OWNER’S MANUAL
© 2015 MILLER Electric Mfg. Co.
OM-254 719C 2015−09
PipeWorx 400 And PipePro XC 14-Pin Automation Interface 301071 And 301071001
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.
DANGER ! - Indique une situation dangereuse qui, si elle
n’est pas évitée, entraînera la mort ou des blessures
graves. Les éventuels risques sont représentés par les
symboles joints ou expliqués dans le texte.
Fsafe1 2013-10
Wear safety glasses with side shields.
Porter des lunettes de sécurité avec écrans latéraux.
Fsafe8 2013-10
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible ha-
zards are shown in the adjoining symbols or explained in
the text.
Indique une situation dangereuse qui, si elle n’est pas
évitée, entraînera la mort ou des blessures graves. Les
éventuels risques sont représentés par les symboles
joints ou expliqués dans le texte.
Fsafe2 2013-10
Beware of electric shock from welding electrode or wiring.
Touching the electrode while in contact with the work or
ground can cause electric shock. Always wear dry
gloves. Keep all panels and covers closed.
Attention au risque d’électrocution due au contact avec
l’électrode de soudage ou les fils. Le fait de toucher l’élec-
trode tout en étant en contact avec la pièce ou la terre peut
provoquer une électrocution. Toujours porter des gants
secs. Tous les panneaux et couvercles doivent rester fer-
més.
Fsafe5 2013-10
NOTICE
NOTE
Indicates statements not related to personal injury.
Signale des consignes non associées aux dommages
corporels.
Indicates special instructions.
Fournit des instructions spéciales.
Fsafe3 2013-10
Have only trained and qualified persons install, operate,
or service this unit. Read the safety information at the
beginning of these instructions and in each section. Call
your distributor if you do not understand the directions.
For WELDING SAFETY and EMF information, read
owner’s manual(s).
Ne confiez l’installation, l’exploitation ou l’entretien de cet
appareil qu’à des personnes compétentes et qualifiées.
Fsafe15 2013-10
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.
Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Ca-
lifornie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Ca-
lifornie, chapitre 25249.5 et suivants)
Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers, des
malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation.
Fsafe4 2013-10
TABLE OF CONTENTS
1. Automation Interface Hardware Configuration 2........................................................................
2. Connecting The Automation Interface 3...............................................................................
3. Basic Automation Interface Operation 4...............................................................................
4. Automation Interface Control 5.......................................................................................
5. Weld Process Tables 7...............................................................................................
5-1. Weld Process Information For PipeWorx 400 Non-CE/IEC 7..............................................................
5-2. Weld Process Information For PipeWorx 400 CE 9......................................................................
5-3. Weld Process Information For PipePro XC 11...........................................................................
6. Maintenance & Troubleshooting 12....................................................................................
6-1. Routine Maintenance 12..............................................................................................
6-2. LED Troubleshooting 12..............................................................................................
6-3. Automation Interface Help Codes 12...................................................................................
7. Circuit Diagram 13...................................................................................................
8. Parts List 14.........................................................................................................
OM-254 719 Page 2
1. Automation Interface Hardware Configuration
DIP1
DIP1
Rate
12 3 4
Address
56
ON ON ON ON 40
ON ON 9600
ON ON ON 41
ON 19200
ON ON ON 42
ON 38400
ON ON 43
reserved
ON ON ON 44
ON ON 45
DIP1
Parity
ON ON 46
78
ON 47
ON ON EVEN
ON ON ON 60
ON ODD
ON ON 61
ON NONE
ON ON 62
reserved
ON 63
ON ON 64
ON 65
ON 66
67
Table 1-1. MODBUS Address
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF OFF
OFF
OFF
OFF OFF
OFF OFF OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF OFF
OFF
OFF OFF
OFF OFF
OFF OFF OFF
Switch DIP1
! Turn off welding power
source and disconnect
input power. Disconnect
Automation Interface from
power source.
Remove Automation Interface
cover. Set desired MODBUS
address, baud rate and parity by
setting DIP1 using the following
tables.
Replace cover when task is
completed. Connect Automation
Interface to power source and
PLC.
