OM-253 906D 2012−08 Processes MIG (GMAW) and Pulsed MIG (GMAW-P) Welding TIG (GTAW) Welding Flux Cored (FCAW) Welding Stick (SMAW) Welding Multiprocess Welding Description Arc Welding Power Source Wire Feeder PipeWorx 400 Welding System (380-400 Volt Model) CE File: MIG (GMAW) Visit our website at www.MillerWelds.
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.
DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Welding Power Source Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Memory Card Slot . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 7 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if 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.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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 poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. 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. D Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
1-4. 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 & Safety Code Section 25249.5 et seq.) 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. 1-5.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 7 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. 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. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz comprimé en cas de non utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs. LES FILS DE SOUDAGE peuvent provoquer des blessures.
2-5. Principales normes de sécurité 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 F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
OM-253 906 Page 10
SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground. Safe3 2012−05 Keep your head out of the fumes. Safe6 2012−05 Use forced ventilation or local exhaust to remove the fumes.
Disconnect input plug or power before working on machine. Safe5 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 Flying pieces of parts can cause injury. Always wear a face shield when servicing unit. Safe27 2012−05 Always wear long sleeves and button your collar when servicing unit. Safe28 2012−05 After taking proper precautions as shown, connect power to unit. Safe29 2012−05 Do not discard product with general waste.
? ? V A Consult rating label for input power requirements. Safe34 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. Safe33 2012−05 Become trained and read the instructions before working on the machine or welding. Safe65 2012−06 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.
3-2.
SECTION 4 − SPECIFICATIONS 4-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
B. Dimensions And Weight E Hole Layout Dimensions A 495 mm (19-1/2 in.) B 424 mm (16-7/8 in.) C 806 mm (31-3/4 in.) D 406.4 mm (16 in.) E 5/16-18 in. UNC thread A 806 mm (31-3/4 in.) C 724 mm (28-1/2 in.) B Weight D 495 mm (19-1/2 in.) 102 kg (225 lb) 805 142-A C. Wire Feeder Specifications Input Power 24 Volts AC 11 Amperes Welding Power Source Type Wire Feed Speed Range Wire Diameter Range Welding Circuit Rating IP Rating* Overall Dimensions PipeWorx 400 1.3 To 19.
4-3. MIG Duty Cycle and Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit and void warranty.
SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the 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. 5-2. Selecting a Location Movement Tipping ! Do not move or operate unit where it could tip.
5-3. Remote 14 Accessory Receptacle Information If a remote control is connected to the Remote 14 receptacle, the unit will automatically adjust output control to a primary/secondary configuration. In this configuration, the Amperage Adjust knob on the unit becomes the primary and sets the maximum amperage output of the unit. The remote control becomes the secondary and provides an amperage range of 0 to 100% based on the Amperage Adjust knob setting. .
5-4. Turning On Remote 14 Receptacle Control For Stick ! 1 Stick Remote Off Stick Remote On ON ON 1 2 1 2 Turn Off welding power source, disconnect input power, and check voltage on input capacitors according to Section 7-6 before proceeding. When this control is active and a current/contactor control is connected to the Remote 14 receptacle on the power source front panel, the contactor and primary/secondary amperage control will function in both TIG and Stick modes.
5-5. Changing Wire Feed Speed From Inches Per Minute (IPM) To Meters Per Minute (MPM) 3 2 ! Turn Off welding power source, disconnect input power, and check voltage on input capacitors according to Section 7-6 before proceeding. 1 2 3 PipeWorx Feeder Operator Interface Board Dip Switch Remove feeder wrapper. Move number 1 switch (top switch) to the ON position. Use a small screwdriver to move switch, if necessary. Reinstall wrapper. 1 Rear View Of Wire Feeder Front Panel Tools Needed: 5/16 in.
5-6. Remote 14 Wire Feeder Control Receptacle Information Remote 14 Feeder Control Socket* 8, 12 24 VOLTS AC ÌÌ SERIAL COMMUNICATION POSITIVE VOLT SENSE NEGATIVE VOLT SENSE Ref. 805 144-A / Ref. 048 286-B *The remaining sockets are not used. Notes OM-253 906 Page 22 GND Socket Information 24 volts AC. Protected by supplementary protector CB2. 1,4 24 volts AC return. Connected to chassis common. Completes 24 volts AC power supply circuit to feeder.
