Miller AXCESS E WELDING POWER SOURCES User manual

OM-244 814Q
2016−01
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Air Carbon Arc (CAC-A)
Cutting and Gouging
Automatic Welding
Description
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Automatic Welding Interface And
Arc Welding Power Source
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Axcess E Welding
Power Sources
R
Visit our website at
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 9001:2000 Quality Warranty and service information for your
System 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 AXCESS E 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − SPECIFICATIONS FOR AXCESS E 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − SPECIFICATIONS FOR AXCESS E 675 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − LICENSE AGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − GENERAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Upper Front Panel Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Upper Rear Panel Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Lower Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Network Wire Feeder Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
7
8
8
8
9
9
11
13
13
13
13
13
14
14
15
17
17
17
17
17
18
18
19
21
21
21
21
21
22
22
23
25
25
25
26
26
27
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TABLE OF CONTENTS
8-7. Optional E-Stop Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Connecting 1-Phase Input Power For Axcess E 300 Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − RECOMMENDED SETUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Welding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Using Multiple Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs . . . . . . . . . . . . . . . . .
9-7. 30 Points Of Mechanics In MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-8. Arc Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9. Basic Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Pulse Welding Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Check Web Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Software Error Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-4. E Module Board Stack Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-5. Diagnostic LEDs On E Module Board Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-6. Network And Module Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − WEB PAGES SITE TREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 16 − PARTS LIST FOR AXCESS E 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 17 − PARTS LIST FOR AXCESS E 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 18 − PARTS LIST FOR AXCESS E 675 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
28
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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-244 814 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-244 814 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-244 814 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-244 814 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-244 814 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-244 814 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-244 814 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-244 814 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.
Definitions
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-244 814 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
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
V
V
>5min
= < 60°
V
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.
Safe43 2012−05
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
OM-244 814 Page 10
Definitions
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
Three Phase Static
Frequency
Converter-Transformer-Rectifier
I1
S
X
U0
Input Current
Suitable For
Welding In An
Environment With
Increased Risk Of
Electric Shock
Duty Cycle
Rated No−Load
Voltage (OCV)
Protective Earth
(Ground)
Single / Three
Phase Static
Frequency
Converter-Transformer-Rectifier
1/
I2
I1max
U1
A
Amperes
Maximum Effective
Supply Current
Gas Metal Arc
Welding (GMAW)
Constant Voltage
Power Connection
Rated Maximum
Supply Current
I1eff
V
Volts
Percent
IP
Degree Of
Protection
Maximum Effective
Supply Current
Input Voltage
Direct Current
(DC)
Single Phase
Three Phase
Alternating
Current
(AC)
/
Single /
Three
Phase
Notes
OM-244 814 Page 11
Notes
OM-244 814 Page 12
SECTION 4 − SPECIFICATIONS FOR AXCESS E 300
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.
on connecting input power
Input
Power
Rated
Welding
Output
Single
Phase
175 A @
22.8 V
DC,
100%
Duty
Cycle
Three
Phase
Voltage
Range
Wire Feed
Speed
Range**
10-44
Standard:
50-1400
ipm
(1.3-35.6
mpm)
225 A @
25.3 V
DC,
100%
Duty
Cycle
Wire
Diameter
Range
.035-1/16
in.
(0.8-1.6
mm)
Max
Open
Circuit
Voltage
DC
Amperes Input At Rated Load Output 60 Hz,
Single-Phase/Three-Phase
Input
kVA
Input
KW
208 V
230 V
380V
400V
460 V
575 V
25.3
(0-1A*)
23.0
(0-1A*)
13.5
(0-1A*)
12.8
(0-1A*)
10.9
(0-1A*)
8.6
(0-1A*)
5.3
(0.2*)
4.9
(0.04*)
19.9
(0-1A*)
17.8
(0-1A*)
10.9
(0-1A*)
10.3
(0-1A*)
9.0
(0-1A*)
7.3
(0-1A*)
7.1
(0.2*)
6.8
(0.04*)
75
*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)
E
21-3/4 in.
(552 mm)
26-1/2 in.
(673 mm)
C
B
Weight
117 lb (53 kg) Net
139 lb (63 kg) Ship
17-3/32 in.
(434 mm)
D
Ref. 273 496-A
4-4. Environmental Specifications
IP Rating
IP 23C
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23 2014−06
OM-244 814 Page 13
E300 Spec
4-2. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-7, 8-9, and 8-10 for information
4-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
500
WELDING AMPERES
400
300
3 PHASE
OPERATION
250
225
200
SINGLE
PHASE
OPERATION
150
100
10
15
20
25 30
40
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.
50 60 70 80 90100
% DUTY CYCLE
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 − 178 651
4-6. 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
. This
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
70
VOLTGE
60
50
40
30
20
10
0
0
100
200
300
AMPERAGE
400
500
600
va_curve1 4/95
OM-244 814 Page 14
4-7. 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 Single Phase
Input Voltage (V)
208
230
380
400
460
575
Input Amperes (A) At Rated Output
25.3
23.0
13.5
12.8
10.9
8.6
Time-Delay Fuses 2
30
25
15
15
10
10
3
40
35
20
20
15
15
10
10
14
14
14
14
108
(33)
132
(40)
141
(43)
156
(48)
207
(63)
323
(99)
10
10
14
14
14
14
Max Recommended Standard Fuse Rating In Amperes1
Normal Operating Fuses
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
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.
50/60 Hz Three Phase
Input Voltage (V)
208
230
380
400
460
575
Input Amperes (A) At Rated Output
19.9
17.8
10.9
10.3
9.0
7.3
Time-Delay Fuses 2
20
20
10
10
10
8
3
30
25
15
15
15
10
12
12
14
14
14
14
94
(29)
116
(35)
204
(62)
226
(69)
299
(91)
467
(142)
12
12
14
14
14
14
Max Recommended Standard Fuse Rating In
Amperes1
Normal Operating Fuses
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
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-244 814 Page 15
E300 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
Notes
OM-244 814 Page 16
SECTION 5 − SPECIFICATIONS FOR AXCESS E 450
5-1. 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.
5-2. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-7 and 8-9 for information on connecting input power
Three
Phase
Rated
Welding
Output
450 A @
36.5 V DC,
100%
Duty
Cycle
Voltage
Range
10-44
Wire Feed
Speed
Range**
Wire
Diameter
Range
Standard:
50-1400
ipm
(1.3-35.6
mpm)
.035-3/32 in.
