Auto-Axcess300 (LC499793)

TM-207 991L 2013−03
Eff. w/Serial Number LC499793

Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And

Arc Welding Power Source
Auto-Axcess 300
Visit our website at File: Advanced Manufacturing Systems

www.MillerWelds.com/ams
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-6. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-7. Rear Panel Receptacles And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-8. Connecting To Weld Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-9. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-10. Motor Control Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-12. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-13. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-14. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-15. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-16. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 3 − RECOMMENDED SETUP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-1. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-2. Automated Welding Equipment Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-3. Process Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-4. Welding Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-5. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-6. Using Multiple Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-7. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs . . . . . . . . . . . . . . . . . . 18
3-8. Earth Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-9. 30 Points Of Mechanics In MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-10. Typical Robot Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-11. Weld Cycle Timing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3-12. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-13. Stick Check Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-14. Arc Blow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-15. Basic Welding Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-16. Electrical Functions Of Automated Welding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4-2. Front Panel Controls (See Section 4-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4-3. Front Panel Controls - Continued (See Section 4-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4-4. Arc Adjust vs. Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4-5. Front Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4-6. Robot Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4-7. Robot Auto-Calibration Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4-8. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4-9. Checking Software Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 5 − POWER SOURCE THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TABLE OF CONTENTS
SECTION 6 − PRE-POWER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6-2. Removing Cover and Measuring Input Capacitor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6-3. Prepower Check Of Power Interconnect Circuit Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6-4. Prepower Check Of Auxiliary Power Circuit Board PC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SECTION 7 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7-1. Set Value Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7-3. Troubleshooting ERR TACH Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7-4. Board Level Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7-5. WFM Board PC6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7-6. UIM Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7-7. PCM Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7-8. No Devicenet Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7-9. AIM Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7-10. E-Stop Operation And Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7-11. Control Circuit Board PC1 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7-12. Diagnostic LED’s On Control Circuit Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7-13. Process Control Module PC4 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7-14. Diagnostic LED’s On Process Control Module PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7-15. Wire Feed Module PC6 Diagnostic LED’s And Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7-16. Diagnostic LED’s On Wire Feed Module PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7-17. User Interface Module PC7 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7-18. Diagnostic LED’s On User Interface Module PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7-19. Automation Interface Module PC9 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7-20. Diagnostic LED’s On Automation Interface Module PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7-21. Network And Module Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7-22. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7-23. Troubleshooting Circuit Diagram (Part 1 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7-24. Troubleshooting Circuit Diagram (Part 2 Of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7-25. Power Interconnect Board PC2 Testing Information (Use With Section 7-26) . . . . . . . . . . . . . . . . . . . . 84
7-26. Power Interconnect Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
SECTION 10 − PARTS LIST FOR LC499793 AND FOLLOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage

OM-207 991X - 2013−01, safety_stm 2011−10
DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

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
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Servicing Hazards
The symbols shown below are used throughout this manual FLYING METAL or DIRT can injure eyes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Wear safety glasses with side shields or face
to avoid the hazard. shield during servicing.
Only qualified persons should test, maintain, and repair this D Be careful not to short metal tools, parts, or
unit. wires together during testing and servicing.
During servicing, keep everybody, especially children, away.
HOT PARTS can burn.

ELECTRIC SHOCK can kill.
D Do not touch hot parts bare handed.
D Do not touch live electrical parts. D Allow cooling period before working on
equipment.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using D To handle hot parts, use proper tools and/or
line disconnect switch, circuit breakers, or by removing plug from re- wear heavy, insulated welding gloves and
ceptacle, or stop engine before servicing unless the procedure spe- clothing to prevent burns.
cifically requires an energized unit.
D Insulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground. EXPLODING PARTS can injure.
D Do not leave live unit unattended. D Failed parts can explode or cause other parts to
D If this procedure requires an energized unit, have only personnel explode when power is applied to inverters.
familiar with and following standard safety practices do the job. D Always wear a face shield and long sleeves
D When testing a live unit, use the one-hand method. Do not put both when servicing inverters.
hands inside unit. Keep one hand free.
D Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source. SHOCK HAZARD from testing.
SIGNIFICANT DC VOLTAGE exists in inverter weld- D Turn Off welding power source and wire feeder
ing power sources AFTER removal of input power. or stop engine before making or changing me-
ter lead connections.
D Turn Off inverter, disconnect input power, and discharge input D Use at least one meter lead that has a self-
capacitors according to instructions in Troubleshooting Section be- retaining spring clip such as an alligator clip.
fore touching any parts.
D Read instructions for test equipment.
STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling FALLING EQUIPMENT can injure.
boards or parts.
D Use proper static-proof bags and boxes to D Use lifting eye to lift unit only, NOT running
store, move, or ship PC boards. gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
FIRE OR EXPLOSION hazard. D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Do not place unit on, over, or near combustible D Follow the guidelines in the Applications Manual for the Revised
surfaces. NIOSH Lifting Equation (Publication No. 94−110) when manu-
D Do not service unit near flammables. ally lifting heavy parts or equipment.
Auto-Axcess 300 TM-207 991 Page 1

MOVING PARTS can injure. H.F. RADIATION can cause interference.
D Keep away from moving parts such as fans. D High-frequency (H.F.) can interfere with radio
D Keep away from pinch points such as drive navigation, safety services, computers, and
rolls. communications equipment.
D Have only qualified persons remove doors, D Have only qualified persons familiar with
panels, covers, or guards for maintenance and electronic equipment install, test, and service
troubleshooting as necessary. H.F. producing units.
D Keep hands, hair, loose clothing, and tools D The user is responsible for having a qualified electrician prompt-
away from moving parts. ly correct any interference problem resulting from the installa-
D Reinstall doors, panels, covers, or guards tion.
when maintenance is finished and before re- D If notified by the FCC about interference, stop using the
connecting input power. equipment at once.
D Have the installation regularly checked and maintained.
ELECTRIC AND MAGNETIC FIELDS (EMF) D Keep high-frequency source doors and panels tightly shut, keep
can affect Implanted Medical Devices. spark gaps at correct setting, and use grounding and shielding to
D Wearers of Pacemakers and other Implanted minimize the possibility of interference.
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the
device manufacturer. READ INSTRUCTIONS.
D Use Testing Booklet (Part No. 150 853) when
servicing this unit.
OVERUSE can cause OVERHEATING. D Consult the Owner’s Manual for welding safety
precautions.
D Allow cooling period; follow rated duty cycle. D Use only genuine replacement parts from the manufacturer.
D Reduce current or reduce duty cycle before D Read and follow all labels and the Technical Manual carefully be-
starting to weld again. fore installing, operating, or servicing unit. Read the safety in-
D Do not block or filter airflow to unit. formation at the beginning of the manual and in each section.
1-3. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
1-4. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, restrict access for passers−by or conduct individual risk as-
sessment for welders. All welders should use the following procedures 6. Do not work next to, sit or lean on the welding power source.
in order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
cable cover. About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.
TM-207 991 Page 2 Auto-Axcess 300

SECTION 2 − SPECIFICATIONS
. Appearance of actual unit may vary from unit shown in manual.
2-1. Unit Specifications
Max
Wire Wire Amperes Input At Rated Load Output 60 Hz,
Rated Open
Input Voltage Feed Diam- Single-Phase/Three-Phase Input Input
Welding Circuit
Power Range Speed eter kVA KW
Output Voltage 208 V 230 V 380V 400V 460 V 575 V
Range** Range
DC
175 A @ 25.3 23.0 13.5 12.8 10.9 8.6 5.3 4.9
22.8 V (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0.2*) (0.04*)
Single DC,
Phase 100%
Stan-
Duty
dard: .035-.06
Cycle 50-1400 2 in.
10-44 ipm (0.8-1.6 75
225 A @ 19.9 17.8 10.9 10.3 9.0 7.3 7.1 6.8
(1.3-35.6 mm)
25.3 V (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0-1A*) (0.2*) (0.04*)
mpm)
Three DC,
Phase 100%
Duty
Cycle
*While idling; Input amperage fluctuates while idling and is always less than one Ampere. Use one Ampere for power efficiency calculations.
**Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited.
2-2. Environmental Specifications

IP Rating
IP21S
This equipment is designed for indoor use and is not intended to be used or stored outside.
2-3. Dimensions And Weight
Hole Layout Dimensions

E
A
17-3/32 in. (434
A
mm)
22-1/2 in.
B 17-3/8 in. (441 mm) (572 mm)
C 19-3/32 in. (485 mm)

23 in.
(584 mm)
C B
D 16-3/32 in. (409 mm)
E 1/2 in. (13 mm)
Weight 17-3/32 in.

(434 mm)
112 lb (51 kg) Net

134 lb (61 kg) Ship D
Ref. 803 675-A

2-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
500 fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
400 duty cycle before welding.
WELDING AMPERES
NOTICE − Exceeding duty cycle
300 can damage unit and void warranty.
250 3-PHASE
225
200 OPERATION
SINGLE PHASE
150 OPERATION
100
10 15 20 25 30 40 50 60 70 8090 100
% DUTY CYCLE
100% Duty Cycle At 225 Amperes 60% Duty Cycle At 300 Amperes
Continuous Welding 6 Minutes Welding 4 Minutes Resting
Overheating
0 A/V
15
OR
Minutes Reduce Duty Cycle
duty1 4/95 − 178 651
2-5. Volt-Ampere Curves

CV MODE Volt-ampere curves show minimum
and maximum voltage and
80 amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
70
. This volt-ampere curve
60 represents the dynamic output
of the unit with a static load.
VOLTAGE
50
40
30
20
10
0
0 100 200 300 400 500 600
AMPERAGE
va_curve1 4/95

SECTION 3 − INSTALLATION
3-1. 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.
3-2. Selecting A Location
Movement Tipping ! Do not move or operate

unit where it could tip.
2
OR
Location ! Do not stack units. Beware of

! Special installation may be 3 tipping.
required where gasoline or vola- 1 Lifting Forks
tile liquids are present − see NEC
Article 511 or CEC Section 20. Use lifting forks to move unit.
Extend forks beyond opposite side
of unit.
2 Hand Cart
Use cart or similar device to move
18 in. unit.
(460 mm) 3 Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
Ref: loc_2 3/96 -Ref. 803 675-A
3-3. Connection Diagram

. The proper interface kit must
be installed in the welding
power source/interface unit to
allow it to be connected to the
robot.
2 3 5
1 Robot (Will Vary According To
Application)
4
1 2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
6 5 Robot Control
7 6 Robot Input/Output Cable
12 7 Gas And Motor Control Cable
8 Welding Power
Source/Interface Unit
9 Negative (−) Weld Cable
10 Workpiece
10 8 11 Voltage Sensing Lead
Recommended for Accu-pulse and
RMD (optional).
11 . Positive (+) voltage sensing
lead is contained in the motor
cable.
Ref. 803 675-A / Ref. 801 915-A
9
12 Positive (+) Weld Cable

3-4. Rear Panel Receptacles And Supplementary Protectors
4 5 6
2
1
Ref. 803 676-A
1 115 V 10 A AC Receptacle RC2 CB2 protects the wirefeed motor from Sections 3-3 and 7 for additional
Receptacle supplies 60 Hz single-phase overload. If CB2 opens, the wirefeeder information).
power. Maximum output from RC2 is does not work. 5 Peripheral Receptacle RC25
limited by supplementary protector CB1 to
10 amps. . Press button to reset breaker. If break- Receptacle provides connection to touch
sensor, water flow switch, jog +/−, and n/o
er continue to open, contact a Factory
2 Supplementary Protector CB1 Authorized Service Agent. relay contacts circuitry (see Section 3-7).
3 Supplementary Protector CB2 6 Robot Interface Receptacle RC72
4 Wirefeed/Gas Receptacle RC8
CB1 protects 115 volt receptacle RC2 from Use receptacle to connect robot input/out-
overload. If CB1 opens, RC2 does not Use receptacle to connect gas and motor put cable (see Sections 3-3 and 7 for addi-
work. control cable to power source (see tional information).
3-5. Connecting To Weld Terminals

Tools Needed: . If using an electrode negative (straight polarity)
process, the volt sense lead must be connected
3/4 in. (19 mm) to the work.
6
3
Do not place
anything between
weld cable terminal
and copper bar.
5
1
2 Correct Installation Incorrect Installation

Ref. 803 675-A / 803 778-A
! Turn off power before connecting to cable size. 6 Copper Bar

weld output terminals. 1 Positive (+) Weld Output Terminal
Remove supplied nut from weld output
! Failure to properly connect weld 2 Negative (−) Weld Output Terminal
terminal. Slide weld cable terminal onto
cables may cause excessive heat Connect positive weld cable to Positive (+) weld output terminal and secure with nut so
and start a fire, or damage your weld terminal and negative (−) cable to that weld cable terminal is tight against
machine. Negative weld terminal. copper bar. Do not place anything
Determine total cable length in weld circuit 3 Weld Output Terminal between weld cable terminal and copper
(both positive and negative cables bar. Make sure that the surfaces of the
combined) and maximum welding 4 Supplied Weld Output Terminal Nut weld cable terminal and copper bar are
amperes. See Section 3-7 to select proper 5 Weld Cable Terminal clean.

3-6. Selecting Weld Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size*** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding****
350 ft 400 ft
150 ft 200 ft 250 ft 300 ft
100 ft (30 m) or Less (105 (120
(45 m) (60 m) (70 m) (90 m)
m) m)
Weld Output
Terminals
! Turn off power before 10 − 60% 60 − 100%
connecting to weld Welding
Duty Duty 10 − 100% Duty Cycle
output terminals. Amperes**
Cycle Cycle
! Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
4/0 4/0
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)
(120) (120)
4/0 2 ea. 2/0 2 ea. 2/0

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x70)
4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x95) (2x95)
4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

350 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x95) (2x95) (2x120)
4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

400 1/0 (60) 2/0 (70) 3/0 (95)
(120) (2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
500 2/0 (70) 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x95)
Positive Negative 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0
) * 600 3/0 (95) 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120)
Ref. 803 677-A
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0
700 4/0 (120)
(2x70) (2x95) (2x120) (3x95) (3x120) (3x120) (4x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0
800 4/0 (120)
(2x70) (2x95) (2x120) (3x120) (3x120) (4x120) (4x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart)
Ref. S-0007-G 2009−08
. In pulse welding applications using inverter power sources, peak currents can result in extreme voltage drops producing poor welding characteris-
tics with undersized cables. A recommendation for weld cable size is a minimum of 2/0 for 300 ampere welding power sources and 4/0 for 450
ampere welding power sources when total cable length is less than 100 ft (30m).

3-7. Peripheral Receptacle Functions
Function Socket Socket Information
A Not used.
C B
D
A B Not used.
E L
M C* Circuit common.
F K
H J Purge
D Contact closure to C completes 24 volts DC solenoid
circuit to purge shielding gas line.
E Contact closure to F indicates coolant flow switch is

closed and recirculating coolant system is
Coolant Flow operational.
Switch Input Signal
F* Circuit common.
Jog H** Contact closure to circuit common advances welding

wire at wire drive assembly.
Retract J** Contact closure to circuit common retracts welding

wire at wire drive assembly.
K Contact closure to L energizes Touch Sensor

circuitry.
Touch Sensor ON L* Circuit common.

And Output Signal
Ref. 803 675-A
M Part touched +24 volts DC output signal referenced
to circuit common.
*Circuit common is same electrical reference point.

**Speed of Jog + (advance) and Jog − (retract) is 60 ipm for 3 seconds, then it automatically changes to 700 ipm.
Note: A customer supplied matching amphenol plug, factory Part No. 194 847, [Amphenol Part No. 97-3106A-20-33P(B)(621) and strain relief
clamp 97-3057-12(0621)] is required to use peripheral receptacle.
3-8. Motor Control Receptacle Functions
Socket Socket Information

C
G
A A Not used.
J F
E B B Motor negative (−).

K
H D
C Tach A.
D Motor positive (+).
E Tach common.
F Gas valve.
G Electrode sense.
H Tach +5 volts DC.
J Tach B.
Ref. 803 675-A

K Gas valve.

3-9. Electrical Service Guide Elec Serv 2011−08
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
50/60 Hz Single Phase

Input Voltage (V) 208 230 380 400 460 575
Input Amperes (A) At Rated Output 25.3 23.0 13.5 12.8 10.9 8.6
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses 2 30 25 15 15 10 10
Normal Operating Fuses 3 40 35 20 20 15 15
Min Input Conductor Size In AWG 4 10 10 14 14 14 14
108 132 141 156 207 323
Max Recommended Input Conductor Length In Feet (Meters)
(33) (40) (43) (48) (63) (99)
Min Grounding Conductor Size In AWG 4 10 10 14 14 14 14
Reference: 2011 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
50/60 Hz Three Phase

Input Voltage (V) 208 230 380 400 460 575
Input Amperes (A) At Rated Output 19.9 17.8 10.9 10.3 9.0 7.3
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses 2 20 20 10 10 10 8
Normal Operating Fuses 3 30 25 15 15 15 10
Min Input Conductor Size In AWG 4 12 12 14 14 14 14
94 116 204 226 299 467
Max Recommended Input Conductor Length In Feet (Meters)
(29) (35) (62) (69) (91) (142)
Min Grounding Conductor Size In AWG 4 12 12 14 14 14 14
Reference: 2011 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.

