Miller PipePro 450 RFC Owner's Manual
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Miller PipePro 450 RFC Owner's Manual

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PipePro 450 RFC
OM-223 586S
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Multiprocess Welding
Description
Arc Welding Power Source
R
File: Pipe Welding Products
2009−12

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Summary of Contents for Miller PipePro 450 RFC

  • Page 1 Stick (SMAW) Welding MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding TIG (GTAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Multiprocess Welding Description Arc Welding Power Source PipePro 450 RFC File: Pipe Welding Products 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

    ........5-14. PipePro 450 RFC Set Up For Carbon Arc Gouging (CAC-A) Equipment...
  • Page 4 ..........5-21. Welding Stainless Steel With And Without Backing Gas Using PipePro 450 RFC .

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2009−08 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 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 oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: 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 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2009−08 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 Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

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

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-223 586 Page 10...

  • 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. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand.

  • Page 16: Weee Label

    > 5 min 219 844-A Warning! Watch Out! There are Do not touch fully charged can explode or cause other parts to possible hazards as shown by the capacitors. explode. symbols. Flying pieces of parts can cause Always wait 5 minutes after power is injury.

  • Page 17: Symbols And Definitions

    3-3. Symbols And Definitions Direct Current Alternating Amperage Voltage (DC) Current (AC) Output Circuit Breaker Remote Positive Negative Voltage Input Protective Earth Arc Force Constant Voltage Inductance (Ground) Three Phase Static Frequency Con- Gas Metal Arc Increase Line Connection verter- Welding (GMAW) Transformer- Rectifier...

  • Page 18: Section 4 − Installation

    SECTION 4 − INSTALLATION Appearance of actual unit may vary from unit shown in manual. 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front panel. Use rating label to determine input power requirements and/or rated output.

  • Page 19: Duty Cycle And Overheating

    4-4. Duty Cycle And Overheating 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. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

  • Page 20: Volt-Ampere Curves

    4-5. Volt-Ampere Curves Volt-ampere curves show minimum CV MODE maximum voltage amperage output capabilities of unit. Curves of other settings fall between curves shown. This volt-ampere curve represents the dynamic output of the unit with a static load. AMPERES CC MODE SMAWMin SMAW GTAWMIN...

  • Page 21: Selecting A Location

    4-6. Selecting A Location Do not move or operate Movement Tipping unit where it could tip. Location Do not stack units. Beware of tipping. Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit. Hand Cart 18 in.

  • Page 22: Proper Ring Terminal Connection To Volt Sense Lead

    4-7. Proper Ring Terminal Connection To Volt Sense Lead If volt sense lead is cut or broken at end with ring terminal, be sure that new ring terminal is connected as shown. DO NOT allow braided shield to touch center conductor or workpiece.

  • Page 23: Connecting To Weld Terminals

    4-9. Connecting To Weld Terminals If using an electrode negative (straight polarity) process, the volt sense lead must be connected to the work. Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in. (19 mm) Correct Installation Incorrect Installation Ref.

  • Page 24: 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-G 2009−08 OM-223 586 Page 20...

  • Page 25: Arranging Welding Cables To Reduce Welding Circuit Inductance

    4-11. Arranging Welding Cables To Reduce Welding Circuit Inductance Welding Power Source Electrode Cable Extension Cable (Optional) Work Cable Volt Sense Lead Wire Feeder Workpiece The method used to arrange cables has significant affect welding properties. As an example, Pro-pulse and RMD welding processes can produce high welding circuit inductance depending on...

  • Page 26: Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs

    4-12. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A. Bad Setup Ref. 804 460-A Welding Power Source Workpiece across the workpiece will not be measured correctly for the voltage feedback signal. Electrode Cable This arrangement is a bad setup due to Voltage feedback to the welding power Extension Cable (Optional) sensing leads being directly in the current...
  • Page 27 B. Ideal Setup Ref. 804 461-A Welding Power Source Wire Feeder the welding power sources. The most accurate voltage sensing may not be Electrode Cable Workpiece achieved due to voltage drops in the Feeder Control Cable workpiece. This require Work Cable This arrangement is a better setup for compensation in the welding parameters.

  • Page 28: Rear Panel Receptacles And Supplementary Protectors

    4-13. Rear Panel Receptacles And Supplementary Protectors 115 V 10 A AC Receptacle RC2 Receptacle supplies single-phase power. Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps. Supplementary Protector CB1 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload.

  • Page 29: Peripheral Receptacle Functions

    4-14. Peripheral Receptacle Functions Function Socket Socket Information Not used. Not used. Circuit common. Not used. Contact closure to F indicates coolant flow switch is closed and recirculating coolant system is Coolant Flow operational. Switch Input Signal Circuit common. Not used. Not used.