(0.8-1.6 mm)
Max
Open
Circuit
Voltage
DC
75
Amperes Input At Rated Load Output 60 Hz,
Three-Phase
208 V
230 V
380 V
400V
460 V
575 V
54.0
(0-1A*)
49.0
(0-1A*)
29.0
(0-1A*)
28.0
(0-1A*)
24.0
(0-1A*)
19.0
(0-1A*)
Input
kVA
Input
KW
19.9
(0.8*)
19.2
(0.17*)
E450 Spec
Input
Power
*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.
(552 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
273 497-A
5-4. Environmental Specifications
IP Rating
IP 23C
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23 2014−06
OM-244 814 Page 17
5-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
500
If unit overheats, thermostat(s)
3 PHASE
opens, output stops, and cooling
OPERATION fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
WELDING AMPERES
500
400
300
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
200
150
100
0
10
15
20
25
30
40
50 60 70 80 90 100
% DUTY CYCLE
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
5-6. 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
. This
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
70
VOLTAGE
60
50
40
30
20
10
0
0
100
OM-244 814 Page 18
200
300
400
AMPERAGE
500
600
700
va_curve1 4/95 − 220 486-A
5-7. 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.
. 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
200/208
230
380
400
460
575
54
49
29
28
24
19
Time-Delay Fuses 2
70
60
35
35
30
25
3
90
70
45
45
35
30
6
8
8
10
10
12
123
(38)
104
(32)
283
(86)
205
(63)
272
(83)
256
(78)
8
8
10
10
10
12
Input Voltage (V)
Input Amperes (A) At Rated Output
Normal Operating Fuses
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet
(Meters)
Min Grounding Conductor Size In AWG 4
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-244 814 Page 19
E450 Spec
Max Recommended Standard Fuse Rating In Amperes 1
Notes
OM-244 814 Page 20
SECTION 6 − SPECIFICATIONS FOR AXCESS E 675
6-1. 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.
6-2. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 6-7 and 8-9 for information on connecting input power
Input
Power
Three
Phase
Rated
Welding
Output
Voltage
Range
675 A @
44 V DC,
100%
Duty
Cycle
10-44
Wire Feed
Speed
Range**
Wire
Diameter
Range
Standard:
50-1400
ipm
(1.3-35.6
mpm)
.035-.062 in.
(0.8-1.6 mm)
Max
Open
Circuit
Voltage
DC
75
Amperes Input At Rated Load Output 60 Hz,
Three-Phase
230 V
400V
460 V
575 V
89
(0-1A*)
50
(0-1A*)
44
(0-1A*)
35
(0-1A*)
Input
KVA
Input
KW
35.5
(0.8*)
34
(0.17*)
*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.
6-3. Dimensions And Weight
A
A
15-1/8 in. (384 mm)
B
16 in. (406 mm)
C
19-3/32 in. (485
mm)
D
13-5/8 in. (346 mm)
E
11/32 in. (9 mm)
E
21-3/4 in.
(552 mm)
42-3/4 in.
(1086 mm)
C
B
Weight
220 lb (100 kg) Net
237 lb (108 kg) Ship
17-3/32 in.
(434 mm)
D
Ref. 250 647-B
6-4. Environmental Specifications
IP Rating
IP 23C
This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless
sheltered.
IP23 2014−06
OM-244 814 Page 21
E675 Spec
Hole Layout Dimensions
6-5. Duty Cycle And Overheating
WELD AMPERES
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.
1000
900
800
700
600
500
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
400
300
200
100
10
20
30
40
50
60 70 80 90 100
% DUTY CYCLE
100% Duty Cycle At 675 Amperes
Continuous Welding
Overheating
A/V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 206 789-A
6-6. 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
. This
70
volt-ampere
curve
represents the dynamic output
of the unit with a static load.
60
VOLTAGE
50
40
30
20
10
0
0
100
200
300
400
500
AMPERES
600
700
800
900
1000
va_curve1 4/95 − 221 502-A
OM-244 814 Page 22
6-7. 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.
. 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.
60 Hz Three Phase
Input Voltage (V)
230
400
460
575
Input Amperes (A) At Rated Output
89
50
44
35
Time-Delay Fuses 2
110
60
50
40
3
125
80
70
50
3
6
8
8
173
(53)
275
(84)
231
(70)
361
(110)
6
8
8
10
Max Recommended Standard Fuse Rating In Amperes 1
Normal Operating Fuses
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
E675 Spec
Reference: 2011 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-244 814 Page 23
Notes
OM-244 814 Page 24
SECTION 7 − LICENSE AGREEMENT
You have acquired a device (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 8 − GENERAL INSTALLATION
. Appearance of actual unit may vary from unit shown in manual.
8-1. Selecting A Location
Movement
!
Do not move or operate unit
where it could tip.
1
OR
3
OR
2
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.
1
2
Lifting Eyes
Lifting Forks
Use lifting eyes or lifting forks to move unit.
18 in.
(460 mm)
If using lifting forks, extend forks beyond opposite side of unit.
3
Hand Cart
Use cart or similar device to move unit.
4
Line Disconnect Device
General
Locate unit near correct input power supply.
18 in.
(460 mm)
loc_axcess 2015-04
OM-244 814 Page 25
8-2. Connection Diagram
1
2
3
4
5
6
7
8
3
4
5
2
Welding Power Source
Wire Feeder
Gas Cylinder
Gas Hose
Network Feeder Cable
Negative (−) Weld Cable
Workpiece
Voltage Sensing Lead
Recommended for Accu-pulse and
required for RMD.
1
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
9
Positive (+) Weld Cable
7
8
9
6
245 739-B
8-3. Upper Front Panel Receptacles
1
1
USB Host Receptacle A
USB receptacle provides a connection
for various USB host devices.
245 746-B
OM-244 814 Page 26
8-4. Upper Rear Panel Receptacles
3
4
5
6
1
2
1
Ethernet Receptacle Port A
Ethernet Receptacle Port B
Port A and Port B are identified by the IP
address from the network server.
2
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. 245 741-C
8-5. Lower Rear Panel Receptacles And Supplementary Protectors
1
115 V 10 A AC Receptacle RC2
Receptacle
supplies
60
Hz
single-phase power. Maximum output
from RC2 is limited by supplementary
protector CB1 to 10 amps.
2
3
5
1
Supplementary Protector CB1
Supplementary Protector CB2
CB1 protects 115 volt receptacle RC2
from overload. If CB1 opens, RC2 does
not work.
2
CB2 protects the wirefeed motor from
overload. If CB2 opens, the wirefeeder
does not work.
