PipeWeldingHandbook.pdf

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M-247 250B

2012−07

Pipe Welding

Handbook

Visit our website at

www.MillerWelds.com

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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

.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

1-6.

EMF Information

4

..........................

5

2-1.

Symboles utilisés

....................................................................

5

2-2.

Dangers relatifs au soudage à l’arc

.....................................................

5

2-3.

Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

.....

7

2-4.

Proposition californienne 65 Avertissements

..............................................

8

2-5.

Principales normes de sécurité

.........................................................

9

2-6.

Informations relatives aux CEM

........................................................

9

SECTION 3 − GMAW FUNDAMENTALS

.......................................................

11

3-1.

Basic Information

....................................................................

11

3-2.

Welding Positions

....................................................................

15

3-3.

GMAW (MIG) / FCAW PipePro System

..................................................

16

3-4.

Typical PipeWorx Connection Diagram For MIG (GMAW) Equipment With Feeder

On Power Source

....................................................................

17

3-5.

Typical PipeWorx Connection Diagram For MIG (GMAW) Equipment With Feeder On Cart

.......

18

3-6.

Process Variable Definitions

...........................................................

19

3-7.

Joint Preparation And Typical Recommendations For 1G, 5G, 6G, And 6GR

...................

20

3-8.

RMD Open Root Joint Preparation

......................................................

21

3-9.

5G Welding Technique Recommendations

...............................................

23

3-10. 1G Welding Technique Recommendations

...............................................

3-11. Welding Passes And Appropriate Process With Parameter Ranges

27

..........................

30

3-12. Troubleshooting Guide

................................................................

38

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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som 2011−10

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 ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2.

Arc Welding Hazards

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.

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.

When making input connections, attach proper grounding conduc-

tor first − double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

Only qualified persons should install, operate, maintain, and

repair this unit.

Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

Turn off all equipment when not in use.

During operation, keep everybody, especially children, away.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

ELECTRIC SHOCK can kill.

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

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.

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

Do not touch live electrical parts.

Wear a safety harness if working above floor level.

Wear dry, hole-free insulating gloves and body protection.

Keep all panels and covers securely in place.

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in

use.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present on

unit.

Additional safety precautions are required when any of the follow-

ing 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 unavoid-

able 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 volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of input power.

Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can burn.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

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).

To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

M-247 250 Page 1

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