Miller Electric Auto Axcess 675 Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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1-1.

Symbol Usage

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1-2.

Arc Welding Hazards

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1-3.

Additional Symbols For Installation, Operation, And Maintenance

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1-4.

California Proposition 65 Warnings

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1-5.

Principal Safety Standards

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1-6.

EMF Information

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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2-1.

Symboles utilisés

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2-2.

Dangers relatifs au soudage à l’arc

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2-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4.

Proposition californienne 65 Avertissements

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2-5.

Principales normes de sécurité

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2-6.

Information EMF

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SECTION 3 − INSTALLATION

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3-1.

Specifications

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3-2.

Dimensions And Weight

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3-3.

Duty Cycle And Overheating

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3-4.

Volt-Ampere Curves

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3-5.

Selecting A Location

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3-6.

Connection Diagram

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3-7.

Rear Panel Receptacles And Supplementary Protectors

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3-8.

Connecting To Weld Terminals

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3-9.

Selecting Weld Cable Sizes*

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3-10. Peripheral Receptacle Functions

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3-11. Motor Control Receptacle Functions

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3-12. Electrical Service Guide

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3-13. Connecting Input Power

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3-14. Touch Sensor Operation

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3-15. Remote Program Select

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3-16. Remote Program Setting

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SECTION 4 − OPERATION

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4-1.

Operational Terms

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4-2.

Front Panel Controls (See Section 4-3)

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4-3.

Front Panel Controls - Continued (See Section 4-2)

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4-4.

Front Panel Switches

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4-5.

Robot Calibration Mode

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4-6.

Robot Auto-Calibration Sample Programs

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4-7.

Reset Mode

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SECTION 5 − MAINTENANCE

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5-1.

Routine Maintenance

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5-2.

Blowing Out Inside Of Unit

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SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING

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6-1.

Symbol Usage

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6-2.

Servicing Hazards

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6-3.

California Proposition 65 Warnings

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6-4.

EMF Information

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Summary of Contents for Auto Axcess 675

Page 1: ...Processes Description MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding Automatic Welding Automatic Welding Interface And Arc Welding Power Source File Advanced Manufacturing Systems Visit ou...

Page 2: ...tinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...12 3 5 Selecting A Location 13 3 6 Connection Diagram 13 3 7 Rear Panel Receptacles And Supplementary Protectors 14 3 8 Connecting To Weld Terminals 15 3 9 Selecting Weld Cable Sizes 16 3 10 Peripher...

Page 4: ...e Feed Module PC6 Diagnostic LED s And Dip Switch Settings 39 7 7 Diagnostic LED s On Wire Feed Module PC6 39 7 8 User Interface Module PC7 Diagnostic LED s 40 7 9 Diagnostic LED s On User Interface M...

Page 5: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Page 6: ...s they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the...

Page 7: ...ans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels cove...

Page 8: ...York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 91...

Page 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivante...

Page 10: ...de protection LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peu provoquer leur clatement Des ti...

Page 11: ...e pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteil...

Page 12: ...de provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur t...

Page 13: ...O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid r...

Page 14: ...OM 201 540 Page 10...

Page 15: ...y Cycle 10 44 Standard 50 1400 ipm 1 3 35 6 mpm 035 062 in 0 8 1 6 mm 85 89 7 0 1A 52 0 0 1A 43 7 0 1A 21 2 0 1A 35 7 0 8 34 4 0 17 While idling Input amperage fluctuates while idling and is always le...

Page 16: ...can damage unit and void warranty Overheating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 206 789 A Continuous Welding 100 Duty Cycle At 675 Amperes 3 4 Volt Ampere Curves va_curve1 4 95 221 502...

Page 17: ...ip Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref 802 913 B Ref 801 915 A The proper interface kit must be installed in t...

Page 18: ...t work Press button to reset breaker If breaker continue to open contact a Factory Authorized Service Agent 4 Wirefeed Gas Receptacle RC8 Use receptacle to connect gas and motor control cable to power...

Page 19: ...10 to select proper cable size 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal Connect positive weld cable to Positive weld terminal and negative cable to Negative weld terminal 3 Wel...

Page 20: ...a 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 2 ea 4 0 2x120 500 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 4 0 2x120 3 ea 3 0 3x95 3 ea 3 0 3x95 600 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2...

Page 21: ...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 And...

Page 22: ...trol 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 Tach A D Motor positive E Tach common F Gas valve G Electrode sense H Tach 5 volts dc J...

Page 23: ...available 60 Hz Three Phase Input Voltage 230 400 460 575 Input Amperes At Rated Output 89 7 52 0 43 7 21 2 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 Time Delay 2 110 60 50 40...

Page 24: ...local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Install strain relief of proper size for u...

Page 25: ...E LIVE appears on the front panel display 3 15 Remote Program Select Remote Program Select is factory set to On WaveWriter or File Management software is required to turn this function Off When Remote...

Page 26: ...reduction Provides less heat input into workpiece minimizes distortion and allows use of larger diameter wire on thin gauge materials Wire Type Selection of wire type by alloys and classification Gas...

Page 27: ...t with the optional PDA with File Management software 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...

