 . . . . . . . . . . . . . . . . 219842
. . . 17 . . . . . . . . . . . . . . . . 213386
. . . 18 . . . . HD2 . . . . . . 182918
. . . 19 . . . . . . . . . . . . . . . . 220377
. . . 20 . . . . . . . . . . . . . . . . 204846
. . . 21 . . . . . . . . . . . . . . . . 247392
. . . 22 . . . . PC14 . . . . . . 229967
. . . 23 . . . . . . . . . . . . . . . . 148025
. . . 24 . . . . . . . . . . . . . . . . 220376
. . . 25 . . . . . . . . . . . . . . . . 213372
. . . 26 . . . . . . . . . . . . . . . Fig 16-6
14
. Hardware is
common and
not available unless listed.
15
2
1
3
4
5
6
7
12
13
11
8
9
33
10
6
34
35
7
17
16
18
19
32
31
20 21
30
29
23
24
25
23
27
13
36
28
26
22
23
38
37
802 955-C
Figure 16-2. Windtunnel Assembly LH And RH
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-2. Windtunnel Assembly LH And RH
(Fig 16-1 Item 7)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
................
................
. . . . . L1 . . . . . . .
................
. . . R3, C4 . . . . .
................
. . . D1, D2 . . . . .
................
................
. . . . . T1 . . . . . . .
. . . . . Z1 . . . . . . .
................
................
................
................
................
................
................
................
214597
196351
213940
214519
233052
199840
201531
196347
196349
203408
220496
170647
179276
196355
010546
242680
196332
030170
196259
. . . Windtunnel, LH w/Components (including). . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Heat Sink Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Xfmr, HF Litz/Litz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Output Inductor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . .
. . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . .
. . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . .
. . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . .
. . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
2
1
3
1
1
2
4
6
1
1
1
2
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 120
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-2. Windtunnel Assembly LH And RH
(Fig 16-1 Item 6) (Continued)
115092
115091
196231
201695
203912
210507
261556
214015
270832
196143
196378
182918
196384
196343
196840
109056
196345
196514
196512
196330
196588
196365
199136
272326
204846
083147
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor,Elctlt 2400 Uf 500 VDC Can 2.50 Dia . . . . . . . . . . . . . . . .
. . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . .
. . . . Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead . . . . . . . . . . . .
. . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . .
. . . . Bracket, Mtg Current Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Transducer, Current 400A Module Supply V +/− 15v . . . . . . . . . . . . . .
. . . . Cable, Transducer 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistors, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Insulator, Resistors/Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . .
. . . . Coil, Inductor (Pre−regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Plugs, w/Leads (PC2 To PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Control (Inverter 300A) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . .
1
1
1
2
2
2
1
3
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
4
4
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 121
E450 Parts
......................
......................
. . . . . . . . . . CT1 . . . . . .
. . . 20 . . . . . . . . . . . . . . . .
. . . 21 . . . C1, C2 . . . . .
. . . 22 . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . . .
. . . 24 RT1,RT2,RT3 . .
. . . 25 . . . . PC2 . . . . . .
. . . 26 . . . . . C3 . . . . . . .
. . . 27 . . . . . . . . . . . . . . . .
. . . 28 . . . . HD1 . . . . . .
......................
. . . 29 . . . R1, R2 . . . . .
......................
. . . 30 . . . . . . . . . . . . . . . .
. . . 31 . . . . . L2 . . . . . . .
. . . 32 . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . . .
......................
......................
. . . 36 . . . . PC1 . . . . . .
. . . 37 . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . . . . . . .
. Hardware is
common and
not available unless listed.
1
3
4
2
17
15
16
14
13
5
18
7
12
8
11
10
6
9
245 871-E
Figure 16-3. E-module w/Ethernet And USB Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-3. E-module w/Ethernet And USB Assembly
(Fig 16-1 Item 3)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . . . . . . . . . . . . . 250516
. . . . . . . . . . . . . . . . 115440
. . . . . . . . . . . . . . . ♦244985
. . . . . . . . . . . . . . . . 000527
. . . . . . . . . . . . . . . . 242645
. . . . . . . . . . . . . . . ♦242007
. . . . . . . . . . . . . . . . 241996
. . . . . . . . . . . . . . . . 246591
. . . . . . . . . . . . . . . . 222808
. . . . . . . . . . . . . . . . 245350
. . . . . . . . . . . . . . . . 250299
. . . . . . . . . . . . . . . . 244237
. . . . . . . . . . . . . . . . 244239
. . . . . . . . . . . . . . . . 203423
. . . . . . . . . . . . . . . . 246545
. . . . . . . . . . . . . . . . 244980
. . . . . . . . . . . . . . . . 244257
. . . . . . . . . . . . . . . . 170647
. . . Assy, Axcess E Circuit Card Board Stack . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, No 6−32 X .687 Lg .250 Hex Al Fem . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Axcess E MWCI Interface . . . . . . . . . . . . . . . . . . . . . .