3-10. Connecting 3-Phase Input Power
3
= GND/PE Earth Ground
8
10
L1
4 L2 6
L3
9
WARNING
ELECTRIC SHOCK can kill;
SIGNIFICANT DC VOLTAGE
exists after removal of
input power.
S Always wait 5 minutes after power
is turned off before working on unit.
S Check input capacitor voltage, and
be sure it is near 0 before touching
any parts.
Read Owner’s Manual.
6 Three−Phase Input Connection

5
Route input power cable L3
through tubing inside unit. L2
L1
Route ground conductor

through current transducer to GND/PE GND/PE
ground terminal. 218005− C
4 3
Tools Needed:
5/16 in.
Input5 2012−05 − Ref. 803 766-C / 803 676-A / 218 005-C

3-10. Connecting 3-Phase Input Power (Continued)
! Turn Off welding power source, and See rating label on unit and check input 6 Input Conductors L1 (U), L2 (V) And L3
check voltage on input capacitors voltage available at site. (W)
according to Section 5-8 before Connect input conductors L1 (U), L2 (V) and
1 Input Power Conductors (Customer
proceeding. Supplied Cord) L3 (W) to welding power source line
! Installation must meet all National and terminals.
Select size and length of conductors using
Local Codes − have only qualified per- Section 3-9. Conductors must comply with Reinstall side panel onto welding power source.
sons make this installation. national, state, and local electrical codes. If Disconnect Device Input Power
! Disconnect and lockout/tagout input applicable, use lugs of proper amperage Connections
power before connecting input capacity and correct hole size.
7 Disconnect Device (switch shown in
conductors from unit. Follow estab- the OFF position)
Welding Power Source Input Power
lished procedures regarding the in-
Connections 8 Disconnect Device (Supply) Grounding
stallation and removal of lockout/
tagout devices. Terminal
2 Strain Relief
9 Disconnect Device Line Terminals
! Make input power connections to the Install strain relief of proper size for unit and
welding power source first. input conductors. Route conductors (cord) Connect green or green/yellow grounding
through strain relief and tighten screws. conductor to disconnect device grounding
! Always connect green or terminal first.
green/yellow conductor to supply 3 Welding Power Source Grounding
Connect input conductors L1 (U), L2 (V), and
grounding terminal first, and never to Terminal
L3 (W) to disconnect device line terminals.
a line terminal.
4 Green Or Green/Yellow Grounding 10 Overcurrent Protection
. The Auto-Line circuitry in this unit Conductor
Select type and size of overcurrent protection
automatically links the power source to the Route green or green/yellow grounding using Section 3-9 (fused disconnect switch
primary voltage being applied. Check input conductor through current transducer and shown).
voltage available at site. This unit can be connect to welding power source grounding
connected to any input power between 208 terminal first. Close and secure door on line disconnect de-
and 575 VAC without relinking the power vice. Follow established lockout/tagout pro-
source. 5 Welding Power Source Line Terminals cedures to put unit in service.
Input5 2012−05
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

3-11. Connecting 1-Phase Input Power
12 =GND/PE Earth Ground
14
11
13
L1
2
5 L2
3 1
5 10
Route input power cable

4 through tubing inside unit.
6
Route ground conductor
through current transducer to
ground terminal.
1
8 9
Tools Needed:
5/16 in.
Input7 2012−05 − Ref. 803 766-C / 803 676-A / Ref. 218 005-A

3-11. Connecting 1-Phase Input Power (Continued)
! Turn Off welding power source, and 1 Input Power Conductors (Customer 10 Welding Power Source Line Terminals
check voltage on input capacitors Supplied Cord) Route green or green/yellow grounding
according to Section 5-8 before Select size and length of conductors using conductor through current transducer and
proceeding. Section 3-9. Conductors must comply with connect to welding power source grounding
! Installation must meet all National and national, state, and local electrical codes. If terminal first. Then connect input conductors L1
Local Codes − have only qualified per- applicable, use lugs of proper amperage and L2 to welding power source line terminals.
sons make this installation. capacity and correct hole size.
Reinstall side panel onto welding power source.
Three Conductor Power Cord Preparation
! Disconnect and lockout/tagout input Disconnect Device Input Power
power before connecting input 2 Black And White Input Conductors
(L1 And L2) Connections
conductors from unit. Follow estab-
lished procedures regarding the in- 3 Red Input Conductor 11 Disconnect Device (switch shown in
stallation and removal of lockout/ OFF postion)
4 Insulation Sleeving
tagout devices. 12 Disconnect Device (Supply) Grounding
5 Green Or Green/Yellow Grounding
! Make input power connections to the Conductor Terminal
welding power source first. 6 Electrical Tape Connect green or green/yellow grounding
! Always connect green or conductor to disconnect device grounding
Insulate and isolate red conductor as shown.
green/yellow conductor to supply terminal first.
Welding Power Source Input Power
grounding terminal first, and never to Connections 13 Disconnect Device Line Terminals
a line terminal.
7 Strain Relief Connect input conductors L1 and L2 to
. The Auto-Line circuitry in this unit
Install strain relief of proper size for unit and
disconnect device line terminals.
automatically links the power source to the input conductors. Route conductors (cord) 14 Over-current Protection
primary voltage being applied. Check input through strain relief and tighten screws.
voltage available at site. This unit can be Select type and size of over-current protec-
connected to any input power between 208 Connect input conductors as shown in tion using Section 3-9 (fused disconnect
and 575 VAC without relinking the power illustration. switch shown).
source. 8 Current Transducer Close and secure door on line disconnect
See rating label on unit and check input 9 Welding Power Source Grounding device. Follow established lockout/tagout
voltage available at site. Terminal procedures to put unit in service.
Input7 2012−05
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

3-12. Touch Sensor Operation
The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source. The weld output terminals pro-
vide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle. Turning on touch sensor causes a DC voltage to be
present on the welding wire. When welding wire touches the weldment, the voltage sensing circuit closes, and a +24 volts DC output signal is sent to the
robot control indicating weldment detection. Touch sensor DC voltage on the welding wire is 80 volts DC. As soon as touch sensor turns on, WIRE LIVE
appears on the front panel display.
3-13. Remote Program Select

. Remote Program Select is factory set to “On”. WaveWriter software is required to turn this function “Off”.
When Remote Program Select is On, a remote device or robot pendant may be used to select programs. When Off, program selection must be done
from the robot pendant.
3-14. Remote Program Setting

. When Remote Program Select is “On”, program selection will be determined by remote input once a weld is initiated. Prior to welding, program
selection can be done in a normal manner from the welding power source front control panel.
See the following table for the remote program select binary code.
Program No. Output A Output B Output C
1 Off Off Off
2 On Off Off
3 Off On Off
4 On On Off
5 Off Off On
6 On Off On
7 Off On On
8 On On On
Notes

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:
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 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 (optional) 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.
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 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.
Arc Control Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse, and RMD
(optional).
Arc Length Distance from end of wire electrode to workpiece.
Auto Thread Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously will
automatically feed wire. Default setting is 72 inches at a feed rate of 700 ipm. Pressing jog, purge, or trigger
switch will terminate the auto-threading feature. These values can be changed using a PDA with File
Management/WaveWriter software.
Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends (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).
Gas Type Selection of shielding gas being used in application.
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.
Postflow Setting a time value for gas flow after arc end (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 Manage-
ment software).
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).
Process A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
Process Set Up Selection procedure for entering program.
Program Eight active slots for selection of various processes, wire types, and parameters.
Program Load Enters selected program information (process, wire type, gas, etc.) into program slot (1-8).
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), (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).
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, 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).
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.
Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (only available on Auto Axcess
optional PDA with File Management software).

4-1 . Operational Terms (Continued)
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.
Time Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in the Arc On
and Analog input or the Arc On and No Analog input modes).
Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.
Weld Sequence function that allows for a timed weld operation [(0 to 999 seconds) only available on Auto Axcess
optional PDA with File Management software].
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, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power level on wire electrode
(one knob control).
Table 4-1. Welding Wire And Gas Abbreviations*
Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation
Steel STL E70, E100, E120 100% CO2, CO2
90% Argon/10% CO2, C10
85% Argon/15% CO2, C15
75% Argon/25% CO2, C25
95% Argon/5% CO2, C5
95% Argon /5% O2, OX5
98% Argon/2% O2 OX2
Stainless Steel SS 308, 309, 312, 316 98% Argon, 2% O2 OX2
(81Ar/18HE/1CO2 Tri Gas
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO2 Tri Gas
MIG/RMD/Accu-pulse)
Cored Tubular Wire MCOR 71, 76, 86R, 409, 439 90% Argon/10% CO2 C10
98% Argon/2% O2 OX2
Aluminum ALUM 4XXX, 5XXX 100% Argon ARGN
* Not all wire types may be available with your unit.
Notes

4-2. Front Panel Controls (See Section 4-3)
15 14 13
4
12
Program Vo l t s ArcAdjust
A
3
Wire Speed Amps 11
Process Wirefeed
Wire Type Gas 10
Gas Type Contactor
5
6
8
9
16
7
Setup Adjust Arc Control
. When an LED is lit, it means the related function is active.

200 410-A
1 Program Display The lit LED indicates which setup mode is 7 Setup Push Button
active. Setup mode parameters are shown in Press button to select Process, Wire Type,
Displays the number of the active program.
Display Windows (see Items 13 and 15). Wire Diameter, or Gas Type parameters.
2 Adjust Knob
Turn the Adjust knob to change program
Process LED . In order for selections to be retained in
When this LED is lit, turn the Adjust knob to memory, the Setup push button must be
number, Setup, Arc Control, and weld
select the desired weld process. Choices pressed six times before any other push
parameters.
include pulse welding (displayed as PULS), button is pressed: once to select Process,
3 Program Push Button LED Accu-pulse, MIG welding (MIG), and Accu again to select Wire Type, again to select
The LED lights when the Program Push Puls/RMD [Regulated Metal Deposition Wire Alloy, again to select Wire Size,
Button is active. (optional)]. again to select Gas Type, and a sixth time
to store selections in memory. The
4 Program Push Button Wire Type LED displays will temporarily show “PROG
Press push button (LED lights) and turn Adjust When this LED is lit, turn the Adjust knob to LOAD” to indicate the data is being stored
knob to select active program. select the desired wire type, wire alloy, and in memory.
size. Wire type and size choices vary 8 Arc Control LED
The letter C is displayed with the program
according to the selected weld process. The LED lights to indicate the Arc Control
number if the program has been changed from Choices may include steel (displayed as
the factory settings using the optional PDA button is active. Light goes out when button is
STL), stainless steel (SS), metal core inactive.
with File Management/WaveWriter software
(MCOR), aluminum (ALUM). See Table 4-1 9 Arc Control Push Button
(see File Management/WaveWriter Owner’s
for all wire abbreviations.
Manual). This push button allows fine tuning inductance
Gas Type LED for MIG programs, and Arc Control for
. The program cannot be changed through When this LED is lit, turn the Adjust knob to
programs other than MIG. When the push
the front panel while welding. button is pressed, the upper display (item 15)
select the desired weld gas. Gas type choices shows INDU for inductance, or ARC for Arc
Press and hold button to see program name. vary according to the selected weld process. Control to indicate which parameter is
Custom programs are named using optional
See Table 4-1 for all gas abbreviations. selected for change. The range of possible
PDA with File Management/WaveWriter
values is 0-99 for inductance, and 0-50 for arc
software. Program name is shown in upper 6 Setup Push Button LED
control. Turn the Adjust knob to change the
and lower displays (items 13 and 15).
The LED lights to indicate one of the setup parameter value. Press button to deactivate
5 Setup Mode Indicators modes is active. arc control mode (LED goes out).

4-3. Front Panel Controls - Continued (See Section 4-2)
10 Wire Feed/Gas/Contactor LEDs Display Command Values mode. Only wire 14 Volts And Arc Adjust LEDs
The Wirefeed LED lights when the wire feeder speed command will be displayed while
welding if the unit is set in Display Command The lit LED indicates whether voltage or arc
is energized. For example, when the front length is being displayed.
panel Jog or Retract button is pressed, the Values mode, even if the Wire Feed
Wirefeed LED lights. Speed/Amps Display button is pressed. 15 Upper Display
The Gas LED lights when the gas valve is The upper display shows different information
energized. . Displays show actual or command values depending on the active function of the unit
as determined by configuration menu and the weld process being used. When the
The Contactor LED lights when the output display shows voltage (for a MIG process),
when using a PDA with File Management/
contactor is energized, making the weld the Volts LED lights. When it shows arc adjust
WaveWriter software. Command values
output terminals live. [for a pulsed and RMD (optional) weld
are displayed prior to welding and actual
11 Wire Speed And Amps LEDs values are displayed while welding unless process], the Arc Adjust LED lights. However,
a PDA with File Management/WaveWriter during any weld process (MIG and pulse), the
The lit LED indicates whether wire speed or
software was used to set the unit in the unit will display actual arc voltage unless a
amps are being displayed.
”Display Command Values” mode. In the PDA with File Management/WaveWriter
12 Wire Feed Speed/Amps Display Push Display Command Values mode, software has set the unit in the ”Display
Button command values are displayed while Command Values” mode.
13 Lower Display welding. 16 Lock LED
Press Wire Feed Speed/Amps Display button
• The lock LED is illuminated when one or more
to show weld amperage or wire feed speed in
lower display (the applicable LED under the
. If a PDA with File Management/WaveWriter programs have been locked using an optional
software is used to change wire feed units PDA with File Management/WaveWriter
lower display lights to indicate which is
(IPM, MPM) or display welding information software. This indicates that some programs
shown). When welding, actual value is shown.
(command or actual),save the changes and have been disabled. A disabled program will
If amperage was selected for display, the unit then turn the power to the unit off and then not show up for selection.
will show actual welding amperage prior to on again for the changes to be carried out Refer to the File Management/WaveWriter
and while welding unless the the unit is in by the unit. Owner’s Manual for additional information.
4-4. Front Panel Switches
1 4
8
5
7
Ref. 803 677-A
6 2
1 Power Switch AUTO 6 Wirefeed LED

Turns unit On or Off. 300
Wirefeed LED illuminates when wire feeds or
The power-up sequence may last up to 30 AUTO 300 indicates the software being retracts.
seconds before the unit is ready to weld. loaded.
7 Retract Push Button
During power-up, the front panel will display 2 Contactor LED
messages indicating the status of the unit. The Contactor LED illuminates when weld output is Press button to retract wire. Wirefeed LED
first message is: illuminates when Retract push button is
energized.
pressed.
NET 3 Purge Push Button
WAIT Auto-Threading feature is activated by
Press button to purge gas line.
NET WAIT is an abbreviation for ”network pressing the Jog and Retract buttons
updating” and means the internal control 4 Gas LED simultaneously. Pressing the Jog, Purge, or
network is powering up. The next message is Gas LED illuminates when Purge push button trigger switch will turn off the Auto-Threading
is pressed. feature.
DTEC
ROBT (Robot Type) 5 Jog Push Button 8 PDA Port
The final message is: Press button to jog wire. 9 PC Port

4-5. Robot Calibration Mode
Use the robot calibration mode to
custom-calibrate the power source to
the robot command signals. This
ensures the wire speed, voltage, and
arc adjust are the same on the control
pendant as on the power source.
DTEC . The factory recommendation is to

perform the calibration on all
installations or code updates.
ROBT
Follow this procedure if the factory
settings are not as accurate as
desired. Synchronization of the robot
and power source signals makes
installation easier and improves the
operation of the system.
. The robot pendant must have

Turn unit On. Unit displays abbreviated name of robot detected. Weld enabled, and there can be
no start/stop crater conditions set
in the robot.
The calibration mode will execute as a
”dry run” from the operator’s
perspective. The welding power
source provides the robot with
feedback so the robot thinks a weld is
underway, yet the robot torch need not
move during the calibration.
. If you wish to stop the calibration

procedure, turn unit input power
off and then on again.
If the calibration is performed correctly
the ROBT CAL message stops being
displayed; however, if it is performed
To enter calibration mode while robot name appears on front panel, incorrectly, the message remains on
press and hold wire feed/amps button until “ROBT CAL” appears on the display.
front panel. “ROBT CAL” message will not display until after the
power-up sequence is completed (approximately 20 seconds). To start the calibration procedure over
again, turn unit input power off and
then on again.
CIRCULER
Use robot pendant or other method to enter two weld schedules into the
robot. Maintain schedule 1 for at least 10 to 20 seconds minimum before
moving on to schedule 2. Maintain schedule 2 for 10 to 20 seconds
before ending the simulated weld. Schedule data is shown below:
Schedule 1 Schedule 2
10.0 Volts 44.0 Volts

100 IPM 1000 IPM
When the robot calibration mode ends, the

ROBT CAL message stops and the unit will
display normal front panel information.
200 410-A

4-6. Robot Auto-Calibration Sample Programs
. It is critical to make certain that NO start power, start conditions, run-in, or crater parameters of any kind are present in the robot program. The
welding power source is looking for 2 distinct welding conditions. If there is a “start power” condition, the welding power source will equate this
as the first condition and fail to execute Auto-Cal correctly. If there is a “crater fill” condition, the welding power source will equate this as the second
condition and fail to execute Auto-Cal correctly.
Actual Motoman Welder Condition File Sample Auto-Calibration Routine For Fanuc Robot
<Welding Current Output Char.> 1: Call Safehome
NO. REF (V) MEASURE (A) 2: J P[1] 40% Fine
01 0.01 1 Arcstart [10.0Volts, 100.0IPM]
02 7.00 500 3: L P[2] 10.0 sec Fine
03 13.99 999 Arc End [0.0Volts, 0.0IPM, 0.0Sec]
04 0.00 000 4: Wait 1.00 (Sec)
<Welding Voltage Output Char.> 5: J P[3] 40% Fine
NO. REF (V) MEASURE (V) Arcstart [44.0Volts, 1000.0IPM]
01 0.14 0.5 6: L P[4] 10.0 sec Fine
02 7.00 25.0 Arc End [0.0Volts, 0.0IPM, 0.0Sec]
03 14.00 50.0 7: Call Safehome
04 Sample Auto-Calibration Routine For ABB Robot
Sample Auto-Calibration Routine For Motoman Robot Move J home, v500, z50, tweldgun;
0000 NOP Arcl \ on, *, v500, sm1, wd1, wv0, z50, tweldgun;
0001 Mov J Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;
0002 AWELD 1.40 WaitTime 5;
(AWELD direct input of 1.40Volts = 100 ipm) Arcl \ on, *, v500, sm1, wd2, wv0, z50, tweldgun;
0003 VWELD 2.80 Arcl \ off, *, v500, sm1, wd1, wv0, z50, tweldgun;
(VWELD direct input of 2.80Volts = 10.0 volts) Move J home, v500, z50, tweldgun;
0004 Arcon
0005 Timer T=10.00
0006 Arcof
0007 AWELD 14.00
(AWELD direct input of 14.00Volts = 1000 ipm)
0008 VWELD 12.32
(VWELD direct input of 12.32Volts = 44.0 volts)
0009 Arcon
0010 Timer T=10.00
0011 Arcof
0012 End *Seam Data values must all be set at zero.
Weld Data 1: Weld Data 2:

weld_sched:=0 weld_sched:=0
weld_speed:=5 weld_speed:=5
weld_voltage:=10 weld_voltage:=44
weld_wfs:=100 weld_wfs:=1000
org_weldspeed:=0 org_weldspeed:=0
org_weldvoltage:=0 org_weldvoltage:=0
org_weldwfeed:=0 org_weldwfeed:=0

