Miller AXCESS E WIRE FEEDER User Owner’s Manual

PDF
Document
OM-245 592F
2013−05
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
R
Axcess E Wire Feeder
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 S&Eacute;CURIT&Eacute; − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilis&eacute;s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage &agrave; l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers suppl&eacute;mentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de s&eacute;curit&eacute; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. 9-Pin Network Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Feeder Display At Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Dual Schedule Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Feeder Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Process Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. User Interface Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Error Code Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Check Web Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Software Error Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − WEB PAGES SITE TREE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
1
3
4
4
4
5
5
5
7
8
9
9
11
11
13
14
14
14
14
14
15
16
16
17
18
19
20
20
21
22
23
23
24
25
26
26
27
28
35
35
36
36
37
43
43
45
46
48
50
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
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.
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 for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
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 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.
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-245 592 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.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
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 protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
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 may 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-245 592 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments 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.
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.
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.
BATTERY EXPLOSION can injure.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
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.
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
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.
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 maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
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 Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D
D
D
D
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.
ARC WELDING can cause interference.
MOVING PARTS can injure.
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.
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.
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-245 592 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 &amp; 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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 30333 (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). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may 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-245 592 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 S&Eacute;CURIT&Eacute; − LIRE AVANT UTILISATION
fre_som_2011−10
7
Pour &eacute;carter les risques de blessure pour vous−m&ecirc;me et pour autrui — lire, appliquer et ranger en lieu s&ucirc;r ces consignes relatives
aux pr&eacute;cautions de s&eacute;curit&eacute; et au mode op&eacute;ratoire.
2-1. Symboles utilis&eacute;s
DANGER! − Indique une situation dangereuse qui si on
l’&eacute;vite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montr&eacute;s par les symboles
joints ou sont expliqu&eacute;s dans le texte.
Indique une situation dangereuse qui si on l’&eacute;vite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montr&eacute;s par les symboles joints ou
sont expliqu&eacute;s dans le texte.
NOTE − Indique des d&eacute;clarations pas en relation avec des blessures
personnelles.
. Indique des instructions sp&eacute;cifiques.
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
aff&eacute;rant pour les actions n&eacute;cessaires afin d’&eacute;viter le danger.
2-2. Dangers relatifs au soudage &agrave; l’arc
Les symboles repr&eacute;sent&eacute;s ci-dessous sont utilis&eacute;s dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
pr&eacute;sence de l’un de ces symboles, prendre garde et suivre les
instructions aff&eacute;rentes pour &eacute;viter tout risque. Les instructions
en mati&egrave;re de s&eacute;curit&eacute; indiqu&eacute;es ci-dessous ne constituent
qu’un sommaire des instructions de s&eacute;curit&eacute; plus compl&egrave;tes
fournies dans les normes de s&eacute;curit&eacute; &eacute;num&eacute;r&eacute;es dans la Section 2-5. Lire et observer toutes les normes de s&eacute;curit&eacute;.
D
Seul un personnel qualifi&eacute; est autoris&eacute; &agrave; installer, faire fonctionner, entretenir et r&eacute;parer cet appareil.
D
Pendant le fonctionnement, maintenir &agrave; distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE D&Eacute;CHARGE &Eacute;LECTRIQUE peut
entra&icirc;ner la mort.
Le contact d’organes &eacute;lectriques sous tension peut
provoquer des accidents mortels ou des br&ucirc;lures
graves. Le circuit de l’&eacute;lectrode et de la pi&egrave;ce est
sous tension lorsque le courant est d&eacute;livr&eacute; &agrave; la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont &eacute;galement sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le d&eacute;rouleur, le bloc de
commande du rouleau et toutes les parties m&eacute;talliques en contact avec le fil sont sous tension
&eacute;lectrique. Un &eacute;quipement install&eacute; ou mis &agrave; la terre
de mani&egrave;re incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pi&egrave;ces &eacute;lectriques sous tension.
D Porter des gants isolants et des v&ecirc;tements de protection secs et
sans trous.
D S’isoler de la pi&egrave;ce &agrave; couper et du sol en utilisant des housses ou
des tapis assez grands afin d’&eacute;viter tout contact physique avec la
pi&egrave;ce &agrave; couper ou le sol.
D Ne pas se servir de source &eacute;lectrique &agrave; courant &eacute;lectrique dans les
zones humides, dans les endroits confin&eacute;s ou l&agrave; o&ugrave; on risque de
tomber.
D Se servir d’une source &eacute;lectrique &agrave; courant &eacute;lectrique UNIQUEMENT si le proc&eacute;d&eacute; de soudage le demande.
D Si l’utilisation d’une source &eacute;lectrique &agrave; courant &eacute;lectrique s’av&egrave;re
n&eacute;cessaire, se servir de la fonction de t&eacute;l&eacute;commande si l’appareil
en est &eacute;quip&eacute;.
D D’autres consignes de s&eacute;curit&eacute; sont n&eacute;cessaires dans les conditions suivantes : risques &eacute;lectriques dans un environnement
humide ou si l’on porte des v&ecirc;tements mouill&eacute;s ; sur des structures
m&eacute;talliques telles que sols, grilles ou &eacute;chafaudages ; en position
coinc&eacute;e comme assise, &agrave; genoux ou couch&eacute;e ; ou s’il y a un risque
&eacute;lev&eacute; de contact in&eacute;vitable ou accidentel avec la pi&egrave;ce &agrave; souder ou
le sol. Dans ces conditions, utiliser les &eacute;quipements suivants,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
dans l’ordre indiqu&eacute; : 1) un poste &agrave; souder DC &agrave; tension constante
(&agrave; fil), 2) un poste &agrave; souder DC manuel (&eacute;lectrode) ou 3) un poste &agrave;
souder AC &agrave; tension &agrave; vide r&eacute;duite. Dans la plupart des situations,
l’utilisation d’un poste &agrave; souder DC &agrave; fil &agrave; tension constante est recommand&eacute;e. En outre, ne pas travailler seul !
Couper l’alimentation ou arr&ecirc;ter le moteur avant de proc&eacute;der &agrave; l’installation, &agrave; la r&eacute;paration ou &agrave; l’entretien de l’appareil. D&eacute;verrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de s&eacute;curit&eacute;).
Installez, mettez &agrave; la terre et utilisez correctement cet &eacute;quipement
conform&eacute;ment &agrave; son Manuel d’Utilisation et aux r&eacute;glementations
nationales, gouvernementales et locales.
Toujours v&eacute;rifier la terre du cordon d’alimentation. V&eacute;rifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccord&eacute; &agrave; la borne de terre du sectionneur ou que la fiche du
cordon est raccord&eacute;e &agrave; une prise correctement mise &agrave; la terre.
En effectuant les raccordements d’entr&eacute;e, fixer d’abord le conducteur de mise &agrave; la terre appropri&eacute; et contre-v&eacute;rifier les connexions.
Les c&acirc;bles doivent &ecirc;tre exempts d’humidit&eacute;, d’huile et de graisse;
prot&eacute;gez−les contre les &eacute;tincelles et les pi&egrave;ces m&eacute;talliques
chaudes.
V&eacute;rifier fr&eacute;quemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas alt&eacute;r&eacute; ou &agrave; nu, le remplacer imm&eacute;diatement s’il l’est.
Un fil &agrave; nu peut entra&icirc;ner la mort.
L’&eacute;quipement doit &ecirc;tre hors tension lorsqu’il n’est pas utilis&eacute;.
Ne pas utiliser des c&acirc;bles us&eacute;s, endommag&eacute;s, de grosseur insuffisante ou mal &eacute;piss&eacute;s.
Ne pas enrouler les c&acirc;bles autour du corps.
Si la pi&egrave;ce soud&eacute;e doit &ecirc;tre mise &agrave; la terre, le faire directement
avec un c&acirc;ble distinct.
Ne pas toucher l’&eacute;lectrode quand on est en contact avec la pi&egrave;ce,
la terre ou une &eacute;lectrode provenant d’une autre machine.
Ne pas toucher des porte &eacute;lectrodes connect&eacute;s &agrave; deux machines
en m&ecirc;me temps &agrave; cause de la pr&eacute;sence d’une tension &agrave; vide doubl&eacute;e.
N’utiliser qu’un mat&eacute;riel en bon &eacute;tat. R&eacute;parer ou remplacer sur-lechamp les pi&egrave;ces endommag&eacute;es. Entretenir l’appareil conform&eacute;ment &agrave; ce manuel.
Porter un harnais de s&eacute;curit&eacute; si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le c&acirc;ble de retour de fa&ccedil;on &agrave; obtenir un bon contact m&eacute;talm&eacute;tal avec la pi&egrave;ce &agrave; souder ou la table de travail, le plus pr&egrave;s possible de la soudure.
Isoler la pince de masse quand pas mis &agrave; la pi&egrave;ce pour &eacute;viter le
contact avec tout objet m&eacute;tallique.
Ne pas raccorder plus d’une &eacute;lectrode ou plus d’un c&acirc;ble de
masse &agrave; une m&ecirc;me borne de sortie de soudage. D&eacute;brancher le
c&acirc;ble pour le proc&eacute;d&eacute; non utilis&eacute;.
OM-245 592 Page 5
Il reste une TENSION DC NON N&Eacute;GLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coup&eacute;e.
D Arr&ecirc;ter les convertisseurs, d&eacute;brancher le courant &eacute;lectrique et
d&eacute;charger les condensateurs d’alimentation selon les instructions
indiqu&eacute;es dans la partie Entretien avant de toucher les pi&egrave;ces.
LES PI&Egrave;CES CHAUDES peuvent
provoquer des br&ucirc;lures.
D Ne pas toucher &agrave; mains nues les parties
chaudes.
D Pr&eacute;voir une p&eacute;riode de refroidissement avant de
travailler &agrave; l’&eacute;quipement.
D Ne pas toucher aux pi&egrave;ces chaudes, utiliser les outils recommand&eacute;s et porter des gants de soudage et des v&ecirc;tements &eacute;pais pour
&eacute;viter les br&ucirc;lures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectu&eacute; sur des conteneurs ferm&eacute;s tels
que des r&eacute;servoirs, tambours ou des conduites peut
provoquer leur &eacute;clatement. Des &eacute;tincelles peuvent
&ecirc;tre projet&eacute;es de l’arc de soudure. La projection d’&eacute;tincelles, des
pi&egrave;ces chaudes et des &eacute;quipements chauds peut provoquer des
incendies et des br&ucirc;lures. Le contact accidentel de l’&eacute;lectrode avec
des objets m&eacute;talliques peut provoquer des &eacute;tincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
v&eacute;rifier et s’assurer que l’endroit ne pr&eacute;sente pas de danger.
D D&eacute;placer toutes les substances inflammables &agrave; une distance de
10,7 m de l’arc de soudage. En cas d’impossibilit&eacute; les recouvrir
soigneusement avec des protections homologu&eacute;s.