5-7. Supplementary Protector CB2 1 Supplementary Protector CB2 CB2 protects the 24 volts ac power supply to the wire feeder (see Section 5-6). Press button to reset supplementary protector.
5-8. 115 Volts AC Single Receptacle And Supplementary Protector 1 2 115 V 10 A AC Receptacle (Cooler Power Supply Only When Power Source Is On) Supplementary Protector CB1 CB1 protects single 115 volt AC receptacle. Press button to reset supplementary protector.
5-9. Lifting Eye On Power Source ! Turn Off welding power source, disconnect input power. 1 Lifting Eye The wire feeder allows access to the lifting eye on the power source. The entire welding system as shown with cable hangers, cooler with coolant, dual feeder, and running gear can be lifted with the lifting eye. The control cable must be disconnected from the feeder. Use of a lifting strap may be necessary. 1 Total weight is approximately 525 lb (238 kg) excluding welding guns and cables. .
5-10. Electrical Service Guide Elec Serv 2011−04 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 generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
Notes OM-253 906 Page 27
5-11. Connecting 3-Phase Input Power 3 = GND/PE Earth Ground 9 12 8 4 L1 L2 10 L3 11 1 2 3 4 L1 L2 L3 5 6 7 Tools Needed: 5/16 in.
5-11. Connecting 3-Phase Input Power (Continued) ! Installation must meet all National and Local Codes − have only qualified persons make this installation. national, state, and local electrical codes. If applicable, use lugs of proper amperage capacity and correct hole size. Connect input conductors L1 (U), L2 (V) and L3 (W) to welding power source line terminals. ! Disconnect and lockout/tagout input power before connecting input conductors from unit.
5-12. Installing Optional Handles, Running Gear And Cooler Tools Needed: 1/2 in. 5/16 in. ! Turn Off welding power source, disconnect input power. 1 2 3 4 5 Running Gear 234 359 Cooler Wheel 163 463 (2) Flat Washer 602 250 (4) Retaining Ring 121 614 (2) Install wheels on cylinder tray as shown. 9 Set cooler on running gear. . If not installing a cooler, set power source on running gear.
5-13. Assembling And Installing Cable Hanger 1 2 3 1 Bracket Tube Cap (4) Cable Holder Tube (2) Install caps in tubes. Assemble cable holder tubes to bracket using supplied hardware. Place cable holder assembly on top of power source or cart and set wire feeder on cable hanger. 2 3 Tools Needed: 3/8 in. 7/16 in.
5-14. Proper Ring Terminal Connection To Volt Sense Lead 2 1 3 If volt sense lead is cut or broken at end with ring terminal, be sure that new ring terminal is connected as shown. 1 2 Jacket Insulated Tape Or Heat-Shrink Tubing 4 3 Center Conductor 10 ga 4 Ring Terminal 1/2 in. Opening Tools Needed: Ref. 239 780-B 5-15. Connecting Volt Sense Lead And Work Cable To Clamp 1 2 3 Volt Sense Lead Work Cable Clamp .
5-16. Weld Output Terminals And Selecting Cable Sizes* Recommended For PipeWorx 400 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.
5-17. Connecting Weld Output Cables 1 4 Do not place anything between weld cable terminal and copper bar. 2 Tools Needed: 3 19 mm (3/4 in.) Incorrect Installation ! Turn off power before connecting to weld output terminals. ! Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. Notes OM-253 906 Page 34 1 Weld Output Terminal 2 Supplied Weld Output Terminal Nut 3 Weld Cable Terminal 4 Copper Bar Remove supplied nut from weld output terminal.
5-18. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Power Source 4 2 7 1 9 6 5 3 9 11 8 10 254 079-A ! Do not put feeder where welding wire hits cylinder. ! Do not move or operate equipment when it could tip. 1 Welding Power Source 2 Wire Feeder 3 MIG Connection 4 Positive (+) Weld Cable 5 Feeder Control Cable Connection 6 Gas Hose 7 Gas Cylinder Connect 14-pin plug to rear of power source, and connect 14-socket plug to rear of wire feeder.