Setting Switch DIP1
Table 1-2. Baud Rate Data
Table 1-3. Parity Data
OM-254 719 Page 3
2. Connecting The Automation Interface
254 912-A
Set switch DIP1 inside the Automation In-
terface box prior to connecting to the weld-
ing system (PipeWorx 400 System
shown).
1 Automation Interface To Welding
Power Source
Connect 14−pin plug (male) on end of
cable directly to the back of the power
source (front of power source for PipePro
XC model).
2 Automation Interface To Wire Feeder
Connect 14−socket plug (female) on end of
cable to the back of the wire feeder using
a Feeder Control Cable (see Parts List).
3 Automation Interface To PLC
Connect a PLC to the RS−485 MODBUS
RTU port on the front of the interface box
using a shielded RJ45 network cable. See
Table 2-1 for pin out information.
NOTICE − The RJ45 network cable is not
an Ethernet connection. It is not designed
for connection to an IP network.
NOTICE − Connecting a crossed cable to
a 2-wire MODBUS system may cause
damage.
1
2
3
Table 2-1. MODBUS Address
RJ45 Pin Circuit
4 D+
5 D−
8 Common
OM-254 719 Page 4
3. Basic Automation Interface Operation
1. To enable welding control from the Automation Interface, set the “Automation Enable” bit (0x2000) in the Command Flags register (MODBUS
Holding Register 101).
2. Select a Process
Write the desired process to Holding Register 102 using the appropriate table in Section 5.
S Not all values are used for all processes. For example, STICK processes do not use Registers 103 or 104.
S If the process or output selected is not available, the process will not be changed. Read Input Register 102 for verification of process change.
3. Obtain Minimum and Maximum values
Read from the Minimum and Maximum values section of Table 4-4.
4. Set Weld Output Parameters
Set ALL parameters (Holding Registers 103−108) to their desired values. They must be within the minimum and maximum values in Step 2.
S Preflow and Postflow can be set to their minimum value for default operation (see Table 4-2).
S ALL parameters must be initialized after each process selection.
5. Enable Output
Enable weld output by setting the Output Enable Flag to 1 in the Command Flags Holding Register (see Table 4-2 and Table 4-3). This will enable
the weld output of the power source.
6. Read Feedback Values
Read from the System Feedback Values section of Table 4-4.
7. Disable Output
To disable weld output, clear the Output Enable Flag to 0 in the Command Flags Holding Register (see Table 4-2 and Table 4-3).
S While controlled by the MODBUS Master, the PipeWorx operator interface buttons and knobs are disabled. However, the interfaces will still
display parameters and feedback values.
S When there is NO communication from the MODBUS Master to the Automation Interface the power source will operate as if there is NO
Automation Interface connected. The Automation Interface must receive a valid request at least every second, otherwise control will return to
the operator interface.
OM-254 719 Page 5
4. Automation Interface Control
Implemented MODBUS Function Codes
Table 4-1. MODBUS Function Codes
Function
Function Code
Read Input Register 4
Read Holding Register 3
Write Single Register 6
Write Multiple Registers 16
Read/Write Multiple Registers 23
MODBUS Registers
Table 4-2. Holding Registers
Register Address
Register Name Register Description
PDU MODBUS
100 101 Command Flags See Command Flags Table 4-3
101 102 Process Select See Appropriate Process Table (Section 5)
102 103 Voltage Command Voltage/Arc Length Command (x10)
103 104 Wire Speed Command Wire Feed Speed in IPM
104 105 Arc Control Inductance/Sharp Arc/DIG
105 106 Current Command Current Command (Amps)
106 107 Preflow* Preflow (0.1 sec increments)
107 108 Postflow* Postflow (1 sec increments)
*Setting Preflow and Postflow to −1 (minimum value) will result in default values.
