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PipePro 450 RFC

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2. lt lt 2 8 RI 4 lt lt 5 7 lt lt LER PC2 INTERCONNECT BOARD L1 1 2 RC1 PLG11 RC3 PLG12 RC6 PLG14 1 12 CHASSIS 4 RCI 4 gt gt 2 gt gt RCI 1 gt gt ACT 2 AC3 0 9 9 BUS SENSE ROSA PLZ ARA dne RO3 3 gt 4 p MA ena RC3 7 gt 5 10 0 RC3 27 gt MT 1 gt gt eno RC3 5 gt ax RC3 6 gt HF XFMR ho MT aca I Z lt 3 ul XRC3 1 RECT 9 1 77 RC1 6 255 7 lt lt RO5 6 1 1 gt gt amp lt lt 5 1 RCI 8 gt gt lt 5 RC1 4 gt lt lt 5 4 RC5 3 Zk RC5 7 77 lt RC5 2 RC5 8 RC1 32 RC1 7 gt RC1 2 gt RC1 8 gt RCB 3 RC6 7 lt RC6 13 lt 6 5 lt 225 226 228 D INVERTER MODULE 1 SECONDARY HEATSINK HEATSINK PRIMARY X RC4 4 RT 2 RC4 8 gt gt RT 1 1 FED PLG16 RC16 22 RC10 255 gt 3 1 RC7 3 gt gt RC10 127 SHEET 2 INPUT INDUCTOR CONTROL BOARD RC2 PLG2 RC3 PLG3 RC4 PLC4 RC5 PLGS RC6 PLG6 78 RC7 PLG7 09 7 gt RCB PLGB 1 Rc
3. 1 eli ah cath 186621 BOOT Generic dus ee af siot a fe Ta 2 OB aid ted UE 221527 Nameplate Front 1 ix 210865 Terminal pwr output red 1 210473 Panel Front CE a GRE 1 210483 Bracket lift eye 1 C 210358 Bolt eye shld thd stem 500 13 X 1 500 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Ordering Information For PCM AIM And UIM Circuit Boards The UIM AIM and PCM boards must have compatible programs in order to communicate together and provide proper system performance If the program has been updated since the system was received the original program revision may not match the serial number of the PipePro 450 RFC shown in Table 9 1 In order to provide the correct replacement board it is necessary to know the program revision for each of the boards in the PipePro 450 RFC Follow the procedure to Check Program Revision for each board according to Section 4 22 The last three n
4. 1 aise CT1 196231 Xfmr Current Sensing 200 1 1 tisch es Ace 201695 Clamp Capacitor 2 2 Give CI xs 203912 Capacitor Elctlt 2400 Uf 500 VDC Can 2 5 Dia 2 ix 222 eru tees 210507 Clamp Capacitor Top 2 n 217625 Kit Input Pre regulator And Inverter Module 1 24 RT1 RT2 RT3 214015 Thermistor NTC 30K Ohm 25 Deg C 7 amp 18in Lead 3 tos Dre Pe deua 222661 Circuit Card Assy Power Interconnect 1 Vues bene le 199107 Clip Wire Stdf 20 30 Bndl 156hole 031 078thk 1 RE 199108 Clip Wire Stdf 30 40 Bndl 156hole 031 078thk 1 sud O cds 196143 Capacitor Polyp Met Film 16 Uf 400 VAC 10 1 iud uris deoa 196378 Bracket Mtg Current Xfmr 1 ces IHDT us 182918 Transducer Current 400A Module Supply V 15v 1 He PIE 196384 Cable Transducer 20 1 29 R1 R2 196343 Resistors W Leads 8 Plug 1 196840 Insulator Resistors Interface Board
5. TEMP WAIT Indicates a temperature error Indicates a UIM communication error UNIT ERR COMM SENS Indicates a CRC PCM bus error Indicates no ocv E ERR STOP UNKN Indicates an emergency stop error Indicates an unknown error OVER NET CRNT WAIT Indicates an Indicates a network overcurrent error communication error ERR ARC arc error indicates an arc outage occurred possibly from a wire feeder error or power source error Check wire feeder and power source Press any button on front panel to clear error ERR GND The ground current error occurs if weld current is detected in the earth ground connection May be caused by a conductor making contact with unit chassis Check and repair feeder weld connections Press any button on front panel to clear error ERR LINE The line error indicates input power is outside of unit operating range Check and correct input power Cycle power to clear error ERR STRT The start error occurs if the user has the trigger held for more than 3 seconds without striking an arc and Start Err is enabled This error also occurs if trigger jog runs for 30 sec onds or more The error may be cleared by releasing the trigger and pressing any but ton on the front
6. PipePro DX series feeders will automatically select an active program when welding begins The program selected will match the active program in the feeder i e if program 5 is selected in the welding power source and program 3 is selected in the DX feeder when welding begins the power source will change to program 3 Press and hold button to see program name Custom programs are named using optional PDA with PipePro Program Management software PipeProMgr Program name is shown in upper and lower displays items 13 and 15 5 Setup Mode Indicators The lit LED indicates which setup mode is active Setup mode parameters are shown in Display Windows see Items 13 and 15 Process LED When this LED is lit turn the Adjust knob to select the desired weld process Choices include pulse welding displayed as PULS Pro pulse displayed as PRO MIG welding displayed as MIG RMD Pro displayed as RMD stick welding displayed as STIK lift TIG welding displayed as LIFT TIG flux core arc welding displayed as FCAW and carbon arc gouging displayed as CARB ARC 200 410 Wire Type LED When this LED is lit turn the Adjust knob to select the desired wire type wire alloy and size Wire type and size choices vary according to the selected weld process Choices may include steel displayed as STL stainless steel SS metal core MCOR See Table4 1 for all wire abbreviations Gas Type LED When this LE
7. C25 100 CO2 90 Argon 10 C10 85 Argon 15 C15 E70 0 040 1 0 75 Argon 25 C25 Steel STL 100 CO2 90 Argon 10 C10 85 Argon 15 C15 0 045 1 2 75 Argon 25 C25 100 CO2 85 Argon 15 C15 E80 0 035 0 9 100 CO2 100 CO2 FCAW N A Gas YES or NO Stainless Steel ESS Press Wire Feed Speed Amps Display Are Soft button to turn output on EX10 Stick Use a remote control must have Steel contactor and amperage control EX18 Ciri Remt remote adapter 300248 required if not using DX feeder Carbon Arc Gouging N A Ctrl Panl Press Wire Feed Speed Amps Display button to turn output on Lift TIG Git Rent Use a remote control must have contactor and amperage control remote adapter 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 221 771 Page 43 4 20 Basic Parameters For PipePro 450 RMD Wire Size Wire Feed Speed Arc Adjust Trim Arc Control Shielding Gas 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 0 100 300 w 200 Nominal 47 53 w 50 Nominal 2 5 7 7 w 5 1 Nominal 035 0 100 300 w 200 Nominal 47 53 w 50 Nominal 2 5 7 7 w 5 1 Nominal 035 0 100 300 w 200 Nominal 47 53 w 50 Nominal 2 5 7 7 w 5 1 Nominal
8. Arc Control 200 410 221 771 Page 38 4 15 PipePro 450 RFC Set Up For Carbon Arc Gouging CAC A Equipment See Table 4 1 for selection choices 1 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 EF If the desired program has been previously loaded only the program number needs to be selected This process does not have to be followed every time a different program is selected 2 Push Setup button once Use the Adjust knob to choose Carbon Arc Gouging Process 3 Push Setup button again The display will read PROG LOAD and welding power source is now ready for the welding operation No changes are saved until PROG LOAD appears on the display after completing the settings If the Setup button is pressed to review the settings and nothing is changed PROG LOAD will not appear on the display for the program that was just loaded ES gt gt CA e Volts Arc Adjust Wire Speed 6 Amps Arc Control 200 410 OM 221 771 Page 39 4 16 Isolating Two Processes Using Polarity Reversing Isolation Control 042 871 With HF Unit 3 e 1 Electrode 1 it A C 2 Electrode 2 3 A Terminal 4 B Terminal 5 C Terminal 1 2 3 4 5 WIRE FEEDER POLARITY REVERSING
9. LED1 LED2 1 B Em T 6 TEES ur Ba us uua HEEL UN E Am lt 51 52 us R55 1 4 67 4 216 956 A Ref 803 250 C 7 6 Diagnostic LEDs On Process Control Module PC4 LED Status Diagnosis 1 On Indicates 25 volts DC is present on process control module PC4 Off Indicates 25 volts DC is not present on process control module PC4 2 On Indicates 25 volts DC is present on process control module PC4 Off Indicates 25 volts DC is not present on process control module 4 3 4 On See Network Status Table in Section 7 11 Off See Network Status Table in Section 7 11 OM 221 771 Page 55 7 7 User Interface Module PC7 Diagnostic LEDs ES e
10. 7 221 7710 2012 07 m Processes Miller Stick SMAW Welding MIG GMAW Welding RMD Modified Short Circuit Pulsed MIG GMAW P Flux Cored FCAW Welding 2 N a TIG GTAW Welding Air Carbon Arc CAC A Cutting and Gouging i PA Multiprocess Welding PS Description Arc Welding Power Source PipePro 450 RFC OWNER S MANUAL Visit our website at File Pipe Welding Products PET www MillerWelds com K From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right 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 Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hardias you do every power source from will help you protect yourself against po
11. RC4 6 2 RC4 7 gt gt 1 CONTROL BOARD RC2 PLG2 RC3 PLG3 RC4 PLG4 RC5 PLG5 RC6 PLG6 RC7 PLG7 RCB PLGB RC9 PLG9 RC10 PLG10 lt RCB 4 RCB 7 BSF 54 221 768 D Part 1 Of 2 OM 221 771 Page 63 por E SHED 5 aw OW 1 DISPLAY 44 42 MODULE 195 OW 5 BLACK 24 COMMON J1 PLG73 94 52 gt J4 PLG72 y4 2 gt gt 42 x 58 pL Tom 1350 Pd _ 8 PUER FERRITE CORE i RCS B RC6 320 p 2 2 E 2 03 12 RC7 5 gt gt E STOP BOARD ROA D 229 RC1 PLG75 RC2 PLG76 RC4 27 257 RC3 PLG77 RC2 1 RC4 PLG78 222 Rcs PLoso 82 22 RC6 PLGB1 RC7 PLGBA RC2 7 gt gt _ RC2 10 gt gt 2 th 2 11 gt gt 9 We 25 RARER CONHCTOR 9 CONTACTOR 227 2 3 2 6 gt gt 7 25 lt 2 9 u5 3 9 42 SENSE CAMP 2 8 gt gt 8 42 anc 128 b id 72 lt 2 4 gt 28 2 2 422 VAE _ 05 25539 c c 40 LY Y Y SHELDED CABLE 45 42 ms morum 4 ak Rce 7 gt 3 gt 27 Ton 22 K J1
12. 1 Welding Power Source Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 2 Negative Volt Sense Cable Connect plug on end of volt sense cable to volt sense receptacle on front of welding power source 3 Interconnect Cable Connect 14 pin socket into wire feeder 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 4 Negative Weld Cable 5 Positive Weld Cable 6 Workpiece 7 Wire Feeder 14 Pin Plug Turn off welding power source before connecting to wire feeder 14 pin plug 8 Wire Feeder 9 Trigger Receptacle 10 Gun 11 Gas Hose 12 Gas Cylinder Extension cable maximum length not to exceed 150 ft 46 m 13 Extension Cable Optional 10 804 374 D OM 221 771 Page 29 4 6 Typical Connection Diagram For MIG GMAW Equipment Using A Digital Feeder e fer Do not mount feeder on top of power source Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip 1 Welding Power Source Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 2 Negative Volt Sense Cable 3 Interconnect Cable Connect 14 pin socket into wire feeder control cable or op
13. 170647 Bushing Snap in Nyl 1 312 Id X 1 500 Mtg Hole 2 wee UE 179276 Bushing Snap in 1 000 Id X 1 375 Mtg Hole Cent 4 NOCERE REOR 196355 Insulator e cete reet epa nde eee da 6 non RUE T CENE 010546 Bushing Snap in 375 Id X 500 Mtg Hole 1 dO esa uet 222958 Windtunnel RH w Components including 1 nrc 196332522 Windtunnel RH Pa a ae So e t ut a 1 030170 Bushing Snap in Nyl 750 Id X 1 000 Mtg Hole Cent 2 When ordering a component originally displaying a precautionary label the label should also be ordered This kit contains two modules and instructions Be sure to follow the field kit instructions when performing the installation To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor 221 771 Page 68 No Mkgs No Description Quantity Figure 9 2 Windtunnel Assembly LH And RH Fig 9 1 Item 6 Jt E 2 cn 196259 Plugs w Leads amp Current Xfmr including 1 115092 Housing Plug amp Skts 1 pU iade es 115091 Housing amp Skts
14. lt RC70 54 AUTOSET A lt 70 53 AUTOSET B lt RC70 65 AUTOSET D RCBO PLG49 RC81 PLG48 rH RCB3 PLGS0 EGND lt RC70 9 VOLTS COMMAND lt RC70 16 VOLTS COMMAND lt RC70 5 WFS COMMAND lt RC70 34 WFS COMMAND lt RC70 20 RA COMMON lt RC70 3 E STOP lt RC70 6 VFB TO ROBOT 229 E lt 85 1 lt 70 33 RA COMMON E lt RC5 2 lt RC70 7 TO ROBOT P lt RC5 3 25 CONDUCTOR lt RC70 8 RA COMMON p lt RC5 4 lt 8070 10 MOTOMAN VOLTS COMMAND e lt lt RC15 1 lt RC70 4 RA COMMON 42 2 p lt RC15 2 RC 4 lt RC70 19 MOTOMAN WFS COMMAND STUD STUD rh lt RC70 21 RD COMMON E STOP SHEET SHEET 0 lt RC8 2 lt RC70 22 PANASONIC 10V REF lt lt RCB 5 lt RCB 1 lt RC70 46 ABB RETRACT pe ecg lt RC70 35 ABB CONTACTOR lt RC70 47 ABB JOG lt RC70 23 ABB PURGE lt RC70 36 RD COMMON lt RC70 11 ABB 5 EGND lt RC70 12 ABB RPS B 2 lt 70 24 ABB RPS C TO _115VAC SHEET 1 RETURN aa 4 _ 115 RETURN 42 Ras lt 70 60 115 rh lt RC70 48 115VAC RETURN WELD STUD 39 WELD STUD 40 X p lt RC70 72 WELD STUD CHASSIS GND GRN 22 lt RC70 59 WELD STUD lt RC1 2 TRANSMIT lt RC70 71 CHASSIS GND i SERIAL COMMUNICATION lt RC1 3 RECEIVE
15. 040 1 100 275 w 175 Nominal 50 55 w 53 Nominal 2 5 7 0 w 4 4 Nominal 040 1 100 275 w 175 Nominal 47 53 w 50 Nominal 2 5 7 0 w 4 4 Nominal RMD Steel 040 1 100 275 w 175 Nominal 50 55 w 53 Nominal 2 5 7 0 w 4 4 Nominal 85 15 75 25 040 1 100 275 w 175 Nominal 50 55 w 53 Nominal 2 5 7 0 w 4 4 Nominal 045 1 100 200 w 150 Nominal 47 53 w 50 Nominal 2 5 5 1 w 3 8 Nominal 045 1 100 200 w 150 Nominal 47 53 50 Nominal 2 5 5 1 w 3 8 Nominal 045 1 100 200 w 150 Nominal 47 53 50 Nominal 2 5 5 1 w 3 8 Nominal 045 1 100 200 w 150 Nominal 47 53 w 50 Nominal 2 5 5 1 w 3 8 Nominal 035 0 225 600 w 250 Nominal 52 57 56 Nominal b 7 15 2 w 6 4 Nominal 035 0 120 780 w 250 Nominal 52 57 w 56 Nominal 30 35 3 0 19 8 w 6 4 Nominal 040 1 120 600 w 250 Nominal 52 56 56 Nominal ProPulse Steel Using 3 0 15 2 w 6 4 Nominal A Positioner Rolling The Pipe 040 1 120 600 w 250 Nominal 52 56 w 56 Nominal 25 3 0 15 2 w 6 4 Nominal 045 1 140 500 w 250 Nominal 52 57 56 Nominal 25 3 6 12 7 w 6 4 Nominal 045 1 140 500 w 250 Nominal 52 57 56 Nominal 25 3 6 12 7 w 6 4 Nominal 035 0 120 780 w 200 Nominal 52 57 w 54 Nominal 3 0 19 8 w 5 1 Nominal 035 0 120 780 w 200 Nominal 52 57 54 Nominal 30 35 3 0 19 8 w 5 1 Nominal 040 1 120 600 w 175 Nominal 52 56 54 Nominal ProPulse Steel 3 0 15 2 w 4 4 Nominal Welding In Position 1 120 600 w 175 Nominal 52 56 w 54 Nominal 25 3 0 15 2 w 4
