Issued Apr. 2010 • Index No. PWS/1.0 PipePro Welding System ® Multiprocess Pipe Welding Systems Root-Fill-Cap Welding Quick Specs Pipe Welding Applications Processes Process Piping Offshore Piping Onshore Piping Pipe Fabrication Field Construction Stick (SMAW) TIG (GTAW) Air Carbon Arc Cutting and Gouging (CAC-A) (3/8 in carbons max.) MIG (GMAW) RMD™ Pro (Modified Short Circuit) Pro-Pulse™ MIG (GMAW-P) Pulsed MIG (GMAW-P) Flux Cored (FCAW) Rated Output Voltage Range Ship Weight 450 A at 44 VDC, 100% Duty Cycle 10 – 44 V PipePro 450 RFC: 163 lb (72.9 kg) PipePro 12RC SuitCase: 25.5 lb (11.6 kg) PipePro DX Feeder: 45 lb (20.4 kg) PipePro Dual DX Feeder: 87 lb (35.5 kg) Bernard PipeWorx 250-15: 9 lb (4.1 kg) Bernard PipeWorx 300-15: 10 lb (4.6 kg) Bernard PipeWorx 400-15: 10 lb (4.6 kg) The Power of Blue . ® 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. The PipePro® 450 RFC power source can be combined with either the PipePro SuitCase® or PipePro DX Bench Feeders and Bernard® PipeWorx™ Guns to offer a total solution for pipe welding applications in the shop or field. PipePro DX Bench Feeder Provides a reliable wire feeder solution for shop applications. The dual-feeder version allows the operator to easily switch from one process/wire for root pass welding to another process/wire for fill and cap welding. IMPROVED WELD PERFORMANCE Regulated Metal Deposition (RMD™ Pro) Precisely controlled short-circuit transfer technology provides welders with an easy to use welding process with excellent puddle control for the root pass. Calm, stable arc/puddle reduces weld training and improves quality. PipePro 450 RFC Provides one versatile power source to produce pipe welds using conventional and advanced processes in shop and field applications. Pro-Pulse™ This method of pulse welding is easier to use than conventional pulse in out-of-position pipe welding applications. This is accomplished through precise control of the arc and puddle even in narrow joints, which provides optimum molten puddle control for out-of-position welding. Precise control of puddle produces excellent side wall fusion on all pipe joint designs. 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 or 400-15 Provides a heavy-duty solution to producing root, fill and cap welds on pipe. 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 450 RFC Welding System ® (See page 3 for programs available for PipePro 450 RFC.) The PipePro 450 Welding System provides one versatile solution for pipe welding in a package for both field and shop fabrication. Standard welding processes include RMD™ Pro and Pro-Pulse™, conventional MIG, GMAW-P, FCAW, Stick, TIG, and Air Carbon Arc cutting. The RMD Pro and Pro-Pulse welding processes are optimized for steel and stainless steel pipe. Programs are provided for the most common gases, wire types and wire diameters used in the pipe welding industry. Contact Miller for more information on less common materials and gas combinations. PipePro® 450 RFC Features 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 400 V only. 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, FCAW and Air Carbon Arc. Wind Tunnel Technology Circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability. Field or Shop Can be used with either a SuitCase feeder for field construction, or a single or dual bench-style feeder for shop fabrication. ™ ™ 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. Specifications (Subject to change without notice.) Rated Output Voltage Range Amperage Range in CC Mode Max. Open-Circuit Voltage Amps Input at Rated Output for Typical Voltages +/- 10%, 50/60 Hz 208 V 230 V 400 V* 460 V* 575 V KVA KW Dimensions 450 A at 44 VDC, 100% Duty Cycle 10 – 44 V 5 – 600 A 80 VDC 67 23.8 22.9 H: 41 in (1041 mm) W: 15-1/2 in (394 mm) D: 22 in (559 mm) 59 34 29 23 Ship Weight 163 lb (72.9 kg) *Note: CE units are limited to 400 V nominal. Control Panels Back Panel Front Panel 7 1 11 2 3 12 8 13 4 5 