Miller PipePro XC Owner's Manual
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Miller PipePro XC Owner's Manual

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PipePro XC
Welding System
(380-400 Volt Model)
CE
OM-269631D
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Stick (SMAW) Welding
Description
Arc Welding Power Source
Wire Feeder
R
File: MIG (GMAW)
2016−07

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Summary of Contents for Miller PipePro XC

  • Page 1 OM-269631D 2016−07 Processes MIG (GMAW) and Pulsed MIG (GMAW-P) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding Description Arc Welding Power Source Wire Feeder PipePro XC Welding System (380-400 Volt Model) File: MIG (GMAW) Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 ..............6-6. PipePro XC RMD Feeder Front Panel Controls .

  • Page 5: Declaration Of Conformity

    DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
  • Page 6 EMF DATA SHEET FOR ARC WELDING POWER SOURCE Product/Apparatus Identification Product Stock Number PIPEPRO 400XC 380/400V (CE) 907675 Compliance Information Summary Applicable regulation Directive 2014/35/EU Reference limits Directive 2013/35/EU, Recommendation 1999/519/EC Applicable standards IEC 62822-1:2016, IEC 62822-2:2016 Intended use for occupational use for use by laymen Non-thermal effects need to be considered for workplace assessment Thermal effects need to be considered for workplace assessment...

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 8 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 14: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.
  • Page 16 Disconnect input plug or power before working on machine. Safe5 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Flying pieces of parts can cause injury. Always wear a face shield when servicing unit. Safe27 2012−05 Always wear long sleeves and button your collar when servicing unit.
  • Page 17 Consult rating label for input power requirements. Safe34 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. Safe33 2012−05 Do not use one handle to lift or support unit. Safe31 2012−05 Environmental Protection Use Period (China) Safe123 2016−06...

  • Page 18: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Direct Current Alternating Amperage Voltage (DC) Current (AC) Protective Earth Circuit Breaker (Ground) Shielded Metal Arc High Frequency - Negative Positive Welding (SMAW) General Three Phase Static Frequency Con- Gas Metal Arc Increase Line Connection verter- Welding (GMAW) Transformer-...

  • Page 19: Section 4 − Specifications

    Input Power Overall Dimensions Circuit Source Type Range Range Rating 24 Volts AC PipePro XC 1.3 To 12.7 mpm 0.9 To 1.2 mm 100 Volts, Length: 508 mm (20 in.) 15.2 kg 9 Amperes (50 To 500 ipm) (.035 To .045 in.) 500 Amperes, Width: 203 mm (8 in.)

  • Page 20: Environmental Specifications

    4-4. Environmental Specifications A. IP Rating IP Rating IP23 This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless sheltered. IP23 2014−06 B. Information On Electromagnetic Compatibility (EMC) This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−...

  • Page 21: Mig Duty Cycle And Overheating

    4-5. MIG Duty Cycle and Overheating A. 405 C (1045 F) Operation Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.
  • Page 22 B. 505 C (1225 F) Operation Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

  • Page 23: Stick Duty Cycle And Overheating

    4-6. Stick Duty Cycle and Overheating A. 405 C (1045 F) And 505 C (1225 F) Operation Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs.

  • Page 24: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 25: Equipment Connection Diagram For Self-Shielded Flux Core

    5-2. Equipment Connection Diagram For Self-Shielded Flux Core Turn Off wire feeder and welding power source. Use only with the PipePro XC Power Source. PipePro XC Welding Power Supply Weld Cable To Feeder Electrode Negative Work Cable To Workpiece Weld cable and work cable connec- tions to power source.

  • Page 26: Equipment Connection Diagram For Mig/Rmd

    5-3. Equipment Connection Diagram For MIG/RMD Turn Off wire feeder and welding power source. Use only with the PipePro XC Power Sources. PipePro XC Welding Power Supply Weld Cable To Feeder Work Cable To Workpiece Weld cable and work cable connec- tions to power source.

