SoLuciOnes Optimas

8/10/2019 SoLuciOnes Optimas

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Soluciones ptimas para lasoldadura en lneas de tuberas"

Welding Produc ts Group Latin Amer ica


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Marcas Independientes- Soluciones Integradas

ITW Welding


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Tendencias


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Tendencia - Desarrollo de Aceros En el ultimo tiempo se han

desarrollado o estn en desarrollouna serie de aceros para tuberasde alta resistencia, con un limitede fluencia entre 90 ksi y 120 ksi,con buena tenacidad a bajatemperatura.

Presiones de operacin mas altas Reduccin de la cantidad de material.

Disminucin de los tiempos defabricacin y transporte en el campo.

Disminucin en el tiempo desoldadura de las unionescircunferenciales.


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Tendencia - Desarrollo de Aceros

Estos aceros de altaresistencia son susceptiblesal agrietamiento.

Causas del agrietamiento:

1. Hidrogeno generado porla soldadura.

2. Formacin deestructuras frgiles.

3. Tensiones residuales.


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Tendencia - Desarrollo de Aceros

1. Control del Precalentamiento y laTemperatura Interpases.

2. Empleo de procesos de soldadura queaporten menos Hidrogeno.

3. Emplear entregas trmicas bajas.

Proceso de Soldadura H. Difusible (ml/100

Electrodos Celulsicos 36

Electrodos Bsicos (sin secar) 9.5

Electrodos Bsicos (secos) 5.5

Alambre slido/ Alma Metlica 2-3

Alambre Tubular sin Gas 7

Alambre Tubular con gas 6


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TendenciaAlta Productividad

Procesos GMAW and

FCAW Bajo Hidrogeno

Menor tiempo

de soldadura

Empleo de juntas mas

estrechas paradisminuir los tiempos

de soldadura.


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Tendencia - Falta de Soldadores

1. Equipamiento de fcil set

up y operacin

2. Facilitar los sistemas de

unin para hacer

Soldaduras de Calidad

3. Personal que cubra las

requerimientos de los

proyectos


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TendenciaLugares Extremos

Altas/bajas temperaturas

Humedad y Polvo

Impacto y Vibracin

Fuentes de Poder en Pay

Welders (Up to 60 C)


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Objetivo

Reduccin de costos sin comprometer la

integridad y productividad


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Conceptos Generales


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Manual

-Raz SMAW

-Relleno + SMAW

Semiautomtico

-Raz RMD (GMAW-S)

-Relleno + ProPulse (GMAW-P)

FCAW-SS

FCAW-GS

Mecanizada/Automatizada

GMAW

FCAW-G

Procesos de Soldadura


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Short Circuit GMAW vs RMD

Weld Deposit


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RMD vs. Stick Electrode

RMD Metal Core Root Pass

Less Undercut

SMAW Root Pass


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RMD

Excelente velocidad de avance en verticaldescendente (300 mm/min).

Excelentes propiedades mecnicas Menos paradas e inicios que con Electrodos

revestidos

Excelente fusin de las paredes sin escoriaatrapada

No se requiere pase en caliente antes deiniciar el uso de FCAW.

Limpieza mnima.

Proceso de bajo hidrogeno difusible (3.3ml/100g vs 35 ml/100g electrodo)

Alta eficiencia del electrodo (95% vs 50%electrodos)


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Alambres Tubulares con Alma

Metlica Incremento de las tasas de deposito

en un 30% sobre los alambres

slidos.

Mas baja entrega trmica para unadeterminada tasa de deposito.

Bajo niveles de salpicadura, y mnimao ninguna limpieza.

Bajo HD 4ml/100g for Metal Core 16ml/100g for Cellulosic

Habilidad para unir aberturas sinburn throughCono de Soldadura mas ancho-incrementa la fusin lateral


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Metal Cored Wires:


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Soluciones


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Por que FCAW-S con la nueva

generacin de alambres auto protegid Alta productividad (sobre 2 kg/h)

Bajo nivel de hidrogeno (menores H

Bajo nivel de salpicaduras

Excelente desprendimiento de esco

Excelente propiedades mecnicas

Mejora

Alta Calidad y productividad

Soluciones para los pases de

Relleno y Terminacin


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Soluciones ptimas


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Solucin ITW

Pase de raz- Proceso RMD & Alam

con ncleo metlico.

GMAW-SMetalloy 80N1; 0.045

Soldadura de Relleno y terminacin- FCAW

FCAW-SFabshield81N1+; 1/16 & 5/64

FabshieldX80; 1/16 & 5/64

FCAW-G

TM101; 0.045


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Soluciones Optimizadas

PipePro 400 XC System

Big Blue 350 PipePro

Big Blue 700X Duo Pro


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ocus on TOTALSolution Design equipment and consumables across ITW

business to meet challenges of high strength steelpipe welding

Big Blue 350 Pipe Pro (Power Source):

Best Arc for Pipe Welding

Suitcase X-TREME 8 HD DS(Feeder):

Dual schedule with new Bernard Dura-Flux DS (Gun)

Wireless Remote control:

less wires, more mobility

Hobart 79T8(81N1+) Flux Core Wire:

Designed for speed and arc control.



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Low Speed Diesel Engine

Improved Arc Stick and FCAW performance

Tier 4i Compliant - meets EPA standards

Line-X cover - standard

Work bench tough top cover

Compactsize & weight

Easy-to-use - simple controls

/front panel layout



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Designed to meet challenges of high strength steel pipe welding Suitcase X-TREME 8 HD DS(Feeder):

Dual schedule with new Bernard Dura-Flux DS (Gun)

Wireless Remote control: less wires, more mobility

Hobart 79T8(81N1+) Flux Core Wire: Designed for speed and arc control.

Using 2- 350 Pipe Pro modules

2 x 300A @ 100% duty cycle

Deluxe Model Features Include:

Two independent power generators 5Kw & 27Kw Parallel Switch

Intake Manifold Heater

Oil Pan Heater


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More Power! Up to 800 Amps of weld power

32,000 Watts of peak power

Quiet/Smooth diesel engine Deutz D2011L04i, 48.6hp

Sound Level 70% reduction!

75dB @ 7m (100Lwa) vs

83.2dB @ 7m (108Lwa) - Du-Op

Utilize the BB600X base & case

11% Smaller & 15% Lighterthan current Du-Op



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Pre-Calentamiento

Uniform Heating

Quick Time-To-Temperature


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Pre-Calentamiento por Induccin

Air CooledBlanketPower

Source

and

Controlle

r

Optional

Running

GearPower

Extension

Cable

TC

Extension

Cable


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Aplicac iones en Lneas de Tubera


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Proyecto East West pipeline II; 7000 km; China

Material X80 (4000 km); 48; 18.4 - 22 mm

ProcesoSoldadura

Raz: RMD (GMAW-S);TM80Ni1

Relleno: FCAW-SS; FSD X80

Produccion 50 uniones/da; (48 & 18.4 mm)

Raz: 2 o 3 soldadores F&C: 14 soldadores

Tasa de Rechazo Menor al 2%.

Aplicaciones


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Aplicaciones


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Aplicaciones


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Gracias!Leonardo.Rodr iguez@mil lerwelds.com

Weld ing Produc ts Group Lat in Am erica


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FEATURES: BENEFITS:

Excellent operator appeal Increases productivity Fast-freezing slag Suitable for all-position welding Easy slag removal Reduces clean-up time, increases productivity High impact strengths at low temperatures Resists cracking in severe applications No shielding gas required Suitable for welding outdoors Smaller diameter T8 electrode Easier welding and training

APPLICATIONS: APL 5L Grades X70 and below API 5L oil and gas transmission pipelines

with proper welding procedures Distribution pipeline

SLAGSYSTEM: Fast freezing, basic type, flux-cored wire

SHIELDINGGAS: None required

TYPEOFCURRENT:Direct Current Electrode Negative (DCEN)

STANDARDDIAMETERS: 1/16 (1.6mm), 5/64 (2.0mm)

RE-DRYING: Not recommended

STORAGE: Product should be stored in a dry, enclosed environment, and in its original intact packaging

TYPICALWELDMETALPROPERTIES* (Chem Pad):

Note:AWS specification single values are maximums.

TYPICALDIFFUSIBLEHYDROGEN*:

TYPICALMECHANICALPROPERTIES* [Aged 48 Hrs. @ 200F (93C)]:

TYPICALCHARPYV-NOTCHIMPACTVALUES* (As Welded):

Mechanical Tests 5/64 (2.0mm) Diameter AWS Spec1/16 (1.6mm) Diameter

Tensile Strength 82,000 psi (565 MPa) 70,000-90,000 psi (490-620 MPa)80,000 psi (552 MPa)

Yield Strength 71,000 psi (490 MPa) 58,000 psi (400 MPa) Minimum71,000 psi (490 MPa)Elongation % in 2 (50 mm) 25% 20% Minimum29%

*The information contained or otherwise referenced herein is presented only as typical without guarantee or warranty, and Hobart Brothers Companyexpressly disclaims any liability incurred from any reliance thereon. Typical data are those obtained when welded and tested in accordance with the AWSA5.29 specification. Other tests and procedures may produce different results. No data is to be construed as a recommendation for any welding condi-tion or technique not controlled by Hobart Brothers Company.