9 PipePro 450 RFC ® 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 10 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. Process RMD Pro Wire Type Diameter Pro-Pulse programs designed for fill and cap welding in all positions. Gas Mixtures Process Wire Type Diameter Gas Mixtures ProPulse™ Steel E70 .035/.040/.045/.052 C10, C15 Steel E70 .052/.062 C10 Steel E70 .035/.040/.045 in CO2, C25, C10, C15 Steel E80 .035 in CO2, C15 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 3 PipePro DX Single and Dual Feeder Features ® Tool less rotatable drive assembly allows operator to rotate the drive housing, eliminating severe bends in the wire feed path which reduce gun liner life. Also aids in feeding difficult wires. PipePro DX Dual Feeder Dual tension control adds flexibility for the operator to fine-tune the pressure on the wire independently when feeding a variety of wires. Trigger Receptacle Oriented in a downward position to reduce potential damage. Trigger Hold Reduces operator fatigue by allowing the operator to make long welds without having to hold the trigger continuously. ™ Posifeed Wire Drive Assembly • Quick-change drive rolls • Quick-release, calibrated drive-roll pressure adjustment arm allows drive roll change without losing spring preload setting • Floating positive drive systems provide trouble-free feeding on a variety of wires Stored Programs Allows the operator to select weld programs from the feeder (8 on a single feeder or 4 on each of the feeders of the dual) to improve cycle time from root to fill and cap. Remote Trigger Select Allows operator to change programs (weld process and stored parameters) without returning to the feeder. Dual Schedule Allows the operator to switch between two sets of parameters to provide consistent penetration and improve pipe weld quality in fixed position. Weld Sequence Control Provides gas preflow and postflow for welding of stainless steel and high alloy pipe materials. Improves start and stop conditions by providing run-in, crater and burn-back controls. Range Locks Allows weld parameters to be adjusted within a specified range of set-point to ensure welding procedures are maintained on the shop floor. Specifications (Subject to change without notice.) Input Power Wire Feed Speed Range Wire Diameter Capacity Input Welding Circuit Rating Maximum Spool Size Capacity Dimensions Single Dual 40 VDC, 10 Amps 50 –780 IPM (1.3 –19.8 MPM) .023 – 1/8 in (0.6 – 3.2 mm) 100 Volts, 750 Amps, 100% Duty Cycle 60 lb (27 kg) H: 14 in (356 mm) W: 12-1/2 in (318 mm) D: 27 in (686 mm) H: 14 in (356 mm) W: 12-1/2 in (318 mm) D: 35 in (889 mm) Net Weight Single Dual 45 lb (20.4 kg) IP Rating= IP 21 Single Feeder Control Panel 1 5 6 2 7 8 9 10 3 ® 4 4 11 12 PipePro DX Model 1. Program Display 2. Program # Select 3. Weld Sequence 4. MIG/Stick(TIG) 5. Voltage/Time Select 6. Voltage/Time Display Meter 7. Wire Feed/Amperage Select 8. Wire Speed/Amperage Display Meter 9. Control Knob 10. Trigger Hold/Dual Schedule Control 11. Standard 14-Pin Receptacle 12. Jog/Purge 87 lb (35.5 kg) PipePro® Feeder Drive Roll Kits (Order from Miller Service Parts.) Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include 4 drive rolls, the necessary guides and feature an anti-wear sleeve for the inlet guide. “V” groove for hard wire #151 026 #161 190 #151 027 #151 028 #151 029 — — — Wire size .035 in (0.9 mm) .040 in (1.0 mm) .045 in (1.1/1.2 mm) .052 in (1.3/1.4 mm) 1/16 in (1.6 mm) .068/.072 in (1.8 mm) 5/64 in (2.0 mm) 3/32 in (2.4 mm) Wire Guides “V” knurled for hard-shelled cored wires #151 052 — #151 053 #151 054 #151 055 #151 056 #151 057 #151 058 Wire size .023 – .040 in (0.6 – 1.0 mm) .045 – .052 in (1.1 – 1.4 mm) 1/16 – 5/64 in (1.6 – 2.0 mm) 3/32 – 7/64 in (2.4 – 2.8 mm) Inlet Guide #150 993 #150 994 #150 995 #150 996 Intermediate Guide #149 518 #149 519 #149 520 #149 521 PipePro 12RC SuitCase Features ® ® 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. Available