  • Page 27: Remote 14 Accessory Receptacle Information

    5-4. Remote 14 Accessory Receptacle Information If a remote control is connected to the Remote 14 receptacle, the unit will automatically adjust output control to a primary/secondary configuration. In this configuration, the Amperage Adjust knob on the unit becomes the primary and sets the maximum amperage output of the unit. The remote control becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage Adjust knob setting.

  • Page 28: Supplementary Protector Cb2

    5-6. Supplementary Protector CB2 Supplementary Protector CB2 CB2 protects the 24 volts ac power supply to the wire feeder. Press button to reset supplementary protector. Ref. 250 702-B Notes OM-269631 Page 22...

  • Page 29: Connecting To Weld Output Terminals

    5-7. Connecting To Weld Output Terminals Turn off power before connecting to weld output terminals. Do not use worn, damaged, under- sized, or repaired cables. Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal Connect positive weld cable to Positive (+) weld terminal and negative (−) cable to Negative weld terminal.

  • Page 30: Weld Output Terminals And Selecting Cable Sizes

    **Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ( ) = mm for metric use ***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart). Ref. S-0007-L 2015−02 Notes...

  • Page 31: Electrical Service Guide

    5-10. Electrical Service Guide Elec Serv 2014−01 NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera- tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

  • Page 32: Connecting 3-Phase Input Power

    5-11. Connecting 3-Phase Input Power GND/PE Earth Ground Tools Needed: 5/16 in. input5 2016−04 Ref. 269 652 OM-269631 Page 26...
  • Page 33 5-11. Connecting 3-Phase Input Power (Continued) Select size and length of conductors using Input Conductors L1, L2, L3 Turn Off welding power source, and Section 5-10. Conductors must comply with check voltage on input capacitors Connect input conductors L1, L2, and L3 to national, state, and local electrical codes.

  • Page 34: Proper Ring Terminal Connection To Work Sense Lead

    5-12. Proper Ring Terminal Connection To Work Sense Lead If work sense lead is cut or broken at end Jacket Center Conductor with ring terminal, be sure that new ring ter- Insulated Tape Or Heat-Shrink minal is connected as shown. Tubing Ring Terminal 1/2 in.

  • Page 35: Wire Feeder Remote 14 Control Receptacle Information

    5-14. Wire Feeder Remote 14 Control Receptacle Information Remote 14 Feeder Control Socket* Socket Information A, B 24 volts AC. Protected by supplementary protector CB2. 24 VOLTS AC C, D 24 volts AC return. Connected to chassis common. Completes 24 volts AC power supply circuit to feeder.

  • Page 36: Installing And Aligning Wire Guide And Drive Rolls

    5-16. Installing And Aligning Wire Guide And Drive Rolls Installing Wire Guide And Drive Rolls: Drive Roll Nut Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier. Drive Roll Slide drive roll onto drive roll carrier. Turn nut one click.

  • Page 37: Connecting Welding Gun

    5-17. Connecting Welding Gun Turn Off wire feeder and welding power source. Gun Securing Knob Gun Block Gun Power Pin Power Pin Groove Gun Locking Tab Loosen knob, insert gun end into block. Position power pin as close as possible to drive rolls without touching.

  • Page 38: Connecting Shielding Gas

    5-18. Connecting Shielding Gas Gas Hose With 5/8-18 Right-hand Thread Fittings Shielding Gas Cylinder Shielding gas pressure not to exceed 90 psi (620 kPa). Rear View Valve Flowmeter Close valve on cylinder when fin- ished welding. Items 1−4 are user supplied. Tools Needed: 5/8 in.

  • Page 39: Installing And Threading Welding Wire

    5-20. Installing And Threading Welding Wire Installing Wire And Adjusting Hub Tension: Retaining Nut Hub Tension Adjustment Screw Remove retaining ring, and install Hold wire tightly spool so hub pin fits spool hole. Re- to keep it from install retaining nut. unraveling.