Weld Metal Analysis Fabshield 71T8 AWS Spec

Carbon (C) 0.02 0.12

Manganese (Mn) 1.44 1.50

Silicon (Si) 0.06 0.80

Sulphur (S) 0.004 0.03

Phosphorus (P) 0.010 0.03

Aluminum (Al) 1.00 1.80

Nickel (Ni) 0.95 0.80-1.10

Hydrogen Equipment Fabshield 71T8 AWS Spec

(GASCHROMATOGRAPHY) 5.5ml/100g 8.0ml/100g Maximum

CVN Temperatures 5/64 (2.0mm) Diameter AWS Spec1/16 (1.6mm) Diameter

Avg. at -20F (-30C) 295 ftlbs (400 Joules) 256 ftlbs (347 Joules) 20 ftlbs (27 Joules) Minimum

Avg. at -40F (-40C) 135 ftlbs (183 Joules) 20 ftlbs (27 Joules) Minimum J Requirement141 ftlbs (191 Joules)

Fabshield71T8

AWS A5.29: E71T8-Ni1 J H8

Hobart Brothers Company 101 Trade Square East Troy, OH 45373

PH: (800) 424-1543

FX: 800-541-6607

www.hobartbrothers.com

WELDINGPOSITIONS:


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Fabshield71T8

Diameter

Inches (mm)

Weld

Position Amps Volts

Wire-Feed

Speed

in/min (m/min)

Deposition

Rate

lbs/hr (kg/hr)

Contact Tip to

Work Distance

Inches (mm)

1/16 (1.6)1/16 (1.6)

1/16 (1.6)1/16 (1.6)

All PositionAll Position

Flat, HorizontalFlat, Horizontal

160180

200225

1718

1921

95 (2.4)110 (2.8)

130 (3.3)160 (4.1)

2.8 (1.3)3.5 (1.6)

4.1 (1.9)5.1 (2.3)

3/4 (19)3/4 (19)

3/4 (19)3/4 (19)

5/64 (2.0)5/64 (2.0)5/64 (2.0)5/64 (2.0)

All PositionAll Position

Flat, HorizontalFlat, Horizontal

170190220240

17181920

70 (1.8)80 (2.0)85 (2.2)95 (2.4)

2.7 (1.2)3.4 (1.5)3.9 (1.7)5.0 (2.3)

1 (25)1 (25)1 (25)1 (25)

CAUTION:Consumers should be thoroughly familiar with the safety precautions on the warning label posted in each shipment and in the American National StandardZ49.1, Safety in Welding and Cutting, published by the American Welding Society, 550 NW LeJune Road, Miami, FL 33126; OSHASafety and HealthStandards 29 CFR 1910 is available from the U.S. Department of Labor, Washington, D.C. 20210

Maintaining a proper welding procedure - including pre-heat and interpass temperatures - may be critical

depending on the type and thickness of steel being welded.

All positions include: Flat, Horizontal, Vertical Down, and Overhead.

STANDARDDIAMETERSANDPACKAGES: For a complete list of diameters and packaging, please contact Hobart Brothers at(800) 424-1543, or (937) 332-5188 for International Customer Service.

CONFORMANCESANDAPPROVALS: AWS A5.29, E71T8-Ni1 J H8 AWS A5.29M, E491T8-Ni1 J H8 ASME SFA 5.29, E71T8-Ni1 J H8

Diameter

Inches (mm)

14-lb. (6.4kg)

Coil

10-lb. (4.5kg)

Vacuum-Packed Spool

1/16 (1.6) S228519-P01S228519-P32

5/64 (2.0) S228525-P01S228525-P32

Material Safety Data Sheets on any Hobart Brothers Company product may be obtained from Hobart Customer Service or at www.hobartbrothers.com.

Because Hobart Brothers Company is constantly improving products, Hobart reserves the right to change design and/orspecifications without notice.

Fabshield is a registered trademark of Hobart Brothers Company, Troy, Ohio.

Revision Date: 130712 (Replaces 130507)

640-S, INDEX


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FEATURES: BENEFITS:

Excellent operator appeal Increases productivity Fast-freezing slag Suitable for all-position welding Easy slag removal Reduces clean-up time, increases productivity High impact strengths at low temperatures Resists cracking in severe applications No shielding gas required Suitable for welding outdoors Excellent mechanical properties Assists in producing high quality welds

APPLICATIONS: API 5L Grade X80 Storage tanks Piping Structural applications

SLAGSYSTEM: Fast freezing, basic type, flux-cored wire

SHIELDINGGAS: None required


STANDARDDIAMETERS: 5/64 (2.0mm)




Note: AWS specification single values are maximums.

TYPICALDIFFUSIBLEHYDROGEN*:

TYPICALMECHANICALPROPERTIES* [Aged 48 hrs @ 200F (93C)]:

TYPICALCHARPYV-NOTCHIMPACTVALUES* (ASWELDED):

Mechanical Tests 5/64 (2.0mm) Diameter AWS Spec

Tensile Strength 94,000 psi (649 MPa) 80,000-100,000 psi (550-690 MPa)

Yield Strength 84,000 psi (578 MPa) 68,000 psi (470 MPa) MimimumElongation % in 2 (50 mm) 25% 19% Minimum

*The information contained or otherwise referenced herein is presented only as typical without guarantee or warranty, and Hobart Brothers Companyexpressly disclaims any liability incurred from any reliance thereon. Typical data are those obtained when welded and tested in accordance with AWSA5.29 specification. Other tests and procedures may produce different results. No data is to be construed as a recommendation for any welding condi-tion or technique not controlled by Hobart Brothers Company.

Weld Metal Analysis Fabshield X80

Carbon (C) 0.04

Manganese (Mn) 1.37

Silicon (Si) 0.06

Sulphur (S) 0.002

Phosphorus (P) 0.011

Aluminum (Al) 0.93

Nickel (Ni) 2.38

AWS Spec

0.12

1.50

0.80

0.03

0.03

1.80

1.75-2.75

Hydrogen Equipment Fabshield X80

(GASCHROMATOGRAPHY) 7.3ml/100g

AWS Spec

8.0ml/100g Maximum

CVN Temperatures 5/64 (2.0mm) Diameter AWS Spec

Avg. at -20F (-30C) 107 ftlbs (138 Joules) 20 ftlbs (27 Joules) Minimum

Avg. at -40F (-40C) 96 ftlbs (134 Joules) 20 ftlbs (27 Joules) Minimum J requirement

FabshieldX80

AWS A5.29: E81T8-Ni2J H8

Hobart Brothers Company 101 Trade Square East Troy, OH 45373

PH: (800) 424-1543

FX: 800-541-6607

www.hobartbrothers.com

WELDINGPOSITIONS:


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FabshieldX80

DiameterInches (mm)

WeldPosition Amps Volts

Wire-FeedSpeed

in/min (m/min)

DepositionRate

lbs/hr (kg/hr)

Contact Tip toWork Distance

Inches (mm)

5/64 (2.0)

5/64 (2.0)

5/64 (2.0)

All Position

All Position

All Position

180

200

225

18

18

19

62 (1.6)

72 (1.8)

86 (2.2)

2.9 (1.3)

3.2 (1.4)

4.0 (1.8)

1 (25)

1 (25)

1 (25)

Maintaininzg a proper welding procedure - including pre-heat and interpass temperatures - may be critical

depending on the type and thickness of steel being welded.

All positions include: Flat, Horizontal, Vertical down, and Overhead.

CONFORMANCESANDAPPROVALS: AWS A5.29, E81T8-Ni2J, ASME SFA 5.29, E81T8-Ni2J AWS A5.29M, E551T8-Ni2J H8

CAUTION:Consumers should be thoroughly familiar with the safety precautions on the warning label posted in each shipment and in the American National StandardZ49.1, Safety in Welding and Cutting, published by the American Welding Society, 550 NW LeJune Road, Miami, FL 33126; OSHA Safety and HealthStandards 29 CFR 1910 is available from the U.S. Department of Labor,Washington, D.C. 20210

Material Safety Data Sheets on any Hobart Brothers Company product may be obtained from HobartCustomer Service or at www.hobartbrothers.com.

Because Hobart Brothers Company is constantly improving products, Hobart reserves the right to changedesign and/or specifications without notice.

Fabshield is a trademark of Hobart Brothers Company, Troy, Ohio.

Revision Date: 110616 (Replaces 081007)640-Q, INDEX

STANDARDDIAMETERSANDPACKAGES: For a complete list of diameters and packaging,please contact Hobart Brothers at (800) 424-1543, or (937) 332-5188 for International Customer Service.

DiameterInches (mm)

14-lb. (6.4kg)Coil

5/64 (2.0) S228825-P01


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FEATURES: BENEFITS:

Excellent operator appeal Increased productivity Fast-freezing slag Excellent for all-position welding Good slag removal Reduces time spent in cleaning weld beads Excellent low temperature impact Welds remain ductile at low temperatures

APPLICATIONS: API 5L Grade X80 overmatch

SLAGSYSTEM: Fast freezing, basic type, self-shield flux cored wire

SHIELDINGGAS: Not required


STANDARDDIAMETERS: 5/64 (2.0mm)




Note: Single values are maximums.

TYPICALDIFFUSIBLEHYDROGEN:

TYPICALMECHANICALPROPERTIES* [Aged 48 Hrs. @ 220F (104C)]:

TYPICALCHARPYV-NOTCHIMPACTVALUES* (As Welded):

*The information contained or otherwise referenced herein is presented only as typical without guarantee or warranty, and Hobart Brothers Companyexpressly disclaims any liability incurred from any reliance thereon. Typical data are those obtained when welded and tested in accordance with AWSA5.29 specification. Other tests and procedures may produce different results. No data is to be construed as a recommendation for any welding condi-tion or technique not controlled by Hobart Brothers Company.

Weld Metal Analysis Typical

Carbon (C) 0.04

Manganese (Mn) 1.56

Silicon (Si) 0.09

Sulphur (S) 0.004

Phosphorus (P) 0.008

Aluminum (Al) 1.05

Nickel (Ni) 2.92

Hydrogen Equipment Typical

(GASCHROMATOGRAPHY) 6.2 ml/100g

Mechanical Tests 5/64 (2.0mm)

Tensile Strength 101,000 ksi (696 MPa)

Yield Strength 90,000 ksi (621 MPa)

Elongation % in 2 (50 mm) 24%

CVN Temperatures 5/64 (2.0mm)

Avg. at -4F (-20C) 122 ftlbs (165 Joules)



FabshieldX90AWS E91T8-G H8

Hobart Brothers Company101 Trade Square East

Troy, OH 45373

PH: (800) 424-1543 FX: 800-541-6607 www.hobartbrothers.com

WELDINGPOSITIONS:


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Diameter

Inches (mm)

Weld

Position Amps Volts

Wire-Feed

Speed

in/min (m/min)

Deposition

Rate

lbs/hr (kg/hr)

Contact Tip to

Work Distance

Inches (mm)

5/64 (2.0)

5/64 (2.0)

5/64 (2.0)5/64 (2.0)

All Position

All Position

All PositionFlat, Horizontal

180

200

225250

18

18

1920

62 (1.6)

72 (1.8)

86 (2.2)100 (2.5)

2.9 (1.3)

3.2 (1.4)

4.0 (1.8)4.8 (2.2)

1 (25)

1 (25)

1 (25)1 (25)

FabshieldX90

STANDARDDIAMETERSANDPACKAGES: For a complete list of diameters and packaging,please contact Hobart Brothers at (800) 424-1543, or (937) 332-5188 for International Customer Service.