4-7. Reset Mode
. Reset mode is not active when
Program Lock is enabled.
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
RST . System configuration data will be
lost during the Reset operation.
NO
Enter reset mode by turning power On and pressing the Program

Push Button until the RST NO message is displayed. RST NO
message will not display until after the power-up sequence is
completed (approximately 20 seconds).
RST RST CYCL

YES YES PWR
Rotate Adjust knob to change NO Press the Arc Control button to Cycl Pwr message appears on the display
to YES. confirm the reset. when programs complete loading.
The reset message is displayed for Turn power off, wait 10 seconds, and turn
2 seconds while factory program power back on again to complete the reset
settings are being reloaded. operation.
During the reset mode the following
factory default programs are loaded
. After Reset is complete, be sure to load
appropriate programs that contain the
into the unit:
correct wire size, process, and shielding gas
for the welding operation
Program 1 Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2 MIG
.035 Mild Steel
75% Argon, 25% CO2
Program 3 Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
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
200 410-A / 803 246-B

SECTION 5 − POWER SOURCE THEORY OF OPERATION
1 Power Switch S1
Provides on/off control of welding
power source. Controls input power 1 20 21
to first module. Power Switch
Inductors Resistors
2 Input Contactor W1 S1 R1, R2
L1, L2
Connects input power to second in-
verter engine.
3 E-Stop Board PC12 W1 8
Distributes power from control board
PC1. Three-Phase Pre-Regulator Interconnect Inverter
Line Input Module Board PC2 Module
4 Auxiliary Power Board PC3 Power
Controls buss voltage and supplies
900 volts AC to control transformer
T2. 13
5 Control Transformer T2 Hall
Supplies power to control board PC1 Device
and E-Stop board PC12. Power HD2
Cord
6 Circuit Breaker CB1 Green 900
Lead 4 VAC 6 7
Provides overload protection for 115
volt AC receptacle RC2. Auxiliary 115
Circuit VAC 115 Volts AC
Power Board Breaker Receptacle
7 115 Volt AC Receptacle RC2 PC5 CB1 RC2
Connects auxiliary equipment to
welding power source. 900 115
8 Interconnect Board PC2 5 VAC VAC 11
Provides electrical connection for in-
ductors L1 and L2, resistors R1 and Control
Transformer T2 Fan Motors
R2, capacitors C1, C2, C3, and C4, FM1, FM2
and diodes D1 and D2. Also, PC2
provides electrical connection for the 115 28 18 15
Pre-Regulator module and the Invert- VAC VAC VAC VAC
er module. Center- 9
Tapped
9 Control Board PC1
Controls weld output by changing
gate pulses to the inverter module on Control Board PC1
PC1.
10 Current Transformer CT1
Provides current feedback to control
board PC1 from primary of HF trans-
former T1. 3 15 16
11 Fan Motors FM1, FM2 40 40 Motor
VDC Circuit VDC Control Board
Cool internal components. E-Stop Breaker
Board CB2 PC6
12 Process Control Board PC4 PC12
Process inputs from automation
Motor Signal
module PC9 and display module 24
PC7. Communicates by devicenet to 24 18 17 VDC
motor control board PC6, display VAC VAC
Motor
board PC7, automation module PC9, 2 Filter Board Tach
and external devices. Controls weld PC11 Feedback
output and the welding process. Input Contactor Signal
Contactor Signal
13 Hall Device HD2 W1 Tach Feedback
Provides feedback when current is Signal
detected on ground lead of power 18
cable. Wire
PDA Port Feed
14 Thermistors RT1, RT2, RT3 Motor
PC Port
Detect heating conditions in secon- DeviceNet
dary heatsink (RT1), primary heat-
sink (RT2), and input inductor (RT3). 12 19
28
15 Circuit Breaker CB2 VAC Process Motor Signal Automation
Control Board Module
Provides overload protection for the PC4 PC9
40 volts AC used to operate wire feed Input Ground
motor. Fault Signal DeviceNet
TM-207 991 Page 22 Auto Axcess 300

16 Motor Control Board PC6
Controls motor signals and receives
22
tach feedback signal from wire feed
Input motor.
Capacitors
C1, C2 17 Motor Filter Board PC11
Filters out high frequency noise from
outside the welding power source.
10 18 ISO/Comm Board PC13
Current 23 24
Transformer Provides connection point for a PDA
Output Diodes or laptop PC to allow software down-
CT1 Main D1, D2
Transformer loads.
T1 Capacitor C4
Resistor R3 19 Automation Board PC9
Provides an interface for I/O signals,
voltage feedback signals, and digital
and analog signals from the robot
controller.
T1 Primary 25 27 20 Inductors L1, L2
Current Hall
Feedback Stabilizer Limit voltage and current in IGBT’s
Device during turn-on and turn-off.
HD1 Z1
21 Resistors R1, R2
R1 is a snubber for the IGBT’s and
R2 is a snubber for the boost circuit.
26 26 22 Buss Capacitors C1, C2
Negative (−) Positive (+) Maintain buss voltage level. C2 fil-
14 Weld Output Weld Output ters primary voltage to transformer
Terminal Terminal T1.
Thermistor 23 Transformer T1
RT1, RT2, RT3
Steps down buss voltage for weld
output.
Work Electrode 24 Output Diodes D1, D2
Rectifies output of transformer T1.
Voltage Feedback 25 Hall Device HD1
Current Feedback Provides weld or secondary feed-

back signal to control board PC1.
Voltage Feedback 26 Weld Output Studs Positive (+)
And Negative (−)
27 Stabilizer Z1
28
Smooths out welding current.
User Interface Module PC7 28 Display Board PC7 (Front And
Panel)
DeviceNet
Consists of voltmeter, ammeter, wire
Voltmeter Ammeter feed display, setup, program select,
V A arc control, and adjust knob.
29 Filter Board PC10 (Robot
Connection)
Setup Program Filters noise on I/O signal from re-

Select ceptacle RC70.
Arc Adjust
Control Knob
Ribbon 29
Cable AC Or DC Control Circuits
Filter 72 Pin
Board Robot
PC10 Connector 3φ Power
RC70
Weld Current Circuit
Auto Axcess 300 TM-207 991 Page 23

PRE-POWER CHECKS
5-1. Checking Unit Before Applying Power
. See Sections 3-10 and 3-11 for test points
and values and Section 8 for parts loca-
tion.
. Use MILLER Testing Booklet (Part No.

150 853) when servicing this unit.
. See the Miller Extranet for service memos

that may aid in the repair of this product.
! Discharge input capacitors according to Section 5-8 and be sure voltage is near zero before touching any parts.
! Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.
! Although some parts are briefly checked in the pre-power procedures, more complete tests may be needed later for these parts.
This procedure is simply to get a basic okay to power up unit.
. The pre-power checklist should be followed if any of the following conditions exist:
the unit is completely inoperative;
the symptoms are unknown;
visual damage is found on any of the following components: capacitors C1 and C2, control board PC1, IGBT power modules MOD1 and MOD2,
or interconnect board PC2;
there is no output or limited output.

PRE-POWER CHECKS
5-2. 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.
User Interface Module User Interface Module

Error Type Reference
Upper Display Lower Display
Emergency Stop E STOP Section 5-2. A
Arc Error ERR ARC Section 5-2. B
No Coolant Flow ERR COOL Section 5-2. C
Ground Current
ERR GND Section 5-2. D
Detect Error
Line Error ERR LINE Section 5-2. E
Motor Over Current ERR MOTR Section 5-2. F
Arc Start Error ERR STRT Section 5-2. G
No Tach Error ERR TACH Section 5-2. H
Thermal Over
ERR TEMP Section 5-2. I
Temperature
Unknown Error ERR UNKN Section 5-2. J
Motor Communications Error MOTR COMM Section 5-2. K
Over Average Current OVER AVE Section 5-2. L
Over Current OVER CRNT Section 5-2. M
Release Trigger REL TRIG Section 5-2. N
Trigger Stuck TRIG STUK Section 5-2. O
Wire Feed Speed ERR WFS Section 5-2. P
Flow Error ERR FLOW Section 5-2. Q
Stop Error ERR STOP Section 5-2. R
Stuck Error ERR STUK Section 5-2. S
Weld Wait WELD WAIT Section 5-2. T
Please Wait PLS WAIT Section 5-2. U
Low Wire Feed Speed LOW WFS Section 5-2. V
Robot Memory ROBT MEM Section 5-2. W
Unit Communication UNIT COMM Section 5-2. X
RMD Done RMD DONE Section 5-2. Y

PRE-POWER CHECKS
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.
When relay CR1 on E-Stop board PC12 is de-energized, it drops out the 18 volts AC from transformer T1 that powers the
E inverter control board(s).
When relay CR2 on E-Stop board PC12 is de-energized, it breaks the contactor signal being sent to the inverter engine
STOP 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 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.
ARC
C. No Coolant Flow Error
ERR
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.
COOL
D. Ground Current Detect Error
ERR
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.
GND
E. Line Error
Indicates that primary power has dropped below the operating point of the welding power source. Signal is sent from in-
verter engine module(s) (RC6, Pin 9 on inverter control board PC1) to process control module PC4 (J2, Pin 1). Check for a
ERR 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 dis-
played when this voltage drops below 858 volts DC. This could happen when attempting to draw near rated output power
LINE with an input voltage below 190 volts AC, three phase. This causes the boost section to go into current limit trying to sup-
ply 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
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.
MOTR

PRE-POWER CHECKS
G. Arc Start Error
ERR 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
STRT 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:
S Press JOG button on the front panel.
S Does the motor run wide open immediately?
S YES Replace Motor Board PC6.
ERR S Does the motor ramp up in speed?
S YES Bad motor tach. Contact nearest Factory Authorized Service Agent.
TACH 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.
I. 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 con-
trol 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.
S If LED 1 is lit, this indicates an over-temperature condition on the primary heat sink.
ERR 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
TEMP 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 sec-
tion 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
Indicates error bit from process control module PC4 is set, but error value sent does not match anything defined with the
UIM board PC7.
UNKN

PRE-POWER CHECKS
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).
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 (−).
MOTR 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
COMM 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.
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.
The current limit is as follows:
OVER 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 approxim-
ately 5 minutes. This cooling period is determined by an internal timer, and turn off power will not reset the timer since it is
AVE 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.

PRE-POWER CHECKS
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).
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.
OVER 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
CRNT 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 ca-
pacitors 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.
N. Release Trigger Error
REL 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.
TRIG
O. Trigger Stuck Error

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.
TRIG 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
STUK trigger command.
S If LED2 is lit on ROI board PC10, a contactor signal is being sent from the robot.
P. Wire Feed Speed Error
ERR
Indicates actual wire feed speed does not match wire feed speed command. Press Jog/Purge button to clear error.
WFS
Q. Flow Error
ERR
Indicates no gas flow to the gun. The error may be reset by reestablishing gas flow to the gun, and then pressing the Jog/
Purge button.
FLOW
R. Stop Error
ERR
Indicates obstructions in the wire feed system or a faulty wire drive system. Check wire feed and wire drive systems.
Press Jog/Purge button to clear error.
STOP

PRE-POWER CHECKS
S. Stuck Error
ERR
Indicates the welding wire is stuck to the workpiece at the end of a weld. May be caused by poor weld conditions. The
error may be cleared by cutting wire from workpiece, and pressing the Jog/Purge button.
STUK
T. Weld Wait Error
WELD
Indicates unit was not ready for a weld sequence. Press Jog/Purge button to clear error.
WAIT
U. Please Wait Error
PLS
Indicates user interface board lost data communications. Press Jog/Purge button to clear error. If condition persists, con-
tact nearest Factory Authorized Service gent.
WAIT
V. Low Wire Feed Speed Error
LOW
Indicates actual wire feed speed is lower than wire feed speed command. Check for obstructions in the wire feed system
or a faulty wire drive system. Press Jog/Purge button to clear error.
WFS
W. Robot Memory Error
ROBT
Indicates robot lost memory data. Press Jog/Purge button to clear error.
MEM
X. Unit Communication Error
UNIT
Indicates the data bus on the PCM board is not functioning properly. Press Jog/Purge button to clear error.
COMM
Y. RMD Done Message
RMD
Indicates the RMD demo is completed. Pressing Jog/Purge button will change the screen to CYCL PWR on the display.
Turn unit power off and back on again.
DONE

PRE-POWER CHECKS
5-3. Board Level Diagnostics
This diagnostics is for the following circuit boards:
PCM Board PC4
UIM Board PC7
WFM Board PC6
AIM Board PC9
Auxiliary Power Board PC3
Inverter Engine Boards:
Interconnect Board PC2
Inverter Control Board PC1
Module Testing
Error Type UIM Upper Dis- UIM Lower Dis- Possible Cause
play play
No Error or Error Clear* —— —— No active error is present in the system. The PCM board
will send an error type equal to zero (0) when an error is
cleared.
Thermal Over Temperature ERR TEMP Indicates one or more of the inverter engines overheated.
Sent from inverter engine module(s) (RC6, Pin 12, on In-
verter board PC1) to PCM board PC4 (J2, Pin 7). Check fan
on inverter engine(s) and weld currents.
Emergency Stop E STOP Indicates Emergency Stop is active. This condition is not
monitored in the Devicenet system; however, this is moni-
tored by the RIO board and sent by Devicenet to the PCM
board PC4. The E-Stop will still work, but no error will be
displayed or sent since the RIO board is disconnected from
the network.
Over-current OVER CRNT Indicates one or more of the inverter engines has latched
with an over-current. Sent from engine module(s) (RC6, Pin
11, on Inverter board PC1) to PCM board PC4 (J2, Pin 6).
RMD Demo Timeout RMD DONE Indicates the RMD Demo process (a cold, low spatter short
circuit transfer process) has expired. Cycle power to clear
message from displays.
Cycle Power CYCL PWR Request to cycle power from welding power source.
No Tach Error ERR TACH See Section 5-2.
Wire Speed Error ERR WFS Indicates actual wire feed speed does not match wire feed
speed command. Press Jog/Purge button to clear error.
Arc Start Error ERR STRT Indicates the contactor either is or was active, but the sys-
tem failed to start an arc. Conditions for a valid arc start are
at least 1/2 of arc start current, voltage less than 60.0 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/Wa-
veWriter software.
Gas Flow Error ERR GAS Indicates no gas flow to the gun. The error may be reset by
reestablishing gas flow to the gun, and then pressing the
Jog/Purge button.
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.
Ground Current Detect Error ERR GND Indicates that weld current is flowing through the primary
ground. This a latching error and welding power source
power must be cycled off and back on again.
Wire Stuck ERR STUK Indicates the welding wire is stuck in the weld puddle. If a
short occurs at the end of the weld routine, time will be add-
ed to the stop to allow the short to clear. This process will
occur up to 3 times before a wire stuck error occurs. Wire
stuck can be enabled or disabled using an optional PDA
with File Management/WaveWriter software.

PRE-POWER CHECKS
Line Error ERR LINE Indicates that primary power has dropped below the operat-
ing point of the welding power source. Sent from inverter
engine module(s) (RC6, Pin 9, on Inverter board PC1) to
PCM board PC4 (J2, Pin 1). Check for a brown-out condi-
tion. The primary boost capacitors have dropped below an
acceptable minimum voltage threshold.
Motor Communications Error MOTR COMM The motor board has lost communication with the PCM
board PC4. Check cabling and cable routing for boom sys-
tem motor cable and secondary cables. Separate cable as
much as possible.
Robot Communications Error ROBT COMM The robot I/O module has lost communication with the weld-
ing power source. Contact nearest factory authorized ser-
vice agent.
Low Wire Feed Speed Command LOW WFS Indicates a wire feed speed rate has been requested, but it
is below the minimum operating point of the active weld
program. Check wire feed speed setting.
PCM Buss Off The PCM board PC4 Devicenet has gone offline. Turn weld-
ing power source power off and back on again to clear the
communication issue.
Motor Over-current ERR MOTR Indicates that the motor has been drawing too much current
for too long. To remedy this, reduce the wire feed speed or
the wire feeder torque load/duty cycle. Press Jog/Purge
button to clear error.
Arc Error ERR ARC 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.
RIO Bus Warning* —— —— Indicates the RIO Devicenet is losing packets of data. Turn
welding power source power off and back on again to clear
the communication issue.
Wire Feed Bus Warning* —— —— Indicates the WFM board PC6 Devicenet is losing packets
of data. Turn welding power source power off and back on
again to clear the communication issue.
UIM Bus Warning* —— —— Indicates the UIM board PC7 Devicenet is losing packets of
data. Turn welding power source power off and back on
again to clear the communication issue.
PCM Bus Warning UNIT COMM Indicates the PCM board PC4 Devicenet is losing packets
of data. Press Jog/Purge button to clear error.
Over Average Current OVER AVG Output current is exceeding the thermal capabilities of the
welding power source for approximately 25 seconds. De-
faults are Auto-Axcess 675 limit is 910 A average, Auto-Ax-
cess 450 limit is 610 A average, and Auto-Axcess 300 limit
is 310 A average). This is a duty cycle error and requires 5
minutes with power on and NO welding to clear the error.
Release Trigger REL TRIG Indicates a timed weld has expired, but the trigger is still
active. Press Jog/Purge button to clear error.
Trigger Stuck 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.
Unknown Error ERR UNKN Indicates error bit from PCM board PC4 is set, but error
value sent does not match anything defined with the UIM
board PC7.
Network Wait NET WAIT Indicates that the UIM board PC7 is no longer communicat-
ing with the PCM board PC4 by Devicenet.
*— — Indicates no error message on the displays.