5-19. Typical Connection Diagram For MIG (GMAW) Equipment With Feeder On Cart 8 1 7 13 5 2 6 3 4 10 13 10 9 12 11 254 086-A ! Do not put feeder where welding wire hits cylinder. ! Do not move or operate equipment when it could tip.
5-20. Wire Feeder Rear Panel Connections And Rotating Drive Assembly 1 2 14-Pin Control Cable Shielding Gas Valve Fittings Requires fitting with 5/8-18 right-hand threads. Connect customer-supplied gas hose. 3 4 5 6 7 3 9 8 To rotate the drive assembly, loosen drive assembly rotation knob, rotate drive assembly, and tighten knob.
5-21. Gun Trigger Receptacle 1 2 Left Gun Trigger Receptacle RC2 Right Gun Trigger Receptacle RC3 (Dual Model Only) Connect gun trigger plug to appropriate receptacle on feeder.
5-22. Installing And Threading Welding Wire Install wire guides and anti-wear guide. Install wire spools. Adjust tension nuts so wire is taut when wire feed stops. Install drive rolls. Pressure Adjust Rear Rolls Pressure Indicator Scale Pressure Adjust Front Rolls No Wire Slip Wire Slips NONCONDUCTIVE SURFACE NONCONDUCTIVE SURFACE Tools Needed: Drive Rolls Back Of Gun 3/16, 5/64 in. 15/16, 3/8 in. End Of Liner .
5-23. Voltage Sensing Lead And Work Cable Connections For Multiple Welding Arcs A. Ideal Setup 1 2 5 3 1 6 4 5 2 3 4 805 289-B 1 Welding Power Source 2 Composite Cable 3 Work Cable 4 Volt Sense Lead The volt sense lead must be used to provide an accurate voltage feedback OM-253 906 Page 40 signal to the welding system. Use of this lead is critical for stable welding performance.
B. Bad Setup 1 2 5 3 4 6 805 290-B 1 2 3 4 5 Welding Power Source Composite Cable Work Cable Voltage Sensing Lead Wire Feeder 6 Workpiece This arrangement is a bad setup due to sensing leads being directly in the current flow path of the welding arc. Interaction between welding circuits will affect voltage drop in the workpiece. The voltage drop across the workpiece will not be measured correctly for the voltage feedback signal.
5-24. Arranging Welding Cables To Reduce Welding Circuit Inductance 1 2 3 4 5 6 1 Ideal 5 2 3 Welding Power Source Composite Cable Work Cable Volt Sense Lead Wire Feeder Workpiece The method used to arrange cables has a significant affect on welding performance. 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 puddle.
5-25. Typical Connection Diagram For Stick (SMAW) Equipment 1 2 3 4 5 6 1 Welding Power Source Work (−) Weld Cable Stick (+) Weld Cable Workpiece Electrode Holder Volt Sense Lead . Attach volt sense lead to work clamp and attach work clamp as close to arc as possible.
5-26. Typical Connection Diagram For Two Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 1 2 3 4 5 6 7 8 1 Welding Power Source Gas Hose TIG (−) Weld Cable Work (+) Weld Cable Workpiece TIG Torch Volt Sense Lead Remote Foot Control (Optional) . Attach volt sense lead to work clamp and attach work clamp as close to arc as possible.
5-27. Typical Connection Diagram For One Piece Air-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 1 2 3 4 5 6 7 8 9 1 3 Welding Power Source Gas Hose 237 415 (Short Black Hose Supplied With Power Source) TIG Block (Customer Supplied) TIG (−) Weld Cable Work (+) Weld Cable Workpiece TIG Torch Volt Sense Lead Remote Foot Control (Optional) . Attach volt sense lead to work clamp and attach work clamp as close to arc as possible.
5-28. Typical Connection Diagram For Liquid-Cooled TIG (GTAW) Torch (Using Gas Solenoid Inside Power Source) 1 2 3 4 Welding Power Source Gas Hose TIG Block (Customer Supplied) Coolant Out Hose 237 416 (Short Red Hose Supplied With Cooler) 5 TIG (−) Weld Cable 6 Coolant Return Hose 7 Work (+) Weld Cable 8 Workpiece 9 TIG Torch 10 Volt Sense Lead 11 Remote Foot Control (Optional) 1 3 . Attach volt sense lead to work clamp and attach work clamp as close to arc as possible.
