DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining ...
247250C 2018−08 Guidelines For Pipe Welding For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com
247250C
2018-08
Guidelines For Pipe Welding
For product information, Owner's Manual translations,
and more, visit
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 - GMAW FUNDAMENTALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2-1. Basic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Welding Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-3. GMAW (MIG) / FCAW PipePro System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-4. Typical PipeWorx Connection Diagram For MIG (GMAW) Equipment With Feeder On Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-5. Typical PipeWorx Connection Diagram For MIG (GMAW) Equipment With Feeder On Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-6. Process Variable Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-7. Joint Preparation And Typical Recommendations For 1G, 5G, 6G, And 6GR . . . . . . . . . . . . . . . . . . . 14
2-8. RMD Open Root Joint Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-9. 5G Welding Technique Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-10. 1G Welding Technique Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2-11. Welding Passes And Appropriate Process With Parameter Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2-12. Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING
som 2018-01
7
Protect yourself and others from injury -- read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
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.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
NOTICE - Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work or ground. D Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to its Owner's Manual and national, state, and local codes.
D Always verify the supply ground - check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first - double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
D Frequently inspect input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or repaired cables. D Do not drape cables over your body. D If earth grounding of the workpiece is required, ground it directly
with a separate cable. D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine. D Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be present. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use. D Use GFCI protection when operating auxiliary equipment in damp or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed. D Allow cooling period before working on
equipment. D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
247250 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
D Keep your head out of the fumes. Do not breathe the fumes. D Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed. D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Safety Data Sheets (SDSs) and the manufacturer's instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your helmet.
D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame-resistant material (leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards.
D Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
D Do not weld where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.
D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Wear body protection made from durable, flame-resistant material
(leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. D After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. D Use only correct fuses or circuit breakers. Do not oversize or bypass them. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. D Read and understand the Safety Data Sheets (SDSs) and the manufacturer's instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
D Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use. D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
D Wear approved ear protection if noise level is high.
247250 Page 2
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder - explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in use or connected for use.
D Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport cylinders.
D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near combustible surfaces.
D Do not install unit near flammables. D Do not overload building wiring - be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
D Use correct procedures and equipment of adequate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94-110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before
starting to weld again. D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face. D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper face, hand, and body protection. D Sparks can cause fires -- keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling boards or parts.
D Use proper static-proof bags and boxes to store, move, or ship PC boards.
MOVING PARTS can injure.
D Keep away from moving parts. D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do so.
D Do not point gun toward any part of the body, other people, or any metal when threading welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards
closed and securely in place. D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary. D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner's Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.
D Use only genuine replacement parts from the manufacturer. D Perform installation, maintenance, and service according to the
Owner's Manuals, industry standards, and national, state, and local codes.
247250 Page 3
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equipment at once.
D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots.
D Be sure all equipment in the welding area is electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive electronic equipment.
D Be sure this welding machine is installed and grounded according to this manual.
D If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm.
For more information, go to www.P65Warnings.ca.gov.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers-by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body. 247250 Page 4
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csagroup.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices--phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 - GMAW FUNDAMENTALS
2-1. Basic Information
A. Overview Of Welding Processes
The two basic types of metal transfer are short circuit and spray.
In short circuit transfer, the wire short circuits to the workpiece and weld wire is transferred with each short circuit. Short circuit transfer uses smaller wire diameters at lower arc voltages and higher slope settings. See Figure 2-1.
A
B
C
D
E
F
WORK
Figure 2-1. Mechanics Of Short Circuiting Transfer
S-0568
In spray transfer, a steady stream of small droplets of weld wire are transferred into the weld. Spray transfer uses larger diameter wires at higher arc voltages and lower slope settings. See Figure 2-2.
Steady State
WORK
Figure 2-2. Mechanics Of Spray Transfer
S-0567
For short circuit transfer, a constant voltage welding power source is required. Adjustable slope and inductance are desirable. Slope slows the response rate of the welding power source and lowers maximum short circuit current. A constant speed wire feeder is recommended for short circuit transfer.
For spray transfer, either a constant voltage or constant current welding power source can be used. A voltage sensing wire feeder is recommended for spray transfer.
The values in the following tables are a starting point for setting up a weld. Most settings can be varied while welding to fine tune the arc. 247250 Page 5
Table 2-1. Short Circuit Transfer For Mild And Low Alloy Steel*
Electrode Diameter
Amperage Range DCEP
.030 in.
70-130 A
.035 in.
80-190 A
.045 in.
100-225 A
*Using CO2 shielding gas for mild steel and Argon-CO2 for low alloy steel.
Load Voltage 15-21 V 16-22 V 17-22 V
Power Source CV CV CV
Table 2-2. Spray Transfer For Mild And Low Alloy Steel*
Electrode Diameter
Amperage Range DCEP
Load Voltage
Power Source
.030 in.
