OPERATION MANUAL for External Longitudinal Seam Welders

Transcription

1 OM-LW OPERATION MANUAL for External Longitudinal Seam Welders March 2013 Effective with Serial Number IMPORTANT Read this manual carefully before installing, commissioning or operating this product. Jetline Engineering, 15 Goodyear Street, Irvine, CA Telephone: (949) Fax: (949) Web Site:

2 Longitudinal Seam Welders - Models LWI, LWP, LWS, LWX - ii -

3 Longidudinal Seam Welders - Models LWI, LWP, LWS, LWX LIMITED WARRANTY Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects in material and workmanship for the period of one (1) year, provided that the equipment is installed and operated according to instructions. Jetline Engineering s obligation under this warranty is expressly limited to replacing or repairing any defective part or correcting any manufacturing defect without charge during the warranty period, if Jetline s inspection confirms the existence of such defects. Jetline s option of repair or replacement will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of any kind will be allowed. The warranty period begins on the date of sale to the original-purchase user of the equipment. Jetline Engineering will not be liable for any loss or consequential damage or expense accruing directly or indirectly from the use of equipment covered by this warranty. This warranty supersedes all previous Jetline warranties and is exclusive with no other guarantees or warranties expressed or implied. - iii -

4 Longitudinal Seam Welders - Models LWI, LWP, LWS, LWX NOTICE The installation, operation and maintenance guidelines set out in this manual will enable you to maintain the equipment in peak condition and achieve maximum efficiency with your welding operation. Please read these instructions carefully to become aware of every advantage. CAUTION Only experienced personnel familiar with the operation and safe practice of welding equipment should install and/or use this equipment. - iv -

5 Longidudinal Seam Welders - Models LWI, LWP, LWS, LWX Table of Contents Section I...1 Safety Precautions...1 A. Arc Welding...1 B. Electric Shock...1 C. Arc Rays...2 D. Fumes and Gases...2 E. Cylinders...2 F. Welding...3 G. Moving Parts...3 H. EMF Information...3 I. Principal Safety Standards...4 J. California Proposition 65 Warning...4 Section II...5 Introduction...5 Section III...7 Initial Inspection...7 Section IV...9 Specifications...9 A. Input Requirements...9 B. Carriage Speed Ranges...9 D. Chill Bar Selection - GTAW...12 E. Chill Bar Selection - GMAW...13 F. Distance Between Fingertips...14 G. Air Regulator Settings...14 Section V...15 Installation...15 A. System Operating Conditions...15 B. Mechanical Installation...15 C. Electrical Installation v -

6 Longitudinal Seam Welders - Models LWI, LWP, LWS, LWX Section VI...19 Theory of Operation...19 A. Mechanical Operation...19 B. Base Section...19 C. Mainstay...19 D. Mandrel...20 E. Tabletop...20 F. Track...22 G. Carriage Control...24 Section VII...25 Start-up and Operation...25 A. Initial Setup...25 B. Operation...25 Section VIII...27 Trouble Shooting...27 A. Fixture...27 A. GTAW Process...29 Section IX...33 Mechanical Maintenance...33 A. Adjustment & Replacement of the Clamping Fingers...33 B. Replacement of the Clamping Hoses...34 C. Replacement of the Mandrel...34 D. Adjustment of the Mandrel...36 E. Adjustment of the Track to the Insert...36 F. Vertical Track Adjustment...37 G. Horizontal Adjustment...37 H. Preventive Maintenance...38 Section X...39 Parts List vi -

7 Section I Safety Precautions WARNING A. Arc Welding Arc Welding can be hazardous. Protect yourself and others from possible serious injury or death. Keep children away. Pacemaker wearers keep away until consulting your doctor. In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed at the end of this section. Read and follow all Safety Standards. Have all installation, operation, maintenance and repair work performed only by qualified people. B. Electric Shock Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. When using mechanized wire feed, the wire, wire reel, drive roll housing and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. 1. Do not touch live electrical parts. 2. Wear dry, hole-free insulating gloves and appropriate body protection. 3. Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR (see Safety Standards). 4. Properly install and ground this equipment according to the operation manual and national, state and local codes. 5. Always verify the supply ground-check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. 6. When making input connections, attach proper grounding conductor first - doublecheck connections. 7. Frequently inspect input power cord for damage or bare wiring. Replace cord immediately if damaged - bare wiring can kill. 8. Turn off all equipment when not in use. 9. If earth grounding of the workpiece is required, ground it directly with a separate cable - do not use work clamp or work cable. 10. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. 11. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. 12. Wear a safety harness if working above floor level. 13. Keep all panels and covers securely in place. 14. Clamp work cable with good metal-tometal contact to workpiece or worktable as near the weld as practical

