Miller Electric PipePro Dual User manual

Miller Electric PipePro Dual User manual
PipePro Welding System
™
Issued Sept. 2005 • Index No. PWS/1.0
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
Solid Wire/Metal Core
Pulsed MIG (GMAW-P)
Pro-Pulse™ 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 Feeder: 58 lb (26 kg)
PipePro Dual Feeder: 87 lb (35.5 kg)
Bernard® PipeWorx 250-15: 9 lb (4.1 kg)
Bernard PipeWorx 300-15: 10 lb (4.6 kg)
The Power of Blue .
®
The PipePro™ 450 RFC power source can be
combined with either the PipePro SuitCase™ or
PipePro Bench Feeders and Bernard PipeWorx™
Guns to offer a total solution for pipe welding
applications in the shop or field.
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.
with Multiprocess
Capability
PipePro 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.
ADVANCED SOFTWARE TECHNOLOGY
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. Combine metal core wire for higher
deposition rates in semiautomatic and automatic welding in 1G (rolled) welding position.
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.
Power source is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
PipePro 450 RFC Welding System
™
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 new patented RMD™ Pro and Pro-Pulse™, conventional
MIG, FCAW, Stick, TIG, and Air Carbon Arc Cutting. The RMD Pro and
Pro-Pulse welding processes are optimized for steel and stainless steel
pipe using solid and metal core wires. Programs are provided for the most
common gases, wire types and wire diameters used in the pipe welding
industry. Programs for new process and different materials are planned
and currently in development. 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) with no manual linking. Compensates for voltage spikes and drops
within the entire range. CE units are limited to 380 – 630 V nominal. Same machine can be used anywhere in the world.
1/4-turn steel connectors
Allow for faster installation of system and reduces thread stripping.
Select any process
Use any conventional process or advanced MIG process without making any hardware changes. Select the program
and weld.
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
Rated Output
450 A at 44 VDC,
100% Duty Cycle
(Subject to change without notice.)
Voltage
Range
Amperage Range
in CC Mode
Max. OpenCircuit Voltage
Amps Input at Rated Output for Typical Voltages, 50/60 Hz
208 V* 230 V* 400 V 460 V 575 V KVA KW
10 – 44 V
5 – 600 A
80 VDC
67
59
34
29
23
23.8 22.9
Dimensions
H: 41 in (1041 mm)
W: 15-1/2 in (394 mm)
D: 22 in (559 mm)
Ship
Weight
163 lb
(72.9 kg)
*Note: CE units are limited to 380 – 630 V nominal.
Control Panels
Back Panel
Front Panel
7
1
11
2
3
12
8
13
4
5
9
10
6
1. Voltage/Arc Length
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. Sharp Arc and Inductance Control
11. Peripheral Connector
12. Remote Connector
13. Wirefeed Connector
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
Gas Mixtures
RMD Pro
Steel E70
Steel E80
Steel E100
Stainless Steel
308 and 316
Metal Core
Pipemaster MC70,
MC90 and MC100
Chrome Steel
5 Chrome
.035/.040/.045 in
.035 in
.040 in
.035/.040/.045 in
CO2, C25, C10, C15, Ox5
CO2, C15
C15
TRI-H, Ox2, C2
ProPulse™
C10, C15, C20, Ox5
.045 in
C10, C15
.035/.040/.045/
.052/.062 in
.035 in
.040/.045 in
.045 in
.035/.045 in
.035 in
C25
Ox2= 98% Ar, 2% O2
Ox5= 95% Ar, 5% O2
HE25 = 75% Ar, 25% He
TRI-A= 81% Ar, 18% He, 1% CO2
TRI-H = 7.5% Ar, 90% He, 2.5% CO2
TRI3 = 69% Ar, 30% He, 1% CO2
Pulse
Steel E70
Steel E80
Steel E100
Steel E120
Stainless Steel
308 and 316
Metal Core
Pipemaster MC70,
MC90 and MC100
Inconel 625
Duplex Stainless
Steel E70
Stainless Steel
308 and 316
Inconel 625
.045/.052 in
C15
C15
C10
TRI-H, TRI-A,
C2, Ox2
C15, C10
.045 in
.045 in
.035/.045/.052/.062 in
.035/.045 in
HE25
TRI3
C5, C10, C15, Ox5
TRI-A, C2
.045 in
75%Ar/25%He
PipePro System Manager Package
™
PipePro System Manager Package #300 131
(Includes Palm™, cable and data card with software for service and
system management)
The new Miller File Management, Palm™ OS-based software turns a
standard handheld PDA into a storage device and remote pendant control
for all PipePro Systems. By using a PDA in this manner, we have built a
powerful intuitive interface on a common affordable, portable platform.