150-265 A
24-28 V
CV or CC
.035 in.
175-290 A
24-28 V
CV or CC
.045 in.
200-315 A
24-30 V
CV or CC
1/16 in.
275-500 A
24-32 V
CV or CC
3/32 in.
350-600 A
24-33 V
CV or CC
*Using Argon - 5% Oxygen shielding gas or C10 - 90% Argon - 10% Oxygen shielding gas for mild and low alloy steel.
Table 2-3. Short Circuit Transfer For Stainless Steel 300 Series*
Electrode Diameter
Amperage Range DCEP
Load Voltage
.030 in.
50-145 A
17-22 V
.035 in.
65-175 A
17-22 V
.045 in.
100-210 A
17-22 V
*Using tri-gas mixture - 90% He; 7-1/2% Ar; 2-1/2% CO2 and flow rates of approximately 20 CFH.
Power Source
CV power source with characteristics for short circuiting
transfer.
Table 2-4. Spray Transfer For Stainless Steel 300 Series*
Electrode Diameter
Amperage Range DCEP
.030 in.
160-210 A
.035 in.
180-255 A
.045 in.
200-300 A
1/16 in.
215-325 A
3/32 in.
225-375 A
*Using Argon-Oxygen shielding gas. Oxygen percentage varies from 1 - 5%.
Load Voltage 24-28 V 24-29 V 24-30 V 24-32 V 24-32 V
Power Source CV or CC CV or CC CV or CC CV or CC CV or CC
Table 2-5. Flux Cored Arc*
Electrode Diameter
Amperage Range
Load Voltage
.045 in.
200-300 A
24-30 V
1/16 in.
200-425 A
24-29 V
5/64 in.
250-450 A
27-31 V
3/32 in.
300-500 A
29-33 V
7/64 in.
360-550 A
29-34 V
1/8 in.
425-650 A
29-34 V
*Using CO2 as the shielding gas. Flow rates depend on nozzle diameter, surrounding air movement, and electrode extension. Welding in still
air generally requires flow rates from 30 to 40 CFH. Drafty conditions or longer electrode extension may require higher flow rates.
Most manufacturers recommend an extension of 3/4 to 1-1/2 in. for gas shielded electrodes. Follow the electrode manufacturer's
recommendations.
247250 Page 6
B. Advanced Process: RMD
RMD (Regulated Metal Deposition) is 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 operator 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.
S Ideally suited to root pass welding
S Consistent side wall fusion
S Less weld spatter
S Tolerant to hi-lo fit-up conditions
S More tolerant of changes in tip-to-work distance
S Less personnel training time
S Thicker root passes can eliminate hot pass
S Eliminate backing gas on some stainless steel applications
RMD Carbon Steel
RMD Stainless
Figure 2-3. RMD Root Pass Welds
RMD Ball Transfer
Current Waveform
<-Wet-> Pinch
Clear
Blink
BackBall ground
Figure 2-4. RMD Ball Transfer
Pre-short
247250 Page 7
C. Advanced Process: 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 personnel training time. The process also improves fusion 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.
S Ideally suited to fill and cap pass welding
S Easier puddle control than conventional spray pulse
S Shorter arc lengths and narrow arc cone for out-of-position welding
S More tolerant of tip-to-work variation
S Improve fusion and fill at toe of weld
S Less heat input reduces interpass cooling time and improves weld cycle time
S Enables one-wire and one-gas weld procedures
Pro-Pulse Carbon
Pro-Pulse Stainless
Figure 2-5. Pro-Pulse Weld Bead
247250 Page 8
Figure 2-6. Pro-Pulse Voltage And Current Waveforms
2-2. Welding Positions
Welding position is determined by the pipe position and if the pipe is in a fixed position or rotating.
15° 15°
5G Fixed
1G Rotating
45° ±5°
2G Fixed
6G Inclined Fixed
Figure 2-7. Pipe Positions
Ref. 805 024-A / Ref. 805 028-A
247250 Page 9
2-3. GMAW (MIG) / FCAW PipePro System
11
1 9
3
. Attach volt sense
lead as close to arc as possible.
2 4
5
10
8 7 6
! Do not mount feeder on top of power
source.
! Do not put feeder where welding
wire hits cylinder.
! Do not move or operate equipment
when it could tip. 1 Welding Power Source
. Attach volt sense lead as close to arc
as possible.
247250 Page 10
2 Negative Volt Sense Cable 3 Positive (+) Weld Cable 4 Negative (-) Weld Cable 5 Workpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder
804 097-B / Ref. 804 374-C
10 14-Pin Feeder Control Cable
11 Interconnect Cable
Connect 14-pin socket into wire feeder control cable or optional extension cable. Connect 72-pin connector to I/O receptacle RC72 on rear of power source. Connect 10-pin connector into receptacle RC8 on rear of power source.
