Miller Auto-Axcess 675 DI Owner's Manual
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Miller Auto-Axcess 675 DI Owner's Manual

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Auto-Axcess 675 DI
OM-240 146J
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
File: Advanced Manufacturing Systems
2012−06

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  • Page 1 OM-240 146J 2012−06 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 675 DI  Visit our website at File: Advanced Manufacturing Systems www.MillerWelds.com/ams...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING ........6-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose.

  • Page 8: California Proposition 65 Warnings

    1-4. 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.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com).
  • Page 14 OM-240 146 Page 10...

  • Page 15: Section 3 − Installation

    SECTION 3 − INSTALLATION Appearance of actual unit may vary from unit shown in manual. 3-1. Specifications Wire Amperes Input At Rated Load Output 60 Hz, Rated Wire Open Input Voltage Feed Input Input Three-Phase Welding Diameter Circuit IP Rating Power Range Speed...

  • Page 16: Duty Cycle And Overheating

    3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 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.

  • Page 17: Serial Number And Rating Label Location

    3-5. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. 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. 3-6.

  • Page 18: Optional Tandem Connection Diagram

    3-8. Optional Tandem Connection Diagram Î Î Î Î 805 329-A Robot Control Recommended for Accu-pulse and RMD The proper interface kit must be (optional). E-Stop Cable (2) installed in welding power source/interface unit to allow it to be Gas And Motor Control Cable (2) Positive (+) voltage sensing lead is connected to the robot.

  • Page 19: Rear Panel Receptacles And Supplementary Protectors

    3-9. Rear Panel Receptacles And Supplementary Protectors Ref. 805 224-A 115 V 10 A AC Receptacle RC2 does not work. E-Stop Receptacle RC Receptacle supplies 60 Hz single-phase A short across the two sockets allows unit Press button to reset breaker. If power.

  • Page 20: Selecting Weld Cable Sizes

    ( ) = mm 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.

  • Page 21: Devicenet Receptacle

    3-12. Devicenet Receptacle Socket Socket Information Chassis ground. +24 volts DC; available current is 1 ampere. +24 volts DC common. CAN H. Ref. 804 578-A CAN L. 3-13. Motor Control Receptacle Functions Socket Socket Information Not used. Motor negative (−). Tach A, 0 volts = low and 3.5 volts = high.

  • Page 22: Electrical Service Guide

    3-16. 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.
  • Page 23 Notes OM-240 146 Page 19...

  • Page 24: Connecting 3−Phase Input Power

    3-20. Connecting 3−Phase Input Power = GND/PE Earth Ground 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.

  • Page 25: Connecting 3−Phase Input Power

    3-21. Connecting 3−Phase Input Power See rating label on unit and check input volt- Welding Power Source Line Terminals Turn Off welding power source, and age available at site. check voltage on input capacitors Input Conductors L1, L2, L3 according to Section 7-3 before Input Power Conductors (Customer Connect input conductors L1, L2, and L3 to proceeding.

  • Page 26: Section 4 − Operation

    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.
  • Page 27 4-1 . Operational Terms (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).

  • Page 28: Front Panel Controls (See Section 4-3)

    4-2. Front Panel Controls (See Section 4-3) Program Volts Arc Adjust Wire Speed Amps Process Wirefeed Wire Type Gas Type Contactor Setup Adjust Arc Control When an LED is lit, it means the related function is active. 198 993 Program Display The lit LED indicates which setup mode is Setup Push Button active.

  • Page 29: Front Panel Controls - Continued (See Section 4-2)

    4-3. Front Panel Controls - Continued (See Section 4-2) 10 Wire Feed/Gas/Contactor LEDs shown). When welding, actual value is shown. (IPM, MPM) or display welding information (command or actual),save the changes and If amperage was selected for display, the unit The Wirefeed LED lights when the wire feeder then turn the power to the unit off and then will show actual welding amperage prior to...

  • Page 30: Reset Mode

    4-5. 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. System configuration data will be lost during the Reset operation. Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed.

  • Page 31: Section 5 − Maintenance

    SECTION 5 − MAINTENANCE 5-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose...
  • Page 32 SECTION 6 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 6-1. Symbol Usage OM-240 146J - 2012−06, safety_stm 2011−10 DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 33 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 navigation, safety services, computers, and D Keep away from pinch points such as drive communications equipment. rolls.