16. BOARD lt RC1 5 COMMON RC2 PLG83 lt RCI 7 READY TO SEND RC2 4 lt RC1 8 CLEAR TO SEND lt RC2 3 lt RC2 2 gt RC3 2 RECEIVE 4 RC2 1 gt RC3 3 TRANSMIT 4 RC2 5 gt RC3 5 COMMON 4 RC2 6 gt RO3 7 READY TO SEND gt RC3 8 CLEAR TO SEND 221 768 D Part 2 Of 2 OM 221 771 Page 65 SECTION 9 PARTS LIST Hardware is common and not available unless listed ny S LL 16 Fig 9 5 15 Ref 804 573 B Figure 9 1 Main Assembly 221 771 Page 66 Item Dia Part No Mkgs No Description Quantity Figure 9 1 Main Assembly mr 212543 Xfmr Control Toroidal 665 VAC Pri 1900 60 2 1 ius ud 210492 COVER it tenaces Ree 1 Bx 210481 Plate Mtg Toroid Xfmr 1 seio TE Fig 9 3 Top Tray Assembly 1 5 1 IM2 222959 MODULE inverter assy 300A Fig 9 2 2 EL Du IS eatis ems 198961 Panel Module Divider 1 ap Fig 9 4 Rear Panel 1 DECRE 227793 Panel Side W Insulator 2 mov 210482
17. abled the front panel can be reset resetting all 8 programs see Section 4 23 or a new program can be loaded from the PDA Refer to the PipePro Program Management Owner s Manual for additional information 4 4 Front Panel Switches ES gt gt CA 1 Power Switch Turns unit On or Off The power up sequence may last up to 30 seconds before the unit is ready to weld During power up the front panel will display messages indicating the status of the unit The first message is NET WAIT NET WAIT is an abbreviation for network updating and means the internal control network is powering up The next message is XXXX Adapter Type XXXX identifies the adapter being used as identified by the unit To ensure proper opera tion of the system verify the adapter displayed corresponds to the actual adapter being used The final message is RFC 450 RFC 450 indicates the final set up sequence of the system Ref 803 246 B 2 Contactor LED Contactor LED illuminates when weld output is energized 3 PDA Port 4 PC Port OM 221 771 Page 28 4 5 Typical Connection Diagram For MIG GMAW Equipment Using A Suitcase Feeder AA 75 4 7
18. formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants OM 221 771 Page 8 HAUTE FREQUENCE risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les qui pements de radio navigation et de com munication les services de s curit et les ordi nateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des Sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lect
19. 1 877 413 5184 website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 2 6 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises Limiter par exemple tout acc s aux passants ou proc der une valuation des risques individuels pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rasse
20. Do not put feeder where welding wire hits cylinder Do not move or operate equipment when it could tip 1 Welding Power Source 2 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 Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 3 Volt Sense Cable Negative Weld Cable 5 Positive Weld Cable 804 780 B Workpiece Electrode Holder Hand Control Wire Feeder Turn off welding power source before connecting to wire feeder 14 pin plug OD Lx Extension cable maximum length not to exceed 150 ft 46 m 10 Extension Cable Optional 11 Remote Switch To STICK TIG OM 221 771 Page 37 4 14 PipePro 450 RFC Set Up For Stick SMAW Equipment See Table 4 1 for selection choices 1 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 EF If the desired program has been previously loaded only the program number needs to be selected This process does not have to be followed every time a different program is selected Push Setup button once Use the Adjust knob to choose Stick weld Process
21. Enter the Set Value mode by pressing the Setup and Arc Control push buttons at the same time When in the Set Value mode the display windows briefly shows SET VALU and the blinking LEDs under the display windows indicate whether Volts Arc Adjust or Wire Speed can be changed turning the Adjust knob Depending on the defined weld process either volts MIG or arc adjust pulse Pro pulse or RMD Pro can be changed in the top display Wire speed can be changed in the Arc Control bottom display Press the Wire Feed Speed Amps push button to toggle between selecting information in the top display or bottom display The LED under the active display will blink to indicate the value that can be changed Rotate the Adjust knob to change values Exit the Set Value mode by pressing the Setup and Arc Control push buttons at the same time or turning power source off and then back on again OM 221 771 Page 51 7 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 receptacle from a line disconnect box be sure that the line disconnect switch or main breaker is in the ON position Wi
22. OM 221 771 Page 73 Notes Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way 2 Miller Effective January 1 2012 Equipment with a serial number preface of MC newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY 15 EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in
23. Push Setup button again Use the Adjust knob to choose electrode type EX10 EX18 OR ESS Push Setup button again Use the Adjust knob to choose arc characteristic ARC SOFT or ARC STIF cy m m Push Setup button again Use the Adjust knob to choose type of Control CTRL PANL or CTRL REMT a If Panel control is selected press the Wire Feed Speed Amps display button for amperage output Use the Adjust knob to set the desired amperage b If Remote control is selected connect a remote device to the front of the DX Feeder feeder switch must be in 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 6 Push Setup button again The display will read PROG LOAD and welding power source is now ready for the welding operation No changes are saved until PROG LOAD appears on the display after completing the settings If the Setup button is pressed to review the settings and nothing is changed PROG LOAD will not appear on the display for the program that was just loaded 3 PA Vols Arc Adjust Wire Speed Amps Wirefeed Gas Contactor
24. When welding stainless steel with or without backing gas the following guidelines are recommended 1 Only use stainless steel wire with a high silicon content as it helps the flow of the weld puddle and the silicon acts as de oxidizer 2 tis important to have proper joint preparation and fit up Use a bevel at the pipe joint of 35 37 5 degrees 70 75 degrees inclusive with a land of a knife edge to 1 16 in 1 6 mm and a minimum gap of 1 8 in 3 2 mm 3 Besurethat any mill scale is remove from inside the pipe joint before welding the root weld This can be done by grinding the inside of the joint area 4 Use Tri H 90 helium 7 5 Argon 2 5 CO shielding gas 98 2 Argon is available but the Tri H mixture is the optimal choice for the applica tion 5 Always use a down hill technique when welding with the RMD process for the root pass weld 6 Itis very important to feather tack welds to ensure these are consumed when completing the root pass weld 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 4 22 Checking Program Revision To enter the program revision mode turn on welding power source and press and hold the Setup push button in
25. Without HF Unit 40 4 18 Isolating Three Processes Using Polarity Reversing Isolation Control 042 871 With HF Unit 41 TABLE OF CONTENTS 4 19 Isolating Three Processes Using Polarity Reversing Isolation Control 042 871 Without HF Unit 41 4 20 Basic Parameters For PipePro 450 44 4 21 Welding Stainless Steel With And Without Backing Gas Using PipePro 450 RFC 46 4 22 Chiecking Program Revision io ker xD PEE E ee NP 46 4 23 Reset Moda a a e que xm eine RU c PE x neret dor dense 47 SECTION 5 MAINTENANCE 3 us ebay Se a RO dd 48 5 1 Routine Maintenance 48 5 2 Blowing Out Inside 48 SECTION 6 SAFETY PRECAUTIONS FOR 49 6512 Symbol ee en pl tede Re lene A 49 6 2 Servicing Hazards ux retenues GUERRA ETE QUEEN 49 6 3 California Proposition 65 08 50 6 4 EMF Information 3223 542 Re a RR 50 SECTION7 TROUBLESHOOTING err rear 51 71 Set Value oro LU AIME
26. ment ce manuel e Porter un harnais de s curit si doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage D brancher le c ble pour le proc d non utilis OM 221 771 Page 5 reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie Entretien avant de toucher les pi ces LES PI CES CHAUDES peuvent provoquer des br lures Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e E
27. such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized Service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABL
28. 1 7 C8 222488 Capacitor 3 NAE 213102 Choke Common Mode w Leads 2 ss testas eee aA 025248 Stand off Insul 250 20 X 1 250 Lg X 437 Thd 2 sn autos 207897 cae BUS Bar 2 Ree oem t gars oe t nec 2 210866 Terminal pwr output black 1 Dale cic RED a ras 214664 Receptacle Common Mode Choke 1 Gs Tarte eR Ud 216966 Cover Connector D sub 9 pin Male w Chain 1 dise erre ERA 216965 Cover Connector D sub 9 skt Female w Chain 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 221 771 Page 72 Item Dia Part No Mkgs No Description Quantity Figure 9 5 Front Panel Assembly Fig 9 1 Item 14 Continued ud ees 215467 Label Volt Sense 1 ene tede 219843 Label Volt Sense 1 eee Le 207896 Box Louver
29. 250VAC Frict 1 ms d gos PEA ea 216213 Circuit Card Assy Motor Filter 1 14 RC2 604176 Receptacle w Leads 115V Duplex 1 mittens 216596 Strap Grounding 4 50 in long 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 221 771 Page 71 Hardware is common and not available unless listed Ref 803 249 C Ref 803 682 B Figure 9 5 Front Panel Assembly Item Dia Part No Mkgs No Description Quantity Figure 9 5 Front Panel Assembly Fig 9 1 Item 14 sud ste S1 207456 Switch Assy Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg 1 Un 207895 Insulator Switch 1 Wee TO eua sonar utens 179851 Knob Pointer 1 670 Dia X 250 Id Push On W Spring 1 T ADT P User Interface Module UIM see Table 9 1 1 Ve UD aeris FM 196313 Fan Muffin 115V 50 60 Hz 3000 Rpm 6 378 Mtg Holes 2 sis ims 208071 Circuit Card Assy ISO COMM
30. 60 35 30 25 Normal Operating Fuses 80 70 45 35 30 Min Input Conductor Size In AWG 4 6 8 10 10 12 Max Recommended Input Conductor Length In Feet Meters Ps 63 83 78 Min Grounding Conductor Size In AWG 4 8 8 10 10 12 Reference 2011 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class 5 up to and including 60 amps and UL class 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 15 B 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements Notes OM 221 771 Page 23 3 18 Connecting 3 Phase Input Power GND PE Earth Ground i e e 9739 Ed E
31. 871 Without HF Unit JUMPER A TOB SWITCH 1 B FROM POWER SOURCE POLARITY REVERSING 1 Tools Needed 3 13 16 POLARITY REVERSING SWITCH 2 MIG STICK 1 WORK TIG oak wn Electrode 1 Electrode 2 A Terminal Bus Bar B Terminal C Terminal Ref 099 082 C Ref 098 115 B OM 221 771 Page 41 Table 4 1 Weld Programs Diameter Process Wire Type Alloy Type Gas Mixture inch mm 0 045 1 2 N A N A Metal Core MCOR 76 0 052 1 3 N A N A 0 062 1 6 N A N A MIG 0 035 0 9 N A N A Stainless Steel SS 308 309 312 316 0 045 1 2 N A N A 0 035 0 9 N A N A Steel STL E70 0 045 1 2 N A N A Inconel INCO 625 0 045 1 2 75 Argon 25 Helium HE25 90 Argon 10 C10 0 045 1 2 85 Argon 15 C15 Metal Core MCOR 76 90 Argon 10 C10 0 052 1 3 85 Argon 15 15 98 Argon 2 C2 98 Argon 2 Oxygen OX2 0 035 0 9 81 Argon 18 Helium 1 TRIA 90 Helium 7 5 Argon 2 5 TRIN 308 309 312 316 98 Argon 2 C2 Stainless Steel SS 98 Argon 2 Oxygen OX2 0 045 12 81 Argon 18 Helium 1 TRIA Pro pulse 90 Helium 7 5 Argon 2 5 TRIH 69 Argon 30 Helium 0 040 1 0 1 TRIS OPER 69 Ai 30 H
32. CB2 is rated at 15 amperes and protects La the wire feeder from overload If CB2 opens the wire feeder does not work Press button to reset breaker If breaker continue to open contact a Factory Authorized Service Agent 4 Wire Feed Gas Receptacle RC8 Use receptacle to connect PipePro interconnect cable to power source see Sections 3 15 and 8 for additional information 5 Peripheral Receptacle RC25 Receptacle provides connection to the water flow switch see Section 3 14 6 Interface Receptacle RC72 Use receptacle to connect PipePro interconnect cable see Section 8 for additional information Ref 803 245 B 3 14 Peripheral Receptacle Functions Function Socket Socket Information A Not used B Not used C Circuit common D Not used E Contact closure to F indicates coolant flow switch is Coolant Flow closed and recirculating coolant system is Switch Input operational Signal F Circuit common H Not used J Not used Ref 803 245 B K Not used L Not used M Not used Circuit common is same electrical reference point Note A customer supplied matching amphenol plug factory Part No 194 847 Amphenol Part No 97 3106A 20 33P B 621 and strain relief clamp 97 3057 12 0621 is required to use per
