Miller Electric PipePro Dual Owner's Manual
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Miller Electric PipePro Dual Owner's Manual

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PipePro Dual
DX Feeder
OM-230 009F
2008−01
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
File: MIG (GMAW)

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Summary of Contents for Miller Electric PipePro Dual

  • Page 1 PipePro Dual Visit our website at www.MillerWelds.com DX Feeder OM-230 009F 2008−01 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder File: MIG (GMAW)
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... . 1-2.

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

    DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment.
  • Page 6 OM-230 009 Page 2 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

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

    ACCUMULATIONS risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux.

  • Page 12: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures.

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
  • Page 14 OM-230 009 Page 10...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions S-178 936 A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage during operation −...

  • Page 16: Symbols And Definitions

    3-2. Symbols And Definitions Some symbols are found only on CE products. Amperes Degree Of Protection Set Up Purge Time Increase Primary Voltage SECTION 4 − INTRODUCTION 4-1. Specifications Type of Input Welding Power Power Source Type 40 Volts DC PipePro 450 RFC with 10 Amperes 14-Pin And Contactor...

  • Page 17: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Typical Connection Diagram For MIG Equipment Do not mount feeder on top of pow- er source. Do not put feeder where welding wire hits cylinder. Do not move or operate equipment when it could tip. Welding Power Source Negative Volt Sense Cable Positive (+) Weld Cable...

  • Page 18: Typical Connection Diagram For Tig Equipment

    5-2. Typical Connection Diagram For TIG Equipment Do not mount feeder on top of pow- er source. Do not put feeder where welding wire hits cylinder. Do not move or operate equipment when it could tip. Welding Power Source OM-230 009 Page 14 The illustration shows remote control connected through the wirefeeder.

  • Page 19: Typical Connection Diagram For Stick Equipment

    5-3. Typical Connection Diagram For Stick Equipment Do not mount feeder on top of pow- er source. Do not put feeder where welding wire hits cylinder. Do not move or operate equipment when it could tip. The illustration shows remote control connected through the wirefeeder. The wirefeeder is not connected to the power source output..

  • Page 20: Rear Panel Connections And Rotating Drive Assembly

    5-4. Rear Panel Connections And Rotating Drive Assembly Tools Needed: 9/16, 5/8 in 3/16 in OM-230 009 Page 16 14-Pin Control Cable Shielding Gas Valve Fittings Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. Weld Cable Terminal Jumper Weld Cable Weld Cable Drive Assembly...

  • Page 21: 14-Pin Plug Information

    5-5. 14-Pin Plug Information Pin* 40 volts dc with respect to socket G. Circuit common for 40 volts dc circuit. Contact closure to K completes contactor control circuit. Contact closure to B completes contactor control circuit. +10 volts dc input from power source to wire feeder with respect to socket D. Remote volt control circuit common.

  • Page 22: Installing And Threading Welding Wire

    5-6. Installing And Threading Welding Wire Install wire spools. Adjust tension nuts so wire is taut when wire feed stops. Pressure Indicator Pressure Scale Adjust Rear Rolls For best wire feeding performance, be sure that the outlet cable has the proper size liner for the welding wire size being used.

  • Page 23: Setting Internal Dip Switches

    5-7. Setting Internal DIP Switches Right Side Motor Control Board PC1 Position Settings And Results For DIP Switch S1 On PC1 And PC101 Automatic Run-In (ON) Automatic Run-In (OFF) (Factory Default) S1-1 And S1-2 Off = Run-In speed is set using On = Run-In speed is approximately 1/2 weld wire potentiometer P1 located on Motor...

  • Page 24: Display Board Dip Switch Settings

    5-8. Display Board DIP Switch Settings Tools Needed: 1/4 in OM-230 009 Page 20 Remove wrapper. Install wrapper when finished. Factory Set Default Settings For DIP Switches S1 And S4 In the DIP switch S1and S4 il- lustration, the elevated slider on each switch is shown in white.

  • Page 25: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Operational Terms The following is a list of terms and their definitions as they apply to this wire feeder: General Terms: Cold Wire Jog Feeding wire without contactor or gas valve being energized. Sequence A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow. Weld Program A group of sequences that make up a weld cycle.

  • Page 26: Jog/Purge Switch

    6-4. Jog/Purge Switch 6-5. Front Panel Controls Section Program Start Crater Pre/Postflow Sequence Section 6-11 OM-230 009 Page 22 V/Trim Time (sec) Wire Speed Amps Dual Schedule Trigger Hold Adjust Setup Section Section 6-10 Jog/Purge Switch Gun Trigger Receptacle Adjust Control Pressing the Jog/Purge switch allows the operator to jog wire without energizing the weld pow-...