There are two basic types of files used with the PipePro 450 RFC
power source:
1. Program files — Contain all the welding data that creates an arc; amps,
volts, wire feed rates, wire type and size, gas and appropriate arc control.
2. Configuration files — Contains information to set-up the PipePro Systems
and information about the system. This includes error function selection,
program locks, software version information, and cycle count information.
Back-up — Contains programs and configuration files from the power
source in the Palm™.
The welding power source holds the main library of welding programs. The
Palm™ acts as an interim storage device where files can be pulled from the
power source, stored or modified. A password protected lockout feature
allows end users to establish a password to protect programs from
download by unauthorized personnel.
With PipePro File Management software installed on your Palm™ OS
PDA you can:
Save and store program and configuration files
Transfer program and configuration files
• Machine-to-machine
• Machine-to-computer
• E-mail programs anywhere worldwide
Configure one machine or several machines
All of the files can be cut, copied, pasted, and modified. Un-protected
files can also be beamed. Copyright-protected and Miller Proprietary
files cannot be transferred, such as Palm™ File Management, RMD™ Pro
and Pro-Pulse™ welding processes.
3
PipePro Single and Dual Feeder Features
™
Single Feeder
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.
Toolless 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.
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 energize 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
• Four sealed ball bearing all-gear-driven drive-roll carriers for smooth, positive and accurate wire feed with long
uninterrupted service life
• Solid-state speed control and brake circuit eliminates the need for electrical/mechanical relays and increases service life
• Covered drive rolls provides easy access with heavy-duty, molded composite cover over drive assembly
• Floating positive drive systems provide trouble-free feeding on a variety of wires
Specifications
(Subject to change without notice.)
Input
Power
Wire Feed
Speed Range
40 VDC,
10 Amps
50 –780 IPM
.023 – 1/8 in
(1.3 –19.8 MPM) (0.6 – 3.2 mm)
IP Rating= IP 21
4
Wire Diameter Input Welding
Capacity
Circuit Rating
Maximum Spool
Size Capacity
100 Volts,
60 lb (27 kg)
750 Amps,
100% Duty Cycle
Dimensions
Single
Dual
H: 14 in (356 mm)
H: 14 in (356 mm)
W: 12-1/2 in (318 mm) W: 12-1/2 in (318 mm)
D: 26-1/2 in (673 mm) D: 35 in (889 mm)
Net Weight
Single
Dual
58 lb
(26 kg)
87 lb
(35.5 kg)
Control Panels
PipePro Single Feeder
PipePro Dual Feeder
1
1
2
2
3
3
5
4
7
4
5
6
6
1.
2.
3.
4.
5.
6.
Voltage Meter
Wire Speed Meter
Wire Speed Control
Trigger Hold Switch
Voltage Control
Jog/Purge Push Button
1.
2.
3.
4.
