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MAGNATECH 609AF0A0C0, Operating And Maintenance Instruction Manual, Page: 1 / 50

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MAGNATECH 609AF0A0C0 Operating And Maintenance Instruction Manual Download Page 1

 

 

6 Kripes Road - PO Box 260 - East Granby, CT 06026 USA 

Fax: (860) 653-0486 

 

E-Mail: info@magnatech-lp.com 

Phone:  (860) 653-2573 

 

Web: 

www.magnatech-lp.com

 

 

 
 
 
 
 

Operating and Maintenance 

Instruction Manual 

 

For 

 

Pipeliner II Model 609A 

Orbital Weld Head 

- Wire Feed on Floor (WFOF) version 

- Wire Feed on Hand (WFOH version 

- Wire Feed Push-pull (WFPP) version 

 
 
 

For Use With 

MPS 4000 Power Source &  Model 712 Controller 

(See Separate Manual) 

 
 
 

Rev 01-14-2009

Summary of Contents for 609AF0A0C0

Page 1: ...2573 Web www magnatech lp com Operating and Maintenance Instruction Manual For Pipeliner II Model 609A Orbital Weld Head Wire Feed on Floor WFOF version Wire Feed on Hand WFOH version Wire Feed Push...

Page 2: ...revention 3 6 Compressed Gas Cylinder Handling 3 7 Equipment Warning Labels 3 8 Additional Safety and Health Information 4 0 WARRANTY POLICY SUPPORT 11 4 1 General 4 2 Support 5 0 SPECIFICATIONS 16 5...

Page 3: ...ectrical Connections 12 4 Prevent Torch Cable Wrap Up 12 5 Observe Torch Position Before Oscillating or Centering Torch 12 6 Always Stop Motors Before Reversing 12 7 Abrasive Grinding Dust Will Cause...

Page 4: ...procedure development The appropriate interconnect cables and accessories are provided When the equipment is first received we recommend that a quick inventory is taken of all items using the packing...

Page 5: ...or mounted Feeder with Pneumatic Mounting 1 Weld Head 103951 P 1 Torch Cable 103090 15 P 1 Accessories Kit 104017 1 1 Dual Regulator 38416 1 Operation Manual Manual 1Pipeliner II Weld Head Model 609 6...

Page 6: ...ssories Kit 104017 1 1 Dual Regulator 38416 1 Operation Manual Manual 1Pipeliner II Weld Head Model 609A 609AGECW9 Pneumatic Mounting 2 Roll Head Mounted Feeder 50 15m Torch Cable w Pendular Oscillato...

Page 7: ...serious injury or death and possible damage to other equipment if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experie...

Page 8: ...correct mating receptacles Check ground for electrical continuity before using equipment 3 3 2 Torch and Work Cables Inspect cables often for damage to the insulation Replace or repair cracked or worn...

Page 9: ...irculation especially at floor level Do not permit anyone to view the arc unless he uses a correct hand shield or helmet 3 5 TOXIC FUME PREVENTION Breathing the fumes created during welding or cutting...

Page 10: ...ver Keep temperature below 130 degrees F 3 6 2 Pressure Regulators Use the correct regulator for the gas and cylinder at hand Remove any suspected faulty regulator and return to manufacturer s service...

Page 11: ...on Batterymarch Park Quincy MA 02269 3 8 7 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS Order from the Compressed Gas Association 1235 Jeff Davis Highway Arlington VA 22202 3 8 8 CS...

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Page 14: ...be accomplished at the factory and Magnatech assumes no obligation to perform warranty service at a customer s facility If requested Magnatech shall supply warranty parts for customer installation bu...

Page 15: ...aster Pipemaster and Pipeliner systems are intended to be used SOLELY for GTAW or GMAW FCAW orbital welding applications Any other use is deemed to be not for the intended purpose and the manufacturer...

Page 16: ...roduct Name S N Product Name S N Product Name S N Product Name S N Company Name Company Address Dealer Date Purchased Individual Purchasing Name Address Phone Fax E Mail Individual to Be Contacted abo...

Page 17: ...14 Magnatech Ltd Partnership P O Box 260 East Granby CT 06026 Magnatech Limited Partnership Attn Sales Dept P O Box 260 East Granby CT 06026 Affix Postage...

Page 18: ...t Exec Asst Ext 10 Europe Middle East India Tel 31 321 38 6677 Fax 31 321 31 4165 E Mail info magnatech europe com W Wijnholds Cell 31 653 32 5818 Ralph Wijnholds Cell 31 653 548891 B Spare Parts Brya...

Page 19: ...Size 0 8 0 9 1 0 1 2mm 030 035 0 040 045 Other sizes available Speed Capability 0 22m min 0 722 min Spool Size 4 5 5 kg 10 lb Wire Feed on Head or 12kg 25lb Wire Feed on Floor and Push Pull OSCILLATI...

Page 20: ...66 7 cm 26 7cm 36 8cm 14 4 kg WFOH 26 25 10 5 14 5 31 75 lbs 1 Center of oscillation stroke 2 Center of vertical stroke 3 Weight without wire spool WFOH Includes 1 6 kg 3 5 of Torch Cable Weight Parti...