33. Clean or replace gun liner if necessary Trouble with Program Select when using a DX model wire feeder PipePro DX series feeders will automatically select an active program when welding begins The program selected will match the active program in the feeder i e if program 5 is selected in the welding power source and program 3 is selected in the DX feeder when welding begins the power source will change to program 3 If programs in the welding power source do not change when changing programs in the DX wire feeder check the cable connections between the welding power source and wire feeder Programs are selected by Remote Program Select A and Remote Program Select B RPS A and RPS B lines in the wire feeder cable RPS A is a pulse width modulated PWM signal that creates an analog signal to select 1 of 4 programs RPS B is a digital signal that select a bank of programs 1 4 or 5 8 OM 221 771 Page 52 7 3 Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors Explanations are in the text below ERR ERR ERR ERR OVER ERR ARC GND LINE STRT AVG STUK Indicates an arc error Indicates a ground current error Indicates a line error Indicates an arc start error Indicates an over average current error Indicates a wire Stuck error ERR PLS
34. FLYING METAL or DIRT can injure eyes p Wear safety glasses with side shields or face shield during servicing e Be careful not to short metal tools parts or wires together during testing and servicing HOT PARTS can burn e Do not touch hot parts bare handed Allow cooling period before working on equipment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns EXPLODING PARTS can injure e Failed parts can explode or cause other parts to explode when power is applied to inverters e Always wear a face shield and long sleeves when servicing inverters SHOCK HAZARD from testing Turn Off welding power source and wire feeder or stop engine before making or changing me ter lead connections Use at least one meter lead that has self retaining spring clip such as an alligator clip e Readinstructions for test equipment FALLING EQUIPMENT can injure Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OM 221 771 Page 49 MOVING PARTS can injure Keep away
35. High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep Spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 221 771 Page 3 1 4 California Proposition 65 Warnings We
36. Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example restrict access for passers by or conduct individual risk as sessment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 221 771 Page 4 This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use Spectrum Way Suite 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standardfor Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Qui
37. PipePro Program Management software PipeProMgr is used to change wire feed units IPM MPM or display welding information command or actual save the changes and then turn the power to the unit off and then on again for the changes to be carried out by the unit 14 Volts And Arc Adjust LEDs The lit LED indicates whether voltage or arc length is being displayed 15 Upper Display The upper display shows different information depending on the active function of the unit and the weld process being used When the display shows voltage for a MIG process the Volts LED lights When it shows arc adjust for a pulsed and RMD Pro optional weld process the Arc Adjust LED lights However during any weld process MIG and pulse the unit will display actual arc voltage unless a PDA with PipePro Program Management software PipeProMgr has set the unit in the Display Command Values mode 16 Lock LED The lock LED is illuminated when one or more programs have been locked using an optional PDA with PipePro Program Management software PipeProMgr This may indicate that some programs have been disabled A dis abled program will not show up for selection Other programs may be locked against edit ing The lock LED will also illuminate if the selected program is a custom program indicated by a C next to the program number indicating that it cannot be changed from the front panel To clear a custom program when lock is not en
38. Replacement Parts Model and serial number required when ordering parts from your local distributor OM 221 771 Page 70 Hardware is common and not available unless listed 803 248 D Figure 9 4 Rear Panel Assembly Item Dia Part No Mkgs No Description Quantity Figure 9 4 Rear Panel Assembly Fig 9 1 Item 8 zar d beste POO esti nates Automation Interface Module AIM see Table 9 1 1 eet isi apu 199297 Stand off no 6 32 amp 8 32 x 2 50 19 312 hex alm m 4 said sess PCW wisis 214855 Circuit Card Assy Robot Interface Filter 1 Las E E 199295 Stand off 8 32 x 500 Ig 312 hex al m amp f 4 xus TOL ceca ter edet se Rd 217297 Cover Receptacle Weatherproof Duplex Rept 1 se ey 210475 Panel Rear sert ear ERE 1 E RE 210358 Bolt eye shld thd stem 500 13 X 1 500 1 se 210505 Nameplate 1 EORR 201058 Connector Rect 72 Pin Assy 1 mo E 210483 Bracket lift eye 1 11 CB1 083432 Circuit Breaker Man Reset 1P 10A 250VAC Frict 1 ve TL 093995 Circuit Breaker Man Reset 1P 15A
39. Turn power off wait 10 seconds and turn power back on again to complete the reset operation gt After Reset is complete be sure to load appropriate programs that contain the correct wire size process and shielding gas for the welding operation Program 1 Program 2 Program 3 Program 4 Program 5 Program 6 Program 7 Program 8 RMD Pro 035 Mild Steel E70 85 Argon 15 Pro pulse 035 Mild Steel E70 85 Argon 15 RMD Pro 045 Mild Steel E70 8596 Argon 1596 CO2 Pro pulse 045 Mild Steel E70 85 Argon 15 RMD Pro 035 Stainless Steel 316 98 Argon 2 Pro pulse 035 Stainless Steel 316 98 Argon 2 CO2 FCAW Gas Shielded Pro pulse 045 Metal Core 71 85 Argon 15 198 993 Ref 803 246 B OM 221 771 Page 47 SECTION 5 MAINTENANCE 5 1 Routine Maintenance Check lt Change Clean Replace Reference To be done by Factory Authorized Service Agent a c x Al 9 2 RV A Disconnect power gt Maintain more often before maintaining during severe conditions 3 id Unreadable Labels Weld Terminals Damaged Gas Hose Weld Cables Months lt X Cords Gun Cables Every 6 Months f Drive Rolls Q Inside Unit 5 2 Blowing Out Inside Of Unit ar A Do not remove case w
40. charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie destin e cet usage Les PI CES MOBILES peuvent causer des blessures e S abstenir toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section E e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal
41. ecce xe REIP Ee UE Tes Es 1 bx TO 180270 Contactor DEF PRP 40A 24VAC Coil W Boxlug 1 ned esum esed w nus 213386 Assembly Filter Primary 1 12 HD2 182918 Transducer Current 400A Module Supply V 15V 1 SUR E Rune ated 250783 LEM cable ed p pe REC d c 198951 Block Terminal 3 Pole 1 vesc WAL 148025 Lug Univ W SCR 600V 2 0 6 Wire 266 Stud 1 Dente eerte Sada ety 213372 Filter Assy Secondary 1 6216 RE Fig 9 5 Front Panel Assembly 1 oa A ig SOR rS Dr des 227855 Kit Connectors W Washer For Power Cables Includes 1 o VERDE 204839 Insulator Base Inverter Control Circuit Card 1 san darts 228896 Strap Grounding 17 25 in 1 bd gue en ets 228897 Strap Grounding 26 75 1 Ve oie dg dee 226550 Filter Assy Secondary W Screw 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggeste
42. from being enabled 24 On Input signal On from relay K4 to indicated wire stuck in weld joint Off Input signal Off from relay K4 to indicate wire is not stuck in weld joint 25 Indicates 5 volts DC is present on automation module PC9 221 771 Page 58 LED Status Diagnosis Off Indicates 5 volts DC is not present on automation module PC9 26 On Input signal on from relay K5 for flow shielding gas or coolant present Off Input signal off from relay K5 for flow shielding gas or coolant not present 27 On Indicates 15 volts DC is present on automation interface module PC9 Off Indicates 15 volts DC is not present on automation interface module PC9 28 On Indicates 15 volts DC is present on automation interface module PC9 Off Indicates 15 volts DC is not present on automation interface module PC9 29 On Input signal on from relay K6 for arc detected Off Input signal off from relay K6 for no arc detected 30 31 On See Network Status Table in Section 7 11 Off See Network Status Table in Section 7 11 32 On Input signal on for aux relay energized Off Input signal off for aux relay energized 33 On Input signal on touch sensor touch detected Off Input signal off touch sensor touch not detected Indicates that the signal is used on the PipePro 450 RFC 7 11 Network And Module Status LEDs A Network Status LEDs The following are network status LEDs LED1 on the UIM c
43. in at toes increasing travel speed and deposition and more tolerant to poor fit up and gaps Conventional pulse program using peak background pulse width frequency and peak voltage as factory taught data Adaptive method is controlled by frequency adjustment RMD Pro refers to Regulated Metal Deposition A precisely controlled short circuit transfer Benefits of RMD Pro are well suited to root pass welding on pipe improves gap filling and spatter reduction Provides less heat input into workpiece minimizes distortion and allows use of larger diameter wire on thin gauge materials In pulse and Pro pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory pulse data In RMD Pro this control will affect the arc in much the same way as inductance Provides voltage arc adjust wire feed rate and time value for modified arc starts which is only adjustable with the optional PDA with PipePro Program Management software PipeProMgr Stick SMAW welding uses a flux covered consumable electrode that produces a shielding gas and slag to shield the arc and molten weld puddle Synergic refers to the unit s ability to use preprogrammed pulse parameters to determine the actual pulse settings of Peak Amperage Background Amperage Pulse Frequency and Pulse Width at any specific wire feed Speed setting TIG GTAW welding uses a nonconsumable tungsten electrode and shielding gas to produce a strong clean high quality w
44. le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz comprim en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Les bouteilles de gaz comprim contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de g
45. locales Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les c bles doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entra ner la mort e L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform
46. panel OVER AVG The over average error indicates that current is outside the average range for the set program parameters Check and correct program parameters Leave the unit pow ered up for five minutes and then turn on the contactor to clear the fault ERR STUK The stuck error occurs if the welding wire sticks to the workpiece at the end of a weld May be caused by poor weld conditions The error may be cleared by cutting wire from workpiece and pressing any button on the front panel ERR TEMP The temperature error indicates welding power source has overheated shutdown The error may be cleared by allowing unit to cool down and cycle power to clear error If problem persists check fan motors for proper operation If unit is not overheated check that input line voltages are within specifications input line voltages are okay contact nearest factory authorized Service Agent PLS WAIT The uim communication error indicates user interface module PC7 lost data communications Press any button on front panelto clear error If condition persists con tact nearest factory authorized Service Agent UNIT COMM The unit communication error indicates the data bus on the PCM board is not functioning properly Press Jog Purge button to clear error Leave the unit powered up for five minutes and then turn on the con tactor to clear the fault ERR SENS The sensing error indicates no ocv when o
47. to select proper Do not place anything between weld cable terminal and copper bar cable size 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal Connect positive weld cable to Positive weld terminal and negative cable to Negative weld terminal 3 Weld Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal Incorrect Installation Ref 803 244 B 803 778 A 6 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean OM 221 771 Page 16 3 10 Weld Output Terminals And Selecting Cable Sizes NOTICE The Total Cable Length in Weld Circuit see table below is the combined length of both weld cables For example if the power source is 100 ft 30 m from the workpiece the total cable length in the weld circuit is 200 ft 2 cables x 100 ft Use the 200 ft 60 m column to determine cable size Weld Cable Size and Total Cable Copper Length Weld Circuit Weld Output Not Exceeding Terminals A Turn off power be fore connecting to weld output termi dua mic L 150ft 200ft 25
