Miller PipePro Single DX Feeder OM-230 010F Owner's Manual
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Miller PipePro Single DX Feeder OM-230 010F Owner's Manual

Miller PipePro Single DX Feeder OM-230 010F Owner's Manual

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PipePro Single
DX Feeder
OM-230 010F
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 PipePro Single DX Feeder OM-230 010F

  • Page 1 OM-230 010F 2008−01 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding (Gas- And Self-Shielded) Description Wire Feeder PipePro Single DX Feeder 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 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 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 Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your 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 cause injury. 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_2007−04 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 in les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. Le soudage effectué sur des conteneurs fermés tel D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peu 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

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation.

  • Page 12: Proposition Californienne 65 Avertissements

    LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :...

  • Page 14: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions 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 − keep hands and metal objects clear.

  • Page 15: Symbols And Definitions

    3-2. Symbols And Definitions Some symbols are found only on CE products. Amperes Volts Alternating Current Duty Cycle Degree Of Hertz Program Wire Feed Protection Output Trigger Line Connection Set Up Sequence Trigger Hold On Trigger Hold Off Purge Press To Set Start Crater Time...

  • Page 16: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Typical Connection Diagram For MIG Equipment 804 675-C Negative Volt Sense Cable Gas Hose Do not mount feeder on top of power source. Positive (+) Weld Cable Gas Cylinder Do not put feeder where welding Negative (−) Weld Cable 10 14-Pin Feeder Control Cable wire hits cylinder.

  • Page 17: Typical Connection Diagram For Tig Equipment

    5-2. Typical Connection Diagram For TIG Equipment The illustration shows remote control connected through the wirefeeder. The wirefeeder is not connected to the power source output.. 804 779-A Gas Cylinder Wire Feeder Do not mount feeder on top of pow- er source.

  • Page 18: Typical Connection Diagram For Stick Equipment

    5-3. Typical Connection Diagram For Stick Equipment The illustration shows remote control connected through the wirefeeder. The wirefeeder is not connected to the power source output.. 804 780-A Welding Power Source Hand Control Do not mount feeder on top of pow- er source.

  • Page 19: Rear Panel Connections And Rotating Drive Assembly

    5-4. Rear Panel Connections And Rotating Drive Assembly 14-Pin Control Cable Shielding Gas Valve Fitting Connect customer-supplied gas hose with 5/8-18 right-hand threads. Shielding gas pressure not to exceed 100 PSI (689 kPa). Weld Cable Terminal Weld Cable Drive Assembly Drive Assembly Rotation Knob Rating Label Location...

  • Page 20: 14-Pin Plug Information

    5-5. 14-Pin Plug Information Pin* Pin Information 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 21: Installing And Threading Welding Wire

    5-6. Installing And Threading Welding Wire Install wire guides and Install wire spool. Adjust tension nut so anti-wear guide. wire is taut when wire feed stops. Install drive rolls. Pressure Indicator Scale Pressure Adjust Rear Pressure Rolls Adjust Front Rolls No Wire Slip Wire Slips NONCONDUCTIVE...

  • Page 22: Setting Internal Dip Switches

    5-7. Setting Internal DIP Switches Remove wrapper. DIP Switch S1 And S4 DIP Switch S1 On Motor Board PC1 DIP switches S1 and S4 should remain in the factory default settings. Install wrapper when finished. Factory Set Default Settings For DIP Switches S1 And S4 This illustration shows the factory setting of S1.

  • Page 23: 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 24: Jog/Purge

    6-3. Jog/Purge Jog/Purge Switch Pressing the Jog switch allows the operator to jog wire without energiz- ing the weld power or gas valve cir- cuit. • Jog speed can be adjusted by the Adjust control when the unit is jogging wire. The unit displays jog speed when the unit is being jogged.

  • Page 25: Program Push Button

    6-5. Program Push Button Program Display The number of the active program is displayed. Program Push Button Press button to activate program select feature. To change the pro- gram number, press the Program push button and rotate the Adjust control. Program Push Button LED The LED lights to indicate the Pro- Program...

  • Page 26: Lower Display

    6-7. Lower Display Wire Speed Amps • Adjusting wire speed while in a welding state Lower Display cate which value is being shown. will modify the weld segment of the weld pro- The lower display shows wire speed or gram. Wire speed for other segments of the amperage.

