Miller Electric Auto-Axcess 450 manual Connecting To Weld Terminals, Incorrect Installation

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3-8. Connecting To Weld Terminals

.If using an electrode negative (straight polarity) process, the volt sense lead must be connected to the work.

1

6

2

3

Do not place

anything between

weld cable terminal and copper bar.

4

5

Tools Needed:

3/4 in (19mm)

Correct Installation

Incorrect Installation

Ref. 803 244-B / 803 778-A

!Turn off power before connecting to weld output terminals.

!Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine.

Determine total cable length in weld circuit (both positive and negative cables combined) and maximum welding amperes. See Section 3-9to select proper

cable size.

1Positive (+) Weld Output Terminal

2Negative (−) Weld Output Terminal

Connect positive weld cable to Positive (+) weld terminal and negative (−) cable to Negative weld terminal.

3Weld Output Terminal

4Supplied Weld Output Terminal Nut

5Weld Cable Terminal

6 Copper Bar

Remove supplied nut from weld output terminal. Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar. Do not place anything between weld cable terminal and copper bar. Make sure that the surfaces of the weld cable terminal and copper bar are clean.

OM-210 540 Page 15

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Contents File Advanced Manufacturing Systems OM-210 540SProcesses DescriptionFrom Miller to You Table of Contents Troubleshooting − TroubleshootingHOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killFlying Metal or Dirt can injure eyes Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionMoving Parts can cause injury Welding Wire can cause injuryFire or Explosion hazard Falling Unit can cause injuryAbout Implanted Medical Devices Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationUNE Décharge Électrique peut entraîner la mort Symboles utilisésLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion LA Chute DE L’APPAREIL peut blesser LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées Risque D’INCENDIE OU D’EXPLOLES Fils DE Soudage peuvent provoquer des blessures Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences Information EMF Principales normes de sécuritéEn ce qui concerne les implants médicaux OM-210 540 17-3/32 in 434 mm 17-3/8 in 441 mm 19-3/32 in 485 mm − InstallationSpecifications Dimensions And WeightOverheating Duty Cycle And OverheatingVolt-Ampere Curves 100% Duty Cycle At 450 AmperesPositive + Weld Cable Connection DiagramSelecting a Location Do not stack units. Beware of tippingRear Panel Receptacles And Supplementary Protectors Incorrect Installation Connecting To Weld TerminalsSelecting Weld Cable Sizes Function Socket Socket Information Peripheral Receptacle FunctionsMotor Control Receptacle Functions 136 263 228 356 Electrical Service GuideHz Three Phase Input Voltage 230 400 460 575Welding Power Source Input Power Connections Connecting Input PowerDisconnect Device Input Power Connections Program No Output a Output B Output C Remote Program SettingTouch Sensor Operation Remote Program SelectOperational Terms − OperationPostflow StartWeld CraterGas Type LED Wire Type LEDFront Panel Controls See Section Process LEDSTL Xxxx Robot Type Front Panel SwitchesRobot Abbreviations Manufacturer Robot AbbreviationSchedule Robot Calibration Mode100 IPM 1000 IPM Actual Motoman Welder Condition File Robot Auto-Calibration Sample ProgramsSample Auto-Calibration Routine For Motoman Robot Sample Auto-Calibration Routine For ABB Robot Sample Auto-Calibration Routine For Fanuc RobotWeld Data Accu-pulse Reset ModePulse Mild SteelRoutine Maintenance − MaintenanceBlowing Out Inside Of Unit Exploding Parts can cause injury − Safety Precautions for ServicingShock Hazard from testing Servicing HazardsCalifornia Proposition 65 Warnings Set Value Mode − TroubleshootingDiagnostics Indicates RMD demo is done Command errorIndicates a CRC PCM bus error Indicates a UIMIndicates a trigger closed error Indicates a contactor on errorRemoving Cover and Measuring Input Capacitor Voltage Status Diagnosis Process Control Module PC4 Diagnostic LED’sDiagnostic LED’s On Process Control Module PC4 Process Control Module PC4Diagnostic LED’s On Wire Feed Module PC6 Diagnostic LED’s On User Interface Module PC7 User Interface Module PC7 Diagnostic LED’sLED33 Automation Interface Module PC9 Diagnostic LED’sLED32 Diagnostic LED’s On Automation Interface Module PC9 Input signal off for aux. relay energized Input signal on from relay K6 for arc detectedInput signal off from relay K6 for no arc detected Input signal on for aux. relay energizedCircuit board is operating normally Network And Module Status LED’s Network Status LED’sModule Status LED’s RedTrouble Remedy TroubleshootingOM-210 540 Circuit Diagram For Welding Power Source Part 1 − Electrical Diagrams207 903-G Part 1 Circuit Diagram For Welding Power Source Part 2 207 903-G Part 2 Circuit Diagram For 72 Pin Robot Interface 219 266-C Circuit Diagram For Peripheral/Motor Interface 219 267-B 16 − Fig − Parts ListWindtunnel Assembly LH And RH Windtunnel Assembly LH And RH -1Item Top Tray Assembly Rear Panel Assembly Front Panel Assembly -1Item Front Panel AssemblyDia Part Your distributor also gives ServiceSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact