User manual | PipePro Welding System Quick Multiprocess Pipe

Issued Jan. 2011 • Index No. PWS/4.0
PipePro Welding System
®
Quick
Specs
Pipe Welding Applications
Processes
Onshore Transmission Piping
Field Construction
Process Piping
Stick (SMAW)
TIG (GTAW)
MIG (GMAW)
RMD™ (Modified Short Circuit)
Pro-Pulse™ (GMAW-P)
Flux Cored (FCAW)
The Power of Blue .
Multiprocess Pipe
Welding Systems
Rated Output
PipePro 300: 225 A at 29 VDC, 100% Duty Cycle
PipePro 450 RFC: 450 A at 44 VDC, 100% Duty Cycle
Voltage Range
Ship Weight
10 – 44 V
PipePro 300: 127 lb (58 kg)
PipePro 450 RFC: 163 lb (72.9 kg)
PipePro 12RC SuitCase: 25.5 lb (11.6 kg)
Bernard PipeWorx 250-15: 9 lb (4.1 kg)
Bernard PipeWorx 300-15: 10 lb (4.6 kg)
The PipePro® Welding System provides a productive solution for welding on pipe in field
construction applications. The welding system includes a PipePro power source, PipePro
SuitCase® feeder, and Bernard® PipeWorx™ welding guns.
®
Bernard PipeWorx 250-15
Provides an ergonomic solution
to producing root passes on
pipe and other medium-duty
applications. Designed by
welders to reduce fatigue and
improve visibility of the puddle
on the root pass.
Bernard PipeWorx 300-15
Provides a heavy-duty solution
to producing root, fill and cap
welds on pipe.
PipePro 450 RFC
The PipePro 450 provides the same capabilities and
benefits of the PipePro 300 with a higher amperage
output — up to 650 amps. The higher output of the
PipePro 450 provides greater flexibility for the following
applications (see specifications on page 2):
• Larger-diameter flux cored wires
• High-ambient-temperature applications
• Roll welding with MIG or FCAW (high wire-feed speeds)
PipePro 12RC SuitCase
Provides a durable wire feeder
solution for field applications.
The impact-resistant case
design protects the wire and
drive mechanism from moisture,
dust and contamination.
NEW! PipePro 300
Multiprocess welding power source is capable of the
following processes: Stick, TIG, MIG, RMD (Modified
Short Circuit MIG), Pulsed MIG, and Flux Cored. The
RMD Process is optimized for root pass welding on
carbon and stainless steel pipe with solid and metalcored wires. Programs are available for the most
common shielding gases, wire types and wire diameters.
IMPROVED WELD PERFORMANCE
See page 3 for more information on
Regulated Metal Deposition (RMD™ Pro)
and Pro-Pulse™ welding processes.
Power source is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
Equipment Sales US and Canada
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 866-931-9730
FAX: 800-637-2315
International Phone: 920-735-4554
International FAX: 920-735-4125
www.MillerWelds.com
PipePro 300 and 450 RFC Power Sources
®
Features
Specifications
Model
Auto-Line™
Allows for any input voltage hook-up (190–630 V, 50/60 Hz) with no
manual linking. Compensates for voltage spikes and drops within the
entire range. CE units are limited to 305 – 460 V range.
1/4-turn connectors
Allow for faster installation of system and reduces thread stripping.
Multiprocess
Select from Stick, TIG, MIG, GMAW-P, RMD Pro, Pro-Pulse MIG,
and FCAW.
Wind Tunnel Technology™
Circulates air over components that require cooling, not over electronic
circuitry, which reduces contaminants and improves reliability.
Fan-On-Demand™
Cooling system operates only when needed. Reduces amount of
airborne contaminants pulled through the machine.
Easy to operate
Simple front panel layout makes it easy to select programs.
(Subject to change without notice.)
Rated Welding
Output
Voltage Amperage Max. Open- Amperes Input at Rated Output for
Range in Range in Circuit
Typical Voltages +/-10%, 50/60 Hz
CV Mode CC Mode Voltage
208 V 230 V 380 V 400 V 460 V 575 V
KVA
KW
Dimensions
Ship
Weight
PipePro 225 A at 29 VDC, 10 – 44 V
300
100% Duty Cycle
10 – 300 A
80 VDC
22.8* 20.6* 12.4
11.8
10.3* 8.6*
8.3
7.8
H: 23 in (584 mm)
127 lb
W: 17-3/32 in (434 mm) (58 kg)
D: 22-1/2 in (572 mm)
PipePro 450 A at 44 VDC,
450 RFC 100% Duty Cycle
5 – 600 A
80 VDC
67*
34
29*
23.8
22.9
H: 41 in (1041 mm)
W: 15-1/2 in (394 mm)
D: 22 in (559 mm)
10 – 44 V
59*
36
23*
163 lb
(72.9 kg)
*Note: CE units are limited to 305 – 460 V range.