PRE-POWER CHECKS
5-4. WFM Board PC6 Diagnostics
A. Power Supplies
Check to see if the WFM board PC6 has power. This can be done by checking yellow LED1 and LED2 on the board.
If LED’s are not lit:
1. Check and reset motor power supplementary protector CB2 on back of welding power source.
2. Check voltage at connector J16-1 and J16-2 on WFM board, measurement should read approximately 40 volts DC. If power is present, but
power LED’s are not lit, replace WFM board.
If power is not present, check symptoms as follows:
a. Check +15 volts DC power supply at connector J14-2 (+) and J14-4 (−).
b. Check +5 volts DC power supply at connector J7-1 (+) and J7-4 (−).
c. Check +5 volts DC motor tachometer power supply at connector J14-1 (+) and J14-4 (−).
d. Check +24 volts DC motor Devicenet power supply at connector J10-2 (+) and J10-5 (−).
B. No Devicenet Communications
Check if WFM board PC6 code is install and if microprocessor is running. Check LED3 and LED4 on PC6.
If neither LED is lit (Red or Green), download WFM code to welding power source. If neither LED turns on after downloading code and cycling power,
replace 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 LED’s lit) and the AIM board PC9 is on-line (two green LED’s lit). If UIM board PC7 and/or AIM board
are off-line, it possibly due to cabling or the PCM board.
1. Check all Devicenet grey harness connections between control boards (PCM, UIM, WFM, and AIM).
2. Check PCM board for +24 volts DC at 6-pin connector J6-2 (+) and J6-5 (−).
If no +24 volts is present at the connector, proceed as follows:
a. Disconnect connector J10 and J11 from WFM board. 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 the PCM board to the WFM board.
If +24 volts DC is present at either connector, replace the WFM board.
b. If +24 volts DC is not present at either J10 or J11 connector, check PCM board 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 the PCM board.
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.
1. 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 impedance across motor
isolation barrier on motor housing. All measurements should read high impedance.
C. Err Tach
Press the Jog switch on the front panel to check if the motor turns (ERR TACH will not be displayed when switch is pressed).
D. Err WFS
The motor control loop cannot maintain the requested speed. This is usually caused by an intermittent lead between the motor and the WFM board PC6.
The lead can be either motor power or tachometer related. Possible other causes can include contact tip, liner and wire delivery system.
E. Err COM
See No Devicenet Communications Section 5-4B.

PRE-POWER CHECKS
5-5. UIM Diagnostics
A. Net Wait
1. Check LED1 and LED2 for flashing red/green which indicates the UIM board PC7 is not communicating with the PCM board PC4. Check all
Devicenet grey harness connections between control boards (PCM, UIM, WFM, and AIM). Check other boards for green/green LED’s.
2. Check UIM board DIP switches and verify correct settings (see Section 5-30).
B. UIM Board PC7 Displays All Segments On

1. No code loaded on UIM board. Download code to welding power source.
2. Replace UIM board.
C. Segments Missing On Segmented Displays

1. Gently push on segmented displays to reseat them in the connectors.
2. Check for varnish in the headers, especially J1 that joins the display board to the UIM micro board.
D. Individual LED’s Or Push Buttons Not Working Properly

1. Verify that correct revision of code is loaded on all control boards (PCM, UIM, WFM, and AIM).
2. Verify that welding power source is identified correctly on the displays (e.g. AUTO 450).
3. Perform a software reset of the system.
5-6. PCM Diagnostics

A. Power Supplies
1. Check PCM board PC4 incoming AC power supply. The yellow LED’s in the upper right corner of the PCM board indicate the board is receiving
18 volts AC from the E-stop board PC12. If these LED’s are not lit, then check connection J2-2 and J2-3 for −35 volts AC on PCM board. Also,
check for burnt diodes D3, D4, D6, and D7 in upper right corner of board.
2. Check PCM board +15 volts DC supply. Do NOT short any testpoints together as this will cause a power supply failure. This DC supply can be
checked at the board testpoint TP4 located under electrolytic capacitor and to right of upper center mounting screw. Measure from TP4 to
ground using the large braided grounding strap located at center bottom of the PCM board.
3. Check PCM board −15 volts DC supply. Do NOT short any testpoints together as this will cause a power supply failure. This DC supply can be
checked at the board testpoint TP3 located to the left of the electrolytic capacitor and to right of upper center mounting screw. Measure from
TP3 to ground using the large braided grounding strap located at center bottom of the PCM board.
4. Check PCM board +5 volts DC supply. Do NOT short any testpoints together as this will cause a power supply failure. This DC supply can be
checked at the board testpoint TP24 located to the left of large black heatsinks. Measure from TP24 to ground using the large braided ground-
ing strap located at center bottom of the PCM board.
5. Check Devicenet +24 volts DC isolated supply. This DC isolated supply can be checked at any of the following locations: J6-2 to J6-3, J7-2 to
J7-3, or J8-2 to J8-3. If 24 volts DC is not present, disconnect all Devicenet connectors (J6, J7 and J8) and remeasure at the previous loca-
tion(s). Also, check J3-1 to J3-2 for approximately 28 volts AC.

PRE-POWER CHECKS
B. No Devicenet Communications
LED3 And LED4 Are Not Lit
1. Check Serial Communication board PC13 (where PDA connects). The two switches on the board must be lifted up and away from the board or
the PCM board PC4 will not exit bootloader.
2. Download latest code to PCM board (may not have code loaded).
LED3 Is Green And LED4 Is Not Lit
This condition indicates the PCM board has not detected another board on the Devicenet lines. Could be backwards installed tantalum capacitors.
2. Check all control boards for proper DIP switch settings (UIM, AIM and WFM boards).
3. Check that motor/Devicenet cabling is not tied or routed near secondary power cables.
4. Disconnect Devicenet grey cable from WFM board PC6 to AIM board PC7 leaving just PCM board and AIM board connected to the network.
Check AIM board PC9 to see if it is receiving power and is on line with the network. If AIM board does not power up and is not on line, disconnect
AIM Devicenet grey cable from the PCM board. Disconnect WFM board Devicenet grey cable from AIM board and connect it to the PCM board.
If neither the WFM board or AIM board receive power and go on line with the network, replace the PCM board.
LED3 Is Green And LED4 Is Red
When LED 3 is green and LED4 is red this indicates the PCM board has detected another board on the Devicenet lines, but cannot maintain commu-
nications. This condition is usually caused by noise on the lines or a cabling issue.
1. Check all Devicenet grey harness connections between control boards (PCM, UIM, WFM, and AIM). Check that motor/Devicemet cabling is
not tied or routed near secondary power cables.
2. Check and secure connections between all control boards.
3. Check all control boards for proper DIP switch settings (UIM, AIM and WFM boards).
C. Welding Issues
1. Check entire welding system (contact tip, liner, wire feed system, gas flow, secondary cables, ground, etc).
2. Perform a system reset (see Section 4-7). Remember to perform the Auto-Cal procedure on the welding power source (see Section 4-6). Load
a program from the default program library and try welding. If the reset procedure does not correct the condition, load the latest code on control
boards and verify that all boards have been updated to the latest code.
3. Go to SetVal mode so that analog inputs are now controlled by the front panel controls (see Section 5-20). Run a program and check the weld. If
condition is corrected, perform the Auto-Cal procedure on the welding power source (see Section 4-6) and use a PDA with ServicePak soft-
ware to diagnose system.
4. During power up, be sure that front panel display of power source type matches the welding power source. If power source type is not correct,
load the latest code on control boards and verify that all boards have been updated to the latest code.
5. Check robot type using a PDA with ServicePak software and view the Configuration and Error Log screens.
6. Ensure that valid weld commands are being sent to the PCM board. Use a PDA with ServicePak software and view the Weld Data Diagnostics
screen. Verify contactor, program select (while welding), gas, motor, arc adjust (while welding), arc control (while welding), and wire feed
speed (while welding).
7. Check voltage feedback by comparing open-circuit voltage to voltage displayed on front panel. If there is a difference of +/−3 volts, measure
OCV between testpoint P21 and grounding strap on PCM board. Testpoint TP21 is located on left-hand side of board, about 1-1/2 in (38 mm)
above connector J5. Do NOT touch workpiece when checking OCV. To obtain OCV, release pressure rolls on wire drive and trigger the sys-
tem. TP21 is scaled 1 volt measured equals 10 volts actual (e.g. OCV of approximately 75 volts should measure approximately 7.5 volts).
When no arc is established, the system stops attempting to weld after 3 seconds. If no voltage is present at TP21, check voltage feedback
inputs at connector J5 for a short at Vsense + and Vsense − leads.
8. Check engine enable signal by measuring for 15 volts between J2-9 and grounding strap with engine off (no trigger). When system is triggered,
this should measure approximately 0 volts for 3 seconds.
a. Check current feedback signal either while welding or connecting to a load bank. Measure between testpoint TP8 and grounding strap on
PCM board. Testpoint 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 mea-
sured equals 100 amperes actual.
b. Verify engine command signal by measuring between testpoint TP11 and grounding strap. Load the Accupulse 0.045 E70S C10 program at
the front panel. Do NOT weld, but measure during the 3 seconds of OCV:
675 Ampere Power Source = 5.45 Volts
D. Memory Save Issues

To test the memory, perform the test in the following order:
1. Use a PDA with File Management/WaveWriter software to backup power source program data.
2. Load a non-factory default program into all eight program slots [e.g. use the pulse (not Accupulse) aluminum program].
3. Use a PDA with File Management/WaveWriter software to modify the configuration file (e.g. turn an error code on or off).
4. For the current program displayed, modify the Trim or Voltage and WFS settings.
5. Cycle power on the unit.

PRE-POWER CHECKS
6. After system start up is complete, verify that WFS and Trim or Voltage remained set with the values from Step 4.
7. Verify configuration remained set with the change from Step 3.
8. Verify the active eight programs remained set from Step 2.
9. If any conditions changed from those stated in the previous steps, replace PCM board PC4. If all conditions remained unchanged, restore
backup programs from Step 1.
E. Cannot Download Code To PCM Board

1. Verify that the power source is not a PipePro unit.
2. Check connection at cradle and/or serial port for PDA.
3. Cycle power on power source and retry downloading code.
4. Be sure that PDA has latest version of ServicePak software.
5. Reset PDA by pushing button located inside hole in back of PDA (see PDA Owner’s Manual).
6. Verify that cable is connected to J4 on PCM board and other end is connected to Serial Communication board PC13 (where PDA connects).
7. Check Serial Communication board (where PDA connects). The two switches on the board must be lifted up and away from the board or the
PCM board PC4 will not exit bootloader.
8. Code 225008A for the PCM board will NOT allow code to be downloaded until the User Interface is on line and operational. The PCM board can
be forced into download mode by pressing both switches down on the Serial Communication board. Cycle power on the welding power source.
Download only the PCM code using the PDA (click “continue anyway” for any errors that appear on the PDA screen). When PCM code has
downloaded, lift the two switches up (away from the board) on the Serial Communication board. Cycle power on the welding power source,
then download the code for the remaining boards.
F. Unit Does Not Auto-Calibrate

1. Press and hold in the Setup button, and cycle power on the unit. Verify that all control boards report software numbers.
2. Use a PDA with ServicePak software and verify weld schedule data by viewing the Comm Diagnostics or Weld Data Diagnostics screen.
Settings should be 10 volts at 100 ipm for 15 seconds followed by 44 volts at 1000 ipm (999 ipm for Motoman) for 15 seconds. Sample programs
are provided in Section 4-6 for Motoman, Fanuc, and ABB robots. Even without auto-calibrate complete, analog inputs should be similar to the
previously stated settings (a noticeable low wire feed speed and voltage or trim command followed by a noticeable high wire feed speed and
voltage or trim command).
3. Auto-calibration cycle must be completed in its entirety. If it is interrupted, cycle power on the unit and perform the auto-calibration again.
4. Robot must have the weld enabled output signal. The robot must send the contactor signal to let the power source know it is sending the correct
analog inputs. Use a PDA with ServicePak software and verify weld schedule data by viewing the Comm Diagnostics or Weld Data Diagnos-
tics screen.
5. Use a PDA with File Management/WaveWriter software and verify system set up for Robot Control (PS, wire, gas) or Shared Control (Arc on,
analog); otherwise, the Power Src Cntl (Arc on, no analog) setting does not use robot analog inputs.

PRE-POWER CHECKS
G. Other PCM Board Issues
1. Perform a system reset (see Section 4-7). Remember to perform the Auto-Cal procedure on the welding power source (see Section 4-6). Load
a program from the default program library and try welding. If the reset procedure does not correct the condition, load the latest code on control
boards and verify that all boards have been updated to the latest code.
2. During power up, be sure that front panel display of power source type matches the welding power source. If power source type is not correct,
load the latest code on control boards and verify that all boards have been updated to the latest code.
3. Check for an E-Stop signal and reset, if necessary (only applies to units equipped with E-Stop option).
a. Ensure that valid weld commands are being sent to the PCM board. Use a PDA with ServicePak software and view the Weld Data Diagnos-
tics screen. Verify contactor, program select (while welding), gas, motor, arc adjust (while welding), arc control (while welding), and wire feed
speed (while welding).
b. Auto-calibration cycle must be completed in its entirety. If it is interrupted, cycle power on the unit and perform the auto-calibration again.
5-7. AIM Board Diagnostics

A. Analog Inputs (WFS/Voltage/Trim)
. Most robots will only provide an analog output (or update the outputs) when the contactor is active (when trying to weld).
Any measurement of analog outputs from the robot must be taken while the robot attempts to weld and prior to any robot or power source generated arc
start error. Use a PDA with File Management/WaveWriter software and check the Dry Run box in the Configuration screen. If a robot is not available,
use a robot analog simulator.
B. Welding Issues
1. Separate commands coming in through AIM board PC9 from internal power source welding function to isolate power source from AIM board.
Go to SetVal mode so that analog inputs are now controlled by the front panel controls (see Section 5-20). Set weld parameters on front panel
and try welding.
a. If weld looks good, exit SetVal mode and try welding again using the same parameters from the robot. If performance is different, use a PDA
with File Management/WaveWriter software and set system for Power Src Cntl (Arc on, no analog) that does not use robot analog inputs.
b. If weld is not good, continue in SetVal mode to isolate AIM board, and check welding parameters and system function.
2. Check scaling of the robot analog outputs:
a. Voltage and trim 0 to 10 volts command = 0 to 50 volts actual (normal configuration) 0 to 100 trim actual (optional trim configuration)
For Motoman robots only, scaling is 0 to 14 volts command:
0.14 volts command = 0.5 volts actual
b. WFS 0 to 10 volts command = 0 to 1000 ipm actual (normal configuration) 0 to 1400 ipm actual (optional WFS configuration)
For Motoman robots only, scaling is 0 to 14 volts command:
0.14 volts command = 1 ipm actual
3. Check connection at 72-socket receptacle RC70 and be sure there are not bent pins in the plug.
4. Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the analog channels, Cmd is command, AI is a rough
estimate of the analog input voltage, and ADC is the raw analog to digital converter output.
5. Remove top cover from power source and be sure that robot is connected to the 72-socket receptacle RC70. Check AIM board is properly
seated in unit, board will bend away from 72-socket receptacle if there is any misalignment in the receptacle. Verify that ribbon cable is seated
properly to receptacle RC52 on AIM board.
6. Check continuity of WFS command pin in the 72-pin plug to the robot. Verify voltage while robot tries to weld (robot will only typical attempt the
welding command for 1 to 3 seconds before generating an arc error in the robot).
a. WFS command common is pin 34 for all robots.
b. All robots except Motoman WFS command is pin 5, at 0 to 10 volts command to provide approximately 100 ipm/volt for 0 to 1000 ipm scaling.
c. Motoman WFS command is pin 19, at 0 to 14 volts command to provide approximately 70 ipm/volt for 0 to 999 ipm scaling.
7. Check continuity of voltage/trim command pin in the 72-pin plug to the robot. Verify voltage while robot tries to weld (robot will only typical
attempt the welding command for 1 to 3 seconds before generating an arc error in the robot).
a. All robots voltage/trim command common is pin 16.
b. All robots except Motoman voltage/trim command is pin 9, at 0 to 10 volts command to provide approximately 5 volts/volt or 10 trim/volt for 0
to 50 volts scaling.
c. Motoman voltage/trim command is pin 10, at 0 to 14 volts command to provide approximately 3.5 volts/volt or 7 trim/volt for 0 to 50 volts
scaling.
C. Analog Outputs
1. Voltage feedback signal is pin 6 in the 72-pin plug to the robot. By default a 0 to 10 volt signal represents 0 to 100 volts. This voltage is averaged
over a default time of 100 ms. The default minimum and maximum output range is 0 to 10 volts.
2. Current feedback signal is pin 7 in the 72-pin plug to the robot. By default a 0 to 10 volt signal represents 0 to 1000 amperes. This amperage is
averaged over a default time of 100 ms. The default minimum and maximum output range is 0 to 1000 amperes.