SECTION 6 − OPERATION 6-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: 98/2 Ox Gas mixture of 98% Argon and 2% O2. Amps Indicates average amperage while welding and holds the value for 10 seconds at end of weld. Arc Control The adjustment of arc cone width and arc characteristics in the RMD and Pulse processes.
6-1 . Operational Terms (Continued) Pulse (Pro-Pulset) An advanced pulse spray transfer process suited for the fill and cap passes on pipe. The Pulse process utilizes constant current ramps with constant voltage control of peaks and backgrounds. Adaptive response is controlled by peak and minimum current levels.
6-2. Welding Power Source Controls A. Front Panel Controls 2 3 4 1 12 6 7 8 14 13 19 11 9 5 10 15 17 18 16 252 613-B . Only 7 Stick Electrode Type Select Button 14 Wire Diameter Select Button 8 Ammeter Display 1 2 3 4 5 6 15 Gas Type Select Button 9 Amperage Adjust Knob illuminated controls can be changed or adjusted.
6-3. Memory Card Slot 1 1 Memory Card Slot This is the memory card slot. The memory card slot uses an SD memory card. A memory card can be inserted into the slot and used for storing and retrieving operator settings, providing custom MIG type weld process data, and loading firmware updates to the unit. If the power source has multiple users, each user may use a card to store and load their own personal settings. Push in and release the card edge to eject it from the slot. A. Memory Function Controls 1.
B. Using Optional Memory Card 1. 2. 3. Memory Card Insertion a. Lift and hold memory card access cover open. b. Insert memory card into slot (push card all the way into slot and then release). c. Close memory card access cover. Memory Card Removal a. Lift and hold memory card access cover open. b. Push in and release memory card to eject card. c. Grasp memory card and remove from slot. d. Close memory card access cover. Optional Program Card Operation a.
D. Stick And TIG Welding Process Controls 1. Stick Process Select Button Press and release this button to activate the stick welding process controls. The STICK text below the button illuminates as well as the active stick electrode type text and the swoosh above the amperage adjust knob. The operator must select the desired stick electrode type and adjust the amperage knob to the appropriate setting within a range from 40 to 400 amps. 2.
S Ramp down time − 0.0 to 10.0 seconds S Final amperage − 10 to 350 amps S Final time − 0.0 to 10.0 seconds (2T only) S Postflow time − 0 to 60 seconds 2T Trigger Operation When in the 2T trigger mode the following weld sequence will occur: S Press and hold the TIG torch trigger to start the sequence. S Preflow is conducted for the programmed time. S After preflow, the weld sequence starts in accordance to the programmed parameters (initial amperage and time, ram-up time).
5. Gas Selection Table The gas selection table provides the available shielding gas selections. For any MIG process except FCAW, gas selections are structured into columns based first on WIRE TYPE type and then on MIG process selections. The gas type text illuminates to indicate the active gas selection. Shielding gas selections are as follows: C8-C15 (92% Argon/8% CO2 to 85% Argon/15% CO2) C20 (80% Argon/20% CO2) C25 (75% Argon/25% CO2) CO2 (100% CO2) C2 (98% Argon/2% CO2) 98/2 Ox (98% Argon/2% O2) 6.
6-4.
6-5. Stick Process Selection Setup Example 1 2 4 3 350 Ref. 252 613-B . Only illuminated controls can be changed or adjusted.
6-6. TIG Process Selection Setup Example 3 1 2 4 350 Ref. 252 613-B . Only illuminated controls can be changed or adjusted.
6-7. MIG Process Selection Setup Example 1 7 2 1 3 4 5 6 . Only illuminated controls can be changed or adjusted. 2 Carbon Steel Wire Type Selected 5 Trigger Select On 3 0.
6-8. MIG Process Selection Setup Example 2 7 3 2 1 5 4 6 252 613-B . Only illuminated controls can be changed or adjusted. 2 Stainless Steel Wire Type Selected 5 Trigger Select On 3 0.