Control Panels
Back Panel
Front Panel
7
1
11
2
3
12
8
13
4
5
9
10
6
1. Voltage/Arc Adjust
Display Meter
2. Program Display
3. Program # Select
4. Power Switch
2
5. Process Setup Button
• Weld Process
• Wire Size and Type
• Gas Type
6. Control Knob
7. Wire Speed/Amperage
Digital Display Meter
8. Palm™/PC RS-232 Ports
9. Wire Feed/Amperage Select
10. Arc Control and Inductance Control
11. Peripheral Connector
12. Remote Connector
13. Wirefeed Connector
Welding Process Capabilities
RMD™ (Regulated Metal Deposition) Pro
RMD Ball Transfer
A precisely controlled short-circuit metal transfer that provides a calm, stable arc
and weld puddle. This provides less chance of cold lap or lack of fusion, less
spatter and a higher quality root pass on pipe. The stability of the weld process
lessens the puddle manipulation required by the welder and is more tolerant to
hi-lo conditions, reducing training requirements. Weld bead profiles are thicker
than conventional root pass welds which can eliminate the need for a hot pass,
improving weld productivity. In some stainless steel applications, it may be
possible to eliminate the backing (purge) gas to further improve productivity
and reduce welding costs.
Current
Wave Form
<- Wet -> Pinch
Clear
Blink
Ball
Background
Pre-short
Ideally suited to root pass welding
Tolerant to hi-lo fit-up conditions
Thicker root passes can eliminate hot pass
Consistent side wall fusion
More tolerant of tip to work distance
Eliminate backing gas on some stainless steel applications
Less weld spatter
Less welder training time
Pro-Pulse™
This method of pulse welding provides a shorter arc length, narrower arc cone
and less heat input than with traditional spray pulse transfer. Since the process
is synergic, arc wandering and variations in tip-to-work distances are virtually
eliminated. This provides easier puddle control for both in-position and out-of
position welding, reducing welder training time. The process also improves fusion
and fill at the toe of the weld, permitting higher travel speeds and higher deposition.
This process coupled with RMD Pro for root pass welding permits welding
procedures with one wire and one gas to eliminate process switch-over time.
Ideally suited to fill and cap
pass welding
Shorter arc lengths and narrow arc
cone for out-of-position welding
Less heat input reduces interpass cooling time and improves
weld cycle time
Easier puddle control than
conventional spray pulse
More tolerant of tip to work variation
Enables one-wire with one-gas weld procedures
Improve fusion and fill at toe of weld
PipePro® Welding Programs
RMD Pro programs designed for root pass welding on deep groove
welds in all positions.
Pro-Pulse programs designed for fill and cap welding in all positions.
Process
Wire Type
Diameter
Gas Mixtures
Process Wire Type
Diameter
RMD Pro
Steel E70
.035/.040/.045 in
CO2, C25, C10, C15
Steel E70
.035/.040/.045/.052
C10, C15
Steel E80
.035 in
CO2, C15
ProPulse™
Steel E70
.052/.062
C10
Stainless Steel
308 and 316
.035/.040/.045 in
TRI-H, Ox2, C2
Steel E80
.040/.045 in
C15
.035/.045 in
Metal Core
.045 in
C10, C15
Stainless Steel
308/309/312/316
TRI-H, TRI-A,
C2, Ox2
Chrome Steel
5 Chrome
.045 in
C25
Metal Core
.045/.052 in
C10, C15
Inconel 625
.045 in
HE25
Duplex Stainless
.040/.045 in
TRI3
Ox2= 98% Ar, 2% O2
HE25 = 75% Ar, 25% He
C2= 98% Ar, 2% CO2
TRI-A= 81% Ar, 18% He, 1% CO2
TRI-H = 90% He, 7.5% Ar, 2.5% CO2
TRI3 = 69% Ar, 30% He, 1% CO2
Gas Mixtures
3
PipePro 12RC SuitCase
®
®
Features
Specifications
Rugged Construction
Designed for use in field construction.