3
. Press
button to reset breaker. If
breaker continue to open, contact a
Factory Authorized Service Agent.
4
Network Wire Feeder Receptacle
RC1
Use receptacle to connect network
feeder cable to power source (see
Section 8-2).
5
Optional E-Stop Receptacle RC4
Ref. 245 741-C
OM-244 814 Page 27
General
4
8-6. Network Wire Feeder Receptacle Functions
Pin*
9
F
E
G
D
I
H
A
C
Pin Information
A
Not used.
B
Shield.
C
Volt sense.
D
Can low.
E
Can high.
F
+24 volts DC common.
G
+ 24 volts DC
H
Motor voltage +40 volts DC common
I
Motor voltage +40 volts DC
B
Ref. 245 741-C
*The remaining pins are not used.
8-7. Optional E-Stop Receptacle Functions
A
B
Socket
Socket Information
A
A short to socket B allows unit to weld.
B
A short to socket A allows unit to weld.
Ref. 245 741-C
The E-Stop option comes with a 2-pin amphenol receptacle, matching plug, and 30 ft (9 m) of high density molded cord to allow connecting the
welding power source into an E-Stop circuit. An integrator will need to supply a closure for the non E-Stop condition. When the E-Stop input
connection changes it state from closed to open, the welding power source goes into an E-Stop mode where all welding outputs shutdown
immediately. Once the input connection returns to a closed state, the unit will start a reset routine and be ready for operation when it completes
the reset routine.
OM-244 814 Page 28
8-8. Removing Cover and Measuring Input Capacitor Voltage
!
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.
Tools Needed:
5/16 in.
Remove cover
1
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.
1
2
3
Typical Bleeder Resistor
An example of a typical bleeder resistor
is shown on this page.
Proceed with job inside unit. Reinstall
cover when finished.
+ lead to left bus terminal, − lead to right bus terminal
1
2
3
+ lead to left bus terminal, − lead to right bus terminal
Typical Bleeder Resistor
General
25 to 1000 ohm,
5 watt resistor
#16 AWG 1000 volts DC
insulation rating, approx
3 in. (76 mm) leads
802 985 / Ref. 245 768-C
OM-244 814 Page 29
8-9. Connecting 3-Phase Input Power
3
= GND/PE Earth Ground
8
10
7
L1
4
L2
6
L3
9
1
5
6
Route input power cable
through tubing inside unit.
Route ground conductor through
current transducer to ground terminal.
4
3
2
Tools Needed:
5/16 in.
Input5 2013−04 − Ref. 803 766-C / 245 742-C / 218 005-A
OM-244 814 Page 30
8-9. Connecting 3-Phase Input Power (Continued)
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 8-8 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.
NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be connected to any input power between 208 and
575 VAC without removing cover to relink the
power source.
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 4-7. 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.
3 Welding Power Source Grounding
Terminal
4 Green Or Green/Yellow Grounding
Conductor
Route green or green/yellow grounding conductor through current transducer and connect to welding power source grounding terminal first.
5 Welding Power Source Line Terminals
6 Input Conductors L1, L2, L3
Connect input conductors L1, L2, and L3 to
welding power source line terminals.
Reinstall side panel on welding power source.
Disconnect
Device
Input
Power
Connections
7 Disconnect Device (switch shown in the
OFF position)
8 Disconnect Device Grounding Terminal
9 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.
10 Over-Current Protection
Select type and size of over-current protection using Section 4-7 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.
Input5 2013−04
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-244 814 Page 31
General
Notes
8-10. Connecting 1-Phase Input Power For Axcess E 300 Only
1
12
=GND/PE Earth Ground
14
11
13
L1
L2
5
2
2
3
1
10
5
4
Route input power cable
through tubing inside unit.
6
Route ground conductor
through current transducer to
ground terminal.
1
8
9
7
Tools Needed:
5/16 in.
Input7 2012−05 − Ref. 803 766-C / Ref. 144 221 / Ref. 070 399 / 803 668-A / 248 842-B / Ref. 218 005-A
OM-244 814 Page 32
8-10. Connecting 1-Phase Input Power For Axcess E 300 Only (Continued)
!
Turn Off welding power source, and
check voltage on input capacitors
according to Section 8-8 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.
. The
Auto-Line circuitry in this unit
automatically links the power source to the
primary voltage being applied. Check input
voltage available at site. This unit can be
connected to any input power between 208
and 575 VAC without relinking the power
source.
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 4-7. Conductors must comply with
national, state, and local electrical codes. If
applicable, use lugs of proper amperage
capacity and correct hole size.
Three Conductor Power Cord Preparation
2
3
4
5
6
Black And White Input Conductors
(L1 And L2)
Red Input Conductor
Insulation Sleeving
Green Or Green/Yellow Grounding
Conductor
Electrical Tape
Insulate and isolate red conductor as shown.
Welding Power Source Input Power
Connections
7
Strain Relief (Customer Supplied)
Install strain relief of proper size for unit and
input conductors. Route conductors (cord)
through strain relief. Tighten strain relief.
Connect input conductors as shown in
illustration.
8
9
Current Transducer
Welding Power Source Grounding
Terminal
10 Welding Power Source Line Terminals
Route green or green/yellow grounding
conductor through current transducer and
connect to welding power source grounding
terminal first. Then connect input conductors L1
and L2 to welding power source line terminals.
Reinstall side panel onto welding power source.
Disconnect
Device
Connections
Input
Power
11 Disconnect Device (switch shown in
OFF position)
12 Disconnect Device (Supply) Grounding
Terminal
Connect green or green/yellow grounding
conductor (see Item 5) to disconnect device
grounding terminal first.
13 Disconnect Device Line Terminals
Connect input conductors L1 and L2 to
disconnect device line terminals.
14 Over-current Protection
Select type and size of over-current
protection using Section 4-7 (fused
disconnect switch shown).
Close and secure door on line disconnect
device. Follow established lockout/tagout
procedures to put unit in service.
Input7 2012−05
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-244 814 Page 33
General
Notes
SECTION 9 − RECOMMENDED SETUP PROCEDURES
9-1. Connecting To Weld Terminals
1
2
3
6
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Correct Installation
Incorrect Installation
Tools Needed:
3/4 in. (19 mm)
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
!
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-244 814 Page 34
273 497-A / 803 778-A
combined) and maximum welding
amperes. See Section 9-2 to select proper
cable size.
1
2
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
Connect positive weld cable to Positive (+)
weld terminal and negative (−) cable to
Negative weld terminal.
3
4
Weld Output Terminal
Supplied Weld Output Terminal Nut
5
Weld Cable Terminal
6
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.
