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Miller Electric Auto Axcess 675 manual

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Table of contents for the manual

  • Page 1

    OM-201 540K 2007−10 Auto Axcess 675 Processes Description MIG (GMA W) W elding Pulsed MIG (GMAW -P) Flux Cored (FCA W ) W elding Automatic W elding Automatic Welding Interface And Arc Welding Power Source ™ File: Advanced Manufacturing Systems V isit our website at www.MillerWelds.com/ams[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 7 − TROUBLESHOOTING 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Set V alue Mode 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Diagnostics 3[...]

  • Page 5

    OM-201 540 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols o[...]

  • Page 6

    OM-201 540 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Page 7

    OM-201 540 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-201 540 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and [...]

  • Page 9

    OM-201 540 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures grave[...]

  • Page 10

    OM-201 540 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

  • Page 11

    OM-201 540 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 12

    OM-201 540 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de t o ucher[...]

  • Page 13

    OM-201 540 Page 9 2-5. P ri nc ipa le s nor me s de s éc ur ité Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American [...]

  • Page 14

    OM-201 540 Page 10[...]

  • Page 15

    OM-201 540 Page 1 1 SECTION 3 − INST ALLA TION . Appearance of actual unit may vary from unit shown in manual. 3-1. Specifications Input Power Rated W elding Output V oltage Range Wire Feed Speed Range** Wire Diameter Range Max Open Circuit V oltage Amperes Input At Rated Load Output 60 Hz, Three-Phase Input KV A Input KW Power W elding Output Ra[...]

  • Page 16

    OM-201 540 Page 12 3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle ca n damag[...]

  • Page 17

    OM-201 540 Page 13 3-5. Selecting A Location loc_2 3/96 -Ref. 802 913-B ! Do not stack units. Beware of tipping. 1 Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit. 2 Hand Cart Use cart or similar device to move unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Loca[...]

  • Page 18

    OM-201 540 Page 14 Ref. 802 915-A 1 1 15 V 10 A AC Receptacle RC2 Receptacle supplies 60 Hz single-phase power . Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps. 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects 1 15 volt receptacle RC2 from o v e r l oad. If CB1 opens, RC2 does not work. CB2 prot[...]

  • Page 19

    OM-201 540 Page 15 3-8. Connecting T o W eld T erminals Ref. 802 913-B / 803 778-A 1 2 T ools Needed: 3/4 in (19mm) 6 4 5 Do not place anything between 3 weld cable terminal and copper bar . Correct Installation Incorrect Installation ! T urn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause e[...]

  • Page 20

    OM-201 540 Page 16 3-9. Selecting Weld Cable Sizes* ! ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor . Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is install[...]

  • Page 21

    OM-201 540 Page 17 3-10. Peripheral Receptacle Functions B C Function Socket Socket Information A B C L D A Not used. K M J L E F B Not used. K J H F C* Circuit common. Purge D Contact closure to C completes 40 volts dc solenoid circuit to purge shielding gas line. Coolant Flow Switch Input Signal E Contact closure to F indicates coolant flow switc[...]

  • Page 22

    OM-201 540 Page 18 3-1 1. Motor Control Receptacle Functions A C G Socket Socket Information B E K F J A G A Not used. D H B E K B Motor negative (−). C T ach A. D Motor positive (+). E T ach common. F Gas valve. G Electrode sense. H T ach +5 volts dc. J T ach B. Ref. 802 915-A K Gas valve.[...]

  • Page 23

    OM-201 540 Page 19 3-12. Electrical Service Guide Failure to fo llow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. NOTICE − INCORRECT INPUT POWER can damage this welding [...]

  • Page 24

    OM-201 540 Page 20 3-13. Connecting Input Power 802 915-A / Ref. 803 766-A / 218 005-A T ools Needed: 5/16 in Route ground conductor through current transducer to ground terminal. Route input power cable through tubing inside unit. Three-Phase Input Connection Read Owner’s Manual. ELECTRIC SHOCK can kill; SIGNIFICANT DC VOL T AGE exists after rem[...]