Remote Voltage Control
Comes standard with PipePro 12RC SuitCase.
Standard Gas Solenoid
Controls gas flow.
Flame-Retardant Case
Totally enclosed and impact resistant, this case provides strength and
durability while protecting components and weld wire from moisture,
dust and contaminants.
Drive Roll Accessibility
Easy to install wire, adjust tension and change drive rolls.
Digital Meter
Wirefeed and voltage display comes standard on SuitCase.
Portable
Lightweight feeder can be used with 150 ft cables from power source.
(Subject to change without notice.)
Input
Power
Welding Power
Source Type
Input Welding
Circuit Rating
Wire Feed
Speed Range
Wire Diameter Capacity
Maximum Spool
Size Capacity
40 VDC,
10 Amps
ConstantVoltage (CV)
500 Amps at
100% Duty Cycle
75 – 700 IPM
(1.9 – 17.7 m/min)
Solid Wire: .035 – 5/64 in
(0.9 – 2.0 mm)
12 in (305 mm)
44 lb (20 kg)
Drive Roll Kits
Control Panel
H: 16 in (406 mm)
W: 7-1/4 in (184 mm)
D: 20 in (508 mm)
Net
Weight
25.5 lb
(11.6 kg)
(1 kit required, order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits
include 2 drive rolls, necessary guides and feature an anti-wear sleeve for the inlet guide.
1
2
6
3
4
7
5
MADE IN
1.
2.
3.
4.
5.
6.
7.
4
Dimensions
MILLER ELECTRIC MFG. CO., APPLETON, WI
Trigger Hold Switch
Purge Switch
Meter Display
Volt/Amp Switch
Voltage Control
Power Control Switch
Wire Speed Control
Wire size
“V” groove for hard wire
“V” knurled for
hard-shelled cored wires
.035 in (0.9 mm)
#079 595
#079 606
.040 in (1.0 mm)
#161 189
—
.045 in (1.1/1.2 mm)
#079 596
#079 607
.052 in (1.3/1.4 mm)
#079 597
#079 608
1/16 in (1.6 mm)
#079 598
#079 609
.068/.072 in (1.8 mm)
—
#089 984
5/64 in (2.0 mm)
—
#079 610
Bernard PipeWorx Guns
®
™
The PipeWorx 250-15 Gun is recommended for root pass welding, especially in fixed-position
applications where visibility is difficult. The PipeWorx 300-15 is recommended for fill and cap pass
welding with Flux Cored arc or Pulsed MIG welding processes. In roll welding applications where one
gas and one wire are used to make the weld, the PipeWorx 300-15 can be used to deposit the root
pass. (A smaller nozzle diameter should be considered for improved puddle visibility and should be
used for stainless steel root pass welding without purge gas.)
Features
Specifications
Versatility
Can be used for MIG (solid and metal cored wires), Pulsed MIG, and
Flux Cored (shielded and self-shielded wires).
Ergonomics
Compact, lightweight gun with high-amperage capability reduces operator
fatigue. improving productivity.
Visibility
The combination of tapered tips and nozzles and 60˚ neck provides excellent
visibility on root passes in pipe joints.
Centerfire™ Tip
Provides “drop-in” tip with no threads providing quick changeover.
No tools are required.
(Subject to change without notice.)
Bernard Model
100% Duty Cycle NEMA
100% Duty Cycle CE
60% Duty Cycle CE
35% Duty Cycle CE
Gas Type
Cable Length
Net Weight
PipeWorx 250-15
300 A
250 A
300 A
365 A
100% CO2
15 ft (4.6 m)
9 lb (4.1 kg)
—
210 A
250 A
300 A
80% Argon/20% CO2
350 A
320 A
370 A
470 A
CO2 Gas
15 ft (4.6 m)
10 lb (4.6 kg)
—
270 A
270 A
390 A
80% Argon/20% CO2
PipeWorx 300-15
Key Gun Consumables
Description
Part Number
Package Quantity
Description
Part Number
Package Quantity
.035 in Tapered Tip
TT-0351
10
Nozzle 5/8 in D
NS-5818C2
10
.040 in Tapered Tip
TT-039
10
Nozzle 5/8 in ID
N-5818C
10
.045 in Tapered Tip
TT-045
10
Nozzle 1/2 in ID
NS-1218C
10
.035 in Tip
T-035
10
Nozzle 3/4 in ID
N-3418C
10
.040 in Tip
T-039
10
Nozzle 3/8 in ID Tapered Tip
NT-3800C
10
.045 in Tip
T-0452
10
Nozzle 3/8 in ID Tapered Tip
NST-3800B
10
.052 in Tip
T-052
10
Nozzle 3/8 in ID Extended Tapered Tip
NST-38XTB1
10
1/16 in Tip
T-062
10
Diffuser
D-1
10
.035 – .045 Liner
431151,2
1
Diffuser
DS-11,2
10
.045 – .062 Liner
44215
1
Q Tube Assembly 60°
QT2-601,2
1
Q Tube Assembly 80°
QT2-80
1
O-Ring
4929
10
Standard part on PipeWorx 250-15. Standard part on PipeWorx 300-15.