Page 21: ...ble wrap around the work piece 6 2 Install and connect electrical service to the MPS 4000 Power Supply and Model 712 according to the instructions in the separate manual provided 6 3 For the head moun...

Page 22: ...Controller 7 2 ARC GAP CONTROL TORCH PROXIMITY CONTROL The contact tip to work piece distance is manually adjustable via a JOG switch on the Remote Control Pendant The vertical correction motion is pr...

Page 23: ...system consisting of the powered V rollers driving against the two V belts which are attached to the guide ring surface U S Patent No Guide Rings consist of two identical half sections which quickly...

Page 24: ...ow the tractor may hesitate or stall as the rollers cross the joint This can be corrected by careful use of a hammer or heavy pliers 8 2 INSTALL WELD HEAD ON GUIDE RING 8 2 1 The Pipeliner II Head is...

Page 25: ...provides a preset pressure at a fitting to which the pneumatic hose is attached A secondary pressure regulator flow meter provide standard control of torch shielding gas American Bottle Threading Orde...

Page 26: ...ications but must be removed for ID welding 8 3 ADJUST HEAD FOR NEW GUIDE RING SIZE 8 3 1 If necessary change location of limit pins see Section 8 2 8 3 2 If necessary install or remove adaptors see S...

Page 27: ...24...

Page 28: ...5 2 WELD HEAD SET UP PIPELINER IIC 8 5 2 1 Explain guide ring function 8 5 2 2 Demonstrate guide ring installation 8 5 2 3 Special attention to gap spacing at dovetail joint being equal and distance a...

Page 29: ...come familiar with each parameter and adjustment 8 5 3 WELDING Note It is recommended that the initial welding demonstration be carried out by the instructor using developed parameters Perform demonst...

Page 30: ...alloy and how these choices select a preferred shielding gas J Explain the synergic concept and that this operates in both Standard and Pulsed modes Explain Arc Trim K Explain Power Boost function if...

Page 31: ...is necessary to use an oversize Guide Ring and spacers adaptors to create additional air spaces between the Guide Ring weld Head and hot pipe surface We recommend using a Guide Ring which is oversized...

Page 32: ...existing square tubes or subsequently remove them 10 2 To allow use of a standard guide ring on a special non standard size of pipe While Magnatech has the capability of engineering a guide ring for...

Page 33: ...maller in size and will use the rectangular tube The case with either the square or rectangular tube where the flat metal shim is required because of an intermediate size To order adaptor kits separat...

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Page 35: ...DING M 8 CONTACT TIPS MUST BE USED WITH M 8 CONTACT TIP HOLDER ETC WIRE CONDUIT MAGNATECH P N DESCRIPTION 101664 45 2 160 Tube Wire guide Outlet 0 35 045 9mm 1 1mm x 16 41cm 101664 45 1 030 Tube Wire...

Page 36: ...nd on exposed skin 12 3 CHECK ELECTRICAL CONNECTIONS Be sure that all external electrical connections are clean and tight In particular the ground to work clamp must make a good electrical contact to...

Page 37: ...ld Head and Pendant Grinding dust is extremely abrasive and should not be allowed to contact weld Head and controls 12 8 BE CAUTIOUS ABOUT HEAT DAMAGE TO HEAD Remove the weld Head from preheated pipe...

Page 38: ...epeat the weld changing only one parameter at a time Always develop a procedure with the goal of making it as tolerant as possible to weldment variations 13 1 GENERAL COMMENTS ON WELD PROCEDURE DEVELO...

Page 39: ...on 2 Shorten arc length 3 Clean weld joint area 4 Reduce electrode wire stick out 5 Increase oscillation width and dwell 6 Reduce travel speed Dirty welds 1 Maintain gas nozzle closer to weld puddle 2...

Page 40: ...37 Undercutting 1 Reduce power 2 Reduce welding speed 3 Shorten arc length...

Page 41: ...may freeze too rapidly trapping escaping gas moisture and causing worm tracks on the weld surface The electrode stick out should be approximately 25mm 1 or more from the contact tip Many welders are...

Page 42: ...ects of surface contaminants clean the area with a grinder before welding Another way to reduce porosity is to avoid weaving If the correct size flux cored electrode is utilized weaving is not require...

Page 43: ...40 Remote Pendant...

Page 44: ...____________________________________________________________ CONTACT TIP SIZE FLUSH EXTENDED___________________________________________________ CONTACT TIP SIZE STD TAPERED____________________________...

Page 45: ...age Range Used _________________________________________________________________ Lead or Lag Angle ______________ Shield Gas Composition ______________________________________________________________...

Page 46: ...43 14 0 ELECTRODE EXTENSION OFTEN NEGLECTED WHEN USING SELF SHIELDED CORED WIRES...

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Page 49: ...46 15 0 PREVENTING THE EFFECTS OF MOISTURE CONTAMINATION OF FLUX CORE WIRE...

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