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Axcess 450
with Axcess Dedicated Wire Feeder
Digital Semi-Automatic
MIG Welding System
Issued June 2003 Index No. DC/33.0
Sharp Start feature provides
consistent arc starts by electronically
assuring a ball is not left on the wire
when welding is stopped. This provides
a predictable condition for the next
arc start.
The Power of Blue
®
.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
Rated Output
450 A at 44 VDC, 100% Duty Cycle
(460 VAC, 3-Phase)
Voltage Range
10 44 V
Auxiliary Power
120 VAC, 10 A Duplex
Ship Weight
150 lb (79.5 kg)
Power source is warranted for 3 years, parts and labor.
Separate 9-pin Palm handheld
(PDA) and 9-pin RS-232 serial
communication port provide
Axcess with data transfer and
optional program downloads.
Flexible, expandable and upgradeable! Precise,
digitally controlled, software-driven Multi-MIG
capable welding system.
Axcess the ability to accommodate welding data
file exchange through downloadable upgrades and
new hybrid welding processes using e-mail or
Palm handheld (PDA).
Accu-Pulse MIG process delivers
precise control of the arc even over
tack welds and in tight corners.
Accu-Pulse provides optimum molten
puddle control for out-of-position welding.
Multi-MIG process capabilities include
common carbon steel, aluminum and
stainless welding programs including
new, patented Accu-Pulse , standard
or adaptive pulse, conventional MIG
and metal core programs using the
most popular wire diameters and
gas combinations.
DESIGNED
AND BUILT IN
Digital control technology combined with
inverter welding power source. Designed to
reduce complexity of a semi-automatic pulsed
MIG system, simplify installation and provide
superior welding performance.
Photo for reference only (subject to change).
Optional Axcess-able software:
RMD (Regulated Metal Deposition)
Palm Axcess file management system
WaveWriter Palm pulse wave shaping
Axcess four-drive-roll wire drive
feeder is combined with operator
interface leaving no controls back at
the power supply. Provides positive
feeding for the appropriate
pre-programmed wire diameters
from 50 1400 IPM. HARDWARE
1/4-turn steel connectors
Allow for faster installation of system and reduces thread stripping.
Wind Tunnel Technology Circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants
and improves reliability.
115 VAC duplex receptacle
Provides 10 amp circuit-breaker-protected auxiliary power, regardless of primary power.
Lifting eyes and forklift holes
Provide for easy transportation.
Fan-on-Demand Cooling system operates only when needed. Reduces amount of airborne contaminants pulled through the machine.
SOFTWARE
Trigger program select
Allows changing weld programs from gun trigger to take advantage of up to 8 programs of Multi-MIG
welding process capabilities.
Dual schedule
Toggle between two settings using a single wire.
2T and 4T
When trigger is released, output will operate at different ranges.
SureStart
Wire-specific algorithms combined with SharpStart to fine tune the exact energy required to initiate the arc.
IMPROVED! SharpArc
®
Control offers a simple way to tailor factory pulse weld programs by adjusting the arc plasma cone to accommodate
a variety of welding applications without the need for any reprogramming or changing any hardware.
Additional Features
2
Process
RMD Regulated
Metal Deposition (Optional)
Standard Spray
Pulsed Spray
Accu-Pulse
Standard
Short Circuit
Flat/Horizontal
All Position Performance
Thin Materials/Gap Filling
Weld Puddle
Control
Multi-MIG Process Capability
Axcess the ideal welding process for any
weld joint at hand. Whether you need high travel
speed combined with high deposition rates or
require gaps to be filled, any combination of the
available welding processes can be Axcess-ed
either at the start of a welding sequence or
anywhere in the weld while actually welding by
using trigger program select.
For a given wire-feed speed, the following
shows from left (hottest) to right (coolest) all
the possible arc mode transfer ranges of
Axcess-able MIG processes. This shows
compatible spray gas combinations such as
90 Ar/10 CO
2
(90% Argon and 10% Carbon
Dioxide) on steel using the same wire-feed speed
and also gives an indication of puddle control
characteristics based on arc type selected. AA-40G Wire Feed Motor with Volt-Sense Kit
(Optional. To be used with remote operator interface.)
Axcess 450
DeviceNet Interconnecting
Control Cable
Must be ordered separately.
5, 10, 25, 50, 75, and 100 ft
lengths are available.
Axcess
Power
Supply
Remote
Interface
AA-40G
Drive Motor
Motor Control Cord
Supplied with AA-40G
Drive Motor Kit, 50 ft or 20 ft.
3
Specifications
(Subject to change without notice.)