  • Page 40: 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 interface unit: General Terms: Amps Indicates average amperage while welding and holds the value for 10 seconds at end of weld. Arc Control The adjustment of arc cone width and arc characteristics in the SS FCAW, MIG and RMD processes.

  • Page 41: Ce Welding Power Source Controls

    6-2. CE Welding Power Source Controls 269 545-A Stick Process Select Button Feeder Select Button Memory Card In Use Indicator Light AMPS Display Memory Card Program Save Button Electrode Select Button Amperage Adjustment Knob Memory Card Program Load Button Memory Card Busy Indicator Light The memory card slot uses an SD memory card.

  • Page 42: Welding Power Source Operation Description

    6-3. Welding Power Source Operation Description Stick Process Select Press and release this button to activate the stick welding process controls. The STICK text below the button Button illuminates as well as the active stick electrode type text and the swoosh above the amperage adjustment knob. The operator must select the desired stick electrode type and adjust the amperage knob to the appropriate setting within a range from 40 to 350 amps.

  • Page 43: Memory Card Slot

    6-4. Memory Card Slot Memory Card Slot A. Description Memory Card Slot This is the memory card slot. A memory card can be inserted into the slot and used for storing and retrieving operator settings, providing custom MIG type weld process data, and loading software updates to the unit. If the power source has multiple users, each user may use a card to store and load their own personal settings.

  • Page 44: Feeder Units Switch

    6-5. Feeder Units Switch Feeder Units Switch Switch position up for inches per minute. Switch position down for meters per minute. Ref. 250 764-A Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.

  • Page 45: Pipepro Xc Rmd Feeder Front Panel Controls

    6-6. PipePro XC RMD Feeder Front Panel Controls 269 634-A Power Control Button Wirespeed Adjustment Knob 10 FCAW Process Select Button Purge Button 11 MIG Process Select Button Volts/Arc Length Display Arc Control Button 12 Wire Diameter Select Button Wirespeed/Amps Display...

  • Page 46: Pipepro Xc Rmd Feeder Ce Operation Description

    6-7. PipePro XC RMD Feeder CE Operation Description Power Control Button Press this button to power up or power down the wire feeder. When powered down, the feeder is still in a standby mode allowing it to power up when the power control button is pressed. When in the standby mode, a decimal point will flash in the lower right corner of the wire speed display.
  • Page 47 6-7. PipePro XC RMD Feeder Operation Description (Continued) FCAW Process Select Press this button to select the desired FCAW process. Possible selections include “NO GAS” (self-shielded Button FCAW) or “GAS” (gas-shielded FCAW). The process type text will illuminate to show the active process.

  • Page 48: Section 7 − Maintenance And Troubleshooting

    SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. n = Check ~ = Clean l = Replace Every Months l Unreadable Labels ~ Weld Terminals nl Weld Cable l Cracked Parts n 14-Pin Cord n Gas Hose and Fittings n Gun Cable l Cracked Electrode nl Gun Cables...

  • Page 49: Cleaning Debris From Shielding Gas Filter Fitting

    7-3. Cleaning Debris From Shielding Gas Filter Fitting Disconnect power before maintaining. Shielding Gas Filter Fitting Remove fitting from gas valve on Rear View of Feeder back panel of feeder. Blow compressed air through the threaded male end of fitting to dis- lodge debris from internal mesh screen.

  • Page 50: Restoring Factory Defaults

    7-4. Restoring Factory Defaults Full System A full factory reset can be accomplished by pressing STICK and FEEDER buttons on the power source simultaneously for more than four seconds. The display will show “rSt” and then go to dashes when the reset is complete. 7-5.

  • Page 51: Removing Right Side Panel And Measuring Input Capacitor Voltage

    7-7. Removing Right Side Panel and Measuring Input Capacitor Voltage Turn Off welding power source, disconnect input power. Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.