6-9. Wire Feeder Controls A. Front Panel Controls 14 3 2 4 1 5 6 13 7 8 10 9 11 12 252 620-C . Only illuminated controls can be changed or adjusted.
1. Left Side Controls Select Button Press and release this button to activate the wire feeder left side controls. The LEFT text below the button will illuminate and the swooshes above the volts/arc length adjustment knob and wire feed speed adjustment knob will illuminate. See Section 6-2 for the procedure to select the appropriate MIG process type parameters. Pressing the left side welding gun trigger will also active the left side controls.
6. Wire Feed Speed Adjust Knob Use this knob to adjust the desired wire feed speed setting [1.3 to 19.8 mpm (50 to 780 ipm)]. Rotating the knob clockwise increases wire feed speed and counter-clockwise decreases wire feed speed. Wire feed speed adjustment is active when the swoosh above the knob is illuminated. The setting can be different for left and right sides and MIG process type, and the unit will hold these settings for both sides. 7.
6-10. Preflow And Postflow Adjustment . Postflow will not function without an arc initiation. Preflow and Postflow times can be configured for each of the TIG, Wire Feeder Left and Wire Feeder Right outputs. These times are global settings (i.e. all memory slots share the same three preflow and postflow settings; it is not possible to set different postflow times between memory slots). The unit is shipped in the standard configuration (“Std” appears on the display).
Unit will display PSt on the Voltage display. 7. Adjust postflow time to desired value by rotate the Wire Feed Speed knob. Available selections include Std and numeric values from 0 to 60 seconds. 8. Press any button to return to the normal display. 6-11. Wire Feeder Left Side Active Setup Example 16.5 1 225 4 2 252 620-C 3 . Only illuminated controls can be changed or adjusted.
6-12. Wire Feeder Right Side Active Setup Example (Dual Feeder Only) 0 1 150 4 2 3 . Only illuminated controls can be changed or adjusted.
6-13. Wire Feeder Non-MIG Setup Example --- 2 1 . Only illuminated controls can be changed or adjusted.
6-14. Wire Feeder Timed Purge Example 2 3 30 252 620-C 1 . Only 1 illuminated controls can be changed or adjusted.
6-15. Wire Feeder Auto Jog Example 2 3 15.3 5 4 780 1 . Only 1 illuminated controls can be changed or adjusted.
6-16. Basic Parameters For PipeWorx 400 Steel Process Wire Size mm Wire Feed Speed mpm Arc Length Shielding Gas 0.9 2.5-8.9 w/5.1 Nominal +3.0 to −3.0 w/zero Nominal C8-C15 0.9 2.5-8.9 w/5.1 Nominal +3.0 to −3.0 w/zero Nominal C20 0.9 2.5-8.9 w/5.1 Nominal +3.0 to −3.0 w/zero Nominal C25 0.9 3.8-8.9 w/5.1 Nominal +3.0 to −3.0 w/zero Nominal 100% CO2 1.0 2.5-6.4 w/4.4 Nominal +3.0 to −3.0 w/zero Nominal C8-C15 1.0 2.5-7.6 w/4.4 Nominal +3.0 to −3.0 w/zero Nominal C20 1.0 2.5-7.
Steel Process ProPulse Carbon Using A Positioner (Rolling The Pipe) ProPulse Carbon Welding In Position OM-253 906 Page 70 Wire Size mm Wire Feed Speed mpm Arc Length Shielding Gas 0.9 2.5-19.8 w/5.1 Nominal +3.0 to −3.0 w/zero Nominal C8-C15 0.9 2.5-19.8 w/5.1 Nominal +3.0 to −3.0 w/zero Nominal C20 1.0 2.5-19.8 w/4.4 Nominal +3.0 to −3.0 w/zero Nominal C8-C15 1.0 2.5-19.8 w/4.4 Nominal +3.0 to −3.0 w/zero Nominal C20 1.2 1.9-12.7 w/3.8 Nominal +3.0 to −3.