PRE-POWER CHECKS
D. Digital Inputs
Sinking digital inputs use RD common pins 13, 17, 21, 36, 44, 52, 56, 57, and 70. These signals are activated by pulling the input to RD common. The
inactivate state is +5 volts DC (even if the robot has a pull-up potential of +24 volts DC).
Sourcing digital input pin 14 provides a +24 volts DC source to activate a sourcing input (used on ABB robots). Alternatively, a +24 volts DC source may
be provided by the robot, but this source must be referenced (tied) to RD common.
1. E-stop sinking digital input is pin 3 in the 72-pin plug to the robot. Active low, Off state (E-stop active) should measure +5 volts DC, and On state
(power source ready) should measure 0 volts DC. LED21 on the AIM board PC9 will be on if the E-stop is activated and there is no E-stop error.
. E-stop will disable the power source and wire feeder. The E-stop connection must be shorted to RD common to allow welding.
2. Contactor (trigger) sinking digital input is pin 69 in the 72-pin plug to the robot. Active low, Off state should measure +5 volts DC, and On state
should measure 0 volts DC. LED2 on the AIM board will be on if the contactor is activated.
3. ABB robot contactor (trigger) sourcing digital input is pin 35 in the 72-pin plug to the robot. Active high, Off state should measure +0 volts DC,
and On state should measure +24 volts DC. LED2 on the AIM board will be on if the contactor is activated.
4. Purge sinking digital input is pin 67 in the 72-pin plug to the robot. Active low, Off state should measure +5 volts DC, and On state should
measure 0 volts DC. LED12 on the AIM board will be on if purge is activated.
5. ABB robot purge sourcing digital input is pin 47 in the 72-pin plug to the robot. Active high, Off state should measure +0 volts DC, and On state
should measure +24 volts DC. LED12 on the AIM board will be on if purge is activated.
6. Jog sinking digital input is pin 64 in the 72-pin plug to the robot. Active low, Off state should measure +5 volts DC, and On state should measure
0 volts DC. LED1 on the AIM board will be on if jog is activated.
7. ABB robot jog sourcing digital input is pin 47 in the 72-pin plug to the robot. Active high, Off state should measure +0 volts DC, and On state
should measure +24 volts DC. LED1 on the AIM board will be on if jog is activated.
8. Retract sinking digital input is pin 58 in the 72-pin plug to the robot. Active low, Off state should measure +5 volts DC, and On state should
measure 0 volts DC. LED11 on the AIM board will be on if retract is activated.
9. ABB robot retract sinking digital input is pin 46 in the 72-pin plug to the robot. Active highl, Off state should measure +0 volts DC, and On state
should measure +24 volts DC. LED11 on the AIM board will be on if retract is activated.
10. Touch sense or sensor on sinking digital input is pin 27 in the 72-pin plug to the robot. Active low, Off state should measure +5 volts DC, and On
state should measure 0 volts DC. LED14 on the AIM board will be on if touch sensor is activated.
11. ABB robot touch sense or sensor on sinking digital input is pin 29 in the 72-pin plug to the robot. Active high, Off state should measure +0 volts
DC, and On state should measure +24 volts DC. LED14 on the AIM board PC9 will be on if touch sensor is activated.
12. Program select sinking digital input consists of three input pins: 68 RPS-A (least significant bit), 63 RPS-B (second significant bit), 41 RPS-C
(most significant bit) in the 72-pin plug to the robot. The RPS bits are only active while welding, and they do not affect the active program while
the power source in not welding (in idle state the power source program can be changed by the front panel). Active low, Off state should mea-
sure +5 volts DC, and On state should measure 0 volts DC.
RPS-C Pin 41 RPS-B Pin 63 RPS-A Pin 41 Program Number

LED4 LED13 LED3
1
X 2
3
X X 4
X X 5
X X 6
X X 7
X X X 8
a. In addition to the digital inputs, a PDA with File Management/WaveWriter software can be used to disable Remote Program Select. Use a
PDA with File Management/WaveWriter software to enable Remote Program Select in the Configuration screen to make the RPS bits func-
tional.
b. Individual programs may also be disabled using a PDA with File Management/WaveWriter software to set Program Locks. A locked program
cannot be accessed using the RPS bits.

PRE-POWER CHECKS
13. ABB robot program select sinking digital input consists of three input pins: 11 RPS-A (least significant bit), 12 RPS-B (second significant bit), 24
RPS-C (most significant bit) in the 72-pin plug to the robot. The RPS bits are only active while welding, and they do not affect the active program
while the power source in not welding (in idle state the power source program can be changed by the front panel). Active low, Off state should
measure +5 volts DC, and On state should measure 0 volts DC.
RPS-C Pin 24 RPS-B Pin 12 RPS-A Pin 11 Program Number

LED4 LED13 LED3
1
X 2
3
X X 4
X X 5
X X 6
X X 7
X X X 8
a. In addition to the digital inputs, a PDA with File Management/WaveWriter software can be used to disable Remote Program Select. Use a
PDA with File Management/WaveWriter software to enable Remote Program Select in the Configuration screen to make the RPS bits func-
tional.
b. Individual programs may also be disabled using a PDA with File Management/WaveWriter software to set Program Locks. A locked program
cannot be accessed using the RPS bits.
E. Digital Outputs
Sinking digital outputs use RD common pins 13, 17, 21, 36, 44, 52, 56, 57, and 70. These signals are activated by pulling the output to RD common. The
inactivate state is +5 volts DC.
Sourcing digital output pin 14 provides a +24 volts DC source to activate a sourcing output (used on ABB robots). Alternatively, a +24 volts DC source
may be provided by the robot, but this source must be referenced (tied) to RD common.
1. Touch sinking digital output is pin 28 in the 72-pin plug to the robot. This output is pulled to RD common when welding wire has touched the
workpiece when the system is in touch sense mode. LED33 on the AIM board will be on when workpiece is touched.
2. ABB robot touch sourcing digital output is pin 18 in the 72-pin plug to the robot. This output is pulled to +24 volts DC when welding wire has
touched the workpiece when the system is in touch sense mode.
3. Error sinking digital output is pin 26 in the 72-pin plug to the robot. This output is pulled to relay common when system is not ready to weld and
when power source input power is off.
4. Ready sinking digital output is pin 2 in the 72-pin plug to the robot. This output is pulled to relay common when system is ready to weld. LED23
on the AIM board will be on when ready to weld.
5. Current detect sinking digital output is pin 2 in the 72-pin plug to the robot.
6. Wire stuck sinking digital output is pin 61 in the 72-pin plug to the robot. This output is pulled to relay common when there is a wire stuck error
condition. LED24 on the AIM board will be on when the wire stuck error occurs.
7. Wire stuck common is pin 49 in the 72-pin plug to the robot and is used for wire stuck normally open relay.
8. Wire stuck normally open is pin 51 in the 72-pin plug to the robot. This output is pulled to wire stuck common when there is a wire stuck error
condition.
9. Water flow error normally open is pin 37 in the 72-pin plug to the robot. This output is pulled to relay common when there is a water flow error
condition. LED26 on the AIM board will be on when there is not water flow error.
10. Water flow error normally closed is pin 25 in the 72-pin plug to the robot. This output is open if there is a water flow error condition; otherwise, this
output is pulled to relay common.
F. Bus Warning
All these errors should be disabled by default and are meant for factory testing only. This error is used to check for missing data packets (usually caused
by noise interference) on the Devicenet communication lines.
1. Check that motor/Devicemet cabling is not tied or routed near secondary power cables.
4. Check for TIG welding operation near power source.
G. Line Error
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 by 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
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.

PRE-POWER CHECKS
H. Motor Communications Error
Check if WFM board PC6 code is install and if microprocessor is running. Check LED3 and LED4 on PC6.
If neither LED is lit (Red or Green), download WFM code to welding power source. If neither LED turns on after downloading code and cycling power,
replace 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 LED’s lit) and the AIM board PC9 is on-line (two green LED’s lit). If UIM board PC7 and/or AIM board
are off-line, it possibly due to cabling or the PCM board.
2. Check PCM board for +24 volts DC at 6-pin connector J6-2 (+) and J6-5 (−).
If no +24 volts is present at the connector, proceed as follows:
a. Disconnect connector J10 and J11 from WFM board. 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 the PCM board to the WFM board.
If +24 volts DC is present at either connector, replace the WFM board.
b. If +24 volts DC is not present at either J10 or J11 connector, check PCM board 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 the PCM board.
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.
I. Over-Current Condition
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.
1. 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 approxi-
mately 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.
2. A shorted output diode will cause an over-current error and no weld output will be available.
3. Very early inverter control boards were susceptible to noise and could result in unbalanced gate pulses to the inverter IGBT’s. This condition
would unbalance the transformer and cause over-current errors. This problem is no longer an issue.
J. Over-Average Current
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 approxi-
mately 25 seconds and can also be expressed as exceeding the power source duty cycle.
The current limits are as follows:
Auto-Axcess 675 is 910 amperes
This alarm cannot be reset. To clear the condition, the power source must be turned on and 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 testpoint TP8 and grounding strap on PCM board.
Testpoint 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 of approximately 13 volts DC, disconnect LEM device from
engine at a time to see if either one 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 feed-
back scaling, check individual inverter engines.

PRE-POWER CHECKS
K. PCM Board PC4 Bus Off
This condition is not normally seen due to the UIM board PC7 being off line, but it may appear in a system log. The error occurs due to the PCM board
Devicenet bus (communication channel) going off line and results from the board not receiving any Devicenet packets for several seconds.
1. Check PCM board Devicenet power for +24 volts DC. LED’s 3 and 4 will both be off if there is no Devicenet power. Disconnect all Devicenet
connectors (J6, J7 and J8) and measure at the following locations: J6-2 to J6-5, J7-2 to J7-5, or J8-2 to J8-5. If 24 volts DC is not present,
replace PCM board.
2. If there is Devicenet power, reconnect all Devicenet connectors (J6, J7 and J8) and remeasure at the previous locations. If Devicenet power is
present, then one of the Devicenet boards is shorting or overloading the Devicenet power. Connect boards to Devicenet bus one at a time to
determine which board is bad and replace it.
3. Check for any noise issues, motor isolation, TIG welding operation near power source, latest code on control boards (PCM, UIM, WFM, and
AIM), and cable routing.
4. Assume a PCM board Devicenet driver issue, and replace the PCM board.
L. Robot I/O Board PC10 Communications Error

If yellow LED’s 25, 27, and 28 are lit (located near top center of board by ribbon cable) this indicates the Robot I/O board has power. The Robot I/O board
receives +24 volts DC power from the E-Stop board. If LED’s are not lit, check the E-Stop board.
When yellow LED’s are not lit, disconnect plugs from RC8 and RC9 on the Robot I/O board. Measure voltage on the wiring harness at RC8-2 to RC8-5
and at RC9-2 and RC9-5. One of the two measurements must read +24 volts DC to ensure that the +24 volts DC Devicenet lines are being sent from the
PCM board PC4 to the Robot I/O board. If +24 volts DC is present at one of the harness connectors, replace the Robot I/O board. If +24 volts DC is not
present at either harness connector, check PCM board Devicenet power for +24 volts DC. Disconnect all Devicenet connectors (J6, J7 and J8) and
measure at the following locations: J6-2 to J6-5, J7-2 to J7-5, or J8-2 to J8-5. If 24 volts DC is not present, replace PCM board.
1. If Robot I/O board LED’s 30 and 31 are flashing red/green or LED’s are solid red, this indicates Robot I/O board is not communicating with the
PCM board. Check that the UIM board has two green lit LED’s indicating it is on line, and that the WFM board has two green lit LED’s indicating it
is on line. If UIM board and/or WFM board is not on line, check cabling and PCM board.
a. Check all Devicenet grey harness connections between control boards (PCM, UIM, WFM, and AIM).
b. If multiple boards are not on line and all grey harnesses are inspected and connections are secure, assume a PCM board Devicenet driver
chip failure, and replace the PCM board.
2. If Robot I/O board LED’s 30 and 31 are green, this indicates Robot I/O board went off line and then recovered. This condition is usually a result
of noise.
a. Check all Devicenet grey harness connections between control boards (PCM, UIM, WFM, and AIM).
b. Check 72-pin plug cable routing to the robot. Be sure that cable is not routed near any TIG welding operations and system is properly
grounded.
3. If Robot I/O board LED’s 30 and 31 are off, this indicates a software download was interrupted. Download software to Robot I/O board again.
M. RMD Demo Timeout

The RMD demo process has expired. Once the RMD demo times out, no further RMD welding can be performed without purchasing the RMD upgrade
package.
1. The RMD demo cannot be reset.
2. No additional demo time is available.
3. After the demo times out, cycle power and any RMD program in the power source will be overwritten when the unit is powered up. The replace-
ment programs should be configured for standard processes, wire, and gas currently available on the power source.
N. Release Trigger 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

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.
1. Use a PDA with ServicePak software and view the Comm Diagnostics screen to see the source of the contactor or trigger command.
2. If LED2 is lit on the RIO board PC10 this indicates a contactor signal is being sent from the robot.

PRE-POWER CHECKS
P. Thermal Over-Temperature Condition
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’s 1 and 2 on the inverter control board.
1. If LED 1 is lit, this indicates an over-temperature condition on the primary heatsink.
2. If LED 2 is lit, this indicates an over-temperature condition on the secondary heatsink 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:
a. Auxiliary Power board PC3 must be up and operating to supply prepower of +15 volts DC to the boost section of the inverter control board.
b. The peak voltage of the input line power must be greater than 150 volts peak.
c. The DC bus voltage must be greater than 85% of the rectified line voltage. This bus voltage also turns on the pre-charge relay.
d. 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.
Notes

PRE-POWER CHECKS
5-8. Removing Cover and Measuring Input Capacitor Voltage
! Turn Off welding power source,
and disconnect input power.
! Significant DC voltage can remain
on capacitors after unit is Off. Al-
Tools Needed: ways check the voltage as shown
to be sure the input capacitors have
5/16 in. discharged before working on unit.
Remove cover
1 Power Interconnect Board PC2
2 Voltmeter
Measure the DC voltage across the + bus
terminal and − bus terminal on PC2 as
shown until voltage drops to near 0 (zero)
volts. Measure input capacitor voltage on
both inverter assemblies before
proceeding.
. If the capacitor voltage does not drop

to near zero after several minutes, use
a bleeder resistor of between 25 and
1000 Ohms, at least 5 watts, #16
AWG 1000 volts DC insulating rating
wire to discharge the capacitor(s).
3 Typical Bleeder Resistor
An example of a typical bleeder resistor is
shown on this page.
Proceed with pre-power checks.
1
2
+ lead to left bus terminal, − lead to right bus terminal
Typical Bleeder
Resistor
25 to 1000 ohm, 5
watt resistor
#16 AWG 1000 volts dc

insulation rating, approx
3 in (76 mm) leads
802 985 / Ref. 803 679-B

PRE-POWER CHECKS
5-9. Power Interconnect Board PC2 Prior To MA040453U (Use With Section 5-11)
! Discharge input capacitors according to Section 5-8, and
be sure voltage is near zero before touching any parts.
1 2 3 4
22
7
21
20
9
19
18 17 16 15 14 13 12 11 10
Ref. 803 679-B / 201 619-D
1 Control Circuit Board PC1 5 Inductor L1 14 Diode D3

2 Power Interconnect Circuit Board 6 AC2 15 Diode D4
PC2 (Located behind PC1) 7 Diode D6 16 HF-XFMR
Remove PC1 from each Inverter Module 8 AC3 17 Test Point TP2
and perform prepower checks on Power
Interconnect circuit board PC2. 9 Diode D7 18 Diode D2
1 Inductor L2 10 Resistor R14 19 Diode D1
2 −Bus 11 Inductor L1-L2 20 Test Point TP3
3 Diode D5 12 Test Point TP1 21 +Bus
4 AC1 13 Resistor R9 22 Test Point TP4

PRE-POWER CHECKS
5-10. Power Interconnect Board PC2 Prior To MA040453U
Component DVM Positive Lead DVM Negative Lead DVM Diode DVM Ohms
Pre-Charge Resistor R14 (Left) R14 (Right) —— 200 Ω

Pre-Reg IGBT R9 (Right) L1 − L2 —— Open
Pre-Reg IGBT −Bus L1 − L2 0.200 − 0.900 ——
Pre-Reg IGBT Gate R9 (Right) R9 (Left) —— 100 kΩ
Pre-Reg Snub Diode L1 − L2 TP1 (C6 − C7) 0.200 − 0.900 ——
Input SCR AC1 L1 0.200 − 0.900 ——
Input SCR AC2 L1 0.200 − 0.900 ——
Input SCR AC3 L1 0.200 − 0.900 ——
Input Diode −Bus AC1 0.200 − 0.900 ——
Diode D5, D6, D7 —— —— 0.200 − 0.900 ——
IGBT HF-XFMR +Bus 0.200 − 0.900 ——
IGBT −Bus HF-XFMR 0.200 − 0.900 ——
Diode (14-11) L2 TP4 (C1 Bottom) 0.200 − 0.900 ——
Diode (12-11) TP1 (C6, C7) TP4 (C1 Bottom) 0.200 − 0.900 ——
Diode (11-7) TP4 (C1 Bottom) +Bus 0.200 − 0.900 ——
IGBT Snubber TP2 ((T4 Sec Left) HF-XFMR 0.200 − 0.900 ——
IGBT Snubber TP2 (T4 Sec Left) TP3 (C2 Bottom) 0.200 − 0.900 ——
Diode D1, D2, D3, D4 —— —— 0.200 − 0.900 ——
Output Diode D1 (isolate Terminal Anode Heatsink 0.200 − 0.900 ——
from D2)
Output Diode D2 (isolate Terminal Anode Heatsink 0.200 − 0.900 ——

from D1)
Resistor R1 and R8 —— —— —— 30 kΩ
(check resistance across
both resistors)

PRE-POWER CHECKS
5-11. Power Interconnect Board PC2 Eff w/MA040453U (Use With Section 5-12)
Test Equipment Needed:
5
Diode D5
3 4 K A
6
Diode D6
K A
15
14 7
Diode D7
K A
13 12 11 10 9 8 Ref. 803 679-B / 237 373-A
! Read and follow safety information and perform Pre-Power checks on Power 12 Suppressor VS5
in Section 5-1 before proceeding. Interconnect board PC2. 13 Suppressor VS2
! Wear an earth grounded wrist strap 3 Bleed Resistor R1 14 Transistor Q1
when performing pre-power and 4 Bleed Resistor R8
power off checks. Remove wrist 15 Suppressor VS4
5 Input Diode D5
strap before performing any checks Visually inspect PC2 for damage.
or procedures with power applied to 6 Input Diode D6
the machine. 7 Input Diode D7 Check all measurements for PC2 circuit.
1 Control Circuit Board PC1 8 Precharge Resistor R14 If all measurements passed, continue to
9 Suppressor VS1 the end of the pre-power checks.
2 Power Interconnect Circuit Board
PC2 (Located behind PC1) 10 Suppressor VS3 . If any measurements failed, replace
Remove PC1 from each Inverter Module 11 Transistor Q2 PC2.