  • Page 25

    OM-201 540 Page 21 3-14. T ouch Sensor Operation Th e touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source. The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle. T urning on touch sensor causes a dc voltage to be presen[...]

  • Page 26

    OM-201 540 Page 22 SECTION 4 − OPERA TION 4-1. Operational T erms The following is a list of terms and their definitions as they apply to this interface unit: General T erms: 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 Fr[...]

  • Page 27

    OM-201 540 Page 23 4-1 . Operational T erms (Continued) Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (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). W eld Sequence funct[...]

  • Page 28

    OM-201 540 Page 24 4-2. Front Panel Controls (See Section 4-3 ) Program Process Wire T ype Gas T ype Adjust V olts Arc Adjust Wire Speed Amps Setup Arc Control Wirefeed Gas Contactor . When an LED is lit, it means the related function is active. 1 Program Display Displays the number of the active program. 2 Adjust Knob T urn the Adjust knob to chan[...]

  • Page 29

    OM-201 540 Page 25 4-3. Front Panel Controls - Continued (See Section 4-2) 8 Arc Control LED The LED lights to indicate the Arc Control button is active. Light goes out when button is inactive. 9 Arc Co ntrol Push Button This push button allows fine tuning inductance for MIG programs, and Arc Control for programs other than MIG. When the push butto[...]

  • Page 30

    OM-201 540 Page 26 T able 4-2. Robot Abbreviations Manufacturer Robot Abbreviation ABB ABB Fanuc F ANU Daihen DAHN Kawasaki KA WA Kuka KUKA Comau COMU Hitachi HCHI Nachi NCHI Panasonic P ANA Motorman MOTO Robot Adapter DTEC Detect Disabled OFF None Robt DTEC 4-4. Front Panel Switches Ref. 802 914-A 1 Power Switch T urns unit On or Of f. The power-u[...]

  • Page 31

    OM-201 540 Page 27 4-5. Robot Calibration Mode 198 993 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 robot pendant as o n t h e p o w e r s o u r c e . . Th e factory recommendation is t o perform the calibration on all insta[...]

  • Page 32

    OM-201 540 Page 28 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 [...]

  • Page 33

    OM-201 540 Page 29 Sample Auto-Calibration Routine For Fanuc Robot 1: Call Safehome 2: J P[1] 40% Fine Arcstart [10.0V olts, 100.0IPM] 3: L P[2] 10.0 sec Fine Arc End [0.0V olts, 0.0IPM, 0.0Sec] 4: W ait 1.00 (Sec) 5: J P[3] 40% Fine Arcstart [44.0V olts, 1000.0IPM] 6: L P[4] 10.0 sec Fine Arc End [0.0V olts, 0.0IPM, 0.0Sec] 7: Call Safehome Sample[...]

  • Page 34

    OM-201 540 Page 30 4-7. Reset Mode 198 993 / 803 246-B . Reset mode is not active when Program Lock is enabled. Th e reset mode allows the operator t o reload factory program settings for all eight active programs in the unit. . System configuration data will be lost during the Reset operation. Enter reset mode by turning power On and pressing the [...]

  • Page 35

    OM-201 540 Page 31 SECTION 5 − MAINTENANCE 5-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every Every 3 Months l Unreadable Labels ~ W eld T erminals l Damaged Gas Hose nl Weld Cab[...]

  • Page 36

    OM-201 540 Page 32 SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read and follow these precautions. 6-1. Symbol Usage OM-201 540K - 2007−10, safety_stm 2007−04 DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in[...]

  • Page 37

    OM-201 540 Page 33 F ALLING UNIT can cause injury . D Use lifting eye to lift unit only , NOT running gear , gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. MOVING P ARTS can cause injury [...]

