Miller Electric Auto-Axcess 450 manual Operational Terms

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SECTION 4 − OPERATION

4-1. Operational Terms

The following is a list of terms and their definitions as they apply to this interface unit:

General Terms:

 

Synergic

Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual pulse

 

settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed

 

speed setting.

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.

Program

Eight active slots for selection of various processes, wire types, and parameters.

Process

A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).

MIG

CV weld process with individual settings of voltage and wire speed.

Pulse

Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory

 

taught data. Adaptive method is controlled by frequency adjustment.

Accu-pulse

Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds.

 

Adaptive response is controlled by peak 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.

Accuspeed

CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is designed to be

 

tight and fast. Front panel display is ACCU − SPED.

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.

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.

Wire Type

Selection of wire type by alloys and classification.

Gas Type

Selection of shielding gas being used in application.

Process Set Up

Selection procedure for entering program.

Program Load

Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).

Volts

Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.

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).

Arc Length

Distance from end of wire electrode to workpiece.

WFS

Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In

 

pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power level on wire electrode

 

(one knob control).

Amps

Indicates average amperage while welding and 3 seconds hold value at end of weld.

Arc Control

Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD

 

(optional).

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.

Sharp Arc

In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory

 

pulse data. In RMD (optional) this control will affect the arc in much the same way as inductance.

Adjust

Control knob used to change or set parameters and functions.

Sequence

Selecting Sequence will allow setting of preflow, start, crater, postflow, and retract times and parameters (only

 

available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes).

Preflow

Setting a time value for gas flow prior to arc start (only available on Auto Axcess models in the Arc On and

 

Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with File

 

Management software).

OM-210 540 Page 22

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Contents Description OM-210 540SProcesses File Advanced Manufacturing SystemsFrom Miller to You Table of Contents − Troubleshooting TroubleshootingElectric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsWelding can cause fire or explosion Fumes and Gases can be hazardousARC Rays can burn eyes and skin Flying Metal or Dirt can injure eyesFalling Unit can cause injury Welding Wire can cause injuryFire or Explosion hazard Moving Parts can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings About Implanted Medical DevicesSymboles utilisés UNE Décharge Électrique peut entraîner la mortLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux Risque D’INCENDIE OU D’EXPLO LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-210 540 Dimensions And Weight − InstallationSpecifications 17-3/32 in 434 mm 17-3/8 in 441 mm 19-3/32 in 485 mm100% Duty Cycle At 450 Amperes Duty Cycle And OverheatingVolt-Ampere Curves OverheatingDo not stack units. Beware of tipping Connection DiagramSelecting a Location Positive + Weld CableRear Panel Receptacles And Supplementary Protectors Connecting To Weld Terminals Incorrect InstallationSelecting Weld Cable Sizes Peripheral Receptacle Functions Function Socket Socket InformationMotor Control Receptacle Functions 230 400 460 575 Electrical Service GuideHz Three Phase Input Voltage 136 263 228 356Disconnect Device Input Power Connections Connecting Input PowerWelding Power Source Input Power Connections Remote Program Select Remote Program SettingTouch Sensor Operation Program No Output a Output B Output C− Operation Operational TermsCrater StartWeld PostflowProcess LED Wire Type LEDFront Panel Controls See Section Gas Type LEDSTL Manufacturer Robot Abbreviation Front Panel SwitchesRobot Abbreviations Xxxx Robot Type100 IPM 1000 IPM Robot Calibration ModeSchedule Sample Auto-Calibration Routine For Motoman Robot Robot Auto-Calibration Sample ProgramsActual Motoman Welder Condition File Weld Data Sample Auto-Calibration Routine For Fanuc RobotSample Auto-Calibration Routine For ABB Robot Mild Steel Reset ModePulse Accu-pulseBlowing Out Inside Of Unit − MaintenanceRoutine Maintenance Servicing Hazards − Safety Precautions for ServicingShock Hazard from testing Exploding Parts can cause injuryCalifornia Proposition 65 Warnings − Troubleshooting Set Value ModeDiagnostics Indicates a UIM Command errorIndicates a CRC PCM bus error Indicates RMD demo is doneIndicates a contactor on error Indicates a trigger closed errorRemoving Cover and Measuring Input Capacitor Voltage Process Control Module PC4 Process Control Module PC4 Diagnostic LED’sDiagnostic LED’s On Process Control Module PC4 Status DiagnosisDiagnostic LED’s On Wire Feed Module PC6 User Interface Module PC7 Diagnostic LED’s Diagnostic LED’s On User Interface Module PC7LED32 Automation Interface Module PC9 Diagnostic LED’sLED33 Diagnostic LED’s On Automation Interface Module PC9 Input signal on for aux. relay energized Input signal on from relay K6 for arc detectedInput signal off from relay K6 for no arc detected Input signal off for aux. relay energizedRed Network And Module Status LED’s Network Status LED’sModule Status LED’s Circuit board is operating normallyTroubleshooting Trouble RemedyOM-210 540 − Electrical Diagrams Circuit Diagram For Welding Power Source Part 1207 903-G Part 1 Circuit Diagram For Welding Power Source Part 2 207 903-G Part 2 Circuit Diagram For 72 Pin Robot Interface 219 266-C Circuit Diagram For Peripheral/Motor Interface 219 267-B − Parts List 16 − FigWindtunnel Assembly LH And RH Windtunnel Assembly LH And RH -1Item Top Tray Assembly Rear Panel Assembly Front Panel Assembly Front Panel Assembly -1ItemDia Part Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s