  • Page 34: Section 7 − Troubleshooting

    SECTION 7 − TROUBLESHOOTING 7-1. Set Value Mode Program Volts Arc Adjust Wire Speed Amps Process Wirefeed Wire Type Gas Type Contactor Setup Adjust Arc Control The Set Value mode is a troubleshooting tool display windows briefly shows SET VALU and active display will blink to indicate the value that allows certain robot command values to the blinking LEDs under the display windows...

  • Page 35: Diagnostics

    7-2. Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors. Explanations are in the text below: TACH MOTR STRT STOP FLOW Indicates a Indicates a motor Indicates a wire Indicates an arc Indicates an arc Indicates a gas tachometer error.
  • Page 36 7-2. Diagnostics (Continued) WELD MOTR ROBT WAIT WAIT STOP Indicates a UIM Indicates a CRC Indicates an Indicates a weld Indicates a motor Indicates a low WFS communication error. robot memory error. emergency stop error. cycle wait error. communication error. command error.

  • Page 37: Removing Cover And Measuring Input Capacitor Voltage

    7-3. Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power source, disconnect input power. Significant DC voltage can Tools Needed: remain on capacitors after unit is Off. Always check the voltage as shown to be sure 5/16 in. the input capacitors have discharged before working on unit.

  • Page 38: Process Control Module Pc4 Diagnostic Leds

    7-4. Process Control Module PC4 Diagnostic LEDs Process Control Module PC4 Diagnostic LEDs are visible inside unit, located on PC4 mounted on the top tray. Refer to Section 7-5 for information on diagnostic LEDs. Reinstall cover after checking diagnostic LEDs. LED1 LED2 LED3...

  • Page 39: Wire Feed Module Pc6 Diagnostic Leds And Dip Switch Settings

    7-6. Wire Feed Module PC6 Diagnostic LEDs And Dip Switch Settings Wire Feed Module PC6 Diagnostic LEDs are visible inside unit, located on PC6 mounted on the top tray assembly. Refer to Section 7-7 for information on diagnostic LEDs. Reinstall top cover after checking diagnostic LEDs.

  • Page 40: User Interface Module Pc7 Diagnostic Leds

    7-8. User Interface Module PC7 Diagnostic LEDs LED1 LED2 218 559-A / 805 334-A User Interface Module PC7 Reinstall cover after checking diagnostic Dip switches are used to identify each circuit board on the internal network. Dip LEDs. Diagnostic LEDs are visible inside unit, switch settings are different for each circuit located on PC7 mounted behind the front board.

  • Page 41: Network And Module Status Leds

    7-10. Network And Module Status LEDs A. Network Status LEDs 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 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.

  • Page 42: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram For Welding Power Source (Part 1 Of 2) OM-240 146 Page 38...
  • Page 43 237 935-D (Part 1 Of 2) OM-240 146 Page 39...
  • Page 44 Figure 8-2. Circuit Diagram For Welding Power Source (Part 2 Of 2) OM-240 146 Page 40...
  • Page 45 237 935-D (Part 2 Of 2) OM-240 146 Page 41...
  • Page 46 Ref. 219 267-B Figure 8-3. Circuit Diagram For Peripheral/Motor Interface OM-240 146 Page 42...
  • Page 47 Notes OM-240 146 Page 43...

  • Page 48: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 4 Fig.9−3 5 Fig.9−2 7 Fig.9−4 16 Fig. 9−5 805 330-C Figure 9-1. Main Assembly OM-240 146 Page 44...
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....212543 . . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz ....
  • Page 50 Hardware is common and not available unless listed. 20 21 802 955-A Figure 9-2. Windtunnel Assembly LH And RH Item Dia. Part Mkgs. Description Quantity Figure 9-2. Windtunnel Assembly LH And RH (Fig 9-1 Item 6) ....214597 .
  • Page 51 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Windtunnel Assembly LH And RH (Fig 9-1 Item 6) ....201695 ..Clamp, Capacitor (Bottom) .
  • Page 52 Hardware is common and not available unless listed. 802 916-B Figure 9-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-3. Top Tray Assembly (Fig 9-1 Item 4) ..PC12 ..239623 .
  • Page 53 Hardware is common and not available unless listed. 805 331-B Figure 9-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-4. Rear Panel Assembly ....217297 .
  • Page 54 Hardware is common and not available unless listed. 802 918-C Figure 9-5. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-5. Front Panel Assembly ....207456 .
  • Page 55 Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 56 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2012 Miller Electric Mfg. Co. 2012−01...

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