PipePro Welding System

Transcription

1 PipePro Welding System Root-Fill-Cap Welding Issued Apr. 00 Index No. PWS/.0 Multiprocess Pipe Welding Systems Quick Specs Pipe Welding Applications Process Piping Offshore Piping Onshore Piping Pipe Fabrication Field Construction The Power of Blue. The PipePro 0 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. PipePro 0 RFC Provides one versatile power source to produce pipe welds using conventional and advanced processes in shop and field applications. Bernard PipeWorx 0- 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 00- or 00- Provides a heavy-duty solution to producing root, fill and cap welds on pipe. Processes Stick (SMAW) TIG (GTAW) Air Carbon Arc Cutting and Gouging (CAC-A) (/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 0 V Ship Weight 0 A at VDC, 00% Duty Cycle PipePro 0 RFC: lb (7.9 kg) PipePro RC SuitCase:. lb (. kg) PipePro DX Feeder: lb (0. kg) PipePro Dual DX Feeder: 87 lb (. kg) Bernard PipeWorx 0-: 9 lb (. kg) Bernard PipeWorx 00-: 0 lb (. kg) Bernard PipeWorx 00-: 0 lb (. kg) PipePro RC 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. 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. 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. Power source is warranted for years, parts and labor. Miller Electric Mfg. Co. An Illinois Tool Works Company West Spencer Street Appleton, WI 9 USA Equipment Sales US and Canada Phone: FAX: International Phone: International FAX: Web Site

2 PipePro 0 RFC Welding System (See page for programs available for PipePro 0 RFC.) The PipePro 0 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 0 RFC Features Auto-Line /-turn connectors Multiprocess Wind Tunnel Technology Field or Shop Fan-On-Demand Easy to operate Allows for any input voltage hook-up (90 0 V, 0/0 Hz) with no manual linking. Compensates for voltage spikes and drops within the entire range. CE units are 00 V only. Allow for faster installation of system and reduces thread stripping. Select from Stick, TIG, MIG, GMAW-P, RMD Pro, Pro-Pulse MIG, FCAW and Air Carbon Arc. Circulates air over components that require cooling, not over electronic circuitry, which reduces contaminants and improves reliability. Can be used with either a SuitCase feeder for field construction, or a single or dual bench-style feeder for shop fabrication. Cooling system operates only when needed. Reduces amount of airborne contaminants pulled through the machine. Simple front panel layout makes it easy to select programs. Specifications (Subject to change without notice.) Rated Output 0 A at VDC, 00% Duty Cycle Voltage Range 0 V Amperage Range in CC Mode 00 A Max. Open-Circuit Voltage 80 VDC Amps Input at Rated Output for Typical Voltages +/- 0%, 0/0 Hz 08 V 0 V 00 V* 0 V* 7 V KVA KW Dimensions H: in (0 mm) W: -/ in (9 mm) D: in (9 mm) Ship Weight lb (7.9 kg) *Note: CE units are limited to 00 V nominal. Control Panels 7 Front Panel 8 Back Panel PipePro 0 RFC 9 0. Voltage/Arc Adjust Display Meter. Program Display. Program # Select. Power Switch. Process Setup Button Weld Process Wire Size and Type Gas Type. Control Knob 7. Wire Speed/Amperage Digital Display Meter 8. Palm /PC RS- Ports 9. Wire Feed/Amperage Select 0. Arc Control and Inductance Control. Peripheral Connector. Remote Connector. Wirefeed Connector

3 Welding Process Capabilities RMD (Regulated Metal Deposition) Pro 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 RMD Ball Transfer <- Wet -> Pinch Clear Blink Ball Background Pre-short Ideally suited to root pass welding Consistent side wall fusion Less weld spatter Tolerant to hi-lo fit-up conditions More tolerant of tip to work distance Less welder training time Thicker root passes can eliminate hot pass Eliminate backing gas on some stainless steel applications 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 Easier puddle control than conventional spray pulse Shorter arc lengths and narrow arc cone for out-of-position welding More tolerant of tip to work variation Improve fusion and fill at toe of weld Less heat input reduces interpass cooling time and improves weld cycle time Enables one-wire with one-gas weld procedures PipePro Welding Programs RMD Pro programs designed for root pass welding on deep groove welds in all positions. Process Wire Type Diameter Gas Mixtures RMD Pro Steel E70.0/.00/.0 in CO, C, C0, C Steel E80.0 in CO, C Stainless Steel.0/.00/.0 in TRI-H, Ox, C 08 and Metal Core.0 in C0, C Chrome Steel.0 in C Chrome Ox= 98% Ar, % O TRI-A= 8% Ar, 8% He, % CO HE = 7% Ar, % He TRI-H = 90% He, 7.% Ar,.% CO C= 98% Ar, % CO TRI = 9% Ar, 0% He, % CO Pro-Pulse programs designed for fill and cap welding in all positions. Process Wire Type Diameter Gas Mixtures Pro- Steel E70.0/.00/.0/.0 C0, C Pulse Steel E70.0/.0 C0 Steel E80.00/.0 in C Stainless Steel.0/.0 in TRI-H, TRI-A, 08/09// C, Ox Metal Core.0/.0 in C0, C Inconel.0 in HE Duplex Stainless.00/.0 in TRI