D Ne pas souder dans un endroit l&agrave; o&ugrave; des &eacute;tincelles peuvent tomber
sur des substances inflammables.
LES FUM&Eacute;ES ET LES GAZ peuvent
&ecirc;tre dangereux.
D Se prot&eacute;ger et d’autres personnes de la projection d’&eacute;tincelles et
de m&eacute;tal chaud.
Le soudage g&eacute;n&egrave;re des fum&eacute;es et des gaz. Leur
inhalation peut &ecirc;tre dangereux pour votre sant&eacute;.
D Des &eacute;tincelles et des mat&eacute;riaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Eloigner votre t&ecirc;te des fum&eacute;es. Ne pas respirer les fum&eacute;es.
D Surveiller tout d&eacute;clenchement d’incendie et tenir un extincteur &agrave;
proximit&eacute;.
D &Agrave; l’int&eacute;rieur, ventiler la zone et/ou utiliser une ventilation forc&eacute;e au
niveau de l’arc pour l’&eacute;vacuation des fum&eacute;es et des gaz de
soudage.
D Le soudage effectu&eacute; sur un plafond, plancher, paroi ou s&eacute;paration
peut d&eacute;clencher un incendie de l’autre c&ocirc;t&eacute;.
D Si la ventilation est m&eacute;diocre, porter un respirateur anti-vapeurs
approuv&eacute;.
D Lire et comprendre les sp&eacute;cifications de s&eacute;curit&eacute; des mat&eacute;riaux
(MSDS) et les instructions du fabricant concernant les m&eacute;taux, les
consommables, les rev&ecirc;tements, les nettoyants et les d&eacute;graisseurs.
D Travailler dans un espace ferm&eacute; seulement s’il est bien ventil&eacute; ou
en portant un respirateur &agrave; alimentation d’air. Demander toujours &agrave;
un surveillant d&ucirc;ment form&eacute; de se tenir &agrave; proximit&eacute;. Des fum&eacute;es et
des gaz de soudage peuvent d&eacute;placer l’air et abaisser le niveau
d’oxyg&egrave;ne provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne pr&eacute;sente aucun danger.
D Ne pas souder dans des endroits situ&eacute;s &agrave; proximit&eacute; d’op&eacute;rations
de d&eacute;graissage, de nettoyage ou de pulv&eacute;risation. La chaleur et
les rayons de l’arc peuvent r&eacute;agir en pr&eacute;sence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des m&eacute;taux munis d’un rev&ecirc;tement, tels que l’acier
galvanis&eacute;, plaqu&eacute; en plomb ou au cadmium &agrave; moins que le rev&ecirc;tement n’ait &eacute;t&eacute; enlev&eacute; dans la zone de soudure, que l’endroit soit
bien ventil&eacute;, et en portant un respirateur &agrave; alimentation d’air. Les
rev&ecirc;tements et tous les m&eacute;taux renfermant ces &eacute;l&eacute;ments peuvent
d&eacute;gager des fum&eacute;es toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des br&ucirc;lures dans les
yeux et sur la peau.
Le rayonnement de l’arc du proc&eacute;d&eacute; de soudage
g&eacute;n&egrave;re des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des br&ucirc;lure
dans les yeux et sur la peau. Des &eacute;tincelles sont projet&eacute;es pendant le
soudage.
D Porter un casque de soudage approuv&eacute; muni de verres filtrants
appropri&eacute; pour prot&eacute;ger visage et yeux pour prot&eacute;ger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 &eacute;num&eacute;r&eacute; dans les normes de s&eacute;curit&eacute;).
D Porter des lunettes de s&eacute;curit&eacute; avec &eacute;crans lat&eacute;raux m&ecirc;me sous
votre casque.
D Avoir recours &agrave; des &eacute;crans protecteurs ou &agrave; des rideaux pour
prot&eacute;ger les autres contre les rayonnements les &eacute;blouissements
et les &eacute;tincelles ; pr&eacute;venir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des v&ecirc;tements confectionn&eacute;s avec des mati&egrave;res r&eacute;sistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-245 592 Page 6
D Ne pas effectuer le soudage sur des conteneurs ferm&eacute;s tels que
des r&eacute;servoirs, tambours, ou conduites, &agrave; moins qu’ils n’aient &eacute;t&eacute;
pr&eacute;par&eacute;s correctement conform&eacute;ment &agrave; AWS F4.1 et AWS A6.0
(voir les Normes de S&eacute;curit&eacute;).
D Ne soudez pas si l’air ambiant est charg&eacute; de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le c&acirc;ble de masse sur la pi&egrave;ce le plus pr&egrave;s possible de la
zone de soudage pour &eacute;viter le transport du courant sur une
longue distance par des chemins inconnus &eacute;ventuels en provoquant des risques d’&eacute;lectrocution, d’&eacute;tincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour d&eacute;geler des conduites gel&eacute;es.
D En cas de non utilisation, enlever la baguette d’&eacute;lectrode du porte&eacute;lectrode ou couper le fil &agrave; la pointe de contact.
D Porter des v&ecirc;tements de protection d&eacute;pourvus d’huile tels que des
gants en cuir, une chemise en mat&eacute;riau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
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 achev&eacute;, assurez−vous qu’il ne reste aucune
trace d’&eacute;tincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropri&eacute;s.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achev&eacute;, assurez−vous qu’il ne reste aucune
trace d’&eacute;tincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropri&eacute;s.
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 &agrave; chaud et avoir de la surveillance et un
extincteur &agrave; proximit&eacute;.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’&eacute;caillement, le passage de la pi&egrave;ce &agrave; la brosse en
fil de fer, et le meulage g&eacute;n&egrave;rent des &eacute;tincelles et des particules
m&eacute;talliques volantes. Pendant la p&eacute;riode de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de s&eacute;curit&eacute; avec &eacute;crans lat&eacute;raux ou un &eacute;cran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou m&ecirc;me la mort.
D Fermer l’alimentation du gaz comprim&eacute; en cas
de non utilisation.
D Veiller toujours &agrave; bien a&eacute;rer les espaces confin&eacute;s ou se servir d’un respirateur d’adduction
d’air homologu&eacute;.
Les CHAMPS &Eacute;LECTROMAGN&Eacute;TIQUES (CEM)
peuvent affecter les implants m&eacute;dicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants m&eacute;dicaux doivent rester &agrave;
distance.
D Les porteurs d’implants m&eacute;dicaux doivent consulter leur
m&eacute;decin et le fabricant du dispositif avant de s’approcher de la
zone o&ugrave; se d&eacute;roule du soudage &agrave; l’arc, du soudage par points, du
gougeage, de la d&eacute;coupe plasma ou une op&eacute;ration de chauffage
par induction.
LE BRUIT peut endommager l’ou&iuml;e.
Le bruit des processus et des &eacute;quipements peut
affecter l’ou&iuml;e.
D Porter des protections approuv&eacute;es pour les
oreilles si le niveau sonore est trop &eacute;lev&eacute;.
LES BOUTEILLES peuvent exploser
si elles sont endommag&eacute;es.
Les bouteilles de gaz comprim&eacute; contiennent du gaz
sous haute pression. Si une bouteille est
endommag&eacute;e, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du
proc&eacute;d&eacute; de soudage, les manipuler avec
pr&eacute;caution.
D Prot&eacute;ger les bouteilles de gaz comprim&eacute; d’une chaleur excessive,
des chocs m&eacute;caniques, des dommages physiques, du laitier, des
flammes ouvertes, des &eacute;tincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les emp&ecirc;cher de tomber ou
de se renverser.
D Tenir les bouteilles &eacute;loign&eacute;es des circuits de soudage ou autres
circuits &eacute;lectriques.
D Ne jamais placer une torche de soudage sur une bouteille &agrave; gaz.
D Une &eacute;lectrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressuris&eacute;e − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprim&eacute;, r&eacute;gulateurs,
tuyaux et raccords convenables pour cette application sp&eacute;cifique;
les maintenir ainsi que les &eacute;l&eacute;ments associ&eacute;s en bon &eacute;tat.
D D&eacute;tourner votre visage du d&eacute;tendeur-r&eacute;gulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du d&eacute;tendeur doit toujours &ecirc;tre en place, sauf lorsque
la bouteille est utilis&eacute;e ou qu’elle est reli&eacute;e pour usage ult&eacute;rieur.
D Utiliser les &eacute;quipements corrects, les bonnes proc&eacute;dures et suffisamment de personnes pour soulever et d&eacute;placer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprim&eacute;,
l’&eacute;quipement connexe et le d&eacute;pliant P-1 de la CGA (Compressed
Gas Association) mentionn&eacute; dans les principales normes de s&eacute;curit&eacute;.
2-3. Dangers suppl&eacute;mentaires 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
&agrave; proximit&eacute; de surfaces inflammables.
D Ne pas installer l’appareil &agrave; proximit&eacute; de produits inflammables.
D Ne pas surcharger l’installation &eacute;lectrique − s’assurer que
l’alimentation est correctement dimensionn&eacute;e et prot&eacute;g&eacute;e avant
de mettre l’appareil en service.
LA CHUTE DE L’&Eacute;QUIPEMENT 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 &eacute;quipement de levage de capacit&eacute;
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour d&eacute;placer l’unit&eacute;, s’assurer que les fourches sont suffisamment longues pour d&eacute;passer
du c&ocirc;t&eacute; oppos&eacute; de l’appareil.
D Tenir l’&eacute;quipement (c&acirc;bles et cordons) &agrave; distance des v&eacute;hicules
mobiles lors de toute op&eacute;ration en hauteur.
D Suivre les consignes du Manuel des applications pour l’&eacute;quation
de levage NIOSH r&eacute;vis&eacute;e (Publication N&ordm;94–110) lors du levage
manuelle de pi&egrave;ces ou &eacute;quipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER L’&Eacute;QUIPEMENT.
D Pr&eacute;voir une p&eacute;riode de refroidissement ; respecter le cycle op&eacute;ratoire nominal.
D R&eacute;duire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES &Eacute;TINCELLES PROJET&Eacute;ES
peuvent provoquer des blessures.
D Porter un &eacute;cran facial pour prot&eacute;ger le visage et
les yeux.
D Aff&ucirc;ter l’&eacute;lectrode au tungst&egrave;ne uniquement &agrave; la
meuleuse dot&eacute;e de protecteurs. Cette
manœuvre est &agrave; ex&eacute;cuter dans un endroit s&ucirc;r
lorsque l’on porte l’&eacute;quipement homologu&eacute; de
protection du visage, des mains et du corps.
D Les &eacute;tincelles risquent de causer un incendie − &eacute;loigner toute substance inflammable.
LES CHARGES &Eacute;LECTROSTATIQUES peuvent endommager les circuits imprim&eacute;s.
D &Eacute;tablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pi&egrave;ces.