8 C. Arc Rays Arc rays can burn eyes and skin; noise can damage hearing; flying slag or sparks can injure eyes. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Noise from some processes can damage hearing. Chipping, grinding and weld cooling throw off pieces of metal or slag. 1. Use approved ear plugs or ear muffs if noise level is high. 2. Use a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching. 3. Wear approved safety glasses with side shields. 4. Use protective screens or barriers protect others from flash and glare; warn others not to watch the arc. 5. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection where necessary. D. Fumes and Gases Fumes and gases can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 1. Keep your head out of the fumes. Do not breathe the fumes. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 3. If ventilation is poor, use an approved air-supplied respirator. 4. Read the Material Safety Data Sheets (MSDS) and the manufacturer s instruction for metals, consumables, coatings, cleaners, and degreasers. 5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch person nearby. 6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. 7. Do not weld on coated metals, such as galvanized, lead or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. E. Cylinders Cylinders can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. 1. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. 2. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. 3. Keep cylinders away from any welding or other electrical circuits. 4. Never weld on a pressurized cylinder - explosion will result

9 5. Use only correct shielding gas cylinders, regulators, hoses and fittings designed for the specific application; maintain them and associated parts in good condition. 6. Turn face away from valve outlet when opening cylinder valve. 7. Keep protective cap in place over valve except when cylinder is in use or connected for use. 8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. F. Welding Welding can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. 1. Protect yourself and others from flying sparks and hot metal. 2. Do not weld where flying sparks can strike flammable material. 3. Remove all flammables within 35 ft. (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. 4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. 5. Watch for fire, and keep a fire extinguisher nearby. 6. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWSF4.1 (see safety Standards). 7. Connect work cable to the work as close to the welding area as practical to prevent welding current traveling long, possibly unknown paths and causing electric shock and fire hazards. 8. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. G. Moving Parts Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. 1. Keep all doors, panels, covers, and guards closed and securely in place. 2. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary. H. EMF Information Considerations About Welding and the Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989):... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does - 3 -

10 not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions abut questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks. To reduce magnetic fields in the work place, use the following procedures: 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around the body. 4. Keep welding power source and cables as far away as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information. I. Principal Safety Standards Reference as applicable Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C National Electric Code, NFPA Standard 70 from National Fire Protection Association, Batterymarch Park, Quincy, MA Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 Sales Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA J. California Proposition 65 Warning This product contains chemicals, including lead, known to the state of California to cause cancer and birth defects or other reproductive harm. Wash hands after use

11 Section II Introduction Congratulations on your purchase of a Jetline Longitudinal Seam Welder. Its quality workmanship will bring many years of dependable service and consistent high quality seam welds. The Jetline seam welder uses the chill shunt principle of tooling to conduct heat away from the part and minimize burn-through, warping, or excessive distortion. Jetline seam welders are designed to clamp a part with a butt-joint type seam. A motorized carriage on which a torch is mounted welds the seam. Variables or factors that determine the design include type of material to be used, minimum and maximum material thicknesses, and type of weld process. The seam welder can be designed to handle a variety of shapes and sizes. Seam welders can accommodate part lengths from 3 inches to 40 feet (76 mm to 12 m), dependent on the model ordered. Prior to welding, the part is positioned on the mandrel insert, clamped, and is then welded in a stationary position. A welding torch is mounted to the side beam carriage with a torch holder and bracket. This allows the torch and carriage to traverse the entire length of the part while performing the weld. The clamping of the part ensures that the joint is aligned down the centerline of the machine. With the part on center and the torch mounted above the weld joint, in many applications the welding of a butt-joint becomes a simple operation without the necessity of tack welding prior to welding. Jetline longitudinal seam welders are comprised of several integral assemblies: a base/mainstay, mandrel, tabletop, track, carriage, and a control panel. See Figure 1. These assemblies combined create an efficient welding unit. The base is made of tubular steel and serves as the main support for the system. The mainstay houses all of the plumbing and electrical clamping control boxes. Attached to the mainstay is a mandrel on which is mounted an insert; this can be water cooled as an option. The tabletop is mounted to the top of the mainstay. This is where the hold down clamping fingers are mounted. Mounted directly on the tabletop are two or three track supports, depending on the welding length of the tabletop. These track supports hold up the main track assembly which extends the entire length of the tabletop. Riding on the track assembly is a motorized carriage. The control panel controlling the carriage speed and weld time is mounted to the carriage face thus making the Jetline longitudinal seam welder a well-integrated system

12 Track Support Carriage Track Pressure Gauge Mandrel Tape Switch Ground Lug Latch Base Mainstay Plug Figure 1 Longitudinal Seam Welder - 6 -