. Maximum cable length not to exceed
150 feet.
2-4. Typical PipeWorx Connection Diagram For MIG (GMAW) Equipment With Feeder On Welding Power Source
2 7
4 1
9
6
5 3
9
11 8
10
! Do not put feeder where welding
wire hits cylinder.
! Do not move or operate equipment
when it could tip.
1 Welding Power Source
2 Wire Feeder 3 MIG Connection 4 Positive (+) Weld Cable
5 Feeder Control Cable Connection
6 Gas Hose
7 Gas Cylinder
Connect 14-pin plug to rear of power source, and connect 14-socket plug to rear of wire feeder. Connect one end of weld cable to weld terminal on rear of power source. Connect remaining end of weld cable to wire feeder drive housing. Connect one end of gas hose to regulator/flowmeter on gas cylinder and connect remaining end
805 144-B
of gas hose to gas solenoid connector on rear of feeder or Y-hose for dual wire feeder. 8 Work (-) Weld Cable
. Attach volt sense lead to work clamp
and attach work clamp as close to arc as possible. 9 Volt Sense Cable 10 Workpiece 11 Welding Gun
247250 Page 11
2-5. Typical PipeWorx Connection Diagram For MIG (GMAW) Equipment With Feeder On Cart
8 7 13
5
1
2 6 3
4 10
13
10 9
12
11
! Do not put feeder where welding
wire hits cylinder.
! Do not move or operate equipment
when it could tip. 1 Welding Power Source 2 Wire Feeder 3 Feeder Cart 4 Composite Cable 5 MIG Connection 6 Positive (+) Weld Cable 7 Gas Hose
247250 Page 12
8 Gas Cylinder
Locate end of composite cable where gas hose extends out of sleeve approximately 50 inches (1270 mm). This end of the composite cable connects to the power source. Connect 14-pin plug to rear of power source, and connect 14-socket plug to rear of wire feeder. Connect one end of weld cable to weld terminal on rear of power source and secure cable in clamp block on rear panel. Connect remaining end of weld cable to wire feeder drive housing and secure cable in clamp block on feeder base. Connect one end of gas hose to regulator/flowmeter on gas cylinder and
805 317-B
connect remaining end of gas hose to gas solenoid connector on rear of feeder or Y-hose for dual wire feeder.
9 Work (-) Weld Cable (2/0 minimum)
. Attach volt sense lead to work clamp
and attach work clamp as close to arc as possible. 10 Volt Sense Cable 11 Workpiece
12 Welding Gun
13 Strain Relief Clamp
2-6. Process Variable Definitions
The following is a list of terms and their definitions:
General Terms: Arc Control
Arc Length
Inductance Control
Trim Volts WFS
The adjustment of arc cone width and arc characteristics in the RMD and Pulse processes. Increasing Arc Control value increases the arc cone width and subsequently effects the arc length (end of electrode to workpiece).
Distance from end of wire electrode to workpiece. This term is also used to represent arc length adjustments in RMD and Pulse processes. Increasing Arc Length increases the actual arc length; likewise, decreasing Arc Length shortens actual arc length.
Allows setting inductance in MIG and FCAW. In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit transfers per second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes the welding puddle more fluid.
See Arc Length description.
Preset voltage in MIG mode at idle, actual voltage while welding, and 10 seconds hold value at end of weld.
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting. In Pulse and RMD, adjusting wire feed speed also increases power level on wire electrode (one knob control).
Notes
247250 Page 13
2-7. Joint Preparation And Typical Recommendations For 1G, 5G, 6G, And 6GR
A. Establish Good Technique
As with any welding process, success with the RMD process requires establishing and maintaining good preparation and welding techniques. The following guidelines, which are extremely easy to follow, lead to proven success and increased productivity for welding stainless steel pipe. Start with pipe joint sections that have the standard 37.5 degree bevels, for a total included angle of 75 degrees. The lands can range from a knife edge to 3/32 in. Use a minimum 1/8 in. root opening to ensure proper root reinforcement on the weld's backside. An easy way to space the gap is with a filler rod that matches the desired gap size.
B. Tack Welding System
Tack the pipe with the RMD process, making tacks (in this order) at the 12-, 6-, 3-, and 9-o'clock positions. Remove the filler metal spacer after making the first tack, then check the gap with a tool designed for that purpose. Tacks on smaller diameter pipe can be 1/4- to 1/2-in. long. Tack on larger pipe may be 1 in. or longer. Note that tack welds will shrink during cooling, causing the gap to close up. In areas with less than a 1/8-in. gap, grind the joint using a 3/32-in. cutting wheel to open the root. Finish preparing the pass by grinding each tack weld to a feather edge to ensure that the root pass consumes the tack weld.