. . . Blank, Snap−in Nyl .875 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Axcess E Top Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Amp W/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Chassis, Axcess E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Ground Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Tubing, GL Acryl .750- .786 ID 8.000 Yel FA1 . . . . . . . . . . . . . . . . . . . . .
. . . Assembly, Personality Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Auto−Axcess E Top Front . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cable, USB Type A, Sealed Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing,Strain Relief .300/.360 ID X .689 Sq Mtg . . . . . . . . . . . . . . . . . .
. . . Bracket,Axcess E Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Ethernet LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cable Assy, RJ45 Male/M12 Female .4m . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap-in Nyl 1.312 ID X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
1
4
1
1
1
1
1
2
1
1
1
1
1
3
1
1
2
1
*Recommended Spare Parts.
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 122
. Hardware is
1
common and
not available unless listed.
3
4
9
2
8
5
7
6
249 750-A
Figure 16-4. Top Tray Assembly
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-4. Top Tray Assembly (Fig 16-1 Item 6)
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
. . . . PC12 . . . . . .
. . . . PC3 . . . . . .
................
................
................
................
................
................
. . . . PC6 . . . . . .
239623
239598
210490
134201
170647
210491
223439
198122
245594
. . . Circuit Card Assy, E−stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off, PC Card .312/.375/Post&Lock .43 . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, Circuit Card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . .
. . . Wire Feed Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 123
E450 Parts
Item
No.
. Hardware is
common and
not available unless listed.
10
1
6
2
9
11
3
12
14
7
13
8
4
5
15
249 766-B
Figure 16-5. Auto-Axcess E 450 Analog Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-5. Auto-Axcess E 450 Analog Rear Panel Assembly
(Fig 15-1 Item 10)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
. . . . PC9 . . . . . . 250456
. . . . . . . . . . . . . . . . 212628
. . . . PC10 . . . . . . 239627
. . . . . . . . . . . . . . . . 217297
. . . . . . . . . . . . . . . +210475
. . . . . . . . . . . . . . . . 245352
. . . . . . . . . . . . . . . . 210505
. . . . . . . . . . . . . . . . 201058
. . . . . . . . . . . . . . . . 210483
. . . . CB1 . . . . . . 083432
. . . . CB2 . . . . . . 093995
. . . . PC11 . . . . . . 239631
. . . . RC2 . . . . . . 604176
. . . . . . . . . . . . . . . . 216596
. . . . . . . . . . . . . . . . 219842
. . . Automation Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, no 6−32 x 1.000 lg .250 hex nyl fem . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Connector, Rect 72 Pin Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . .
. . . Circuit Card Assy, Motor Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Receptacle (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label,Warning Input Connections/Electric Shock CE . . . . . . . . . . . . . . .
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 124
19
. Hardware is
common and
not available unless listed.
4
2
1
18
5
3
7
8
17
6
5
11
10
16
13
9
14
12
10
13
803 249-D
Figure 16-6. Auto-Axcess E 450 Analog Front Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-6. Auto-Axcess E 450 Analog Front Panel
Assembly (Fig 15-1 Item 25)
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
. . . . . S1 . . . . . . .
................
................
................
. PC15,PC20 . . .
. . . . . FM . . . . . . .
................
................
................
................
................
................
................
207456
207895
179851
251414
244993
196313
210865
244989
207897
025248
210866
249819
186621
. . . Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . .
. . . Panel, PC Card Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Stud Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Vsense Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . .
. . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
2
2
1
1
2
2
1
1
2
OM-251440 Page 125
E450 Parts
15
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-6. Auto-Axcess E 450 Analog Front Panel
Assembly (Fig 15-1 Item 25) (Continued)
...
...
...
...
...
...
14
15
16
17
18
19
................
................
PB1, PB2, PB3 . .
................
................
................
219843
207896
199443
249680
210483
245352
. . . Label, Work Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
1
1
1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-251440 Page 126
Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
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.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
* MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in,
or for a minimum of one year — whichever is
greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2016-01
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.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2016 Miller Electric Mfg. Co.
2016−01