13 Section III Initial Inspection Upon receipt of the equipment, examine the shipping crate for freight damage. If the crate appears to have suffered major damage, the unit should be examined carefully for possible damage and/or possible misalignment in the track and mandrel. Although Jetline has packaged your equipment well, long and/or extremely rough shipping can have an adverse effect on the equipment. As a result, please spend a few extra minutes to insure that the assembly pieces are in good order. The crate in which the seam welder has arrived will have to be dismantled. Be careful to dismantle the equipment safely. Damage to the unit and personal injury can occur during unpacking, therefore follow all safety precautions. Your seam welder was thoroughly tested and verified it met specifications before shipping. After receipt, visual inspection of all adjustment points should be made. See Figure 1. If a cable carrier assembly was purchased as an option, the carrier may have been removed from the track and packed separately. Verify that it too has arrived in good condition before proceeding with its installation. The carriage assembly is normally shipped mounted on the track and requires only the removal of the temporary mounting bracket. If the seam welder has an optional riser (for larger diameters than standard) the carriage was removed before the seam welder was shipped. If this is the case, the carriage will be mounted on the crate deck next to the seam welder. Verify there is no apparent damage to it or to the equipment mounted to it. After this initial inspection is completed, installation of the longitudinal seam welder can begin. System is strapped down prior to crating. Lattice crate packing - 7 -

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15 Section IV Specifications A. Input Requirements Electrical (Standard): 115 Volts, Single Phase, 50/60 Hz. Electrical (Optional): 230 Volts, Single Phase, 50/60 Hz. Compressed Air: 80 PSI (5.6 kg / sq cm.) Air pressure will generate up to 5,000 lb/ft (74.4 kg/cm) of clamping force on the part. See the air regulator settings chart in this section to set the correct clamping pressure for the material thickness being welded. Welding equipment varies according to process, manufacturer, and usage. Specific inputs for shield gas, primary electrical, and water cooler/ recirculator are contained in the original manufacturer s manuals. B. Carriage Speed Ranges For seam welders up to 16 ft (4.8 m) long: The SWCA-3 carriage is rated for 300 lb (136 kg) capacity with the center of gravity out 12 (305 mm) from the face of the carriage. (See the SWC-3 Carriage Manual for more details.) SWCA-3A: 3 to 135 IPM (75 to 3,450 mm/min) SWCA-3B: 1.2 to 60 IPM (30 to 1,500 mm/min) SWCA-3D: 0.2 to 188 IPM (5 to 4,775 mm/min) Optional For seam welders over 16 ft (4.8 m) long: The SWC-6 medium duty carriage is rated for 1000 lb (450 kg) capacity with the center of gravity out 12 (305 mm) from the face of the carriage. They are designed for use with a TKMV style V-way track for structural integrity. (See the SWC-6 Carriage Manual for more details.) SWC-6A: 4 to 165 IPM (102 to 4,191 mm/min) SWC-6B: 3 to 108 IPM (76 to 2,743 mm/min) SWC-6C: 2 to 67 IPM (51 to 1,702 mm/min) SWC-6D: 1 to 45 IPM (25 to 1,143 mm/min) For LWX Ultra Precision seam welders: The SWC-4 linear drive carriage is rated for 300 lb (136 kg) capacity with the center of gravity out 12 (305 mm) from the face of the carriage. The linear drive provides smooth, backlash free carriage movement. SWCA-4A: 4 to 170 IPM (102 to 4,318 mm/min) SWCA-4B: 2 to 85 IPM (51 to 2,160 mm/min) SWCA-4C: 0.32 to 160 IPM (8 to 4,060 mm/min) Optional SWCA-4D: 0.22 to 106 IPM (5 to 2,700 mm/min) Optional - 9 -

16 *Model Number A B C D E F Welding Length in/mm **Min. Dia ***Min. Dia. Overall length Overall Width Overall height Part Part in/mm in/mm in/mm in/mm in/mm Approx. Ship Weight Lb/Kg LW-24 24/ /67 32/800 70/ / / /1040 LW-36 36/ /89 32/800 82/ / / /1180 LW-48 48/ /108 32/800 94/ / / /1810 LW-60 60/ /133 32/ / / / /2130 LW-72 72/1829 6/152 32/ / / / /2400 LW-84 84/ /175 32/ / / / /2680 LW-96 96/ /184 32/ / / / /2900 LW / /241 32/ / / / /5440 LW / /311 32/ / / / /5890 LW / /387 32/ / / / /6330 LW / /464 32/ / / / /6780 LW / /539 32/ / / / /7240 LW / /616 32/ / / / /7690 Letters A through F in table above refer to Figure 2. * Prefix taken from model as noted below. ** Can be modified at any time by purchasing new mandrel. *** Can be increased to any convenient height by using optional riser block. LWS Standard Seam Welder Application: to 3/8 (0.5 to 10 mm) all weldable metals Travel Accuracy: (0.4 mm) per 10 ft (3 m) Carriage Drive: Rack and Pinion LWP Precision Seam Welder Application: to 3/8 (0.1 to 10 mm) - all weldable metals Travel Accuracy: (0.1 mm) per 10 ft (3 m) Carriage Drive: Rack and Pinion LWX Ultra-Precision Seam Welder Application: For critical applications to 3/8 (0.1 to 10 mm) - all weldable metals Travel Accuracy: (0.1 mm) per 10 ft (3 m) Carriage Drive: Linear Drive