C. Welding In The 1G Rolled Position
Start the arc in the center of a tack around the 1:30- to 2-o'clock position. Hold the gun perpendicular to the pipe with a 5- to 10-degree drag angle. Use a 3/8- to 5/8-in. electrode stick-out. In some cases, this may require a recessed contact tip to help maintain correct stick-out. Establish the weld puddle and position the electrode in the center of the weld puddle as the pipe rolls away from the operator (essentially, the operator is dragging the weld puddle). Watch the puddle closely to ensure that it ties into the sidewalls. Normally, do not use a weave technique. However, if the gap is greater than 3/16-in., the operator may need to weave the electrode slightly across the gap and up the sidewall to bridge it. When the electrode is properly positioned in the weld puddle, the RMD process creates a muted buzzing sound that is much softer than the "crackling bacon" sound of traditional short circuit GMAW. Although the RMD process appears colder than typical GMAW, the weld puddle fuses into the sidewall and penetrates the joint due to the calm metal transfer and stable arc. The face of a good root weld appears flat (neither concave or convex) and, as noted, it is thicker than a traditional GMAW root. With traditional GMAW, operators position the arc on the leading edge of the puddle. Do not do this with RMD, as the arc will stutter and create spatter and greater penetration on the inside of the pipe (note that an optimum root has about a 1/16-in. reinforcement). If travel speeds become too slow and the electrode becomes unstable (listen for a sound more like traditional GMAW. Also, the weld face will be convex. If this happens, grind out the high spots to prevent areas of lack of fusion on the next pass). If the joint is misaligned, continue to concentrate the arc in the center of the joint. Do not favor the high side of the joint; the new technology will automatically compensate. Let the arc do the work.
D. Welding In The 5G Fixed Position
Begin welding in the 12-o'clock position. As with the 1G position, start the arc in the center of a tack weld using a 5- to 10-degree drag angle and a 3/8- to 5/8-in. stick-out. At the start of the weld, keep the arc in the center of the puddle, but move the electrode back and forth across the gap using a half moon motion (with the face of the moon pointing down). At about the 1-o'clock position, gravity starts to push the puddle down the joint. Once gravity takes over, stop weaving and concentrate on directing the electrode into the center of the weld puddle. At about the 5-o'clock position, us a slight side-to-side motion until reaching 6-o'clock, ending the bead on the feathered tack weld. The side-to-side motion flattens the weld bead and minimizes grinding. If the weld does not end on a tack weld (e.g., the operator breaks the arc for whatever reason), this may lead to a pin-hole at the end of the weld. Grind out the end of the weld before resuming. After completing the root pass, also grind out starts, stops and high points before making the first fill pass (remember that the root pass with the modified process can eliminate the hot pass).
247250 Page 14
2-8. RMD Open Root Joint Preparation
1. Bevel pipe end to 37.5° (standard pipe bevel)leaving a 1/16 to 3/32 in. (1.6 to 2.4 mm) land.
37.5°
2. Align pipe ends together leaving a minimum of1/8 in. (3.2 mm) gap.
1/16-3/32 in. (1.6-2.4 mm)
LAND
1/8 in.
3. Tack pipe ends together in four locations approximately 90° apart and 1 in. (25.4 mm) long on pipe that is 6 in. (152.4 mm) or larger diameter. Use appropriate sized tack welds on smaller pipe.
1 in. (25.4 mm) TACK WELDS 90°
4. Grind each end of the tack weld to a feather edge (knife edge).
GRIND TO FEATHER
EDGE
1 in. (25.4 mm)
Ref. 805 029-A
247250 Page 15
2-9. 5G Welding Technique Recommendations
1. Start arc on sidewall or in center of tack weld, not in the gap. 12 O' CLOCK
9
3
6 O' CLOCK
MAINTAIN DRAG ANGLE
2. After puddle is established, maintain the arc on the center of the puddle with a 1/2 to 5/8 in. (12.7 to 15.9 mm) tip to work distance.
10-15°
MAINTAIN DRAG ANGLE
3. Move across the gap.
247250 Page 16
805 024-A / 805025-A
4. Move slightly up the sidewall.
5. Stay in the puddle and move the electrode back across the gap. Move the electrode down the joint in a half-moon
motion.
6. Continue moving back and forth (weaving) across the gap until reaching the 1 o'clock position.
7. At the 1 o'clock position, stop weaving. Concentrate the arc on the center of the weld puddle and move down the pipe joint until the 5 o'clock position.
805025-A / 805026-A
247250 Page 17
8. At the 5 o'clock position, repeat steps 3 - 6. However, at Step 6 the instruction should read "until reaching the 6 o'clock position" instead of the 1 o'clock position.
9. End the weld at the 6 o'clock position by moving the electrode onto the feathered tack weld.
12 O' CLOCK
12 O' CLOCK
9
3
6
9
3
6
10. DO NOT stop welding in the root. This may cause pinholes. Be sure to grind the weld at the stop position to ensure pinhole is removed and weld is feathered.