  • Page 30: Motor Control Receptacle Functions

    4-15. Motor Control Receptacle Functions Socket Socket Information Not used. +40 volts DC. Not used. +40 volts DC return. Not used. Not used. Electrode sense. Not used. Not used. Not used. Ref. 803 245-B OM-223 586 Page 26...

  • Page 31: Remote 14 Receptacle Information

    4-16. Remote 14 Receptacle Information Socket Socket Information +40 volts DC with respect to socket G. Circuit common for +40 volts DC circuit. Contact closure to socket K completes contactor control circuit. Contact closure to socket B completes contactor control circuit.

  • Page 32: Electrical Service Guide

    4-17. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. NOTICE −...

  • Page 33: Connecting 3-Phase Input Power

    4-18. Connecting 3-Phase Input Power = GND/PE Earth Ground Route input conductors to filter board. Route ground conductor through tubing and current transducer to ground terminal. Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk 219 842-A Tools Needed: 5/16 in. 803 852-A / 803 766-A / 219 842-A applicable, use lugs of proper amperage Disconnect Device...

  • Page 34: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: Adjust Control knob used to change or set parameters and functions. Amps Indicates average amperage while welding and 3 seconds hold value at end of weld. Arc Adjust Term used to represent arc length adjustments in pulse programs.

  • Page 35: Front Panel Controls (See Section 5-3)

    5-2. Front Panel Controls (See Section 5-3) Setup Adjust Arc Control When an LED is lit, it means the related function is active. 219 712-A Program Display the welding power source and program 3 Wire Type LED is selected in the DX feeder, when welding When this LED is lit, turn the Adjust knob to Displays the number of the active program.

  • Page 36: Front Panel Controls - Continued (See Section 5-2)

    5-3. Front Panel Controls - Continued (See Section 5-2) Arc Control LED to show weld amperage or wire feed speed in 15 Upper Display lower display (the applicable LED under the The LED lights to indicate the Arc Control The upper display shows different information lower display lights to indicate which is button is active.

  • Page 37: Typical Connection Diagram For Mig (Gmaw) Equipment Using A Suitcase Feeder

    5-4. Typical Connection Diagram For MIG (GMAW) Equipment Using A Suitcase Feeder Welding Power Source Attach volt sense lead to work clamp and attach work clamp as close to arc as possible. Negative Volt Sense Cable Connect plug on end of volt sense cable to volt sense receptacle on front of welding power source.

  • Page 38: Typical Connection Diagram For Mig (Gmaw) Equipment Using A Digital Feeder

    5-5. Typical Connection Diagram For MIG (GMAW) Equipment Using A Digital Feeder 804 097-C Negative Volt Sense Cable Welding Gun Do not mount feeder on top of power source. Interconnect Cable Wire Feeder Connect 14-pin socket into wire feeder Do not put feeder where welding Turn off welding power source before control cable or optional extension cable.

  • Page 39: Typical Connection Diagram For Mig (Gmaw) Equipment Using A Dx Feeder

    5-6. Typical Connection Diagram For MIG (GMAW) Equipment Using A DX Feeder 804 665-C Interconnect Cable Wire Feeder Do not mount feeder on top of pow- er source. Connect 14-pin socket into wire feeder Turn off welding power source before control cable or optional extension cable.

  • Page 40: Pipepro 450 Rfc Set Up For Mig (Gmaw) Equipment

    5-7. PipePro 450 RFC Set Up For MIG (GMAW) Equipment See Table 5-1 for selection choices. Turn welding power source Power switch on (approximately 30 seconds for complete operation). Push Program button. Use the Adjust knob to choose a desired program number from the 1 through 8 selection.

  • Page 41: Typical Connection Diagram For Tig (Gtaw) Equipment

    5-8. Typical Connection Diagram For TIG (GTAW) Equipment Welding Power Source Interconnect Cable Connect 14-pin socket into remote foot control cable or optional extension cable. Connect 72-pin connector to I/O receptacle RC72 on rear of power source. Connect 10-pin connector into receptacle RC8 on rear of power source.

  • Page 42: Typical Connection Diagram For Tig (Gtaw) Equipment Using A Dx Feeder

    5-9. Typical Connection Diagram For TIG (GTAW) Equipment Using A DX Feeder The illustration shows remote control connected through the wire feeder. The wire feeder is not connected to the power source output.. 804 779-A Connect 14-pin socket into remote foot Workpiece Do not mount feeder on top of pow- control cable or optional extension cable.