48. while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection WELDING cause fire or explosion
49. writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original Main Power Rectifiers Only to Include SCRs Diodes and Discrete Rectifier Modules 2 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are Warranted Separately by the Engine Manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor TJransformer Rectifier Power Sources Water Coolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices QCoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors Field Options NOTE Field options are covered for the remaining warranty period of the product they are in
50. 0 4 ea 4 0 2x70 2x95 2x120 3x95 3x120 3x120 4x120 800 4 0 120 2 ea 2 0 2 ea 3 0 2ea 4 0 3 ea 4 0 3 ea 4 0 4 ea 4 0 4 ea 4 0 2x70 2x95 2x120 3x120 3x120 4x120 4x120 900 2 ea 2 0 2 ea 3 0 2 ea 4 0 3ea 3 0 2x70 2x95 2x120 8x95 1000 2 ea 2 0 2 ea 3 0 2ea 4 0 3ea 3 0 2x70 2x95 2x120 8x95 1250 2 ea 3 0 2 ea 4 0 3ea 3 0 4 3 0 2x95 2x120 8x95 4x95 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable 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 J 2011 07 OM 221 771 Page 17 3 11 Arranging Welding Cables To Reduce Welding Circuit Inductance DO NOT coil cables DO NOT share work clamps no more than 1 machine per clamp NOT tangle cables from different machines splice weld cables NOT allow volt sense lead braided shield to touch center conductor or workpiece Ideal Use shortest cables possible for the job Use proper sized work clamp and weld cables to accommodate peak amperages e Separate volt sense lead and
51. 0 4 Pca SHEET 1 RC6 1355 26 3555 lt lt 022 PROCESS CONTROL BOARD 142 gt 22 ___ HK 10 3 8 255 AD 424 22 pore J1 PLG33 lt 524 COMMON RO SUMMED 12 PL034 8 52 EET RC6 225 S COMMAND n2 J3 PLG35 18 1 gt gt CAN H RCG 1020 77 JB SUMMED CON Seda mms 38 43 BE E 8 RC6 67 K J1 6 J6 PLG43 18 3 gt gt PUE Rp Rce a 5 _ 275 COMMAND COM ka 8 re T2 N 2 9 POWER J10 PLGB1 WU MED Pe ANA Rce 1120 222 22 LATCH e 2 6 43 199 GAL SHEET 1 2 Sue por RC6 12 gt gt 227 MO 07 2 7 RCo PLGG 1 52 LINVERTER 8 6 1 gt MODULE 1 J4 1 gt gt 222 SHEET 1 14 25 257 EcL 2 225 4 27 JS 228 J4 5 gt gt _ 24 44 65 22 EGND OM 221 771 Page 64 Figure 8 2 Circuit Diagram For Welding Power Source Part 2 Of 2 WARNING e Do not touch live electrical parts Disconnect input power or stop engine before servicing 7 Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit 4 RC70 27 SENSOR ON SINK lt RC70 29 SENSOR ON SOURCE lt RC70 17 RD COMMON 26 CONDUCTOR lt 870 28 TOUCHED SINK RC70 18 TOUCHED SOURCE RC52 RC42 lt RC70 15 RELAY COMMON j lt RC70 26 ERROR lt RC70 2 STANDBY 55 X l
52. 0ft 300ft 350ft 400 ft Do not use worn 30 m or Less 45m 60m 70m 90m 105 m 120 m damaged under sized or poorly spliced cables 10 60 60 100 Welding Duty Duty 10 100 Duty Cycle Amperes Cycle Cycle AWG mm AWG mm AWG mm 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 ea 2 0 2 ea 2 0 250 2 85 1 50 1 0 60 2 0 70 3 0 95 40 120 ooo 70 2 ea 2 0 2ea 3 0 2ea 3 0 300 1 50 1 0 60 20 7 3 0 95 40 120 ax 2x95 2x95 2 ea 2 0 2ea 3 0 2 ea 3 0 2 ea 4 0 350 1 0 60 2 0 70 3 0 95 40 120 ooo 2 95 2x95 2x120 2 ea 2 0 2ea 3 0 2 ea 4 0 2 ea 4 0 2x70 2x95 2x120 2x120 400 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2 ea 3 0 2ea 4 0 3 ea 3 0 3 ea 3 0 2 0 7 4 0 12 Soie TE 500 0 70 3 0 95 0 120 2x70 2x95 2x120 3x95 3x95 2ea 2 0 2 3 0 2ea 4 0 3 ea 3 0 3 ea 4 0 3 ea 4 0 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 700 4 0 120 2 ea 2 0 2 ea 3 0 2 4 0 3 0 3ea 4 0 3ea 4
53. 1 2 Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 2 and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet a BUILDUP OF GAS can injure or kill e Shut off compressed gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing No
54. 1 Sp OO ci ee wd eek ote 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 1 nb gaits Oe eden dee edt 196514 Gasket Inductor Mounting 2 BAGO NE 196512 Bracket Inductor Mounting 2 s MOL E 196330 Heat Sink Power Module 1 L2 estes 196345 Coil Inductor 1 REES DC A RES EX 196588 Baffle Foam Rubber 1 STIL 196365 Plugs w Leads Fan 1 aah Gentile gin Md 199136 Plugs w Leads PC2 1 1 36 1 239612 Circuit Card Assy Control Inverter 300A 1 Od don hoes SWR wate 204846 Insulator 4 rar nate a den 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 High 4 When ordering a component originally displaying a precautionary label the label should also be ordered This kit contains two modules and instructions Be sure to follow the field kit instructions when performing the installation To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial numbe
55. 3 Front Panel Controls Continued See Section 4 2 28 4 4 Front Panel Switches 28 4 5 Typical Connection Diagram For MIG GMAW Equipment Using A Suitcase Feeder 29 4 6 Typical Connection Diagram For MIG GMAW Equipment Using A Digital Feeder 30 4 7 Typical Connection Diagram For GMAW Equipment Using DX Feeder 31 4 8 PipePro 450 Set Up For MIG GMAW Equipment 32 4 9 Typical Connection Diagram For TIG GTAW 33 4 10 Typical Connection Diagram For TIG GTAW Equipment Using A DX Feeder 34 4 11 PipePro 450 RFC Set Up For Lift TIG GTAW Equipment 35 4 12 Typical Connection Diagram For Stick GMAW 36 4 13 Typical Connection Diagram For Stick GMAW Equipment Using DX Feeder 37 4 14 PipePro 450 RFC Set Up For Stick GMAW Equipment 38 4 15 PipePro 450 RFC Set Up For Carbon Arc Gouging CAC A Equipment 39 4 16 Isolating Two Processes Using Polarity Reversing Isolation Control 042 871 With HF Unit 40 4 17 Isolating Two Processes Using Polarity Reversing Isolation Control 042 871
56. 4 California Proposition 65 08 4 1 5 Principal Safety Standards 4 1 6 EMF Information iR AREE REX 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles gt oes Mae ae ete is SR EE RET E ESL ERA EN 5 2 2 Dangers relatifs au soudage l arc 5 2 8 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 4 9 2 6 Informations relatives aux 9 SECTON 3 INSTALLATION 22222525524 3 op ue Eie dette 11 3 1 Serial Number And Rating Label Location 11 3 2 Specifications nan dC ERE D US E d d ded e d RR 11 3 3 Dimensions And 11 3 4 Duty Cycle And Overheating 12 3 5 Volt Ampere cs PURO US Rex d dee RR RN 13 3 6 Selecting A Locatio
57. 4 Nominal 045 1 140 500 w 175 Nominal 50 55 w 53 Nominal 25 3 6 12 7 w 4 4 Nominal 045 1 140 500 w 175 Nominal 50 55 w 53 Nominal 3 6 12 7 w 4 4 Nominal OM 221 771 Page 44 Stainless Steel Wire Size Wire Feed Speed Arc Adjust Trim Arc Control Shielding Gas in mm IPM mpm 035 0 9 120 290 w 200 Nominal 47 51 w 50 Nominal 25 Tri H 3 0 7 4 w 5 1 Nominal 040 1 0 120 275 w 200 Nominal 48 52 w 50 Nominal 30 Tri H 3 0 7 4 w 5 1 Nominal z 040 1 0 120 275 w 200 Nominal 48 52 w 50 Nominal 25 98 2 RMD Stainless Steel 3 0 7 4 w 5 1 Nominal 040 1 0 120 275 w 200 Nominal 48 52 w 50 Nominal 25 98 2 Ox 3 0 7 4 w 5 1 Nominal 045 1 1 120 160 w 150 Nominal 48 52 w 50 Nominal 25 3 0 4 1 w 3 8 Nominal 035 0 9 150 780 w 175 Nominal 53 57 w 55 Nominal 25 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 52 57 w 56 Nominal 16 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 48 54 w 53 Nominal 18 98 2 3 8 19 8 w 4 4 Nominal ProPulse Stainless Steel Using 035 0 9 150 780 w 175 Nominal 48 52 w 51 Nominal 18 98 2 Ox A Positioner 3 8 19 8 w 4 4 Nominal Rolling The Pipe 045 1 1 140 450 w 200 Nominal 52 55 w 55 Nominal 25 3 6 11 4 w 5 1 Nominal 045 1 1 120 525 w 200 Nominal 53 57 w 55 Nominal 16 98 2 3 0 13 3 w 5 1 Nominal 045 1 1 120 525 w 200 Nominal 53 57 w 55 Nominal 25 98 2 Ox 3 0 13 3 w 5 1 Nominal 035 0 9 150 780 w 175 Nominal 53 57 w 55 Nominal 2
58. 5 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 52 56 w 54 Nominal 16 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 48 52 w 50 Nominal 18 98 2 3 8 19 8 w 4 4 Nominal 035 0 9 150 780 w 175 Nominal 46 50 w 48 Nominal 18 98 2 Ox ProPulse 3 8 19 8 w 4 4 Nominal Stainless Steel Welding In Position 045 1 1 120 525 w 140 Nominal 53 57 w 55 Nominal 25 3 0 13 3 w 3 6 Nominal 045 1 1 120 525 w 140 Nominal 50 55 w 53 Nominal 16 98 2 3 0 13 3 w 3 6 Nominal 045 1 1 120 525 w 140 Nominal 50 55 w 53 Nominal 25 98 2 Ox 3 0 13 3 w 3 6 Nominal 045 150 500 w 300 Nominal 50 55 w 53 Nominal 25 30 Argon Inconel 625 3 8 12 7 w 7 6 Nominal OM 221 771 Page 45 Wire Size Rolling Pipe In Position Voltage Shielding Gas in mm Wire Feed Speed IPM mpm 045 1 1 175 780 w 200 Nominal 24 5 32 w 24 5 75 25 Flux Core GMAW 4 4 19 8 w 5 1 Nominal Nominal Note Arc Control is arc width and Arc Adjust Trim is arc length Wire feed speed and voltage synergic for the RMD and ProPulse processes Therefore when adjusting wire feed speed the voltage is automatically adjusted so it is not necessary to adjust Arc Adjust Trim These are only starting parameters the operator must make final adjustments depending on material and conditions See wire manufacturer for recommended wire feed speed and gas mixture 4 21 Welding Stainless Steel With And Without Backing Gas Using PipePro 450 RFC
59. 9 L1 E E Route input power cable through tubing inside unit 2 x Route ground conductor E through current transducer to ke ground terminal FE Jt Jd Tools Needed aS gt 5 16 in Three Phase Input Connection GND PE 218005 C Input5 2012 05 Ref 803 766 C Ref 803 245 C 218 005 C OM 221 771 Page 24 3 18 Connecting 3 Phase Input Power Continued IN Turn welding power source and check voltage on input capacitors according to Section 7 4 before proceeding Installation must meet all National and Local Codes have only quali fied persons make this installation Disconnectand lockout tagout input power before connecting input conductors from unit Follow estab lished procedures regarding the in stallation and removal of lockout tagout devices A Make input power connections to the welding power source first Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal NOTICE The Auto Line circuitry in this unit automatically adapts the power source to the primary voltage being applied Check in put voltage available at site This unit can be connected to any input powe
60. D is lit turn the Adjust knob to select the desired weld gas Gas type choices vary according to the selected weld process See Table 4 1 for all gas abbreviations 6 Setup Push Button LED The LED lights to indicate one of the setup modes is active 7 Setup Pushbutton Press button to select Process Wire Type Wire Diameter or Gas Type parameters 5 In order for selections to be retained in memory the Setup pushbutton must be pressed up to six times before any other button is pressed The displays will temporarily show PROG LOAD to indicate the data is being stored in memory 8 Arc Control LED The LED lights to indicate the Arc Control button is active Light goes out when button is inactive OM 221 771 Page 27 4 3 Front Panel Controls Continued See Section 4 2 9 Arc Control Pushbutton This button allows fine tuning inductance for MIG and FCAW programs and Arc Control for pulse programs and DIG for Stick and Carbon Arc programs When the button is pressed the upper display item 15 shows INDU for inductance ARC for Arc Control and DIG for Dig Control to indicate which parameter is selected to change The range of possible values is 0 99 for inductance and dig and 0 50 for arc control factory default value is 25 Turn the Adjust knob to change the parameter value Press button to deactivate arc control mode LED goes out 10 Wire Feed Gas Contactor LEDs The Contactor LED lights when t
61. E FOR DIRECT INDIRECT SPECIAL INCIDENTAL CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller_warr 2012 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style N
62. E handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards 2 N MOVING PARTS injure Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can injure e Do not press gun trigger until instructed to do 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire 5 BATTERY EXPLOSION injure e Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose MOVING PARTS can injure e Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes H F RADIATION can cause interference e
63. Hose 10 Gas Cylinder I Extension cable maximum length not to exceed 150 ft 46 m 11 Extension Cable Optional 12 Remote Switch To MIG OM 221 771 Page 31 4 8 PipePro 450 RFC Set Up For MIG GMAW Equipment See Table 4 1 for selection choices 1 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 EF If the desired program has been previously loaded only the program number needs to be selected This process does not have to be followed every time a different program is selected 2 Push Setup button once Use the Adjust knob to choose weld Process MIG Pro Pulse RMD Pro FCAW FCAW has no wire settings but does have a gas setting go to Step 6 3 Push Setup button again Use the Adjust knob to choose Wire INCO MCOR CrMo SS or STL 4 Push Setup button again Use the Adjust knob to choose Alloy Type filler metal classification 5 Push Setup button again Use the Adjust knob to choose Wire Diameter MIG has no gas options go to Step7 6 Push Setup button again Use the Adjust knob to choose Gas Mixture For FCAW choose YES or NO 7 Push Setup button again The display will read PROG LOAD and welding power source is now ready for the welding operation If using a DX feeder the Remote switch on the front near the bottom of the feeder m