Maintaining a proper welding process, such as pre-heat, interpass temperature, and material thickness may be

critical depending on the types of steel being welded.

See Above:

All positions include: Flat, horizontal, vertical down, and overhead.

Diameter

Inches (mm)

10-lb. (4.5kg)

Vacuum Packed Spool

5/64 (2.0) S228925-P32

CONFORMANCESANDAPPROVALS:AWS A5.29, Class E91T8-G H8ASME SFA 5.29, Class E91T8-G H8

CAUTION:Consumers should be thoroughly familiar with the safety precautions on the warning label posted in each shipment and in the

American National Standard Z49.1, Safety in Welding and Cutting, published by the American Welding Society, 550 NW LeJuneRoad, Miami, FL 33126; OSHA Safety and Health Standards 29 CFR 1910 is available from the U.S. Department of Labor,Washington, D.C. 20210

Material Safety Data Sheets on any Hobart Brothers Company product may be obtained from HobartCustomer Service or at www.hobartbrothers.com.

Because Hobart Brothers Company is constantly improving products, Hobart reserves the right to changedesign and/or specifications without notice.

Fabshield is a trademark of Hobart Brothers Company, Troy, Ohio.

Revision Date: 130322 (Replaces 101202)


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il

as

Pipe

line

ITW Welding

W E L D I N G & H E AT I N G S O L U T I O N


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Partnering with Miller and Hobart Brothers gives you

decades of global experience a history that includes

pipeline construction in some of the harshest and most

remote environments on Earth.

High-strength materials like API 5L Grades X70 to X100 are designed to expedite

pipe lay time, reduce costs and simplify transport. Whether its building across desert

terrain, up the side of a mountain or through the frigid tundra, high-strength steel offers

a history of quality, safety and proven results.

Excellent strength properties provide greater carrying capacity, along with the ability

to withstand increased pressure tolerances.

The ability to withstand temperature extremes, thermal expansion and contraction,

frost and other environmental loadings for global construction.

Thinner wall thicknessesthat require less time to weld, less filler metals to

complete passes and lower costs for transporting materials to jobsites.

Lower cost per footcompared to lower-strength steels.

As high-strength steels become more prevalent in the global pipeline market, matching

the proper filler metals, welding processes and heat treatment to the pipe can ensure

the highest level of integrity, quality and productivity in pipeline construction.

Meeting the Challenges of High-Strength Pipeline Integrity

Our world is growing

and changing. An

increasingly urbanized

population poised to

reach 9 billion by 2050

is driving demand for

new energy sources

and innovation in energy-

based construction and

infrastructure. We can

help you meet those

demands.

2


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Addressing the challenges of welding high-strength steels

High-strength steels require special attention to maintain their integrity throughout the

welding process. Key to achieving that goal is minimizing the opportunity for hydrogen-

induced cracking.

High-strength steels also require:

Filler metalsto match the various alloying strategies for high-strength steels and

meet the necessary impact properties.

New welding systemswith innovative processes to optimize the weld performance

and durable designs to meet the rugged requirements of pipeline construction.

Tightly-controlled pre-heat temperaturesof the root pass and interpasstemperatures for the fill and cap passes.

Together, Miller and Hobart Brothers have developed proven innovative solutions to

address these needs. From welding equipment and filler metals tailored to high-

strength steels, to induction heating designed to control pre-heating, interpass

temperatures and post-weld stress relief, our technologies work together to reduce the

risk of hydrogen-induced cracking and ensure you achieve the highest quality welds.

Ask our global network of welding professionals to help you place the

most reliable welding and heating systems for this demanding application

in the hands of your team.


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Maintaining the quality and safety of the pipeline is absolutely critical. Our

metal-cored wires and the Regulated Metal Deposition (RMD) process for root

passes, combined with induction heating, ensure the consistency and quality

you need.

Before you even strike an arc, induction heating can help drive out moisture and

minimize hydrogen in the weld joint. The process minimizes the opportunity for

cracking by slowing the cooling rate, allowing hydrogen to diffuse, and offsetting

thermal shock.

Adding to those pre-weld advantages, metal-cored wire and the RMD processfurther improve the integrity of the root pass by providing consistent and reliable

root reinforcement. The technologies also provide:

An exceptionally stable arc and calm weld puddle both of which help

improve weld quality and consistency, and reduce the opportunity for defects

like lack of fusion.

Greater toleranceof code-allowable high-low misalignment.

A fast-freezing puddlethat can bridge gaps up to 5 mm (3/16 inch) and

provide a root pass with a throat between 3 to 5 mm (1/8 to 3/16 inch) thick

(for .045-inch wire).

A weld bead with little or no spatterthat typically does not require interpass

grinding or cleaning due to the lack of slag in the process. A consistent arc length, even at varying wire stick-out, to simplify training.

Greater deposition efficiencycompared to cellulosic Stick electrodes.

Metal-cored wire/RMD root pass

E6010 SMAW electrode root pass

Getting to the Root of Welding

High-Strength Steels

4

Induction heating process


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RMD root face

RMD root side

The increased deposition efciency of metal-cored wire vs. E6010 cellulosic Stickelectrode ensures that the majority of metal-cored wire is going into the puddleas finished weld vs. the Stick electrode where a large percentage is being lost inspatter, slag and stub loss.

100%

90%

80%

70%

60%

50%

40%

Efficiency

Wire Feed Speed (IPM) & Amps for SMAW

Deposition Efficiency (%) Deposition Efficiency (%) SMAW

Deposition Efficiency for Metal-Cored Wire

Using RMD vs. SMAW E6010

(100) (125) (150) (175) (200) (225)95 115 130 145 165 175

The low hydrogen solution of metal-cored and self-shielded ux-cored wire willdeposit less hydrogen into the weld puddle, decreasing the chance for hydrogen-induced cracking.

44.0

40.0

36.0

32.0

28.0

24.0

20.0

16.0

12.0

8.0

4.0

0.0

DiffusibleHydrogen

(ml/100g)

1 2 3 4

Cellulosic EXX10 31.0 39.6 28.2 40.3

Metalloy Metal-Cored 2.5 3.3 6.4 2.3

Fabshield FCAW-S Flux-Cored 6.4 5.5 7.3

Typical Diffusible Hydrogen Levels of

SMAW EXX10 vs. Metal-Cored & FCAW-S

Hobart Brothers Metal-Cored WiresProducts AWS Class Shielding Gas Tensile

psi (MPa)

Yield

psi (MPa)

CVN @ Temp

ft-lb (Joules)

Typical Diffusible

Hydrogen*

(ml/100g)

Recommended Pipe Grade

Metalloy

76

E70C-6M H4 7595% Argon (Ar)/Balance

Carbon Dioxide (CO2)

87000

(600)

77000

(530)

53 (72)

@ -20F (-30C)

1.9 Root pass up to X70 Pipe

Metalloy

71SG

E70C-6M H4 7590% Argon (Ar)/Balance


84000

(579)

74000

(510)

88 (120)

@ -40F (-40C)

3.3 Root pass up to X70

Pipe & sour gas pipeline

applications

Metalloy

80N1

E80C-Ni1 H8 7595% Argon (Ar)/Balance


91000

(627)

83000

(527)

56 (76)

@ -50F (-45C)


Metalloy

90

E90C-K3 H4 7595% Argon (Ar)/Balance


102000

(703)

94000

(648)

47 (64)

@ -60F (-51C)


Metalloy

110

E110C-K4 7595% Argon (Ar)/Balance


118000

(810)

105000

(725)

43 (58)

@ -60F (-51C)


Completed welds provide excellent impact properties as low as -40 degrees F/C to compensate for extreme temperatures. Weld depositsfeature as low as 4 ml of diffusible hydrogen per 100 g of weldment compared to up to 16 ml per 100 g with cellulosic Stick electrodes.

*Typical diffusible hydrogen data with shielding gas 75-80% Argon (Ar)/Balance Carbon Dioxide (CO2)


46/88

The alloy in high-strength steels, combined with the high hydrogen levels that

cellulosic Stick electrodes produce, makes welds more prone to hydrogen-

induced cracking. Shifting from Stick welding (SMAW) to Self-Shielded Flux-Cored

welding (FCAW-S) for fill and cap passes reduces hydrogen content, helps ensure

weld integrity and offers substantial benefits to the welding process:

Easily welds API 5L Grades X70 up to X100:qualified and currently used in

high-strength steel applications around the globe.

Lower hydrogen content to reduce cracking:Self-shielded ux-cored wires

feature less than 8 ml of diffusible hydrogen per 100 g of weldment (compared

to greater than 16 ml per 100 g for cellulosic Stick electrodes).

Excellent impact properties:To combat the environmental extremes high-

strength pipelines are subjected to, self-shielded ux-cored wires feature

excellent Charpy V-Notch (CVN) impact values at temperatures as low as

-40 degrees Fahrenheit/Celsius.

Increases in speed and deposition efficiency:Self-Shielded

Flux-Cored welding provides faster travel speeds more pounds per hour

and offers greater filler metal deposition efficiency compared to welding with

cellulosic Stick electrodes. In short, your operators will use less filler metal to

do the same job and do it in less time.

Better arc control:Excellent arc quality and dual schedule capabilities give

the welding operator better control over the welding arc, even in difficultpositions toward the bottom of the pipe (4 to 6 oclock).

Eliminates shielding gas: Process eliminates the need for a shielding gas,

reducing the cost, transportation and storage of gas bottles.

