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Pipeliner Pro Welding Machine

The Magnatech Pipeliner Pro is a mechanized orbital GMAW/FCAW pipe welding system, engineered for high-performance applications. It integrates advanced Fronius technology through the TPS400i Digital Inverter Power Source, offering exceptional welding control and reliability.

System programming and parameter management are facilitated via the Magnatech Pipeliner Digital Programmer (PDP), which features a 10.4-inch color touchscreen interface and a wired remote pendant for precise, real-time adjustment during welding operations.

The complete Pipeliner Pro welding machine consists of:

  • The Pipeliner Pro welding head Model 616 (Part No: 6160HEB000)
  • The digital inverter power source TPS400i (Part No.: TPS400i)
  • The welding head controller Model 716 (Part No.: 7160GMB0M0)
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Product Advantages

PIPELINER PRO WELDING HEAD 616

The Pipeliner Pro welding head 616 operates with a 400A water-cooled torch and is mounted on the field-proven, rugged tractor. Interchangeable guide rings provide mounting on the pipe, allowing the Pipeliner Pro to cover a broad size range. It can be used for FCAW uphill welding, GMAW high-speed downhill welding with narrow groove bevel geometry, and also offers root pass welding capability. It incorporates pendular and straight-line torch oscillation.

The rapid repositioning system allows for quick and stable torch recentering. Up to 4″ (101.6 mm) of motion.

WELDING HEAD MOUNTING/ROTATION

  • Patented pneumatic clamping system delivers fast, secure, and tool-free installation.
  • Powered by compressed gas, it ensures precise, repeatable clamping while reducing setup time and enhancing safety.
  • Clutch system allows the head to be positioned on the pipe very quickly.

The Pipeliner Pro welding head 616 comes with a starter kit of required consumables (gas nozzle, gas diffuser, tip holder, contact tip, isolation gasket) as well as a tool kit to operate the machine.

Everything is securely enclosed in a robust, heavy-duty storage case, ensuring optimal protection and easy portability.

DIGITAL INVERTER POWER SOURCE TPS400i

The TPS400i is a digital inverter power source for GMAW/FCAW process welding applications. The TPS400i provides synergic control of electrode speed and power output – the welder has only to change electrode speed, and the power supply will adaptively change the output parameters to maintain a stable process.

FEATURES

  • LSC (Low Spatter Control) with advanced root programs
  • Penetration and arc length stabilizer
  • Root pass capability
  • Pulsed/spray modes
  • Multi-pass pipe welding
  • Auto-ranging power input
  • Pre-set programs for standard materials
  • Custom programs for special alloys

Also included:

  • Wire feeder operating wire spool
    from 10 to 44 lbs (5 to 20 kg)
  • Water cooler with flow sensor
  • Cart with bottle rack

PENETRATION STABILIZER

Intelligent wire control maintains consistent current and penetration despite variations in stick-out. This ensures a significantly more stable arc and uniform penetration throughout the process.

ARC LENGTH STABILIZER

By reducing the arc length, the arc length stabilizer in the spray arc with LSC Universal enables stable and regular short circuit behaviour, with the arc always being maintained at the same short length. There is no need for the user to carry out manual readjustment in the event of external interference (e.g. caused by changing welding torch position, material misalignment, changing pipe thicknesses or uneven heat extraction).

LOW SPATTER CONTROL (LSC)

During critical phases of the process, such as short-circuiting or droplet detachment, the current is rapidly decreased to stabilize the arc and minimize spatter generation.

Highlights & benefits

  • Minimal spattering
  • Reduced heat input with increased deposition rate during root pass welding
  • High welding speed
  • Arc control stabilizers for consistent penetration and arc stability
  • Enhanced arc performance and process reliability
  • Consistent weld quality and arc stability, even with extended torch leads
  • No need for external sensor integration compared to competitor systems

Model 716 controller AND PIPELINER DIGITAL PROGRAMMER

The Pipeliner Digital Programmer (PDP) enables touchscreen programming of all weld head parameters for up to 9 weld passes. Designed for seamless integration with the TPS400i Power Source, it combines intuitive, icon-based operation with rugged hardware ideal for field use.

FEATURES

PIPELINER DIGITAL PROGRAMMER

  • 10.4” HD color touchscreen, side-mounted on the power source
  • Rapid and user-friendly weld parameter adjustment via icon-based interface
  • Test mode enables the operator to configure settings without initiating an arc
  • Password protection for program security
  • USB port for fast, easy software updates
  • Steel enclosure with gasketed lockable cover

ADVANCED PROGRAMMING TOOLS

  • Run pendant allows limited override for flexibility and safety
  • Stored pre-set programs optimized for common materials
  • Custom program development available

CONTROLLER CAPABILITIES

  • Input power: 230 VAC, 1-phase
  • Integrated compatibility: designed for direct integration with the Fronius TPS400i power source

Specifications

PIPELINER PRO WELDING HEAD 616

Required Accessories

The guide rings serve to securely position the welding head around the pipe, enabling precise and stable rotation during operation. This rotation is achieved through a friction drive system composed of powered V-rollers that engage with two V-belts mounted on the surface of the guide ring.