9-2. 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.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
60 − 100%
Duty Cycle
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)
900
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
1000
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
1250
2x3/0 (2x95)
2x4/0 (2x120)
3x3/0 (3x95)
4x3/0 (4x95)
* This
chart is a general guideline and may not suit all applications. If cable overheating occurs, use next size larger cable.
**Cable should be sized for Peak Amperage (Apk) for pulse welding applications.
***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-K 2013−09
. In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding characteris-
General
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-244 814 Page 35
9-3. Welding Circuit
. Minimizing the welding circuit loop can prevent extreme voltage drops that produce poor welding characteristics.
1
2
3
4
5
6
7
1
Standard Welding Circuit
3
ECL
2
6
4
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.
The length of a welding circuit is
determined as follows:
5
Gun
Travel
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
Wire Feeder
Workpiece
Welding Circuit = Electrode Cable
Length (ECL) + Work Cable Length
(WCL) + Workpiece Length (WL)
WCL
See Section 9-2 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
7
It is important to connect the voltage
sensing lead as near to the weld as
possible, but not in the return current
path.
Current Flow Path
Large Weld Structure
1
3
ECL
2
6
4
5
2
WCL
7
WL
Current Flow Path
Ref. 273 498-A
OM-244 814 Page 36
9-4. Arranging Welding Cables To Reduce Welding Circuit Inductance
1
2
3
4
5
6
7
Bad
1
The arrangement of the cables has an
effect that is significant to the welding
properties. As an example, Accupulse
welding process 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
2
6
5
4
7
Better
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.
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
3
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
Wire Feeder
Workpiece
2
6
4
5
7
Best
3
6
General
1
2
4
5
7
Ref. 273 499-A
OM-244 814 Page 37
. Welding on a single workpiece using multiple welding power sources can cause arc blow and arc impedance to develop or intensify.
9-5. Using Multiple Welding Power Sources
1
2
3
4
5
6
7
1
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
Wire Feeder
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.
3
It is important to connect the voltage
sensing lead as near to the weld as
possible, but not in the return current
path.
2
Connect voltage sensing lead at the end
of the weld joint.
6
The direction of the welding path should
be away from the work cable
connections.
4
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.
5
1
7
5
Gun
Travel
3
2
6
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.
4
Current Flow Path
Ref. 273 501-A
OM-244 814 Page 38
9-6. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs
A. Bad Setup
1
3
2
6
4
5
1
3
2
7
5
6
4
Ref. 273 502-A
1
2
3
4
5
6
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
Wire Feeder
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-244 814 Page 39
General
Current Flow Path
B. Better Setup
1
3
2
6
4
5
1
7
3
2
6
4
5
Current Flow Path
Ref. 273 503-A
1
2
3
4
5
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
Voltage Sensing Lead
OM-244 814 Page 40
6
Wire Feeder
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
3
2
6
4
5
7
1
5
3
2
6
4
General
Current Flow Path
Ref. 273 504-A
1
2
3
4
Welding Power Source
Electrode Cable
Feeder Cable
Work Cable
5
Voltage Sensing Lead
6
Wire Feeder
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-244 814 Page 41
9-7. 30 Points Of Mechanics In MIG Welding
1.
Check primary power connection at line disconnect switch or receptacle and/or cord plug.
2.
Check primary power connection at welding power source.
3.
Check secondary weld output connections at welding power source.
4.
Inspect condition and routing of positive weld cable to wire drive motor.
5.
Check connection of positive weld cable to wire drive motor.
6.
Inspect condition and routing of negative weld cable to fixture.
7.
Check connection of negative weld cable to fixture.
8.
Inspect condition of any rotary grounds, grounding shoes or other auxiliary grounds.
9.
Check gas hose connection to shielding gas supply regulator.
10.
Check shielding gas flow rate.
11.
Check gas hose routing.
12.
Check gas hose connection at wire drive housing.
13.
Inspect condition of dereeler. Check for wear at quick-connect coupling and replace if necessary.
14.
Check placement of payoff pack or drum for smooth feed path.
15.
Inspect condition and routing of input conduit.
16.
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.
17.
Check drive rolls and replace if worn.
18.
Check for drive roll tension setting.
19.
Check intermediate guide for proper size to match wire size and replace if worn.
20.
Check gun connection at wire drive and be sure O−rings seal at drive housing.
21.
Check installation, routing and condition of welding gun.
22.
Check for proper length of liner at both ends and be sure it is cut without burrs.
23.
Check liner for proper size to match wire size.
24.
Check liner for wear and clean out to prevent plugging.
25.
Check contact tip for proper size to match wire size.
26.
Check contact tip for wear and change at regular intervals.
27.
Check contact tip for a tight fit and secure installation at gun.
28.
Check condition of gas diffuser.
29.
Check condition of nozzle.
30.
Check O-ring for proper sealing at nozzle.
9-8. Arc Blow
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-244 814 Page 42
9-9. 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
Porosity in weld
Replace fuse or reset circuit breaker and find overload condition
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
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
OM-244 814 Page 43
General
Weld output is present, but wire stops Wire feeder protective fuse blown or circuit breaker
feeding while welding
tripped
Trouble
Porosity in weld (Continued)
Excessive spatter
Probable Cause
Remedy
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 distoo great
tance
Wandering, hunting or erratic arc
OM-244 814 Page 44
Wrong transfer mode
Set proper transfer mode
Travel speed too slow
Increase travel speed so that arc is on leading edge
of weld puddle
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]
Wandering, hunting or erratic arc
(Continued)
Probable Cause
Remedy
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 9-8
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
Make sure all switches are in correct position, repair power source if necessary
Adjust burnback setting or turn off completely
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
OM-244 814 Page 45
General
Trouble
Trouble
Probable Cause
Shutdown at arc initiation using robot No arc detected
controller
Robot times out before arc detected
Remedy
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
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
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
Notes
OM-244 814 Page 46
SECTION 10 − OPERATION
10-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
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.
Carbon Arc Cutting/Gouging
A cutting process by which metals are melted by the heat of an arc using a carbon electrode. Molten
metal is forced away from the cut by compressed air.
Crater
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends.
DS (Dual Schedule)
Dual Schedule allows selecting a program within a pair of programs by means of a dual schedule
switch.
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 (optional)
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.
Start
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts.
TDS (Trigger Dual Schedule)
TDS allows the operator to select between a pair of weld programs by using the gun trigger. In TDS
mode, momentarily release and close the gun trigger while welding to cycle between a pair of
preselected weld programs.