Final cap pass with Hobart

Fabshieldflux-cored wire

A New Pass at Fill and Cap

6


47/88

Hobart Brothers Self-Shielded Flux-Cored Wires

Products AWS Class Shielding

Gas

Tensile

psi (MPa)

Yield

psi (MPa)

CVN @ Temp

ft-lb (Joules)

Typical Diffusible

Hydrogen

(ml/100g)

Recommended Pipe

Grade

Fabshield81N1 E71T8-Ni1 J H8 None 75000

(517)

65000

(448)

206 (280) @ -40F (-40C) 6.4 Fill & Cap up to

X65 Pipe

Fabshield 81N1+ E71T8-Ni1 J H8 None 82000

(565)

71000

(490)

106 (128) @ -20F (-29C)

71 (96) @ -40F (-40C)

5.5 Fill & Cap up to

X70 Pipe

Fabshield X80 E81T8-Ni2 J H8 None 94000(649)

84000(578)

83 (113) @ -20F (-29C)70 (95) @ -40F (-40C)

5.2 Fill & Cap up toX80 Pipe

Hobart Brothers Gas-Shielded Flux-Cored WiresProducts AWS Class Shielding

Gas

Tensile

psi (MPa)

Yield

psi (MPa)

CVN @ Temp

ft-lb (Joules)

Typical Diffusible

Hydrogen

(ml/100g)

Recommended Pipe

Grade

Formula XL-550 E71T-1C /

E71T-12CJ H4

100% Carbon Dioxide (CO2) 85000

(586)

77000

(531)

75 (102) @

-40F (-40C)


X65 Pipe

FabCO712M E71T-1MJ H4 /

E71T-9MJ H4 /E71T-12J H4

75-80% Argon (Ar)/Balance


79000

(544)

70000

(482)

100 (135) @

-40F (-40C)


X65 Pipe

Tri-MarkTM-101 E101T1-GM 75% Argon (Ar)/25% Carbon

Dioxide (CO2)

110000

(758)

102000

(703)

52 (71) @

-40F (-40C)


X80 Pipe

FabCO XTREME120

E121T5-GC H4 100% Carbon Dioxide (CO2) 125600(866)

110700(763)

75 (101) @-76F (-60C)

3.4 Fill & Cap up toX100 Pipe

Other customized formulations for specific applications available upon request.

Induction heating helps maintain critical

interpass temperature control, removing

moisture and hydrogen between passes,

further reducing cracking and improving

weld quality.

75%

70%

65%

60%

55%

50%

45%

40%

6.0

5.0

4.0

3.0

2.0

1.0

0.0

Efficie

ncy

DepositionR

ate

(lb/hr)

Wire Feed Speed (IPM) & Amps for SMAW

Deposition Rate and Efficiency for Self-Shield

FCAW-S vs. SMAW EXX10 Cellulosic Electrodes

(65) (75) (85) (90) (100) (125)

95 115 130 145 165 175

Deposition Efficiency of

SMAW EXX10

Deposition Rate of

SMAW EXX10

Deposition Efficiency of

Fabshield FCAW-S

Deposition Rate of

Fabshield FCAW-S

This graph illustrates the increase in deposition rate and more consistentdeposition efciency when using a self-shielded ux-cored wire vs. an EXX10cellulosic Stick electrode.


48/88

Miller PipePro XC welding systemThe PipePro XC welding system from Miller is optimized for both the RMDprocess with metal-coredwire on root passes and the Self-Shielded Flux-Cored process with ux-cored wires for ll and cappasses. These systems offer easy operation through intuitive design and interface, are fast to setup in the eld and ensure optimal performance with rugged design and construction. The PipePro XCsystem is also compact for optimal transport and space considerations on-site.

Multiprocess system is optimized for the welding processes RMD and Self-Shielded Flux-Cored and best suited to reduce hydrogen in the weld.

Excellent arc performance and greater tolerance for varying welder techniques support consistentweld quality.

Intuitive design, controls and interface make it easy to set up and train welders ensures weldersget up to speed faster and are more productive.

Durable construction withstands extreme conditionsrelated to temperature, moisture, dust,vibration and shock.

Lightweight, small footprint facilitates tractor mounting and is portable for tie-ins and repairs.

Upgradeable software, custom programs and optional features available through memory card.

Bernard PipeWorx Gun

PipePro XC

Power Source PipePro XC

RMD FeederPipeProXC

Feeder

Bernard PipePro

Dura-Flux Gun

8

Each component of the welding process filler metal and equipment can affect the amount of

hydrogen in the weld, but combining their attributes into one optimized system ensures the best

results. These systems from Miller and Hobart Brothers are easy to operate and are designed

to withstand the harshest environments found in pipeline construction tested above and beyond

the highest industry standards to ensure durability and performance.

Welding Solutions


49/88

Hobart Brothers metal-cored and flux-cored wiresHobart Brothers manufactures metal-cored and ux-cored wires designedto drive hydrogen out of the weld, ensure pipeline integrity with excellentstrength and impact propertiesin harsh environments, and workseamlessly with Miller welding power sources and feeding technologies.Wires optimized for each process include:

Metal-cored and RMD: HobartMetalloy76, Metalloy 71SG, Metalloy80N1, Metalloy 90 and Metalloy 110

Self-shielded ux-cored wires: Fabshield81N1, 81N1+ and X80

Gas-shielded ux-cored wires: Hobart Formula XL-550, FabCO712M,FabCO XTREME120 and Tri-MarkTM-101

Miller Big Blue engine-driven welder/generatorsThe Big Blue 350 PipePro and the Big Blue 700 Duo Pro diesel engine-driven welder/generators,matched with SuitCase X-TREME HD wire feeders, are optimized for pipeline and specically for Self-Shielded Flux-Cored welding on fill and cap passes. Both machines are built to withstand temperatureand environmental extremes for optimal performance regardless of conditions. The Big Blue 700 alsorepresents the industrys only dual operator welding system for transmission pipeline construction.


Excellent arc performancedesigned specically for self-shielded ux-cored wires in pipelineapplications promotes weld quality.

Easy-to-use operator interfacesimplifies training and equipment setup.

Built and tested in high and low environmental extremes as well as against moisture, dust,

vibration and shock ensuring reliability and performance even in the toughest environments. Greater fuel efciency to reduce fuel transportation costs and labor;lower emissions for reduced

carbon footprint.

Big Blue 700 Duo Pro

Features two welding arcs that match the quality and reliabilityof the Big Blue 350 PipePro.

Increases productivity by allowing two welders to work from the same machine simultaneously.

Uses 35 percent less fuel and offers a lower total cost of ownership than two comparable engine-driven units, saving resources and costs.

Costs lessto transport to the jobsite than two individual engine-driven units and takes up aconsiderably smaller footprint to save space.

Big Blue350 PipeProwith SuitCaseX-TREME

HD and Bernard Dura-Flux Gun (Engine Driven)

Big Blue 700 Duo Pro

Hobart Brothers

tubular wires


50/88

10

Pre- and post-weld heat treatment is a critical requirement in eliminating

hydrogen-induced cracking in high-strength steels. Whether on the mainline, on

tie-ins or at compressor/pumping stations, induction heating provides superior

preheating and stress relief that is more effective, faster, more versatile and

extremely safe compared to other methods. The induction heating process:

Drives and keeps moisture out of the weldto

prevent hydrogen-induced cracking. This is a particular

improvement over heating with a torch/rosebud, which

actually introduces water vapor into the weld joint.

Heats uniformlyto prevent localized hot and cold

spots that can affect weld integrity and offers real-time

thermocouple feedback, along with tighter control over

welding interpass temperaturesto ensure heating

consistency.

Reduces the potential for damageand the associated

repair time to surrounding parts/components/coatings

by limiting heat to the targeted area.

Improves safety by eliminating open flames and exposed

heating elements.

Improves safetyin confined spaces, as induction heating does not burn

oxygen like heating with a torch or rosebud, which can lead to insufficientbreathable air for the worker.

Provides faster time-to-temperaturethan other heating methods, increasing

productivity.

Allows equipment and accessories to be carried on the same tractor or sled

as the welding power sources for improved portability and accessibility.

Eliminates heating gas purchase, storage and transport lowering costs

over time and improving site logistics.

Optional digital recorder stores temperature data for quantifiable verification

of critical preheating and stress-relieving temperatures.

Superior Pre-Heat and

Post-Weld Heat with Induction Heating

The ProHeat 35 induction heating system

from Miller diffuses moisture out of the weld,

further reducing hydrogen in the weld and

the chance of hydrogen-induced cracking.


51/88

Our ITW Partners

Miller and Hobart Brothers are just two of the ITW Welding companies who have a well-established history

of providing proven, innovative products to the pipeline industry. ITW has a global, market-leading portfolio of

best-in-class brands that serve the industry with reliable and responsive technical expertise. Our other oil and

gas pipeline partners include:

Pipe Welding Technology (PWT) (www.pwtsrl.com) is a manufacturer and supplier of

advanced equipment and tools for automatic welding in outdoor applications. This includes

advanced mechanical, electronic and arc control technology for the pipeline industry. PWTs

vast field experience and consultative approach ensures customers have the most suitablewelding techniques, systems and training available for every job.

E.H. Wachs(www.ehwachs.com) is a leading manufacturer of portable pipe machining tools,

valve exercisers and related equipment used for on-site cutting, squaring, beveling and facing

pipe of all sizes and thicknesses. Its cold cutting machine tools are designed to eliminate

the hazards associated with thermal cutting and improve the overall safety of pipeline

operators. The company has been an industry leader in pipeline maintenance since 1949.

ITW Insulation Systems (www.itwinsulation.com) is an established leader in the manufacture

of products used in mechanical insulation systems for pipes, tanks and other equipment.

ITW Insulation Systems provides high-performance mechanical insulation, vapor retarder lmand metal jacketing products designed to meet specifications for a wide range of industrial

and commercial applications.

Tempil(www.tempil.com), a leader in the development of precision temperature indication

technologies, including indicating sticks, electronic surface thermometers and infrared

thermometers, for over 75 years. These visual product solutions check critical

temperatures in the welding processes and ensure the performance of completed pipelines.

Tempil stays at the forefront of the industry through constant research and product

development that address the direct needs of its customers.


52/88

As your global partner in pipeline construction,

we pledge to support your success with our unique

multi-discipline knowledge and in-depth pipeline

construction experience. Our goal is to ensure you

achieve consistent weld integrity, no matter how

challenging the environment and no matter

where you are in the world.

Countless capabilities.

Trusted advice.Integrated solutions.