D Utiliser des pochettes et des bo&icirc;tes antistatiques pour stocker, d&eacute;placer ou exp&eacute;dier des
cartes de circuits imprimes.
OM-245 592 Page 7
Les PI&Egrave;CES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FR&Eacute;QUENCE
(H.F.)
risque
de
provoquer des interf&eacute;rences.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D Le rayonnement haute fr&eacute;quence (H.F.) peut
provoquer des interf&eacute;rences avec les &eacute;quipements de radio−navigation et de communication, les services de s&eacute;curit&eacute; et les ordinateurs.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la g&acirc;chette avant d’en
avoir re&ccedil;u l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pi&egrave;ce m&eacute;canique 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 d&eacute;marrer
des v&eacute;hicules &agrave; l’aide de c&acirc;bles de d&eacute;marrage,
sauf si l’appareil dispose d’une fonctionnalit&eacute;
de charge de batterie destin&eacute;e &agrave; cet usage.
D Demander seulement &agrave; des personnes qualifi&eacute;es familiaris&eacute;es
avec des &eacute;quipements &eacute;lectroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un &eacute;lectricien
qualifi&eacute; les interf&eacute;rences r&eacute;sultant de l’installation.
D Si le FCC signale des interf&eacute;rences, arr&ecirc;ter imm&eacute;diatement l’appareil.
D Effectuer r&eacute;guli&egrave;rement le contr&ocirc;le et l’entretien de l’installation.
D Maintenir soigneusement ferm&eacute;s les portes et les panneaux des
sources de haute fr&eacute;quence, maintenir les &eacute;clateurs &agrave; une distance correcte et utiliser une terre et un blindage pour r&eacute;duire les
interf&eacute;rences &eacute;ventuelles.
Les PI&Egrave;CES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir ferm&eacute;s et verrouill&eacute;s les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est n&eacute;cessaire pour des travaux d’entretien et de
d&eacute;pannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifi&eacute;.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est termin&eacute; et avant de rebrancher
l’alimentation &eacute;lectrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
&eacute;tiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de s&eacute;curit&eacute; au d&eacute;but du
manuel et dans chaque section.
D N’utiliser que les pi&egrave;ces de rechange recommand&eacute;es par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’&eacute;tat et locaux.
LE SOUDAGE &Agrave; L’ARC risque de
provoquer des interf&eacute;rences.
D
D
D
D
D
D L’&eacute;nergie &eacute;lectromagn&eacute;tique risque de
provoquer des interf&eacute;rences pour l’&eacute;quipement
&eacute;lectronique sensible tel que les ordinateurs et
l’&eacute;quipement command&eacute; par ordinateur tel que
les robots.
Veiller &agrave; ce que tout l’&eacute;quipement de la zone de soudage soit
compatible &eacute;lectromagn&eacute;tiquement.
Pour r&eacute;duire la possibilit&eacute; d’interf&eacute;rence, maintenir les c&acirc;bles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller &agrave; souder &agrave; une distance de 100 m&egrave;tres de tout &eacute;quipement &eacute;lectronique sensible.
Veiller &agrave; ce que ce poste de soudage soit pos&eacute; et mis &agrave; la terre
conform&eacute;ment &agrave; ce mode d’emploi.
En cas d’interf&eacute;rences apr&egrave;s avoir pris les mesures pr&eacute;c&eacute;dentes, il incombe &agrave; l’utilisateur de prendre des mesures suppl&eacute;mentaires telles que le d&eacute;placement du poste, l’utilisation de c&acirc;bles blind&eacute;s, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les &eacute;quipements de soudage et de coupage produisent des
fum&eacute;es et des gaz qui contiennent des produits chimiques
dont l’&Eacute;tat de Californie reconna&icirc;t qu’ils provoquent des malformations cong&eacute;nitales et, dans certains cas, des cancers.
(Code de sant&eacute; et de s&eacute;curit&eacute; de Californie, chapitre 25249.5
et suivants)
OM-245 592 Page 8
Ce produit contient des produits chimiques, notamment du
plomb, dont l’&Eacute;tat de Californie reconna&icirc;t qu’ils provoquent
des cancers, des malformations cong&eacute;nitales ou d’autres
probl&egrave;mes de procr&eacute;ation. Se laver les mains apr&egrave;s
utilisation.
2-5. Principales normes de s&eacute;curit&eacute;
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, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.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 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant &eacute;lectrique qui traverse tout conducteur g&eacute;n&egrave;re des champs
&eacute;lectromagn&eacute;tiques (CEM) &agrave; certains endroits. Le courant de soudage
cr&eacute;e un CEM autour du circuit et du mat&eacute;riel de soudage. Les CEM
peuvent cr&eacute;er des interf&eacute;rences avec certains implants m&eacute;dicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants m&eacute;dicaux doivent &ecirc;tre prises: Limiter par
exemple tout acc&egrave;s aux passants ou proc&eacute;der &agrave; une &eacute;valuation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les proc&eacute;dures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
4. Maintenir la t&ecirc;te et le torse aussi loin que possible du mat&eacute;riel du
circuit de soudage.
1. Rassembler les c&acirc;bles en les torsadant ou en les attachant avec
du ruban adh&eacute;sif ou avec une housse.
2. Ne pas se tenir au milieu des c&acirc;bles de soudage. Disposer les
c&acirc;bles d’un c&ocirc;t&eacute; et &agrave; distance de l’op&eacute;rateur.
3. Ne pas courber et ne pas entourer les c&acirc;bles autour de votre
corps.
En ce qui concerne les implants m&eacute;dicaux :
5. Connecter la pince sur la pi&egrave;ce aussi pr&egrave;s que possible de la
soudure.
6. Ne pas travailler &agrave; proximit&eacute; 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
d&eacute;vidoir.
Les porteurs d’implants doivent d’abord consulter leur m&eacute;decin avant
de s’approcher des op&eacute;rations de soudage &agrave; l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le m&eacute;decin approuve, il est recommand&eacute; de suivre les
proc&eacute;dures pr&eacute;c&eacute;dentes.
OM-245 592 Page 9
OM-245 592 Page 10
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
Do not discard product (where applicable) 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 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
OM-245 592 Page 11
Do not weld on drums or any closed containers.
Safe16 2012−05
Do not remove or paint over (cover) the label.
Safe20 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 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
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
OM-245 592 Page 12
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
Output
X
Amperes
V
Direct Current
(DC)
Volts
IP
Degree Of
Protection
Duty Cycle
Wire Feed
Percent
Input
Cold Jog (Inch)
Towards
Workpiece
Purge By Gas
Fast
Constant Current
Circuit Breaker
Constant Voltage
Slow
Trigger Hold Off
Trigger Hold On
Rated Welding
Current
Increase
Conventional Load
Voltage
Locked
Read Instructions
I1
A
U1
Primary Voltage
I2
U2
Primary Current
Sequence
Program
Process
Wire Type
Gas Type
Variable
Inductance
Time
Arc Control
Trigger Control
Single Phase
Three Phase
Trigger Hold On
Indicator Light
Trigger Hold
Off Indicator Light
Line Connection
Notes
OM-245 592 Page 13
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications
Type of Input
Power
Welding Power
Source Type
40 Volts DC
10 Amperes
Axcess E Series
Wire Feed Speed Range
Wire Diameter
Range
Welding Circuit
Rating
Overall
Dimensions
Weight
Standard: 40 To 1400 ipm
(1.0 To 35.6 mpm)
.035 To 3/32 in. (0.8
To 2.4 mm)
100 Volts,
750 Amperes,
100% Duty
Cycle
Length: 27 in.
(686 mm)
46 lb
(20.9 kg)
Max Spool Weight:
60 lb (27 kg)
Width: 12-1/2 in.
(318 mm)
Height: 14-1/2
in.
(368 mm)
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
Tipping
!
Do not move or operate
unit where it could tip.
2
OR
1
Location
!
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
Lifting Forks
Use lifting forks to move unit.
3
Extend forks beyond opposite side
of unit.
2
Hand Cart
Use cart or similar device to move
unit.
3
18 in.
(460 mm)
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
loc_2 3/96 - Ref. 245 867-A
OM-245 592 Page 14
5-2. Connection Diagram
3
4
5
2
1
1
2
3
4
5
6
7
8
Welding Power Source
Wire Feeder
Gas Cylinder
Gas Hose
Network Feeder Cable
Negative (−) Weld Cable
Workpiece
Voltage Sensing Lead
Recommended for Accu-pulse.
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
7
9
8
Positive (+) Weld Cable
9
6
245 739-A
Notes
OM-245 592 Page 15
5-3. Rear Panel Connections And Rotating Drive Assembly
1
2
9-Pin Network Receptacle
Shielding Gas Valve Fitting
Requires fitting with 5/8-18
right-hand threads. Connect
customer supplied gas hose.
1
3
4
5
6
7
2
7
Weld Cable Terminal
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
Rating Label Location
To rotate the drive assembly,
loosen drive assembly rotation
knob, rotate drive assembly, and
tighten knob.
3
4
5
6
Tools Needed:
9/16, 5/8 in.
3/16 in.
802 825-A / 803 503-A
5-4. 9-Pin Network Receptacle Information
9
F
E
G
H
I
D
C
A
B
OM-245 592 Page 16
Pin
Pin Information
A
Capacitor C1 to ground
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
I
Motor voltage +40 volts
5-5. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Adjust
Rear
Rolls
Pressure
Indicator
Scale
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Drive Rolls
Tools Needed:
3/16, 5/64 in.
Gun Cable
15/16, 3/8 in.
End Of Liner
. Be sure that outlet cable has proper size . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
liner for the welding wire size. When
installing
gun,
position
liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
This unit is equipped with Auto Thread
capability. 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. The
default feed rate is 700 ipm. These settings
can be changed using the HTML pages.
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If
contact tip is completely blocked, wire
should slip at the feeder (see pressure
adjustment above).Cut wire off. Close
cover.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / 802 954 / S-0627-A
OM-245 592 Page 17
5-6.
Feeder Display At Power Up
1
2
While the system is initializing, the
display will alternate between “Net
Wait” and counting up dashes
before the power source is fully
operational.
1
Program
Volts
Time
WFS
Amps
Arc Adjust
Arc Ctl
Process
Sequence
Wire Type
Gas Type
Trigger Hold
Power Source
2
Trigger Control
Adjust
Process Set Up
Upper Display
Feeder Set Up
Lower Display
Net
Wait
Net
Wait
Voltage Range
—
— —
Net
Wait
— — —
Net
Wait
— — — —
Net
— — — —
Net
— — — —
Net
— — — —
Net
— — — —
Axcess E
OM-245 592 Page 18
Upper Display
Lower Display
Wait
—
Wait
— —
Wait
— — —
Wait
— — — —
Net
Wait
DTEC
OFF
Axcs
300/450/675
10
44
5-7. Dual Schedule Switch Option
1
Maint 2P (Maintained-Contact
2-Pole Switch)
DSS-9M Part# 041 793
2
1
DSS-9M 1
2
2
A
3
B
4
1
Adapter
Adapter
Part# 157 364 needed for Bernard
and Tregaskiss dual schedule
torches.