  • Page 43: Pipepro 450 Rfc Set Up For Lift Tig (Gtaw) Equipment

    Lift TIG cannot have the Volt Sense lead connected to the PipePro 450 RFC when connected for Electrode Negative (straight polarity). Push Setup button again. The display will read PROG LOAD and welding power source is now ready for the welding operation.

  • Page 44: Typical Connection Diagram For Stick (Smaw) Equipment

    5-11. Typical Connection Diagram For Stick (SMAW) Equipment Welding Power Source Interconnect Cable Connect 14-pin socket into remote foot control cable or optional extension cable. Connect 72-pin connector to I/O receptacle RC72 on rear of power source. Connect 10-pin connector into receptacle RC8 on rear of power source.

  • Page 45: Typical Connection Diagram For Stick (Smaw) Equipment Using A Dx Feeder

    5-12. Typical Connection Diagram For Stick (SMAW) Equipment Using A DX Feeder The illustration shows remote control connected through the wire feeder. The wire feeder is not connected to the power source output.. 804 780-B Connect 72-pin connector to I/O receptacle Workpiece Do not mount feeder on top of pow- RC72 on rear of power source.

  • Page 46: Pipepro 450 Rfc Set Up For Stick (Smaw) Equipment

    Stick/TIG position) or connect a remote device using a remote cable adapter (300 248) to connect to an Interconnect Cable and then connect this cable to the PipePro 450 RFC. The remote device and the welding power source are now in a master/slave control configuration. The Adjust knob on the welding power source is used to control the maximum amperage that can be set by the remote device.

  • Page 47: Pipepro 450 Rfc Set Up For Carbon Arc Gouging (Cac-A) Equipment

    5-14. PipePro 450 RFC Set Up For Carbon Arc Gouging (CAC-A) Equipment See Table 5-1 for selection choices. Turn welding power source Power switch on (approximately 30 seconds for complete operation). Push Program button. Use the Adjust knob to choose a desired program number from the 1 through 8 selection.

  • Page 48: Isolating Two Processes Using Polarity Reversing/Isolation Control (042 871) With Hf Unit

    5-15. Isolating Two Processes Using Polarity Reversing/Isolation Control (042 871) With HF Unit Electrode 1 Electrode 2 A Terminal B Terminal C Terminal WIRE FEEDER DRIVE MOTOR POLARITY REVERSING SWITCH #1 E #2 FROM POWER SOURCE E #1 HF-251D-1 W/SECONDARY CONTACTOR ELECTRODE ELECTRODE WORK...

  • Page 49: Isolating Three Processes Using Polarity Reversing/Isolation Control (042 871) With Hf Unit

    5-17. Isolating Three Processes Using Polarity Reversing/Isolation Control (042 871) With HF Unit Electrode 1 Electrode 2 A Terminal Bus Bar B Terminal C Terminal POLARITY REVERSING SWITCH #2 E #2 JUMPER A TO B POLARITY REVERSING SWITCH #1 E #2 STICK FROM E #1...

  • Page 50: Isolating Three Processes Using Polarity Reversing/Isolation Control (042 871) Without Hf Unit

    5-18. Isolating Three Processes Using Polarity Reversing/Isolation Control (042 871) Without HF Unit Electrode 1 Electrode 2 A Terminal Bus Bar B Terminal C Terminal POLARITY REVERSING SWITCH #2 E #2 JUMPER A TO B POLARITY REVERSING SWITCH #1 E #2 STICK FROM E #1...
  • Page 51 85% Argon, 15% CO 0.045 85% Argon, 15% CO Pulse Inconel INCO 0.045 75% Argon, 25% Helium HE25 *PipePro 450 RFC does not require a gas mixture selection for this process. See wire manufacturer for recommended gas mixture. OM-223 586 Page 47...
  • Page 52 Use a remote control (must have contactor and amperage control) (remote adapter Ctrl Remt 300248 required if not using DX feeder) *PipePro 450 RFC does not require a gas mixture selection for this process. See wire manufacturer for recommended gas mixture. OM-223 586 Page 48...

  • Page 53: Front Panel Switches

    5-19. Front Panel Switches Ref. 803 246-B Power Switch XXXX (Adapter Type) Contactor LED Turns unit On or Off. Contactor LED illuminates when weld output is XXXX identifies the adapter being used as energized. The power-up sequence may last up to 30 identified by the unit.

