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Miller Electric PipePro Dual manual

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Table of contents for the manual

  • Page 1

    PipePro Dual DX Feeder Processes Description MIG (GMA W) W elding Flux Cored (FCA W ) Welding (Gas- And Self-Shielded) Wire Feeder OM-230 009F 2008 − 01 File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-230 009 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007 − 04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. 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[...]

  • Page 6

    OM-230 009 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poo[...]

  • Page 7

    OM-230 009 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-230 009 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and [...]

  • Page 9

    OM-230 009 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007 − 04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures gra[...]

  • Page 10

    OM-230 009 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. DES PIÈCES CH[...]

  • Page 11

    OM-230 009 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

  • Page 12

    OM-230 009 Page 8 LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de toucher d[...]

  • Page 13

    OM-230 009 Page 9 2-5. P ri nc ipa le s no rm es d e sé cu ri té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American[...]

  • Page 14

    OM-230 009 Page 10[...]

  • Page 15

    OM-230 009 Page 1 1 SECTION 3 − DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear . 1 Electric[...]

  • Page 16

    OM-230 009 Page 12 3-2. Symbols And Definitions . Some symbols are found only on CE products. A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Program Wire Feed Jog Output Trigger Line Connection Set Up Sequence Trigger Hold On Trigger Hold Of f Purge Press T o Set Start Crater T ime Preflow Time Postflow Time Re[...]

  • Page 17

    OM-230 009 Page 13 SECTION 5 − INST ALLA TION 5-1. T ypical Connection Diagram For MIG Equipment ! Do not mount feeder on top of pow- er source. ! Do not put feeder where welding wire hits cylinder . ! Do not move or operate equipment when it could tip. 1 Welding Power Source 2 Negative V olt Sense Cable 3 Positive (+) Weld Cable 4 Negative ( −[...]

  • Page 18

    OM-230 009 Page 14 . Th e illustration shows remote control connected through the wirefeeder. The wirefeeder is not connected to the power source output.. 5-2. T ypical Connection Diagram For TIG Equipment 804 779-A ! Do not mount feeder on top of pow- er source. ! Do not put feeder where welding wire hits cylinder . ! Do not move or operate equipm[...]

  • Page 19

    OM-230 009 Page 15 . Th e illustration shows remote control connected through the wirefeeder. The wirefeeder is not connected to the power source output.. 5-3. T ypical Connection Diagram For Stick Equipment 804 780-A ! Do not mount feeder on top of pow- er source. ! Do not put feeder where welding wire hits cylinder . ! Do not move or operate equi[...]

  • Page 20

    OM-230 009 Page 16 5-4. Rear Panel Connections And Rotating Drive Assembly Ref. 804 766-A / 803 067 / 802 825-A 2 1 14-Pin Control Cable 2 Shielding Gas V alve Fittings Requires fitting with 5/8-18 right- hand threads. Connect customer- supplied gas hose. 3 Weld Cable T erminal 4 Jumper Weld Cable 5 Weld Cable 6 Drive Assembly 7 Drive Assembly Rota[...]

  • Page 21

    OM-230 009 Page 17 5-5. 14-Pin Plug Information Pin* Pin Information A 40 volts dc with respect to socket G. G Circuit common for 40 volts dc circuit. B Contact closure to K completes contactor control circuit. K Contact closure to B completes contactor control circuit. A J B K I C +10 volts dc input from power source to wire feeder with respect to[...]

  • Page 22

    OM-230 009 Page 18 . For best wire feeding performance, be sure that the outlet cable has the proper size liner for the welding wire size being used. Also, when the gun is installed, the liner extending from the back of the gun should be as close to the drive rolls as possible, without touching. Install gun. Lay gun cable out straight. Cut of f end[...]

  • Page 23

    OM-230 009 Page 19 5-7. Setting Internal DIP Switches Position Settings And Results For DIP Switch S1 On PC1 And PC101 On = Current detect over- ride. For welding power sources that don’t provide current feedback through the 14-pin receptacle. Run- in is inactive. Off = Current must be detected from power sources that provide current feedback thr[...]