  • Page 38

    OM-201 540 Page 34 SECTION 7 − TROUBLESHOOTING 7-1. Set V alue Mode Program Process Wire T ype Gas T ype Adjust V olts Arc Adjust Wire Speed Amps Setup Arc Control Wirefeed Gas Contactor The Set V alue mode is a troubleshooting tool that allows certain robot command values to be manually over-ridden. 1 Setup Push Button 2 Arc Control Push Button [...]

  • Page 39

    OM-201 540 Page 35 7-2. Diagnostics ERR T ACH • T ach error for T ach A occurs 2 seconds after the loss of tachometer feedback. The motor speed is regulated through the monitoring of voltage and current. Press Jog/Purge button to clear error . • T ach error for T ach B occurs 2 seconds after the loss of tachometer feedback. The motor speed is r[...]

  • Page 40

    OM-201 540 Page 36 7-2. Diagnostics (Continued) WELD W AIT • The weld wait erro r indicates unit was not ready for a weld sequence. Press Jog/ Purge button to clear error . MOTR COM • The motor communication erro r indi- cates motor board lost data communica- tions. Press Jog/Purge button to clear error . If condition persists, contact nearest [...]

  • Page 41

    OM-201 540 Page 37 7-3. Removing Cover and Measuring Input Capacitor V oltage Turn Of f welding power source, a n d disconnect input power . Remove cover 1 Power Interconnect Board PC2 2 V oltmeter Measure the dc voltage across th e + bus terminal and − bus terminal on PC2 as shown until voltage drops to near 0 (zero) volts. Measure input capacit[...]

  • Page 42

    OM-201 540 Page 38 1 Process Control Module PC4 Diagnostic LED’ s are visible inside unit, located on PC4 mounted on the top tray . Refer to Section 7-5 for information on diagnostic LED’s. Reinstall cover after checking diagnostic LED’ s. 216 956-A / Ref. 803 001-B 7-4. Process Control Module PC4 Diagnostic LED’ s 1 LED2 LED1 LED4 LED3 7-5[...]

  • Page 43

    OM-201 540 Page 39 1 Wire Feed Module PC6 Diagnostic LED’s are visi ble inside unit, located on PC6 mounted on the top tray assembly . Refer t o Section 7-7 for information on diagnostic LED’ s. Reinstall top cover after checking diagnostic LED’s. 2 Dip Switch S1 Dip switches are used to identify each circuit board on the internal network. Di[...]

  • Page 44

    OM-201 540 Page 40 1 User Interface Module PC7 Diagnostic LED’ s are visible inside unit, located on PC7 mounted behind the front panel. Refer to Section 7-9 for information on diagnostic LED’s. Reinstall cover after checking diagnostic LED’ s. 2 Dip Switch S1 3 Dip Switch S2 Dip switches are used to identify each circuit board on the interna[...]

  • Page 45

    OM-201 540 Page 41 1 Automation Interface Module PC9 Diagnostic LED’s are visible inside unit, located on PC9 mounted on left side. Refer to Section 7-1 1 for information on diagnostic LED’s. Reinstall cover after checking diagnostic LED’ s. 2 Dip Switch S4 Dip switches are used to identify each circuit board on the internal network. Dip swit[...]

  • Page 46

    OM-201 540 Page 42 7-1 1. Diagnostic LED’ s On Automation Interface Module PC9 LED Status Diagnosis 1 On Input signal On from robot for jog advance Of f Input signal Off from robot for no jog advance 2 On Input signal On from robot to energize contactor Of f Input signal Off from robot to not energize contactor 3 On Input signal On remote program[...]

  • Page 47

    OM-201 540 Page 43 LED Diagnosis Status 24 On Input signal On from relay K4 to indicated wire stuck in weld joint Of f 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 interface module PC9 Of f Indicates +5 volts dc is not present on automation interface module PC9 26 On[...]

  • Page 48

    OM-201 540 Page 44 7-12. Network And Module Status LED’ s A. Network Status LED’ s The following are network status LED’s: LED1 on the UIM circuit board LED4 on the WFM and PCM circuit boards LED30 on the AIM circuit board. Status Diagnosis Of f T he circuit board is not on-line with the network or there is no power applied to the circuit boa[...]