  • Page 27: Program Push Button

    6-6. Program Push Button 6-7. Upper Display Upper Display The upper display shows voltage/trim or time. The unit displays both preset and actual arc voltage. When the unit is in a welding state, ac- tual arc voltage is displayed. The upper dis- play shows welding sequence time when the Time LED is illuminated.

  • Page 28: Lower Display

    6-8. Lower Display Lower Display The lower display shows wire speed or amperage. Lower Display Push Button Press button to choose between wire speed or amperage functions. Lower Display Push Button LED The lower display push button LED illuminates to indicate that wire feed speed can be ad- justed with the Adjust control.

  • Page 29: Adjust Control

    6-10. Adjust Control 6-11. Sequence Push Button Start Crater Pre/Postflow Sequence For more information on Setting Sequence Parameters see Section 7-1. The Sequence push button allows the selection of welding sequences. Five weld- ing sequences are available. The default sequence is the Weld sequence. The Weld sequence is active on power up.

  • Page 30: Auxiliary Menus

    6-12. Auxiliary Menus Program Start Crater Pre/Postflow Sequence Reset To Factory Settings A reset menu is displayed if the following four push buttons are pressed simulta- neously: Program, Sequence, upper dis- play, and Setup. The upper display indi- cates “WIPE” . The lower display indicates “OFF”.
  • Page 31 Only one of the values needs to be set to enable the program. For example, setting a Trim of 100 and leaving the Wire Speed at OFF will allow the welder to adjust the Wire Speed to full range Wire Feed Speed Units Wire feed speed setting indicated by “WFS”...

  • Page 32: Remote-14 Receptacle Information

    6-13. Remote-14 Receptacle Information OM-230 009 Page 28 If the remote switch is set to MIG, the feeder operates normally. A re- mote control may be left attached while the remote switch is in the MIG mode, as the remote has no af- fect on the operation of the wire feeder.

  • Page 33: Section 7 − Setting Sequence Parameters

    SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program Sequence 1. Preflow 2. Run-In 3. Start 4. Weld 5. Crater 6. Burnback 7. Postflow X = Setting available. Preflow Time Run-In Start Preflow Trigger Pressed SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS 8-1.

  • Page 34: Diagnostics

    8-2. Diagnostics Note: The error messages are shown on the upper and lower displays to indi- cate specific errors. Ex- planations are in the text below: LED3-Related Error Indications Error conditions are indicated by LED3 on PC1, PC101, and LED4 on PC70. To view LED3, 4 turn Off unit, remove wrapper, and turn unit On.

  • Page 35: Section 9 − Maintenance & Troubleshooting

    SECTION 9 − MAINTENANCE & TROUBLESHOOTING 9-1. Routine Maintenance n = Check ~ = Clean Every Months l Unreadable Labels ~ Weld Terminals n 14-Pin Cord n Gas Hose and Fittings Every Months ~ Inside Unit ~ Drive Rolls Disconnect power before maintaining. l = Replace nl Weld Cable n Gun Cable...

  • Page 36: Troubleshooting

    9-2. Troubleshooting Trouble Wire feeds, shielding gas flows, but Check cable connections. Check cables for continuity, and repair or replace cables if necessary electrode wire is not energized. (see Section 5-4). Wire feeder is on, display does not light Check and reset circuit breaker at welding power source. up, motor does not run, gas valve and welding power source contactor do not pull in.
  • Page 37 Notes MATERIAL THICKNESS GAUGE OM-230 009 Page 33...

  • Page 38: Section 10 − Electrical Diagram

    SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram OM-230 009 Page 34...
  • Page 39 229 867-A OM-230 009 Page 35...

  • Page 40: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. Fig.11−3 Fig.11−2 804 741-A Figure 11-1. Main Assembly OM-230 009 Page 36...
  • Page 41 Item Part ....159 647 ....159 646 .
  • Page 42 Item Dia. Part Mkgs....204 722 ......
  • Page 43 Item Dia. Part Mkgs..GS1,101 . . . 219 047 ....010 494 ....134 201 .
  • Page 44 Hardware is common and not available unless listed. See Table 11-1 For Drive Roll & Wire Guide Kits Item Dia. Part Mkgs....010 668 .
  • Page 45 Item Dia. Part Mkgs..... . 203 642 ..... 203 631 .
  • Page 46 Guide Intermediate Guide Inlet OM-230 009 Page 42...
  • Page 47 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 48: Owner's Record

    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. 2008 Miller Electric Mfg. Co. 2008−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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