  • Page 24

    OM-230 009 Page 20 5-8. Display Board DIP Switch Settings Remove wrapper . 1 DIP Switch S1 And S4 . DI P switches S1 and S4 should remain in the factory default settings. Install wrapper when finished. 804 666-B / 803 063 1 12345678 O N Factory Set Default Settings For DIP Switches S1 And S4 . In the DIP switch S1and S4 il- lustration, the elevated[...]

  • Page 25

    OM-230 009 Page 21 SECTION 6 − OPERA TION 6-1. Operational T erms The following is a list of terms and their definitions as they apply to this wire feeder: General T erms: Cold Wire Jog Feeding wire without contactor or gas valve being energized. Sequence A portion of the weld program, such as preflow , run-in, start, weld, crater , burnback, and[...]

  • Page 26

    OM-230 009 Page 22 6-4. Jog/Purge Switch 804 668-B 3 2 1 Jog/Purge Switch 2 Gun Trigger Receptacle 3 Adjust Control Pressing the Jog/Purge switch allows the operator to jog wire without energizing the weld pow- er or gas valve circuit. • Jog speed can be adjusted by the Adjust control when the unit is jogging wire. The unit displays jog speed whe[...]

  • Page 27

    OM-230 009 Page 23 6-6. Program Push Button 1 3 Program 2 1 Program Display The number of the active program is displayed. 2 Program Push Button Press button to activate program select feature. T o change the pro- gram number , press the Program push button and rotate the Adjust control. 3 Program Push Button LED The LED lights to indicate the Pro-[...]

  • Page 28

    OM-230 009 Page 24 6-8. Lower Display 1 Lower Display The lower display shows wire speed or amperage. 2 Lower Display Push Button Press button to choose between wire speed or amperage functions. 3 Lower Display Push Button LED Th e lower display push button LED illuminates to indicate that wire feed speed can be ad- justed with the Adjust control. [...]

  • Page 29

    OM-230 009 Page 25 6-10. Adjust Control Adjust 1 1 Adjust Control Th e Adjust control is used to change various parameters. Start Crater Pre/Postflow Sequence 6-1 1. Sequence Push Button . For more information on Setting Sequence Parameters see Section 7-1. • The Sequence push button allows the selection of welding sequences. Five weld- ing seque[...]

  • Page 30

    OM-230 009 Page 26 6-12. Auxiliary Menus Program Start Crater Pre/Postflow T rigger Hold Adjust V/Trim Time (sec) Wire Speed Amps Sequence Setup Dual Schedule 3 4 2 9 8 1 5 7 6 1 Program Display 2 Program Push Button 3 Sequence Push Button 4 Upper Display 5 Upper Display Push Button 6 Lower Display 7 Lower Display Push Button 8 Adjust Control 9 Set[...]

  • Page 31

    OM-230 009 Page 27 Range Locks Range locks are indicated by “LOCK” in the upper display for wire speed or “LOCK” in the lower display for voltage range. In a MIG program, the voltage range lock ranges from +/ − 0 to 10 volts. In a pulse program, the trim range lock ranges from +/ − 0 to 100. Th e wire speed range lock ranges from +/ −[...]

  • Page 32

    OM-230 009 Page 28 6-13. Remote-14 Receptacle Information 804 667-B 1 Remote Switch 2 Remote-14 Receptacle If the remote switch is set to MIG, the feeder operates normally . A re- mote control may be left attached while the remote switch is in the MI G mode, as the remote has no af- fect on the operation of the wire feeder . If the remote switch is[...]

  • Page 33

    OM-230 009 Page 29 SECTION 7 − SETTING SEQUENCE P ARAMETERS 7-1. Sequence Parameters In A Program . For more information on Sequence Push Button see Section 6-1 1. If time is set to zero in W eld sequence, welding continues until gun trigger is released. If time is set to zero in any timed sequence except Weld, the sequence is skipped. T rigger P[...]

  • Page 34

    OM-230 009 Page 30 8-2. Diagnostics 804 804-A 1 LED3 On Right Side Motor Control Board PC101 2 LED4 On Dual Board PC70 3 LED3 On Left Side Motor Control Board PC1 LED3-Related Error Indications Error conditions are indicated by LED3 on PC1, PC101, and LED4 on PC70. T o view LED3, 4 turn Of f unit, remove wrapper , and turn unit On. The LED blinks i[...]