Dual Feeder Drive Roll Kits
Voltage Meter
Wire Speed Meter
Left/Right Select Switch
Wire Speed Controls
(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
“U” groove for soft
wire or soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
.035 in (0.9 mm)
#151 026
#151 036
#151 052
.040 in (1.0 mm)
#161 190
—
—
.045 in (1.1/1.2 mm)
#151 027
#151 037*
#151 053
.052 in (1.3/1.4 mm)
#151 028
#151 038
#151 054
1/16 in (1.6 mm)
#151 029
#151 039
#151 055
.068/.072 in (1.8 mm)
—
—
#151 056
5/64 in (2.0 mm)
—
#151 040
#151 057
3/32 in (2.4 mm)
—
#151 041
#151 058
7/64 in (2.8 mm)
—
#151 042
#151 059
1/8 in (3.2 mm)
—
#151 043
#151 060
Wire size
5. Jog/Purge Push Buttons
6. Voltage Controls
7. Trigger Hold Switches
Wire Guides
Wire size
.023 – .040 in (0.6 – 1.0 mm)
Inlet Guide
#150 993
Intermediate
Guide
#149 518
.045 – .052 in (1.1 – 1.4 mm)
#150 994
#149 519
1/16 – 5/64 in (1.6 – 2.0 mm)
#150 995
#149 520
1/16 – 5/64 in (2.4 – 2.8 mm)
#150 996
#149 521
1/8 in (3.2 mm)
#150 997
#149 522
*Accommodates .045 and .047 (3/64 in) wire.
5
PipePro SuitCase Features
™
™
Rugged Construction
Designed for use in field construction.
Remote Voltage Control
Comes standard with 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)
Drive Roll Kits
Wire Diameter Capacity
Solid Wire: .023 – 5/64 in
(0.6 – 2.0 mm)
Flux Cored: .030 – 5/64 in
(0.8 – 2.0 mm)
Maximum Spool
Size Capacity
12 in (305 mm)
44 lb (20 kg)
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)
Control Panels
(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.
Dimensions
1
2
6
3
Wire size
“V” groove for hard wire
“U” groove for soft or
soft-shelled cored wires
“V” knurled for hardshelled cored wires
.023/.025 in (0.6 mm)
#087 131
—
—
.030 in (0.8 mm)
#079 594
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
.040 in (1.0 mm)
#161 189
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
.068/.072 in (1.8 mm)
—
—
#089 984
5/64 in (2.0 mm)
—
#079 602
#079 610
4
7
5
1.
2.
3.
4.
5.
6.
7.
6
Trigger Hold Switch
Purge Switch
Meter Display
Voltage/Amperage Switch
Voltage Control
Power Control Switch
Wire Speed Control
Bernard PipeWorx Guns Features
®
™
Specifications
Versatility
Can be used for MIG (Solid and Metal Cored Wires), Pulsed MIG,
FCAW (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
PipeWorx 250-15
300 A
250 A
300 A
—
210 A
250 A
350 A
320 A
—
270 A
PipeWorx 300-15
Gas Type
Cable Length
Net
Weight
365 A
100% CO2
15 ft (4.6 ft)
9 lb (4.1 kg)
300 A
80% Argon/20% CO2
370 A
470 A
CO2 Gas
15 ft (4.6 ft)
10 lb (4.6 kg)
270 A
390 A
80% Argon/20% CO2
Key Gun Consumables
Description
Part Number
Package Quantity
Description
Part Number
Package Quantity
.035 in Tapered Tip
TT-035*
10
Nozzle 5/8 in ID
NS-5818B
10
.040 in Tapered Tip
TT-039
10
Nozzle 1/ 2 in ID
NS-1218B
10
.045 in Tapered Tip
TT-045
10
Nozzle 3/8 in ID Tapered Tip
NST-3818B
10
.035 in Tip
T-035
10
NST-38XTB*
10
.040 in Tip
T-039
10
Nozzle 3/8 in ID
Extended Tapered Tip
.045 in Tip
T-045
10
Diffuser
DS-1*
1
.052 in Tip
T-052
10
Q Tube Assembly 60°
QT2-60*
1
1/16 in Tip
T-062
10
Q Tube Assembly 80°
QT2-80
1
0-Ring
4929
1
.035 – .045 Liner
43115*
1
.045 – .062 Liner
43215
1
*Standard part on PipeWorx 250-15
Genuine Miller Accessories
(For bench-style feeder.)