1
1
2
2
3
3
2
4
OM-245 592 Page 19
SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:
General Terms:
Arc Adjust
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases
the actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by
volts in MIG programs.
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.
OM-245 592 Page 20
General Terms:
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.
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.
6-2. Power Switch
1
Power Switch
1
803 504-A
OM-245 592 Page 21
6-3. Front Panel Controls
See
Section
6-5
See
Section
6-4
Program
Time
WFS
Amps
See
Section
6-6
Arc Adjust
Arc Ctl
Process
Sequence
Wire Type
Trigger Control
Gas Type
Trigger Hold
Process Set Up
See
Section
6-9
OM-245 592 Page 22
Volts
Adjust
See
Section
6-8
Feeder Set Up
See
Section
6-7
6-4. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
3
Program Push Button
Program Push Button LED
The LED lights to indicate that
programs can be changed using
the Adjust knob.
Momentarily press button to
illuminate LED. To change the
program number, rotate Adjust knob
to select one of eight programs.
1
Program
Pressing and holding the push
button will display current wire size,
wire type and process.
3
2
6-5. Upper Display
3
1
2
4
Volts
Arc Adjust
5
1
Upper Display
The upper display shows voltage or arc
length. The unit displays either preset voltage
or arc length when not welding. When welding,
actual arc voltage is displayed.
2
Upper Display Push Button
Press the button to illuminate the LED and
allow changing information in the display.
Release button to display voltage.
4
5
3
The LEDs below the display illuminate to
indicate which value is being shown.
Upper Display Push Button LED
The upper display push button LED
illuminates to indicate that information
displayed can be changed by the Adjust
control.
Volts LED (Weld Voltage In MIG)
Arc Adjust LED (Pulse Mode)
At any time while welding, the unit permits the
adjustment of the weld voltage and overrides
the display of actual arc voltage.
OM-245 592 Page 23
6-6. Lower Display
5
7
Time
1
6
2
WFS
Amps
Arc Ctl
3
1
Lower Display
The lower display shows WFS (wire feed
speed), AMPS (amperage), ARC CTL (arc
control), or Time. The feeder displays only
preset wire speed at idle (not welding). While
welding, the average amperage is displayed.
The lower display shows welding sequence
time when the Time LED is illuminated.
2
WFS (Wire Feed Speed) LED
LED illuminates to indicate the preset wire feed
value is being displayed and can be adjusted
using the Adjust knob.
3
Amps LED
LED illuminates to indicate the average
amperage is being displayed while welding
and for 3 seconds after welding is terminated.
The amperage must be above a minimum
value of 25 amps for this function to operate.
OM-245 592 Page 24
4
4 Arc Ctl (Arc Control) LED
LED illuminates to indicate that inductance
(MIG) or ARC (Pulse or Accu-pulse) is being
displayed and can be adjusted using the
Adjust knob.
5 Time LED
LED illuminates to indicate that a time value is
being displayed for a sequence function and
can be adjusted using the Adjust knob.
6 Lower Display Push Button
7 Lower Display Push Button LED
Pressing the button illuminates the LED and
selects either WFS or Arc Ctl value for
changing using the Adjust knob.
To select Arc Ctl, press and hold lower display
button for 2 seconds. The top display will show
either INDU/SLPE for a MIG program or ARC
for Pulse or Accu-pulse. To exit Arc Ctl or
INDU, either press the upper display push button or press and hold the lower display push
button for 2 seconds.
During a welding program operation, it is
possible to change WFS (wire feed speed) by
using the Adjust knob regardless of the active
program sequence that appears on the
display.
When the Arc Ctl LED is illuminated, it is
possible to change values while welding by
using the Adjust knob. To return to actual
values on the display, exit the Arc Ctl display.
. The
lower display push button has
additional functions when entering the
sequence and trigger control functions
(see Section 6-7).
6-7. Feeder Set Up Push Button
3
4
Sequence
5
Trigger Control
Trigger Hold
Start
Time
2
Crater
Time
Preflow
Time
1
Retract
Time
Postflow
Time
6
Sequence Diagram
Feeder Set Up
1 Feeder Set Up Push Button
2 Feeder Set Up Push Button LED
Press button to choose sequence, trigger
control, or trigger hold.
3 Sequence LED
4 Trigger Control LED
5 Trigger Hold LED
 When the Feeder Set Up button is pressed
while in standby, the Feeder Set Up push
button LED illuminates and the top display
will be active. Use the Adjust control to
select preflow (PRE), start (STRT), crater
(CRTR), retract (RTRC), or postflow
(POST) parameters.
 Press the lower display push button to allow
the bottom display to become active. The
time LED will automatically begin flashing
and the unit will be in the time mode. Initially,
all sequences will appear as off. Use the
Adjust control display time and enable the
time sequence. Setting a time automatically
enables a sequence. To turn off a sequence,
change time setting to OFF.
 If the sequence has a voltage or arc adjust
setting, pressing the lower display push
button a second time will cause either volts
or arc adjust to appear on the display. Use
the Adjust control to set either parameter.
 If the sequence has a wire feed setting,
pressing the lower display push button a
third time will cause wfs to appear on the
display. Use the Adjust control to set wire
speed parameter. Additional sequence set
up changes can be made using the HTML
pages. Refer to the HTML pages for additional
information.
 Press the lower display push button a fourth
time will cycle the display back to time.
 Press the Feeder Set Up button a second
time to go to Trigger Control mode and allow
the top display to become active. Use the
Adjust control to cycle through trigger
control methods as follows: dual schedule,
trigger hold, trigger dual schedule, program
select, 4T, and ignore (see Section 6-1 and
Table 6-1). The lower display will show the
current state of each trigger control method
as being either on or off. Not all trigger
control methods are compatible with each
other, and turning on certain functions will
cause other trigger functions to turn off.
 Press the lower display push button to allow
the bottom display to become active. Use
the Adjust control to turn selected trigger
control methods on or off. If trigger hold is
set to on, the trigger hold LED will illuminate.
Note: if 4T is set to on, trigger hold will
automatically be set to on since this
parameter is necessary for the 4T function.
 Press the Feeder Set Up button a third time
to cycle back to standby mode.
6 Lock LED
 The lock LED is illuminated when one or more
programs have been locked using the HTML
pages. This indicates that some programs
have been disabled. A disabled program will
not show up for selection.
Refer to the HTML pages for additional
information.
Table 6-1. Trigger Control Chart
Trigger Control
Function
Trigger Hold
4T
Trigger Dual Schedule
Trigger Program
Select
Dual Schedule
Trigger Hold
X
Yes
No
Yes
Yes
4T
Yes
X
No
Yes
No
Trigger Dual Schedule
No
No
X
Yes
No
Trigger Program
Select
Yes
Yes
Yes
X
Yes
Dual Schedule
Yes
No
No
Yes
X
The following trigger control functions are the possible selections that limit the choices that appear on the display depending upon which one
the user turns on. Only certain trigger functions will work with the other trigger functions.
OM-245 592 Page 25
6-8. Adjust Control
1
Adjust Control
The Adjust control is used to
change
various
sequence
parameters, and to select various
sequences. Refer to the section for
the function in question for
information related to using the
Adjust control.
1
Adjust
6-9. Process Set Up Push Button
1
2
3
3
Process Set Up Push Button
Process Set Up LED
Program Selection LEDs
Process
Wire Type
Gas Type
2
1
Process Set Up
 Press the Process Set Up push button the
first time will illuminate the button LED and
Process LED above the button. Both
displays will show the current process and,
if desired, these displays will be active to
allow selecting a new process. Default
processes are MIG, PULSE, and ACCU
PULSE.
 Pressing the Process Set Up push button a
second time will illuminate the Wire Type
LED and the bottom display will show wire
OM-245 592 Page 26
types available for the selected process. To
make a selection, rotate the Adjust control.
and wire size selection. To select an item,
rotate the Adjust control.
 Pressing the Process Set Up push button a
third time will keep Wire Type LED lit, but the
upper display will be active and show wire
sizes available for the current wire type. To
make a selection, rotate the Adjust control.
 Pressing the Process Set Up push button a
fifth time will load the program that matches
the selected parameters (process, wire
type, wire size, gas). The upper display will
show PROG and the lower display will show
LOAD.
 Pressing the Process Set Up push button a
fourth time will illuminate the Gas Type LED
and both displays will show available gas
selections for the process, and wire type
If no changes were made to any setup items,
no program will be loaded, and unit will return
to standby mode.
Table 6-2. Welding Wire And Gas Abbreviations*
Wire Description
Wire Abbreviation
Alloy Type
Gas Type
Gas Abbreviation
Steel
STL
E70, E100, E120
100% CO2,
90% Argon/10% CO2,
85% Argon/15% CO2,
80% Argon/20% CO2,
75% Argon/25% CO2,
95% Argon/5% CO2,
95% Argon /5% O2,
98% Argon/2% O2
CO2
C10
C15
C20
C25
C5
OX5
OX2
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O2,
(81Ar/18HE/1CO2
Accu-pulse),
90HE/7-1/2Ar/2-1/2CO2
MIG/Accu-pulse),
98% Argon/2% CO2
OX2
Tri Gas
HE90
C2
Cored Tubular Wire
MCOR
71, 76, 86R, 409, 439,
MATRIX
90% Argon/10% CO2,
98% Argon/2% O2,
95% Argon/5% CO2,
95% Argon /5% O2,
100% CO2
C10
OX2
C5
OX5
CO2
Aluminum
ALUM
4XXX, 5XXX
100% Argon
ARGN
Flux Cored Tubular Wire
FCOR
E70T-0
E70T-1
100% CO2
75% Argon/25% CO2
CO2
C25
*Not all wire types may be available with your unit.
6-10. Jog/Purge
1
2
3
Jog/Purge Push Button
Adjust Control
Gun Trigger Receptacle
2
3
1
803 505-A
The Jog/Purge switch provides the following
functions:
 Pressing left side of the Jog/Purge switch
allows the operator to feed wire without
energizing the weld power or gas valve
circuit. The wire will feed at a 60 ipm rate for
3 seconds, then the rate ramps up to 700
ipm until the Jog switch is released.
 Jog speed can be adjusted by modifying the
minimum and maximum speed limits using
the HTML pages.
 The unit also provides the ability to jog the
wire feeder by means of the gun trigger.