Table 4-3. Command Flags (MODBUS 101)
Flag Name Bitmask Description
Output Enable 0x0001 Enable Weld Output
Wire Jog 0x0002 Feed wire
Gas Purge 0x0004 Open gas valve
Automation
Enable
0x2000 Enable welding control from Automation Interface
Ignore E-Stop 0x4000 Disable E-Stop signal from 14-pin Remote
Reset Faults 0x8000 Reset a fault condition (all other bits must be 0)
OM-254 719 Page 6
Table 4-4. Input Registers
Register Address
Register Name Register Description
PDU MODBUS
100 101 Command Flags
Used for Holding Register Verification
(see Holding Register Table 4-2)
101 102 Process Select
102 103 Voltage Command
103 104 Wire Speed Command
104 105 Arc Control
105 106 Current Command
106 107 Preflow
107 108 Postflow
System Feedback Values
200 201 Status Flags See Status Flags Table 4-5
201 202 Voltage Feedback Voltage Feedback (volts x 10)
202 203 Current Feedback Current Feedback (Amps)
203 204 Help Code System Help Code during errors (0 otherwise)
Minimum/Maximum Values (dependent on Process Select)
300 301 Voltage Minimum Minimum Value for MODBUS 103
301 302 Voltage Maximum Maximum Value for MODBUS 103
302 303 Wire Speed Minimum Minimum Value for MODBUS 104
303 304 Wire Speed Maximum Maximum Value for MODBUS 104
304 305 Arc Control Minimum Minimum Value for MODBUS 105
305 306 Arc Control Maximum Maximum Value for MODBUS 105
306 307 Current Minimum Minimum Value for MODBUS 106
307 308 Current Maximum Maximum Value for MODBUS 106
308 309 Preflow Minimum Minimum Value for MODBUS 107
309 310 Preflow Maximum Maximum Value for MODBUS 107
310 311 Postflow Minimum Minimum Value for MODBUS 108
311 312 Postflow Maximum Maximum Value for MODBUS 108
System Information
400 401 Power Source Version High Byte − Major Version# / Low Byte − Minor Version#
401 402 Automation Box Version High Byte − Major Version# / Low Byte − Minor Version#
The Process Select register (Input Register 102) is undefined when an error occurs.
Table 4-5. Status Flags (MODBUS 201)
Flag Name Bitmask Description
Valid Arc 0x0001 A valid welding arc has been established
OM-254 719 Page 7
5. Weld Process Tables
The following tables provide weld process information for the Automation Interface.
5-1. Weld Process Information For PipeWorx 400 Non-CE/IEC
Table 5-1. Weld Process Data (PipeWorx 400 Non-CE/IEC
Process Wire Type
Wire Diameter
in. (mm)
Gas Type
Process Code
Left Torch Right Torch
TIG
HF N/A N/A 0x0001
LIFT N/A N/A 0x0011
STICK
EXX10 N/A N/A 0x0002
EXX18 N/A N/A 0x0012
FCAW N/A N/A N/A 0x0003 0x000B
MIG
CARBON
.035 (0.9)
C8C15 0x0004 0x000C
C20 0x3004 0x300C
C25 0x1004 0x100C
CO2 0x2004 0x200C
.040 (1.0)
C8C15 0x0204 0x020C
C20 0x3204 0x320C
C25 0x1204 0x120C
CO2 0x2204 0x220C
.045 (1.2)
C8C15 0x0104 0x010C
C20 0x3104 0x310C
C25 0x1104 0x110C
CO2 0x2104 0x210C
STAINLESS
.035 (0.8)
C2 0x0014 0x001C
98O2 0x1014 0x101C
TRIH 0x2014 0x201C
TRIA 0x3014 0x301C
.040 (1.0)
C2 0x0214 0x021C
98O2 0x1214 0x121C
.045 (1.2)
C2 0x0114 0x011C
98O2 0x1114 0x111C
TRIH 0x2114 0x211C
TRIA 0x3114 0x311C
OM-254 719 Page 8
Table 5-1. Weld Process Data (PipeWorx 400 Non-CE/IEC) (Continued)
Process Wire Type
Wire Diameter
in. (mm)
Gas Type
Process Code
Left Torch Right Torch
RMD
CARBON
.035 (0.9)