64. MIG DRIVE MOTOR MIG SWITCH 1 O B 2 FROM s1 POWER SOURCE HF 251D 1 W SECONDARY CONTACTOR ELECTRODE ELECTRODE IN OUT WORK WORK INPUT OUTPUT Tools Needed 3 13 16 Ref 099 082 C Ref 098 115 4 17 Isolating Two Processes Using Polarity Reversing Isolation Control 042 871 Without HF Unit N 42 1 Electrode 1 D mid Wy m D 2 Electrode 2 3 A Terminal 4 B Terminal 5 C Terminal 1 2 3 4 5 WIRE FEEDER POLARITY REVERSING MIG DRIVE MOTOR MIG SWITCH 1 B 2 FROM 51 WORK POWER SOURCE TIG gt gt E 1 Tools Needed IE 13 16 in Ref 099 082 C Ref 098 115 B OM 221 771 Page 40 4 18 Isolating Three Processes Using Polarity Reversing Isolation Control 042 871 With HF Unit JUMPER A TOB SWITCH 1 B FROM POWER SOURCE POLARITY REVERSING 1 Tools Needed IE 13 16 in ELECTRODE ELECTRODE IN OUT WORK INPUT OUTPUT STICK 1 2510 1 W SECONDARY WORK won Electrode 1 Electrode 2 A Terminal Bus Bar B Terminal C Terminal Ref 099 082 C Ref 098 115 B 4 19 Isolating Three Processes Using Polarity Reversing Isolation Control 042
65. Off Remote Jog off from peripheral plug 10 On Input signal On Remote Purge on from peripheral plug Off Input signal Off Remote Purge off from peripheral plug 11 On Input signal On from robot for jog retract Off Input signal Off from robot for no jog retract 12 On Input signal On from robot for purge Off Input signal Off from robot for no purge 13 On Input signal On remote program B selected Off Input signal Off remote program B not selected 14 On Input signal On Touch Sensor on from robot or peripheral plug Off Input signal Off Touch Sensor off from robot or peripheral plug 15 On Spare 0 not assigned Off Spare 0 not assigned 16 On Spare 2 not assigned Off Spare 2 not assigned 17 On Input signal On Autoset A selected Off Input signal Off Autoset A not selected 18 On Input signal On Autoset D selected Off Input signal Off Autoset D not selected 19 On Input signal On Remote Retract on from peripheral plug Off Input signal Off Remote Retract off from peripheral plug 20 On Input signal On Remote Water Flow on from peripheral plug Off Input signal Off Remote Water Flow off from peripheral plug 21 On Input signal On from robot for no emergency stop Off Input signal Off from robot for emergency stop 23 On Input signal On from relay K3 for welding power source ready and no detected errors present Off Input signal Off from relay for welding power source not ready detected errors are present or unit is in operating mode preventing the weld ready signal
66. R RR Med RE 51 7 2 Troubleshooting Welding Power Source Wire Feeder Issues 52 7 3 Diagnostics s rues D SpA ui Cd ee aea de tal ss b teles 53 7 4 Removing Cover and Measuring Input Capacitor Voltage 54 7 5 Process Control Module Diagnostic LEDs 55 7 6 Diagnostic LEDs On Process Control Module 55 7 7 User Interface Module Diagnostic LEDs 56 7 8 Diagnostic LEDs On User Interface Module 7 56 7 9 Automation Interface Module PC9 Diagnostic LEDS 57 7 10 Diagnostic LEDs On Automation Interface Module PC9 58 7 11 Network And Module Status LEDs 59 7 12 Troubleshooting Ed EE d COEUR ME 60 SECTION 8 ELECTRICAL DIAGRAMS 62 SECTION 9 PARTS LIST ex IIIA RLW 66 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2011 10 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 i
67. Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on containers that have held combustibles or on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes OM 221 77
68. ace Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal Disconnect cable for process not in use SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn e Do not touch hot parts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns OM 221 771 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or
69. az font normalement partie du proc d de soudage les manipuler avec pr caution e Prot gerles bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs Placerles bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz comprim r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Lecouvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Associati
70. d Replacement Parts Model and serial number required when ordering parts from your local distributor OM 221 771 Page 67 Hardware is common and not available unless listed 13 802 955 Figure 9 2 Windtunnel Assembly LH RH Item Dia Part No Mkgs No Description Quantity Figure 9 2 Windtunnel Assembly LH And RH Fig 9 1 Item 6 xe 214597 Windtunnel LH w Components including 1 O 196351 Windtutnnel BED uoi E ua ove at re eee ore eR ea o n 1 917 213940 Inductor Ihput coti RE RO 1 PE Ip EE 214519 Insulator Heat Sink Rectifier 1 RS couv 233052 1 Sn Oo Biot hid che eles 199840 Bus Bar Diode 2 7 D1 D2 201531 Kit Diode Power Module 2 Rau ra adu ei b aud 196347 vza Heat Sink Rectifier cie cir eb 1 D cox atten wis 196349 Spacer Windtunnel 3 zw dE tasso 203408 Xfmr HF Litz Litz 1 Los at ZA Assis 220496 Output Inductor Assy 1
71. d program has been previously loaded only the program number needs to be selected This process does not have to be followed every time a different program is selected 2 Push Setup button once Use the Adjust knob to choose TIG weld Process 3 Push Setup button again Use the Adjust knob to choose type of Control CTRL PANL or CTRL REMT a If Panel control is selected press the Wire Feed Speed Amps display button for amperage output Use the Adjust knob to set the desired amperage b If Remote control is selected connect a remote device to the front of the DX Feeder feeder switch must be in 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 Lift TIG cannot have the Volt Sense lead connected to the PipePro 450 RFC when connected for Electrode Negative straight polarity 4 Push Setup button again The display will read PROG LOAD and welding power source is now ready for the welding operation No changes are saved until PROG LOAD appears on the display after completing the settings If the Setup button is pressed to review the settings and nothing is changed PROG LOAD will not appear on the disp
72. di tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants Indique des instructions sp cifiques cal Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger dans l ordre indiqu 1 un poste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentationselon la norme OSHA 29 CFR 1910 147 voir nor mes de s curit e Installez mettez la terre et utilisez correctement cet quipement conform ment son Manuel d Utilisation et aux r glementations nationales gouvernementales et
73. e In CC Mode Three DC 54 0 49 0 28 0 24 0 19 0 19 9 IP23 19 2 Phase 100 10 44 V T 0 1A 0 1 0 1 0 1 0 1 0 8 0 17 Duty In CV Cycle inod In CV Mode While idling Input amperage fluctuates while idling and is always less than one Ampere Use one Ampere for power efficiency calculations This equipment is designed for outdoor use It be stored but is not intended to be used outside during precipitation unless sheltered 3 3 Dimensions And Weight Hole Layout Dimensions E p 22 1 2 in 572 mm A 17 3 32 in 434 mm D B 17 3 8 in 441 mm 31 in C 19 3 32 in 485 mm 787 mm D 16 3 32 in 409 mm c B E 1 2 in 13 mm Weight 17 3 22 in 434 163 Ib 74 kg Net 180 Ib 82 kg Ship D Ref 803 244 B OM 221 771 Page 11 3 4 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated 600 load without overheating 00 3 PHASE f unit overheats thermostat s 400 OPERATION output stops and cooling fan runs Wait fifteen minutes for 300 unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle a 200 can damage unit and void warranty 100 0 10 ae 40 EE T TY S B 00 DUTY CYCLE 100 Duty Cycle At 450 Amperes 60 Duty Cycle At 580 Amp
74. e de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux Le soudage l caillement
75. eld Preset voltage in MIG mode at idle actual voltage while welding and 3 seconds hold value at end of weld Selection of wire type by alloys and classification Term used to represent wire feed speed In MIG mode wire feed setting is independent of voltage setting In pulse Pro pulse and RMD Pro adjusting wire feed speed also increases power level on wire electrode one knob control 4 2 Front Panel Controls See Section 4 3 13 12 WireSpeed Amps 11 Wirefeed e Gas 10 Contactor 8 Arc Control 07 When an LED is lit it means the related function is active 1 Program Display Displays the number of the active program 2 Adjust Knob Turn the Adjust knob to change program number Setup Arc Control and weld parameters Panel Remote amperage control is set for each individual program When set to remote the control range is from minimum to the value set on the front panel 3 Program Pushbutton LED The LED lights when the Program Pushbutton is active 4 Program Pushbutton Press button LED lights and turn Adjust knob to select active program The letter C is displayed with the program number if the program has been changed from the factory settings using the optional PDA with PipePro Program Management software PipeProMgr The program cannot be changed through the front panel while welding
76. elding Power Source 7 Workpiece across the workpiece will not be measured 2 Electrode Cable Thi correctly for the voltage feedback signal IS arrangement is bad setup due 10 Voltage feedback to the welding power e em sensing leads being directly in the current sources will not be correct at either sense flow path of the welding arc Interaction lead and result in poor arc starts and arc 5 Voltage Sensing Lead between welding circuits will affect voltage quality 6 Wire Feeder drop in the workpiece The voltage drop OM 221 771 Page 19 B Ideal Setup Ref 804 461 1 Welding Power Source 6 Wire Feeder the welding power sources The most 2 Electrode Cable accurate voltage sensing may not be 3 Extension Cable Optional T Workpiece due RO drops in the workpiece is may require E Work Cable This arrangement is a better setup for compensation in the welding parameters 5 Voltage Sensing Lead supporting separate voltage feedback to OM 221 771 Page 20 3 13 Rear Panel Receptacles And Supplementary Protectors 1 115V 10 AC Receptacle RC2 Receptacle supplies 60 Hz single phase power Maximum output from RC2 is limited by supplementary protector CB1 to 10 amps 2 Supplementary Protector CB1 3 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload If CB1 opens RC2 does not work
77. eli Argon 30 Helium 0 045 1 2 1 CO TRIS 90 Argon 10 C10 0 035 0 9 85 Argon 15 C15 90 Argon 10 C10 0 040 1 0 85 Argon 15 C15 90 Argon 10 C10 Steel STL 0 045 1 2 85 Argon 15 C15 0 052 1 3 90 Argon 10 10 0 062 1 6 90 Argon 10 10 0 040 1 0 85 15 15 0 045 1 2 85 15 15 Pulse Inconel INCO 625 0 045 1 2 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 221 771 Page 42 Table 4 1 Welding Programs Continued Diameter 55 Alloy Type Gas Mixture inch mm Chrome Moly CrMo 596 0 045 1 2 75 Argon 25 C25 0 045 1 2 90 Argon 10 C10 Metal Core MCOR 76 0 045 1 2 85 Argon 15 15 98 Argon 2 C2 96 A 296 0 035 09 98 Argon 2 Oxygen OX2 90 Helium 7 5 Argon 2 5 CO TRIB 98 Argon 2 C2 Stainless Steel SS 308 316 001245 28 Argon 2 Oxygen 0x2 90 Helium 7 5 Argon 2 5 CO TRIS 98 Argon 2 C2 0 045 12 98 Argon 2 Oxygen OX2 90 Helium 7 5 Argon 2 5 CO TRIR RMD Pro 90 Argon 10 C10 85 Argon 15 C15 0 035 0 9 75 Argon 25
78. enfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tincelles sont projet es pendant 1 soudage casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 221 771 Page 6 LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des q
79. eres Continuous Welding 6 Minutes Welding 4 Minutes Resting Overheating gt AN by e Oy OR Minutes Reduce Duty Cycle duty1 4 95 220 485 A Notes OM 221 771 Page 12 3 5 Volt Ampere Curves Volt ampere curves show minimum and maximum voltage amperage output capabilities of unit Curves of other settings fall between curves shown Lx This volt ampere represents the dynamic output CV MODE of the unit with a static load VOLTS 0 100 200 300 400 500 600 700 AMPERES CC MODE SMAW MIN SMAW MAX GTAW MIN VOLTS GTAW MAX 0 200 400 600 AMPERES va curve1 4 95 220 486 OM 221 771 Page 13 3 6 Selecting A Location CL Pi Movement Tipping A Do not move or operate unit where it could tip Location A Do not stack units Beware of tipping 1 Lifting Forks Use lifting forks to move unit Extend forks beyond opposite side of unit 2 Use cart or similar device to move unit 3 Line Disconnect Device Locate unit near correct input 18 in Special installation may be 460 mm required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 loc 2 3 96 Ref 803 244 OM 221 771 Pa
80. f not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards The symbols shown below used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch li