Stainless Steel Process Wire Size mm Wire Feed Speed mpm Arc Length Shielding Gas 0.9 2.5-8.9 W/5.1 Nominal +3.0 to −3.0 w/zero Nominal C2 0.9 2.5-8.9 W/5.1 Nominal +3.0 to −3.0 w/zero Nominal 98/2 Ox 1.0 2.5-7.6 w/4.4 Nominal +3.0 to −3.0 w/zero Nominal C2 1.0 2.5-7.6 w/4.4 Nominal +3.0 to −3.0 w/zero Nominal 98/2 Ox 1.2 1.9-6.4 w/3.8 Nominal +3.0 to −3.0 w/zero Nominal C2 1.2 1.9-6.4 w/3.8 Nominal +3.0 to −3.0 w/zero Nominal 98/2 Ox 0.9 1.9-19.8 w/5.1 Nominal +3.0 to −3.
Flux Core Process Wire Size mm Rolling Pipe/In Position Wire Feed Speed mpm Voltage Shielding Gas Flux Core/GMAW Not Dependent 1.3-19.8 w/6.4 Nominal* 24.5-32 w/25.0 Nominal Not Dependent Note: Arc Length − Length of arc from end of wire to weld puddle. Wire feed speed and voltage are synergic for the RMD and ProPulse processes. This means when adjusting wire feed speed, the voltage is automatically adjusted so it is not necessary to adjust the Arc Length.
SECTION 7 − MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance ! n = Check ~ = Clean Disconnect power before maintaining. l = Replace Every 3 Months Every 6 Months l Unreadable Labels ~ Weld Terminals nl Weld Cable n 14-Pin Cord n Gas Hose and Fittings n Gun Cable l Cracked Electrode Holder Parts l Cracked Torch Body l Cracked Parts Or ~ Inside Unit ~ Drive Rolls 7-2. Blowing Out Inside of Unit ! Do not remove case when blowing out inside of unit.
7-3. Restoring Factory Defaults Full System A full factory reset can be accomplished by pressing memory location buttons 1 and 4 on the power source simultaneously for more than four seconds. The display will show rSt and then go to dashes when the reset is complete. Memory Location See Section 6-2 C2 the reset procedure. 7-4. Viewing Software Revision Pressing the MIG TYPE and SIDE SELECT buttons behind the door on the power source simultaneously will display the Software Revision. 7-5.
6. 7. 8. 9. Calibrate STICK voltage as follows: a. Connect voltmeter from STICK stud (front left) to Work stud (front center). b. Press memory 3 button on the power source front panel. Open circuit voltage should now be present from STICK output stud to the Work stud. c. Using the knob on the power source front panel, set the display voltage to the measured value on the voltmeter. d. Press memory 3 button on the power source front panel to end the STICK voltage calibration. e.
7-6. Removing Right Side Panel and Measuring Input Capacitor Voltage ! Turn Off welding power source, and disconnect input power. ! Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit. Turn Off welding power source, and disconnect input power. 1 1 Right Side Panel To remove panel, remove screws securing panel to unit.
7-7. Welding Power Source And Feeder Diagnostic Help Codes H 0 1 Display Example Display Code Fault Description H01 Primary Power Circuit Over Current Indicates a malfunction in the primary power circuit. If this code appears on the display, contact the nearest Factory Authorized Service Agent. H02 Temperature Sensor Malfunction H03 Secondary Circuit Over Temperature Indicates left side of unit has overheated. Unit has shutdown to allow fans to lower left side temperature.
H44 Motor Low Bus H45 Button Stuck Feeder H46 Trigger Stuck Left H47 Trigger Stuck Right H48 Trigger Fault Left H49 Trigger Fault Right Indicates right trigger was held too long in trigger jog (the lesser of 60 seconds or 30 ft (9.1 m) of wire. H60 Memory Card Fault Indicates unable to read memory card. Faulty memory card or wrong format. H61 File Read Error Indicates faulty file on memory card. H62 File Write Error Indicates full or faulty memory card.
7-8. 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.
7-9. Welding Power Source Troubleshooting Trouble No weld output; unit completely inoperative. Remedy Place line disconnect switch in On position (see Section 5-11). Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-11). Check for proper input power connections (see Section 5-11). No weld output; meter display On. Check, repair, or replace remote control. Unit overheated. Allow unit to cool with fan On (see Section 4-4). Check voltmeter/ammeter Help displays.