C8C15 0x0005 0x000D
C20 0x3005 0x300D
C25 0x1005 0x100D
CO2 0x2005 0x200D
.040 (1.0)
C8C15 0x0205 0x020D
C20 0x3205 0x320D
C25 0x1205 0x120D
CO2 0x2205 0x220D
.045 (1.2)
C8C15 0x0105 0x010D
C20 0x3105 0x310D
C25 0x1105 0x110D
CO2 0x2105 0x210D
CARBON_MC .045 (1.2)
C20 0x3125 0x312D
C25 0x1125 0x112D
STAINLESS
.035 (0.9)
C2 0x0015 0x001D
98O2 0x1015 0x101D
TRIH 0x2015 0x201D
TRIA 0x3015 0x301D
.040 (1.0)
C2 0x0215 0x021D
98O2 0x1215 0x121D
.045 (1.2)
C2 0x0115 0x011D
98O2 0x1115 0x111D
TRIH 0x2115 0x211D
TRIA 0x3115 0x311E
PULSE
CARBON
.035 (0.9)
C8C15 0x0006 0x000E
C20 0x3006 0x300E
.040 (1.0)
C8C15 0x0206 0x020E
C20 0x3206 0x320E
.045 (1.2)
C8C15 0x0106 0x010E
C20 0x3106 0x310E
CARBON_MC .045 (1.2) C8C15 0x0126 0x012E
STAINLESS
.035 (0.9)
C2 0x0016 0x001E
98O2 0x1016 0x101E
TRIH 0x2016 0x201E
TRIA 0x3016 0x301E
.040 (1.0)
C2 0x0216 0x021E
98O2 0x1216 0x121E
.045 (1.2)
C2 0x0116 0x011E
98O2 0x1116 0x111E
TRIH 0x2116 0x211E
TRIA 0x3116 0x311E
OM-254 719 Page 9
5-2. Weld Process Information For PipeWorx 400 CE
Table 5-2. Weld Process Data (PipeWorx 400 CE)
Process Wire Type
Wire Diameter
mm
Gas Type
Process Code
Left Torch Right Torch
TIG
HF N/A N/A 0x0001
LIFT N/A N/A 0x0011
STICK
EXX10 N/A N/A 0x0002
EXX18 N/A N/A 0x0012
FCAW N/A N/A N/A 0x0003 0x000B
MIG
CARBON
0.9
C8C15 0x0004 0x000C
C20 0x3004 0x300C
C25 0x1004 0x100C
CO2 0x2004 0x200C
1.0
C8C15 0x0204 0x020C
C20 0x3204 0x320C
C25 0x1204 0x120C
CO2 0x2204 0x220C
1.2
C8C15 0x0104 0x010C
C20 0x3104 0x310C
C25 0x1104 0x110C
CO2 0x2104 0x210C
STAINLESS
0.9
C2 0x0014 0x001C
98O2 0x1014 0x101C
1.0
C2 0x0214 0x021C
98O2 0x1214 0x121C
1.2
C2 0x0114 0x011C
98O2 0x1114 0x111C
OM-254 719 Page 10
Table 5-2. Weld Process Data (PipeWorx 400 CE Continued)
Process Wire Type
Wire Diameter
mm
Gas Type
Process Code
Left Torch Right Torch
RMD
CARBON
0.9
C8C15 0x0005 0x000D
C20 0x3005 0x300D
C25 0x1005 0x100D
CO2 0x2005 0x200D
1.0
C8C15 0x0205 0x020D
C20 0x3205 0x320D
C25 0x1205 0x120D
CO2 0x2205 0x220D
1.2
C8C15 0x0105 0x010D
C20 0x3105 0x310D
C25 0x1105 0x110D
CO2 0x2105 0x210D
CARBON_MC 1.2
C20 0x3125 0x312D
C25 0x1125 0x112D
STAINLESS
0.9
C2 0x0015 0x001D
98O2 0x1015 0x101D
1.0
C2 0x0215 0x021D
98O2 0x1215 0x121D
1.2
C2 0x0115 0x011D
98O2 0x1115 0x111D
PULSE
CARBON
0.9
C8C15 0x0006 0x000E
C20 0x3006 0x300E
1.0
C8C15 0x0206 0x020E
C20 0x3206 0x320E
1.2
C8C15 0x0106 0x010E
C20 0x3106 0x310E
CARBON_MC 1.2 C8C15 0x0126 0x012E
STAINLESS
0.9
C2 0x0016 0x001E
98O2 0x1016 0x101E
1.0
C2 0x0216 0x021E
98O2 0x1216 0x121E
1.2
C2 0x0116 0x011E
98O2 0x1116 0x111E
OM-254 719 Page 11
5-3. Weld Process Information For PipePro XC
Table 5-3. Weld Process Data (PipePro XC)
Process Electrode Type
Wire Diameter
mm
Gas Type Process Number
Process Available
Feeder Type
Basic RMD
Stick
EXX10 NA NA 0x0001 X X
EXX18 NA NA 0x0011 X X
FCAW
NA NA FCAW (w/o Gas) 0x0003 X X
NA NA FCAW (w/Gas) 0x1003 X
MIG
NA 0.9
C20/C25
0x1004 X
NA 1.0 0x1104 X
NA 1.2 0x1204 X
RMD
NA 0.9
SOLID C15/C25
0x2005 X
NA 1.0 0x2105 X
NA 1.2 0x2205 X
NA 0.9
SOLID 100% CO
2
0x3005 X
NA 1.0 0x3105 X
NA 1.2 0x3205 X
NA 1.2 RMD MC 0x1205 X
PULSE*
NA 0.9
C20/C25
0x1006 X
NA 1.0 0x1106 X
NA 1.2 0x1206 X
*Pulse process only available with Custom SD Card Program.
