Miller PipeWorx 400 Owner's Manual Page 1

OM-253 906D 2012−08ProcessesMIG (GMAW) and Pulsed MIG(GMAW-P) WeldingMultiprocess WeldingDescriptionPipeWorx 400Welding System(380-400 Volt Model)CEF

OM-253 906 Page 41-4. California Proposition 65 WarningsWelding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State

OM-253 906 Page 94. Hardware is common andnot available unless listed.254 082-A12345789101112131211101415166252627171819212224402829323334363738392342

OM-253 906 Page 95DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-2. Single Wire FeederQuantity1 +234243 Wrapper, Single Feeder 1... ... .. ...

OM-253 906 Page 96DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-2. Single Wire Feeder (Continued)QuantityRear Panel Assy, Single Feeder (Includes) 1...

OM-253 906 Page 97. Hardware is common andnot available unless listed.254 081-A13245678765910111216171819212625242728323335363740424443383839391523222

OM-253 906 Page 98DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-3. Dual Wire FeederQuantity1 142838 Bracket, Mtg Spool RH 1... ... .. ...

OM-253 906 Page 99DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-3. Dual Wire Feeder (Continued)QuantityRear Panel Assy, Dual Feeder (Includes) 1...

OM-253 906 Page 100See Table 9-1 For Drive Roll & Wire Guide Kits. Hardware is common andnot available unless listed.803 790-A20113736353433323130

OM-253 906 Page 101QuantityDescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-4. Drive Assembly, Wire (Continued)203 642 Pressure Arm, R & Vert L 4 Roll (

OM-253 906 Page 102Table 9-1. Drive Roll And Wire Guide KitsWire SizeInlet GuideIntermediateGuideV-GROOVE VK-GROOVEFraction Metric 4 Roll Kit Drive Ro

OM-253 906 Page 103. Hardware is common andnot available unless listed.805 302-b12134789910112565Figure 9-5. Running Gear

OM-253 906 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONfre_som_2011−107Pour écarter les risques de blessure pour vous−même et pour

OM-253 906 Page 104DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-5. Running GearQuantity1 236827 Handle, Power Source 2... ... .. ...

OM-253 906 Page 105805 301-A / Ref. 239 780-B. Hardware is common andnot available unless listed.81234567449Figure 9-6. Composite CablesQuantityDescri

OM-253 906 Page 106. Hardware is common andnot available unless listed.805 148-B132Figure 9-7. Cable Hanger AssemblyDescriptionPartNo.Dia.Mkgs.ItemNo.

OM-253 906 Page 107805 318-A. Hardware is common andnot available unless listed.812345679101311121415Figure 9-8. Feeder Cart

OM-253 906 Page 108DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-8. Feeder CartQuantity1 217255 Slide, Drawer 2... ... .. ...

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 2012-01Your distributor also givesyou ...ServiceYou always get the

ORIGINAL INSTRUCTIONS − PRINTED IN USA  2012 Miller Electric Mfg. Co. 2012−01Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer

OM-253 906 Page 6Il reste une TENSION DC NON NÉGLIGEABLE dansles sources de soudage onduleur UNE FOISl’alimentation coupée.D Arrêter les convertisseur

OM-253 906 Page 7LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou même la mort.D Fermer l’alimentation du gaz comprimé en casde non utili

OM-253 906 Page 8Les PIÈCES MOBILES peuventcauser des blessures.D Ne pas s’approcher des organes mobiles.D Ne pas s’approcher des points de coincement

OM-253 906 Page 92-5. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,is available as a free downl

OM-253 906 Page 10

OM-253 906 Page 11SECTION 3 − DEFINITIONS3-1. Manufacturer’s Warning Label DefinitionsWarning! Watch Out! There are possible hazards as shown by the s

OM-253 906 Page 12Disconnect input plug or power before working on machine.Safe5 2012−05When power is applied failed parts can explode or cause other

OM-253 906 Page 13?V?AConsult rating label for input power requirements.Safe34 2012−05Drive rolls can injure fingers.Safe32 2012−05Welding wire and dr

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-253 906 Page 143-2. Miscellaneous Symbols And DefinitionsAAmperageDirect Current(DC)AlternatingCurrent (AC)VVoltageGas Input Circuit Breaker To Pow

OM-253 906 Page 15SECTION 4 − SPECIFICATIONS4-1. Important Information Regarding CE Products (Sold Within The EU)A. Information On Electromagnetic Fie