7-10. Wire Feeder Troubleshooting ! Disconnect power before troubleshooting. Trouble Wire feeds, shielding gas flows, but electrode wire is not energized. Remedy Check cable connections. Check cables for continuity, and repair or replace cables if necessary. Wire feeder is on, display does not light Check and reset circuit breaker at welding power source. up, motor does not run, gas valve and welding power source contactor do not pull in.
7-11. Cooler Troubleshooting ! Disconnect power before troubleshooting. Trouble Coolant system does not work. Remedy Be sure input power cord is plugged into energized receptacle. Check supplementary protector CB1 at welding power source, and reset if necessary. Motor overheated. Unit starts running when motor has cooled. Have Factory Authorized Service Agent check motor. Decreased or no coolant flow. Add coolant. Check for clogged hoses or coolant filter.
Notes OM-253 906 Page 83
SECTION 8 − ELECTRICAL DIAGRAM Figure 7-1.
254 310-B OM-253 906 Page 85
Figure 7-2.
236 220-E OM-253 906 Page 87
SECTION 9 − HIGH FREQUENCY 9-1. Welding Processes Requiring High Frequency 1 High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. 1 Work TIG high_freq 5/10 − S-0693 9-2.
9-3. Recommended Installation To Reduce HF Interference 7 Weld Zone 3 50 ft (15 m) 50 ft (15 m) 5 1 6 2 8 4 8 Ground all metal objects and all wiring in welding zone using #12 AWG wire. Nonmetal Building Ground workpiece if required by codes. 9 Best Practices Followed Metal Building 8 8 11 10 Ref. S-0695 / Ref.
SECTION 10 − PARTS LIST . Hardware is common and not available unless listed. 8 7 6 79 14 1 2 3 90 10 4 89 5 11 12 13 19 9 29 20 18 15 21 16 17 91 88 22 23 76 77 28 86 30 85 87 74 84 71 25 31 73 72 75 83 95 27 93 43 24 96 32 34 33 35 36 70 94 26 37 38 93 82 81 68 69 97 39 92 80 66 65 67 41 43 37 44 100 64 98 40 42 45 46 59 60 99 48 58 61 47 63 49 57 62 50 56 78 55 51 79 54 53 52 Figure 9-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly . . . 1 . . . . . . . . . +250832 . . Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . CB2 . . 093995 . . Supplementary Pro, Man Reset 1P 15A 250VAC Frict . . . . . . . . . . . . . . . . . . . . . . 3 . . PC11 . 244471 . . Circuit Card Assy, PS/Feeder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly (Continued) . . . 39 . . . . . . . . . . 210866 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . . PC6 . . 244459 . . Circuit Card Assy, Remote Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . 182665 . . Terminal, Pwr Output Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Main Assembly (Continued) . . . 80 . . . . . . . . . . . . . 81 . . . . . . . . . . . . . 82 . . . . . . . . . . ................ . . . 83 . . . PC9 . . . . . 84 . . . . . . . . . . . . . 85 . . . PC1 . . . . . 86 . . . PC2 . . ................ . . . 87 . . . . . . . . . . ................ . . . 88 . . . . . . . . . . . . . 89 . . . . . . . . . . . . . 90 . . . PC5 . . . . . 91 . . . . T2 . . . . . 92 . . . . . . . . . . . . . 93 . C7,8,11 .
. Hardware is common and not available unless listed. 7 6 8 9 10 11 4 1 12 13 12 11 10 14 5 2 15 3 38 32 33 34 37 31 − Figure 9-4 39 16 40 41 42 36 30 24 35 17 29 28 23 25 21 22 18 26 27 20 19 254 082-A Figure 9-2.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-2. Single Wire Feeder . . . 1 . . . . . . . . . +234243 . . Wrapper, Single Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . 179310 . . Label, Warning General Precautionary Static&Wire Fe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Assy, PCB Support (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-2. Single Wire Feeder (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Panel Assy, Single Feeder (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . PC3 . . 244471 . . . . Circuit Card Assy, PS/Feeder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . GS1 . . 228036 . . . . Valve, 24VAC 1way .750−14 Thd 2.0mm Orf 100 PSI . . . . . . . . . . . . . . . . . .