81. feeder control cable from weld cables Place weld cables together if possible Connect work clamp as close to welding arc as possible Welding Power Source Electrode Cable Extension Cable Optional Work Cable Volt Sense Lead Wire Feeder Workpiece The method used to arrange cables has a significant affect on welding properties As an example Pro pulse and RMD welding processes can produce high welding circuit inductance depending on cable length and arrangement This can result in limited current rise during droplet transfer into the welding The electrode sense lead is contained in the feeder control cable and is enabled for all processes The work sense lead connects to the welding power source 4 pin connector located above the negative output terminal This work sense lead automatically compen sates for work cable voltage drop when connected to the welding power source Do not coil excess cables Use cables that are the appropriate length for the application Whenever using long weld cables longer than 50 ft 15 m try to arrange positive and negative weld cables together to reduce the magnetic field surrounding the cables Avoid coupling the feeder and work sense leads with the weld cables Ref 804 458 A OM 221 771 Page 18 3 12 Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A Bad Setup PE Ref 804 460 A 1 W
82. from moving parts such as fans Keep away from pinch points such as drive rolls e Have only qualified persons remove doors panels covers or guards for maintenance and troubleshootingas necessary Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power can affect Implanted Medical Devices KR e Wearers of Pacemakers and other Implanted A M Medical Devices should keep away from serv icing areas until consulting their doctor and the device manufacturer E OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit o ELECTRIC AND MAGNETIC FIELDS EMF T 6 3 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 amp Safety Code Section 25249 5 et seq 6 4 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wea
83. ge 14 3 7 Proper Ring Terminal Connection To Volt Sense Lead If volt sense lead is cut or broken at ERE 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 1 Jacket Insulated Tape Or Heat Shrink Tubing Braided Shield Inner Core Center Conductor Ring Terminal Tools Needed 3 8 Connecting Volt Sense Lead And Work Cable To Clamp E 1 Volt Sense Lead 2 Work Cable 3 Clamp Be sure that volt sense lead ring terminal is on top of work cable ring terminal when connecting to clamp Connect volt sense lead and work cable to clamp Tools Needed 5 1 2 in 3 1 2 805 030 A OM 221 771 Page 15 3 9 Connecting To Weld Terminals d If using an electrode negative straight polarity process the volt sense lead must be connected to the work Correct Installation Tools Needed 3 4 in 19 mm A Turn off power before connecting to weld output terminals A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine Determine total cable length in weld circuit both positive and negative cables combined and maximum welding amperes See Section 3 10
84. he avant de poursuivre le soudage Ne pas obstruer les passages d air du poste UN L EMPLOI EXCESSIF _ peut LES TINCELLES PROJET ES peuvent provoquer des blessures y Porter un cran facial pour prot ger le visage ei les yeux e Aff ter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette man uvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps Les tincelles risquent de causer un incendie loigner toute sub stance inflammable LES CHARGES LECTROSTATI QUES peuvent endommager les cir LS cuits imprim s CIS 2 e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antista tiques pour stocker d placer ou exp dier des cartes de circuits imprimes OM 221 771 Page 7 Les 5 MOBILES peuvent causer des blessures e Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent provoquer des blessures Ne pas appuyer sur la g chette avant d en avoir recu l instruction Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en engageantle fil de soudage L EXPLOSION DE LA BATTERIE peut provoquer des blessures Ne pas utiliser l appareil de soudage pour
85. he output contactor is energized making the weld output terminals live 11 Wire Speed And Amps LEDs The lit LED indicates whether wire speed or amps are being displayed 12 Wire Feed Speed Amps Display Pushbutton This button toggles display information in pulse MIG Pro pulse and RMD Pro pro cesses Also it is used to enable and disable the contactor in panel mode for stick TIG and Carbon Arc 13 Lower Display Press Wire Feed Speed Amps Display button to show weld amperage or wire feed speed in lower display the applicable LED under the lower display lights to indicate which is shown When welding actual value is shown If amperage was selected for display the unit will show actual welding amperage prior to and while welding unless the the unit is in Display Command Values mode Only wire speed command will be displayed while welding if the unit is set in Display Command Values mode even if the Wire Feed Speed Amps Display button is pressed x Displays show actual or command values as determined by configuration menu when using a PDA with PipePro Program Management software PipeProMgr Command values are displayed prior to welding and actual values are displayed while welding unless a PDA with PipePro Program Management software Pipe ProMgr was used to set the unit in the Display Command Values mode In the Display Command Values mode command values are displayed while welding If a PDA with
86. hen blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown Ref 803 244 B OM 221 771 Page 48 SECTION 6 SAFETY PRECAUTIONS FOR SERVICING A Protect yourself and others from injury read follow and save these important safety precautions and operating instructions 6 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 6 2 Servicing Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard A Only qualified persons should test maintain and repair this unit During servicing keep everybody especially children away e ELECTRIC SHOCK can kill e Do not touch live electrical parts Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from re ceptacle or stop engine before servicing unles
87. int Follow recommended settings in Operation section of manual to select a starting point for welding Recommended joint preparation and fit up is 1 32 1 16 in 0 8 1 6 mm land and a 1 8 in 3 2 mm root opening Porosity in weld bead Check shielding gas supply that there is enough gas and supply is turned on Check shielding gas flow rate at regulator Check that gas pressure to the wire feeder does not exceed 90 psi 621 kPa Check all shielding gas fitting and tighten if necessary Remove gun end from wire drive housing and check condition of O rings Replace any worn or missing O rings Check power pin end of gun and tighten with a wrench Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end Check and clean shielding gas nozzle on gun Trouble feeding wire when welding Check drive rolls and wire guides to make sure they match the wire style and size Check drive roll tension and readjust if necessary Be sure that gun end is fully inserted into wire drive housing and knob is tightened down to secure gun end Check if hub tension at wire spool is too tight or too loose and readjust if necessary Be sure that welding gun cable is as straight as possible from wire feeder to workpiece Check if contact tip is correct size for the wire size and that end of contact tip is not plugged Check if gun liner is the correct size for the wire size and liner is not dirty or damaged
88. ipheral receptacle OM 221 771 Page 21 3 15 Motor Control Receptacle Functions Socket Socket Information A Not used B 40 volts DC C Not used SS N E e D 40 volts DC return E Not used e E e 5 E F Not used G Electrode sense H Not used J Not used Ref 803 245 B K Not used 3 16 Remote 14 Receptacle Information Socket Socket Information A 40 volts DC with respect to socket G Circuit common for 40 volts DC circuit B Contact closure to socket K completes contactor control circuit K Contact closure to socket B completes contactor control circuit C 10 volts DC input from power source to wire feeder with respect to socket D D Remote volt control circuit common E 0 to 10 volts DC remote volt trim signal from wire feeder to power source with respect to socket D H Voltage feedback 0 to 10 volts DC 1 volt per 10 arc volts F Current feedback 0 to 10 volts DC 1 volt per 100 amper es M 0 to 10 volts DC remote WFS signal from wire feeder to power Source with respect to socket N 1 volt per 100 IPM When doing Stick SMAW or TIG GTAW welding the 0 to 10 volts DC is a scale of the power source front panel setting Ref 804 374 A N Remote WFS control circui
89. ircuit 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 Both LEDs Green The circuit board is operating normally and the on line connection is made with the network Flashing Green The circuit board is waiting for an on line connection to be made with the network Red The circuit board has encountered a communication link failure with the network Check DeviceNet cable connections Verify dip switch positions according to Sections 7 7 and 7 9 Replace circuit board if necessary B Module Status LEDs The following are module status LEDs LED2 on the UIM circuit board LED3 on the WFM and PCM circuit boards LED31 on the AIM circuit board Status Diagnosis Off There is no power applied to the circuit board or the board software is not executing its functions Green The circuit board is operating normally Flashing Red The circuit board has encountered a recoverable fault Wait or cycle power to clear fault Red The circuit board has encountered an unrecoverable fault 221 771 Page 59 7 12 Troubleshooting god Trouble Remedy No weld output completely inoperative Place line disconnect in On position see Section 3 18 Check and replace line fuse s if necessary or reset circ
90. isconnect device line terminals 10 Over Current Protection Select type and size of over current protec tion using Section 3 17 fused disconnect switch shown Close and secure door on disconnect device Follow established lockout tagout procedures to put unit in service Input5 2012 05 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 221 771 Page 25 SECTION 4 OPERATION 4 1 Operational Terms The following is a list of terms and their definitions as they apply to this interface unit General Terms Adjust Amps Arc Adjust Arc Control Arc Length Flux Cored Arc Welding Gas Type Gouging Inductance MIG Process Process Set Up Program Program Load Pro pulse Pulse RMD Pro Sharp Arc Start Stick Synergic TIG Volts Wire Type WFS OM 221 771 Page 26 Control knob used to change or set parameters and functions Indicates average amperage while welding and 3 seconds hold value at end of weld Term used to represent arc length adjustments in pulse programs Increasing Arc Adjust increases the actual arc length Likewise decreasing arc adjust shortens arc length Arc Adjust is replaced by volts in MIG programs Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse Pro pulse and RMD Pro Also this button allows setting dig in stic
91. ise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Compressed gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct compressed gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installati
92. k mode Distance from end of wire electrode to workpiece Flux cored arc welding FCAW is a continuous electrode that is fed into the arc and depends on shielding gas from either an external source or is generated from the decomposition of gas forming ingredients contained in the electrode s core Selection of shielding gas being used in application The removal of molten metal from a workpiece surface using an electrode and gas source such as in air carbon arc gouging or plasma arc gouging In short circuit GMAW welding an increase in inductance will decrease the number of short circuit transfers per second provided no other changes are made and increase the arc on time The increased arc on time makes the welding puddle more fluid CV weld process with individual settings of voltage and wire speed A selection made for MIG Pulse Pro pulse RMD Pro Stick Carbon Arc Flux Core FCAW and Lift TIG Selection procedure for entering program Eight active slots for selection of various processes wire types and parameters Enters selected program information process wire type gas etc into program slot 1 8 Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds Adaptive response is controlled by peak and minimum current levels Benefits are shorter arc lengths better puddle control more tolerant of tip to work variation less audible noise no arc wandering allows weld to fill
93. lay for the program that was just loaded gt AC Volts Arc Adjust Arc Control 200 410 OM 221 771 Page 35 4 12 Typical Connection Diagram For Stick SMAW Equipment ES 1 Welding Power Source 2 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 Attach volt sense lead to work clamp and attach work clamp as close to arc as possible Volt Sense Cable Negative Weld Cable Positive Weld Cable Workpiece 14 Pin Plug On Remote Hand Control Cable Turn off welding power source before connecting to hand control 14 pin plug 8 Remote Hand Control 9 Electrode Holder Extension cable maximum length not to exceed 150 ft 46 m 10 Extension Cable Optional 11 Remote Adapter 300 248 804 788 C OM 221 771 Page 36 4 13 Typical Connection Diagram For Stick SMAW Equipment Using A DX Feeder 7 EZ CS The illustration shows remote control connected through the wire feeder The wire feeder is not connected to the power source output Do not mount feeder on top of pow er source