OM-244 814 Page 47
General
General Terms:
General Terms:
TH (Trigger Hold)
Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger. In trigger
hold mode, momentarily press gun trigger, and wire will feed until gun trigger is momentarily pressed
again.
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).
TPS (Trigger Program Select)
TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily
pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total
of 8 programs.
Trigger Control
Selecting Trigger Control allows activating trigger functions such as DS, IGNR, TH, 4T, TDS, and
TPS.
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).
4T
4T allows the operator to select between weld parameters and crater parameters using the gun
trigger. Crater time must be set for at least 0.2 seconds to make this function operational. If gun
trigger is released during welding, unit goes into trigger hold, then pressing and holding trigger again
causes unit to stay in crater until trigger is released and crater parameter times out.
10-2. Pulse Welding Terms
3
Amps
1
2
4
Time
1 Apk = Peak Amperage
Increasing Apk increases penetration.
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
Increasing PPS increases travel
speed.
4 PWms = Pulse Width In
Milliseconds
Increasing PWms increases bead
width.
10-3. Front Panel Switches
1
Power Switch
Turns unit On or Off.
2
Pilot Light
Light indicates status of welding power
source, on when unit is on and off when
unit is off.
2
1
Ref. 245 746-B
OM-244 814 Page 48
SECTION 11 − MAINTENANCE
11-1. 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
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
l = Replace
l Damaged Gas Hose
Reference
nl Weld Cables
OR
~ Drive Rolls
~ Inside Unit
11-2. Blowing Out Inside Of Unit
!
Do not remove case when
blowing out inside of unit.
273 497-A
OM-244 814 Page 49
Maintenance
To blow out unit, direct airflow
through front and back louvers as
shown.
SECTION 12 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
12-1. 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.
12-2. 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).
OM-244 814 Page 50
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.
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. 150 853) 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.
12-3. 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.
12-4. 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.
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.
OM-244 814 Page 51
Safety
FALLING EQUIPMENT can injure.
Notes
OM-244 814 Page 52
SECTION 13 − TROUBLESHOOTING
13-1. Troubleshooting
Trouble
Remedy
Place line disconnect in On position (see Section 8-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker
(see Section 8-9).
Check for proper input power connections (see Section 8-9).
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 9-2).
errors displayed.
Clean and tighten all weld connections.
No 115 volts AC at the duplex
receptacle.
Reset supplementary protector CB1 (see Section 8-5).
Wire does not feed.
Check supplementary protector CB2 and reset if necessary (see Section 8-5).
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
flowing; wire feeds.
Check gas valve and flow meter.
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.
13-2. Check Web Message Display
When an existing Axcess power source is upgraded to an Axcess E, the first time the unit is powered up the message CHCK WEB will appear on the
display (see Figure 12-1).
1
Program
CHCK
Volts
Time
Arc Adjust
WEB
WFS
Amps
Arc Ctl
Process
Sequence
Wire Type
Trigger Control
Gas Type
Trigger Hold
Process Set up
Adjust
Feeder Set Up
Figure 12-1. Feeder Display On First Power Up After Upgrade
OM-244 814 Page 53
Trouble
No weld output; completely inoperative
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.
Figure 12-2. Web Site For Axcess E Information
OM-244 814 Page 54
13-3. Software Error Message Display
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.
1
Program
ERR
Volts
Time
Trouble
1.
Arc Adjust
SW
WFS
Amps
Arc Ctl
Process
Sequence
Wire Type
Trigger Control
Gas Type
Trigger Hold
Process Set up
Adjust
Feeder Set Up
Figure 12-3. Feeder 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.
Notes
OM-244 814 Page 55
13-4. 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 / Ref. 250 294-C
1 E Module Board Stack
Diagnostic LEDs are visible inside unit, located on the E Module Board Stack.
OM-244 814 Page 56
Refer to Section 13-5 for information on
diagnostic LEDs.
Reinstall cover after checking diagnostic
LEDs.
13-5. Diagnostic LEDs On E Module Board Stack
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.
LED1
LED2
D7
Function
——
——
DSP AWAKE
Status
——
——
——
ARM AWAKE
Flashing
Off
D11
ARM AUX
Flashing
Off
D19
D21
AD AUX
AD AWAKE
See Section 13-6.
——
Flashing
Off
D10
Diagnosis
Flashing
Trouble
LED
Indicates DSP communicating
Indicates DSP not communicating
Indicates ARM communicating
Indicates ARM not communicating
Indicates auxiliary in use
Indicates auxiliary not in use
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-244 814 Page 57
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
13-6. Network And Module Status LEDs
A.
Network Status LED
LED2 on the E Module board stack
Status
Off
Green
Flashing Green
Red
B.
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.
Module Status LED
LED1 on the E Module board stack
Status
Off
Green
Flashing Red
Red
OM-244 814 Page 58
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.
Trouble
Notes
OM-244 814 Page 59
SECTION 14 − 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
Welder
Configuration
Advanced
Locks
Errors
OM-244 814 Page 60
Welding Wire
Setup
Program Setup
Weld
Sequencer
Feed/Torch
Logs/Reports
Trigger
Functions
Weld Cable
Setup
Process Setup
Secondary Data
System Log
Trouble
Home Page
Diagnostics
Errors
Software
Communications
System Settings
Weld
Ethernet
Settings
Axcess Upgrade
Options
Subselect and
type additional
text here
Short Term
Weld Data
More
Time Settings
Welder
Information
Subselect and
type additional
text here
Machine
Lifetime
Report
OM-244 814 Page 61
TABLE OF CONTENTS
SECTION 15 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 15-1. Circuit Diagram For Axcess E 300 (1 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
63
Figure 15-2. Circuit Diagram For Axcess E 300 (2 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
Figure 15-3. Circuit Diagram For Axcess E 450 (1 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
Figure 15-4. Circuit Diagram For Axcess E 450 (2 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
Figure 15-5. Circuit Diagram For Axcess E 675 (1 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
Figure 15-6. Circuit Diagram For Axcess E 675 (2 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
Figure 15-7. Circuit Diagram For Axcess E Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
OM-244 814 Page 62
Circuits
SECTION 15 − ELECTRICAL DIAGRAMS
248 763-F (Part 1 Of 2)
Figure 15-1. Circuit Diagram For Axcess E 300 (1 Of 2)
OM-244 814 Page 63
Figure 15-2. Circuit Diagram For Axcess E 300 (2 Of 2)
OM-244 814 Page 64
Circuits
248 763-F (Part 2 Of 2)
OM-244 814 Page 65
Figure 15-3. Circuit Diagram For Axcess E 450 (1 Of 2)
OM-244 814 Page 66
Circuits
245 131-G (Part 1 Of 2)
OM-244 814 Page 67
Figure 15-4. Circuit Diagram For Axcess E 450 (2 Of 2)
OM-244 814 Page 68
Circuits
245 131-G (Part 2 Of 2)
OM-244 814 Page 69
Figure 15-5. Circuit Diagram For Axcess E 675 (1 Of 2)
OM-244 814 Page 70
Circuits
250 570-D (Part 1 Of 2)
OM-244 814 Page 71
Figure 15-6. Circuit Diagram For Axcess E 675 (2 Of 2)
OM-244 814 Page 72
Circuits
250 570-D (Part 2 Of 2)
OM-244 814 Page 73
Figure 15-7. Circuit Diagram For Axcess E Module
OM-244 814 Page 74
Circuits
250 571-D
OM-244 814 Page 75
SECTION 16 − PARTS LIST FOR AXCESS E 300
. Hardware is
common and
not available unless listed.