  • Page 27: Adjust Control

    6-9. Adjust Control Adjust Control The Adjust control is used to change various sequence parame- ters, and to select various se- quences. Refer to the section for the function in question for informa- tion related to using the Adjust con- trol.

  • Page 28: Auxiliary Menus

    6-11. Auxiliary Menus Program Display Program Push Button Sequence Push Button Upper Display Upper Display Push Button Lower Display Program Lower Display Push Button V/Trim Time (sec) Adjust Control Setup Push Button Wire Speed Amps Start Trigger Hold Crater Pre/Postflow Dual Schedule Sequence Adjust...
  • Page 29 Trigger Program Select trim command and vice versa). Code Press the Upper Display Pushbutton to select The upper display shows “TSEL”. Lower dis- Upon leaving the auxiliary menu, the user is play shows “On” or “Off”. The Adjust control Voltage/Trim Command Range Locks. asked if a password code, indicated by is used to select either “On”...

  • Page 30: Remote-14 Receptacle Information

    6-12. Remote-14 Receptacle Information Remote Switch Remote-14 Receptacle 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 31: Section 7 − Setting Sequence Parameters

    SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program For more information on Sequence Push Button see Section 6-10. If time is set to zero in Weld sequence, welding continues until Sequence Parameters gun trigger is released. If time is set to zero in any timed Volts Seconds...

  • Page 32: Section 8 − Setting Dual Schedule Parameters

    SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS 8-1. Optional Dual Schedule Switch Diagrams A DSS-8 will not function with Dual Schedule With DSS-9 Dual Schedule With DSS-8 (Maintained Contact) (Maintained Contact) trigger hold and dual schedule. A DSS-9 is recommended for this application.

  • Page 33: Diagnostics

    9-2. Diagnostics Wrapper Motor Control Board PC1 LED3 DIP Switch S1 There is a two-position DIP switch S1 located on motor control board PC1. These switches are factory-set in the off position and must remain in that position for the unit to op- erate correctly.

  • Page 34: Troubleshooting

    9-3. Troubleshooting Disconnect power before troubleshooting. Trouble Remedy 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.
  • Page 35 Notes OM-230 010 Page 31...

  • Page 36: Section 10 − Electrical Diagram

    SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram OM-230 010 Page 32...
  • Page 37 230 222-A OM-230 010 Page 33...

  • Page 38: Section 11 − Parts List

    SECTION 11 − PARTS LIST Hardware is common and not available unless listed. Fig 11-3 Fig 11-2 804 744-A Figure 11-1. Main Assembly OM-230 010 Page 34...
  • Page 39 Item Item Part Part Description Description Quantity Quantity Figure 11-1. Main Assembly ....159 647 Insulator, Motor Clamp ......... . .
  • Page 40 Hardware is common and not available unless listed. 804 745-A Figure 11-2. Control Box Item Diagram Part marking Description Quantity Figure 11-2. Control Box (Figure 11-1 Item 21) ....200 555 Wrapper, Feeder .
  • Page 41 Item Diagram Part marking Description Quantity Figure 11-2. Control Box (Figure 11-1 Item 21) (Continued) . . . L13,21,27 . . . 213 030 Core, Toroidal 19.00mm Id X 29.01mm Od X 7.62mm Th ... . .
  • Page 42 Hardware is common and not available unless listed. See Table 11-1 For Drive Roll & Wire Guide Kits 803 790-A Figure 11-3. Drive Assembly, Wire Item Diagram Part marking Description Quantity Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4) .
  • Page 43 Item Diagram Part marking Description Quantity Figure 11-3. Drive Assembly, Wire (Continued) ..... 203 631 Pressure Arm, S/L & Vert S/R 4 Roll (Consisting Of) .
  • Page 44 Table 11-1. Drive Roll And Wire Guide Kits OM-230 010 Page 40...
  • Page 45 Notes Start Your Professional Over 80,000 trained 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! since 1930! 1-800-332-9448 www.welding.org...
  • Page 46 Notes SOCKET/WRENCH SELECTION TABLE SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size U.S. Bolt Decimal Bolt Bolt Decimal Bolt Diameter Equivalent Diameter Equivalent 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm...
  • Page 47 Effective January 1, 2008 (Equipment with a serial number preface of LJ 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 48: Options And Accessories

    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. © PRINTED IN USA 2008 Miller Electric Mfg. Co. 2008−01...

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