17 Figure 2 Dimensions - Longitudinal Seam Welder

18 D. Chill Bar Selection - GTAW TIG-DCSP TIG-AC TIG-DCSP GROUP I* GROUP II** GROUP III Base Metal: Base Metal: Base Metal: Steel Aluminum Titanium Stainless Magnesium Molybdenum Aluminum Zircalloy Magnesium Tantalum Copper Rene 41 Hastelloy Inconel Haynes 25 Thickness *Copper Insert ** Steel or Stainless Insert Fusion.040W.010D -.040W.125D Filler - - Fusion.063W.010D -.125W.100D Filler - - Fusion.093W.010D.093W.010D Filler.125W.020D.093W.015D Fusion.125W.020D.125W.015D Filler.187W.025D.125W.020D Fusion.125W.020D.156W.015D Filler.187W.025D.156W.020D Fusion.187W.020D.187W.015D Filler.250W.040D.187W.020D Fusion.187W.020D.250W.020D Filler.250W.040D.250W.025D Fusion.250W.040D.312W.020D Filler.312W.040D.312W.030D Fusion.312W.020D.375W.030D Filler.375W.050D.375W.040D Fusion -.375W.030D Filler -.438W.040D.187W.100D.250W.100D.312W.100D

19 E. Chill Bar Selection - GMAW GROUP I* Base Metal: Steel Stainless Aluminum Magnesium Copper GROUP II** Base Metal: Aluminum Magnesium Thickness *Copper Chill Bar ** Steel or Stainless Insert MIG MIG MIG MIG MIG MIG MIG MIG MIG MIG W.040D.187W.050D.187W.050D.250W.050D.250W.050D.312W.060D.375W.060D.437W.080D W.040D.125W.040D.187W.050D.250W.050D.250W.050D.312W.060D.375W.060D.437W.080D SUB-ARC SUB-ARC SUB-ARC SUB-ARC SUB-ARC SUB-ARC SUB-ARC SUB-ARC SUB-ARC SUB-ARC W.035D.140W.040D.187W.050D.375W.055D.470W.060D.630W.065D

20 F. Distance Between Fingertips GROUP I* Base Metal: Steel Stainless Aluminum Magnesium Copper GROUP II** Base Metal: Aluminum Magnesium Thickness Distance Distance " ( mm).063" (1.6 mm) " ( mm).100" (2.5 mm) " ( mm).125" (3.2 mm).312" (8 mm) " ( mm).187" (4.8 mm).375" (10 mm) " ( mm).250" (6 mm).500" (12.7 mm) " ( mm).375" (10 mm).625" (16 mm) " ( mm).438" (11 mm).750" (19 mm) " ( mm).500" (12.7 mm).875" (22 mm) " ( mm).565" (14 mm) 1.0" (25 mm) G. Air Regulator Settings Material Thickness Regulator Settings " ( mm) 10 PSI (4.5 kg/sq mm) " ( mm) 15 PSI (6.8 kg/sq mm) " ( mm) 20 PSI (9 kg/sq mm) " ( mm) 25 PSI (11 kg/sq mm) " ( mm) 37 PSI (17 kg/sq mm) " ( mm) 50 PSI (22.7 kg/sq mm) " ( mm) 75 PSI (34 kg/sq mm) NOTE Use these settings as a guide only. When the material to be welded has been formed to match well and lay flat, less hold-down pressure is required. Always use the least amount necessary

21 Section V Installation A. System Operating Conditions Temperature range: 0 to 40C Humidity: 5 to 95% RH non condensation Altitude: Up to 1000 meters Mounting: Secured to reinforced concrete floor Electrical Input: Export: 400VAC, 3 phase, 50 Hz nominal USA: 460 VAC, 3 phase 60 Hz Export: Single Phase, 220VAC, 50 Hz USA: 120VAC, 60 Hz domestic Compressed Air: Clean, dry air at 80 PSI (5.6 kg/sq cm) Welding Gas: Bottled or bulk supply at 100 PSI (7 kg/ sq cm) minimum pressure Transportation, Storage: -20 C Degrees to 60 C Degrees -4 F Degrees to 140 F Degrees Vibration, Shock: 1G rms 5 to 500 Hz B. Mechanical Installation Tools Required: Typically a forklift or overhead crane with at least 7000 pounds (3175Kg) capacity. For larger systems greater capacity lifting is required. Two lifting straps rated for 4000 pounds (1800Kg). For larger systems greater capacity lifting is required. General Hand tools - claw hammer, screw driver(s), hex keys or allen wrenches, set of box end wrenches, and adjustable wrench. Air or electric impact drill if concrete anchoring bolts needed. Digital VOM electrical meter. Installation personnel should be trained and experienced and locally qualified in moving heavy loads, setting up electric/mechanical systems. Familiarity with local procedures and standards is necessary. A licensed electrician should be involved in making primary connections. Uncrate the machine, remove the skid and set the equipment at the desired location. Orientate the seam welder according to your desired factory floor layout. One of four mounting holes for use with overhead crane. Two are located on each end of the tabletop