For all your global pipeline welding solution needs contact:

MillerWelds.com HobartBrothers.com

ITW Welding

# 259846 2012 Miller Electric Mfg. Co.

Welding Industries of [email protected]

Beijing [email protected]

ITW Welding SASFrance33-1-6004-1166

[email protected]

ITW [email protected]

ITW Welding [email protected]

Welding Products GroupLatin [email protected]

ITW Welding Products [email protected]

ITW WeldingMiddle East (FZE)[email protected]

ITW Welding Products BVNetherlands/[email protected]

Weldwell New Zealand

[email protected]

North American [email protected]


ITW Welding Singapore Pte. [email protected]



53/88

ProcessesStick (SMAW)MIG (GMAW)RMD (Modified Short Circuit)

Flux-Cored (FCAW)

Pipe Welding ApplicationsPipeline Construction

PipePro

XC Welding System Multiprocess PipeWelding SystemsIssued Oct. 2011 Index No. PWS/

The Power of Blue

.

Rated Output 400 A at 34 VDC, 100% Duty Cycle

Voltage Range 10 39 V

Ship Weight PipePro 400XC: 56.7 kg (125 lb.)PipePro XC Feeder: 15.2 kg (33.5 lb.)Bernard PipeWorx 250-15: 4.1 kg (9 lb.)Bernard PipeWorx 300-15: 4.6 kg (10 lb.)Bernard PipePro Dura-Flux: 4.5 kg (10 lb.)

Power source is warranted for 3 years, parts and labor.

QuickSpecs

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

Web Sitewww.MillerWelds.com

Equipment Sales US and CanadaPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125

PipePro 400XC Power SourceAble to perform simple Stick (SMAW)welding to advanced MIG RMD welding.The arc performance and ease-of-use is

optimized to provide quality and productivity,while simplifying welding training.

Fill and Cap Pass System Components(order separately) PipePro 400XC power source PipePro XC suitcase-style feeder

Bernard PipePro Dura-Flux gun(self-shielded FCAW)

Root-Fill-Cap Pass System Components(order separately) PipePro 400XC power source PipePro XC RMD suitcase-style feeder

Bernard PipePro Dura-Flux gun(self-shielded FCAW)

Bernard PipeWorx gun (gas-shielded)

Bernard PipeWorx 250-15 GunDesigned by welders to reduce fatigue andimprove visibility of the puddle on the root pas

Bernard PipeWorx 300-15 GunProvides a heavy-duty solution to producing rofill and cap welds on pipe.

Bernard PipePro Dura-Flux GunUniquely designed to perform self-shielded FCAW with

the PipePro System for onshore pipeline applications. Thegun features a dual schedule switch to enable two sets ofwelding parameters wire feed speed and voltage.

The PipePro XC Welding System is designed specifically to meet the rugged demands ofpipeline applications. The system is optimized to provide excellent arc performance using theHobart Fabshield family of self-shielded FCAW filler metals.

PipePro XC FeederUniquely designed tooperate with thePipePro XC powersource to performFCAW self-shieldedweld process for filland cap pass weldingon pipelines. This

economical solutionoptimizes the weldprocess using theHobart Fabshield familyof self-shielded wires.

PipePro XC RMDFeederThis feeder providesthe most versatilewelding solution wheused with the PipePrXC power source. Itcan provide MIG andMIG RMD (solid wire

and metal-cored wireand FCAW (self-shieldor gas-shielded wireAll welding processeare optimized for pipwelding.


54/88

Features Benefits

Durability Specifically designed for the rugged environments of pipeline construction,reducing downtime and service requirements. Temperature power source rating is based on 50C ambient. Moisturemeets IP23 standards. Horizontal control boards are potted. Shock and vibrationthe power source base is designed with shock mounts to

reduce vibration when mounted on tractors.

Dust Wind Tunnel Technology

circulates air over components that requirecooling (not electronic circuitry). Fan-On-Demand cooling system operates onlywhen needed. This reduces the amount of airborne contaminants in the machine.

Weld performance Designed to provide optimum weld performance using either the standard PipeProXC suitcase-style feeder (for self-shielded FCAW) or the more versatile PipePro XCRMD suitcase-style feeder. The excellent arc performance reduces training timeand promotes weld quality using all welding processes.

Ease of use Designed to be simple to understand and operate. The operator interface on thepower source is limited to the Stick (SMAW) welding process. All MIG and FCAWprocess controls are located on the feeders. Minimal training is required to set-upand use the PipePro XC System.

Remote control A Stick remote control (either cabled or wireless remote) can be attached to thefront of the power source. The remote control provides the welder with the ability

to optimize weld parameters for quality and ease of welding. The wireless remoteprovides this capability without a control cable.

Portability Lightweight at 56.7 kg (125 lb.) with a small dimensional footprint. Two carryinghandles are provided to carry the power source in applications where the tractorcannot access the pipeline.

Memory Equipped with a memory card reader to provide new capabilities into the future. Updates new software (available free on MillerWelds.com). Stores weld parameters for all welding processes. Any PipePro 400 XC can be

loaded with personal settings. Enables the use of custom programs for future applications. Provides range locks to be sure PipePro can be limited to the procedure range

for wire feed speed and voltage to comply with quality requirements. Provides Accu-Power (Instantaneous Power Display) to comply with new ASME

Requirements for Complex Wave Form Welding Processes. Provides diagnostic information and operational information (arc hours and arc

cycles by welding process type) in a text file format.

1 6

7

8

9

2

3

4

5

2

Control Panel

1. Stick Select Pushbutton2. Memory Card Program Save Pushbutton3. Memory Card Busy Indicator Light4. Memory Card Program Load Pushbutton5. Memory Card In Use Indicator Light6. Amps Display Meter7. Feeder Select Pushbutton8. Amperage Adjustment Control9. Electrode Select Pushbutton

PipePro400XC Power Source (One Power Source Stick to RMD Optimized for Pipeline Applications.)

WeldingProcess

Stick

MIG/FCAW

Rated WeldingOutput

350 A at 34 VDC,100% Duty Cycle

400 A at 34 VDC,100% Duty Cycle

AmperageRange inCC Mode

40350 A

VoltageRange inCV Mode

1039 V

KVA380 V 400 V

15.7 15.9

18.0 18.0

KW380 V 400 V

13.2 13.2

15.5 15.6

ShipWeight

56.7 kg(125 lb.)

Max. Open-CircuitVoltage

80 VDC

80 VDC

Amperes Input atRated Output, 50/60 Hz380 V 400 V

23.5 22.7

27.1 25.7

Dimensions

H: 375 mm (14.75 in.)W: 464 mm (18.25 in.)D: 686 mm (27 in)

Specifications (Subject to change without notice.)


55/88

PipeProXC Feeder (Designed to perform self-shielded FCAW for fill and cap passes.)

PipePro

XC RMD Feeder (Designed to perform MIG, MIG RMD and both gas-shielded and self-shielded FCAW.)

Features Benefits

Durability Specifically designed for the rugged environments of pipeline construction. Thetotally enclosed and impact-resistant case provides strength and durability whileprotecting internal components and filler metal from moisture and dust. The wirfeeder meets IP23 durability standards, reducing downtime and service requiremen

Weld performance Performance has been optimized to perform self-shielded FCAW arc welding onpipeline applications. The system is ideally designed to operate with the Hobart

Fabshield family of self-shielded FCAW wires.

Ease of use Provides wire feed speed and voltage control with digital meters to enable totalprocess control and monitoring remote from the power source. The wire is easilinstalled and adjusted to simplify spool change-over. Reduces training time andsetup time.

Dual schedule Provides two sets of weld parameters (wire feed speed and voltage) through theactuation of the dual schedule switch built into the PipePro Dura-Flux gun. Thisfunction enables the welder to change parameters at the four oclock position onthe pipe to maintain consistent penetration without complicated weldingtechniques. This maintains quality and reduces training time.

Portability Lightweight and ergonomically designed to carry.

This feeder adds the following features/benefits to those listed above.

Gas controls Equipped with a gas solenoid, purge button and gas control settings for preflowand postflow. This enables this feeder to be used for gas-shielded MIG and FCAWwelding processes.

Weld performance Welding processes have been optimized for pipe welding applications. Thisincludes the weld start and stop.

RMD Provides RMD welding processes (Modified Short Circuit MIG). This process isuniquely designed for root pass welding on pipe using both solid and metal corewire. See below for additional information.

Ease of use Simply select the welding process and wire diameter. The feeder is preset at thefactory to provide nominal settings for the process. Conventional MIG and FCAWadjust the wire feed speed and voltage, as norm RMDadjust the wire feed speed and the voltage is automatically set by

the weld program. The arc length can be adjusted to suit the application andwelder preference.

Future flexibility Can operate with custom programs available through the PipeWorx Memory Car

CurrentWave Form

RMD Ball Transfer

Pinch Clear Blink Ball Background Pre-short

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 processlessens 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.

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

RMD (Regulated Metal Deposition)


56/88

Control Panels

InputPower

24 VAC,9 Amps

Welding PowerSource Type

PipePro 400XC

Wire FeedSpeed Range

1.3 12.7 m/min.(50 500 IPM)

Dimensions

H: 438 mm (17.25 in.)W: 203 mm (8 in.)D: 508 mm (20 in.)

Wire DiameterCapacity

0.9 2.0 mm(.035 5/64 in.)

MaximumSpool Weight

15 kg (33 lb.)

IP Rating

IP 23

Input WeldingCircuit Rating

100 Volts,500 Amps at100% Duty Cycle

ShipWeight

15.2 kg(33.5 lb.)

PipeProXC Feeders

V knurled forWire size V groove for hard wire hard-shelled cored wires

0.9 mm (.035 in.) #079 595

1.0 mm (.040 in.) #161 189

1.1/1.2 mm (.045 in.) #079 596 #079 607

1.3/1.4 mm (.052 in.) #079 597 #079 608

1.6 mm (1/16 in.) #079 609

1.8 mm (.068/.072 in.) #089 984

2.0 mm (5/64 in.) #079 610

Select drive roll kits from chart below according to type and wire size being used. Drive roll kits

include two drive rolls, necessary guides and feature an anti-wear sleeve for the inlet guide.

Drive Roll Kits (One kit required, order from Miller Service Parts.)