  • Page 49

    OM-201 540 Page 45 7-13. T roubleshooting T rouble Remedy No weld output; completely inoperative Place line disconnect in On position (see Section 3-13 ). Check and replace line fuse(s), if necessary , or reset circuit breaker (see Section 3-13 ). Check for proper input power connections (see Section 3-13 ). No weld output; meter display on with no[...]

  • Page 50

    OM-201 540 Page 46 SECTION 8 − ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For Welding Power Source (1 Of 2)[...]

  • Page 51

    OM-201 540 Page 47 198 992-G (Part 1 Of 2)[...]

  • Page 52

    OM-201 540 Page 48 Figure 6-2. Circuit Diagram For Welding Power Source (2 Of 2)[...]

  • Page 53

    OM-201 540 Page 49 198 992-G (Part 2 Of 2)[...]

  • Page 54

    OM-201 540 Page 50 Figure 6-3. Circuit Diagram For 72 Pin Robot Interface[...]

  • Page 55

    OM-201 540 Page 51 219 266-C[...]

  • Page 56

    OM-201 540 Page 52 Figure 6-4. Circuit Diagram For Peripheral/Motor Interface[...]

  • Page 57

    OM-201 540 Page 53 219 267-B[...]

  • Page 58

    OM-201 540 Page 54 SECTION 9 − P ARTS LIST . Hardware is common and not available unless listed. Ref. 802 919-C 8 8 3 1 2 11 15 13 14 12 9 15 10 6 5 5 6 4 − Fig 9-3 5 − Fig 9-2 7 − Fig 9-4 16 − Fig 9-5 15 17 19 18 18 Figure 9-1. Main Assembly[...]

  • Page 59

    OM-201 540 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quanti ty 1 T2 212543 Xfmr , Control T oroidal 665 V AC Pri 1900 V A 60 Hz 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 210492 Cover , T op 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 60

    OM-201 540 Page 56 Description Part No. Dia. Mkgs. Item No. Figure 9-2. Windtunnel Assembly LH And RH (Fig 9-1 Item 6) Quanti ty 1 214597 Windtunnel, LH w/Components (including). 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196351 Windtunnel, LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 61

    OM-201 540 Page 57 . Hardware is common and not available unless listed. 802 916-B 1 2 3 4 5 6 7 8 9 10 11 Figure 9-3. T op T ray Assembly Description Part No. Dia. Mkgs. Item No. Figure 9-3. T op T ray Assembly (Fig 9-1 Item 4) Quanti ty 1 PC12 209676 Circuit Card Assy , E−stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 62

    OM-201 540 Page 58 . Hardware is common and not available unless listed. 802 917-B 11 9 6 7 14 12 10 8 5 4 3 2 1 13 15 Figure 9-4. Rear Panel Assembly Description Part No. Dia. Mkgs. Item No. Figure 9-4. Rear Panel Assembly Quanti ty 1 PC9 221279 Automation Interface Module 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 63

    OM-201 540 Page 59 . Hardware is common and not available unless listed. Ref. 802 918-B 1 2 3 5 7 6 4 27 26 25 9 18 17 16 8 19 23 22 21 21 20 12 13 10 11 10 12 24 15 14 Figure 9-5. Front Panel Assembly Description Part No. Dia. Mkgs. Item No. Figure 9-5. Front Panel Assembly Quanti ty 1 S1 207456 Switch Assy , Rotary 2 Posn 1P 40A 600V AC PNLMTG 90[...]

  • Page 64

    OM-201 540 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 9-5. Front Panel Assembly (Continued) Quanti ty 13 220815 Bus Bar , Output 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 210864 Bus Bar , Output 1 . . . . . . . . . . . . . . . . . . . .[...]

  • Page 65

    Notes[...]

  • Page 66

    Notes[...]

  • Page 67

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expert[...]

  • Page 68

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 9 20-735-4134 Int ernational F AX : 9 20-735-4125 European Headquarters ?[...]