22 CAUTION Remove this shipping bracket from the carriage and discard. Look for tag as shown below. When moving the seam welder by fork lift truck, do not put the forks under the mandrel or the track. Always move the seam welder by placing the forks under the base or through the base structural tubes from the mainstay end of the machine. The fixture is free-standing and can be placed on floor without anchoring to concrete. The seam welder base should be secured to concrete flooring if (a) the seamer is integrated with a conveyor system or (b) a riser is being used to weld larger diameter shells. In these two cases the seamer base must be secured to reinforced concrete floor by use of anchor bolts/red heads. After the fixture has been removed and placed in its location in your factory, it can be anchored to the floor using 10 mm concrete anchors. Carriage Installation Procedure The welding head and carriage are fitted to the side beam track and require the removal of one shipping bracket. The shipping bracket is bolted to the carriage and the track, keeping the carriage from moving during shipment. The bracket is located on the top portion of the track and carriage and is held in place with two bolts. If the carriage has been removed for shipment, use the following procedure: At each end of the track are two mechanical stops. These stops serve as a safety device to prevent the carriage from falling off the end of the track. Remove the carriage angle stop from the top end of the track. Rotate the cam handles so that the motor pinion is disengaged. We recommend using a crane or fork lift truck to hoist the carriage up to the track (see Figure 1). When lifting the carriage, you will find a ½-13 tapped hole on top of the carriage. This hole, along with an eye bolt (not supplied), can be used for lifting the carriage. As an alternative, use the lift holes located in the gussets at either end of the carriage to slide the carriage onto the track. Refer to Figure 3 to verify it is correctly aligned. Once the carriage is mounted on the track, replace the mechanical stop on the end of the track to its original position

23 Figure 3 Carriage Assembly

24 The wire feeder is often removed for shipping purposes and put in separate box. The wire feeder should be installed onto the mounting brackets located on the carriage. Make the weld power, electrical, shield gas, air and water connections to the seam welder system. A cable channel, which protects welding gas lines and control cables from the rack and gears, is provided. The cables are located at the end of the cable carrier and are marked as to purpose. The air supply to the seam welder is ready to be connected. In order for the seam welder to operate properly, the shop air supply should be set at 80 PSI (5.6 kg/sq cm) minimum. The air supply must be connected before the filter assembly. NOTE DO NOT BY-PASS THE FILTER. By-passing the filter assembly when connecting the air supply will allow moisture to enter into the solenoid valves causing the valves to fail. Dry run the carriage without welding to be sure the carriage moves back and forth. During shipment, bolts and hardware can be shaken loose. Please check all fasteners to be certain they are tight before operating the system. Read and consult welding power source manuals to insure proper set up, polarity, and that torch consumables are selected and installed properly. Perform trial welds on scrap material to test functioning of system. C. Electrical Installation The electrical input requirements for the seam welder are VAC, 1 phase, 50/60 Hz. If the seam welder must operate on VAC, 1 phase, 50/60 Hz, a step-down transformer can be incorporated in the wiring circuit to achieve this requirement. The standard seam welder is supplied with a model 9627 Microprocessor Carriage Control. The control is normally mounted on the front of the carriage. Refer to the separate 9627 manual supplied. Other controls and equipment may have been purchased and installed on the seam welder carriage. Individual manuals will be supplied for them. Please refer to the appropriate manuals for proper installation guidelines regarding these items