4 PipePro DX Single and Dual Feeder Features PipePro DX Dual Feeder 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. Dual tension control adds flexibil ity for the operator to fine-tune the pressure on the wire independently when feeding a variety of wires. Trigger Receptacle Trigger Hold Posifeed Wire Drive Assembly Stored Programs Remote Trigger Select Dual Schedule Weld Sequence Control Range Locks Oriented in a downward position to reduce potential damage. Reduces operator fatigue by allowing the operator to make long welds without having to hold the trigger continuously. 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 Allows the operator to select weld programs from the feeder (8 on a single feeder or on each of the feeders of the dual) to improve cycle time from root to fill and cap. Allows operator to change programs (weld process and stored parameters) without returning to the feeder. Allows the operator to switch between two sets of parameters to provide consistent penetration and improve pipe weld quality in fixed position. 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. 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 0 VDC, 0 Amps Wire Feed Speed Range IPM (. 9.8 MPM) Wire Diameter Capacity.0 /8 in (0.. mm) Input Welding Circuit Rating 00 Volts, 70 Amps, 00% Duty Cycle Maximum Spool Size Capacity 0 lb (7 kg) Dimensions Single H: in ( mm) W: -/ in (8 mm) D: 7 in (8 mm) Dual H: in ( mm) W: -/ in (8 mm) D: in (889 mm) Net Weight Single Dual lb 87 lb (0. kg) (. kg) IP Rating= IP Single Feeder Control Panel PipePro DX Model. Program Display. Program # Select. Weld Sequence. MIG/Stick(TIG). Voltage/Time Select. Voltage/Time Display Meter 7. Wire Feed/Amperage Select 8. Wire Speed/Amperage Display Meter 9. Control Knob 0. Trigger Hold/Dual Schedule Control. Standard -Pin Receptacle. Jog/Purge

5 V 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 drive rolls, the necessary guides and feature an anti-wear sleeve for the inlet guide. V groove V knurled for Wire size for hard wire hard-shelled cored wires.0 in (0.9 mm) # 0 # 0.00 in (.0 mm) # 90.0 in (./. mm) # 07 # 0.0 in (./. mm) # 08 # 0 / in (. mm) # 09 # 0.08/.07 in (.8 mm) # 0 / in (.0 mm) # 07 / in (. mm) # 08 Wire Guides Intermediate Wire size Inlet Guide Guide.0.00 in (0..0 mm) #0 99 # in (.. mm) #0 99 #9 9 / / in (..0 mm) #0 99 #9 0 / 7/ in (..8 mm) #0 99 #9 PipePro RC SuitCase Features Rugged Construction Specifications (Subject to change without notice.) Remote Voltage Control Standard Gas Solenoid Flame-Retardant Case Drive Roll Accessibility Digital Meter Portable Available in CE or CSA version. Designed for use in field construction. Comes standard with PipePro RC SuitCase. Controls gas flow. Totally enclosed and impact resistant, this case provides strength and durability while protecting components and weld wire from moisture, dust and contaminants. Easy to install wire, adjust tension and change drive rolls. Wirefeed and voltage display comes standard on SuitCase. Lightweight feeder can be used with 0 ft cables from power source. Input Power 0 VDC, 0 Amps Welding Power Source Type Constant- Voltage (CV) Input Welding Circuit Rating 00 Amps at 00% Duty Cycle Wire Feed Speed Range IPM ( m/min) Wire Diameter Capacity Solid Wire:.0 / in (0..0 mm) Flux Cored:.00 / in (0.8.0 mm) Maximum Spool Size Capacity in (0 mm) lb (0 kg) Dimensions H: in (0 mm) W: 7-/ in (8 mm) D: 0 in (08 mm) Net Weight. lb (. kg) Control Panel MADE IN PURGE V V VOLTAGE ON OFF 0V Wire Feeder POWER A WIRE SPEED TM PipePro RC Suitcase. Trigger Hold Switch. Purge Switch. Meter Display. Volt/Amp Switch. Voltage Control MILLER ELECTRIC MFG. CO., APPLETON, WI 7. Power Control Switch 7. Wire Speed Control Drive Roll Kits ( 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 drive rolls, necessary guides and feature an anti-wear sleeve for the inlet guide. V knurled for Wire size V groove for hard wire hard-shelled cored wires.0/.0 in (0. mm) # in (0.8 mm) # in (0.9 mm) #079 9 # in (.0 mm) # 89.0 in (./. mm) #079 9 # in (./. mm) # # / in (. mm) # # /.07 in (.8 mm) # / in (.0 mm) #079 0