Page 28: ...ows see Items 13 and 15 Process LED When this LED is lit turn the Adjust knob to select the desired weld process Choices include pulse welding displayed as PULS Accu pulse MIG welding MIG and Accu Pul...

Page 29: ...Display button is pressed Displays show actual or command values as determined by configuration menu when using a PDA with File Management WaveWriter software Command values are displayed prior to wel...

Page 30: ...used as identified by the unit see Table 4 2 for a list of robot adapters that could be displayed To ensure proper operation of the system verify the robot displayed corresponds to the actual robot b...

Page 31: ...the calibration is performed correctly the ROBT CAL message stops being displayed however if it is performed incorrectly the message remains on the display To start the calibration procedure over aga...

Page 32: ...this as the second condition and fail to execute Auto Cal correctly Actual Motoman Welder Condition File Welding Current Output Char NO REF V MEASURE A 01 0 01 1 02 7 00 500 03 13 99 999 04 0 00 000...

Page 33: ...ation Routine For ABB Robot Move J home v500 z50 tweldgun Arcl on v500 sm1 wd1 wv0 z50 tweldgun Arcl off v500 sm1 wd1 wv0 z50 tweldgun WaitTime 5 Arcl on v500 sm1 wd2 wv0 z50 tweldgun Arcl off v500 sm...

Page 34: ...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 Pul...

Page 35: ...done by Factory Authorized Service Agent Reference Every Every 3 Months l Unreadable Labels Weld Terminals l Damaged Gas Hose nl Weld Cables 3 Months nl Cords nl Gun Cables Every 6 Months OR Drive Ro...

Page 36: ...h the ground D Do not leave live unit unattended D If this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job D When testing a li...

Page 37: ...lding 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...

Page 38: ...iefly shows SET VALU and the blinking LED s under the display windows indicate whether Volts Arc Adjust or Wire Speed can be changed turning the Adjust knob Depending on the defined weld process eithe...

Page 39: ...error occurs if weld current is detected in the earth ground connection May be caused by a conductor making contact with unit chassis Check and repair feeder weld connections Turn power off and back...

Page 40: ...s reset causing the contactor to remain on Press Jog Purge button to clear error TRIG STUK The trigger stuck error indicates the user held the gun trigger during power up Release trigger and turn powe...

Page 41: ...hown on this page Proceed with job inside unit Reinstall cover when finished Tools Needed 5 16 in 802 301 B Ref 803 001 A 900 Volts dc can be present on the capacitor bus and significant DC voltage ca...

Page 42: ...C4 Diagnostic LED s 1 LED2 LED1 LED4 LED3 7 5 Diagnostic LED s On Process Control Module PC4 LED Status Diagnosis 1 On Indicates 25 volts dc is present on process control module PC4 Off Indicates 25 v...

Page 43: ...d For proper operation do not change dip settings from those shown 7 6 Wire Feed Module PC6 Diagnostic LED s And Dip Switch Settings 217 333 B 803 300 A 2 1 LED1 LED2 LED3 LED4 7 7 Diagnostic LED s On...

Page 44: ...ip Switch S2 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...

Page 45: ...hes 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 216 958 A...

Page 46: ...gnal 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 remo...

Page 47: ...t 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 automa...

Page 48: ...h 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 1 2 and 1 3 Replac...

Page 49: ...protector CB1 see Section 3 7 Wire does not feed Check supplementary protector CB2 and reset if necessary see Section 3 7 Check motor control cable connections Wire feeds erratically Readjust hub ten...

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: ...ge 54 SECTION 9 PARTS 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...

Page 59: ...4 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 15 218356 Filter Assy Secondary 3 16 Fig 9 5 Front Panel Assembly 1 227855 Kit Connectors W Washer For Power Cables Includes 1 17 010467 Connector Cl...

Page 60: ...Dia 2 22 210507 Clamp Capacitor Top Machined 2 23 217625 Kit Input Pre regulator And Inverter Module 1 24 RT1 RT2 214015 Thermistor NTC 30K Ohm 25 Deg C 7 18in Lead 1 25 PC2 222661 Circuit Card Assy...

Page 61: ...10 Panel Hole 312 Sq 500 High 24 6 PC4 221277 Process Control Module 1 7 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 1 8 210491 Tray Mtg PC Card 1 9 223439 Insulator Circuit Card Aux Power 1...

Page 62: ...eye shld thd stem 500 13 X 1 500 1 8 210 505 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 1...

Page 63: ...1 3 179851 Knob Pointer 1 670 Dia X 250 Id Push On W Spring 1 4 204393 Panel PC Card Front including 1 204394 Panel PC Card Switch Overlay including 1 5 200410 Nameplate Overlay 1 6 PC20 227879 Circui...

Page 64: ...ouver 1 21 186621 Boot Generic 2 22 PB1 PB2 PB3 199443 Switch Pb Mc No Spst 10A 115VAC w Blk Cap Panelmt 3 23 212780 Nameplate Front 1 24 210865 Terminal pwr output red 1 25 210469 Panel Front 1 26 21...

Page 65: ...Notes...

Page 66: ...Notes...

Page 67: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Page 68: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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