25 Section VI Theory of Operation A. Mechanical Operation The seam welder is comprised of several main assemblies. Each assembly is integrated to form a complete system. The system consists of the following components: base/mainstay, mandrel, tabletop, track, carriage, and control panel. Jetline seam welders use the chill shunt principle of tooling to conduct heat away from the part. This process minimizes burn through, warping and excessive distortion when performing butt-joint welding. The edges of the part are clamped on the top centerline of the mandrel and insert. (The inserts are made of copper, stainless steel or steel, dependent upon the material type being welded.) The part is clamped against the insert by two banks of aluminum clamping fingers, each bank fitted with copper tips (see Figure 4). This clamping concept allows the seam to be welded but restricts the heat from passing through the part. The heat is absorbed by the fingers and the mandrel. The seam welder maintains sufficient force to hold parts with a wall thickness up to (10 mm). However, dependent upon the welding process used, edge preparation may be required and, on thicker materials, multi-pass welds may be required as well. Optional designs to handle thicker parts are available. For welding of material above.375 (10 mm), the application needs to be communicated before manufacture of the seam welder. The LWS, LWP and LWX seam welders are designed to perform butt-joint welds by arc welding on all conventional metals. Some of the arc welding processes include Gas Tungsten Arc Welding (GTAW), Gas Metal Arc Welding (GMAW), Shielded Metal Arc Welding (SMAW), Submerged Arc Welding (SAW) and Plasma Arc Welding (PAW). Materials that can be welded include stainless steel, weldable aluminum, magnesium alloys, zirconium, molybdenum, titanium, mild steel and low carbon steels. Some of these metals require a preparatory edge process in order to be welded successfully. Part configurations which the seam welder can handle are cylinders, cones, truncated cones, open ended boxes, double bowl sinks, flat plates and sheets. B. Base Section The base is made from a rigid tube steel structure which provides stability and safety during operation. The base is equipped with mounting holes to ensure stability of the equipment on uneven surfaces. The base houses the electrical toe-touch clamping switches. These switches run the entire length of the base. When facing the front of the seam welder, the switch closest to the operator controls the front bank of clamping fingers. The switch next in line controls the rear bank of clamping fingers. The third switch controls the rear clamping fingers only. To activate one of the switches, merely touch the switch with your toe. This will either clamp or unclamp a bank of clamping fingers. C. Mainstay The primary purpose for the mainstay is to support the tabletop. On the standard seam welder, the mainstay is high enough to accommodate an approximate 32 (800 mm) diameter part. As an option a riser can be made for diameters greater than 32 (800 mm). The mainstay also houses the control box (FCP- 10B) for the toe-touch switches, the pneumatic

26 valves, water lines if applicable, and electrical solenoids which operate the pressure hose assemblies. The air hose connection, filter, ground lug and electrical box are located on the back side of the mainstay. If a need for 460 volts is required, a step down transformer will be mounted on the mainstay as well. D. Mandrel The mandrel is mounted to the mainstay and is typically round, but can be designed to meet the demands of the application. The mandrel must support the part s weight, along with supporting the clamping forces exerted by the clamping fingers. In most cases, the mandrel is designed to be supported at the mainstay and at the latch end. The mandrel is designed to support a back-up insert and may have optional water cooling capability. Depending on the thickness of the material to be welded and the welding process, the insert will have a specific groove dimension (width and depth) machined into it. When several different thicknesses of materials are to be welded on the same seam welder, additional inserts may be required to obtain a quality weld. The inserts may also be designed to provide gas back-up to the part. This option provides backing gas to the penetration side (bottom) of the weld. Backing gas is required for welding refractory metals and is recommended for stainless steel materials. In high production environments, and/or when welding with high current, an optional watercooled mandrel is required. The water-cooled mandrel provides cooling of the insert using a separate water circulator. This helps to maintain a consistent temperature and weld throughout the production run. E. Tabletop The tabletop houses the two banks of clamping fingers, and supports the side beam track and carriage. One of the most outstanding features of the tabletop design is the ability to view the weld in progress via the naked eye (with weld shield) or with a video camera. The two banks of clamping fingers are set and mounted within the tabletop. The tabletop section will differ in size and weight as the welding length of the seam welder increases. The tabletop is designed to withstand the clamping forces generated by the clamping fingers. On both sides of the tabletop are adjusting screws used to adjust the finger spacing (see Figure 4). There are several screws that are used to adjust the location of the fingers relative to the insert groove. These screws should be adjusted symmetrically to the groove to provide an even chilling effect. The finger spacing as a standard depends largely on the material thickness being welded. See Section IV for Jetline s recommendation. As a safety note, after the adjustments have been completed, there should not be a gap greater than 1/8 (3.2 mm) between fingertip and part when the bank of fingers is in its unclamped state. This adjustment is made to minimize a pinch point condition between the fingers and part being welded. The fingers on a Jetline seam welder are 3 (75 mm) wide and are made of aluminum. At the end of each finger is a copper or optional stainless steel fingertip screwed to the aluminum finger body. These tips are reversible and should be changed if damaged or worn

27 Figure 4 Tabletop Half Section

28 The latch assembly is mounted on the opposite end of the mainstay. The latch must be closed during the clamping of the fingers, thus securing and supporting the mandrel. If the clamping forces are exerted on the mandrel without the latch support, there is a potential for mandrel damage. As a result, we have installed a safety switch which prevents clamping without the latch being closed. NOTE This safety switch should not be by-passed. F. Track Two or three track supports, depending on the welding length of the seam welder, are mounted to the tabletop. The side beam track is bolted securely and mounted to these track supports. There are no supports in the welding area of the seam welder. The track is positioned in such a way that it is suspended over the welding area. See Figure 5. Typically a TKSA style track is adequate to span distances under 192 (4875 mm) of weld length. For longer distances, the TKMV medium duty track is used. These Jetline tracks ensure a tracking accuracy of the carriage along the track of (0.4 mm) in both planes