PRE-POWER CHECKS
5-12. Power Interconnect Board PC2 Test Point Values Eff w/ MA040453U
Component DMM Positive Lead DMM Negative Lead DMM Diode DMM Ohms
R1 Bleeder Resistor R1 Left R1 Right −− 30k Ohms

R8 Bleeder Resistor R8 Top R8 Bottom −− 30k Ohms
R14 Precharge Resistor R14 Left R14 Right −− 200 Ohms
Suppressor VS1 VS1 Left VS1 Right −− 100k Ohms
Suppressor VS2 VS2 Top VS2 Bottom −− 100k Ohms
Suppressor VS3 VS3 Top VS3 Bottom −− 100k Ohms
Suppressor VS4 VS4 Left VS4 Right −− 0.5 − 1 Ohms
Suppressor VS5 VS5 Left VS5 Right −− 0.5 − 1 Ohms
Input Diode D5 D5 Anode D5 Cathode 0.200 − 0.900 −−
Transistor Q1 Q1 Source Q1 Drain 0.200 − 0.900 −−
Transistor Q2 Q2 Source Q2 Drain 0.200 − 0.900 −−
Notes

PRE-POWER CHECKS
5-13. Input And Inverter Modules MOD1 And MOD2 (Use With Section 5-14)
Red
Black Yellow
IGBT/MOSFET Tester Miller Part #043 553
3 4 5
22
21 6
20
19 8
18
17
16 15 14 13 12 11 10 9 Ref. 803 679-B / 237 373-A
! Read and follow safety information 4 Inductor L1-L2 17 Resistor R25

in Section 5-1 before proceeding. 5 AC1 18 Resistor R24
! Wear an earth grounded wrist strap 6 Inductor L1 19 Test Point TP3
when performing pre-power and
7 AC2 20 +Bus
power off checks. Remove wrist
strap before performing any checks 8 AC3 21 Test Point TP4
or procedures with power applied to 9 Resistor R11
the machine. 22 Inductor L2
10 Resistor R12
1 Control Circuit Board PC1 Visually inspect PC2 for damage.
11 Resistor R10
2 Power Interconnect Circuit Board Check all measurements for PC2 circuit.
12 Test Point TP1
PC2 (Located behind PC1)
13 Receptacle RC1 If all measurements passed, continue to
Remove PC1 from each Inverter Module the end of the pre-power checks.
and perform Pre-Power checks on Power 14 Resistor R7
Interconnect board PC2. 15 HF-XFMR . If any measurements failed, replace
3 −Bus 16 Test Point TP2 PC2.

PRE-POWER CHECKS
5-14. Input And Inverter Modules MOD1 And MOD2 Test Point Values
A. Pre-Power Check Of Input Module MOD1
Input Diode −Bus AC1 0.200 − 0.900 −−

Boost IGBT −Bus L1-L2 0.200 − 0.900 −−
Boost Snubber Diode L1-L2 TP1 0.200 − 0.900 −−
Input SCR L1 AC1 OL (Overload) −−
. Perform following tests with IGBT tester.

Component Red Lead Black Lead Gate Lead
Boost IGBT L1-L2 −Bus RC1-1

(With Plug Removed From RC1)
B. Pre-Power Check Of Input Module MOD2

Boost Snubber IGBT L2 TP4 0.200 − 0.900 −−

Boost Snubber IGBT TP1 TP4 0.200 − 0.900 −−
Main Boost Diode TP4 +Bus 0.200 − 0.900 −−
Inverter IGBT HF-XFMR +Bus 0.200 − 0.900 −−
Inverter IGBT −Bus HF-XFMR 0.200 − 0.900 −−
Snubber IGBT TP2 HF-XFMR 0.200 − 0.900 −−
Snubber IGBT TP2 TP3 0.200 − 0.900 −−
Inverter IGBT (with plug +Bus HF-XFMR −− 100k Ohms
removed From RC3
Inverter IGBT (With Plug R7 Bottom −Bus −− 100k Ohms

Removed from RC3
Snubber IGBT (with plug R24 TP2 −− 0.2 − 0.7 Ohms

removed from RC3)
Snubber IGBT (with plug R25 TP2 −− 0.2 − 0.7 Ohms

removed from RC3)

PRE-POWER CHECKS
5-15. Output Diodes D1, D2 (Use With Section 5-16)
! Read and follow safety
information in Section 5-1
before proceeding.
! Wear an earth grounded
wrist strap when performing
pre-power and power off
checks. Remove wrist strap
before performing any
checks or procedures with
power applied to the ma-
chine.
1 Diode D1
2 Diode D2
3 Output Transformer Leads
Visually inspect D1 and D2 for dam-
age.
Remove output transformer
Check all measurements for output
diodes D1 and D2.
. If any of the measurements do

not read correctly, replace both
D1 and D2.
3
Diodes D1, D2
803 678-A / 803 251-B
5-16. Output Diodes D1, D2 Test Point Values

Output Diodes D1 And D2 DVM Positive Lead DVM Negative Lead DVM Diode
D1 Terminal Anode Secondary Heatsink 0.10 - 0.90
D2 Terminal Anode Secondary Heatsink 0.10 - 0.90

PRE-POWER CHECKS
5-17. Auxiliary Power Board PC3 (Use With Section 5-18)
11 10 9 8 7 6 5 4 3 2 1
12
13 14 15 16 17 18 19 20
Tools Needed:
213 556-H / 803 678-A
! Read and follow safety information 8 Resistor R22 19 Resistor R37

in Section 5-1 before proceeding. 9 Diode D17 20 Diode D8
! Wear an earth grounded wrist strap 10 Diode D16
when performing pre-power and Visually inspect PC3 for damage.
power off checks. Remove wrist . Diode D16 present prior to Check all measurements for PC3 circuit.
strap before performing any checks LK420045U.
or procedures with power applied to If all measurements passed, continue to
11 Diode D13 the end of the pre-power checks.
the machine.
12 Diode D5
1 Auxiliary Power Circuit Board PC3
13 Diode D6 . If any measurements failed, replace
2 Receptacle RC1 PC3.
3 Diode D10 14 Resistor R28
4 Diode D12 15 Receptacle RC2 ! Pre-power checks are now com-
plete. Remove earth grounded wrist
5 Resistor R16 16 Diode D9
strap before performing any checks
6 Diode D14 17 Resistor R35 or procedures with power applied to
7 Diode D15 18 Diode D11 the machine.

PRE-POWER CHECKS
5-18. Auxiliary Power Board PC3 Test Point Values
RC1 − RC2 RC2-1 RC1-4 0.200 − 0.900 V ——

RC1 − RC2 RC2-3 RC1-4 0.200 − 0.900 V ——
RC1 RC1-1 RC1-4 0.200 − 0.900 V ——
RC1 − RC2 RC1-2 RC2-1 0.200 − 0.900 V ——
RC1 − RC2 RC1-2 RC2-3 0.200 − 0.900 V ——
RC1 RC1-2 RC1-1 0.200 − 0.900 V ——
Diode D5 Anode Cathode 0.200 − 0.900 V ——
. Diode D16 present

prior to LK420045U.
Resistor R16 —— —— —— 370 to 400 Ohms

5-19. Troubleshooting Table
! Remove earth grounded wrist strap before

performing any checks or procedures with
power applied to the machine.
. See Section 5-35 for test points and values and

Section for 8 parts location.
. Use MILLER Testing Booklet (Part No. 150 853)

when servicing this unit.
. See the Miller Extranet for service memos that may

aid in the repair of this product.
Trouble Remedy
No weld output; completely inoperative Place line disconnect in On position (see Section 3-10 or 3-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-10 or 3-11).
Check for proper input power connections (see Section 3-10 or 3-11).
No weld output; meter display on with no Check to see if the contactor indicator light is lit when contactor line is asserted on.
error displayed.
Erratic or improper weld output with no Use proper size and type of weld cable (see Section 3-6).
errors displayed.
Check that proper program for wire size, process, and shielding gas is loaded.
Clean and tighten all weld connections.
No 115 volts AC at the duplex receptacle. Reset supplementary protector CB1 (see Section 3-4).
Wire does not feed. Check supplementary protector CB2 and reset if necessary (see Section 3-4).
Check motor control cable connections.
Wire feeds erratically. Readjust hub tension.
Readjust drive roll pressure.
Clean or replace dirty or worn drive rolls.
Remove weld spatter around the nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Check motor control cable connections.
Wire feeds as soon as power is supplied. Check LEDs 1, 9, 10, and 11 on PC9 for proper state.
Wire stubbing on low end using a Increase output setting of the power source.
constant current power source.
Check voltage sense lead connection, clean and tighten if necessary.
Gas does not flow or does not stop flow- Check LEDs 12 and 26 on PC9 for proper state.
ing; wire feeds.
Wire burns back to gun contact tip when Check to be sure that volt sense lead is connected to the work.
using electrode negative (straight
polarity) process.

5-20. Set Value Mode
1 2
200 410-A
The Set Value mode is a troubleshooting tool Enter the Set Value mode by pressing the changed in the bottom display. Press the Wire
that allows certain robot command values to Setup and Arc Control push buttons at the Feed Speed/Amps push button to toggle
be manually over-ridden. same time. When in the Set Value mode the between selecting information in the top
display windows briefly shows SET VALU and display or bottom display. The LED under the
1 Setup Push Button the blinking LEDs under the display windows active display will blink to indicate the value
indicate whether Volts, Arc Adjust, or Wire that can be changed.
2 Arc Control Push Button Speed can be changed turning the Adjust
knob. Rotate the Adjust knob to change values.
3 Adjust Knob Depending on the defined weld process, Exit the Set Value mode by pressing the Setup
either volts (MIG) or arc adjust [pulse, and Arc Control push buttons at the same time
4 Wire Feed Speed/Amps Display Push Accu-pulse, or RMD (optional)] can be or turning power source off and then back on
Button changed in the top display. Wire speed can be again.

5-21. E-Stop Operation And Troubleshooting
LED21 is off on the AIM board PC9 indicating the emergency stop is active. The E-Stop signal is not monitored by the Devicenet system, but is moni-
tored by the RIO board and sent through Devicenet to the PCM board, however; no error message is sent to the displays.
The normal operating mode for the E-Stop is to look for a short between receptacle RC70-3 and RC70-21 (RD common) at the 72-socket receptacle on
the rear of the power source. When the short between the pins opens, the E-Stop is active. The E-Stop signal is monitored by the AIM board and sends it
by Devicenet to the rest of the system. If the AIM board loses its Devicenet connection to the PCM board, the E-Stop will still function but no error
message will be displayed.
E-Stop signal monitoring on the AIM board is at receptacle RC54-1 (board ground) and RC54-2 (connected to an opto coupler). When the E-Stop is
shorted (de-activated), the opto coupler is turns on, lighting LED21 on the AIM board, and energizing relay K1 on the AIM board. K1 contacts are nor-
mally open (held open in case of a power loss), and are connected to receptacle RC5-1 and RC5-2.
Receptacle RC5-1 connects to receptacle RC4-1 and receptacle RC5-2 connects to receptacle RC4-2 on the E-Stop board. A closure between RC4-1
and RC4-2 allows +24 volts DC to be supplied to the four relays on the E-Stop board. In an E-Stop situation (relays open), all four relays on the E-Stop
board would de-energize and cut power to the control boards.
When relay CR1 on the E-Stop board is de-energized, it drops out the 18 volts ac from transformer T1 that powers the inverter control board(s).
When relay CR2 on the E-Stop board is de-energized, it breaks the contactor signal being sent to the inverter engine board(s) from the PCM board (J2-9
to RC2-3) and causes a loss of signal to the AIM board (RC2-1 and RC2-2) to micro input (RC5-3 and RC5-4) signaling an E-Stop is active.
When relay CR3 on the E-Stop board is de-energized, it breaks the secondary side of the motor board before it goes to the filter board.
Relay CR4 on the E-Stop board is a soft start relay in parallel with the contacts of relay CR1.
Notes

5-22. Control Circuit Board PC1 Diagnostic LEDs
1 Control Circuit Board PC1
Diagnostic LEDs are visible inside unit,
located on PC1 mounted to the side of the
inverter assembly.
Refer to Section 5-23 for information on
diagnostic LEDs.
Reinstall side panel after checking
diagnostic LEDs.
LED2
LED1
LED4
LED5
239 613-A / Ref. 803 679-B
5-23. Diagnostic LEDs On Control Circuit Board PC1

LED Status Diagnosis
1 On Over temperature condition in primary heatsink

Off Okay
2 On Over temperature condition in secondary heatsink
Off Okay
4 On Over current latch (high IGBT current)
Off Okay
5 On Okay
Off Auxiliary power board not working

5-24. Process Control Module PC4 Diagnostic LEDs
1 Process Control Module PC4
Diagnostic LEDs are visible inside unit, located
on PC4 mounted on the top tray.
Refer to Section 5-25 for information on diagnos-
tic LEDs.
1
Reinstall cover after checking diagnostic LEDs.
LED1
LED2
LED3
LED4
216 956-A / Ref. 803 679-B
5-25. Diagnostic LEDs On Process Control Module PC4

1 On Indicates −25 volts DC is present on process control module PC4

Off Indicates −25 volts DC is not present on process control module PC4
2 On Indicates +25 volts DC is present on process control module PC4
Off Indicates +25 volts DC is not present on process control module PC4
3,4 On See Network Status Table in Section 5-34
Off See Network Status Table in Section 5-34

5-26. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings
1 Wire Feed Module PC6
2 Diagnostic LEDs are visible inside
unit, located on PC6 mounted on
the top tray assembly.
Refer to Section 5-27 for
information on diagnostic LEDs.
Reinstall top cover after checking
diagnostic LEDs.
1 LED1 LED2 2 Dip Switch S1
Dip switches are used to identify
each circuit board on the internal
network. Dip switch settings are
different for each circuit board. For
proper operation, do not change dip
settings from those shown.
LED3
LED4
239 601-A / 803 678-A
5-27. Diagnostic LEDs On Wire Feed Module PC6

1 On Indicates +15 volts DC is present on wire feed module PC6

Off Indicates +15 volts DC is not present on wire feed module PC6
2 On Indicates +5 volts DC is present on wire feed module PC6
Off Indicates +5 volts DC is not present on wire feed module PC6
3,4 On See Network Status Table in Section 5-34

5-28. User Interface Module PC7 Diagnostic LEDs (Prior To LG250035U)
2 LED1
LED2
218 559-A / 803 678-A
1 User Interface Module PC7 Reinstall cover after checking diagnostic Dip switches are used to identify each
Diagnostic LEDs are visible inside unit, LEDs. circuit board on the internal network. Dip
located on PC7 mounted behind the front switch settings are different for each circuit
panel. 2 Dip Switch S1 board. For proper operation, do not change
Refer to Section 5-29 for information on dip settings from those shown.
diagnostic LEDs. 3 Dip Switch S2
5-29. Diagnostic LEDs On User Interface Module PC7 (Prior To LG250035U)

1, 2 On See Network Status Table in Section 5-34


5-30. User Interface Module PC7 Diagnostic LEDs (Eff w/ LG250035U)
1 User Interface Module PC7
Diagnostic LEDs are visible inside
unit, located on PC7 mounted
behind the front panel.
Refer to Section 5-29 for
information on diagnostic LEDs.
1 Reinstall cover after checking
diagnostic LEDs.
LED1
LED2
234 472-D / 803 678-A
5-31. User Interface Module PC7 Diagnostic LED Information (Eff w/ LG250035U)


5-32. Automation Interface Module PC9 Diagnostic LEDs
1 LED11 LED13 LED25 LED28

LED12 LED14 LED27
LED31
LED30
LED1
LED2
LED3
LED4
LED5 2
LED6
LED7
LED8
LED9
LED10
LED32
LED33
LED15
LED20 LED19 LED18 LED16 LED21 LED22 LED23 LED24 LED26 LED29
LED17
216 958-A / Ref. 803 679-B
1 Automation Interface Module PC9 Reinstall cover after checking diagnostic Dip switches are used to identify each
Diagnostic LEDs are visible inside unit, LEDs. circuit board on the internal network. Dip
located on PC9 mounted on left side. 2 Dip Switch S4 switch settings are different for each circuit
Refer to Section 5-33 for information on board. For proper operation, do not change
diagnostic LEDs. dip settings from those shown.