6 Bernard PipeWorx Guns Features Specifications (Subject to change without notice.) Bernard Model PipeWorx 0- PipeWorx 00- PipeWorx 00-00% Duty Cycle NEMA 00 A 0 A 00 A Key Gun Consumables Dual Schedule Switches (For PipePro DX models only.) DSS-9 #07 8 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 stan dard trigger. The PipeWorx 0- Gun is recommended for root pass welding, especially in fixed-position applications where visibility is difficult. The PipeWorx 00- or 00- 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 00 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.) Versatility Ergonomics Visibility Centerfire Tip 00% Duty Cycle CE 0 A 0 A 0 A 70 A 0 A 7 A Description Part Number Package Quantity.0 in Tapered Tip TT in Tapered Tip TT in Tapered Tip TT in Tip T in Tip T in Tip T-0, 0.0 in Tip T-0 0 / in Tip T Liner,,.0.0 Liner Standard part on PipeWorx 0-. Standard part on PipeWorx 00-. Standard part on PipeWorx 00-. Genuine Miller Accessories 0% Duty Cycle CE 00 A 0 A 70 A 70 A A 0 A PipeWorx 00- Gun and Cable Packages ft Cable and Gun Package shown. #00 ft cable and gun package #00 ft cable and gun package #00 0 ft cable and gun package Packages include ( ft) interconnect and feeder control cable, ( or 0 ft) feeder control extension cable, (0 ft) work-sense lead and PipeWorx 00- gun. Can be used for MIG (solid and metal cored wires), Pulsed MIG, and Flux Cored (shielded and self-shielded wires). Compact, lightweight gun with high-amperage capability reduces operator fatigue. improving productivity. The combination of tapered tips and nozzles and 0 neck provides excellent visibility on root passes in pipe joints. Provides drop-in tip with no threads providing quick changeover. No tools are required. % Duty Cycle CE A 00 A 70 A 90 A 0 A A Gas Type 00% CO 80% Argon/0% CO CO Gas 80% Argon/0% CO CO Gas 80% Argon/0% CO Cable Length ft (. m) ft (. m) ft (. m) Net Weight 9 lb (. kg) 0 lb (. kg) 0 lb (. kg) Description Part Number Package Quantity Nozzle /8 in D NS-88C 0 Nozzle /8 in ID N-88C 0 Nozzle / in ID NS-8C 0 Nozzle / in ID N-8C 0 Nozzle /8 in ID Tapered Tip NT-800C 0 Nozzle /8 in ID Tapered Tip NST-800B 0 Nozzle /8 in ID Extended Tapered Tip NST-8XTB 0 Diffuser D- 0 Diffuser DS-, 0 Q Tube Assembly 0 QT-0,, Q Tube Assembly 80 QT-80 0-Ring 99 0 Individual Cables for Typical Installations Interconnect Feeder Typical and Feeder Control Work- Installation Control Extension Sense Setup Cable Y Cable Lead ft ft ft ft* *For 0 ft add one #9 0 Feeder Control Extension Cable.