29 Figure 5 Track Support Assembly

30 G. Carriage Control The carriage is driven by the 9627 Microprocessor Control which is designed for automatic sequencing of carriage travel and power supply starting and stopping. The control is equipped with a two line display which guides the operator through setup and displays travel speed during the weld procedure. The separate 9627 manual contains complete operating instructions. For more advanced systems, a 9900 Computer Controller is used to control the weld process and carriage travel. GTAW Carriage layout with 9900 Computer Controller GTAW Carriage layout with standard 9600 Series Controls - travel, wire, alc Carriage layout with 9600 travel control and Sub-Arc gear Carriage layout with 9600 travel control and GMAW gear

31 Section VII Start-up and Operation A. Initial Setup 1. Edge Preparation It is important that the part edges are prepared so that when they are brought together in the seam welder any resulting joint gap is less that 10% of the part s thickness. Ideally, when using the GTAW or PAW process, the edges are as tight together as possible at the beginning of the weld to minimize burn through. 2. Finger Pressure The finger pressure should be set based on material thickness and the actual application. The Specifications section of this manual gives some recommended pressures for different material thicknesses. 3. Back-up Insert Your back-up insert is designed specifically for certain material types and material thickness ranges. The backup inserts can weld a variety of material types and material thickness spans. Welding a wide range of material types and thicknesses will require additional inserts. The Specifications section of this manual gives recommendations for back-up inserts. These inserts are readily available from Jetline Engineering. The back-up insert, sitting inside the mandrel, should be parallel to the track. Refer to the maintenance section of this manual. 4. Distance Between Fingers The distance between the front and rear banks of fingers is adjustable. Only adjust when fingers are in the up position. It is best to adjust each screw an equal distance and then to close the fingers to inspect the finger distance from the insert groove. One full turn of each screw will move the fingers 1/16 (1.6 mm). Each bank of fingers should be an equal distance from the centerline of the back-up insert. The closer that the fingers are to the groove of the back-up insert, the more chilling effect they wills are apart, the less chilling effect is provided. Fingers that are adjusted close to the groove can increase the control of welding heat input, while wider spaced fingers can tend to give increased travel speeds. Therefore, it is important to set the finger distance based on your specific part. The chart in the Specifications section gives initial recommendations for finger spacing. B. Operation NOTE The latch should be completely closed before welding. 1. Begin with both sets of fingers in the unclamped (up) position. (Seam welders that utilize any automatic loading or centering may need to be cycled in order to start at the beginning of a cycle.) 2. The centering devices should be pushed down and toggled over. Check to make sure that the blade is located over the center of the back-up insert. The back side of the centering device blades should be located on the centerline of the back-up insert. (Or very slightly to the front of center)

32 If the seam welder is equipped with more than two centering devices, use only two, preferably spaced as far apart as possible for your particular part. 3. The part should be loaded into the rear of the seam welder first. Push the edge of the part up against the centering device blades. Once you are sure that the part is located properly, depress the rear finger toe touch strip. This will cause the rear pressure hose to fill, clamping the rear bank of fingers and securing the part in the seam welder. Try to space the part in the seam welder so that the ends of the part are at least half covered by a finger at each end. If the end is being covered by less than half of a finger, then the finger could tilt and result in insufficient chill. If there is difficulty with burn through at the beginning or end of the part, this could be the cause. To solve the problem simply move the part so that the finger coverage is correct or insert a small tab underneath the troublesome finger so the finger bridges evenly between the end of your part and the small tab. 4. Now retract the centering devices. 5. Load the front side (edge) of the part and butt it up against the edge of the part that is already clamped by the rear finger bank. Be sure that the ends are even. 6. Depress the front fingers toe touch strip and clamp the front fingers on the part. The front fingers should always be closed last because these are the push-in fingers. These fingers push in slightly as clamping pressure is applied, ensuring a good fit at the joint. 7. Now that the part is loaded, you can prepare to weld. 8. If limit switches are used to determine the start and stop points of the weld, it is best to set up on a practice part. Move the carriage and torch at the desired starting point, then slide the home limit switch cam until it contacts the home limit switch. Now test this starting point by jogging the carriage forward (12 or more inches if possible) and then returning the carriage to the home position. This will indicate the true starting point. To set the end of weld limit switch, use a similar process. First manually set the contact location, then test it by reversing travel, then moving the carriage to the end of weld. 9. Welding Each and every welding application requires its own unique set of welding parameters. Wire speeds, voltages, travel speeds, gas types, flow rates, back-up bar size, type, finger spacing, clamping pressures, material type, material thickness and joint preparation are some of the many variables that need to be adjusted in order to provide the most robust welding procedure for a particular application. Weld development is the sole responsibility of the owner of the equipment and not the responsibility of Jetline Engineering. 10. Once the seam has been welded successfully, release both sets of fingers, open the latch if needed, and carefully remove the part