When the gun trigger is pressed without
starting an arc, the wire will feed at run-in
speed for the first 3 seconds. During this
time OCV (open circuit voltage) will be
present as indicated on the feeder upper
display. After 3 seconds the weld output
turns off and the wire will feed at 60 ipm for
the next 3 seconds and then ramps up to
700 ipm until trigger is released or 30
seconds elapses. If the gun trigger is still
activated after 30 seconds, the jog
operation is terminated to prevent complete
unspooling of the wire and a “REL TRIG”
message is displayed on the upper and
lower displays. Press the Jog/Purge switch
to clear the error.
. If Start Error is enabled using the HTML
pages, an “ERR STRT” will occur after the
first 3 seconds of run in and jogging from
the trigger is not possible.
 Pressing right side of the Jog/Purge switch
allows the operator to purge gas lines before
welding and to preset gas flow rate at the
regulator.
 This unit is equipped with Auto Thread
capability. 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. The
default feed rate is 700 ipm. These settings
can be changed using the HTML pages.
OM-245 592 Page 27
6-11. User Interface Menu
1
2
1
2
Welding Power Source
Wire Feeder
Turn on welding power source and
wire feeder.
Wait for system to initialize (see
Section 5-6).
Example display shows
a model 450
Program
AXCS
Volts
Time
450
WFS
Amps
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Process Set up
Program
Adjust
Feeder Set Up
AXCS
Volts
Time
450
WFS
Amps
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Process Set up
Adjust
Feeder Set Up
To enter the user interface menu, momentarily press the Program push button and lower display push button at
the same time.
Program
CAC
Volts
Time
ENBL
WFS
Amps
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
After entering the user interface menu,
the initial display will vary by the first
item that appears.
245 746-A / 803 504-B
OM-245 592 Page 28
A. System Reset
. System Reset is not active when
Program Lock is enabled.
Program
CAC
Volts
Time
ENBL
WFS
Amps
Program
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Trigger Hold
Adjust
SYS
Volts
Time
RST
WFS
Amps
Feeder Set Up
Feeder Set Up
RST
Time
YES
WFS
Amps
Adjust
Feeder Set Up
The Set Up push button LED flashes
indicating the unit is ready to perform
the system reset operation. Press the
Set Up push button.
Program
CYCL
Volts
Time
PWR
WFS
Amps
Process Set up
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Adjust
Volts
Time
Amps
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Trigger Hold
Process Set up
Adjust
Feeder Set Up
Rotate Adjust knob to select NO
or YES.
PLS
Volts
WFS
Trigger Hold
Process Set up
RST
Time
WAIT
Sequence
Trigger Control
Feeder Set Up
Process
Wire Type
Gas Type
Arc Ctl
Process
Wire Type
Gas Type
Adjust
Rotate Adjust knob until System Reset
(SYS RST) appears on the display.
Program
Arc Adjust
lost during the Reset operation.
Arc Ctl
Trigger Hold
WFS
Trigger Hold
Adjust
Amps
NO
Sequence
Trigger Control
Volts
. System configuration data will be
Arc Adjust
Sequence
Trigger Control
Process Set up
Arc Ctl
Upper display push button LED
flashes to indicate this menu item
is available for selection. Press
the upper display push button.
Program
Time
Process
Wire Type
Gas Type
Program
Arc Adjust
Process
Wire Type
Gas Type
Process Set up
Volts
WFS
LED
Program
SYS
RST
Process
Wire Type
Gas Type
Process Set up
System Reset allows the operator to
reload factory program settings for all
eight active programs in the unit.
Amps
Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2
MIG
.035 Mild Steel
75% Argon, 25% CO2
Trigger Hold
Program 3
Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
Feeder Set Up
Program 4
Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5
MIG
.045 Mild Steel
75% Argon, 25% CO2
Program 6
Accu-pulse
.045 Mild Steel
90% Argon, 10% O2
Program 7
Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8
MIG
.052 Mild Steel
75% Argon, 25% CO2
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Program 1
Adjust
Unit will go through a soft boot and then
begin initialization (see Section 5-6).
During system reset the following factory
default programs are loaded into the unit:
Feeder Set Up
When System Reset is finished, the display
will show CYCL PWR for cycle power. Turn
the power source off and back on again.
OM-245 592 Page 29
B. Software Revision
The top display shows the board
(PCM, UIM, and WFCM) and the
lower display shows the last 3 digits of
the circuit board part number plus a
letter designator.
Program
SYS
Volts
Time
RST
WFS
Amps
Program
Arc Adjust
Volts
Time
Arc Adjust
REV
Arc Ctl
WFS
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Process Set up
SW
Adjust
Feeder Set Up
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Amps
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Process Set up
Adjust
Feeder Set Up
Rotate Adjust knob until Software
Revision (SW REV) appears on
the display.
LED
Program
SW
Volts
Time
REV
WFS
Amps
Program
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
Upper display push button LED
flashes to indicate this menu item
is available for selection. Press
the upper display push button.
Program
PCM
Volts
Time
321B
WFS
Amps
1
25
Volts
Time
200
WFS
Amps
Feeder Set Up
Process Set up
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Adjust
Feeder Set Up
Unit goes back to its standby status.
OM-245 592 Page 30
Sequence
Trigger Control
Trigger Hold
Adjust
Feeder Set Up
Rotate Adjust knob to scroll
through the software revision for
each circuit board.
PCM
Volts
WFS
Trigger Hold
Adjust
Arc Ctl
Time
321B
The Set Up push button LED flashes indicating
that pressing this button will exit the user
interface menu. Press the Set Up push button.
Program
Process Set up
Arc Ctl
Sequence
Trigger Control
Process Set up
Amps
Arc Adjust
Process
Wire Type
Gas Type
Program
Arc Adjust
Process
Wire Type
Gas Type
Time
WFS
Sequence
Trigger Control
Process Set up
Volts
123A
Arc Ctl
Process
Wire Type
Gas Type
UIM
Amps
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
To exit the user interface menu, momentarily
press the Program push button and lower
display push button at the same time.
C. Carbon Arc Cutting (CAC)
Allows carbon arc cutting to be
enabled or disabled.
. CAC can be loaded on any of the
Program
SW
Volts
Time
REV
WFS
Amps
Program
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
After entering the user interface
menu, the initial display will vary by
the first item that appears.
LED
CAC
Volts
Time
Amps
Adjust
Feeder Set Up
ENBL
Time
YES
WFS
Amps
Feeder Set Up
The Set Up push button LED flashes
indicating that pressing this button will
enable carbon arc cutting. Press the
Set Up push button.
Program
25
Volts
Time
200
WFS
Amps
Time
Amps
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process Set up
Trigger Hold
Adjust
Feeder Set Up
Rotate Adjust knob to select NO
or YES.
ENBL
Volts
Time
Amps
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
To exit the user interface menu, momentarily
press the Program push button and lower
display push button at the same time.
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Volts
WFS
Trigger Hold
Adjust
ENBL
YES
Sequence
Trigger Control
Process Set up
Feeder Set Up
Process
Wire Type
Gas Type
Arc Ctl
Process
Wire Type
Gas Type
Adjust
Rotate Adjust knob until Carbon
Arc Cutting Enable (CAC ENBL)
appears on the display.
Program
Arc Adjust
Arc Ctl
Trigger Hold
WFS
Trigger Hold
Volts
Amps
NO
Sequence
Trigger Control
Upper display push button LED
flashes to indicate this menu item
is available for selection. Press
the upper display push button.
Program
Arc Adjust
Sequence
Trigger Control
Process Set up
Arc Ctl
Process
Wire Type
Gas Type
Process Set up
Time
Process
Wire Type
Gas Type
Program
Arc Adjust
ENBL
WFS
Volts
WFS
Process
Wire Type
Gas Type
Program
CAC
ENBL
Arc Ctl
Sequence
Trigger Control
Process Set up
eight programs by selecting the
process using the Process Set up
button.
Trigger Hold
Adjust
Feeder Set Up
Unit goes back to it standby status.
OM-245 592 Page 31
D. Voltage Feedback
Allows changing the voltage feedback
method from volt sense lead to stud
feedback.
Program
CAC
Volts
Time
ENBL
WFS
Program
Arc Adjust
Amps
Arc Ctl
Trigger Hold
Adjust
Feeder Set Up
LED
VOLT
Volts
Time
Amps
Adjust
Feeder Set Up
FDBK
Volts
Time
VSNS
WFS
Amps
25
Volts
Time
200
WFS
Amps
Feeder Set Up
Process Set up
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Adjust
Feeder Set Up
Unit goes back to its standby status.
OM-245 592 Page 32
Time
Amps
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process Set up
Trigger Hold
Adjust
Feeder Set Up
Rotate Adjust knob to select
STUD or volt sense lead (VSNS).
FDBK
Volts
WFS
The Set Up push button LED flashes
indicating that pressing this button will
change the voltage feedback method.
Press the Set Up push button.
Program
Volts
Time
VSNS
Trigger Hold
Adjust
FDBK
Process
Wire Type
Gas Type
Arc Ctl
Sequence
Trigger Control
Process Set up
Feeder Set Up
Rotate Adjust knob until Voltage
Feedback (VOLT FDBK) appears
on the display.
Program
Arc Adjust
Process
Wire Type
Gas Type
Adjust
WFS
Trigger Hold
Arc Ctl
Trigger Hold
STUD
Sequence
Trigger Control
Upper display push button LED flashes
to indicate this menu item is available
for selection. Press the upper display
push button.
Program
Amps
Sequence
Trigger Control
Process Set up
Arc Ctl
Process
Wire Type
Gas Type
Process Set up
Arc Adjust
Process
Wire Type
Gas Type
Program
Arc Adjust
FDBK
WFS
Time
WFS
Sequence
Trigger Control
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Program
Volts
FDBK
Process
Wire Type
Gas Type
Process Set up
VOLT
Amps
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
To exit the user interface menu, momentarily
press the Program push button and lower
display push button at the same time.
E. Load Bank
Allows setting the load bank feature
on or off.
. Load Bank is a diagnostic tool for
Program
VOLT
Volts
Time
FDBK
WFS
Amps
Program
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
LED
LOAD
Volts
Time
Amps
Upper display push button LED flashes
to indicate this menu item is available
for selection. Press the upper display
push button.
BANK
Volts
Time
ON
WFS
Amps
25
Volts
Time
200
WFS
Amps
Time
Amps
Feeder Set Up
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Trigger Hold
Adjust
Feeder Set Up
Rotate Adjust knob to select OFF
or ON.
BANK
Volts
Time
Amps
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
To exit the user interface menu, momentarily
press the Program push button and lower
display push button at the same time.
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Volts
WFS
Trigger Hold
Adjust
BANK
ON
The Set Up push button LED flashes
indicating that pressing this button will
set the load bank feature on. Press the
Set Up push button.
Program
Process Set up
Arc Ctl
Sequence
Trigger Control
Process Set up
Feeder Set Up
Process
Wire Type
Gas Type
Program
Arc Adjust
Process
Wire Type
Gas Type
Adjust
WFS
Feeder Set Up
Arc Ctl
Trigger Hold
OFF
Trigger Hold
Adjust
Amps
Rotate Adjust knob until Load
Bank (LOAD BANK) appears on
the display.