Rated Output
450 A at 44 VDC,
100% Duty Cycle
Voltage
Range
10 44 V
Amperage Range
in CC Mode
5 600 A
Max. Open-
Circuit Voltage
85 VDC
Dimensions
H: 41 in (1041 mm)
W: 15-1/2 in (394 mm)
D: 22 in (559 mm)
Ship
Weight
150 lb
(79.5 kg)
Gas Valve
Included and
enclosed
Type of Input Power
40 VDC
(from Axcess 450)
Interconnect Cable
50 ft (15.2 m)
or 20 ft (6.1 m)
Wire Feed Speed Range*
50 1400 IPM
(1.3 35.56 MPM)
Dimensions
H: 10 in (254 mm)
W: 12 in (305 mm)
D: 15 in (381 mm)
Wire Diameter Range
.030 3/32 in
(0.8 1.6 mm)
Ship Weight
33 lb
(15 kg)
Remote Interface Option
Allows feeder motor drive to be placed away
from power supply and operator interface. Ideal
for fixed automation applications and updating
or replacing equipment on booms.
*This is the wire feed speed range while using MIG. With pulsed MIG, the wire feed speed range may be more limited.
Axcess Wire Feeder/Operator Interface (Bench/Sled)
Gas Valve
Included
Type of Input Power
40 VDC
(from Axcess 450)
Interconnect Cable
Order separately,
not supplied
Wire Feed Speed Range*
50 1400 IPM
(1.3 35.56 MPM)
Dimensions
H: 14-1/2 in (368 mm)
W: 12-1/2 in (318 mm)
D: 27 in (686 mm)
Wire Diameter Range
.030 3/32 in
(0.8 1.6 mm)
Ship Weight
49 lb
(22 kg)
*This is the wire feed speed range while using MIG. With pulsed MIG, the wire feed speed range may be more limited.
Remote Operator Interface (Detachable)
(Optional.)
Type of Input Power
Supplied from power source
Connector to Motor
Supplied with Motor Kit
(20 ft or 50 ft)
Connector to Power Source
10-pin DeviceNet Feed Control
5, 10, 25, 50, 15, and 100 ft
(Order separately)
Dimensions
H: 11 in (279 mm)
W: 12 in (305 mm)
D: 15 in (381 mm)
Ship Weight
11 lb
(5 kg)
Amps Input at Rated Output, 50/60 Hz
230 V 400 V 460 V 575 V KVA
KW
52
29
26
20
19.8
19
Axcess 450
Rated Output
450 A at 44 VDC,
100% Duty Cycle
Voltage
Range
10 44 V
Amperage Range
in CC Mode
5 600 A
Max. Open-
Circuit Voltage
85 VDC
Dimensions
H: 41 in (1041 mm)
W: 15-1/2 in (394 mm)
D: 22 in (559 mm)
Ship
Weight
150 lb
(79.5 kg)
Amps Input at Rated Output, 50/60 Hz
230 V 400 V 460 V 575 V KVA
KW
52
29
26
20
19.8
19 4
COMPORT
POWER
Axcess
1
2
3
4
Control Panels
1. Power Switch
2. Palm /PC RS-232 Port
3. Motor Connector
4. DeviceNet Connector (Optional)
1. Voltage/Arc Length Display Meter
2. Program Display
3. Program # Select
4. Process Setup Button
5. Control Knob
6. Trigger
7. Wire Speed/Amperage Display Meter
8. Voltage Setup Button
9. Wire Speed Setup Button
10. Feeder Setup Button
11. On/Off Button
Axcess 450 Front Panel
Axcess 450 Rear Panel
Program
Process
Wire Type
Gas Type
Volts
Time
Arc Length
WFS
Amps
Arc Ctl
Process Set Up
Adjust
Feeder Set Up
Trigger Hold
Trigger Control
Sequence
5
4
6
3
2
1
8
9
10
11
7
Axcess Feeder Operator Interface Axcess File Management
#195 249
Simply put, the new Miller Palm OS-based
file management software turns a standard
Palm handheld (PDA) into a data card and
a remote pendant control for all Axcess
systems. This is in addition to all other
functions a Palm is typically used for. By
using a Palm handheld in this manner, we
have built a powerful intuitive interface on a
common affordable, portable platform. This
opens the door to functions and capabilities
not previously available from Miller or from
the welding industry as a whole.
With Millers Palm Axcess File Management
installed on your Palm m Series you can:
E-mail Axcess files anywhere worldwide
Configure any Axcess system as desired
Configure multiple Axcess systems
exactly the same or any way you choose
Save and store Axcess files
Transfer Axcess files to computers
Transfer Axcess files from machine
to machine
Backup Axcess files and programs
Set-up and modify Axcess welding
sequences
Adjust and store welding program
Locks & Limits for restricting or limiting
operator Axcess to programs
Enable Auto-Thread feature to program
torch length into Axcess memory. When
a combination of purge and jog are
depressed, the Axcess feeding system
delivers exact programmed length of wire.
There are 3 basic types of files:
1) Programs Contain all the welding
data that create an arc: volts, amps,
wire feed rates, wire type, size, gas
and appropriate arc control. They also
contain all the time-based functions
typically used in welding: pre-flow,
start conditions, ramps, crater fill,
retract, and post-flow.
2) Configuration