94. lding 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 amp Safety Code Section 25249 5 et seq 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS 4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 14501 George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 1 6 EMF
95. loigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux r
96. manufacturer e Readandfollow all labels and the Technical Manual carefully be fore installing operating or servicing unit Read the safety in formation at the beginning of the manual and in each section This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Donot work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 7 TROUBLESHOOTING 7 1 Set Value Mode Process Wire Type Gas The Set Value mode is a troubleshooting tool that allows certain command values to be manually over ridden 1 Setup Push Button 2 Arc Control Push Button 3 Adjust Knob 4 Wire Feed Speed Amps Display Push Button e Volts Arc Adjust Wire Speed Amps Wirefeed e Gas Contactor E n
97. mbler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps Spectrum Way Suite 100 Ontario Canada LAW 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Mainte
98. n 2 520 E SOON Ret A Ma Ee RE d e ee RU HERR Rn 14 3 7 Proper Ring Terminal Connection To Volt Sense Lead 15 3 8 Connecting Volt Sense Lead And Work Cable To 15 3 9 Connecting To Weld Terminals 16 3 10 Weld Output Terminals And Selecting Cable Sizes 17 3 11 Arranging Welding Cables To Reduce Welding Circuit Inductance 18 3 12 Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs 19 3 13 Rear Panel Receptacles And Supplementary 21 3 14 Peripheral Receptacle Functions 21 3 15 Motor Control Receptacle Functions 22 3 16 Remote 14 Receptacle 1 22 3 17 Electrical Service Guide ea ee a 23 3 18 Connecting 3 Phase Input Power 4 24 SECTION 4 OPERATION 5 2 ee en eee ee Ae i A LR TC TA ERA EVA 26 4 1 Operational Terms veri pp vv te entes e ee ef eser 26 4 2 Front Panel Controls See Section 4 3 27 4
99. ncy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 853 2220 website www osha gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Donot work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2011 10 Pour carter les risques de blessure pour vous m me et pour a
100. ng A DX Feeder e do The illustration shows remote control connected through the wire feeder The wire feeder is not connected to the power source output SS 5 11 804 779 9 Do not mount feeder top of pow Connect 14 pin socket into remote foot 8 Workpiece er source control cable or optional extension cable 9 Foot Control Connect 72 pin connector to I O receptacle RC72 on rear of power source Connect 10 Wire Feeder Do not put feeder where welding 10 pin connector into receptacle RC8 on Turn off welding power source before wire hits cylinder rear of power source connecting to wire feeder 14 pin plug lind i Do not move or operate equipment 9 Gas Cylinder 525 2 MORI length not when it could tip 4 Gas Hose 50 ft 46 5 Positive Weld Cable 15 E cee 1 Welding Power Source emote Switch To 8 cs Weld Gable 13 Volt Sense Receptacle 2 Interconnect Cable 7 Torch Cable Must Be Disconnected OM 221 771 Page 34 4 11 PipePro 450 RFC Set Up For Lift TIG GTAW Equipment See Table 4 1 for selection choices 1 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 EF If the desire
101. nir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la Soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 221 771 Page 9 OM 221 771 Page 10 SECTION 3 INSTALLATION 3 1 Serial Number And Rating Label Location The serial number and rating information for this product is located on front Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual FF Appearance of actual unit may vary from unit shown in manual 3 2 Specifications Amper Max Rated age Volt Open Amperes Input At Rated Load Output 60 Hz Input Weld dn Three Phase Input IP Input P Circuit Volt ower ing R kVA Rating KW Output ange age 208 V 230 V 400V 460 V 575 V DC DC 450 10 600 In CC M 36 5V Mod
102. not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit FERRITES TYP 3 PCS cn ED Rd RO2 B8 BUS 1 A ABA m RC3 355 1 RC3 7 55 25 AA Rose 200 Leen RC3 255 27 A4 X Rc2 2 RC3 1 gt RC5 5 gt 60 202 MAT 5 HF XFMR eRECT 8 2 lt cres s 78 BUS SENSE RC3 1 77 6 gt gt 2 lt lt 5 6 1 1 gt gt gt lt lt 5 1 1 5 gt gt lt lt 5 5 74 RC1 4 gt Soe 13 1 3 lt lt 5 3 1 7 gt gt lt lt 7 lt crecs 2 1 gt gt lt 78 46 lt INVERTER MODULE 2 RED J 1 RI E RC4 4 gt 7 RT 2 1 E P6 RCIE 1 RC10 255 5 gt 2 3 j RC4 8 gt lt lt RC6 14 RC6 7 RC6 13 4 RC6 12 lt lt RC6 5 lt lt RC6 2 lt lt RC6 6 lt lt RC6 11 RC6 10 lt lt RC6 8 lt lt RC6 9 RC6 1 SECONDARY HEATSINK PRIMARY HEATSINK RC10 1 gt
103. o 1 gt gt RC9 PLG9 1 Rc9 8 gt gt 48 RC10 PLG10 47 22 44 1 gt gt 1 4 22 42 Rc9 5 22 20 1 1192 z 1 Rco i2 32 Rco 2 22 24 1 gt gt 6 10 lt RC6 11 RC6 12 RC6 6 RC6 B RC6 9 Im RC6 1 223 217 222 2 6 218 219 AUXPOWER RC1 PLG18 RC2 PLG19 RC2 3 gt RC2 1 gt LY f gt gt lt 17 TO 12 lt SHEET 2 17 NOTE POWER CABLE SUPPLIED amp BY CUSTOMER TO BE NSTALLED S BLACK lt lt lt gt j K Rce 2 gt gt gt gt gt ii gt gt TO SHEET 2 TV 42 PLG79 71 5V 23V VOLET gt 5 2 TO E STOP SHEET 2 1 15V PLG21 RC2 4 gt gt 1 1 SHEET 2 15V 44 gt 6 GRAY 28V GRAY TO PLG 35 SHEET 2 TO PCIO SHEET 2 67 gt NEUTRAL GND RC2 115V RCPT Figure 8 1 Circuit Diagram For Welding Power Source Part 1 Of 2 OM 221 771 Page 62 WARNING Do not touch live electrical parts 7 Disconnect input power or stop engine before servicing Do
104. on Operation And Maintenance ii FIRE OR EXPLOSION hazard 4 Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment T OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit 7 FLYING SPARKS injure y e Wear a face shield to protect eyes and face e Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away N STATIC ESD can damage PC boards gt e Puton grounded wrist strap BEFOR
105. on mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance j Risque D INCENDIE OU h D EXPLOSION Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L QUIPEMENT peut provoquer des blessures e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement cables et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds N SURCHAUFFER L QUIPEMENT Pr voir une p riode de refroidissement res M pecter le cycle op ratoire nominal e R duire le courant ou le facteur de marc
106. ostic Dip switches are used to identify each Diagnostic LEDs are visible inside unit LEDs circuit board on the internal network Dip located on PC9 mounted on left side 2 DipSwitch S4 Switch settings are different for each circuit Refer to Section 7 10 for information on board For proper operation do not change diagnostic LEDs dip settings from those shown OM 221 771 Page 57 7 10 Diagnostic LEDs On Automation Interface Module PC9 LED Status Diagnosis 1 On Input signal On from robot for jog advance Off Input signal Off from robot for no jog advance 2 On Input signal On from robot to energize contactor Off Input signal Off from robot to not energize contactor 3 On Input signal On remote program A selected Off Input signal Off remote program A not selected 4 On Input signal On remote program C selected Off Input signal Off remote program C not selected 5 On Input signal On from E stop board PC12 for no emergency stop Off Input signal Off from E stop board PC12 acknowledges E stop is On from robot 6 On Spare 1 not assigned Off Spare 1 not assigned 7 On Input signal On Autoset C selected Off Input signal Off Autoset C not selected 8 On Input signal On Autoset B selected Off Input signal Off Autoset B not selected 9 On Input signal On Remote Jog on from peripheral plug Off Input signal
107. pecial instructions TK This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers securely in pl
108. perating with electrode negative in Stick TIG or Carbon Arc Remove volt sense lead and press any button on front panel to clear error E STOP The emergency stop error indicates connection is made to the 72 pin connector on the rear of the unit Connect Y cable to rear of welding power source ERR UNKN The unknown error indicates an error was sent from the process control module PC4 to the user interface module 7 but the error condition is unknown Make sure that welding power source is isolated from the welding fixture Leave the unit powered up for five minutes and then turn on the contactor to clear the fault OVER CRNT The over current error indicates welding power source primary current of the inverter is too high Turn welding power source off and disconnect unit for servicing Attempting to reset the display to continue welding may further damage internal components Contact nearest factory authorized service agent NET WAIT The network wait error indicates that the UIM board PC7 is no longer communicating with the PCM board PC4 by DeviceNet Turn welding power source off and disconnect unit for servicing Contact nearest factory authorized service agent 221 771 Page 53 7 4 Removing Cover and Measuring Input Capacitor Voltage 7 1 eu 900 Volts DC can be present on the capacitor bus S and significant DC voltage can remain on capacitors after unit is Off Alwa
109. r between 208 and 575 VAC without removing cover to re link the power source See rating label on unit and check input volt age available at site 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 3 17 Conductors must comply with national state and local electrical codes If applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief and tighten screws 3 Welding Power Source Grounding Terminal 4 Green Or Green Yellow Grounding Conductor Route green or green yellow grounding conductor through current transducer and connect to welding power source grounding terminalfirst Then connect input conductors L1 L2 and L3 to welding power source line terminals 5 Welding Power Source Line Terminals 6 Input Conductors L1 L2 L3 Connect input conductors L1 L2 and L3 to welding power source line terminals Reinstall side panel on welding power source Disconnect Device Power Connections Input 7 Disconnect Device switch shown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to d
110. r required when ordering parts from your local distributor OM 221 771 Page 69 Hardware is common and not available unless listed 6 8 Ref 802 916 B Figure 9 3 Top Tray Assembly Item Dia Part No Mkgs No Description Quantity Figure 9 3 Top Tray Assembly Fig 9 1 Item 4 209676 Circuit Card Assy E stop 1 cd ue POS s 231928 Circuit Card Assy Aux Power 1 QUUD ote eta a EN 210490 Bracket Mtg PC Card 1 PE 134201 Stand Off PC Card 312 375 Post amp Lock 43 4 Sx D dod Wadi reed foa 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 4 Process Control Module PCM see Table 9 1 1 mare 170647 Bushing Snap in 1 312 Id X 1 500 Mtg Hole 1 iub 210491 Tray Mtg PC Card 1 Sus Qu Lille E 223439 Insulator Circuit Card Aux Power 1 AO ul 198122 Stand Off Support PC Card 250 w Post amp Lock 500 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested
111. re feeder has no power when turned on Check if the 72 socket plug is connected to the receptacle on rear of welding power source and check that the 14 pin plug from the wire feeder is connected to the matching receptacle on rear of welding power source Wire does not feed from wire feeder to end of gun Check to see if wire diameter matches the groove size of the drive rolls Check if tension on drive rolls is too loose or too tight Check if gun liner is the correct size for the wire size Check if contact tip is correct size for the wire size and that end of contact tip is not plugged Check if gun end is fully inserted into wire drive housing feeder and knob is tightened down to secure gun end Weld is not consistent from one welding application to another Be sure that ground is connected to a clean paint free area of pipe otherwise grind an area if necessary to make a good ground connection Keep ground as close as possible to joint being welded Check if volt sensing lead is connected to the welding power source and that ground connection is secure Check for any frayed wires at ground end of volt sensing lead that may prevent a good connection Be sure that volt sense lead shielding is not touching center conductor Be sure that wire feeder control cable and volt sensing lead separated from weld cables Be sure gun angle during welding is straight in to 15 degrees back at jo
112. ring medical implants have to be taken For example restrict access for passers by or conduct individual risk as sessment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit A Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 221 771 Page 50 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment install test and service H F producing units The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep Spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference READ INSTRUCTIONS Use Testing Booklet Part No 150 853 when servicing this unit Consult the Owner s Manual for welding safety precautions e Use only genuine replacement parts from the
113. romagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements A Ce produit contient des produits chimiques notamment du plomb dont l Etat de Californie reconnait qu ils provoquent des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 is available as a free download from the American Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS 4 1 from Glob al Engineering Documents phone
114. s the procedure spe cifically requires an energized unit e Insulate yourself from ground by standing or working on dry insulat ing mats big enough to prevent contact with the ground e not leave live unit unattended e lf this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job e When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free e Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists in inverter weld ing power sources AFTER removal of input power e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Troubleshooting Section be fore touching any parts gt STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling boards or parts Ve e Use proper static proof bags and boxes to store move or ship PC boards FIRE OR EXPLOSION hazard Do not place unit on over or near combustible surfaces e Do not service unit near flammables OM 221 771U 2012 07 safety stm 2011 10 gt Indicates special instructions APA This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards
115. stalled in or for a minimum of one year whichever is greater Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HFUnits CE XT Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers NOTE Digital Recorders are Warranted Separately by the Manufacturer Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Welacraft Branded TIG Torches No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Miller but manufactured by others
116. t LEDs circuit board on the internal network Dip located on PC7 mounted behind the front Switch settings are different for each circuit panel 2 Dip Switch S1 pia iuda cundo do not change Refer to Section 7 8 for information on Ip settings those shown diagnostic LEDs 3 Switch S2 7 8 Diagnostic LEDs On User Interface Module PC7 LED Status Diagnosis 1 2 See Network Status Table in Section 7 11 Off See Network Status Table in Section 7 11 221 771 Page 56 7 9 Automation Interface Module PC9 Diagnostic LEDs k LED11 LED13 LED25 LED28 LED31 LED30 ey e vus 633 M DAE mane 21 I ee T e Oe ntu mnm LED32 LED20 LED19 LED18 LED16 LED17 LED21 LED22 LED23 LED24 LED26 LED29 216 958 A Ref 803 250 C 1 Automation Interface Module PC9 Reinstall cover after checking diagn
117. t RG70 1 RELAY COMMON QRC7O 14 24VDC DIAHEN AUTOMATION FILTER ES lt RC70 13 RD COMMON BOARD SENE 20 Res lt RC3 PLG53 bipes SRC70 61 WIRE STUCK lt RCB A RC5 PLG55 RC43 PLG65 CRC70 62 CURRENT DETECT lt KRCB1 4 lt RCB E RC44 PLG66 CRC70 37 WATER ERROR 1 7 lt RC15 PLG62 lt RC70 25 WATER ERROR N C lt lt RC81 8 lt RC8 H CALE lt RC70 49 WIRE STUCK lt lt 1 2 lt RCB U lt RC70 51 WIRE STUCK NO KKRCBI B CRCB F lt RC70 50 lt lt 1 5 CRCB K PAT 107 lt lt 1 lt RCB B lt RC70 69 CONTACTOR 40 WC RET 44 CRCBS 2 lt RC8 D lt RC70 52 RD COMMON lt RC70 67 PURGE 760 06 RC25 A RCB0 529 PURE lt lt RC3 1 26 QE Ur lt RC70 44 RD COMMON RC25 B gt RC80 3 gt amp RO3 S lt RC70 64 JOG 162 RD COMMON RC80 8 gt gt lt lt 2 lt RC70 70 RD COMMON C AM RCBS 043 3 RC25 D 7 764 WATER Y lt RC70 58 RETRACT RC25 C gt RC80 955 ee 05 7 lt RC70 56 RD COMMON 165 RD COMMON RC25 J gt RCB0 422 RS 4 lt RC70 68 RPS A 166 TOUCHED RC25 E RCBO 7 gt gt Fe RC3 B lt RC70 63 RPS B 767 KD COMMON RC25 F gt RC80 1122 XK RC3 6 lt RC70 41 RPS C 168 SENSOR ON RC25 M RC80 1223 75 lt lt 3 10 lt RC70 57 RD COMMON RC25 L lt RC70 66 AUTOSET C RC25 K
118. t common Remote process select A J Remote process select B L Electrode sense OM 221 771 Page 22 3 17 Electrical Service Guide Elec Serv 2011 08 A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source In dedicated circuit installations the National Electrical Code NEC allows the receptacle or conductor rating to be less than the rating of the circuit protection device All components of the circuit must be physically compatible See NEC articles 210 21 630 11 and 630 12 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 5 Actual input voltage should not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available 60 Hz Three Phase Input Voltage V 208 230 400 460 575 Input Amperes A At Rated Output 54 49 28 24 19 Max Recommended Standard Fuse Rating In Amperes Time Delay Fuses 60
119. tential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years NII 0001 of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the 2 8 n exact part you may need to fix the problem the ISO 9001 Quality System Warranty and service information for your Standard particular model are also provided REGISTERED QUALITY SYSTEM 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 To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill Mil Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE 5 1 1 1 Symbol Usage sn cet tet Lhd EE PRESE PE IEEE dde EE UE EC 1 1 2 Arc Welding Hazards 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1
120. tional extension cable Connect 72 pin connector to receptacle RC72 on rear of power source Connect 10 pin connector into receptacle RC8 on rear of power source 4 Positive Weld Cable 5 Negative Weld Cable 6 Workpiece 804 097 C 7 Welding Gun 8 Wire Feeder Turn off welding power source before connecting to wire feeder 14 pin plug 9 Gas Hose 10 Gas Cylinder Lx Extension cable maximum length not to exceed 150 ft 46 m 11 Extension Cable Optional OM 221 771 Page 30 4 7 Typical Connection Diagram For MIG GMAW Equipment Using A DX Feeder e fer A Do not mount feeder on top of pow er source A Do not put feeder where welding wire hits cylinder A Do not move or operate equipment when it could tip 1 Welding Power Source EF Attach volt sense lead to work clamp and attach work clamp as close to arc as possible 2 Negative Volt Sense Cable 3 Interconnect Cable Connect 14 pin socket into wire feeder 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 4 Positive Weld Cable 5 Negative Weld Cable 6 Workpiece 7 Welding Gun 804 665 C 8 Wire Feeder Turn off welding power source before connecting to wire feeder 14 pin plug 9 Gas
121. uipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir Soigneusementavec des protections homologu s Ne pas souder dans un endroit l des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 et AWS A6 0 voir les Normes de S curit Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possibl
122. uit breaker see Section 3 18 Check for proper input power connections see Section 3 18 No weld output meter display on with no error displayed Check to see if the contactor indicator light is lit when contactor line is asserted on Erratic or improper weld output with no errors displayed Use proper size and type of weld cable see Section 3 10 Check that proper program for wire size process and shielding gas is loaded Clean and tighten all weld connections No 115 volts AC at the duplex receptacle Reset supplementary protector CB1 Wire feeder has no power Check supplementary protector CB2 and reset if necessary Check motor control cable connections Wire stubbing on low end using a constant current power source Increase output setting of the power source Check voltage sense lead connection clean and tighten if necessary Wire burns back to gun contact tip when using electrode negative straight polarity process Check to be sure that volt sense lead is connected to the work Notes 221 771 Page 60 Notes OM 221 771 Page 61 SECTION 8 ELECTRICAL DIAGRAMS 6 2 1 al 1 c 7 FERRITES 3 PCS 71 R3 3
123. umber Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller 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 O 2012 Miller Electric Mfg Co 2012 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 For International Locations Visit www MillerWelds com 2 Miller
124. umbers of the program and the program revision letter appear on the display All three boards will match one of the rows horizontally in Table 9 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 9 1 to select the proper replacement board part number s If the program revision cannot be found due to board failure the serial number and or knowledge of a prior update must be used to determine the correct board number Another welding power source at the same location may be used to determine the program revision to remain consistent If using a DX feeder the unit must have revision F PCM program or greater for feeder to function correctly Table 9 1 Program Revisions For Circuit Boards UIM AIM PCM Original Stock Number ud re 907296 907297 w Serial No Software Board Board Software Board Software Board 219142C 238021 249377 219144B 238015 222230B 238003 LF075241 226429A 238023 249378 226431A 238017 222230C 238006 LF310618 226429A 238023 249378 226431A 238017 222230D 238009 LF327831 226429C 238025 249379 226431B 238019 222230F 238011 LG360042G 226429C 238025 249379 226431B 238019 222230G 238013 LH340135G 226429D 246895 249383 226431B 238019 222230H 246554 LK510137G 226429E 247937 249384 226431B 238019 222230J 247935 MA120074G
125. 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 POM Process Control Module HHEX UIM User Interface Module HHEX WECM Wire Feed Control Module HHEX RIO or AIM Robot Input Output or Automation Interface Module HHEX To continue welding power source start up process after viewing program revision levels press the Arc Control push button OM 221 771 Page 46 4 23 Reset Mode Acus Are Cono Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed RST NO message will not display until after the power up sequence is completed approximately 20 seconds Rotate Adjust knob to change NO Press the Arc Control button to to YES confirm the reset The reset message is displayed for 2 seconds while factory program settings are being reloaded During the reset mode the following factory default programs are loaded into the unit 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 Arc Control Cycl Pwr message appears on the display when programs complete loading
126. ust be in the MIG position No changes are saved until PROG LOAD appears on the display after completing the settings If the Setup button is pressed to review the settings and nothing is changed PROG LOAD will not appear on the display for the program that was just loaded ES A a Volts e Arc Adjust Wire Speed 6 Amps Wirefeed er Arc Control 200 410 OM 221 771 Page 32 4 9 Typical Connection Diagram For TIG GTAW Equipment AN gt e 2 1 Welding Power Source Fa Wy KR A EA 2 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 3 Negative Weld Cable 4 Positive Weld Cable 5 Workpiece 6 14 Pin Plug On Remote Foot Control Cable Turn off welding power source before connecting to foot control 14 pin plug 7 Remote Foot Control 8 TIG Torch 9 Gas Hose 10 Gas Cylinder Lx Extension cable maximum length not to exceed 150 ft 46 m 11 Extension Cable Optional 12 Remote Adapter 300 248 13 Volt Sense Receptacle Cable Must Be Disconnected 804 366 C 221 771 Page 33 4 10 Typical Connection Diagram For TIG GTAW Equipment Usi
127. ut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est Sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et les circuits inter nes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talli ques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger pu Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Seservir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e D autres consignes de s curit sont n cessaires dans les con
128. utrui lire appliquer et ranger en lieu s r ces consignes relatives aux pr cautions de s curit et au mode op ratoire 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce ma nuel pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus completes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE pe
129. ve electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic 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 Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install ground and operate this equipment according to its Owner s Manual and national state and local codes EF Indicates s
130. ys check the voltage on both inverter assemblies as shown to be Tools Needed sure the input capacitors have discharged before working on unit CO stein lead to left bus terminal lead to right bus terminal lead to left bus terminal lead to right bus terminal A Turn Off welding power Source and disconnect in put power Remove cover 1 Power Interconnect Board PC2 2 Voltmeter 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 Proceed with job inside unit Reinstall cover when finished 802 985 Ref 803 250 C OM 221 771 Page 54 7 5 gt Process Control Module 4 Diagnostic LEDs 5 1 Process Control Module Diagnostic LEDs are visible inside unit located on PC4 mounted on the top tray Refer to Section 7 6 for information on diagnostic LEDs Reinstall cover after checking diagnostic LEDs

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