Miller PipePro XC Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS - READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Symboles utilisés

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4. Proposition californienne 65 Avertissements

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2-5. Principales normes de sécurité

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2-6. Informations relatives aux CEM

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SECTION 3

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DEFINITIONS

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3-1. Manufacturer’s Warning Label Definitions

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3-2. Miscellaneous Symbols And Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Serial Number And Rating Label Location

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4-2. Unit Specifications

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4-3. Dimensions And Weight

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4-4. Environmental Specifications

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4-5. MIG Duty Cycle and Overheating

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4-6. Stick Duty Cycle and Overheating

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SECTION 5

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INSTALLATION

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5-1. Selecting A Location

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5-2. Equipment Connection Diagram For Self-Shielded Flux Core

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5-3. Equipment Connection Diagram For MIG/RMD

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5-4. Remote 14 Accessory Receptacle Information

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5-5. Power Source Remote 14 Wire Feeder Control Receptacle Information

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5-6. Supplementary Protector CB2

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5-7. Connecting To Weld Output Terminals

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5-8. Connecting Weld Output Cables

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5-9. Weld Output Terminals And Selecting Cable Sizes*

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5-10. Electrical Service Guide

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5-11. Connecting 3-Phase Input Power

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5-12. Proper Ring Terminal Connection To Work Sense Lead

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5-13. Connecting Work Sense Lead And Work Cable To Clamp

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5-14. Wire Feeder Remote 14 Control Receptacle Information

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5-15. Wire Feeder Trigger Receptacle Information

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5-16. Installing And Aligning Wire Guide And Drive Rolls

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5-17. Connecting Welding Gun

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5-18. Connecting Shielding Gas

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5-19. Connecting Weld Cable And Work Sense Lead

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5-20. Installing And Threading Welding Wire

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Summary of Contents for PipePro XC

Page 1: ...site at www MillerWelds com File MIG GMAW Processes MIG GMAW and Pulsed MIG GMAW P Welding Description Flux Cored FCAW Welding Stick SMAW Welding Arc Welding Power Source Wire Feeder PipePro XC Weldin...

Page 2: ...inue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get t...

Page 3: ...al Specifications 14 4 5 MIG Duty Cycle and Overheating 15 4 6 Stick Duty Cycle and Overheating 17 SECTION 5 INSTALLATION 18 5 1 Selecting A Location 18 5 2 Equipment Connection Diagram For Self Shiel...

Page 4: ...utine Maintenance 42 7 2 Blowing Out Inside of Unit 42 7 3 Cleaning Debris From Shielding Gas Filter Fitting 43 7 4 Restoring Factory Defaults 44 7 5 Viewing Software Revision 44 7 6 Power Source Cali...

Page 5: ...uncil Directives S 2006 95 EC Low Voltage S 2004 108 EC Electromagnetic Compatibility S 2011 65 EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment Standar...

Page 6: ...posure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational exposure is below the Exposure...

Page 7: ...neeling 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 semiautomaticDC...

Page 8: ...ared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as clo...

Page 9: ...S can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for ma...

Page 10: ...PA 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...

Page 11: ...s dans un environnement humideou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y...

Page 12: ...br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage v rifier et s assur...

Page 13: ...areil D Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur D Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e P...

Page 14: ...ational 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 Cy...

Page 15: ...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 Safe8 2012 05 Use ventilating fan to remove fumes...

Page 16: ...use or recycle Waste Electrical and Electronic Equipment WEEE by disposing at a designated collection facility Contact your local recycling office or your local distributor for further information Saf...

Page 17: ...ety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Safe38 2012 05 Become trained and read the instructions before work...

Page 18: ...Phase Static Frequency Con verter Transformer Rectifier U0 Rated No Load Voltage OCV U1 Primary Voltage U2 Conventional Load Voltage X Duty Cycle Hz Hertz s Suitable for Some Hazardous Locations I2 Ra...

Page 19: ...ad Output 50 60 Hz Three Phase KVA KW 380 V 400 V 380 400 380 400 Three Phase Stick 350 A 34 Volts DC 100 Duty Cycle 50 C 122 F 40 350 80 23 5 22 7 15 7 15 9 13 2 13 2 MIG 400 A 34 Volts DC 100 Duty C...

Page 20: ...ure by consultation with the distribution network operator if necessary that the system impedance complies with the impedance restrictions ce emc 1 2014 07 C China EEP Hazardous Substance Information...

Page 21: ...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 O...

Page 22: ...nuous Welding 100 Duty Cycle At 400 Amperes 60 Duty Cycle At 500 Amperes 6 Minutes Welding 4 Minutes Resting C 605 C 1405 F Operation Duty Cycle is percentage of 10 min utes that unit can weld at rate...