in CE or CSA version. Specifications (Subject to change without notice.) Input Power Welding Power Source Type Input Welding Circuit Rating Wire Feed Speed Range 40 VDC, 10 Amps ConstantVoltage (CV) 500 Amps at 100% Duty Cycle 75 – 700 IPM (1.9 – 17.7 m/min) 1 2 ON V PURGE OFF 6 V 4 A 7 5 V VOLTAGE WIRE SPEED PipePro 12RC Suitcase TM 40V Wire Feeder MILLER ELECTRIC MFG. CO., APPLETON, WI Trigger Hold Switch Purge Switch Meter Display Volt/Amp Switch Voltage Control Maximum Spool Size Capacity 12 in (305 mm) 44 lb (20 kg) Dimensions 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. POWER 3 1. 2. 3. 4. 5. Solid Wire: .023 – 5/64 in (0.6 – 2.0 mm) Flux Cored: .030 – 5/64 in (0.8 – 2.0 mm) Drive Roll Kits Control Panel MADE IN Wire Diameter Capacity Wire size “V” groove for hard wire “V” knurled for hard-shelled cored wires .023/.025 in (0.6 mm) #087 131 — .030 in (0.8 mm) #079 594 — .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 6. Power Control Switch 7. Wire Speed Control 5 Bernard PipeWorx Guns Features ® ™ The PipeWorx 250-15 Gun is recommended for root pass welding, especially in fixed-position applications where visibility is difficult. The PipeWorx 300-15 or 400-15 are 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 400 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.) 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 400 A 350 A 425 A 520 A CO2 Gas 15 ft (4.6 m) 10 lb (4.6 kg) — 275 A 350 A 425 A 80% Argon/20% CO2 PipeWorx 300-15 PipeWorx 400-15 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-5818C3 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-0452,3 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-38XTB 1/16 in Tip T-062 10 Diffuser D-13 10 .035 – .045 Liner 431151,2,3 1 Diffuser DS-11,2 10 .045 – .062 Liner 44215 1 Q Tube Assembly 60° QT2-601,2,3 1 Q Tube Assembly 80° QT2-80 1 0-Ring 4929 10 Standard part on PipeWorx 250-15. Standard part on PipeWorx 300-15. Standard part on PipeWorx 400-15. 1 2 3 1 10 Genuine Miller Accessories Dual Schedule Switches (For PipePro DX models only.) PipeWorx 400-15 Gun and Cable Packages DSS-9 #071 833 A two-position slide switch which attaches to the gun handle and is used to select the desired welding condition for dual schedule purposes. The gun trigger operates as a standard trigger. #300 241 5 ft cable and gun package #300 242 25 ft cable and gun package #300 243 50 ft cable and gun package Packages include (5 ft) interconnect and feeder control cable, (25 or 50 ft) feeder control extension cable, (50 ft) work-sense lead and PipeWorx 400-15 gun. 5 ft Cable and Gun Package shown. 6 Individual Cables for Typical Installations Interconnect Typical and Feeder Installation Control Setup 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 *For 150 ft add one #195 401 Feeder Control Extension Cable. PipePro Welding System Components ® Wire Reel Assembly (for 60 lb coil) #108 008 (optional, not shown) PipePro® DX Dual Feeder #300 228 (shown) PipePro® DX Feeder #300 227 Remote Control Receptacle (for optional remotes) RFCS-14 HD #194 744 RCC-14 #151 086 RCCS-14 #043 688 RHC-14 #129 340 RPBS-14 #300 666 Polarity Control #042 871 (optional) Used to switch between DCEN (straight polarity) for TIG welding and DCEP (reverse polarity) for MIG or Stick welding. Coolmate™ V3 #043 009 (optional) Weldcraft® TIG Torch PipePro® 450 RFC #907 296 PipeWorx™ 400-15 #300 240 (shown) PipeWorx™ 300-15 #195 400 (not shown) PipeWorx™ 250-15 #195 399 PipePro® System Cart #300 334 Dimensions: 54 H x 32 W x 53 D in (1372 x 813 x 1346 mm). Weight (cart only): 196 lb (89 kg). Work Sense Lead Receptacle 50 ft Work Sense Lead #195 397 Installation Diagrams MIG/ FCAW TIG Stick 3 4 4 5 1 6 2 3 5 The illustrations show the remote control connected through the wire feeder. The wire feeder is not connected to the power source output. 