Instruction/ maintenance manual of the product PipePro 304 Miller Electric
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Pro cesses Descrip ti on TIG (GT A W) Welding Stick (SMAW ) Welding MIG (GMAW) and Pulsed MIG (GMA W -P) Welding Engine Driven Welding Generator OM -492 190 603BF 2007 − 05 PipePro 304 Air Carbon Arc (CAC-A) Cutting and Gouging Flux Cored (FCA W ) Welding Visit our website at www.
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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintenance Label 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-492 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 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 .
OM-492 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. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
OM-492 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can BLIND. Always wear a face shield, rubber gloves, and protective clothing when working on a battery . Stop engine before disconnecting or connect- ing battery cables or servicing battery .
OM-492 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury . Do not touch hot compressor or air system parts.
OM-492 Page 5 H. F . RADIA TION can cause interference. High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation.
OM-492 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-492 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher à mains nues les parties chau - des. Prévoir une période de refroidissement avant d e travailler à l’équipement.
OM-492 Page 8 LES CHAMPS MAGNETIQUES peuv- ent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.
OM-492 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
OM-492 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique. Arrêter ou déconnecter l’équipement avant d e démarrer ou d ’a rrêter le moteur . Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager le moteur électrique à cause d’une tension et d’une fré - quence trop faibles.
OM-492 Page 1 1 2-6. P r oposition californienne 65 A vertissem ents Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers.
OM-492 Page 12 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local T emperature Fuel Engine Oil On Check V a.
OM-492 Page 13 4-2. Dimensions, Weights, and Operating Angles Dimensions A Height 36 in (914 mm) B C Width 24 in (610 mm) C ! D t d tilt l i ld Depth 59 in (1499 mm) D ! Do not exceed tilt angles or engine could be damaged or unit could tip.
OM-492 Page 14 4-4. V olt-Ampere Curves 178 652 / 178 653 V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit.
OM-492 Page 15 193 458 4-5. Fuel Consumption 0 5 0 100 150 200 250 300 350 400 450 500 DC WELD AM PERES A T 100% DUTY CYCLE 3600 RPM 0 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 1.98 0.95 2.84 3.78 5.67 4.73 6.62 7.57 U.S. GAL./HR. LITERS/HR. IDLE Notes W or k l i k e a P r o ! Pros wel d and cut safel y .
OM-492 Page 16 SECTION 5 − INST ALLA TION install2 12/06 − Ref. 800 652 / Ref. 800 477-A / 803 274-A / 804 712 ! Do not weld on base. W elding on base can cause fuel tank fire or explosion.
OM-492 Page 17 5-2. Engine Prestart Checks 802 330-G 1/2 in (13 mm) Full Diesel Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure is too low or en- gine temperature is too high.
OM-492 Page 18 5-3. Adding Coolant T o Radiator Ref. 802 330-G ! Stop engine and let cool. Check coolant level according to Section 5-2 before starting this procedure. If coolant level is below bottom of radiator filler neck, add coolant as follows: 1 Radiator Air Bleed Screw Remove radiator air bleed screw .
OM-492 Page 19 5-5. Installing Exhaust Pipe 802 173-B / Ref. 213 263-B Point exhaust pipe in desired direction but always away from front panel and direction of travel.
OM-492 Page 20 5-6. Connecting T o Weld Output T erminals 80801 941 / Ref. 213 263-B / 802 174-E / 803 778-A T ools Needed: 3/4 in MIG And FCA W W elding Fo r MIG welding Direct Current Electrode Positive (DCEP), connect wire feeder cable to Positive (+) terminal on left and work cable to Negative ( − ) terminal on right.
OM-492 Page 21 5-7. Selecting W eld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in W eld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 3.
OM-492 Page 22 5-9. Guidelines For Installing Customer-Supplied Emergency Air Shutdown V alve A customer-supplied emergency air shutdown valve can be installed to stop the engine imme- diately in emergency situations. These guidelines show the typical installation of a Gator ESD 175-275-L3 air shutdown valve.
OM-492 Page 23 5-10. Operating Engine Block Heater ! Do not touch hot engine block. Engine block gets hot near heater . NOTICE − Do not run engine while coolant heater is on. 1 Coolant Heater 2 Heater Plug Use heater to maintain a constant engine coolant temperature.
OM-492 Page 24 SECTION 6 − OPERA TING WELDING GENERA TOR 6-1. Controls (See Section 6-2 ) Ref. 213 263-B / 802 330-G 45 7 8 10 11 12 13 69 1 14 23.