11 When root weld is complete, remove excess silicon with a wire wheel or with light grinding. Also, grind any high spots on root pass to make it uniform in height.
247250 Page 18
805027-A / 805028-A
2-10. 1G Welding Technique Recommendations
1. Start arc on sidewall or in center of tack weld, not in the gap. 12 O' CLOCK
9
3
6 O' CLOCK
MAINTAIN DRAG ANGLE
PIPE ROTATING
2. After puddle is established, maintain the arc on the leading
edge of the puddle with a 1/4 to 1/2 in. (6.4 to 12.7 mm) tip
to work distance.
10-15°
3. Move across the gap. Watch the puddle, not the arc.
MAINTAIN DRAG ANGLE
PIPE ROTATING
PIPE ROTATING
805 024-A / Ref. 805 025-A
247250 Page 19
4. Move slightly up the sidewall. Keep the electrode near the top of the pipe joint.
5. Stay on the leading edge of the puddle and move the electrode back across the gap. Move the electrode in a half-moon motion.
PIPE ROTATING
PIPE ROTATING
6. Continue moving back and forth (weaving) across the gap. Be sure pipe rotates at a constant speed. Maintain a steady arc length.
7. DO NOT stop welding in the root. This may cause pinholes. Fill the crater by welding into the previous weld start. Use a short arc length to control heat. Be sure to grind the weld at the stop position to ensure any pinhole is removed and weld is feathered.
247250 Page 20
PIPE ROTATING
PIPE ROTATING
8. When root weld is complete, remove excess silicon with a wire wheel or with light grinding. Also, grind any high spots on root pass to make it uniform in height.
Ref. 805 025-A
2-11. Welding Passes And Appropriate Process With Parameter Ranges
A. Welding Process Data Table 2-6. PipePro 450 RFC Welding Programs
Process
Wire Size in (mm)
.035 (0.9)
.035 (0.9)
.035 (0.9)
.035 (0.9)
.040 (1.0)
RMD Steel
.040 (1.0) .040 (1.0)
.040 (1.0)
.045 (1.1)
.045 (1.1)
.045 (1.1)
.045 (1.1)
.035 (0.9)
.035 (0.9)
ProPulse Steel Using A Positioner
(Rolling The Pipe)
.040 (1.0) .040 (1.0)
.045 (1.1)
.045 (1.1)
.035 (0.9)
.035 (0.9)
ProPulse Steel Welding In Position
.040 (1.0) .040 (1.0)
.045 (1.1)
.045 (1.1)
Steel
Wire Feed Speed IPM (mpm)
100-300 w/200 Nominal (2.5-7.7 w/5.1 Nominal)
100-300 w/200 Nominal (2.5-7.7 w/5.1 Nominal)
100-300 w/200 Nominal (2.5-7.7 w/5.1 Nominal)
100-300 w/200 Nominal (2.5-7.7 w/5.1 Nominal)
100-275 w/175 Nominal (2.5-7.0 w/4.4 Nominal)
100-275 w/175 Nominal (2.5-7.0 w/4.4 Nominal)
100-275 w/175 Nominal (2.5-7.0 w/4.4 Nominal)
100-275 w/175 Nominal (2.5-7.0 w/4.4 Nominal)
100-200 w/150 Nominal (2.5-5.1 w/3.8 Nominal)
100-200 w/150 Nominal (2.5-5.1 w/3.8 Nominal)
100-200 w/150 Nominal (2.5-5.1 w/3.8 Nominal)
100-200 w/150 Nominal (2.5-5.1 w/3.8 Nominal)
225-600 w/250 Nominal (5.7-15.2 w/6.4 Nominal)
120-780 w/250 Nominal 3.0-19.8 w/6.4 Nominal
120-600 w/250 Nominal 3.0-15.2 w/6.4 Nominal
120-600 w/250 Nominal 3.0-15.2 w/6.4 Nominal
140-500 w/250 Nominal (3.6-12.7 w/6.4 Nominal)
140-500 w/250 Nominal (3.6-12.7 w/6.4 Nominal)
120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal)
120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal)
120-600 w/175 Nominal (3.0-15.2 w/4.4 Nominal)
120-600 w/175 Nominal (3.0-15.2 w/4.4 Nominal)
140-500 w/175 Nominal (3.6-12.7 w/4.4 Nominal)
140-500 w/175 Nominal (3.6-12.7 w/4.4 Nominal)
Arc Adjust/Trim Arc Control Shielding Gas
47-53 w/50 Nominal
25