OM-253 906 Page 16B. Dimensions And WeightHole Layout DimensionsABCDE805 142-A806 mm(31-3/4 in.)495 mm(19-1/2 in.)724 mm(28-1/2 in.)A 495 mm (19-1/2 i

OM-253 906 Page 174-3. MIG Duty Cycle and OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.If un

OM-253 906 Page 18SECTION 5 − INSTALLATION5-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is loc

OM-253 906 Page 195-3. Remote 14 Accessory Receptacle InformationIf a remote control is connected to the Remote 14 receptacle, the unit will automatic

OM-253 906 Page 205-4. Turning On Remote 14 Receptacle Control For Stick805 288-A! Turn Off welding powersource, disconnect inputpower, and check volt

OM-253 906 Page 215-5. Changing Wire Feed Speed From Inches Per Minute (IPM) ToMeters Per Minute (MPM)805 298-A / 805 429-A! Turn Off welding powersou

OM-253 906 Page 225-6. Remote 14 Wire Feeder Control Receptacle InformationRef. 805 144-A / Ref. 048 286-BRemote 14 Feeder Control Socket* Socket Info

OM-253 906 Page 235-7. Supplementary Protector CB2254 085-A1 Supplementary Protector CB2CB2 protects the 24 volts ac powersupply to the wire feeder (s

DECLARATION OF CONFORMITYfor European Community (CE marked) products.MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declar

OM-253 906 Page 245-8. 115 Volts AC Single Receptacle And Supplementary Protector254 087-A1 115 V 10 A AC Receptacle(Cooler Power Supply OnlyWhen Powe

OM-253 906 Page 255-9. Lifting Eye On Power Source805 293-A! Turn Off welding powersource, disconnect inputpower.1 Lifting EyeThe wire feeder allows a

OM-253 906 Page 265-10. Electrical Service GuideElec Serv 2011−04NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding pow

OM-253 906 Page 27Notes

OM-253 906 Page 285-11. Connecting 3-Phase Input PowerInput3 2011−03 − 254 080-ATools Needed:5/16 in.23= GND/PE EarthGroundL181L2L349101112L1 L2L35346

OM-253 906 Page 29 input3 2012−05! Installation must meet all Nationaland Local Codes − have only qualifiedpersons make this installation.! Disconnect

OM-253 906 Page 305-12. Installing Optional Handles, Running Gear And Cooler805 302-A / 805 292-A! Turn Off welding power source,disconnect input powe

OM-253 906 Page 315-13. Assembling And Installing Cable Hanger805 148-B / 805 141-A1 Bracket2 Tube Cap (4)3 Cable Holder Tube (2)Install caps in tubes

OM-253 906 Page 325-14. Proper Ring Terminal Connection To Volt Sense LeadIf volt sense lead is cut or broken at endwith ring terminal, be sure that n

OM-253 906 Page 335-16. Weld Output Terminals And Selecting Cable Sizes* Recommended For PipeWorx 400NOTICE − The Total Cable Length in Weld Circuit (

OM-253 906 Page 345-17. Connecting Weld Output Cables803 778-B! Turn off power before connecting toweld output terminals.! Failure to properly connect

OM-253 906 Page 355-18. Typical Connection Diagram For MIG (GMAW) Equipment With FeederOn Power Source! Do not put feeder where weldingwire hits cylin

OM-253 906 Page 365-19. Typical Connection Diagram For MIG (GMAW) Equipment With FeederOn Cart! Do not put feeder where weldingwire hits cylinder.! Do

OM-253 906 Page 375-20. Wire Feeder Rear Panel Connections And Rotating Drive Assembly805 155-A / Ref. 804 766-A / 802 825-A1 14-Pin Control Cable2 Sh

OM-253 906 Page 385-21. Gun Trigger Receptacle254 083-A1 Left Gun Trigger ReceptacleRC22 Right Gun Trigger ReceptacleRC3 (Dual Model Only)Connect gun

OM-253 906 Page 39. For best wire feeding performance, besure that the outlet cable has the propersize liner for the welding wire size beingused. Also

OM-253 906 Page 405-23. Voltage Sensing Lead And Work Cable Connections For Multiple Welding ArcsA. Ideal Setup805 289-B1 Welding Power Source2 Compos

OM-253 906 Page 41B. Bad Setup805 290-B1 Welding Power Source2 Composite Cable3 Work Cable4 Voltage Sensing Lead5 Wire Feeder6 WorkpieceThis arrangeme

OM-253 906 Page 42805 291-B1 Welding Power Source2 Composite Cable3 Work Cable4 Volt Sense Lead5 Wire Feeder6 WorkpieceThe method used to arrange cabl

OM-253 906 Page 43805 294-A1 Welding Power Source2 Work (−) Weld Cable3 Stick (+) Weld Cable4 Workpiece5 Electrode Holder6 Volt Sense Lead. Attach vol

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1...1-1. Symbol Usage 1...