1
2 − Figure 16-3
3
4
5 − Figure 16-4
7 − Figure 16-5
6 − Figure 16-2
8
9
10
14
16
15
19 − Figure 16-6
17
18
12
8
11
13
12
9
248 813-G
Figure 16-1. Axcess E 300 Main Assembly
OM-244 814 Page 76
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-1. Axcess E 300 Main Assembly
. . . 1 . . . . . . . . . . . . . . . . 242008
. . . 2 . . . . . . . . . . . . . . . Fig 16-3
. . . 3 . . . . . T2 . . . . . . . 212543
. . . 4 . . . . . . . . . . . . . . . . 210481
. . . 5 . . . . . . . . . . . . . . . Fig 16-4
. . . 6 . . . . IM-1 . . . . . . 214597
. . . . . . . . . . IM-1 . . . . . . 242680
. . . 7 . . . . . . . . . . . . . . . Fig 16-5
. . . 8 . . . . . . . . . . . . . . . +227792
. . . 9 . . . . . . . . . . . . . . . . 134327
. . . 10 . . . . . . . . . . . . . . . . 178551
. . . 11 . . . . . . . . . . . . . . . +210482
. . . 12 . . . . . . . . . . . . . . . . 218004
. . . 13 . . . . . . . . . . . . . . . . 205645
. . . 14 . . . . . . . . . . . . . . . . 213386
. . . 15 . . . . HD2 . . . . . . 182918
. . . 16 . . . . . . . . . . . . . . . . 198951
. . . 17 . . . . . . . . . . . . . . . . 148025
. . . 18 . . . . . . . . . . . . . . . . 213372
. . . 19 . . . . . . . . . . . . . . . Fig 16-6
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Assembly, E−module W/Ethernet & USB . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 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) . . . . . . . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side W/Insulator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Warning General Precautionary Static & Wire . . . . . . . . . . . . .
. . . . Insulator, Side Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
E300 Parts
*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-244 814 Page 77
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 6)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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-244 814 Page 78
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
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) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 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-244 814 Page 79
E300 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
7
12
18
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 2)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . PC16 . . . . . . 244923
. . . . . . . . . . . . . . . . 115440
. . . . . . . . . . . . . . . ♦244985
. . . . . . . . . . . . . . . . 000527
. . . . . . . . . . . . . . . . 242645
. . . . . . . . . . . . . . . ♦242007
. . . . . . . . . . . . . . . . 241996
. . . . . . . . . . . . . . . . 246591
. . . . . . . . . . . . . . . . 222808
. . . . . . . . . . . . . . . . 245350
. . . . . . . . . . . . . . . . 240728
. . . . . . . . . . . . . . . . 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, 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-244 814 Page 80
. Hardware is
common and
not available unless listed.
245 798-A
Figure 16-4. Top Tray Assembly
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-4. Top Tray Assembly (Fig 16-1 Item 5)
...
...
...
...
...
1
2
3
4
5
. . . . PC3 . . . . . .
................
................
................
................
239598
223439
170647
210491
083147
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, circuit card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . .
1
1
1
1
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-244 814 Page 81
E300 Parts
Item
No.
. Hardware is
common and
not available unless listed.
4
3
2
1
11
9
13
10
14
8
5
12
7
6
248 796-C
Figure 16-5. Axcess E 300 Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 16-5. Axcess E 300 Rear Panel Assembly
(Fig 16-1 Item 7)
. . . 1 . . . . . . . . . . . . . . . +210478 . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . 245352 . . . Eye Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . . . 210503 . . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . . 217297 . . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . . 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . CB1 . . . . . . 083432 . . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . .
. . . 7 . . . . CB2 . . . . . . 093995 . . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . .
. . . 8 . . . . RC2 . . . . . . 196814 . . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC12 . . . . . . 239623 . . . Circuit Card Assy, E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . . . 115440 . . . Stand-off, no 6-32 x .687 lg .250 hex al fem . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . . 212764 . . . Plug Assy, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E−stop Connector Factory Installed Option For Axcess (includes) . . . .
. . . 12 . . . . PC14 . . . . . ♦227901 . . . . E−Stop Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . ♦228694 . . . . Jumper, Connector W/Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . . 218005 . . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
4
1
1
1
1
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-244 814 Page 82
. Hardware is
common and
not available unless listed.
16
2
1
3
15
14
8
13
4
3
12
5
6
7
11
10
9
11
Item
No.
Dia.
Mkgs.
Quantity
Figure 16-6. Axcess E 300 Front Panel Assembly
(Fig 16-1 Item 19)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
. . . . . S1 . . . . . . .
................
. . PC15,20 . . . .
. . . . . FM . . . . . . .
................
................
................
................
................
................
................
. . . . . PL1 . . . . . .
................
................
................
................
207456
207895
244993
196313
207980
244989
210866
248552
219843
207979
186621
163562
248553
210865
210483
245352
. . . Switch, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Stud Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Vsense Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Work Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Light, ind white lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
2
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-244 814 Page 83
E300 Parts
248 806-A
Figure 16-6. Axcess E 300 Front Panel Assembly
Part
No.
Description
SECTION 17 − PARTS LIST FOR AXCESS E 450
. Hardware is
1
common and
not available unless listed.