OM-492 Page 25 6-2. Description Of Controls (See Section 6-1 ) The fan motor is thermostatically controlled and only runs when cooling is needed. Engine Lights 1 Engine T emperature Light Light goes on and engine stops if engine tem- perature is too high.
OM-492 Page 26 6-3. Meter Functions The meters display the actual weld output values for approximately three seconds after the arc is broken. Mode Meter Reading At Idle Meter Reading While W elding Scratch Start TIG VA Actual V olts (OCV) Preset Amps 80.
OM-492 Page 27 6-5. Lift-Arc TIG Procedure With Mode Switch in the Lift-Arc TI G position, start an arc as follows: 1 TIG Electrode 2 W orkpiece T ouch tungsten electrode to work- piece at weld start point, hold electrode to workpiece for 1-2 seconds , and slowly lift electrode.
OM-492 Page 28 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. Generator Power Receptacles And Circuit Breakers ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Generator power decreases as weld current increas es.
OM-492 Page 29 7-2. Optional GFCI Receptacles And Circuit Breakers Ref. ST-207 554-A ! If unit does not have GFCI receptacles, use GFCI-pro- tected extension cord.
OM-492 Page 30 7-4. Wiring Instructions For Optional 240 V olt, Single-Phase Plug (NEMA 14-50P) plug1 1 1/03 − 120 813-D The plug can be wired for a 240 V , 2-wire load or a 120/240V , 3-wire load.
OM-492 Page 31 SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Maintenance Label.
OM-492 Page 32 8-2. Routine Maintenance ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.
OM-492 Page 33 8-3. Servicing Spark Arrestor Ref. 213 263-B-B / 802 743 / Ref. 802 656 ! Stop engine and let cool. 1 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. Start engine and run several min- utes to blow out cleanout hole.
OM-492 Page 34 8-4. Servicing Air Cleaner aircleaner1 9/00 − ST-153 929-B / ST -153 585 / Ref. S-0698-B ! Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty .
OM-492 Page 35 8-5. Servicing Engine Lubrication And Fuel Systems Ref. 213 263-B / 802 330-G / S-0842 T ools Needed: 5 4 4 2 3 ! Stop engine and let cool.
OM-492 Page 36 8-6. Servicing Engine Cooling System 802 330-G / 802 581 ! Stop engine and let cool. 1 Radiator Draincock 2 Radiator Cap 3 Radiator Air Bleed Screw Change coolant according to engine manual. Add coolant according to Sec- tion 5-3). Run engine until engine reaches normal operating temperature.
OM-492 Page 37 8-7. Replacing Throttle Solenoid TS1 802 330-B ! Stop engine, and let cool. ! Disconnect battery , negative ( − ) cable first. Remove right side engine panel.
OM-492 Page 38 8-8. Adjusting Engine Speed 802 330-B After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm.
OM-492 Page 39 ! Stop engine. When a supplementary protec- tor or circuit breaker opens, it usually indicates a more seri- ous problem exists. Contact Factory Authorized Service Agent. 1 Supplementary Protector CB5 CB5 protects the 1 15 volt ac output to Remote 14 receptacle RC14.
OM-492 Page 40 8-10. V oltmeter/Ammeter Help Displays Use the voltmeter/ammeter help displays to help determine the cause of no weld output. When a help display is shown, the inverter module weld output has stopped but the en- gine continues to run. Correct the problem before resuming operation.
OM-492 Page 41 8-1 1. T roubleshooting A. Welding T rouble Remedy No weld output. Check control settings. Check weld connections. Disconnect equipment from generator power receptacles during start-up. If using remote control, be sure mode switch is in a position that provides output control at Remote 14 receptacle (see Sections 5-8 and 6-1).
OM-492 Page 42 T rouble Remedy Remote contactor control does not activate contactor . Check and tighten connections to Remote 14 receptacle RC14 (see Section 5-8). Lack of high frequency; difficulty in establishing Gas Tungsten Arc W eld- ing arc. Use proper size tungsten for welding amperage.
OM-492 Page 43 C. Engine T rouble Remedy Engine will not crank. Reset circuit breaker CB8 (see Section 8-9). Check battery voltage. Check battery connections and tighten if necessary . Have Factory Authorized Service Agent check Engine Control switch S2.
