Miller Electric Auto Axcess 675 manual Safety Precautions for Servicing, Servicing Hazards

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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 the adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text.

NOTICE − Indicates statements not related to personal injury.

.Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards.

6-2. Servicing Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.

Only qualified persons should test, maintain, and repair this unit.

During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

DDo not touch live electrical parts.

DTurn Off welding power source and wire feeder

and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from re- ceptacle, or stop engine before servicing unless the procedure spe- cifically requires an energized unit.

DInsulate yourself from ground by standing or working on dry insulat- ing mats big enough to prevent contact with the ground.

DDo not leave live unit unattended.

DIf this procedure requires an energized unit, have only personnel familiar with and following standard safety practices do the job.

DWhen testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free.

DDisconnect input power conductors from deenergized supply line BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

DTurn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Troubleshooting Section be- fore touching any parts.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

DDo not place unit on, over, or near combustible surfaces.

DDo not service unit near flammables.

FLYING METAL or DIRT can injure eyes.

DWear safety glasses with side shields or face shield during servicing.

DBe careful not to short metal tools, parts, or wires together during testing and servicing.

HOT PARTS can cause severe burns.

DDo not touch hot parts bare handed.

DAllow cooling period before working on equipment.

DTo handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

EXPLODING PARTS can cause injury.

DFailed parts can explode or cause other parts to explode when power is applied to inverters.

DAlways wear a face shield and long sleeves when servicing inverters.

SHOCK HAZARD from testing.

DTurn Off welding power source and wire feeder or stop engine before making or changing me- ter lead connections.

DUse at least one meter lead that has a self- retaining spring clip such as an alligator clip.

DRead instructions for test equipment.

OM-201 540 Page 32

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Contents OM-201 540K ProcessesDescription File Advanced Manufacturing SystemsFrom Miller to You Table of Contents Warranty Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal or Dirt can injure eyesWelding Wire can cause injury Fire or Explosion hazardFalling Unit can cause injury Moving Parts can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information About Implanted Medical DevicesSymboles utilisés UNE Décharge Électrique peut entraîner la mortDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut endommager l’ouïe LES Bouteilles peuvent exploser si elles sont endommagéesRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesserProposition californienne 65 Avertissements LES Fils DE Soudage peuvent provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécurité Information EMFEn ce qui concerne les implants médicaux OM-201 540 − Installation SpecificationsDimensions And Weight Duty Cycle And Overheating Volt-Ampere Curves100% Duty Cycle At 675 Amperes OverheatingConnection Diagram Selecting a LocationMovement Do not move or operate Tipping Do not stack units. Beware of tippingRear Panel Receptacles And Supplementary Protectors Connecting To Weld Terminals Incorrect InstallationSelecting Weld Cable Sizes Peripheral Receptacle Functions Socket InformationMotor Control Receptacle Functions Electrical Service Guide Hz Three Phase Input VoltageInput Amperes At Rated Output Normal OperatingConnecting Input Power Welding Power Source Input Power ConnectionsDisconnect Device Input Power Connections Remote Program Setting Touch Sensor OperationRemote Program Select Program No Output a Output B Output C− Operation Operational TermsStart WeldCrater PostflowWire Type LED Front Panel Controls See SectionProcess LED Gas Type LEDSTL Front Panel Switches Robot AbbreviationsManufacturer Robot Abbreviation Xxxx Robot TypeRobot Calibration Mode Schedule100 IPM 1000 IPM Robot Auto-Calibration Sample Programs Actual Motoman Welder Condition FileSample Auto-Calibration Routine For Motoman Robot Sample Auto-Calibration Routine For Fanuc Robot Sample Auto-Calibration Routine For ABB RobotWeld Data Reset Mode PulseMild Steel Accu-pulse− Maintenance Routine MaintenanceBlowing Out Inside Of Unit − Safety Precautions for Servicing Shock Hazard from testingServicing Hazards Exploding Parts can cause injuryCalifornia Proposition 65 Warnings − Troubleshooting Set Value ModeDiagnostics On error Indicates a trigger closed errorIndicates RMD demo is done Indicates an overRemoving Cover and Measuring Input Capacitor Voltage Process Control Module PC4 Diagnostic LED’s Diagnostic LED’s On Process Control Module PC4Status Diagnosis Diagnostic LED’s On Wire Feed Module PC6 User Interface Module PC7 Diagnostic LED’s Diagnostic LED’s On User Interface Module PC7Automation Interface Module PC9 Diagnostic LED’s LED33LED32 Diagnostic LED’s On Automation Interface Module PC9 Input signal on from relay K6 for arc detected Input signal off from relay K6 for no arc detectedInput signal on for aux. relay energized Input signal off for aux. relay energizedNetwork And Module Status LED’s Network Status LED’s Module Status LED’sRed Circuit board is operating normallyTroubleshooting Trouble Remedy− Electrical Diagrams Circuit Diagram For Welding Power Source 1198 992-G Part 1 Circuit Diagram For Welding Power Source 2 198 992-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 − Fig− Fig Windtunnel Assembly LH And RH Windtunnel Assembly LH And RH -1Item Top Tray Assembly Rear Panel Assembly Front Panel Assembly Description Quantity Page Page Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s