  • Page 54: Basic Parameters For Pipepro 450 Rmd

    5-20. Basic Parameters For PipePro 450 RMD Steel Wire Size Wire Feed Speed Arc Adjust/Trim Arc Control Shielding Gas Process in (mm) IPM (mpm) .035 (0.9) 100-300 w/200 Nominal 47-53 w/50 Nominal 90/10 (2.5-7.7 w/5.1 Nominal) .035 (0.9) 100-300 w/200 Nominal 47-53 w/50 Nominal 85/15 (2.5-7.7 w/5.1 Nominal)
  • Page 55 Steel Wire Size Wire Feed Speed Arc Adjust/Trim Arc Control Shielding Gas Process in (mm) IPM (mpm) .035 (0.9) 120-780 w/200 Nominal 52-57 w/54 Nominal 90/10 (3.0-19.8 w/5.1 Nominal) .035 (0.9) 120-780 w/200 Nominal 52-57 w/54 Nominal 30-35 85/15 (3.0-19.8 w/5.1 Nominal) .040 (1.0) 120-600 w/175 Nominal 52-56 w/54 Nominal...
  • Page 56 Stainless Steel Wire Size Wire Feed Speed Arc Adjust/Trim Arc Control Shielding Gas Process in (mm) IPM (mpm) .035 (0.9) 150-780 w/175 Nominal 53-57 w/55 Nominal Tri-H (3.8-19.8 w/4.4 Nominal) .035 (0.9) 150-780 w/175 Nominal 52-57 w/56 Nominal Tri-A (3.8-19.8 w/4.4 Nominal) .035 (0.9) 150-780 w/175 Nominal 48-54 w/53 Nominal...

  • Page 57: Welding Stainless Steel With And Without Backing Gas Using Pipepro 450 Rfc

    7. Always use a tapered nozzle when welding out the root especially with no backing gas to assist in providing adequate shielding gas coverage. Following these guidelines should result in successful welding of stainless steel using the PipePro 450 RFC. Contact the nearest factory-authorized Distributor with any questions about this application.

  • Page 58: Reset Mode

    5-22. Reset Mode Reset mode is not active when Program Lock is enabled. The reset mode allows the operator to reload factory program settings for all eight active programs in the unit. System configuration data will be lost during the Reset operation. Setup Adjust Arc Control...

  • Page 59: Checking Program Revision

    5-23. Checking Program Revision To enter the program revision mode, turn on welding power source, and press and hold the Setup push button in until PCM ###X appears on the display (message appears in approximately 15 seconds). Rotate Adjust knob to check the program revision level of each module as follows: PCM (Process Control Module) ###X...

  • Page 60: Section 6 − Maintenance

    SECTION 6 − MAINTENANCE 6-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every l Unreadable Labels ~ Weld Terminals l Damaged Gas Hose...

  • Page 61: Section 7 − Safety Precautions For Servicing

    SECTION 7 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read and follow these precautions. 7-1. Symbol Usage OM-223 586S, safety_stm 2009−08 DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

  • Page 62: California Proposition 65 Warnings

    MOVING PARTS can injure. H.F. RADIATION can cause interference. D Keep away from moving parts such as fans. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and D Keep away from pinch points such as drive communications equipment. rolls.

  • Page 63: Section 8 − Troubleshooting

    SECTION 8 − TROUBLESHOOTING 8-1. Set Value Mode Setup Adjust Arc Control The Set Value mode is a troubleshooting tool Enter the Set Value mode by pressing the bottom display. Press the Wire Feed that allows certain command values to be Setup and Arc Control push buttons at the Speed/Amps push button to toggle between same time.

  • Page 64: Troubleshooting Welding Power Source/Wire Feeder Issues

    8-2. 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 65: Diagnostics

    8-3. Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors. Explanations are in the text below: STUK TEMP LINE STRT Indicates a wire Indicates a Indicates an arc Indicates a ground Indicates a line Indicates an arc stuck error.
  • Page 66 8-3. Diagnostics (Continued) OVER UNIT WAIT COMM Indicates a network Indicates an over Indicates a CRC communication error. average current error. PCM bus error. OVER AVG UNIT COMM NET WAIT • The over average error indicates that • The unit communication error indicates •...

  • Page 67: Removing Cover And Measuring Input Capacitor Voltage

    8-4. Removing Cover and Measuring Input Capacitor Voltage Turn Off welding power 900 Volts dc can be present on the capacitor bus and source, and disconnect in- significant DC voltage can remain on capacitors put power. after unit is Off. Always check the voltage on both Remove cover.