Each guide ring is made up of two identical hinged half-sections, allowing for easy installation and removal. A total of 38 standard sizes are available to accommodate various pipe diameters.

For applications involving pipes smaller than the intended guide ring diameter, adaptor foot kits can be used to ensure proper fit and functionality (see section: Adaptor Foot Kits).

PART NO. DESCRIPTION
103040-00663 Guide ring, 6.000″ pipe, 6.625″/ 168.30 mm
103040-00863 Guide ring, 8.000″ pipe, 8.625″ / 219.10 mm
103040-01075 Guide ring,  10.000″ pipe, 10.750″ / 273.00 mm
103040-01275 Guide ring, 12.000″ pipe, 12.750″ / 323.9 mm
103040-01400 Guide ring,  14.000″ pipe, 14.000″ / 355.60 mm
103040-01600 Guide ring,  16.000″ pipe, 16.000″ / 406.40 mm
103040-01800 Guide ring,  18.000″ pipe, 18.000″ / 457.00 mm
103040-02000 Guide ring,  20.000″ pipe, 20.000″ / 508.00 mm
103040-02200 Guide ring,  22.000″ pipe, 22.000″ / 559.00 mm
103040-02400 Guide ring,  24.000″ pipe, 24.000″ / 610.00 mm
103040-02600 Guide ring, 26.000″ pipe, 26.000″/ 660.00 mm
103040-02700 Guide ring,  27.000″pipe, 27.000″ / 686.00 mm
103040-02800 Guide ring,  28.000″pipe, 28.000″ / 711.00 mm
103040-03000 Guide ring,  30.000″ pipe, 30.000″ / 762.00 mm
103040-03200 Guide ring, 32.000″ pipe, 32.000″ / 813.00 mm
103040-03400 Guide ring,  34.000″ pipe, 34.000″ / 864.00 mm
103040-03600 Guide ring,  36.000″ pipe, 36.000″ / 914.00 mm
103040-03800 Guide ring,  38.000″ pipe, 38.000″ / 965.00 mm
103040-04000 Guide ring,  40.000″ pipe, 40.000″ / 1016.00 mm
103040-04200 Guide ring, 42.000″ pipe, 42.000″ / 1067.00 mm
103040-04400 Guide ring,  44.000″ pipe, 44.000″ / 1118.00 mm
103040-04600 Guide ring,  46.000″ pipe, 46.000″ / 1168.00 mm
103040-04800 Guide ring,  48.000″ pipe, 48.000″ / 1219.00 mm
103040-05000 Guide ring, 50.000″ pipe, 50.000″ / 1270.00 mm
103040-05200 Guide ring,  52.000″ pipe, 52.000″ / 1321.00 mm
103040-05300 Guide ring, 53.000 ” pipe, 53.000″ / 1346.00 mm
103040-05400 Guide ring, 54.000″ pipe, 54.000″ / 1372.00 mm
103040-05600 Guide ring, 56.000″ pipe, 56.000″ / 1422.00mm
103040-05800 Guide ring, 58.000″ pipe, 58.000″ / 1473.00 mm
103040-06000 Guide ring,  60.000″ pipe, 60.000″ / 1524.00 mm
103040-06200 Guide ring,  62.000″ pipe, 62.000″. / 1575.00 mm
103040-06500 Guide ring,  65.000″ pipe, 65.000″ / 1651.00 mm
103040-06600 Guide ring,  66.000″ pipe, 66.000″ / 1676.00 mm
103040-06800 Guide ring,  68.000″ pipe, 68.000″. / 1727.00 mm
103040-07200 Guide ring, 72.000″ pipe, 72.000″. / 1829.00 mm
103040-07600 Guide ring,  76.000″ pipe, 76.000″ / 1930.00 mm
103040-07800 Guide ring,  78.000″ pipe, 78.000″ / 1981.00 mm
103040-08400 Guide ring, 84.000″ pipe, 84.000″/ 2134.00 mm

Optional Accessories

Adaptor Foot Kits 

Adaptor foot kits may be used with larger guide rings on smaller pipe diameters when preheating is required, preventing overheating of the welding head. They are necessary to reach pipe diameters smaller than 6.625“ / 168.30mm (down to 4.5” / 114.30mm).