47-53 w/50 Nominal
25
90/10 85/15
47-53 w/50 Nominal
25
47-53 w/50 Nominal
25
50-55 w/53 Nominal
25
47-53 w/50 Nominal
25
75/25 CO2 90/10 85/15
50-55 w/53 Nominal
25
50-55 w/53 Nominal
25
47-53 w/50 Nominal
25
47-53 w/50 Nominal
25
75/25 CO2 90/10 85/15
47-53 w/50 Nominal 47-53 w/50 Nominal 52-57 w/56 Nominal 52-57 w/56 Nominal
25 25 25 30-35
75/25 CO2 90/10 85/15
52-56 w/56 Nominal
25
52-56 w/56 Nominal
25
52-57 w/56 Nominal
25
52-57 w/56 Nominal
25
90/10 85/15 90/10 85/15
52-57 w/54 Nominal 52-57 w/54 Nominal 52-56 w/54 Nominal 52-56 w/54 Nominal
25 30-35
25 25
90/10 85/15 90/10 85/15
50-55 w/53 Nominal
25
90/10
50-55 w/53 Nominal
25
85/15
247250 Page 21
Stainless Steel
Process
Wire Size in (mm)
Wire Feed Speed IPM (mpm)
Arc Adjust/Trim Arc Control Shielding Gas
.035 (0.9)
120-290 w/200 Nominal
47-51 w/50 Nominal
25
(3.0-7.4 w/5.1 Nominal)
Tri-H
.040 (1.0)
120-275 w/200 Nominal
48-52 w/50 Nominal
30
(3.0-7.4 w/5.1 Nominal)
Tri-H
RMD Stainless Steel .040 (1.0)
120-275 w/200 Nominal
48-52 w/50 Nominal
25
(3.0-7.4 w/5.1 Nominal)
98/2 CO2
.040 (1.0)
120-275 w/200 Nominal
48-52 w/50 Nominal
25
(3.0-7.4 w/5.1 Nominal)
98/2 Ox
.045 (1.1)
120-160 w/150 Nominal
48-52 w/50 Nominal
25
(3.0-4.1 w/3.8 Nominal)
Tri-H
.035 (0.9)
150-780 w/175 Nominal
53-57 w/55 Nominal
25
(3.8-19.8 w/4.4 Nominal)
Tri-H
.035 (0.9)
150-780 w/175 Nominal
52-57 w/56 Nominal
16
(3.8-19.8 w/4.4 Nominal)
Tri-A
.035 (0.9)
150-780 w/175 Nominal
48-54 w/53 Nominal
18
ProPulse
(3.8-19.8 w/4.4 Nominal)
Stainless Steel Using .035 (0.9)
150-780 w/175 Nominal
48-52 w/51 Nominal
18
A Positioner
(3.8-19.8 w/4.4 Nominal)
(Rolling The Pipe) .045 (1.1)
140-450 w/200 Nominal
52-55 w/55 Nominal
25
(3.6-11.4 w/5.1 Nominal)
98/2 CO2 98/2 Ox
Tri-H
.045 (1.1)
120-525 w/200 Nominal
53-57 w/55 Nominal
16
(3.0-13.3 w/5.1 Nominal)
98/2 CO2
.045 (1.1)
120-525 w/200 Nominal
53-57 w/55 Nominal
25
(3.0-13.3 w/5.1 Nominal)
98/2 Ox
.035 (0.9)
150-780 w/175 Nominal
53-57 w/55 Nominal
25
(3.8-19.8 w/4.4 Nominal)
Tri-H
.035 (0.9)
150-780 w/175 Nominal
52-56 w/54 Nominal
16
(3.8-19.8 w/4.4 Nominal)
Tri-A
.035 (0.9)
150-780 w/175 Nominal
48-52 w/50 Nominal
18
(3.8-19.8 w/4.4 Nominal)
98/2 CO2
.035 (0.9)
150-780 w/175 Nominal
46-50 w/48 Nominal
18
ProPulse
(3.8-19.8 w/4.4 Nominal)
Stainless Steel
Welding In Position .045 (1.1)
120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal)
53-57 w/55 Nominal
25
98/2 Ox Tri-H
.045 (1.1)
120-525 w/140 Nominal
50-55 w/53 Nominal
16
(3.0-13.3 w/3.6 Nominal)
98/2 CO2
.045 (1.1)
120-525 w/140 Nominal
50-55 w/53 Nominal
25
(3.0-13.3 w/3.6 Nominal)
98/2 Ox
.045 Inconel 625
150-500 w/300 Nominal (3.8-12.7 w/7.6 Nominal)
50-55 w/53 Nominal
25-30
Argon
Flux Core
Process
Wire Size in (mm)
Rolling Pipe/In Position Wire Feed Speed IPM (mpm)
Voltage
-- --
Shielding Gas
Flux Core/GMAW
.045 (1.1)
175-780 w/200 Nominal (4.4-19.8 w/5.1 Nominal)*
24.5-32 w/24.5 Nominal
-- --
75/25*
Note: Arc Control is arc width and Arc Adjust/Trim is arc length. Wire feed speed and voltage are synergic for the RMD and ProPulse processes. Therefore, when adjusting wire feed speed, the voltage is automatically adjusted so it is not necessary to adjust Arc Adjust/Trim. These are only starting parameters, the operator must make final adjustments depending on material and conditions.