1

6

7

8

10

9

2

3

4

5

1. Power Control Pushbutton2. Volts Display Meter3. Volts Adjustment Control

4. Arc Control Pushbutton5. Memory Card Indicator Light6. Accu-Power Indicator Light7. Wire Speed/Amps Display Meter8. Wire Speed Adjustment Control9. Trigger Hold Pushbutton

10. Jog Pushbutton

1

8

9

10

12

11

14

13

2

3

5

4

6

7

1. Power Control Pushbutton2. Volts/Arc Length Display Meter3. Volts/Arc Length Adjustment Control4. Purge Pushbutton5. Arc Control Pushbutton6. FCAW Process Select Pushbutton7. Memory Card Indicator Light

8. Accu-Power Indicator Light9. Wire Speed/Amps Display Meter

10. Wire Speed Adjustment Control11. Trigger Hold Pushbutton12. Jog Pushbutton13. MIG Process Select Pushbutton14. Wire Size Select Pushbutton


4

PipePro XC feeder PipePro XC RMD feeder


57/88


58/88

1

2

4

53

1 4

3

2

2

1. Work Cable*2. Work Sense Lead (see chart below)3. Weld Cable (Electrode Negative)*4. Feeder Control Cable (see chart below)

1. Weld Cable*2. Work Sense Lead (see chart below)3. Work Cable*4. Feeder Control Cable (see chart below)5. Gas Hose*

Installation Diagrams

Work-Sense Lead

#300 947 5 m (16 ft.)

#300 461 7.6 m (25 ft.)

#300 462 15.2 m (50 ft.)

Feeder Control Cable

#300 845 10 m (32 ft.)

#300 846 20 m (64 ft.)

Individual Cables for Typical Installations

*Contact your distributor.

Note: Size 70 mm (2/0) weld cable is recommended with PipePro power sources.

6

FCAW(Self-Shielded)

MIG/FCAW(Gas-Shielded)

Wireless Remote Hand Control

Comes Complete with:Wireless hand control transmitterWireless 14-pin receiverBattery box with three AA batteriesBelt clipOwners manual

PowerSupply

Three AABatteries

10 35 VAC or DC

Rated Range*

91 m (300 ft.)

Battery Life

250 hrs.

N/A

Temperature

-25C to +70C(-13F to +158F)

RadioFrequency

2.4 Ghz.(ISM Band)

RF Power


59/88

Recommended Hobart

Filler Metal by Pipe Grade

Pipeline Product AWS Classification


60/88

Power Source Stock No. Description Qty. Price

PipePro 400XC Power Source #907 490 380 400 V, Three-Phase(Add a Wire Feeder, Gun and Cablesto create a system.)

Wire Feeder

PipePro XC Feeder #300 794 Suitcase-style feeder for FCAW self-shielded wire

PipePro XC RMD Feeder #300 844 Suitcase-style feeder for FCAW self-shielded wire,FCAW gas-shielded wire, MIG and RMD

Wire Feeder Accessories

Filter Inline Shielding Gas #195 189

Spool Adapter #047 141 For 6.4-kg (14 lb.) spools

Wire Feeder Drive Roll Kits

V-groove for solid wire #079 595 0.9 mm (.035 in.)(Most common sizes #161 189 1.0 mm (.040 in.)see page 4 for additional sizes.) #079 596 1.1/1.2 mm (.045 in.) one provided w/PipePro XC RMD feeder #300 844

Knurled V-groove for flux-cored wire #079 607 1.1/1.2 mm (.045 in.)(Most common sizes #079 609 1.6 mm (1/16 in.)see page 4 for additional sizes.) #079 610 2.0 mm (5/64 in.) one provided with PipePro XC feeder #300 794

MIG/FCAW Welding Guns

Bernard PipeWorx 250-15 Gun #195 399 250 A air-cooled MIG gun with 4.6-m (15 f t.) cable.Recommended for RMD root pass only

Bernard PipeWorx 300-15 Gun #195 400 300 A air-cooled MIG gun with 4.6-m (15 f t.) cable.Recommended for RMD root pass and FCAW gas-shielded

Bernard PipePro Dura-Flux Gun Contact Self-shielded FCAW gun with 3-m (10 ft.) cable andFactory dual schedule switch. 1.6-mm (1/16 in.) consumables

Contact Self-shielded FCAW gun with 3-m (10 ft.) cable andFactory dual schedule switch. 2.0-mm (5/64 in.) consumables

MIG/FCAW Welding Gun Consumables See page 5

System Cables for Typical Installations

Feeder Control Cable #300 845 10 m (32 ft.)(One required per system.) #300 846 20 m (64 ft.)

Work-Sense Lead #300 947 5 m (16 ft.)#300 461 7.6 m (25 ft.)#300 462 15.2 m (50 ft.)

Wireless Remote Control

Wireless Remote Hand Control w/14-Pin Receiver #300 430 System. See Lit. Index No. AY/6.6

Wireless Remote Hand Control #300 723 Sold individually

Wireless 14-Pin Receiver #300 722 Sold individually

Belt Clip #249 233 Replacement. Order from Miller Service Parts

Battery Box #249 297 Replacement. Order from Miller Service Parts

Remote Control

RHC-14 #242 211 020 6 m (20 ft.). Hand current control and contactor#242 211 100 30.5 m (100 ft.). Hand current control and contactor

PipePro Memory Cards #300 538 Blank card Used to store weld programs(Free software upgrades and calibration software #300 557 Calibration Used to calibrate the PipePro System. For free download,available on MillerWelds.com) visit MillerWelds.com

#300 460Range Locks Provides ability to set nominal parameter values andranges for wire feeder processes

#300 667 Accu-Power Displays instantaneous power during welding to meet thenew ASME requirement for calculating heat input on complex waveformprocesses (RMD)

Date: Total Quoted Price:

Ordering Information (Select a power source, wire feeder, gun and cables for complete system.)

Litho in USA

Distributed by:


61/88

Voltage-Sensing

Wire Feeder

Issued Oct. 2013 Index No. M/6

Processes

MIG (GMAW)

Flux-Cored (FCAW)Pulsed MIG (GMAW-P)

Input Power 14 48 VDC Operating Voltage110 VDC Maximum OCV

Wire Feed Speed 50 780 IPM (1.3 19.8 m/min.)

Weight 8VS: 28 lb. (13 kg) 12VS: 35 lb. (15.9 kg)

Industrial Applications

Shipbuilding

ConstructionHeavy Manufacturing

Rental

Wire feeder is warranted for 3 years, parts and labor.

Built to last in harsh

industrial environments

BUILT

TOLAST

DURABLE

Improved weld quality

BETTER

WELDSWITH LESSREWORK

Miller Electric Mfg. Co.An ITW Company1635 West Spencer StreetP.O. Box 1079Appleton, WI 54912-1079 USA

MillerWelds.comEquipment Sales US and CanadaPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125

IMPROVED!SuitCase X-TREME 8VSwith optional meters

SuitCase X-TREME 12VS

SuitCaseX-TREME8VS&12VSQuick

Specs

Portable wire feeding at its best.

The SuitCase X-TREME 8VS and 12VS provide wire feed speed that is accurate and consistentfrom the start of the weld to the finish, and from one weld to the next. Consistent wire feedspeed is very important with large-diameter cored wire, because small changes in wire feedspeed make large changes in deposition rates.

Wire drive with tachometercontrol improves weldfeed speed accuracy andconsistency to make it easierto produce quality welds.

Plastic case design, pottedPC board and double-filteredgas valve ensure SuitCasewithstands the harshestindustrial environments.


62/882

Digital meters with SunVision technologycan display voltage and wire speed, andalso amperage if desired. Meters canbe seen clearly even in direct sunlight.

(8VS: Meters optional).

Front panel has trigger hold, wire jog,and gas purge all located on front panel.

Polypropylene case with built-in sliderails and the ability to open the door tochange wire with feeder in vertical position.

SuitCaseX-TREME

Features

Gas inlet recessed into back of case isprotected from incidental contact by the weldcable, ensuring consistent and contaminant-free shielding gas delivery to the gun.Double-filtered gas valve helps keep dirtfrom clogging and affecting gas flow.

Potted and trayed main printed circuitboard for the harshest environments addsexceptional reliability. Board has full-triggerisolation so a shorted gun trigger will notaffect feeder operation.

Electronic wire feed speed control withintegrated tachometer ensures wire feed speedaccuracy that rivals the best benchtop feeders.

Wire speed dual schedule reduces wire

speed to 87.5 percent of standard speed.Requires a dual schedule gun or dualschedule switch (sold separately).

Ultra-low drag inlet guide pinsmake loading the wire easy anddoes not deform the wire on the wayinto the drive rolls. Simply threadthe wire through the pins and intodrive rolls. There are two ways toadvance the wire through the driveroll and into the gun. Either openthe pressure arm and thread thewire into the grooves in the driveroll and on into the gun inlet orplace the wire between the pins and

use the jog/purge switch to advancethe wire through the drive roll.

Gun locking tab works with guns havingcorresponding locking grooves to prevent gunfrom being pulled out if the feeder is dragged bythe gun.

Scaled wire pressure knob provideseasy adjustment and consistentpressure on the drive rolls and wire.Wire drive and motor assembly isspecifically designed for mobilewelding applications to providesmooth and consistent wire delivery.Improved motor torque and drive rollsystem are designed to feed small-diameter solid wire (.023 inch) tolarge-diameter cored wire (5/64 inch).


63/88

1

2

3

4

6

5


1. Jog/Purge Switch

2. Voltmeter3. Wire Speed/Amperage Meter

4. Wire Speed Contro5. Trigger Hold Switch6. Power Control Swit

Control Panel

Wire Size

.023/.025 in. (0.6 mm) #087 130

.030 in. (0.8 mm) #053 695

.035 in. (0.9 mm) #053 700 #072 000 #132 958

.040 in. (1.0 mm) #053 696

.045 in. (1.1/1.2 mm) #053 697 #053 701 #132 957 #083 489

.052 in. (1.3/1.4 mm) #053 698 #053 702 #132 956 #083 490

1/16 in. (1.6 mm) #053 699 #053 706 #132 955 #053 708

.068/.072 in. (1.8 mm) #132 959

5/64 in. (2.0 mm) #053 704 #132 960 #053 710

Drive Rolls (Two Required. Order from Miller Service Parts.)Select drive rolls from chart below according to type and wire size being used. Wire inlet guide comes installed on this wire feeder.