1 6 Weld Cable (contact your distributor) Work-Sense Lead Work Cable (contact your distributor) Interconnect and Feeder Control Cable Feeder Control Extension Cable (not required if feeder is on or near power source) 6. Gas Hose (contact your distributor) 1. 2. 3. 4. 5. 4 2 1 2 3 1. 2. 3. 4. 5. 6. Weld Cable and TIG Torch (see page 7) Work Cable (contact your distributor) Interconnect and Feeder Control Cable Control Extension Cable Gas Hose (contact your distributor) Remote with 25 ft cable (see page 8) 5 1. Weld Cable and Electrode Holder (contact your distributor) 2. Work Cable (contact your distributor) 3. Interconnect and Feeder Control Cable 4. Control Extension Cable 5. Remote with 25 ft cable (see page 8) Note: Size 2/0 weld cable is recommended with PipePro 450 RFC. 7 Ordering Information (Select a power source, wire feeder and cable package for complete system.) Power Source and Accessories Stock No. Description PipePro® 450 RFC Inverter Power Supply Add a Wire Feeder and a Cable and Gun Package to create a system. PipePro® 450 System Cart #907 296 #907 297 190 – 630 V, Auto-Line™ CE, 400 V #300 334 Cart with cylinder rack for power source, feeder, cooler, and polarity switch #300 227 #300 228 #300 233 #300 234 #300 235 #142 382 #057 607 #090 389 #108 008 Single feeder Dual feeder Field Kit, 10 ft (3 m). For PipePro DX single feeder only Field Kit, 25 ft (7.6 m). For PipePro DX single feeder only Field Kit, 25 ft (7.6 m). For PipePro DX dual feeder only Bench-Style Wire Feeder and Accessories PipePro® DX Bench-Style Feeders Control Detachment Kit Allows separation of the control module from the wire drive assembly and base. Feeder Cart Spool Covers Wire Reel Assembly Reel Covers #195 412 #091 668 Drive Roll Kit (Required) Dual Schedule Switches #071 833 Qty. For single feeder or left side of dual feeder For right side of dual feeder For 60 lb (27 kg) coil (Reel and Spool Covers cannot be installed if the wire drive assembly is in a rotated position.) For single feeder or left side of dual feeder. For 60 lb (27 kg) coil For right side of dual feeder. For 60 lb (27 kg) coil See page 5 DSS-9 (PipePro DX models only) SuitCase-Style Wire Feeder and Accessories PipePro® 12RC SuitCase® Feeder Flowmeter Kit Filter Inline Shielding Gas Drive Roll Kit (Required) #195 392 #300 343 #195 189 PipeWorx 400-15 Gun and Cable Packages Includes interconnect and feeder control cable (5 ft), feeder control extension cables, work-sense lead and PipeWorx gun. Does NOT include weld cable, work cable, work clamp, and gas regulator/flowmeter. #300 241 #300 242 #300 243 Select a Package OR Select Individual Cables (see page 6) 5 ft (1.5 m) cable and gun package 25 ft (7.6 m) cable and gun package 50 ft (15.2 m) cable and gun package #195 185 #195 395 #195 401 #195 396 #195 397 #195 398 5 ft (1.5 m) (one required per system) 25 ft (7.6 m) 50 ft (15.2 m) 100 ft (30.5 m) 50 ft (15.2 m) 150 ft (45.7 m) #195 399 #195 400 #300 240 250-15 Gun. See page 6 for consumables 300-15 Gun. See page 6 for consumables 400-15 Gun. See page 6 for consumables Accessories for TIG and Stick RFCS-14 HD RCC-14 RCCS-14 RHC-14 RPBS-14 Remote Control Adapter #194 744 #151 086 #043 688 #129 340 #300 666 #300 248 Polarity Control HF-251D-1 Coolmate® V3 #042 871 #042 388 #043 009 Heavy-duty foot control Side-to-side fingertip control Up-and-down fingertip control Hand current control and contactor On-off switch For PipePro® 12RC SuitCase® and #195 407 Single Feeder. Connects remote control cable to feeder control cable Switches between DCEP (reverse polarity) and DCEN (straight polarity) High-frequency remote arc starter with gas solenoid, 115 VAC 115 VAC See page 5 Individual Cables for Typical Installations Interconnect and Feeder Control Cable Feeder Control Extension Cable (Not required if feeder is on or near power source.) Work-Sense Lead Individual MIG/FCAW Guns and Consumables Bernard® PipeWorx™ Guns Date: Total Quoted Price: Distributed by: Litho in USA Price
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project
advertisement