*See wire manufacturer for recommended wire feed speed and gas mixture.
247250 Page 22
Table 2-7. PipeWorx 400 Welding Parameters
Process
Wire Size in. (mm)
.035 (0.9)
.035 (0.9)
RMD Steel
.035 (0.9) .045 (1.1)
.045 (1.1)
.045 (1.1)
ProPulse Steel Using A Positioner 1G
(Rolling The Pipe)
ProPulse Steel Welding In Position
5G
.035 (0.9) .045 (1.1) .035 (0.9) .045 (1.1)
Process RMD Stainless Steel
Wire Size in. (mm) .035 (0.9) .035 (0.9) .035 (0.9) .035 (0.9) .045 (1.1) .045 (1.1) .045 (1.1) .045 (1.1)
Steel
Wire Feed Speed IPM (mpm)
100-350 w/200 Nominal (2.5-8.9 w/5.1 Nominal)
100-350 w/200 Nominal (2.5-8.9 w/5.1 Nominal)
100-250 w/200 Nominal (2.5-6.4 w/5.1 Nominal)
100-250 w/150 Nominal (2.5-6.4 w/3.8 Nominal)
100-250 w/150 Nominal (2.5-6.4 w/3.8 Nominal)
100-200 w/150 Nominal (2.5-5.1 w/3.8 Nominal)
120-780 w/250 Nominal (3.0-19.8 w/6.4 Nominal)
140-500 w/250 Nominal (3.6-12.7 w/6.4 Nominal)
120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal)
140-500 w/175 Nominal (3.6-12.7 w/4.4 Nominal)
Stainless Steel
Wire Feed Speed IPM (mpm)
120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal)
120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal)
120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal)
120-350 w/200 Nominal (3.0-8.9 w/5.1 Nominal)
120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal)
120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal)
120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal)
120-250 w/150 Nominal (3.0-6.4 w/3.8 Nominal)
Arc Length
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
Arc Length
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
Shielding Gas C8 - C15 C20 - C25 CO2 C8 - C15 C20 - C25 CO2 C8 - C15 C8 - C15 C8 - C15 C8 - C15
Shielding Gas C2
98/2 Ox Tri-H Tri-A C2
98/2 Ox Tri-H Tri-A
247250 Page 23
Stainless Steel
Process
Wire Size in. (mm)
Wire Feed Speed IPM (mpm)
Arc Length
Shielding Gas
.035 (0.9)
150-780 w/250 Nominal (3.8-19.8 w/6.4 Nominal)
+3.0 to -3.0
C2
w/zero Nominal
.035 (0.9)
150-780 w/250 Nominal (3.8-19.8 w/6.4 Nominal)
+3.0 to -3.0 w/zero Nominal
98/2 Ox
.035 (0.9)
225-600 w/250 Nominal (5.7-15.2 w/6.4 Nominal)
+3.0 to -3.0 w/zero Nominal
Tri-H
ProPulse Stainless Steel Using A
Positioner 1G
(Rolling The Pipe)
.035 (0.9) .045 (1.1) .045 (1.1)
150-780 w/250 Nominal (3.8-19.8 w/6.4 Nominal)
120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal)
120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal)
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
Tri-A C2 98/2 Ox
.045 (1.1)
140-780 w/200 Nominal (3.6-19.8 w/5.1 Nominal)
+3.0 to -3.0 w/zero Nominal
Tri-H
.045 (1.1)
120-780 w/200 Nominal (3.0-19.8 w/5.1 Nominal)
+3.0 to -3.0 w/zero Nominal
Tri-A
.035 (0.9)
150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal)
+3.0 to -3.0
C2
w/zero Nominal
.035 (0.9)
150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal)
+3.0 to -3.0 w/zero Nominal
98/2 Ox
.035 (0.9)
150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal)
+3.0 to -3.0 w/zero Nominal
Tri-H
ProPulse Stainless Steel Welding In Position
5G
.035 (0.9) .045 (1.1)
150-780 w/175 Nominal (3.8-19.8 w/4.4 Nominal)
120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal)
+3.0 to -3.0 w/zero Nominal
+3.0 to -3.0 w/zero Nominal
Tri-A C2
.045 (1.1)
120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal)
+3.0 to -3.0 w/zero Nominal
98/2 Ox
.045 (1.1)
120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal)
+3.0 to -3.0 w/zero Nominal
Tri-H
.045 (1.1)
120-525 w/140 Nominal (3.0-13.3 w/3.6 Nominal)
+3.0 to -3.0 w/zero Nominal
Tri-A
Flux Core
Process
Wire Size in. (mm)
Rolling Pipe/In Position Wire Feed Speed IPM (mpm)
Voltage
Shielding Gas
Flux Core/GMAW
Not Dependent
175-780 w/200 Nominal (4.4-19.8 w/5.1 Nominal)*
24.5-32 w/24.5 Nominal Not Dependent
Note: Arc Length - Length of arc from end of wire to weld puddle. Wire feed speed and voltage are synergic for the RMD and ProPulse processes. This means when adjusting wire feed speed, the voltage is automatically adjusted so it is not necessary to adjust the Arc Length.
