Miller Electric Axcess 450 Troubleshooting, Removing Cover and Measuring Input Capacitor Voltage

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SECTION 9 − TROUBLESHOOTING

9-1. Removing Cover and Measuring Input Capacitor Voltage

Tools Needed:

5/16 in

!900 Volts dc can be present on the capacitor bus and significant DC voltage can remain on capacitors after unit is Off. Always check the voltage on both inverter assemblies as shown to be sure the input capacitors have discharged before working on unit.

Turn Off welding power source, and disconnect input power.

Remove cover

1Power Interconnect Board PC2

2Voltmeter

Measure the dc voltage across the + bus terminal and − bus terminal on PC2 as shown until voltage drops to near 0 (zero) volts. Measure input capacitor voltage on both inverter assemblies before proceeding.

3 Typical Bleeder Resistor

An example of a typical bleeder resistor is shown on this page.

Proceed with job inside unit.

Reinstall cover when finished.

1

2

+ lead to left bus terminal, − lead to right bus terminal

1

2

3

Typical Bleeder Resistor

25 to 1000 ohm, 5

watt resistor

+ lead to left bus terminal, − lead to right bus terminal

#16 AWG 1000 volts dc insulation rating, approx 3 in (76 mm) leads

802 985 / Ref. 803 419-B

OM-220 389 Page 32

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Contents Description OM-220 389JProcesses File Advanced Manufacturing SystemsFrom Miller to You Table of Contents − Troubleshooting Decstat1/07 DirectivesStandards Page Electric 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-220 389 Manufacturer’s Warning Label Definitions Disconnect input plug or power before working on machine− Definitions Keep your head out of the fumesWeee Label I1eff Symbols And DefinitionsI1max Manufacturer’s Rating LabelDimensions 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 Rear Panel Receptacles And Supplementary Protectors Connecting To Weld Terminals Incorrect InstallationPin Network Wire Feeder Receptacle FunctionsElectrical Service Guide 50/60 HzDisconnect Device Input Power Connections Connecting Input PowerWelding Power Source Input Power Connections − Recommended Setup Procedures Selecting Weld Cable SizesWelding Circuit Gun TravelWCL Current Flow PathBest Using Multiple Welding Power Sources Bad Setup Wire Feeder Drop in the workpiece. The voltage dropBetter Setup Supporting separate voltage feedback to OM-220 389Best Setup PDA Port PC Port OM-220 389 Front Panel Switches− Operation Blowing Out Inside of Unit − MaintenanceRoutine Maintenance Servicing Hazards − Safety Precautions for ServicingShock Hazard from testing Exploding Parts can cause injuryCalifornia Proposition 65 Warnings − Troubleshooting Removing Cover and Measuring Input Capacitor VoltageStatus Diagnosis Process Control Module PC4 Diagnostic LED’sDiagnostic LED’s On Process Control Module PC4 Red Network And Module Status LED’s Network Status LED’sModule Status LED’s Circuit board is operating normallyTroubleshooting Trouble Remedy− Electrical Diagrams Circuit Diagram For Welding Power Source220 420-B − Parts List 16 − FigWindtunnel Assembly LH And RH Windtunnel Assembly LH And RH -1Item Top Tray Assembly Rear Panel Assembly Front Panel Assembly Dia 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