OM-253 906 Page 44805 295-A1 Welding Power Source2 Gas Hose3 TIG (−) Weld Cable4 Work (+) Weld Cable5 Workpiece6 TIG Torch7 Volt Sense Lead8 Remote Fo

OM-253 906 Page 45805 296-A1 Welding Power Source2 Gas Hose 237 415 (Short BlackHose Supplied With PowerSource)3 TIG Block (Customer Supplied)4 TIG (−

OM-253 906 Page 46254 084-A1 Welding Power Source2 Gas Hose3 TIG Block (Customer Supplied)4 Coolant Out Hose 237 416(Short Red Hose Supplied WithCoole

OM-253 906 Page 47SECTION 6 − OPERATION6-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface u

OM-253 906 Page 486-1 . Operational Terms (Continued)Pulse(Pro-Pulset)An advanced pulse spray transfer process suited for the fill and cap passes on p

OM-253 906 Page 496-2. Welding Power Source ControlsA. Front Panel Controls. Only illuminated controls can bechanged or adjusted.1 Memory Card Busy In

OM-253 906 Page 506-3. Memory Card Slot1 Memory Card SlotThis is the memory card slot. Thememory card slot uses an SDmemory card. A memory card canbe

OM-253 906 Page 51B. Using Optional Memory Card1. Memory Card Insertiona. Lift and hold memory card access cover open.b. Insert memory card into slot

OM-253 906 Page 52D. Stick And TIG Welding Process Controls1. Stick Process Select ButtonPress and release this button to activate the stick welding p

OM-253 906 Page 53S Ramp down time − 0.0 to 10.0 secondsS Final amperage − 10 to 350 ampsS Final time − 0.0 to 10.0 seconds (2T only)S Postflow time −

TABLE OF CONTENTSSECTION 6 − OPERATION 47...6-1. Operational Terms 47...

OM-253 906 Page 545. Gas Selection TableThe gas selection table provides the available shielding gas selections. For any MIG process except FCAW, gas

OM-253 906 Page 556-4. TIG Sequence Control1 2T Trigger Icon2 4T Trigger Icon3 Preflow Indicator4 Initial Amperage Indicator5 Ramp-Up Indicator6 Ramp-

OM-253 906 Page 566-5. Stick Process Selection Setup Example. Only illuminated controls can bechanged or adjusted.1 Stick Process Active2 EXX10 Electr

OM-253 906 Page 576-6. TIG Process Selection Setup Example. Only illuminated controls can bechanged or adjusted.1 TIG Process Active2 HF Start Method

OM-253 906 Page 586-7. MIG Process Selection Setup Example 1. Only illuminated controls can bechanged or adjusted.1 MIG Process Active2 Carbon Steel W

OM-253 906 Page 596-8. MIG Process Selection Setup Example 2. Only illuminated controls can bechanged or adjusted.1 Pro-Pulse MIG Process Active2 Stai

OM-253 906 Page 606-9. Wire Feeder ControlsA. Front Panel Controls. Only illuminated controls can bechanged or adjusted.1 Left Side Controls Select Bu

OM-253 906 Page 611. Left Side Controls Select ButtonPress and release this button to activate the wire feeder left side controls. The LEFT text below

OM-253 906 Page 626. Wire Feed Speed Adjust KnobUse this knob to adjust the desired wire feed speed setting [1.3 to 19.8 mpm (50 to 780 ipm)]. Rotatin

OM-253 906 Page 636-10. Preflow And Postflow Adjustment. Postflow will not function without an arc initiation.Preflow and Postflow times can be config

OM-253 906 Page 1SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USINGsom 2011−107Protect yourself and others from injury — read, follow, and save these

OM-253 906 Page 64Unit will display PSt on the Voltage display.7. Adjust postflow time to desired value by rotate the Wire Feed Speed knob.Available s

OM-253 906 Page 656-12. Wire Feeder Right Side Active Setup Example (Dual Feeder Only). Only illuminated controls can bechanged or adjusted.1 Right Si

OM-253 906 Page 666-13. Wire Feeder Non-MIG Setup Example. Only illuminated controls can bechanged or adjusted.1 Non-MIG Process Selected 2 Memory Loc

OM-253 906 Page 676-14. Wire Feeder Timed Purge Example. Only illuminated controls can bechanged or adjusted.1 Purge And Trigger Hold ButtonsPressed S

OM-253 906 Page 686-15. Wire Feeder Auto Jog Example. Only illuminated controls can bechanged or adjusted.1 Jog And Trigger Hold Buttons PressedSimult

OM-253 906 Page 696-16. Basic Parameters For PipeWorx 400SteelProcessWire SizemmWire Feed SpeedmpmArc Length Shielding GasRMD Carbon0.9 2.5-8.9 w/5.1

OM-253 906 Page 70SteelProcessWire SizemmWire Feed SpeedmpmArc Length Shielding GasProPulse Carbon UsingA Positioner(Rolling The Pipe)0.9 2.5-19.8 w/5

OM-253 906 Page 71Stainless SteelProcessWire SizemmWire Feed SpeedmpmArc Length Shielding GasRMD Stainless Steel0.9 2.5-8.9 W/5.1 Nominal +3.0 to −3.0

OM-253 906 Page 72Flux CoreProcessWire Sizemm Rolling Pipe/In PositionWire Feed SpeedmpmVoltage Shielding GasFlux Core/GMAWNotDependent1.3-19.8 w/6.4

OM-253 906 Page 73SECTION 7 − MAINTENANCE AND TROUBLESHOOTING! Disconnect power before maintaining.7-1. Routine Maintenancen = Check ~ = Clean l = Rep

OM-253 906 Page 2Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.FUMES AND GASES can be hazardous.D Ke

OM-253 906 Page 747-3. Restoring Factory DefaultsFull SystemA full factory reset can be accomplished by pressing memory location buttons 1 and 4 on th

OM-253 906 Page 756. Calibrate STICK voltage as follows:a. Connect voltmeter from STICK stud (front left) to Work stud (front center).b. Press memory

OM-253 906 Page 767-6. Removing Right Side Panel and Measuring Input Capacitor Voltage! Turn Off welding powersource, and disconnectinput power.! Sign

OM-253 906 Page 777-7. Welding Power Source And Feeder Diagnostic Help CodesH1Display Example0Display Code Fault DescriptionH01 Primary Power Circuit

OM-253 906 Page 78H44 Motor Low Bus Indicates input primary line voltage is too low.Increase primary line voltage to at least 90% of specifiednominal

OM-253 906 Page 797-8. Troubleshooting Welding Power Source/Wire Feeder IssuesIf the welding power source and wire feeder are NOT responding after eve

OM-253 906 Page 807-9. Welding Power Source TroubleshootingTrouble RemedyNo weld output; unit completely in-operative.Place line disconnect switch in

OM-253 906 Page 81! Disconnect power before troubleshooting.7-10. Wire Feeder TroubleshootingTrouble RemedyWire feeds, shielding gas flows, butelectro

OM-253 906 Page 82! Disconnect power before troubleshooting.7-11. Cooler TroubleshootingTrouble RemedyCoolant system does not work.Be sure input power

OM-253 906 Page 83Notes

OM-253 906 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-253 906 Page 84SECTION 8 − ELECTRICAL DIAGRAMFigure 7-1. Circuit Diagram For Welding Power Source

OM-253 906 Page 85254 310-B

OM-253 906 Page 86Figure 7-2. Circuit Diagram For Single Or Dual Wire Feeder

OM-253 906 Page 87236 220-E

OM-253 906 Page 88SECTION 9 − HIGH FREQUENCY9-1. Welding Processes Requiring High Frequencyhigh_freq 5/10 − S-06931 High-Frequency VoltageTIG − helps

OM-253 906 Page 899-3. Recommended Installation To Reduce HF Interference1 High-Frequency Source (weldingpower source with built-in HF orseparate HF u

OM-253 906 Page 90SECTION 10 − PARTS LIST. Hardware is common andnot available unless listed.254 067-A167823459101179131516171819322921312223242526272

OM-253 906 Page 91DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main AssemblyQuantity1 +250832 Panel, Rear 1... ... .. ...

OM-253 906 Page 92DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main Assembly (Continued)Quantity39 210866 Terminal, Pwr Output Black 1... ...

OM-253 906 Page 93DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 9-1. Main Assembly (Continued)Quantity80 233483 Cover, Top 1... ... .. ....