  • Page 35

    OM-230 009 Page 31 SECTION 9 − MAINTENANCE & TROUBLESHOOTING ! Disconnect power before maintaining. 9-1. Routine Maintenance n = Check ~ = Clean l = Replace Reference Every 3 Months Section 5-4 l Unreadable Labels ~ W eld T erminals nl W eld Cable l Cracked Parts Section 5-4 n 14-Pin Cord n Gas Hose and Fittings n Gun Cable Every 6 Months Or [...]

  • Page 36

    OM-230 009 Page 32 ! Disconnect power before troubleshooting. 9-2. T roubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check cable connections. Check cables for continuity , and repair or replace cables if necessary (see Section 5-4). Wire feeder is on, display does not light up, motor does not run[...]

  • Page 37

    OM-230 009 Page 33 Notes 229895 MA TERIAL THICKNESS GAUGE[...]

  • Page 38

    OM-230 009 Page 34 SECTION 10 − ELECTRICAL DIAGRAM Figure 10-1. Circuit Diagram[...]

  • Page 39

    OM-230 009 Page 35 229 867-A[...]

  • Page 40

    OM-230 009 Page 36 SECTION 1 1 − P ARTS LIST 804 741-A . Hardware is common and not available unless listed. 14 6 7 10 9 8 11 5 12 11 10 15 19 20 16 17 18 3 2 1 22 4 Fig.1 1 − 3 21 Fig.1 1 − 2 9 13 Figure 1 1-1. Main Assembly[...]

  • Page 41

    OM-230 009 Page 37 Description Part No. Item No. Figure 1 1-1. Main Assembly Quantity 1 159 647 Insulator , Motor Clamp 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 159 646 Clamp, Motor Base 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 42

    OM-230 009 Page 38 804 742-A . Hardware is common and not available unless listed. 17 26 2 3 1 28 30 31 27 29 32 4 5 7 23 22 21 20 19 18 7 6 10 11 13 14 15 16 25 24 12 9 8 Figure 1 1-2. Control Box Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Control Box (Figure 11-1 Item 21) Quantity 1 204 722 Wrapper , Feeder 1 . . . . . . . . . . . . .[...]

  • Page 43

    OM-230 009 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 1 1-2. Control Box (Continued) Quantity 20 GS1,101 219 047 V alve, 40VDC 2W ay Custom Port 1/8 Orf W/Frict 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 010 494 Bushing, Snap − In Nyl 1.375 Id X 1.750 Mtg Hole 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 44

    OM-230 009 Page 40 See T able 1 1-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 803 790-A 20 11 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 1 2 3 4 5 6 22 21 19 18 17 16 15 14 19 13 12 11 9 10 8 7 6 5 4 3 2 1 Figure 1 1-3. Drive Assembly , Wire Quantity Description Part No. Dia. Mkgs. Item No. Figure [...]

  • Page 45

    OM-230 009 Page 41 Quantity Description Part No. Dia. Mkgs. Item No. Figure 1 1-3. Drive Assembly , Wire (Continued) 203 642 Pressure Arm, R & V ert L 4 Roll (Includes) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 631 Pressure Arm, S/L & V ert S/R 4 Roll (Includes) 1 . . . . . . . . . . . .[...]

  • Page 46

    OM-230 009 Page 42 .023-.025 in. 0.6 mm 151 024 087 130 .030 in. 0.8 mm 151 025 053 695 .035 in. 0.9 mm 151 026 053 700 151 036 072 000 151 052 132 958 .045 in. 1.1/1.2 mm 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489 .052 in. 1.3/1.4 mm 151 028 053 698 151 038 053 702 151 054 132 956 151 071 083 490 1/16 in. 1.6 mm 151 029 053 69[...]

  • Page 47

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2008-01 Y our distributor also gives you ... Service Y ou 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 expertis[...]

  • Page 48

    PRINTED IN USA © 2008 Miller Electric Mfg. Co. 2008 − 01 Miller Elect ric Mf g. Co. An Illinois T ool Wo rks Co mpany 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F A X: 920-735-4134 Int ernational F AX : 9 20-735-4125 European Headqua rters −[...]