  • Page 68: Process Control Module Pc4 Diagnostic Leds

    8-5. Process Control Module PC4 Diagnostic LEDs Process Control Module PC4 Diagnostic LEDs are visible inside unit, located on PC4 mounted on the top tray. Refer to Section 8-6 for information on diagnostic LEDs. Reinstall cover after checking diagnostic LEDs. LED1 LED2 LED3...

  • Page 69: User Interface Module Pc7 Diagnostic Leds

    8-7. User Interface Module PC7 Diagnostic LEDs LED1 LED2 218 559-A / 803 251-B User Interface Module PC7 Reinstall cover after checking diagnostic Dip switches are used to identify each circuit board on the internal network. Dip LEDs. Diagnostic LEDs are visible inside unit, switch settings are different for each circuit located on PC7 mounted behind the front board.

  • Page 70: Automation Interface Module Pc9 Diagnostic Leds

    8-9. Automation Interface Module PC9 Diagnostic LEDs LED11 LED13 LED25 LED28 LED12 LED14 LED27 LED31 LED30 LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10 LED32 LED33 LED15 LED20 LED19 LED18 LED16 LED21 LED22 LED23 LED24 LED26 LED29 LED17 216 958-A / Ref.

  • Page 71: Diagnostic Leds On Automation Interface Module Pc9

    8-10. Diagnostic LEDs On Automation Interface Module PC9 Status Diagnosis Input signal On from robot for jog advance Input signal Off from robot for no jog advance Input signal On from robot to energize contactor Input signal Off from robot to not energize contactor Input signal On remote program A selected Input signal Off remote program A not selected Input signal On remote program C selected...
  • Page 72 Status Diagnosis Input signal On from relay K4 to indicated wire stuck in weld joint Input signal Off from relay K4 to indicate wire is not stuck in weld joint Indicates +5 volts DC is present on automation module PC9 Indicates +5 volts DC is not present on automation module PC9 Input signal on from relay K5 for flow (shielding gas or coolant) present Input signal off from relay K5 for flow (shielding gas or coolant) not present...

  • Page 73: Network And Module Status Leds

    8-11. Network And Module Status LEDs Network Status LEDs The following are network status LEDs: LED1 on the UIM circuit board LED4 on the WFM and PCM circuit boards LED30 on the AIM circuit board. Status Diagnosis Both LEDs Off The circuit board is not on-line with the network or there is no power applied to the circuit board.

  • Page 74: Section 9 − Electrical Diagrams

    SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Power Source (Part 1 Of 2) OM-223 586 Page 70...
  • Page 75 223 581-B (Part 1 Of 2) OM-223 586 Page 71...
  • Page 76 Figure 9-2. Circuit Diagram For Welding Power Source (Part 2 Of 2) OM-223 586 Page 72...
  • Page 77 223 581-B (Part 2 Of 2) OM-223 586 Page 73...

  • Page 78: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 4 − Fig 10-3 7 − Fig 10-4 5 − Fig 10-2 16 − Fig 10-5 Ref. 804 375-B Figure 10-1. Main Assembly OM-223 586 Page 74...
  • Page 79 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Main Assembly ....212543 . . . Xfmr, Control Toroidal 665 VAC Pri 1900 VA 60 Hz ....
  • Page 80 Hardware is common and not available unless listed. 20 21 802 955-A Figure 10-2. Windtunnel Assembly LH And RH OM-223 586 Page 76...
  • Page 81 Item Dia. Part Mkgs. Description Quantity Figure 10-2. Windtunnel Assembly LH And RH (Fig 10-1 Item 6) ....214597 . . . Windtunnel, LH w/Components (including).
  • Page 82 Hardware is common and not available unless listed. Ref. 802 916-B Figure 10-3. Top Tray Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-3. Top Tray Assembly (Fig 10-1 Item 4) ..PC12 ..209676 .
  • Page 83 Hardware is common and not available unless listed. 803 248-D Figure 10-4. Rear Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-4. Rear Panel Assembly (Fig 10-1 Item 8) ......Automation Interface Module (AIM) (see Table 10-1) .
  • Page 84 Hardware is common and not available unless listed. Ref. 803 249-C Figure 10-5. Front Panel Assembly Item Dia. Part Mkgs. Description Quantity Figure 10-5. Front Panel Assembly (Fig 10-1 Item 14) ....207456 .
  • Page 85 Table 10-1. The WFCM board will appear on the display for earlier versions of program. This board is not used in the PipePro 450 RFC so it can be ignored in this case. Once the board program revisions are identified, use Table 10-1 to select the proper replacement board part number(s).
  • Page 86 Notes...
  • Page 87 Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions...
  • Page 88 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 2009 Miller Electric Mfg. Co. 2009−01...

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