Arc Ctl
Process
Wire Type
Gas Type
Program
Arc Adjust
Sequence
Trigger Control
Process Set up
Program
Arc Adjust
Sequence
Trigger Control
Process Set up
Time
Process
Wire Type
Gas Type
BANK
WFS
Volts
WFS
Sequence
Trigger Control
After entering the user interface
menu, the initial display will vary by
the first item that appears.
Program
LOAD
BANK
Arc Ctl
Process
Wire Type
Gas Type
Process Set up
testing the power conversion
modules, not a welding process
selection.
Trigger Hold
Adjust
Feeder Set Up
Unit goes back to its standby status.
OM-245 592 Page 33
F. Spool Reset
Allows the operator to reset the
date/time when a new spool of wire is
installed to allow wire usage tracking.
Program
LOAD
Volts
Time
Program
Arc Adjust
Amps
Sequence
Trigger Control
Trigger Hold
Adjust
Feeder Set Up
After entering the user interface
menu, the initial display will vary by
the first item that appears.
LED
Program
WIRE
Volts
Time
RST
WFS
Amps
Feeder Set Up
RST
Volts
Time
ON
WFS
Amps
Adjust
25
Volts
Time
200
WFS
Amps
Feeder Set Up
Process Set up
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Adjust
Feeder Set Up
Unit goes back to its standby status.
OM-245 592 Page 34
Time
Amps
Arc Adjust
Arc Ctl
Sequence
Trigger Control
Process Set up
Trigger Hold
Adjust
Feeder Set Up
Rotate Adjust knob to select OFF
or ON.
RST
Volts
WFS
The Set Up push button LED flashes
indicating that pressing this button will
reset the wire installation date/time.
Press the Set Up push button.
Program
Volts
Time
ON
Trigger Hold
Process Set up
RST
Process
Wire Type
Gas Type
Arc Ctl
Sequence
Trigger Control
Feeder Set Up
Rotate Adjust knob until Cable
Compensation (CABL COMP)
appears on the display.
Program
Arc Adjust
Process
Wire Type
Gas Type
Adjust
WFS
Trigger Hold
Arc Ctl
Trigger Hold
OFF
Sequence
Trigger Control
Adjust
Amps
Sequence
Trigger Control
Process Set up
Arc Ctl
Upper display push button LED flashes
to indicate this menu item is available
for selection. Press the upper display
push button.
Program
Arc Adjust
Process
Wire Type
Gas Type
Program
Arc Adjust
Process
Wire Type
Gas Type
Process Set up
Time
WFS
Arc Ctl
Process
Wire Type
Gas Type
Process Set up
Volts
RST
BANK
WFS
WIRE
Amps
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
To exit the user interface menu, momentarily
press the Program push button and lower
display push button at the same time.
SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence mode, see Feeder
Set Up Push Button in Section
6-7.
Sequence
Weld Time can only be set by using
the HTML pages.
Parameters
Volts/Trim
IPM
If time is set to Off in Weld
sequence, welding continues until
gun trigger is released.
Seconds
1. Preflow
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
Off-10.0
2. Start
10.0-44.0/
0-99
40-1400/
0-99
Off-10.0
3. Crater
10.0-44.0/
0-99
40-1400/
0-99
Off-10.0
50-500
Off-10.0
4. Retract
5. Postflow
. Maximum
IPM may actually
be lower depending on wire
size and gas combination.
Additional sequence set up
changes can be made using the
HTML pages. Refer to the HTML
pages for additional information.
Off-10.0
Weld
Crater
Time
Preflow
Time
Retract
Time
Start
Time
Postflow
Time
Time
Preflow
Trigger
Pressed
Start
Weld
Crater
Retract
Postflow Sequence
End
Trigger
Released
OM-245 592 Page 35
SECTION 8 − MAINTENANCE AND TROUBLESHOOTING
8-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
Disconnect power
before maintaining.
~ Weld Terminals
l Damaged Gas Hose
nl Cords
nl Gun Cables
nl Cracked Parts
OR
~ Drive Rolls
Notes
OM-245 592 Page 36
~ Inside Unit
during severe conditions.
l = Replace
l Unreadable Labels
Every
6
Months
. Maintain more often
Reference
nl Weld Cables
8-2. Error Code Troubleshooting Tables
ERR
Display Example
TACH
. The following error codes may appear on the upper and lower displays of the User Interface Module
to indicate specific errors. Explanations of
the error codes are provided in the sections referenced.
Error Type
User Interface Module
Upper Display
User Interface Module
Lower Display
Reference
Emergency Stop
E
STOP
Section 8-2. A
Arc Error
ERR
ARC
Section 8-2. B
No Coolant Flow
ERR
COOL
Section 8-2. C
Ground Current
Detect Error
ERR
GND
Section 8-2. D
Line Error
ERR
LINE
Section 8-2. E
Motor Over Current
ERR
MOTR
Section 8-2. F
Arc Start Error
ERR
STRT
Section 8-2. G
No Tach Error
ERR
TACH
Section 8-2. H
Thermal Over
Temperature
ERR
TEMP
Section 8-2. I
Unknown Error
ERR
UNKN
Section 8-2. J
Motor Communications Error
MOTR
COMM
Section 8-2. K
Over Average Current
OVER
AVE
Section 8-2. L
Over Current
OVER
CRNT
Section 8-2. M
Release Trigger
REL
TRIG
Section 8-2. N
Trigger Stuck
TRIG
STUK
Section 8-2. O
Wire Feed Speed Error
ERR
WFS
Section 8-2. P
Stop Error
ERR
STOP
Section 8-2. Q
Flow Error
ERR
FLOW
Section 8-2. R
Stuck Error
ERR
STUK
Section 8-2. S
Weld Wait
WELD
WAIT
Section 8-2. T
Please Wait
PLS
WAIT
Section 8-2. U
Low Wire Feed Speed
LOW
WFS
Section 8-2. V
Demo Done
DEMO
DONE
Section 8-2. W
Net Wait
NET
WAIT
Section 8-2. X
Software Error
SW
ERR
Section 8-2. Y
Check Web
CHCK
WEB
Section 8-2. Z
OM-245 592 Page 37
A. Emergency Stop Error
Indicates an emergency stop error.
Receptacle RC5-1 connects to receptacle RC1-4 and receptacle RC5-2 connects to receptacle RC4-2 on E-Stop board
PC12. A closure between RC4-1 and RC4-2 allows +24 volts DC to be supplied to the four relays on E-Stop board PC12.
In an E-Stop situation (relays open), all four relays on the E-Stop board de-energize and cut power to the control boards.
E
When relay CR1 on E-Stop board PC12 is de-energized, it drops out the 18 volts AC from transformer T1 that powers the
inverter control board(s).
STOP
When relay CR2 on E-Stop board PC12 is de-energized, it breaks the contactor signal being sent to the inverter engine
board(s) from the process control module PC4 (J2-9 to RC2-3) and causes a loss of signal to the AIM board (RC2-1 and
RC2-2) and to micro input (RC5-3 and RC5-4), signaling an E-Stop is active.
When relay CR3 on E-Stop board PC12 is de-energized, it breaks the secondary side output of the motor board before it
goes to the filter board.
Relay CR4 on E-Stop board PC12 is a soft start relay in parallel with the contacts of relay CR1.
B. Arc Error
ERR
ARC
Indicates voltage has exceeded the programmable limit of a valid arc for the programmed amount of time (default time is
500 ms). Check contact tip, weld conditions, and shielding gas.
Arc error can be enabled or disabled using an optional PDA with File Management/WaveWriter software.
C. No Coolant Flow Error
ERR
COOL
Indicates no coolant flow in water flow switch option. The error may be reset by reestablishing coolant flow to the gun, and
then pressing the Jog/Purge button.
D. Ground Current Detect Error
ERR
GND
Indicates that weld current is flowing through the primary ground. This is a latching error and welding power source power
must be cycled off and back on again.
E. Line Error
ERR
LINE
Indicates that primary power has dropped below the operating point of the welding power source. Signal is sent from inverter engine module(s) (RC6, Pin 9 on inverter control board PC1) to process control module PC4 (J2, Pin 1). Check for a
brown-out condition. The primary boost capacitors have dropped below an acceptable minimum voltage threshold.
This circuit monitors the 940 volts primary DC bus voltage across the electrolytic capacitors C1 and C2. Low line is displayed when this voltage drops below 858 volts DC. This could happen when attempting to draw near rated output power
with an input voltage below 190 volts AC, three phase. This causes the boost section to go into current limit trying to supply the output power. Once current limit is reached, the boost section can no longer hold the bus capacitors at 940 volts
DC. The inverter control will also go into an output current limit mode in an attempt to supply output power.
F. Motor Over Current Error
ERR
MOTR
OM-245 592 Page 38
Indicates that the motor has been drawing too much current for too long a time period. To remedy this fault, reduce the wire
feed speed or the wire feeder torque load/duty cycle. Press Jog/Purge button to clear error.
G. Arc Start Error
ERR
STRT
Indicates the contactor either is or was active, but the system failed to start an arc. Conditions for a valid arc start are at
least 50% of arc start current, voltage less than 60 volts, and voltage greater than min. valid arc voltage (default is 22.5
volts). This situation is usually attributed to a contact tip or feeder issue. The arc start error parameter can be disabled
using an optional PDA with File Management/Wave Writer software.
H. No Tach Error
Indicates loss of tachometer feedback. Determine cause of error as follows:
ERR
TACH
I.
S
Press JOG button on the front panel.
S
Does the motor run wide open immediately?
S
YES Replace Motor Board PC6.
S
Does the motor ramp up in speed?
S
YES Bad motor tach. Contact nearest Factory Authorized Service Agent.
S
Does the motor respond at all?
S
YES Contact nearest Factory Authorized Service Agent.
S
Check motor cable. Is it damaged?
S
YES Replace motor cable.
S
NO Contact factory service personnel.
Thermal Over Temperature Error
Indicates one or more of the inverter engines overheated. Sent from inverter engine module(s) (RC6, Pin 12, on inverter
control board PC1) to process control module PC4 (J2, Pin 7). Check fan on inverter engine(s) and weld currents.
This signal is the sum of two conditions: shutdown that comes from the temperature monitoring circuit on the inverter control board, and Pwr-Up-Cnt that generated by the boost section of the inverter control board. When either of these signals
is active, RC6-12 is pulled low (this is the not ready line out of the inverter control board).
Shutdown is active when there is an over-temperature condition on the primary or secondary heatsink or on the boost
inductor. To determine which of the two locations is at fault, check LED 1 and LED 2 on inverter control board PC1.
ERR
TEMP
S
If LED 1 is lit, this indicates an over-temperature condition on the primary heat sink.
S
If LED 2 is lit, this indicates an over-temperature condition on the secondary heat sink or on the boost inductor.