Page 23: ...id warranty Overheating 0 15 A V OR Reduce Duty Cycle Minutes duty1 4 95 Ref 257 025 A Continuous Welding 100 Duty Cycle At 350 Amperes B 605 C 1405 F Operation Duty Cycle is percentage of 10 minutes...

Page 24: ...nt see NEC Article 511 or CEC Section 20 1 Lifting Forks Extend forks beyond opposite side of unit 2 Lifting Handles Use handles to lift unit 3 Hand Cart Use cart or similar device to move unit 4 Line...

Page 25: ...with the PipePro XC Power Source 1 PipePro XC Welding Power Supply 2 Weld Cable To Feeder Electrode Negative 3 Work Cable To Workpiece Weld cable and work cable connec tions to power source 4 Workpiec...

Page 26: ...ly 2 Weld Cable To Feeder 3 Work Cable To Workpiece Weld cable and work cable connec tions to power source 4 Workpiece 5 Work Sense Lead Connect work sense clamp to workpiece 6 Gun 7 Gun Trigger Recep...

Page 27: ...ONTROL C Output to remote control 10 volts DC D Remote control circuit common E 0 to 10 volts DC input command signal from remote control GND K Chassis common The remaining sockets are not used 5 5 Po...

Page 28: ...631 Page 22 5 6 Supplementary Protector CB2 Ref 250 702 B 1 SupplementaryProtector CB2 CB2 protects the 24 volts ac power supply to the wire feeder Press button to reset supplementary protector 1 CB2...

Page 29: ...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 1 Weld Output Terminal 2 Supplied Wel...

Page 30: ...3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2...

Page 31: ...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 50 Hz Three Phase Input Voltage V 380 400 Input A...

Page 32: ...OM 269631 Page 26 5 11 Connecting 3 Phase Input Power input5 2016 04 Ref 269 652 Tools Needed 5 16 in L1 7 1 L2 L3 3 4 8 6 9 10 GND PE Earth Ground 5 6 4 3 L1 L2 L3 2...

Page 33: ...tors cord through strain relief Tighten strain relief S Use large strain relief for input conductor size 8 and larger S Use small strain relief with reducing washers for input conductor size 10 3 Weld...

Page 34: ...ted Tape Or Heat Shrink Tubing 3 Center Conductor 4 Ring Terminal 1 2 in Opening 1 Tools Needed 3 4 2 Ref 239 780 B 5 13 Connecting Work Sense Lead And Work Cable To Clamp 805 030 A Tools Needed 1 2 i...

Page 35: ...al communication signal I Isolated RS 485 serial communication signal H Isolated serial communication common POSITIVE VOLT SENSE G Positive weld output voltage sense signal NEGATIVE VOLT SENSE F Negat...

Page 36: ...lose to drive rolls as possible without touching Tighten screw Aligning Wire Guide And Drive Rolls View is from top of drive rolls look ing down with pressure assembly open 6 Drive Roll Securing Nut 7...

Page 37: ...5 Gun Locking Tab Loosen knob insert gun end into block Position power pin as close as possible to drive rolls without touching Align the gun power pin groove with the gun locking tab Tighten knob 6 G...

Page 38: ...welding Items 1 4 are user supplied Tools Needed 5 8 in Rear View 1 2 3 4 5 19 Connecting Weld Cable And Work Sense Lead 250 768 A 1 User Supplied Weld Cable Follow wire manufacturer s recom mendation...

Page 39: ...ded to turn spool Threading Welding Wire 3 Pressure Assembly Adjustment Knob Lay gun cable out straight Open pressure assembly hold wire tightly and cut off end Push wire through guides into gun Close...

Page 40: ...is between a continuously fed filler metal consumable electrode and the workpiece Externally supplied gas or gas mixtures provide shielding Preflow The time that the shielding gas flows prior to an a...

Page 41: ...AMPS Display 3 Amperage Adjustment Knob 4 Feeder Select Button 5 Memory Card Program Save Button 6 Memory Card Program Load Button 7 Memory Card In Use Indicator Light 8 Electrode Select Button 9 Mem...

Page 42: ...ration the Amperage Adjustment 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...

Page 43: ...ated The memory CARD text will illuminate on the power source front panel as well as on the feeder front panel to indicate that the optional program is being used from the memory card If applicable se...

Page 44: ...ts Switch Ref 250 764 A 1 Feeder Units Switch Switch position up for inches per minute Switch position down for meters per minute 1 Notes Work like a Pro Pros weld and cut safely Read the safety rules...

Page 45: ...splay 4 Volts Arc Length Adjustment Knob 5 Wirespeed Adjustment Knob 6 Purge Button 7 Arc Control Button 8 Trigger Hold Button 9 Jog Button 10 FCAW Process Select Button 11 MIG Process Select Button 1...

Page 46: ...ustment If no further changes are made to the time period after one second the unit will resume the count down display Arc Control Button Press and release this button to adjust arc control When in a...