33 Section VIII Trouble Shooting A. Fixture Problem 1. Misalignment of torch to the weld joint (insert groove centerline). 2. Carriage will not travel. Cause and Correction a. The track and carriage no aligned parallel to insert groove; readjust as per Section X. b. Alignment devices not adjusted to centerline of insert. Clamp a straight edge or a length of material over centerline of insert groove and adjust the alignment devices by loosening the locking nut on the Allen adjusting screw at the top of the telescoping arm. Adjust the Allen screw so that the device blades contact the straight edge and tighten the lock nut. c. The part is not against the two alignment device blades when the part is clamped by the fingers. Unclamp, align, and clamp. d. Gibbs loose on the weld head cross seam slide; adjust as needed. e.. If an arc length control is incorporated on the fixture, check the ways and wheels in the drive (actuator) for play and adjust. a. The main items to check are: - Input power to carriage control - Control fuse - Check the drive motor brushes, brush springs and caps. - Be sure the clutch is engaged. - Fiber gear in gear head motor may be stripped. b. Refer to the supplied carriage control manual for wiring

34 Problem 3. Travel speed readout with optional tach generator fluctuates. 4. Clamping fingers will not clamp. 5. Can hear air leaking in the vertical riser. 6. Cannot establish tight, even butt-up of final sheared parts. Cause and Correction a. Check the belt that connects the carriage drive motor shaft to the tach generator. Replace the belt if worn or loose. b. Check for binding between the carriage wheels and the rails on the track. Readjust the wheels if required; see supplied carriage manual. c. Refer to supplied control manual for wiring information. a. Check air supply to fixture. b. Check clamping presure air regulator for proper pressure (see Section IV). c. Check fuse in the FCP-10B toe-touch panel. d. Check toe-touch strip for short. If shorted, replace with new. e. Check relays and transformer and toetouch panel. f. Shop line pressure is too low to actuate the pilot actuated air solenoid valve. a. Open hinge door and check: - White poly flow tubing for leaks. - Internal air hoses for leaks. - Clamping hoses for leaks. a. When worn or misaligned, the shear knives can produce a concave cut, convex cut, or shear drag (burr). Once the cut-off shear blades are readjusted, sharpened, or replaced, the straightness of the part should be checked against a straight edge

35 A. GTAW Process Problem 1. Cannot initiate an arc when using GTAW welding equipment. 2. If an arc still will not establish, check the following steps. Cause and Correction a. Remove the torch cap which retains the collet and electrode. If the weld tip of the electrode is blue or contaminated, sharpen it or replace with a new sharpened electrode. If the bore of the collet is worn or does not provide a tight grip of the electrode when installed in the torch, replace collet with a new one. b. A blue finish to the surface of the tungsten implies oxygen contamination. This can be caused by too short of a post flow time, a loose gas fitting, a contaminated gas supply, air turbulence at the weld zone, too small a shield cup on the torch, or too low of a flow rate of gas. c. Check shield gas pressure (PSI) at the regulator and flow (CFH) at the flowmeter. The PSI should not be less than 50 and the CFH should coincide with established welding parameters. d. Make sure the high frequency control at the power supply is switched to the proper mode of start for D.C.S.P. welding or continuous for A.C.H.F. welding. a. Increase the high frequency intensity potentiometer on the power source. b. Amperage setting at the power supply may be too low to initiate an arc. Raise the amperage setting. c. Material to be welded may contain coated or scaled surface. Remove coating or scale by using a fine emery cloth. d. This condition usually occurs at the start of the weld cycle

36 Problem 3. Electrode sticks to part when using GTAW welding equipment. 4. Arc voltage raises or lowers during the weld cycle when using GTAW welding equipment. 5. White smoke appears during GTAW welding process. Cause and Correction a. This condition usually occurs at the start of the weld cycle. - Shut the welder off and stop carriage from traversing. - Raise the torch head to free the electrode - If that fails, unscrew the tube assembly of the torch head and pull the tube, collet, and electrode out. - As a last resort, make sure that the weld mode is in the off position, then cut the tungsten electrode with wire cutters. a. Make sure the electrode is sharp (clean) and the torch collet grips the electrode tightly. b. Check the insert and travel carriage for parallelism. If a variation exists, adjust the track and/or mandrel. c. Make sure all drive gearing, roundways and cam followers are clean. d. If an arc length control (AVC) is used with the fixture, check to see if it is correcting for variations in the arc length (check trouble shooting section in the ALC manual). a. Check the shield gas bottle for pressure. b. Check the shield gas flow at the flowmeter. c. Check the electrode stick-out. Maximum stick-out is 1/4 (6.35 mm) with standard collets, ½ (12.7 mm) with gas lens collet bodies. d. Inspect the torch nozzle for tightness and/ or cracking. A loosely fitted or defective nozzle permits aspiration. Check for too small a nozzle orifice for size of tungsten