2 − Figure 17-3
3
4
5 − Figure 17-4
6 − Figure 17-2
9 − Figure 17-5
8
7
10
11
21 − Figure 17-6
6
12
16
20
19
18
17
10
14
13
20
11
15
14
245 791-G
Figure 17-1. Axcess E 450 Main Assembly
OM-244 814 Page 84
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 17-1. Axcess E 450 Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
. . . . . . . . . . . . . . . . 242008
. . . . . . . . . . . . . . . Fig 17-3
. . . . . T2 . . . . . . . 212543
. . . . . . . . . . . . . . . . 210481
. . . . . . . . . . . . . . . Fig 17-4
. . IM1, IM2 . . . . 242682
. . . . . . . . . . . . . . . . 198961
. . . . . W1 . . . . . . . 180270
. . . . . . . . . . . . . . . Fig 17-5
. . . . . . . . . . . . . . . +227793
. . . . . . . . . . . . . . . . 134327
. . . . . . . . . . . . . . . . 178551
. . . . . . . . . . . . . . . +210482
. . . . . . . . . . . . . . . . 218004
. . . . . . . . . . . . . . . . 205645
. . . . . . . . . . . . . . . . 213386
. . . . HD2 . . . . . . 182918
. . . . . . . . . . . . . . . . 198951
. . . . . . . . . . . . . . . . 148025
. . . . . . . . . . . . . . . . 213372
. . . . . . . . . . . . . . . Fig 17-6
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Assembly, E−module W/Ethernet & USB . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Module, Inverter Assy (300A) (Fig 17-2) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Module Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Contactor, DEF PRP 40A 3P 24VAC Coil W/Boxlug . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side W/Insulator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Warning General Precautionary Static & Wire . . . . . . . . . . . . .
. . . . Insulator, Side Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
2
1
E450 Parts
*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-244 814 Page 85
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
17
7
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 17-2. Inverter Module Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 17-2. Inverter Module Assembly
(Fig 17-1 Item 6)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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-244 814 Page 86
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 17-2. Inverter Module Assembly
(Fig 17-1 Item 6) (Continued)
......................
......................
. . . . . . . . . . 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
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
E450 Parts
*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-244 814 Page 87
. Hardware is
common and
not available unless listed.
1
3
4
2
17
15
16
14
13
5
7
12
18
8
11
10
6
9
245 871-E
Figure 17-3. E-module w/Ethernet And USB Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 17-3. E-module w/Ethernet And USB Assembly
(Fig 17-1 Item 2)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . PC16 . . . . . . 244923
. . . . . . . . . . . . . . . . 115440
. . . . . . . . . . . . . . . ♦244985
. . . . . . . . . . . . . . . . 000527
. . . . . . . . . . . . . . . . 242645
. . . . . . . . . . . . . . . ♦242007
. . . . . . . . . . . . . . . . 241996
. . . . . . . . . . . . . . . . 246591
. . . . . . . . . . . . . . . . 222808
. . . . . . . . . . . . . . . . 245350
. . . . . . . . . . . . . . . . 240728
. . . . . . . . . . . . . . . . 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, 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-244 814 Page 88
. Hardware is
common and
not available unless listed.
245 798-A
Figure 17-4. Top Tray Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 17-4. Top Tray Assembly (Fig 17-1 Item 5)
...
...
...
...
...
1
2
3
4
5
. . . . PC3 . . . . . .
................
................
................
................
239598
223439
170647
210491
083147
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, circuit card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . .
1
1
1
1
4
E450 Parts
*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-244 814 Page 89
. Hardware is
common and
not available unless listed.
2
3
4
1
11
9
10
13
8
5
12
6
14
7
245 810-E
Figure 17-5. Axcess E 450 Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 17-5. Axcess E 450 Rear Panel Assembly
(Fig 17-1 Item 9)
. . . 1 . . . . . . . . . . . . . . . +210474 . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . . 245352 . . . Lift Eye, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . . . 210503 . . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . . 217297 . . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . . 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . CB1 . . . . . . 083432 . . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . .
. . . 7 . . . . CB2 . . . . . . 093995 . . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . .
. . . 8 . . . . RC2 . . . . . . 196814 . . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . PC12 . . . . . . 239623 . . . Circuit Card Assy, E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . . . 115440 . . . Stand-off, no 6-32 x .687 lg .250 hex al fem . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . . 212764 . . . Plug Assy, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E−Stop Connector Factory Installed Option For Axcess (includes) . . .
. . . 12 . . . . PC14 . . . . . ♦227901 . . . . E−Stop Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . ♦228694 . . . . Jumper,Connector W/Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . . 218005 . . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
4
1
1
1
1
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-244 814 Page 90
. Hardware is
common and
not available unless listed.
245 822-A
Item
No.
Dia.
Mkgs.
Figure 17-6. Axcess E 450 Front Panel Assembly
Part
Description
No.
Quantity
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
. . . . . S1 . . . . . . .
................
. . . . . FM . . . . . . .
................
................
. PC15, PC20 . . .
................
................
................
................
................
................
. . . . . PL1 . . . . . .
................
................
................
................
207456
207895
196313
244989
025248
244993
207897
210866
247005
219843
207896
186621
163562
245604
210865
210483
245352
. . . Switch, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Circuit Card Assy, Vsense Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Stud Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Light, ind white lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lift Eye, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
2
2
2
1
1
1
1
2
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-244 814 Page 91
E450 Parts
Figure 17-6. Axcess E 450 Front Panel Assembly
(Fig 17-1 Item 21)
SECTION 18 − PARTS LIST FOR AXCESS E 675
. Hardware is
common and
not available unless listed.
1
3
4 − Figure 18-3
5 − Figure 18-2
6
2
5
7 − Figure 18-5
6
21 − Figure 18-4
8
5
14
9
19
17
16
15
18
19
12
11
10
19
13
12
8
20 − Figure 18-6
9
250 661-F
Figure 18-1. Axcess E 675 Main Assembly
OM-244 814 Page 92
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-1. Axcess E 675 Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
. . . . . T2 . . . . . . . 212543
. . . . . . . . . . . . . . . . 242008
. . . . . . . . . . . . . . . . 210481
. . . . . . . . . . . . . . . Fig 18-3
. IM1,IM2,IM3 . . . 242682
. . . . . . . . . . . . . . . . 198961
. . . . . . . . . . . . . . . Fig 18-5
. . . . . . . . . . . . . . . +227791
. . . . . . . . . . . . . . . . 134327
. . . . . . . . . . . . . . . . 178551
. . . . . . . . . . . . . . . +210482
. . . . . . . . . . . . . . . . 218004
. . . . . . . . . . . . . . . . 205645
. . . . . W1 . . . . . . . 254597
. . . . . . . . . . . . . . . . 213386
. . . . HD2 . . . . . . 182918
. . . . . . . . . . . . . . . . 198951
. . . . . . . . . . . . . . . . 148025
. . . . . . . . . . . . . . . . 218365
. . . . . . . . . . . . . . . Fig 18-6
. . . . . . . . . . . . . . . Fig 18-4
. . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . .
. . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Module, Inverter Assy (Fig 18-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Module Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Side W/Insulator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Label, Warning General Precautionary Static & Wire . . . . . . . . . . . . .
. . . . Insulator, Side Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Electric Shock/Exploding Parts . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . .
. . . Contactor, DEF PRP 60A 3P 24VAC Coil W/Boxlug . . . . . . . . . . . . . . . .
. . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . .
. . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . .
. . . Filter Assy, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Assembly, E−module W/Ethernet & USB . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
3
2
1
2
1
1
1
2
1
1
1
1
1
1
3
1
1
OM-244 814 Page 93
E675 Parts
*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.
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
17
7
16
18
19
32
31
20 21
30
29
23
24
25
23
27
13
36
28
26
22
23
Item
No.
Dia.
Mkgs.
Part
No.
38
37
802 955-C
Figure 18-2. Inverter Module Assembly
Description
Quantity
Figure 18-2. Inverter Module Assembly
(Fig 18-1 Item 5)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
................
................
. . . . . L1 . . . . . . .
................
. . . R3, C4 . . . . .
................
. . . D1, D2 . . . . .
................
................
. . . . . T1 . . . . . . .
. . . . . Z1 . . . . . . .
................
................
................
................
................
................
214597
196351
213940
214519
233052
199840
201531
196347
196349
203408
220496
170647
179276
196355
010546
242680
196332
. . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
2
2
1
3
1
1
2
4
6
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-244 814 Page 94
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-2. Inverter Module Assembly
(Fig 18-1 Item 5) (Continued)
. . . 18 . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . .
......................
......................
. . . . . . . . . . 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 . . . . . . . . . . . . . . . .
030170
196259
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
. . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . .
. . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 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 . . . . . . . . . . . . . .
2
1
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
OM-244 814 Page 95
E675 Parts
*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.
. Hardware is
common and
not available unless listed.
245 798-A
Figure 18-3. Top Tray Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-3. Top Tray Assembly (Fig 18-1 Item 4)
...
...
...
...
...
1
2
3
4
5
. . . . PC3 . . . . . .
................
................
................
................
239598
223439
170647
210491
083147
. . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Insulator, circuit card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . .
. . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . .
1
1
1
1
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-244 814 Page 96
. Hardware is
common and
not available unless listed.
1
3
4
2
17
15
16
14
13
5
7
12
18
8
11
10
6
9
245 871-E
Figure 18-4. E-module w/Ethernet And USB Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-4. E-module w/Ethernet And USB Assembly
(Fig 18-1 Item 21)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
. . . . PC16 . . . . . . 244923
. . . . . . . . . . . . . . . . 115440
. . . . . . . . . . . . . . . ♦244985
. . . . . . . . . . . . . . . . 000527
. . . . . . . . . . . . . . . . 242645
. . . . . . . . . . . . . . . ♦242007
. . . . . . . . . . . . . . . . 241996
. . . . . . . . . . . . . . . . 246591
. . . . . . . . . . . . . . . . 222808
. . . . . . . . . . . . . . . . 245350
. . . . . . . . . . . . . . . . 240728
. . . . . . . . . . . . . . . . 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, 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-244 814 Page 97
E675 Parts
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
. Hardware is
common and
not available unless listed.
2
3
4
1
11
9
13
10
8
5
6
12
7
14
250 629-B
Figure 18-5. Axcess E 675 Rear Panel Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-5. Axcess E 675 Rear Panel Assembly
(Fig 18-1 Item 7)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
. . . . . . . . . . . . . . . +210470
. . . . . . . . . . . . . . . . 245352
. . . . . . . . . . . . . . . . 210503
. . . . . . . . . . . . . . . . 217297
. . . . . . . . . . . . . . . . 210483
. . . . CB1 . . . . . . 083432
. . . . CB2 . . . . . . 093995
. . . . RC2 . . . . . . 196814
. . . . PC12 . . . . . . 239623
. . . . . . . . . . . . . . . . 115440
. . . . . . . . . . . . . . . . 212764
. . . . PC14 . . . . . ♦227901
. . . . . . . . . . . . . . . ♦228694
. . . . . . . . . . . . . . . . 218005
. . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lift Eye, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . .
. . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . .
. . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand-off, no 6-32 x .687 lg .250 hex al fem . . . . . . . . . . . . . . . . . . . . . . .
. . . Plug Assy,Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . E−Stop Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Jumper,Connector W/Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Label, Warning Input Connections/Electric Shock . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
4
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-244 814 Page 98
. Hardware is
common and
not available unless listed.
18
2
17
1
16
15
6
3
14
4
5
6
7
13
8
9
11
5
10
13
12
250 579-A
Item
No.
Dia.
Mkgs.
Figure 18-6. Axcess E 675 Front Panel Assembly
Part
No.
Description
Quantity
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
. . . . . S1 . . . . . . .
................
. . . . . FM . . . . . . .
................
................
. PC15, PC20 . . .
................
................
................
................
207456
207895
196313
244989
025248
244993
220815
210864
210866
250543
. . . Switch, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . . . . . . .
. . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . .
. . . Circuit Card Assy, Vsense Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Stand−off, Insul .250−20 X 1.250 Lg X .437 Thd . . . . . . . . . . . . . . . . . . .
. . . Circuit Card Assy, Stud Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bus Bar,Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
3
1
2
2
1
1
1
1
OM-244 814 Page 99
E675 Parts
Figure 18-6. Axcess E 675 Front Panel Assembly
(Fig 18-1 Item 20)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-6. Axcess E 675 Front Panel Assembly
(Fig 18-1 Item 20) (Continued)
...
...
...
...
...
...
...
...
11
12
13
14
15
16
17
18
................
................
................
. . . . . PL1 . . . . . .
................
................
................
................
219843
203862
186621
163562
250292
210865
210483
245352
. . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Light, ind white lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Lift Eye, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
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-244 814 Page 100
OM-244 814 Page 101
E675 Parts
Notes
Notes
Effective January 1, 2015
(Equipment with a serial number preface of MF 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
* MIG Guns and Subarc (SAW) Torches
thirty (30) days of such defect or failure, at which time Miller will
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 2015-01
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
© 2015 Miller Electric Mfg. Co.
2015−01