Miller Electric Auto-Axcess 450 manual Troubleshooting, Trouble Remedy

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7-13. Troubleshooting

 

 

 

 

 

 

 

 

 

 

 

 

 

Trouble

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

Check to see if the contactor indicator light is lit when contactor line is asserted on.

error displayed.

 

 

 

 

 

Erratic or improper weld output with no

Use proper size and type of weld cable (see Section 3-9).

errors displayed.

 

Check that proper program for wire size, process, and shielding gas is loaded.

 

 

 

 

 

 

 

 

 

 

Clean and tighten all weld connections.

 

 

 

 

No 115 volts AC at the duplex receptacle.

Reset supplementary 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 tension.

 

 

 

 

 

 

 

Readjust drive roll pressure.

 

 

 

 

 

 

 

Clean or replace dirty or worn drive rolls.

 

 

 

 

 

 

 

Remove weld spatter around the nozzle opening.

 

 

 

 

 

 

 

Replace contact tip or liner. See gun Owner’s Manual.

 

 

 

 

 

 

 

Check motor control cable connections.

 

 

 

 

Wire feeds as soon as power is supplied.

Check gun trigger. See gun Owner’s Manual.

 

 

 

 

Wire stubbing on low end using a

Increase output setting of the power source.

constant current power source.

 

Check voltage sense lead connection, clean and tighten if necessary.

 

 

 

 

 

 

 

Gas does not flow or does not stop flow-

Check gas valve and flow meter.

ing; wire feeds.

 

 

 

 

 

Wire burns back to gun contact tip when

Check to be sure that volt sense lead is connected to the work.

using electrode negative (straight

 

polarity) process.

 

 

 

 

 

OM-210 540 Page 46

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Contents Description OM-210 540SProcesses File Advanced Manufacturing SystemsFrom Miller to You Table of Contents − Troubleshooting TroubleshootingElectric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsWelding can cause fire or explosion Fumes and Gases can be hazardousARC Rays can burn eyes and skin Flying Metal or Dirt can injure eyesFalling Unit can cause injury Welding Wire can cause injuryFire or Explosion hazard Moving Parts can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings About Implanted Medical DevicesSymboles utilisés UNE Décharge Électrique peut entraîner la mortLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux Risque D’INCENDIE OU D’EXPLO LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-210 540 Dimensions And Weight − InstallationSpecifications 17-3/32 in 434 mm 17-3/8 in 441 mm 19-3/32 in 485 mm100% Duty Cycle At 450 Amperes Duty Cycle And OverheatingVolt-Ampere Curves OverheatingDo not stack units. Beware of tipping Connection DiagramSelecting a Location Positive + Weld CableRear Panel Receptacles And Supplementary Protectors Connecting To Weld Terminals Incorrect InstallationSelecting Weld Cable Sizes Peripheral Receptacle Functions Function Socket Socket InformationMotor Control Receptacle Functions 230 400 460 575 Electrical Service GuideHz Three Phase Input Voltage 136 263 228 356Disconnect Device Input Power Connections Connecting Input PowerWelding Power Source Input Power Connections Remote Program Select Remote Program SettingTouch Sensor Operation Program No Output a Output B Output C− Operation Operational TermsCrater StartWeld PostflowProcess LED Wire Type LEDFront Panel Controls See Section Gas Type LEDSTL Manufacturer Robot Abbreviation Front Panel SwitchesRobot Abbreviations Xxxx Robot Type100 IPM 1000 IPM Robot Calibration ModeSchedule Sample Auto-Calibration Routine For Motoman Robot Robot Auto-Calibration Sample ProgramsActual Motoman Welder Condition File Weld Data Sample Auto-Calibration Routine For Fanuc RobotSample Auto-Calibration Routine For ABB Robot Mild Steel Reset ModePulse Accu-pulseBlowing Out Inside Of Unit − MaintenanceRoutine Maintenance Servicing Hazards − Safety Precautions for ServicingShock Hazard from testing Exploding Parts can cause injuryCalifornia Proposition 65 Warnings − Troubleshooting Set Value ModeDiagnostics Indicates a UIM Command errorIndicates a CRC PCM bus error Indicates RMD demo is doneIndicates a contactor on error Indicates a trigger closed errorRemoving Cover and Measuring Input Capacitor Voltage Process Control Module PC4 Process Control Module PC4 Diagnostic LED’sDiagnostic LED’s On Process Control Module PC4 Status DiagnosisDiagnostic LED’s On Wire Feed Module PC6 User Interface Module PC7 Diagnostic LED’s Diagnostic LED’s On User Interface Module PC7LED32 Automation Interface Module PC9 Diagnostic LED’sLED33 Diagnostic LED’s On Automation Interface Module PC9 Input signal on for aux. relay energized Input signal on from relay K6 for arc detectedInput signal off from relay K6 for no arc detected Input signal off for aux. relay energizedRed Network And Module Status LED’s Network Status LED’sModule Status LED’s Circuit board is operating normallyTroubleshooting Trouble RemedyOM-210 540 − Electrical Diagrams Circuit Diagram For Welding Power Source Part 1207 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 − Parts List 16 − FigWindtunnel Assembly LH And RH Windtunnel Assembly LH And RH -1Item Top Tray Assembly Rear Panel Assembly Front Panel Assembly Front Panel Assembly -1ItemDia Part Support ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s