OM-492 Page 44 T rouble Remedy Engine does not go to low (idle) speed with Engine Control switch in Run/Idle position. Be sure Engine Control switch S2 is in Run/Idle position. Remove all weld and generator power loads. Turn of f remote device connected to Remote 14 receptacle RC14 (see Section 5-8).
OM-492 Page 45 Notes W or k l i k e a P r o ! Pros wel d and cut safel y . R ead the safety rules at the beginni ng of this m anual..
OM-492 Page 46 SECTION 9 − ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram For Welding Generator.
OM-492 Page 47 212 633-F.
OM-492 Page 48 SECTION 10 − RUN-IN PROCEDURE run_in4 2007 − 05 10-1. W etstacking 2 1 ! Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equip- ment damage may occur .
OM-492 Page 49 10-2. Run-In Procedure Using Load Bank S-0683 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur .
OM-492 Page 50 10-3. Run-In Procedure Using Resistance Grid S-0684 ! Stop engine. ! Do not touch hot exhaust pipe, engine parts, or load bank/grid. ! Keep exhaust and pipe away from flammables. NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur .
OM-492 Page 51 SECTION 1 1 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 1 1-1. Selecting Equipment gen_pwr 2007 − 04 − Ref.
OM-492 Page 52 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
OM-492 Page 53 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Star ting W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 21.
OM-492 Page 54 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/.
OM-492 Page 55 1 1-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP .
OM-492 Page 56 1 1-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices.
OM-492 Page 57 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-492 Page 58 SECTION 12 − P ARTS LIST Hardware is common and not available unless listed. 2 3 1 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 29 104 93 Fig. 12-2 102 101 1000 94 94 99 98 97 96 92 91 90 103 Fig. 12-3 95 105 Figure 12-1.
OM-492 Page 59 802 324-N 30 Fig. 12-4 76 77 89 88 79 81 80 86 87 63 85 62 82 83 84 65 60 61 58 57 59 66 78 64 71 72 74 75 73 68 69 70 54 31 32 35 33 34 36 15 55 56 53 52 51 39 38 37 41 40 42 43 46 48 .
OM-492 Page 60 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 +198 157 P ANEL, generator left 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ +198 873 P ANEL, generator left stainless 1 .
OM-492 Page 61 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 51 202 198 BASE, fuel filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-492 Page 62 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly (Continued) Quantity 213 226 HARNESS, wiring ignition (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-492 Page 63 Hardware is common and not available unless listed. 802 327-F 1 2 3 4 5 6 37 36 35 32 34 33 31 29 28 27 26 6 30 25 38 12 24 23 21 20 22 19 18 8 7 8 9 10 16 15 11 12 39 17 41 40 14 13 Figure 12-2. Front Panel Description Part No. Dia.
OM-492 Page 64 Description Part No. Dia. Mkgs. Item No. Figure 12-2. Front Panel (Continued) Quantity 22 192 265 GAUGE, fuel elec switch w/o switchgage sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 145 247 METER, hour 12 − 24vdc 1.
OM-492 Page 65 Hardware is common and not available unless listed. 802 326-B 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 5 26 18 27 35 34 33 28 32 29 30 31 36 37 39 40 41 42 44 43 38 45 46 47 Figure 12-3. Inverter Assembly Description Part No.
OM-492 Page 66 Description Part No. Dia. Mkgs. Item No. Figure 12-3. Inverter Assembly (Continued) Quantity 23 181 853 INSULA TOR, screw 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-492 Page 67 Hardware is common and not available unless listed. 802 338-B 2 1 11 10 9 6 7 8 4 5 3 Figure 12-4. Generator Description Part No. Dia. Mkgs. Item No. Figure 12-4. Generator Assembly (Figure 12-1, Item 30) Quantity 1 217 046 ENDBELL (includes) 1 .
Notes W or k l i k e a P r o ! Pros wel d and cut safel y . R ead the safety rules at the beginni ng of this m anual..
TM-188 304 Page 2 Invision 354MP Notes.
Notes Over 80,000 trained since 1930! 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Star t Y our Professional W elding Career Now!.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 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.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compan y 1635 West Spenc er S treet Applet on, W I 54914 USA International He adquarters .
An important point after buying a device Miller Electric PipePro 304 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric PipePro 304 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric PipePro 304 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric PipePro 304 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric PipePro 304 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric PipePro 304, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric PipePro 304.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric PipePro 304. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric PipePro 304 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