5-33. Diagnostic LEDs On Automation Interface Module PC9
1 On Input signal On from robot for jog advance

Off Input signal Off from robot for no jog advance
2 On Input signal On from robot to energize contactor
Off Input signal Off from robot to not energize contactor
3 On Input signal On remote program A selected
Off Input signal Off remote program A not selected
4 On Input signal On remote program C selected
Off Input signal Off remote program C not selected
5 On Input signal On from E-stop board PC12 for no emergency stop
Off Input signal Off from E-stop board PC12 acknowledges E-stop is On from robot
6 On Spare 1 not assigned
Off Spare 1 not assigned
7 On Input signal On Autoset-C selected
Off Input signal Off Autoset-C not selected
8 On Input signal On Autoset-B selected
Off Input signal Off Autoset-B not selected
9 On Input signal On Remote Jog on from peripheral plug
Off Input signal Off Remote Jog off from peripheral plug
10 On Input signal On Remote Purge on from peripheral plug
Off Input signal Off Remote Purge off from peripheral plug
11 On Input signal On from robot for jog retract
Off Input signal Off from robot for no jog retract
12 On Input signal On from robot for purge
Off Input signal Off from robot for no purge
13 On Input signal On remote program B selected
Off Input signal Off remote program B not selected
14 On Input signal On Touch Sensor on from robot or peripheral plug
Off Input signal Off Touch Sensor off from robot or peripheral plug
17 On Input signal On Autoset-A selected
Off Input signal Off Autoset-A not selected
18 On Input signal On Autoset-D selected
Off Input signal Off Autoset-D not selected
19 On Input signal On Remote Retract on from peripheral plug
Off Input signal Off Remote Retract off from peripheral plug
20 On Input signal On Remote Water Flow on from peripheral plug
Off Input signal Off Remote Water Flow off from peripheral plug
21 On Input signal On from robot for no emergency stop
Off Input signal Off from robot for emergency stop
23 On Input signal On from relay K3 for welding power source ready and no detected errors present
Off Input signal Off from relay K3 for welding power source not ready, detected errors are present, or unit is
in operating mode preventing the weld ready signal from being enabled

5-33. Diagnostic LEDs On Automation Interface Module PC9 (Continued)
24 On Input signal On from relay K4 to indicated wire stuck in weld joint

Off Input signal Off from relay K4 to indicate wire is not stuck in weld joint
25 On Indicates +5 volts DC is present on automation module PC9
Off Indicates +5 volts DC is not present on automation module PC9
26 On Input signal on from relay K5 for flow (shielding gas or coolant) present
Off Input signal off from relay K5 for flow (shielding gas or coolant) not present
27 On Indicates −15 volts DC is present on automation interface module PC9
Off Indicates −15 volts DC is not present on automation interface module PC9
28 On Indicates +15 volts DC is present on automation interface module PC9
Off Indicates +15 volts DC is not present on automation interface module PC9
29 On Input signal on from relay K6 for arc detected
Off Input signal off from relay K6 for no arc detected
32 On Input signal on for aux. relay energized
Off Input signal off for aux. relay not energized
33 On Input signal on touch sensor touch detected
Off Input signal off touch sensor touch not detected
Notes

5-34. Network And Module Status LEDs
A. Network Status LED Information
The following are network status LEDs:
LED1 on the UIM circuit board
LED4 on the WFM and PCM circuit boards
LED30 on the AIM circuit board.
Status Diagnosis
Off The circuit board is not on-line with the network or there is no power applied to the circuit board.
Green The circuit board is operating normally and the on-line connection is made with the network.
Flashing Green The circuit board is waiting for an on-line connection to be made with the network.
Red The circuit board has encountered a communication link failure with the network. Check DeviceNet cable connections. Verify
dip switch positions according to Sections 5-26, 5-30, and 5-32. Replace circuit board if necessary.
B. Module Status LED Information

The following are module status LEDs:
LED2 on the UIM circuit board
LED3 on the WFM and PCM circuit boards
LED31 on the AIM circuit board.
Status Diagnosis
Off There is no power applied to the circuit board or the board software is not executing its functions.
Green The circuit board is operating normally.
Flashing Red The circuit board has encountered a recoverable fault. Wait or cycle power to clear fault.
Red The circuit board has encountered an unrecoverable fault.
Notes

5-35. Troubleshooting Circuit Diagram (Part 1 Of 2)
! Discharge input capacitors Resistance Values

according to Section 5-8, and
be sure voltage is near zero a) Tolerance − ±10% unless specified
before touching any parts. b) Turn Off unit and disconnect input power
before checking resistance Voltage Readings
R1 thru R5 Less than 1 ohm a) Tolerance − ±10% unless specified
V10 b) Reference − to circuit common (lead

42) unless noted
V1 17 volts AC
V2 17 volts AC
V13 V14 V15
V3 115 volts AC
V4 5 volts AC
R4 V5 23 volts AC
V6, V7 15 volts AC
V8 28 volts AC
R3 V9 575 volts AC
V10 +80 volts DC open-circuit
R5 voltage
V11
V11 940 volts DC − buss
V12 +15 volts DC
V13 +15 volts DC
V14 −15 volts DC
V15 +1 volt DC per 100 amperes
of weld output
R1
R2
V12
V1
V9
V2 V4
V3
V5
V6
See Section
3-4
V7 for RC2
V8 information
207 986-F (Part 1 Of 2)

5-36. Troubleshooting Circuit Diagram (Part 2 Of 2)
! Discharge input capacitors according to Section 5-8, and
be sure voltage is near zero before touching any parts.
V16
V17
V18
V19
V20
V21
V22

Voltage Readings
a) Tolerance − ±10% unless specified
b) Reference − to circuit common (lead
42) unless noted
V16 1 volt DC/35 IPM
V17 Weld voltage during welding
V18 Current feedback of both
inverter engines: 1 volt DC/
Tach Volt 100 A with respect to
Feedback A V25 Sensing summed common
V19 Control voltage: 1 volt
DC/30A with respect to
command common
To
Motor V20 Primary current too high: low
= active, high = okay with
respect to command common
V21 Over current latch high IGBT
Tach current: low = active, high =
Feedback B okay with respect to
To Peripheral command common
V22 Over temperature in primary
or secondary heatsink, or low
bus voltage: low = active, high
= okay with respect to
command common
To
PDA
207 986-F (Part 2 Of 2)

5-37. Control Board PC1 Testing Information (Use With Section 5-38)
! Measure voltage of input
capacitors according to Section
5-8, and be sure voltage is near
zero before touching any parts.
Be sure plugs are secure before test-
ing. See Section 5-38 for values during
testing.
1 RC6 RC9
PC1
RC4
RC2
RC7
RC3
RC5
RC8
201 619-C / Ref. 803 250-C

5-38. Control Board PC1 Test Point Values

PC1 Voltage Readings b) Reference − to circuit common (lead 42)
unless noted
Receptacle Pin Type Value
RC2
! High voltage present. Do not measure.
RC3
! High voltage present. Voltages on this receptacle can exceed 900 volts DC with respect to chassis (GND).
1 Input 940 volts DC with respect to −Bus
2 −− Not used
3 Input Rectified primary voltage with respect to −Bus. Value should be about 1.414 times primary input voltage.
RC4 1 Output +5 volts DC to thermistor with respect to chassis ground
2 Output +5 volts DC to thermistor with respect to chassis ground
3 −− −−
4 Input Secondary heatsink thermistor return
5 −− Shutdown
6 Output +5 volts DC to thermistor with respect to chassis ground
7 Input Output inductor thermistor return
8 Input Primary heatsink thermistor return
RC5 1 Output Do not measure; boost IGBT gate
2 Output Precharge relay coil; −12 volts DC with respect to −Bus when Bus voltage is 90% of rectified voltage.
3 Input Do not measure; boost inductor current feedback
4 Output +15 volts DC with respect to −Bus
5 Output −12 volts DC with respect to −Bus
6 Precom Do not measure; boost IGBT gate drive return
7 Precom Precharge relay common
8 Precom Circuit common reference to −Bus
9 Precom Circuit common reference to −Bus
10 −− Not used
RC6 1 −− Chassis ground
2 Output Current feedback; 1 volt per 100 amperes
5 Input 15 volts DC with contactor off; 0 volts DC with contactor on

5-38. Control Board PC1 Test Point Values (Continued)
RC6 6 −− Current feedback − circuit common
(Continued)
7 Input 18 volts AC with respect to RC6-13
8 −− Command − circuit common
9 Output 5 volts DC normal; 0 volts DC = Err Line
10 Input 0 − 10 volts DC command with respect to RC6-6
11 Output 5 volts DC normal; 0 volts DC = overcurrent latch
12 Output 5 volts DC normal; 0 volts DC = Error Temp
13 −− 18 volts AC with respect to RC6-7
14 Input 115 volts AC with respect to chassis
RC7 1 −− Not used
2 −− Not used
3 Input 1 volt per 100 amperes of output; value should be approximately one-half of the total output of the welding
power source.
4 Output +15 volts DC for hall device with respect to RC7-6
5 Output −15 volts DC for hall device with respect to RC7-6
6 −− Circuit common
RC8 1 −− Not used
2 Output Pre +15 with respect to −Bus
3 Input Top engine only; 15 volts DC from auxiliary power board PC3 with respect to −Bus
5 −− Not used
6 −− Not used
8 −− Not used
RC9 1 Output 18 volts AC with respect to chassis
2 Input 5 volts DC normal; 0 volts DC = Err Line
3 −− Ground
4 Input Current feedback − summed incoming
5 Input Current feedback − summed incoming
6 Output 15 volts DC with contactor off; 0 volts DC with contactor on
7 Output 115 volts AC with respect to chassis
8 Output 18 volts AC with respect to chassis
9 Input 5 volts DC normal; 0 volts DC = Err Temp
10 Input 5 volts DC normal; 0 volts DC = overcurrent latch
11 Output 0 − 10 volts DC command
12 −− Command − circuit common
RC10 1 Output 115 volts AC with respect to RC10-2 when fan is running
2 Output 115 volts AC with respect to RC10-1 when fan is running

5-39. Power Interconnect Board PC2 Testing Information (Prior To MA040453U) (Use With
Section 5-40)
3 1
Test Equipment Needed: 201 619-C / 803 679-B
! Measure voltage on input . Power Interconnect boards PC2 are 1 Power Interconnect Board PC2
capacitors according to Section located underneath Control boards 2 + Bus
5-8, and be sure voltage is near zero PC1 on inverter modules.
before touching any parts. 3 − Bus
Be sure plugs are secure before testing.
See Section 5-40 for specific values during
testing.
5-40. Power Interconnect Board PC2 Test Point Values (Prior To MA040453U)

unless noted
Location Pin Value
+ Bus —— 940 volts DC from + Bus to − Bus
− Bus —— 940 volts DC from + Bus to − Bus

5-41. Power Interconnect Board PC2 Testing Information (Eff w/MA040453U) (Use With
Section 5-42)
! Measure voltage of input capacitors
according to Section 5-8, and be
sure voltage is near zero before
touching any parts.
. Power Interconnect boards PC2 are lo-

cated underneath Control boards PC1
RC6 on inverter modules.
1 Be sure plugs are secure before testing.
See Section 5-42 for values during testing.
PC2
RC3 RC1
803 419-B / 237 373-A

5-42. Power Interconnect Board PC2 Test Point Values (Eff w/MA040453U)

unless noted
RC1 1 Input Do not measure; boost IGBT gate
2 Input Precharge relay coil; −12 volts DC with respect to −Bus when Bus voltage is 90% of rectified voltage
3 Output Do not measure; boost inductor current feedback
4 Input +15 volts DC with respect to −Bus
5 Input −12 volts DC with respect to −Bus
6 Precom Do not measure; boost IGBT gate drive return
7 Precom Precharge relay circuit common
8 Precom Circuit common − reference to −Bus
9 Precom Circuit common − reference to −Bus
10 −− Not used
RC3
! High voltage present. Do not measure.
RC6 1 −− Snubber resistor 1; input boost snubber (located on heat sink)
2 −− Not used
3 −− Snubber resistor 2; inverter snubber (located on heat sink)
4 −− Not used
5 −− Snubber resistor 2; input boost snubber (located on heat sink)
6 −− Not used
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

5-43. Auxiliary Power Board PC3 Testing Information (Use With Section 5-44)
! Measure voltage of input capacitors
according to Section 5-8, and be
sure voltage is near zero before
touching any parts.
Be sure plugs are secure before testing.
See Section 5-44 for values during testing.
1 Auxiliary Power Board PC3
RC1
RC3
RC2
803 251-B / 213 556-H

5-44. Auxiliary Power Board PC3 Test Point Values

unless noted
RC1 1 Output Pre +15 volts DC
2 −− Pre Common
3 −− Not applicable
4 Input 940 volt AC Bus
5 −− Pre +15 volts DC
6 −− Pre Common
RC2 1 Output 625 volts AC with respect to RC2-3
3 Output 625 volts AC with respect to RC2-1
RC3 1 Input Thermistor return
2 Output +5 volts DC to thermistor
Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

5-45. Checking Unit Output After Servicing
1 Weld Output Terminals
Check open-circuit voltage be-
tween terminals according to Sec-
tion 5-35 (voltage V-10)
If correct voltage is not present,
repeat troubleshooting procedures.
Reinstall cover and side panels if
removed.
803 675-A

SECTION 6 − MAINTENANCE
6-1. Routine Maintenance
! Disconnect power . Maintain more often

before maintaining. during severe conditions.
n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent
Every
3 l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose nl Weld Cables
Months
nl Cords nl Gun Cables

Every
6 OR
Months
~ Drive Rolls ~ Inside Unit
6-2. Blowing Out Inside Of Unit

! Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 803 675-A

Notes

SECTION 7 − ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram Wiring Diagram
Auto-Axcess 300 Welding Power LC499793 and following 207 986-F ♦♦

Source
72 Pin Robot Interface LC499793 and following 219 266-C
Peripheral/Motor Interface LC499793 and following 219 267-B
Circuit Board PC1 LC499793 thru MA120361U 214 525-B♦♦
MA120361U and following 239 615-C♦♦
Circuit Board PC2 LC499793 thru LF344449 201 621-A♦♦
LF344450 thru MA040452U 222 663-A♦♦
MA040453U and following 237 371-A♦♦
Circuit Board PC3 LC499793 thru LF082054 213 557-F♦♦
LF082055 thru LG460066U 221 608-A♦♦
LG460067U thru LK420044U 231 928-D♦♦
LK420045U and following 239 598-D♦♦
Circuit Board PC4 LC499793 thru LG230082U 215 023-D♦♦
LG230083U and following 227 697-F♦♦
Circuit Board PC6 LC499793 thru MA021392U 231 109-A♦♦
MA021393U and following 239 601-A♦♦
Circuit Board PC7 LE302305 thru LG250034U 215 020-A♦♦
LG250035U and following 227 543-A♦♦
Circuit Board PC9 LC499793 thru MB210172U 209 694♦♦
MB210173U and following 239 600-G♦♦
Circuit Board PC10 LC499793 thru MC021903U 214 857-B♦♦
MC021904 and following 239 629-C♦♦
♦♦ Not included in this manual

Model Serial Or Style Number Circuit Diagram Wiring Diagram
Circuit Board PC11 LC499793 thru MC020130U 200 572-B♦♦
MC020131U and following 239 633-B♦♦
Circuit Board PC12 LC499793 thru LK290212U 209 679-A♦♦
LK290213U and following 239 625-B♦♦
Circuit Board PC13 LC499793 thru LK310385U 208 073-A♦♦
LK310386U and following 239 621-A♦♦
♦♦ Not included in this manual
Notes

207 986-F (Part 1 Of 2)
Figure 7-1. Circuit Diagram For Welding Power Source (Part 1 Of 2)

Figure 7-2. Circuit Diagram For Welding Power Source (Part 2 Of 2)

207 986-F (Part 2 Of 2)

Figure 7-3. Circuit Diagram For 72 Pin Robot Interface

219 266-C

Figure 7-4. Circuit Diagram For Peripheral/Motor Interface

219 267-B

Figure 7-5. Circuit Diagram For Control Board PC1 (1 Of 2)

214 525-B (Part 1 Of 2)

Figure 7-6. Circuit Diagram For Control Board PC1 (2 Of 2)

214 525-B (Part 2 Of 2)

Figure 7-7. Circuit Diagram For Auxiliary Power Board PC3

213 557-F

201 621-A
Figure 7-8. Circuit Diagram For Power Interconnect Board PC2

209 679-A
Figure 7-9. Circuit Diagram For Emergency Stop Board PC12

Figure 7-10. Circuit Diagram For Robot Interface HF Filter Board PC10
214 857-B

200 572-B
Figure 7-11. Circuit Diagram For Motor HF Filter Board PC11

208 073-A
Figure 7-12. Circuit Diagram For ISO/COM Board PC13

221 660-A
Figure 7-13. Circuit Diagram For AA-40GB/Gas Box (Left Hand)

TM-207 991L 2013−03
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And

Arc Welding Power Source
Auto-Axcess 300
Eff w/LC499793 And Following
Visit our website at File: Advanced Manufacturing Systems

www.MillerWelds.com/ams
SECTION 8 − PARTS LIST FOR LC499793 AND FOLLOWING
. Hardware is common and
not available unless listed.
2
1
4−Fig 8-3
6−Fig 8-4
5−Fig 8-2
14− Fig 8-5
9
10
11
12 7
13
Ref. 803 680-D
Figure 8-1. Main Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 8-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . . 210492 . . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . T2 . . . . . . . 212543 . . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . 210481 . . . Plate, Mtg Toroid Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . . Fig 8-3 . . . Top Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . IM1 . . . . . . 214597 . . . Windtunnel, LH w/Components (Fig 8-2) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . IM1 . . . . . . 222958 . . . Windtunnel, RH w/Components (Fig 8-2) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . Fig 8-4 . . . Rear Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . . 210480 . . . Panel, Side (LH & RH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . . 210482 . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . 213386 . . . Assembly, Filter (Primary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . HD2 . . . . . . 182918 . . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . . 198951 . . . Block, Terminal 3 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . 148025 . . . Lug, Univ W/SCR 600V 2/0−6 Wire .266 Stud . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . 226550 . . . Filter Assy, Secondary w/screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . . . Fig 8-5 . . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 227855 . . . Kit, Connectors (Prior To MC290257U) . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
14
15 . Hardware is common and
2 1
3
4
5
6
7
12 8
13 9
11 33
10 34
29
6 35 17 16
7 18
19
32
31 20 21
30
23 24
25
27 23
36
13
28
26
22
23
38
37
802 955-C
Figure 8-2. Windtunnel Assembly LH And RH