Page 47: ...POWER will illuminate when the Accu Power feature is enabled on the system Pre Post Flow Pressing and releasing the arc control and purge buttons simultaneously will activate the adjustable preflow a...

Page 48: ...adable Labels Weld Terminals nl Weld Cable l Cracked Parts n 14 Pin Cord n Gas Hose and Fittings n Gun Cable l Cracked Electrode Holder Parts nl Gun Cables Every 6 Months Or Inside Unit Drive Rolls 7...

Page 49: ...e fitting from gas valve on back panel of feeder Blow compressed air through the threaded male end of fitting to dis lodge debris from internal mesh screen Replace fitting if blowing com pressed air t...

Page 50: ...will display CAL 4 Calibrate voltage as follows a Connect voltmeter from stud to stud b Press FEEDER button on the power source front panel Open circuit voltage should now be present from stud to the...

Page 51: ...d PC10 3 Voltmeter Measure the dc voltage across the screw terminals on PC10 as shown until voltage drops to near 0 zero volts If the capacitor voltage does not drop to near zero after sev eral minute...

Page 52: ...f this code appears on the display contact the nearest Factory Authorized Service Agent H12 Primary Input Line Voltage Malfunction Indicates input primary line voltage is too low or power source is in...

Page 53: ...see if the attrib utes are read only for a reason the attributes can be altered using a PC Use a different card Remove card or press any button to clear error H66 No Memory Card Detected Indicates no...

Page 54: ...ection S Be sure that work sense lead is separated from weld cables S Be sure gun angle during welding is straight in to 15 degrees back at joint S Follow recommended settings in Operation section of...

Page 55: ...repair or replace cables if necessary Wire feeder is on display does not light up motor does not run gas valve and welding power source contactor do not pull in Check and reset circuit breaker at wel...

Page 56: ...OM 269631 Page 50 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram For CE Welding Power Source...

Page 57: ...OM 269631 Page 51 269 637 D...

Page 58: ...OM 269631 Page 52 Figure 8 2 Circuit Diagram For XC RMD Wire Feeder CE...

Page 59: ...OM 269631 Page 53 269 639 A...

Page 60: ...e 54 SECTION 9 PARTS LIST Hardware is common and not available unless listed 269 788 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 33 28 29 30 32 34 35 36 37 Figure 9 1...

Page 61: ...4 21 233489 Bracket Capacitor Support 1 22 183827 Bus Bar Output 1 23 185214 Bus Bar Interconnecting 1 24 185992 Bus Bar Capacitor 2 25 199840 Bus Bar Diode 4 26 PC4 231559 Circuit Card Assy Intercon...

Page 62: ...t Inductor Mounting E70 Ferrite Core 2 4 250144 Bracket Isolator 2 5 250238 Mount Vibration 50 Duro Flange Mtg 4 6 253523 Insulator Output Inductor 1 When ordering a component originally displaying a...

Page 63: ...nap In Nyl 625 ID X 875 Mtg Hole 1 9 HD1 168829 Transducer Current 1000A Module Max Open Loop 1 10 RT2 209223 Thermistor NTC 30K ohm 25 Deg C 18 00 in Lead 1 11 C11 C14 180778 Capacitor Assy 4 Windtun...

Page 64: ...1 21 L2 270446 Stabilizer Output 1 22 L1 180026 Inductor Input 1 23 W1 180270 Contactor Def Prp 40A 3P 24VAC Coil w Boxlug 1 24 181925 Insulator Stabilizer Lead 1 236287 Plugs W Leads IGBT Gates Incl...

Page 65: ...utput Red 1 8 182707 Terminal Pwr Output Black 1 9 180735 Washer Output Stud 2 10 186621 Boot Generic Output Stud 1 11 181169 Spacer Output Stud 2 12 PC12 244477 Circuit Card Assy SD Card 1 13 PC3 248...

Page 66: ...ess Control w Program Potted 1 4 PC9 253621 Circuit Card Assy VS Disconnect 1 5 FM2 183918 Motor Fan 24VDC 3000 RPM 43 CFM w 10 Ohm Resistor 1 6 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 8...

Page 67: ...ot available unless listed Ref 254 973 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 40 55...

Page 68: ...Bracket Capacitor Support SC12 1 29 SR1 035704 Rectifier Integ Bridge 40 Amp 800V 1 30 248817 Insulator Rear Panel 1 31 269638 Cable Power 1 131204 Housing Plug Skts Service Kit 1 115094 Housing Plug...

Page 69: ...Mkgs Item No Figure 9 7 XC RMD Wire Feeder CE Front Panel 1 248745 Panel Front w Studs 1 2 269634 Nameplate 1 3 248751 Nameplate 1 4 174991 Knob Pointer 1 250 Dia X 250 ID w Spring Clip 21 2 5 250268...

Page 70: ...Notes...

Page 71: ...ns and Subarc SAW Torches 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 suc...

Page 72: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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