Pwr-Up-Cnt (power up control) monitors primary voltage start-up conditions when the power source is first turned on. This
signal is opto-isolated from the boost section of the inverter control board. The following conditions must be met for the
power source to power up:
S
Auxiliary power board PC3 must be powered up and operating to supply prepower of +15 volts DC to the boost section of inverter control board PC1.
S
The peak voltage of the input line power must be greater than 150 volts peak.
S
The DC bus voltage must be greater than 85% of the rectified line voltage. This bus voltage also turns on the
pre-charge relay.
S
The DC bus voltage must be boosted to greater than 858 volts DC.
If any of these conditions are not met, then receptacle RC6-12 is pulled low and weld output is locked out.
J. Unknown Error
ERR
UNKN
Indicates error bit from process control module PC4 is set, but error value sent does not match anything defined with the
UIM board PC7.
OM-245 592 Page 39
K. Motor Communications Error
The motor board has lost communication with the PCM board PC4. Check cabling and cable routing for boom system
motor cable and secondary cables. Separate cable as much as possible.
Check if WFM board PC6 code is installed and if microprocessor is running. Check LED3 and LED4 on WFM board PC6.
Depending on the wire feed speed, check for 0-40 volts DC on J17-3 to J17-1. If there is no voltage present there, check
for 40 volts DC at J16-1 to J16-2. If voltage is present there and neither LED is lit (Red or Green), try to download WFM
code to welding power source. If neither LED turns on after downloading code and cycling power, replace WFM board
PC6.
If LED3 and LED4 are flashing Red or Green or they are solid Red, this indicates the WFM board is still not communicating
with the PCM board PC4. Be sure that the UIM board PC7 is on-line (two green LEDs lit).
MOTR
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
S
Check process control module PC4 for +24 volts DC at 6-pin connector J6-2 (+) and J6-5 (−).
If +24 volts is not present at the connector, proceed as follows:
S
Disconnect connector J10 and J11 from WFM board PC6. Check for +24 volts DC at J10-2 (+) and J10-5 (−), and
J11-2 (+) and J11-5 (−). One of the two connectors must measure +24 volts DC to ensures that the Devicenet lines
are being sent from process control module PC4 to WFM board PC6. If +24 volts DC is present at either connector,
replace WFM board PC6.
S
If +24 volts DC is not present at either J10 or J11 connector, check process control module PC4 at connectors J6, J7,
and J8.Remove plugs from connectors and check for +24 volts DC at pin2 (+) and pin 5 (−). If +24 volts DC is not
present at any of the connectors, replace process control module PC4.
COMM
If LED3 and LED4 are both green this indicates that the WFM board went off-line and then recovered which is usually due
to noise interference.
S
Check wire drive motor isolation. Isolated portion of motor housing should not touch robot arm, welding power source
chassis, lifting eye bolts, or weld secondary common. Measure impedance between chassis and both weld secondary
commons. Measure the impedance across motor isolation barrier on motor housing. All measurements should read
high impedance.
S
Check all Devicenet grey harness connections between process control module PC4, UIM board PC7, and WFM
board PC6.
L. Over Average Current Error
Output current is exceeding the thermal capabilities of the welding power source for approximately 25 seconds.
Default value is as follows:
Axcess 450 limit is 610 A average
This is a duty cycle error and requires 5 minutes with power on and NO welding to clear the error.
This error indicates that an excessive amount of current was drawn over a short period of time. Over-average current is
drawn for a period of approximately 25 seconds and can also be expressed as exceeding the power source duty cycle.
OVER
AVE
The current limit is as follows:
Axcess 450 is 610 amperes
This alarm cannot be reset. To clear the condition, the power source must be turned on and allowed to idle for approximately 5 minutes. This cooling period is determined by an internal timer, and turn off power will not reset the timer since it is
saved with the Configuration data. After the 5 minute cooling period, press the Jog or Purge button, or cycle power to clear
the alarm.
If this alarm was received by mistake, and the power source did not exceed the duty cycle, check the following:
Check current feedback signal either while welding or connecting to a load bank. Measure between test point TP8 and
grounding strap on process control module PC4. Test point TP8 is located on left-hand side of board, about 1 in. (25 mm)
to the right of connector J11. TP8 is scaled: 1 volt measured equals 100 amperes actual. This measurement should read 0
volts when not welding. If the measurement reads approximately 13 volts DC, disconnect LEM device from engine (one at
a time) to determine if either device is bad. If the voltage reading still does not change, unplug the lower inverter control
board; if the reading remains the same, replace the upper inverter control board. Voltage readings should be present while
welding. If voltage readings are not correct for current feedback scaling, check individual inverter engines.
OM-245 592 Page 40
M. Over Current Error
Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6,
Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6).
OVER
The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip
this circuit, only a fault will cause an over-current condition. LED4 will be lit on the inverter control board, and power must
be cycled to clear this error.
S
The most likely fault to trip this circuit is an open 940 volts DC bus bleeder resistor, either R1 or R8 on the interconnect
board. An open resistor will cause the bus, which is split between two series capacitors, to become unbalanced. The
capacitor with the open resistor will go to approximately 340 volts DC. The other capacitor will go to approximately 600
volts DC. Normally, both capacitors are at approximately 470 volts DC. The unit will weld like this most of the time. A
16 uF balancing capacitor in series with the transformer can keep the transformer from saturating under these adverse
conditions. Occasionally, the inverter transformer will saturate, and when this happens, it draws a huge amount of
current and trips the over-current circuit. This condition locks off the inverter control board and eventually the bus capacitors will fail. A change to a different resistor eliminated this situation and the problem is no longer an issue.
S
A shorted output diode will cause an over-current error and no weld output will be available.
CRNT
N. Release Trigger Error
REL
TRIG
Indicates a timed weld has expired, but the trigger is still active. Press Jog/Purge button to clear error.
This error occurs after a timed weld expires and the trigger is not released. A PDA with File Management/WaveWriter
software can be used to set up timed welds. This is strictly an informational−type error.
O. Trigger Stuck Error
TRIG
STUK
Indicates the welding power source was turned on and the trigger signal attempted to weld. Turn welding power source off
and back on again to clear the error.
This error indicates a trigger source was activated while the power source was being powered up. If the trigger source is
removed, the error can be cleared.
S
Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the source of the contactor or
trigger command.
S
If LED2 is lit on RIO board PC10, a contactor signal is being sent from the robot.
P. Wire Feed Speed Error
ERR
WFS
Indicates a wire feed speed error. Press Jog/Purge button to clear error.
This error indicates actual wire feed speed does not match wire feed speed command.
Q. Stop Error
ERR
STOP
Indicates an arc stop error. Press Jog/Purge button to clear error.
This error occurs as a result of obstructions in the wire feed system or a faulty wire drive system. Check wire feed and
wire drive system.
R. Flow Error
ERR
FLOW
Indicates a gas flow error. Press Jog/Purge button to clear error.
This error occurs when there is no gas flow to the gun. Check shielding gas system and reestablish gas flow to the gun.
OM-245 592 Page 41
S. Stuck Error
ERR
STUK
Indicates a wire stuck error. Press Jog/Purge button to clear error.
This error occurs if the welding wire sticks to the workpiece at the end of a weld. This fault may be caused by poor welding
conditions. Cut the welding wire from the workpiece.
T. Weld Wait
WELD
WAIT
Indicates a weld cycle wait error. Press Jog/Purge button to clear error.
This error occurs when the unit is not ready for a weld sequence.
U. Please Wait
PLS
WAIT
Indicates a UIM communication error. Press Jog/Purge button to clear error.
This error occurs when the user interface circuit board loses data communications.
V. Low Wire Feed Speed
LOW
WFS
Indicates a low wire feed speed command error. Press Jog/Purge button to clear error.
This error occurs when actual wire feed speed is lower than the wire feed speed command. Check for obstructions in the
wire feed system or a faulty wire drive system.
W. Demo Done
DEMO
Indicates RMD/Accuspeed demo has expired. Press Jog/Purge button to clear error.
DONE
This message appears when RMD and Accuspeed demos are completed. Pressing the Jog/Purge button will change the
screen to CYCL PWR on the display. Turn unit power off and back on again. RMD and Accuspeed share the same demo
timer. If the time expires for one demo process, both demo processes are deactivated.
X. Net Wait
NET
WAIT
Indicates a communication problem. Press Jog/Purge button to clear error.
If the display remains in NET WAIT status, this indicates there is a communication problem between various circuit boards
in the wire feeder or ROI and welding power source.
Y. Software Error
SW
Indicates incompatible software code. Press Jog/Purge button to clear error.
ERR
This error occurs after a software download and the versions between circuit boards are not compatible or a feeder or ROI
that has not been updated is connected to a power source with incompatible code. This error can also occur if power is
cycled off and on with less than 10 seconds of off time.
Z. Check Web
CHCK
WEB
OM-245 592 Page 42
Indicates an E Module update error. Press Jog/Purge button to clear error.
This error occurs when performing an E Module update to an existing unit. This requires connecting to the web pages to
enter serial number information.
8-3. Troubleshooting
!
Disconnect power before troubleshooting
Trouble
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check and secure weld cable connections (see Section 5-2).
Electrode wire feeding stops or feeds
erratically during welding.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure (see Section 5-5).
Change to correct size drive roll (see Table 11-1).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Motor runs slowly.
Check for correct input voltage.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
8-4. 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 8−1).
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 8−1. Feeder Display On First Power Up After Upgrade
OM-245 592 Page 43
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 8−2.
Figure 8−2. Web Site For Axcess E Information
OM-245 592 Page 44
8-5. Software Error Message Display
1.
During the initial power up sequence, the ARM checks the UIM, WFCM and RIO for software numbers or revisions and compares them to what is stored to see if they are compatible. If these software versions are not
compatible, the ERR S W will appear on the display (see Figure 8−3). Compatible software can be downloaded
from www.MillerWelds.com.
1
Program
ERR
Volts
Time
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 8−3. 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-245 592 Page 45
SECTION 9 − 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-245 592 Page 46
Welding Wire
Setup
Program Setup
Weld
Sequencer
Feed/Torch
Logs/Reports
Trigger
Functions
Weld Cable
Setup
Process Setup
Secondary Data
System Log
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-245 592 Page 47
SECTION 10 − ELECTRICAL DIAGRAM
Figure 10-1. Circuit Diagram
OM-245 592 Page 48
211 005-G
OM-245 592 Page 49
SECTION 11 − PARTS LIST
. Hardware is common and
not available unless listed.
6
7
8
5
9
10
11
12
11
10
9
14
18
13
16
17
4 − Fig 11-3
3
15
23
2
19
1
20
21
22 − Fig
11-2
803 506-C
Figure 11-1. Main Assembly
OM-245 592 Page 50
Item
No.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
...............