Item Dia. Part
Figure 8-2. Windtunnel Assembly LH And RH (Fig 8-1 Item 6)
. . . 1 . . . . . . . . . . . . . . . . 214597 . . . Windtunnel, LH w/Components (including). . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . . 196351 . . . . Windtunnel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . L1 . . . . . . . 213940 . . . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . . 214519 . . . . Insulator, Heat Sink Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . R3, C4 . . . . . 233052 . . . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . 199840 . . . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . D1, D2 . . . . *201531 . . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . . . . 196347 . . . . Heat Sink, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . 196349 . . . . Spacer, Windtunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 10 . . . . . T1 . . . . . . . 203408 . . . . Xfmr, HF Litz/Litz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . Z1 . . . . . . . 220496 . . . . Output Inductor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . 170647 . . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . . . 179276 . . . . Bushing, Snap−in Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . 4
. . . 14 . . . . . . . . . . . . . . . . 196355 . . . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 15 . . . . . . . . . . . . . . . . 010546 . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . 222958 . . . Windtunnel, RH w/Components (including) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . . 196332 . . . . Windtunnel, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . . 030170 . . . . Bushing, Snap−in Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . . . . 196259 . . . . Plugs, w/Leads & Current Xfmr (including) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 115092 . . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 115091 . . . . . . . Housing, Plug & Skts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT1 . . . . . . 196231 . . . . . . . Xfmr, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . . 201695 . . . . Clamp, Capacitor (Bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . C1,C2 . . . . *203912 . . . . Capacitor, Elctlt 2400 Uf 500 VDC Can 2.50 Dia
(Prior to LG380012U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . C1, C2 . . . . *226081 . . . . Capacitor,Elctlt 2400 Uf 500 VDC Can 2.50 Dia
(Eff w/LG380012U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . . . . 210507 . . . . Clamp, Capacitor (Top) Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . . . 217625 . . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . RT1, RT2 . . . . 214015 . . . . Thermistor, NTC 30K Ohm @ 25 Deg C 7&18in Lead . . . . . . . . . . . . 1
. . . 25 . . . . PC2 . . . . . *237370 . . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . C3 . . . . . . . 196143 . . . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . 196378 . . . . Bracket, Mtg Current Xfmr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . HD1 . . . . . *182918 . . . . Transducer, Current 400A Module Supply V +/− 15v . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 196384 . . . . Cable, Transducer 20in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . R1, R2 . . . . . 196343 . . . . Resistors, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 196840 . . . . Insulator, Resistors/Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . 109056 . . . . Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . . 196514 . . . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . . 196512 . . . . Bracket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . . . . 196330 . . . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . L2 . . . . . . . 196345 . . . . Coil, Inductor (Pre−regulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . 196588 . . . . Baffle, Foam Rubber (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 196365 . . . . Plugs, w/Leads (Fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 199136 . . . . Plugs, w/Leads (PC2 To PC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . PC1 . . . . . *239618 . . . Circuit Card Assy, Control (Inverter 400A) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . 196340 . . . Insulator, Screw (Prior To LG380012U) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 37 . . . . . . . . . . . . . . . . 204846 . . . Insulator, Screw (Eff w/LG380012U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 38 . . . . . . . . . . . . . . . . 083147 . . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . 4

. Hardware is common and 1
2
3
5
11 6
10
9
8
802 916-C
Figure 8-3. Top Tray Assembly

Item Dia. Part
Figure 8-3. Top Tray Assembly (Fig 8-1 Item 4)
... 1 . . . . PC12 . . . . . . 239623 . . . Circuit Card Assy, E−stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . PC3 . . . . . *239598 . . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . . . 210490 . . . Panel, Mtg Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . . . 134201 . . . Stand−Off, PC Card .312/.375/Post&Lock .43 . . . . . . . . . . . . . . . . . . . . . 4
... 5 . . . . . . . . . . . . . . . . 083147 . . . Grommet, SCR No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . 4
... 6 . . . . PC4 . . . . . *221277 . . . Process Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . . . 170647 . . . Bushing, Snap−in Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . . . 210491 . . . Panel, Mtg Components Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . . . 223439 . . . Insulator, circuit card (Aux Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . . . 198122 . . . Stand−Off Support, PC Card .250 w/Post&Lock .500 . . . . . . . . . . . . . . . 1
... 11 . . . . PC6 . . . . . . 221280 . . . Wire Feed Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9
not available unless listed. 8
5
7
6
4
3
2
1
10
15
11
12
14
13 803 681-B
Figure 8-4. Rear Panel Assembly
Item Dia. Part

Figure 8-4. Rear Panel Assembly (Fig 8-1 Item 8)
... 1 . . . . PC9 . . . . . *221279 . . . Automation Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . . . 212628 . . . Stand-off, no 6-32 x 1.000 lg .250 hex nyl fem . . . . . . . . . . . . . . . . . . . . . 4
... 3 . . . . PC10 . . . . . *239627 . . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . . . 207676 . . . Stand-off, no 6-32 x .250 lg .250 hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 5 . . . . . . . . . . . . . . . . 217297 . . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . . . 210479 . . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . . . 210358 . . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . . . 210505 . . . Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 . . . . . . . . . . . . . . . . 201058 . . . Connector, Rect 72 Pin Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . . . 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . CB1 . . . . . . 083432 . . . Supplementary Protector, Man Reset 1P 10A 250VAC Frict . . . . . . . . . 1
... 12 . . . . CB2 . . . . . . 093995 . . . Supplementary Protector, Man Reset 1P 15A 250VAC Frict . . . . . . . . . 1
... 13 . . . . PC11 . . . . . *239631 . . . Circuit Card Assy, Motor Filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . RC2 . . . . . . 604176 . . . Receptacle, w/Leads (115V Duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 . . . . . . . . . . . . . . . . 216596 . . . Strap, Grounding 4.50 in long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
1
21
11 7
20
4
19
5
3
18
7
6
10 7
17
11
14 12
13
15
16
16
803 682-B
Figure 8-5. Front Panel Assembly

Item Dia. Part
Figure 8-5. Front Panel Assembly (Fig 8-1 Item 14)
... 1 . . . . . S1 . . . . . . . 207456 . . . Switch Assy, Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg . . . . . . 1
... 2 ................ 207895 . . . Insulator,Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 ................ 179851 . . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . 1
... 4 ................ 233575 . . . Panel, PC Card Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . FM . . . . . . . 196313 . . . Fan, Muffin 115V 50/60 Hz 3000 Rpm 6.378 Mtg Holes . . . . . . . . . . . . . 2
... 6 . . . . PC13 . . . . . . 239619 . . . Circuit Card Assy,ISO/COMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . C6, C7, C8 . . . 206878 . . . Capacitor Assy (Prior To MC290257U) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 7 . C6, C7, C8 . . . 222488 . . . Capacitor Assy (Eff W/MC290257U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 8 . . . . RC5 . . . . . . 214664 . . . Receptacle, Common Mode Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 ................ 216965 . . . Cover, Connector D-sub 9 skt Female w/Chain . . . . . . . . . . . . . . . . . . . . 1

Item Dia. Part
Figure 8-5. Front Panel Assembly (Fig 8-1 Item 14) (Continued)
... 10 ................ 216966 . . . Cover, Connector D-sub 9 pin Male w/Chain . . . . . . . . . . . . . . . . . . . . . . 1

... 11 ................ 213102 . . . Choke, Common Mode w/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 ................ 210866 . . . Terminal, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 ................ 210477 . . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 ................ 219843 . . . Label, Volt Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 ................ 207979 . . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 ................ 186621 . . . Boot, Generic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 PB1, PB2, PB3 . . 199443 . . . Switch, Pb Mc No Spst 10A 115VAC w/Blk Cap Panelmt . . . . . . . . . . . 3
... 18 ................ 212779 . . . Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 ................ 210865 . . . Terminal, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 20 ................ 210483 . . . Bracket, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 ................ 210358 . . . Bolt, eye shld thd stem .500−13 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recommended Spare Parts List

Part Dia.
No. Mkgs. Description Quantity
... 201531 . . . D1, D2 . . . . . . . . . . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

... 203912 . . . C1, C2 . . . . . . . . . . . Capacitor, Elctlt 2400 Uf 500 VDC Can 2.5 Dia (Prior to LG380012U) 2
... 226081 . . . C1, C2 . . . . . . . . . . . Capacitor, Elctlt 2400 Uf 500 VDC Can 2.5 Dia (Eff w/LG380012U) . . 2
... 217625 . . . . . . . . . . . . . . . . . . . . . . Kit, Input/Pre−regulator And Inverter Module . . . . . . . . . . . . . . . . . . . . . . 2
... 182918 . . . . HD2 . . . . . . . . . . . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . . 1
... 237370 . . . . PC2 . . . . . . . . . . . . Circuit Card Assy, Power Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 239612 . . . . PC1 . . . . . . . . . . . . Circuit Card Assy, Control (Inverter 400A) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 239598 . . . . PC3 . . . . . . . . . . . . Circuit Card Assy, Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 221277 . . . . PC4 . . . . . . . . . . . . Process Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 221279 . . . . PC9 . . . . . . . . . . . . Automation Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 239627 . . . . PC10 . . . . . . . . . . . . Circuit Card Assy, Robot Interface Filter HF . . . . . . . . . . . . . . . . . . . . . . . 1
... 239631 . . . . PC11 . . . . . . . . . . . . Circuit Card Assy, Motor Filter Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

See Table 10-1
Drive Roll & Wire Guide Kits
16
26
18
19
20
21 15 not available unless listed.
22
23
18
25
26
6 27
5 7 59
58 57 10 14
8 13
9
4 1112
3
2 65 59
1 66 61
62 60
51
3
2 43 54
1
32 52
28 55
29
30
31
35
36 57
3
37 7
38 2 6 64
39 5
40 34 1 4 58
41 53
42 3 63
2
44 45 56
1
33 48
47
46
49 50
804 105-F
Figure 8-6. Drive Assembly, Wire

Item Dia. Part
Figure 8-6. Drive Assembly, Wire
... 1 . . . . . . . . . . . . . 010 668 . . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

... 2 . . . . . . . . . . . . . 172 075 . . CARRIER, drive roll w/comp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 3 . . . . . . . . . . . . . 149 962 . . SPACER, carrier drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 4 . . . . . . . . . . . . . 149 486 . . PIN, rotation arm rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 5 . . . . . . . . . . . . . 163 281 . . SPRING, pressure arm retaining LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 6 . . . . . . . . . . . . . 165 799 . . WASHER, flat .257 ID x 0.615 OD x .091t stl pld . . . . . . . . . . . . . . . . . . . . . 2
... 7 . . . . . . . . . . . . . 132 750 . . ARM, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 8 . . . . . . . . . . . . . 133 493 . . RING, retaining ext .250 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . . . . 133 350 . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 221 627 . . MOTOR, gear LH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . 223 885 . . MOTOR, gear RH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . MOTOR . 199 446 . . . . MOTOR, gear 1/8hp 40VDC 500 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . 130 204 . . . . HOUSING PLUG PINS+SKTS,(service kit) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . 115 091 . . . . HOUSING PLUG + SKTS (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . 229 550 . . . . ENCODER, quadrature 500 ppr incremental 5V shaftless . . . . . . . . . . . 1
Item Dia. Part
Figure 8-6. Drive Assembly, Wire (Continued)
... 15 ............. 203 631 . . PRESSURE ARM ASSY LH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 15 ............. 203 642 . . PRESSURE ARM ASSY RH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 16 ............. 203 637 . . . . KNOB, w/extension arm long pressure arm . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 ............. 602 200 . . . . WASHER, lock stl split No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 ............. 604 772 . . . . WASHER, flat stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 ............. 182 156 . . . . SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 20 ............. 182 155 . . . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 21 ............. 132 746 . . . . BUSHING, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 22 ............. 182 415 . . . . PIN, cotter hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 23 ............. 181 522 . . . . SHAFT, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 ............. 182 414 . . . . WASHER, flat .406 ID x 0.73 OD x .065 t stl pld 3/8type b . . . . . . . . . . . 1
... 25 ............. 203 632 . . . . CARRIER, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 ............. 133 739 . . . . WASHER, flat buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . . 1
... 27 ............. 203 640 . . . . KNOB, w/extension short pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 28 ............. 167 387 . . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 29 ............. 168 825 . . DRIVE, pinion 24 pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 30 ............. 133 308 . . RING, retaining ext .375 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 31 ............. 108 940 . . SCREW, cap stl hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 32 ............. 604 224 . . SCREW, 250−20 x .75 hex whd .50d stl pld slf fmg tap−rw . . . . . . . . . . . . 2
... 33 ............. 179 263 . . COVER, drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 ............. 184 685 . . ADAPTER ASSY, gun/feeder LH (including) . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 34 ............. 184 686 . . ADAPTER ASSY, gun/feeder RH (including) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 35 ............. 149 959 . . . . FITTING, brs barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 ............. 179 265 . . . . ADAPTER, gun/feeder LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 36 ............. 179 264 . . . . ADAPTER, gun/feeder RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 37 ............. 604 538 . . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 38 ............. 151 437 . . . . KNOB, plstc T 1.125 lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 39 ............. 128 237 . . . . SCREW, mach stl hexwhd 10-32 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 40 ............. 010 910 . . . . WASHER, flat .406 ID x 0.812 OD x .065t stl pld ansi.375 . . . . . . . . . . 1
... 41 ............. 602 213 . . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 42 ............. 601 872 . . . . NUT, stl hex full fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 43 ............. 601 966 . . . . SCREW, cap stl hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 44 ............. 235 932 . . CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 45 ............. 159 360 . . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 46 ............. 604 535 . . SCREW, 312−18 x 1.50 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 47 ............. 604 538 . . WASHER, flat .344ID x 0.688OD x .065T dtl pld ANSI.312 . . . . . . . . . . . . 3
... 48 ............. 156 243 . . CLAMP, motor top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 49 ............. 159 647 . . INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 50 ............. 145 639 . . STRIP, buna-n .062 x 3.000 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 51 ............. 231 451 . . ENCLOSURE, gas valve (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 51 ............. 231 950 . . ENCLOSURE, gas valve (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 52 ............. 219 047 . . VALVE, 40VDC 2 way custom port 1/8 orf w/fr . . . . . . . . . . . . . . . . . . . . . . . 1
... 53 ............. 010 493 . . BUSHING, snap-in nyl .625 ID x .875mtg hole . . . . . . . . . . . . . . . . . . . . . . . 1
... 54 ............. 232 298 . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 55 ............. 231 450 . . COVER, gas valve enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 56 ............. 149 332 . . CLAMP, hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 57 ............. 150 520 . . SPACER, rotation pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 58 ............. 163 282 . . NUT, 250−28 .37HEX .25H STL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 59 ............. 200 221 . . CABLE, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 60 ............. 089 799 . . SCREW, 250−20 x .50 hex whd .61 d gr5 pld . . . . . . . . . . . . . . . . . . . . . . . 2
... 61 ............. 602 207 . . WASHER, lock .255 ID x 0.489 OD x .062t stl pld split.250 . . . . . . . . . . . 2
... 62 ............. 602 241 . . WASHER, flat .281 ID x 0.625 OD x .065t stl pld ansi .250 . . . . . . . . . . . . 2
... 63 ............. 185 725 . . HOSE, sae .187 ID X .410 OD X 9.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 64 ............. 221 537 . . CIRCUIT CARD ASSY, motor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 65 ............. 221 656 . . RECEPTACLE, w/leads (gas box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 66 ............. 137 761 . . NUT, 750 npt 1.31hex .27H nyl blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 10-1. Drive Roll And Wire Guide Kits
Wire Size Inter- V-GROOVE U-GROOVE VK-GROOVE UC-GROOVE

Inlet
mediate 4 Roll Drive 4 Roll Drive 4 Roll Drive 4 Roll Drive
Fraction Metric Guide
Guide Kit Roll Kit Roll Kit Roll Kit Roll
.023-.025 in. 0.6 mm 150 993 149 518 151 024 087 130
.030 in. 0.8 mm 150 993 149 518 151 025 053 695
.035 in. 0.9 mm 150 993 149 518 151 026 053 700 151 036 072 000 151 052 132 958
.040 in. 1.0 mm 150 993 149 518 161 189 053 696
.045 in. 1.1/1.2 mm 150 994 149 519 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489
.052 in. 1.3/1.4 mm 150 994 149 519 151 028 053 698 151 038 053 702 151 054 132 956 151 071 083 490
1/16 in.
1.6 mm 150 995 149 520 151 029 053 699 151 039 053 706 151 055 132 955 151 072 053 708
(.062 in.)
.068-.072 in. 1.8 mm 150 995 149 520 151 056 132 959
5/64 in.
2.0 mm 150 995 149 520 151 040 053 704 151 057 132 960 151 073 053 710
(.079 in.)
3/32 in.
2.4 mm 150 996 149 521 151 041 053 703 151 058 132 961 151 074 053 709
(.094 in.)
7/64 in.
2.8 mm 150 996 149 521 151 042 053 705 151 059 132 962 151 075 053 711
(.110 in.)
1/8 in.
3.2 mm 159 997 149 522 151 043 053 707 151 060 132 963 151 076 053 712
(.125 in.)
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along With 4 Drive Rolls.

Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2013 Miller Electric Mfg. Co. 2013−01

Auto-Axcess300 (LC499793)

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TM-207 991L 2013−03

Eff. w/Serial Number LC499793

Automatic Welding Interface And

Visit our website at File: Advanced Manufacturing Systems

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 6 − PRE-POWER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

1-2. Servicing Hazards

During servicing, keep everybody, especially children, away.

HOT PARTS can burn.

D Insulate yourself from ground by standing or working on dry insulat-

STATIC (ESD) can damage PC boards.

Auto-Axcess 300 TM-207 991 Page 1

1-3. California Proposition 65 Warnings

1-4. EMF Information

TM-207 991 Page 2 Auto-Axcess 300

2-2. Environmental Specifications

2-3. Dimensions And Weight

Hole Layout Dimensions

C 19-3/32 in. (485 mm)

E 1/2 in. (13 mm)

Weight 17-3/32 in.

112 lb (51 kg) Net

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Continuous Welding 6 Minutes Welding 4 Minutes Resting

duty1 4/95 − 178 651

2-5. Volt-Ampere Curves

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3-1. Serial Number And Rating Label Location

3-2. Selecting A Location

Movement Tipping ! Do not move or operate

Location ! Do not stack units. Beware of

3-3. Connection Diagram

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Ref. 803 676-A

3-5. Connecting To Weld Terminals

2 Correct Installation Incorrect Installation

! Turn off power before connecting to cable size. 6 Copper Bar

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4/0 2 ea. 2/0 2 ea. 2/0

4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

4/0 2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

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Function Socket Socket Information

E Contact closure to F indicates coolant flow switch is

Jog H** Contact closure to circuit common advances welding

Retract J** Contact closure to circuit common retracts welding

K Contact closure to L energizes Touch Sensor

Touch Sensor ON L* Circuit common.

*Circuit common is same electrical reference point.

3-8. Motor Control Receptacle Functions

Socket Socket Information

E B B Motor negative (−).

D Motor positive (+).

H Tach +5 volts DC.

Ref. 803 675-A

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50/60 Hz Single Phase

Reference: 2011 National Electrical Code (NEC) (including article 630)

50/60 Hz Three Phase

Reference: 2011 National Electrical Code (NEC) (including article 630)