V groovefor hard wire

U groove forsoft wire orsoft-shelledcored wires

V knurled forhard-shelledcored wires

U coggedfor extremely soft

wire or soft-shelledcored wires (i.e.,hard facing types)


Wire Speed

50780 IPM

(1.319.8

m/min.)

dependent

on arc

voltage.

Max. Spool

Size Capacity

8 in. (203 mm)

14 lb. (6.4 kg)

12 in. (305 mm)

Up to 45 lb.

(20 kg)

Net

Weigh

28 lb.

(13 kg

35 lb.

(15.9

Dimensions

H: 12.75 in. (324 mm)

W: 7.25 in. (184 mm)

D: 18 in. (457 mm)

H: 15.5 in. (394 mm)

W: 9 in. (229 mm)

D: 21 in. (533 mm)

Input Power

Operates on

open-circuit

voltage and

arc voltage:

14 48 VDC/

110 Max OCV

Model

8VS

12VS

Electrode Wire

Diameter Capacity

Solid Wire: .023 .052 in. (0.6 1.4 mm)

Flux Cored: .030 5/64 in. (0.8 2.0 mm)

Solid Wire: .023 .052 in. (0.6 1.4 mm)

Flux Cored: .030 5/64 in. (0.8 2.0 mm)

Welding Power

Source Type

CC or CV DC

power sources.

AC type not

recommended.

Input Welding

Circuit Rating

330 A at

60% Duty

Cycle

425 A at

60% Duty

Cycle

3

4

1

2 6

5


1. Wire Speed Control

2. Trigger Hold Switch3. Voltmeter (Optional)4. Wire Speed/Amperage

Meter (Optional)5. Jog/Purge Switch6. Power Control Switch


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Ordering Information

Equipment and Options Stock No. Description Qty. Price

SuitCase X-TREME 8VS #951 582 With Meters and Bernard Q300 Gun

#951 583 With Bernard Q300 Gun

SuitCase X-TREME 12VS #951 543 With Bernard Q300 Gun

with Meters #951 544 With Bernard Dura-Flux gun

Flowmeter Kit #300 343

Inline Filter #195 189

Spool Adapter #047 141 For 14-lb. spoolsDual Schedule Switch DSS-9-15 #071 833

International Gun Adapter #164 902 Adapter is required to connect SuitCase X-TREME to a Euro-style gun.

Guns

Bernard Dura-Flux (FCAW) See Welding Components and Parts Guide

Bernard Q300 (GMAW) See Welding Components and Parts Guide

Bernard PipePro Dura-Flux (FCAW) Dura-Flux gun with built-in dual schedule switch. See Bernard Lit . No. SPEC DFP-1.2

Ironmate 1260 (FCAW) See Lit. Index No. AY/16.0

Roughneck C-Series (GMAW) See Lit. Index No. AY/17.0

Power Sources

XMT Series See Lit. Index No. DC/18.8 and DC/18.83

Dimension Series See Lit. Index No. DC/19.2

Gold Star Series See Lit. Index No. DC/8.1

Big Blue 400 Pro See Lit. Index No. ED/5.7

Big Blue 500 Pro See Lit. Index No. ED/11.0

Big Blue 800 Air Pak See Lit. Index No. ED/13.0

Bobcat See Lit. Index No. ED/4.4

Trailblazer See Lit. Index No. ED/4.75 and ED/4.78

Consumables

Drive Rolls

Wire

Date: Total Quoted Price:

2013 Miller Electric Mfg. Co.

Distributed by:


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EPA Tier 4iCompliantEPA Tier 4i

CompliantEPA Tier i

Compliant

EPA Tier 4iCompliant

Processes

Stick (SMAW)MIG (GMAW)Flux-Cored (FCAW)

DC TIG (GTAW)Air Carbon Arc (CAC-A)

Single weld mode3/8-inch (9.5 mm) carbonsDual weld mode1/4-inch (6.4 mm) carbons

Heavy IndustrialApplications

Pipe WeldingMechanical Contractor

ConstructionRepair

Issued Sept. 2014 Index No. ED/

Welder/generator is warranted by Miller for 3 years, parts and labor.Engine is warranted separately by engine manufacturer.

Output Range Single weld mode CC: 40800 A, CV: 1440 VDual weld mode CC: 20400 A, CV: 1440 V

Generator Output Rated at 104F (40C)

Base model 5500 watts peak, 4000 watts continuousDeluxe model adds 3-phase, 27,000 watts peak, 20,000 watts continuous1-phase, 15,000 watts peak, 12,000 watts continuous

Multi-arc welding is better than ever!One dependable engine with two premiumpipe-quality arcs, allow operators to workindependently of each other with no arcinteraction. Full multiprocess capability

provides the best Stick, MIG, Flux-Coredand TIG performance available. Multi-operator welding was never easier, simpleror more versatile. Its a one-of-a-kind,go-anywhere engine drive.

The professional welders choicedesigned with the professional in mind,the Big Blue 700X Duo Pro is the best forarc performance, ease of use and reliability.

Double the amperage output. Deluxemodels have a parallel switch thatcombines both independent outputs toa single side. This provides a safe and

easy way to run large electrodes, Studweld or Carbon Arc gouge.

Increase profits with this multi-arcmachine by completing your mostdemanding jobs in half the time comparedto conventional engine-driven welders.With two arcs in one engine drive, fewermachines are required for a job.

Thermal overload protection preventsmachine damage if the duty cycle isexceeded or airflow is blocked.

Low OCV Stick (VRD) reduces the open-

circuit voltage to 15 volts when the weldingpower source is not in use. This feature isnow built in for increased operator safetywithout compromising arc startperformance.

Heavy-duty low-speedindustrial diesel engineis designed to operate over

10,000 hours before the first basicoverhaul. Backed by worldwide supporand service.

Meter maintenance displays Fuel gauge Hour meter function Oil change interval High coolant temperature and

low oil pressure shutdowns Low fuel shutdown engine shuts

down before system runs out of fuel,making restarts easy.

Independent generators provide theflexibility, dependability and reliabilityyou need to get the job done right. One5500-watt-peak/4000-watt-continuoussingle-phase generator is fully independent of weld output. 5500 watts of powis available anytime the engine is runnieven while welding at 700 amps! Thesecond generator has 27,000 watts peaand 20,000 watts continuous available your high power needs.

Standard features include Stick, MIG,Flux-Cored, Lift-Arc TIG, and digitalpreset weld meters, output contactor

control and automatic idle.

Deluxe model includes parallel switch,three-phase auxillary generator power,intake manifold heater and oil pan heate

International deluxe model shown.

Miller Electric Mfg. Co.An ITW Company1635 West Spencer StreetP.O. Box 1079Appleton, WI 54912-1079 USA

MillerWelds.comEquipment Sales US and CanadaPhone: 866-931-9730FAX: 800-637-2315International Phone: 920-735-4554International FAX: 920-735-4125

Big Blue700DuoPro Diesel Engine-DrivenWelder/AC Generator

Quick

Specs


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Engine Specifications (Engines warranted separately by the engine manufacturer.)

EngineBrand

DeutzD2011L04i

Features

EPA Tier 4icompliant

HP

48.6

Type

Direct-injectedfour-cylinder,air/oil-cooledindustrial diesel

Engine Speeds

Idle: 1350 RPMWeld: 1800 RPM

Sound Levels at Rated Output,23 ft. (7 m)

Idle: 67.9 dB (92.7 Lwa)Weld: 74.7 dB (100 Lwa)

Int'l CE Model:Idle: 62.9 dB, full load: 69.6 dB76.2 dB at one meter fromfront panel

Capacities

Fuel: 25 gal. (95 L)Oil: 9 qt. (8.5 L)Coolant: integrated oil

Automatic EngineShutdown

Low oil pressure,high coolant temperature,low fuel level

FUEL CONSUMPTION CURVE

DC WELD AMPERES AT 100% DUTY CYCLE

000.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

2.25

2.50

2.75

0 100 200 300 400 500 600

U.S.

GAL/HR.

IDLE

Single Arc

Dual Arcs

LITERS/HR.

Paralleled Arc

.95

1.90

2.84

3.79

4.73

5.69

6.62

7.57

8.52

9.46

10.41SIMULTANEOUS WELDING AND POWER

No Weld Output

200 A

300 A

400 A

500 A

600 A

700 A

800 A

Weld Amperes

Total Aux. Power Available (Watts)

1-Phase 3-Phase

16,000

11,500

9,000

5,500

4,000

4,000

4,000

4,000

20,000

19,000

13,500

8,000

4,000

3,200

2,400

1,500

Weld Mode/Process

CC/DC(Stick/TIG)

CV/DC(MIG/FCAW)

Output Mode

Separate(dual outputs)

Paralleled(combined)

Separate(dual outputs)

Paralleled(combined)

WeldOutputRange

20400 A(each side)

40800 A

1440 V(each side)

1440 V

Weld Output Ratedat 104F (40C)

300 A at 32 VDC, 100% duty cycle*(each side)400 A at 36 VDC, 40% duty cycle*(one side only)

500 A at 34 VDC, 100% duty cycle700 A at 24 VDC, 60% duty cycle

300 A at 29 VDC, 100% duty cycle*(each side)400 A at 34 VDC, 40% duty cycle*(one side only)

500 A at 34 VDC, 100% duty cycle700 A at 24 VDC, 60% duty cycle

Max.Open-CircuitVoltage

85 VDC

Generator Power OutputRated at 104F (40C)**

Peak: 5500 wattsContinuous: 4000 watts,1-phase, 34/17 A,120/240 VAC, 50/60 Hz

while weldingOptional GeneratorPower for Deluxe Models3-phase: 27 kW peak/20 kW continuous or1-phase: 15 kW peak/12 kW continuous

Dimensions

H: 43 in. (1092 mm)W: 28.5 in. (724 mm)D: 65.125 in. (1654 mm)

Int'l CE Model:

H: 42 in. (1067 mm)W: 35.5 in. (902 mm)D: 73.125 in. (1857 mm)

Add 7 in. (178 mm) toheights for exhaust pipe

Weight

Net: 1729 lb. (784 kg)Ship: 1761 lb. (799 kg)

Int'l CE Model:Net: 1809 lb. (821 kg)

Ship: 1873 lb. (850 kg)

Add 165 lb. (75 kg)when fuel tank is full

*Meets NEMA and IEC ratings. **Will operate either 60 Hz or 50/60 Hz power tools, lights, etc.

Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

Performance Data


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Function Guide

1. Weatherproof Lexan Nameplate is super durableand resists cracking and fading. Color coded forease of operation.

2. Operator Controls. Independent controls formulti-arc welding. A controls are for singleoperator and B controls are for a second operator.

3. Self-Calibrating Digital Weld Meters with

Fault Code Indication display preset or actualweld parameters.

4. Adjustable Arc Control adjusts DIG when processcontrol is in Stick mode and adjusts inductancewhen process control is in FCAW or MIG mode. Theamount of DIG determines how much amperage(heat) varies with Stick arc length. Inductancedetermines the wetness of the weld puddle.

5. Amperage/Voltage Adjust Control

6. Hot Start provides positive Stick electrode startsfor easy starts on all electrodes types and it alsoworks great for bead tie-ins.

7. Great FCAW/MIG Performance and Arc Starts

make the Big Blue 700X Duo Pros arc best in itsclass. Easy to run all wires from .023-inch solidwires to large diameter 5/64-inch flux-cored wires.

8. Lift-Arc TIG with Auto-Stop. See pg 4 for benefits.

9. Standard 14-Pin Receptacle for simple connectionof remote controls and wire feeders. IncludesAuto Remote Sense which automaticallyswitches from panel to remote amperage/voltage(A/V) control with remote connected. Eliminatesconfusion of a panel/remote switch.

10. Weld Output Terminals

11. Separate/Parallel Switch (only available onDeluxe Model).

Use switch to select singleoperator mode (A) or dual operator mode (A/B).

12. Meter Maintenance Displays show fuel level,engine hours, oil change interval and hi temp/low pressure/low fuel shutdown information.

13. Engine Oil Pressure Gauge. Engine stops ifpressure is below 22 PSI (1.5 bar).

14. Engine Coolant Temperature Gauge. Enginestops if temperature exceeds 284F (140C).

15. Glow Plugs assist in cold weather starting.(Standard on Deluxe models.)

16. Engine Control Switch is used to start engine andthen select between Auto Idle and High Speed Lock.

10

11

2

3

4

5

7

6

9

1

8

International Deluxe Model Receptacles and Circuit Breakers17. 20 A, 120 V Receptacles with Ground Fault

18. 120 V Circuit Breaker and 240 V Earth Leakage Circuit Breaker

19. 32 A, 400 V Three-Phase Receptacle(For matching plug, order #255 421.)

20. 30 A, Three-Phase Circuit Breaker

21. 120 and 240 V Circuit Breakers

22. 16 A, 120/240 V Receptacles(For matching plugs, order #255 419 for 120 V and #255 416 for 240 V.)

USA Deluxe Model Receptacles and Circuit Breakers23. 50 A Circuit Breaker

24. 50 A, 120/240 V Receptacle (For matching plug, order #119 172.)

25. 50 A, 240 V, Three-Phase Receptacle(For matching plug, order #254 140.)

26. 20 A, 120 V Receptacles with Ground Fault

27. 20 A, 120 V Circuit Breakers

28. 20 A, 240 V Receptacles

29. 20 A, 240 V Circuit Breaker

USA Deluxe Model Receptacles and Circuit Breakers

International Deluxe Model


68/884

Rigorous Testing for Tough,

Real-World ConditionsTo prove our machines go to thelimit, Miller industrial engine drivesare put to the test in very extremeenvironmental conditions.

Airborne dust and sand.Critical components are exposedto abusive airborne particles in aspecial testing chamber for weeks,helping make sure theyll operatewhile facing extreme levels of dirt,dust or sand on the jobsite.

Humidity and corrosion.Inside our Houston testing room,critical components are subjectedto extended moisture and corrosive

salt exposure to ensure theyll run even when exposed to humidclimates, corrosive coastal environments, and driving rain.

Temperature extremes. Miller industrial engine drives are testedto ensure performance in scorching heat. All Miller engine-drivenmachines are weld rated at 104 degrees Fahrenheit, but actual tests areconducted up to 122 degrees Fahrenheit to assure peak performance.

Jobsite/over-the-road abuse. Miller industrial engine drives areshaken for hours on transportation bed simulators, subjected to severevibration, and test-dropped and jerked to ensure theyll withstand thestresses that can shut down competitive machines.

Continuous operation. Miller industrial engine drives run day andnight, in all weather conditions, to assure theyll perform withoutinterruption in the field.

Superior Circuit Board DesignOur critical circuit boards are engineered to carry low powerand lowheatto reduce thermal stress and minimize expansion and contraction.In contrast, our competitors boards carry high powerand high heat,

making them more vulnerable to failure.

What Makes Miller

Industrial Engine Drives So ?

The Vault Makes Upgrading to Miller CC/CV

Units Worry-FreeConcerns with circuit board reliability have resulted in some operatorssteering clear of CC/CV welder/generators even though they offer asuperior arc and multiple welding processes. Miller circuit boardreliability isnt a concern since all Big Blue multiprocess industrial enginedrives feature the Vault.

Created out of two aluminum halves sealed with silicone, as well aswatertight harness connections, the Vault provides a clean circuit board

environment, protecting the electronicsand controlling outputin heavy industrial applications. No other competitor protects theirelectronics with a sealed vault, leaving critical circuit boards exposed toharsh elements that can disrupt the machines electronics, and therefore,its operation.

Why Industrial Engine

Drive Customers

Choose MillerThe ultimate test of Miller reliabilityis how it performs in the field. Readstories demonstrating our superiorreliability at MillerWelds.com.

ARC STARTwith Lift-Arc

Lift at any angleTouch or scratch

Shieldinggas

Shieldinggas

Arc

Workpiece

ARC ENDwith Auto-Stop

While welding

Shieldinggas

Arc

For Auto-Stop, lift up to terminate arc

Arc endswithout

flare

Move backdown to

maintain gascoverage

Lift upuntil arc

ends

Workpiece

Eliminates need fora remote control

Maintains shieldinggas coverage

Eliminates tungstenand workpiececontamination

Eliminates unwantedarc strikes outsidethe weld area

Reduces oreliminatessticking

Reduces oreliminateselectrode/workcontamination

Low open-circuit voltage

Lift-ArcTIG with Auto-Stop


69/88

Genuine Miller

Accessories

Adapter Cord, Full KVA #300 517 FieldNEMA 14-50P to NEMA 6-50R. Adapts enginedrive 120/240 V plug to common Millermatic

and Spectrum 240 V plug.

Full KVA Plug Kit Field#119 172 1-Phase,120/240 VAC, 50 A plug(NEMA 14-50P)

#254 140 3-Phase,240 VAC, 50 A plug(NEMA 15-50P)

International Plugs Field#255 419 1-Phase,120 VAC, 16 A plug

#255 416 1-Phase,240 VAC, 16 A plug

#255 421 3-Phase,

400 VAC, 32 A plug

Cold Weather Starting Kits* Field#195 307 12 V intake manifold heater.#195 086 120 V oil pan heater element.*For extreme cold weather both starting aids can beused in conjunction. These aids are standard onDeluxe Model.

Engine Filter Kit #246 988 FieldIncludes all filters required for proper enginemaintenance. Oil filter, primary and secondaryfuel filter, and primary air filter.

Spark Arrestor Kit

#195 012 FieldPrevents particlesfrom leaving themuffler that could

potentially start a fire. Mandatory whenoperating on California grasslands, brush, orforest-covered land, and in all National Forests.For other areas, check your state and local laws.Meets U.S. Forest Service standard 5100-1B.

FA-1D Lockable Flame ArrestorFuel Cap #043 947 FieldFuel cap can be padlocked toprevent vandalism. A built-in flamearrestor prevents flames or sparksfrom entering the fuel tank.

Vandalism Lockout Kit#399 802 FieldLockable hinged steelpanels cover and protectname plate gauges andignition switch (padlockincluded). Also includesengine compartmentdoor lock and key.

Cable Holder#043 946 FieldSaddle-bag-style cableholder. Convenient wrap-around storage of coiledcable for transportation.Stores 100 feet of 2/0 cableon each side.

Note: For best results do not weld when cable is coiled!Protective cover cannot be used with cable holder.

Protective Cover#194 683 FieldBlue water-resistantcanvas cover resistsstains and mildew, andprotects the finish ofyour welder.

Note: Protective cover cannot be used with cable holder.

Stick (SMAW) Welding

Weld Leads

2/0 Stick Cable Set, 50 ft. (15 m) #173 851Consists of 50-foot (15 m) 2/0 electrode cablewith holder, and 50-foot (15 m) work cable withclamp. 350 A, 100% duty cycle.

2/0 Stick Cable Set, 100/50 ft. (30.5/15 m)#043 952Consists of 100-foot (30.5 m) 2/0 electrodecable with holder, and 50-foot (15 m) workcable with clamp. 300 A, 100% duty cycle.

MIG (GMAW) or Flux-Cored (FCAW)

SuitCase X-TREME 8VS Wire Feeder#951 593

SuitCase X-TREME 12VS Wire Feeder#951 592

Lightweight, voltage-sensing wire feedersinclude secondary contactor, gas valve,drive roll kit, and Bernard PipePro Dura-Flux

gun with dual schedule switch.

SuitCase 12RC Wire Feeder #951 580Lightweight and flexible enough to run a varieof wires up to .062-inch diameter. Includesremote voltage control and drive roll kit. See LIndex No. M/6.5.

MIG (GMAW)/Flux-Cored (FCAW) GunsSee Lit. Index Nos. AY/15.0, AY/16.0 andAY/17.0 for Miller guns. See Bernard Lit. IndNo. SPEC DFP-1.2 for PipePro Dura-Flux gun

TIG (GTAW) Welding

Dynasty 200 SeriesFor premium portable AC/DTIG arc quality.See Lit. Index No. AD/4.8.

HF-251 Series #042 388HF-251D-1, 115 VACHig

SoLuciOnes Optimas

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