*See wire manufacturer for recommended wire feed speed and gas mixture.
247250 Page 24
B. Root Pass
The first weld pass is referred to as the root pass and is used to fill the gap between two sections of pipe. When using the GMAW process, the root pass is usually with an open root weld (no backing ring). Generally, a manual weld root pass is continuous all the way around and through the tack welds.
C. Hot Pass
The hot pass is usually a single weld that joins the root weld and both groove faces together. A split hot pass is generally an acceptable procedure for 2G welding and when the root opening is larger than normal.
D. Fill Pass
The fill pass should nearly fill the groove. If a bead sequence is necessary, an alternating pattern should be used from face to face of the joint. The location of each bead should have an adequate, uniform lap for each subsequent weld bead. If a narrow cavity should develop between weld beads or between the face of the joint and the weld bead it may result in a lack of fusion or contamination (slag). If possible, grind the area to eliminate the cavity and improve the lap weld before making the next weld.
E. Cap Pass
The cap weld should completely fill the top of the joint with the least amount of excessive build-up beyond the top surface of the pipe. Grinding may be necessary to improve the weld bead shape and remove any contamination before making the final cap pass.
Notes
247250 Page 25
2-12. Troubleshooting Guide
A. Process Issues
Trouble Undercutting
Porosity
Incomplete fusion
Humping and crowning Unmelted electrode on root side ("whiskers") Spatter Excessive melt through Other issues
Possible Causes Travel speed too high Welding voltage too high Dwell time not long enough Gun angle
Inadequate shielding gas coverage Gas in contaminated/leaky connections Electrode contamination Workpiece contamination Arc Voltage too high Excessive contact tube to work distance
Weld zone surfaces not free of film or excessive oxide Insufficient heat input Too large of a weld puddle Improper welding technique Improper joint preparation Excessive travel speed Excessive travel speed Improper welding technique
Remedy Slow down travel speed Decrease arc length, trim, or voltage Pause longer while weaving Maintain 10 to 15 degree drag angle in RMD and 5 to 10 degree angle in pulse Check flowmeter for 35 to 50 SCFH Check fittings, hoses, and shielding gas connections Replace electrode Remove paint, mill scale, rust, oil, and oxide Decrease arc length, trim, or voltage 3/8 to 5/8 in. (10 to 16 mm) stick-out for RMD or pulse 3/4 to 1 in. (19 to 25 mm) stick-out for FCAW Grind or sand to clean off surface Increase wire feed speed Increase travel speed or decrease wire feed speed Re-evaluate welding method for proper technique Increase joint angle Decrease travel speed or increase wire feed speed Slow down travel speed or weave electrode Focus electrode back further on weld puddle
Long arc length Bad shielding gas Welding in globular transfer range (Argon gas) Excessive heat input Improper joint penetration Unable to resolve problem
Shorten arc length or decrease voltage Replace shielding gas Decrease voltage Reduce wire feed speed Shorten root opening Contact factory pipe welding products service (920-735-4001)
B. Parameter Issues
Change Required Deeper penetration Shallower penetration
Larger bead Smaller bead Higher, narrower bead Flatter, wider bead Faster deposition Slower deposition
247250 Page 26
Arc Voltage
Decrease Increase
Welding Current Increase Decrease Increase Decrease
Increase Decrease
Travel Speed
Decrease Increase
Notes
- 27 -
Ref. AWS/ANSI D1.1
WELD JOINT TYPES
GROOVE
FILLET
WELD POSITION:
FLAT
BUTT 1G
T-JOINT 1F HORIZONTAL BUTT 2G
T-JOINT 2F VERTICAL BUTT 3G
T-JOINT 3F
OVERHEAD
BUTT 4G
T-JOINT 4F
Ref. 804 248-A
Owner's Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State
Serial/Style Number
(Date which equipment was delivered to original customer.)
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for: Contact the Delivering Carrier to:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller
File a claim for loss or damage during shipment.
For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer's Transportation Department.
Miller Electric Mfg. LLC
An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA
International Headquarters-USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125
For International Locations Visit www.MillerWelds.com
ORIGINAL INSTRUCTIONS - PRINTED IN USA
© 2018 Miller Electric Mfg. LLC 2018-01
Acrobat Distiller 15.0 (Windows)