159 647
159 646
159 360
Fig 11-3
141 753
058 427
180 571
010 233
057 971
010 191
058 628
058 428
248 974
135 205
200 556
201 781
156 243
145 639
200 552
134 306
200 557
Fig 11-2
216 695
. . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Drive Assembly, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hub &amp; Spindle Assembly, (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Shaft, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spring, Cprsn .970 OD x .120 Wire x 1.250pld . . . . . . . . . . . . . . . . . . .
. . . . Washer, Flat Stl Keyed 1.500 Dia x .125thk . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Fbr .656 ID x 1.500 OD x .125thk . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Tubing, Stl .875 OD x 12 Ga Wall x .562 . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . .
. . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, w/Extension Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strip, Buna N Compressed Sheet .062 x 4.000 x 4.000 . . . . . . . . . . . . . .
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Foot, Rubber 1.250 Dia x 1.375 High No 10 Screw . . . . . . . . . . . . . . . . .
. . Stiffener, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Capacitor, w/Terminals (.027uf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
4
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-245 592 Page 51
. Hardware is common and
1
not available unless listed.
2
7
8
5
9
4
23
3
10
15
13
14
6
12
16
22
17
18
11
19
21
20
803 507-F
Figure 11-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Control Box (Fig 11-1 Item 21)
. . . 1 . . . . . . . . . . . . . . . 134 464
. . . 2 . . . . . . . . . . . . . . +212 781
. . . 3 . . . . . . . . . . . . . . *245 603
. . . 4 . . . . . . . . . . . . . . . 212 808
. . . 5 . . . . PC6 . . . . . *245594
. . . 6 . . . . . . . . . . . . . . . 236 991
. . . 7 . . . . . . . . . . . . . . . 010 494
. . . 8 . . . . . . . . . . . . . . . 236 047
. . . 9 . . . . RC1 . . . . . 211 018
. . . . . . PLG43,46,49,
72 . . . . . . 115 093
. . . 10 . . . . . . . . . . . . . . . 220 805
. . . 11 . . . . . . . . . . . . . . . 228 035
. . . 12 . . . . . . . . . . . . . . . 134 201
. . . 13 . . . . . . . . . . . . . . . 097 132
. . . 14 . . . . . . . . . . . . . . . 236 979
. . . 15 . . . . PC2 . . . . . 212 493
. . . 16 . . . . . S1 . . . . . . 213 632
. . . 17 . . . . PC1 . . . . . 212 459
..
..
..
..
..
..
..
..
..
Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assy, Panel/PC Card/Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Baffle, PC Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Wire Feed Module w/Program . . . . . . . . . . . . . . . . . . .
Enclosure, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Snap−In Nyl 1.375 ID x 1.750 Mtg Hole . . . . . . . . . . . . . . . . . .
Bushing, Snap−In Nyl 1.750 ID x 2.000 Mtg Hole . . . . . . . . . . . . . . . . . . .
Connector, Circ 97/Met 9 Pin Size 20 Rcpt . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
. . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 750-14 NPS 1.48hex .41h Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Valve, 34VDC 1way .750−14thd 2mm Orf 100psi . . . . . . . . . . . . . . . . . . .
. . Stand−Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand−Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Circuit Card Assy, Motor Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch, Rocker DPDT 10A 250VAC/20A 30VAC On-None-On . . . . . . . .
. . Circuit Card Assy, Trigger Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
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-245 592 Page 52
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-2. Control Box (Fig 11-1 Item 21) (Continued)
. . . 18 . . . . RC4 . . . . .
. . . 19 . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . .
.....................
. . . 21 . . . . . S2 . . . . . .
.....................
.....................
. . . 22 . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . .
.....................
.....................
.....................
.....................
.....................
. . . . . . . . . PLG47 . . . .
. . . . . . . . . PLG48 . . . .
. . . . . . . . . . PLG4 . . . . .
. . . . . . . . . PLG81 . . . .
. . . . . . . . . PLG10 . . . .
. . . . . . . . . PLG50 . . . .
. . . . . . . . . PLG44 . . . .
. . . . . . . . . PLG45 . . . .
. . . . . . . . . PLG42 . . . .
. . . . . . . . . PLG40 . . . .
.....................
048 282
211 085
245593
210 998
200 295
131 056
131 052
179 851
216 866
216 696
038 855
224 383
216 872
213 004
115 094
202 592
136 810
115 092
130 203
136 810
131 058
188 352
131 054
201 665
098 691
. . Rcpt w/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nameplate, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Switch Assy, Jog/Purge (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Switch, Rocker SPDT 15A 12V (On)-Off-(On) . . . . . . . . . . . . . . . . . . . .
. . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, Pointer 1.670 Dia x .250 ID Push On W/Spring . . . . . . . . . . . . . .
. . Filter Assy, Sense Lead (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Capacitor, w/Terminals (.027uf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Block, Term 20 Amp 2 Pole Screw Term . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Resistor, w/Terminals (2k 5 watt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cable, Volt Sense 7 in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Cable, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Housing Rcptplug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stand−Off, No 6-32 x .500 Lg .250 Hex Stl M&amp;F . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
*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-245 592 Page 53
. Hardware is common and
11
not available unless listed.
12
13
14
15
See Table 11-1 For
Drive Roll &amp; Wire Guide Kits
16
17
18
9
2
1
3
4
5
8
7
6
12
19
10
13
33
20
32
31
30
25
35
21
22
23
24
26
29
28
27
34
3
4
5
6
2
1
802 950-C
Figure 11-3. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Drive Assembly, Wire (Fig 11-1 Item 4)
. . . 1 . . . . . . . . . . . . . . . 010 668 . . Screw, Cap Stl Sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . . . 172 075 . . Carrier, Drive Roll w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . . . 149 962 . . Spacer, Carrier Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . 149 486 . . Pin, Rotation Arm Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . . . 132 750 . . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . . . 150 520 . . Spacer, Flat Stl .257 ID x .619 OD x .105 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . . . 133 493 . . Ring, Retaining Ext .250 Shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . . 133 350 . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . M1 . . . . . *213 005 . . Motor, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 203 631 . . Pressure Arm (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . . . 182 415 . . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . 203 640 . . . . Knob, w/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . . 203 641 . . . . Washer, Flat Stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . . 182 156 . . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . . 182 155 . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . . 132 746 . . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . 203 633 . . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . . 203 632 . . . . Carrier, Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . 133 739 . . . . Washer, Flat Buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . 203 637 . . . . Knob, w/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . {Encoder Assy, Quad 500 CPR 5 VDC Shaftless w/Plug . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 261 292 . . . . Encoder, Differential E8p 500cpr 1/4” Bore . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 261 293 . . . . Cbl Assy, Shielded 4 Wire 18” Axcess Encoder w/Plug . . . . . . . . . . . . .
4
4
4
2
2
2
2
1
1
1
1
1
2
2
2
2
1
1
2
1
1
1
1
*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.
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-245 592 Page 54
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Drive Assembly, Wire (Fig 11-1 Item 4) (continued)
. . . 21 . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . .
.....................
. . . 25 . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . .
.....................
167 387
168 825
133 308
134 834
184 685
149 959
179 265
604 538
151 437
185 624
601 872
602 213
602 243
601 966
108 940
179 263
178 937
. . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Ring, Retaining Ext .375 Shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Hose, SAE .187 ID x .410 OD (Order By ft) . . . . . . . . . . . . . . . . . . . . . . . . 2ft
. . Adapter Assy, Gun/Feeder LH (Including) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Fitting, Brs Barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Adapter, Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Flat Stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Knob, Plstc T 1.125 Lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Screw, 010-32 x O.50 Hexwhd .40d Stl Pld Slffmg Trilob . . . . . . . . . . . . 2
. . . . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Screw, Cap Stl Hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . Screw, Cap Stl Hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . Cover, Drive Roll (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
{Have nearest Factory Authorized Service Agent replace encoder.
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-245 592 Page 55
OM-245 592 Page 56
Inlet Guide
221030
221030
221030
229919
229919
Wire Sizes
.023 to .040 in. (0.6 to 1.0mm)
.045 to .052 in. (1.1 to 1.4mm)
1/16 to 5/64 in. (1.6 to 2mm)
3/32 to 7/64 in. (2.4 to 2.8mm)
1/8 in. (3.2mm)
Wire Guides
*Accommodates .045 and .047 (3/64 in) wire
**Requires a low speed wire feeder
149522
149521
149520
149519
149518
Intermediate Guide
151042
151043**
151076**
151075
151074
151073
151072
151071
151070
”U” COGGED FOR
EXTREMELY SOFT
WIRE OR SOFT
SHELLED CORED
WIRES
1/16 in. (1.6mm)
.047 in. (1.2mm)
.035 in. (0.9mm)
Wire Size
221912
221912
221912
Inlet Guide
Nylon Wire Guides for Feeding Aluminum Wire
151060**
151059
151058
1/8 in. (3.2 mm)
151055
7/64 in. (2.8 mm)
151039
151054
151053
151041
151029
1/16 in. (1.6 mm)
151038
151037*
3/32 in. (2.4 mm)
151028
.052 in. (1.3/1.4 mm)
151057
151027
.045 in. (1.1/1.2 mm)
151056
161190
.040 in. (1.0 mm)
151052
151040
151026
.035 in. (0.9 mm)
”V” KNURLED FOR
HARDSHELLED
CORED WIRES
5/64 in. (2.0 mm)
151025
.030 in. (0.8 mm)
”U” GROOVE FOR
SOFTSHELLED
CORED WIRES
.068/.072 in. (1.8 mm)
151024
.023/.025 in. (0.6 mm)
WIRE SIZE
”V” GROOVE FOR
HARD WIRE
205937
205936
242417
Intermediate Guide
243235
243234*
243233
”U” GROOVE FOR
ALUMINUM WIRES
CONTAINS NYLON
WIRE GUIDES
Table 11-1. Drive Roll And Wire Guide Kits
Notes
Notes
Effective January 1, 2013
(Equipment with a serial number preface of MD 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) Guns
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.
* Replacement Parts (No labor)
* Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
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 one year 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 Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Oxy-Fuel Cutting Torches (No Labor)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith Series 30 Flowgauge, Flowmeter, and Pressure
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Filtair 400 and Industrial Collector
Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* 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.)
* 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 (Non-Integrated)
* Weldcraft-Branded 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 2013-01
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 &amp; Canada FAX: 920-735-4134
International FAX: 920-735-4125
 2013 Miller Electric Mfg. Co.
2013−01
">
Hello! I am an AI chatbot specifically trained to assist you with the Miller AXCESS E WIRE FEEDER User Owner’s Manual. I have thoroughly reviewed the document and can help you locate the exact information you need or explain the content in clear and simple terms. Whether you’re looking for guidance on specific features, troubleshooting steps, or general usage, feel free to ask your questions. The more details you provide about your concerns or needs, the more accurately and effectively I can assist you!
Assistant typing
Assistant is out of keyboard. Please, try again later.