7 PipePro Welding System Components PipePro DX Dual Feeder #00 8 (shown) PipePro DX Feeder #00 7 Polarity Control #0 87 (optional) Used to switch between DCEN (straight polarity) for TIG welding and DCEP (reverse polarity) for MIG or Stick welding. PipePro 0 RFC #907 9 Wire Reel Assembly (for 0 lb coil) # (optional, not shown) Remote Control Receptacle (for optional remotes) RFCS- HD #9 7 RCC- # 08 RCCS- #0 88 RHC- #9 0 RPBS- #00 Coolmate V #0 009 (optional) Weldcraft TIG Torch PipeWorx 00- #00 0 (shown) PipeWorx 00- #9 00 (not shown) PipePro System Cart #00 Dimensions: H x W x D in (7 x 8 x mm). Weight (cart only): 9 lb (89 kg). PipeWorx 0- #9 99 Work Sense Lead Receptacle 0 ft Work Sense Lead #9 97 Installation Diagrams MIG/ FCAW TIG Stick The illustrations show the remote control connected through the wire feeder. The wire feeder is not connected to the power source output.. 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). Gas Hose (contact your distributor). 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 ft cable (see page 8). Weld Cable and Electrode Holder (contact your distributor). Work Cable (contact your distributor). Interconnect and Feeder Control Cable. Control Extension Cable. Remote with ft cable (see page 8) Note: Size /0 weld cable is recommended with PipePro 0 RFC. 7

8 Ordering Information (Select a power source, wire feeder and cable package for complete system.) Power Source and Accessories Stock No. Description Qty. Price PipePro 0 RFC Inverter Power Supply # V, Auto-Line Add a Wire Feeder and a Cable and Gun Package # CE, 00 V to create a system. PipePro 0 System Cart #00 Cart with cylinder rack for power source, feeder, cooler, and polarity switch Bench-Style Wire Feeder and Accessories PipePro DX Bench-Style Feeders #00 7 Single feeder #00 8 Dual feeder Control Detachment Kit #00 Field Kit, 0 ft ( m). For PipePro DX single feeder only Allows separation of the control module from the #00 Field Kit, ft (7. m). For PipePro DX single feeder only wire drive assembly and base. #00 Field Kit, ft (7. m). For PipePro DX dual feeder only Feeder Cart # 8 Spool Covers #07 07 For single feeder or left side of dual feeder # For right side of dual feeder Wire Reel Assembly # For 0 lb (7 kg) coil (Reel and Spool Covers cannot be installed if the wire drive assembly is in a rotated position.) Reel Covers #9 For single feeder or left side of dual feeder. For 0 lb (7 kg) coil #09 8 For right side of dual feeder. For 0 lb (7 kg) coil Drive Roll Kit (Required) See page Dual Schedule Switches #07 8 DSS-9 (PipePro DX models only) SuitCase-Style Wire Feeder and Accessories PipePro RC SuitCase Feeder #9 9 Flowmeter Kit #00 Filter Inline Shielding Gas #9 89 Drive Roll Kit (Required) See page PipeWorx 00- Gun and Cable Packages Select a Package OR Select Individual Cables (see page ) Includes interconnect and feeder control cable ( ft), #00 ft (. m) cable and gun package feeder control extension cables, work-sense lead and #00 ft (7. m) cable and gun package PipeWorx gun. Does NOT include weld cable, work cable, #00 0 ft (. m) cable and gun package work clamp, and gas regulator/flowmeter. Individual Cables for Typical Installations Interconnect and Feeder Control Cable #9 8 ft (. m) (one required per system) Feeder Control Extension Cable #9 9 ft (7. m) (Not required if feeder is on or near power source.) #9 0 0 ft (. m) # ft (0. m) Work-Sense Lead # ft (. m) # ft (.7 m) Individual MIG/FCAW Guns and Consumables Bernard PipeWorx Guns # Gun. See page for consumables # Gun. See page for consumables # Gun. See page for consumables Accessories for TIG and Stick RFCS- HD #9 7 Heavy-duty foot control RCC- # 08 Side-to-side fingertip control RCCS- #0 88 Up-and-down fingertip control RHC- #9 0 Hand current control and contactor RPBS- #00 On-off switch Remote Control Adapter #00 8 For PipePro RC SuitCase and #9 07 Single Feeder. Connects remote control cable to feeder control cable Polarity Control #0 87 Switches between DCEP (reverse polarity) and DCEN (straight polarity) HF-D- #0 88 High-frequency remote arc starter with gas solenoid, VAC Coolmate V #0 009 VAC Date: Total Quoted Price: Distributed by: Litho in USA