Three types of adaptors can be screwed simply to the guide ring:

  • 1″ (25.4 mm) adaptor square tube
  • 2″ (50.8 mm) adaptor square tube
  • .13 – .5″ (3.3-12.7 mm) adaptor solid bar
    (Magnatech can provide these in any dimension)
PART NO. DESCRIPTION
103070-XXXX* Adaptor foot set
*The quantity of feet necessary for a complete set is defined by the guide ring size. Contact us for more information.

FLX-TRACK™

In addition to welding pipework, the Pipeliner is also used for ID and OD welding on larger tanks, vessels, and ductwork.

  • Flexible track allows mounting on complex curved surfaces.
  • Standard 2.3 m (7.5’) track sections. Multiple sections can be bolted together for longer lengths.
  • Magnetic or vacuum attachments are available depending on the pipe material.
PART NO. DESCRIPTION
SK2460-090 Flex-Track assembly, 90″ / 2,286 mm
SK2474-1 Magnet assembly large diameter, Flex-track
104294-1 Vacuum cup kit  90″ Flex Track

Consumables

Expendable Parts Kit

The expendable parts kit includes all consumables required to operate the Pipeliner Pro welding head 616: tip holder, gas diffuser, gas nozzle, contact tip, wire liner, and feeder roller.

PART NO. DESCRIPTION
EXPEND/616 Expendable parts kit, Model 616

Technical Specifications

Pipe (tube) size range 4.5 – 84″ / 114.30 – 2,134 mm
Cable length 25″ / 7.6 m standard
Filler wire module: Wire size 0.030″, 0.035″, 0.040″, 0.045″, 0.062″/ 0.8, 0.9, 1.0, 1.2, 1.6 mm
Filler wire module: Max. speed capability  100 IPM / 2540 mm/min.
Filler wire module: Spool size 5 to 20 kg (10 to 44 lbs)  (wire feeder supplied with the power source)
Oscillation module: Max. oscillation stroke amplitude 2″ / 50.8 mm
Oscillation module: Max. oscillation speed 100 IPM / 2540 mm/min.
Oscillation module: Oscillation dwell 0 – 1 second
Oscillation module: Cross seam adjustment 3″ (76.20 mm) course adjustment
Arc gap control module: Max stroke amplitude 2.625″ / 66 mm (motorized)
Arc gap control module: Max speed 60 IPM / 1520 mm/min.
Torch propulsion module: Technology Poly-Track® propulsion (patented)
Torch propulsion module: Speed 30 IPM / 0 – 762 mm/min. Higher speed motors
Travel Direction Switch selectable (on head)
Water-cooled torch 300 A continuous. Uses standard torch components
Torch adjustment capability: Torch lead/lag adjustment ± 30 degrees (manual)
Torch adjustment capability: Torch tilt adjustment ± 15 degrees (manual)

Dimensions/weights

Axial Length 1 15.25″ 387 mm
Minimum Radial Clearance 2 9.75″ 248 mm
Overall Width 12″ 305 mm
Weight 9.8 kg 21.5 lbs.

DIGITAL INVERTER POWER SOURCE (TPS400i,) AND WELDING HEAD CONTROLLER (MODEL 716)

Technical Specifications

PROCESS CAPABILITY GMAW/ GMAW – pulsed (optional) / FCAW / LSC (low spatter control) + advanced root program
Power source DIGITAL INVERTER POWER SOURCE (PART NO. TPS400i)
Output rating 400A @ 40% duty cycle, 320A @ 100% duty cycle
Input power Volts 200/230/400/460 12.7 kVA frequency: 50/60 Hz
Autoranging power input 230v / 480v tri-phase eliminates all internal modifications
Maximum output circuit voltage 75V
Degree of protection IP23
Applicable electrical standards IEC 974-1 (IP-23S), CSA, EMC 89/336/EEC, EN 60 974-1
Water Circulation:
Pump Centrifugal
Cooling capacity 2000W (at 20°C/68F)
Maximum delivery capacity/pressure 3.5 liter/min at 4.2 bar
Coolant volume 5.54 liter
Degree of protection IP23
Wire Feeder:
Drive type 4 rolls (various groove geometries available)
Wire diameter 0.03 – 0.062” (0.8 – 1.6 mm)
Wire feed speed 20 – 866 ipm (0.5 – 22 m/min)
Degree of protection IP23
CONTROLLER MODEL 716  WELDING HEAD CONTROLLER (PART NO. 7160GMB0M0)
Input Power 115/230 vac, 1 phase input
Pendant cable length 7.6 m (25’). Extension cables available
Degree of protection IP23 (excluding remote pendant)

Dimensions/weights

Dimensions (D x W x H) 24″ x 43″ x 64″ 610 x 1092 x 1625 mm
Weight 330 lbs 150 kg

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Parts and Accessories

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