Carrying Cart #056 301
A utility cart for the wire feeder and other
miscellaneous welding supplies.
Height: 34 in (863 mm)
Lower tray height: 9 in (228 mm)
Shipped disassembled.
Wire Reel Assembly #108 008
For 60 lb (27 kg) coil of wire.
Spool Covers For 12 in (305 mm) spool.
#057 607 For single feeder or
left side of dual feeder.
#090 389 For right side of dual feeder.
Reel Covers
#058 256 For single feeder or
left side of dual feeder.
#091 668 For right side of dual feeder.
For 60 lb (27 kg) coil. Helps to protect
the welding wire from dust and other
contaminants.
Wire Straightener
#141 580
For .035 –.045 in (0.9 –1.1 mm) dia. wire.
#141 581
For 1/16 –1/8 in (1.6 – 3.2 mm) dia. wire.
Helps reduce the cast in wire to improve
wire feeding performance and increase the
service life of the gun liner and contact tip.
Note: Reel and Spool Covers cannot be installed if
the wire drive assembly is in a rotated position.
7
Ordering Information
(Select a power source, wire feeder and cable package for complete system.)
Power Source and Options
Stock No.
Description
PipePro™ 450 RFC Inverter Power Supply
Add a Cable and Gun Package and
Wire Feeder to create a complete system.
#907 296
#907 297
190 – 630 V, Auto-Line™
CE, 380 – 630 V, Auto-Line™
#300 131
#195 246
Includes Palm™, cable and data card
For power source, feeder and gas cylinder
#195 407
#195 407-02-1
#195 394
#195 394-02-1
Single feeder
Single feeder, CE
Dual feeder
Dual feeder, CE
Power Source Accessories
PipePro™ System Manager Package
Cart
Bench-Style Feeder
PipePro™ Bench-Style Feeders
Bench-Style Feeder Accessories
Carrying Cart
Spool Covers
Spool Adapter
Wire Reel Assembly
Reel Covers
Wire Straightener
#056 301
#057 607
#090 389
#047 141
#108 008
#058 256
#091 668
#141 580
#141 581
Drive Roll Kit (Required)
SuitCase-Style Feeder
PipePro™ SuitCase™ Feeder
SuitCase-Style Feeder Accessories
Flowmeter Kit
Drive Roll Kit (Required)
Cable and Gun Packages
Includes interconnect cable between power
source and feeder, work sense lead with
magnet and PipeWorx 250-15 gun. Does
NOT include weld cable, work clamp and
gas regulator/flowmeter.
Remote Controls (for TIG and Stick)
Remote controls are designed specifically
for the PipePro power source for Stick and
TIG welding.
Individual Guns and Consumables
Bernard® PipeWorx Guns
#195 392
#195 392-02-1
Work-Sense Lead
(Does NOT include magnets.)
For single feeder or left side of dual feeder
For right side of dual feeder
.035 – .045 in diameter wire
1/16 – 1/8 in diameter wire
See page 5
CE
See page 6
#300 101
#300 102
#300 103
#300 104
#300 105
5 ft cable package
25 ft cable package
50 ft cable package
100 ft cable package
150 ft cable package
#300 108
#300 112
#300 126
#300 130
RFCS-14 HD foot control
RCC-14 side-to-side fingertip control
RCCS-14 up and down fingertip control
RHC-14 hand current control and contactor
#195 399
#195 400
250-15 Gun
300-15 Gun
See page 7
#195 185
#300 136
#300 092
#300 140
#300 137
#195 397
#195 398
Date:
5 ft (1.5 m)
25 ft (7.6 m)
50 ft (15.2 m)
100 ft (30.5 m)
150 ft (45.7 m)
50 ft (15.2 m)
150 ft (45.7 m)
Total Quoted Price:
Distributed by:
Litho in USA
For single feeder or left side of dual feeder
For right side of dual feeder
#195 217
Consumables
Individual Cables
Interconnect Cable
Qty.
Price
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