. Hardware is common and not available unless listed. 11 10 9 7 6 5 8 6 7 5 4 16 17 12 2 13 14 13 15 39 39 38 3 1 44 43 38 37 35 36 34 31 − Figure 9-4 26 25 24 33 32 42 40 18 28 30 − Figure 9-4 41 29 27 23 19 20 21 22 254 081-A Figure 9-3.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-3. Dual Wire Feeder . . . 1 . . . . . . . . . . 142838 . . Bracket, Mtg Spool RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . 143160 . . Hub+Spindle Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . 135205 . . . . Nut, 625−11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-3. Dual Wire Feeder (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Panel Assy, Dual Feeder (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . PC3 . . 244471 . . . . Circuit Card Assy, PS/Feeder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . . . . . 233561 . . . . Enclosure, Rear Dual Feeder . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and 13 not available unless listed. 19 11 14 15 See Table 9-1 For Drive Roll & Wire Guide Kits 1 2 3 4 5 16 17 7 6 18 9 8 19 12 10 20 11 21 22 37 34 23 24 25 26 36 35 27 33 28 32 30 31 29 3 4 5 6 2 1 803 790-A Figure 9-4. Drive Assembly, Wire Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-4. Drive Assembly, Wire (Figure 9-2 Item 31 And Figure 9-3 Items 30 And 31) . . . 1 . . . . . . . . . . . . . . . 010 668 . . . 2 . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-4. Drive Assembly, Wire (Continued) ..................... ..................... . . . 11 . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . . . . . 17 . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . 19 . . . . . . . . . . . . . . . . . . 20 . . . .
Table 9-1. Drive Roll And Wire Guide Kits Wire Size V-GROOVE VK-GROOVE Inlet Guide Intermediate Guide 4 Roll Kit Drive Roll 4 Roll Kit Drive Roll 151 052 132 958 Fraction Metric .035 in. 0.9 mm 150 993 149 518 151 026 053 700 .040 in. 1.0 mm 150 993 149 518 161 189 053 696 .045 in. 1.1/1.2 mm 150 994 149 519 151 027 053 697 151 053 132 957 .052 in. 1.3/1.4 mm 150 994 149 519 151 028 053 698 151 054 132 956 1/16 in. (.062 in.) 1.
. Hardware is common and not available unless listed. 5 4 6 5 7 1 2 3 9 8 11 9 10 12 805 302-b Figure 9-5.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-5. Running Gear . . . 1 . . . . . . . . . . 236827 . . . 2 . . . . . . . . . . . 238611 . . . 3 . . . . . . . . . . 236817 . . . 4 . . . . . . . . . +233666 . . . . . . . . . . . . . . . . 200285 . . . 5 . . . . . . . . . . 170647 . . . 6 . . . . . . . . . . 004214 . . . 7 . . . . . . . . . . 188441 . . . 8 . . . . . . . . . . 234359 . . . 9 . . . . . . . . . . 602250 . . . 10 . . . . . . . . . . 121614 . . . 11 . . . . . . . . . . 163463 . . .
2 . Hardware is common and not available unless listed. 1 5 3 4 4 7 8 6 4 9 805 301-A / Ref. 239 780-B Figure 9-6. Composite Cables Quantity Model Item No. Dia. Mkgs. Part No. Description 5 ft 25 ft 50 ft 300 367 300 454 300 456 Figure 9-6. Composite Cables ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 1 2 2 3 3 3 4 5 5 6 7 8 9 9 .............. .............. .............. .............. .............. .............. .............. .............. .............. ...
. Hardware is common and not available unless listed. 1 2 3 805 148-B Figure 9-7. Cable Hanger Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-7. Cable Hanger Assembly . . . 1 . . . . . . . . . . 285304 . . Bracket, Cable Holder w/Edge Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . 238611 . . Cap, Tube .865 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 3 .
. Hardware is common and not available unless listed. 5 2 3 4 1 6 14 15 13 9 7 8 11 10 12 805 318-A Figure 9-8.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-8. Feeder Cart ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... 217255 234505 234546 234554 235121 234556 234553 163463 602250 121614 234545 123557 234555 237215 232470 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. Slide, Drawer . .
Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) 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.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number 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 Miller Electric Mfg. Co.