OM-254 719 Page 12
6. Maintenance & Troubleshooting
6-1. Routine Maintenance
! Disconnect power before maintaining.
n = Check ~ = Clean l = Replace
Every
3
Months
l Cracked Or Damaged
Cord
6-2. LED Troubleshooting
LED Status/Color Description
RC6
Green RX LED receiving data from PLC
Amber TX LED sending data to PLC
D7 Flashing No MODBUS communication
D6
Flashing Bad firmware, update firmware
Very slow toggling; 2 seconds on, 2 seconds off Firmware update in process
6-3. Automation Interface Help Codes
Display Code MODBUS 204 Fault Description
H55 55 E−Stop Indicates an E−stop has oc-
curred. Connect pins A and B of
the power source remote 14 pin
accessory receptacle or disable
E−stop by setting bit 0x4000 of
MODBUS 101.
H56 56 MODBUS control fault Indicates PLC is enabling weld
output, gas, or wire jog on initial
communication. Clear all control
bits of MODBUS 101 to reset.
OM-254 719 Page 13
7. Circuit Diagram
254 720-B
Figure 7-1. Circuit Diagram For PipeWorx 400 And PipePro XC 14-Pin Automation Interface
OM-254 719 Page 14
8. Parts List
. Hardware is common and
not available unless listed.
254 721-A
1
3
2
4
5
6
Figure 8-1. PipeWorx 400 And PipePro XC 14-Pin Automation Interface
Parts Assembly
Quantity
Description
Part
No.
Dia.
Mkgs.
Item
No.
301071 301071001
Figure 8-1. PipeWorx 400 And Pipepro XC 14-Pin
Automation Interface Parts Assembly
Model
PipePro PipeWorx
XC 400
1 PC1 259 060 Circuit Card Assy, Automation w/Prgrm 1 1... ... ..... .. ...................... ....
2 258 793 Cable, Female (Automation) 1... ............. .. ......................................
2 206 305 Cable, Female PipePro XC (Automation) 1... ............. .. ....................
3 258 788 Conn, Circ Cpc Ethernet Skt Sealed 1 1... ............. .. ........................ ....
4 258 790 Conn, Circ Ethernet Panel Mount Protective Cap 1 1... ............. .. ............. ....
5 258 792 Cable, Male (Automation) 1... ............. .. ........................................
5 206 306 Cable, Male PipePro XC (Automation) 1... ............. .. .......................
6 258 791 Case, Automation Machined w/Cover And Hardware 1 1... ............. .. .......... ....
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Table 8-1. Feeder Control Cables (Not Provided)
Part No. Description
300 508 PipeWorx 400 Feeder Control Cable, 5ft
300 465 PipeWorx 400 Feeder Control Cable, 25ft
300 466 PipeWorx 400 Feeder Control Cable, 50ft
300 845 PipePro XC Feeder Control Cable, 10m
300 846 PipePro XC Feeder Control Cable, 20m
301 039 PipePro XC Feeder Control Cable, 25m
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