  • Page 52: Welding Power Source And Feeder Diagnostic Help Codes

    7-8. Welding Power Source And Feeder Diagnostic Help Codes Display Example Display Code Fault Description Primary Power Circuit Over Current Indicates a malfunction in the primary power circuit. If this code appears on the display, contact the nearest Factory Authorized Service Agent.
  • Page 53 7-8. Welding Power Source And Feeder Diagnostic Help Codes (Continued) Trigger Stuck Indicates trigger stuck fault. Fault will clear when trigger is re- leased. Trigger Fault Indicates trigger was held too long in trigger jog (the lesser of 60 seconds or 30 ft (9.1 m) of wire. Memory Card Fault Indicates unable to read memory card.

  • Page 54: Troubleshooting Welding Power Source/Wire Feeder Issues

    7-9. Troubleshooting Welding Power Source/Wire Feeder Issues If the welding power source and wire feeder are NOT responding after everything is connected, follow the items listed below before contacting the nearest factory-authorized service agent: Welding power source is plugged in and there is no power after turning on unit. If unit is directly connected to a line disconnect box or plugged into a receptacle from a line disconnect box, be sure that the line disconnect switch or main breaker is in the ON position.

  • Page 55: Welding Power Source Troubleshooting

    7-10. Welding Power Source Troubleshooting Trouble Remedy No weld output; unit completely in- Place line disconnect switch in On position (see Section 5-11). operative. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11). Check for proper input power connections (see Section 5-11). No weld output;...

  • Page 56: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For CE Welding Power Source OM-269631 Page 50...
  • Page 57 269 637-D OM-269631 Page 51...
  • Page 58 Figure 8-2. Circuit Diagram For XC RMD Wire Feeder CE OM-269631 Page 52...
  • Page 59 269 639-A OM-269631 Page 53...

  • Page 60: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 269 788-A Figure 9-1. Main Assembly OM-269631 Page 54...
  • Page 61 ..269696 Bracket, Mtg Standoff Filter Board Pipepro Xc (CE) ..... .
  • Page 62 Hardware is common and not available unless listed. 269 788-A Figure 9-2. Base Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-2. Base Assembly ... . . 250139 Base ............. . .
  • Page 63 Hardware is common and not available unless listed. 269 788-A Figure 9-3. Windtunnel Assembly LH And RH Item Dia. Part Mkgs. Description Quantity Figure 9-3. Windtunnel Assembly LH And RH ......Windtunnel, LH w/Cmpnts .
  • Page 64 Item Dia. Part Mkgs. Description Quantity Figure 9-3. Windtunnel Assembly LH And RH (Continued) ..173632 ..Thermistor, NTC 30K Ohm @ 25 Deg C 12.00In Lead ....
  • Page 65 Hardware is common and not available unless listed. 269 788-A Figure 9-4. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-4. Front Panel Assembly ... . . 248777 Panel Assy, Front .
  • Page 66 Hardware is common and not available unless listed. 269 788-A Figure 9-5. Control Board Bracket Assembly Item Dia. Part Mkgs. Description Quantity Figure 9-5. Control Board Bracket Assembly ... . . 248768 Bracket, Mtg Circuit Cards .
  • Page 67 Hardware is common and not available unless listed. Ref. 254 973-A Figure 9-6. XC RMD Wire Feeder CE Assembly OM-269631 Page 61...
  • Page 68 Item Dia. Part Mkgs. Description Quantity Figure 9-6. XC RMD Wire Feeder CE Assembly ... . . 248814 Case, Control Feeder Machined SC 12 Blk ......
  • Page 69 Item Dia. Part Quantity Mkgs. Description Figure 9-6. XC RMD Wire Feeder CE Assembly (Continued) ....079607 Kit, Drive Roll .045 VK−Gr 2 Roll ........
  • Page 70 Notes...
  • Page 71 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 72 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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