1
2
5
Installation Diagrams
MIG/
FCAW
TIG
3
4
4
5
1
5
6
2
2
3
1
6
1.
2.
3.
4.
5.
Weld Cable*
Work-Sense Lead (see chart below)
Work Cable*
Interconnect and Feeder Control Cable #195 185
Feeder Control Extension Cable
(see chart below, not required if feeder is on or near power source)
6. Gas Hose*
1.
2.
3.
4.
5.
6.
Weld Cable and TIG Torch*
Work Cable*
Interconnect and Feeder Control Cable #195 185
Remote Control Adapter #300 248
Gas Hose*
Remote with Cable (see page 8)
Stick
Individual Cables for Typical Installations
3
4
Typical
Installation
Setup
Interconnect
and Feeder
Control
Cable “Y”
Feeder
Control
Extension
Cable
WorkSense
Lead
5 ft
195 185
—
195 397
25 ft
195 185
195 395
195 397
50 ft
195 185
195 401
195 397
100 ft
195 185
195 396
195 398
Note: For 150 ft Feeder Control Extension Cable combine one
#195 396 and one #195 401 cable.
2
1
5
1.
2.
3.
4.
5.
6
Weld Cable and Electrode Holder*
Work Cable*
Interconnect and Feeder Control Cable #195 185
Remote Control Adapter #300 248
Remote with Cable (see page 8)
*Contact your distributor.
Note: Size 2/0 weld cable minimum is
recommended with PipePro power sources.
Notes
7
Ordering Information
(Select a power source, wire feeder, cables and gun for complete system.)
Power Source and Accessories
Stock No.
Description
PipePro 300 Power Source
Add a Wire Feeder, Cables and Gun to create a system.
#907 489
#907 435
190–630 V with Auto-Line
305–460 V with Auto-Line™, CE
PipePro® 450 RFC Power Source
Add a Wire Feeder, Cables and Gun to create a system.
#907 296
#907 297
190 – 630 V, Auto-Line™
305–460 V with Auto-Line™, CE
PipePro 12RC SuitCase® Feeder
#195 392
CE
Flowmeter Kit
#300 343
Filter Inline Shielding Gas
#195 189
®
Qty.
™
SuitCase-Style Wire Feeder and Accessories
Drive Roll Kit (Required)
See page 4
Individual Cables for Typical Installations
Interconnect and Feeder Control Cable
#195 185
5 ft (1.5 m) (one required per system)
Feeder Control Extension Cable
(Not required if feeder is on or near power source.)
#195 395
#195 401
#195 396
25 ft (7.6 m)
50 ft (15.2 m)
100 ft (30.5 m)
Remote Control Adapter
#300 248
For PipePro 12RC SuitCase. Required to connect Stick and TIG
remotes to PipePro 14-pin control cable connector
Work-Sense Lead
#195 397
#195 398
50 ft (15.2 m)
150 ft (45.7 m)
#195 399
#195 400
250-15 Gun. See page 5 for consumables
300-15 Gun. See page 5 for consumables
RFCS-14 HD
#194 744
20 ft (6 m) cord. Heavy-duty foot control
RCC-14
#151 086
26.5 ft (8 m) cord. Side-to-side fingertip control
RCCS-14
#043 688
26.5 ft (8 m) cord. Up-and-down fingertip control
RHC-14
#242 211 020
#242 211 100
20 ft (6 m) cord. Hand current control and contactor
100 ft (30.5 m) cord. Hand current control and contactor
Individual MIG/FCAW Guns and Consumables
Bernard® PipeWorx™ Guns
Accessories for TIG and Stick
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Price

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