External Seam Welders Manual

OPERATION MANUALfor LongitudinalSeam Welders

Effective with Serial Number 990547

Standard External Seam Welder - Model LWS

Precision External Seam Welder - Model LWP

Ultra-Precision External Seam Welder - Model LWX

Standard Internal Seam Welder - Model LWI

IMPORTANT

Read this manual carefully before installing,

commissioning or operating this product.

Revised November 2004

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618 Telephone: (949) 951-1515 ! Fax: (949) 951-9237

Web site: www.jetline.com ! E-mail: [email protected]

Longitudinal Seam Welders - LWS, LWP, LWX

ii


iii

LIMITED WARRANTY

Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from defects inmaterial and workmanship for the period of one (1) year, provided that the equipment is installed and operatedaccording to instructions.

Jetline Engineering's obligation under this warranty is expressly limited to replacing or repairing anydefective part or correcting any manufacturing defect without charge during the warranty period, if Jetline'sinspection confirms the existence of such defects. Jetline's option of repair or replacement will be F.O.B. factoryat 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 directlyor indirectly from the use of equipment covered by this warranty.

This warranty supersedes all previous Jetline warranties and is exclusive with no other guarantees orwarranties expressed or implied.


iv

NOTICE

The installation, operation and maintenance guidelines set out in this manual will enable you to maintainthe equipment in peak condition and achieve maximum efficiency with your welding operation. Please read theseinstructions carefully to become aware of every advantage.

CAUTION

Only experienced personnel familiar with the operationand safe practice of welding equipment should install

and/or use this equipment.


v

Table of Contents

Section I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1-

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1-

A. Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -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-

Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5-

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5-

Section III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7-

Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7-

Section IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9-

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9-

A. Carriage Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11-

B. Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11-

C. Chill Bar Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12-

D. Distance Between Finger Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -14-

E. Air Regulator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -14-

Section V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -15-

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -15-

Section VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -17-


vi

Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -17-

Section VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19-

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19-

A. Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19-

B. Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19-

C. Mainstay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19-

D. Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -21-

E. Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -21-

F. Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -22-

G. Carriage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -22-

Section VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25-

Start-up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25-

A. Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25-

B. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25-

Section IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -27-

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -27-

A. Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -27-

B. GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -29-

Section X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -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. Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -37-

Section XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -39-


vii

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -39-

Section XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -47-

Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -47-


viii


-1-

WARNING

Section I

Safety Precautions

A. Arc Welding

Arc Welding can be hazardous. Protect yourself andothers from possible serious injury or death. Keepchildren away. Pacemaker wearers keep away untilconsulting your doctor.

In welding, as in most jobs, exposure to certainhazards occurs. Welding is safe when precautionsare taken. The safety information given below isonly a summary of the more complete safetyinformation that will be found in the SafetyStandards listed at the end of this section. Read andfollow all Safety Standards.

Have all installation, operation, maintenance andrepair work performed only by qualified people.

B. Electric Shock

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. When using mechanized wirefeed, the wire, wire reel, drive roll housing and allmetal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves andappropriate body protection.

3. Disconnect input power before installing orservicing this equipment. Lockout/tagoutinput power according to OSHA 29 CFR1910.147 (see Safety Standards).

4. Properly install and ground this equipmentaccording to the operation manual andnational, state and local codes.

5. Always verify the supply ground-check andbe sure that input power cord ground wire isproperly connected to ground terminal indisconnect box or that cord plug is connectedto a properly grounded receptacle outlet.

6. When making input connections, attachproper grounding conductor first - double-check connections.

7. Frequently inspect input power cord fordamage or bare wiring. Replace cordimmediately if damaged - bare wiring cankill.

8. Turn off all equipment when not in use.

9. If earth grounding of the workpiece isrequired, ground it directly with a separatecable - do not use work clamp or work cable.

10. Do not touch electrode if you are in contactwith the work, ground, or another electrodefrom a different machine.

11. Use only well-maintained equipment. Repairor replace damaged parts at once. Maintainunit according to manual.

12. Wear a safety harness if working above floorlevel.

13. Keep all panels and covers securely in place.

14. Clamp work cable with good metal-to-metalcontact to workpiece or worktable as near theweld as practical.


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C. Arc Rays

Arc rays can burn eyes and skin; noise can damagehearing; flying slag or sparks can injure eyes.

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Noise from someprocesses can damage hearing. Chipping, grindingand weld cooling throw off pieces of metal or slag.

1. Use approved ear plugs or ear muffs if noiselevel is high.

2. Use a welding helmet fitted with a propershade of filter to protect your face and eyeswhen welding or watching.

3. Wear approved safety glasses with sideshields.

4. Use protective screens or barriers to protectothers from flash and glare; warn others notto 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 thesefumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do notbreathe the fumes.

2. If inside, ventilate the area and/or use exhaustat 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 instructionfor metals, consumables, coatings, cleaners,and degreasers.

5. Work in a confined space only if it is wellventilated, or while wearing an air-suppliedrespirator. Always have a trained watchperson nearby.

6. Do not weld in locations near degreasing,

cleaning, or spraying operations. The heat andrays of the arc can react with vapors to formhighly toxic and irritating gases.

7. Do not weld on coated metals, such asgalvanized, lead or cadmium plated steel,unless the coating is removed from the weldarea, the area is well ventilated, and ifnecessary, while wearing an air-suppliedrespirator. The coatings and any metalscontaining these elements can give off toxicfumes if welded.

E. Cylinders

Cylinders can explode if damaged.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

1. Protect compressed gas cylinders fromexcessive heat, mechanical shocks, slag, openflames, sparks, and arcs.

2. Install cylinders in an upright position bysecuring to a stationary support or cylinderrack to prevent falling or tipping.

3. Keep cylinders away from any welding orother electrical circuits.

4. Never weld on a pressurized cylinder -explosion will result.

5. Use only correct shielding gas cylinders,regulators, hoses and fittings designed for thespecific application; maintain them andassociated parts in good condition.

6. Turn face away from valve outlet whenopening cylinder valve.

7. Keep protective cap in place over valveexcept when cylinder is in use or connectedfor use.

8. Read and follow instructions on compressedgas cylinders, associated equipment, andCGA publication P-1 listed in SafetyStandards.


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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 flyoff from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires andburns. Accidental contact of electrode to metalobjects can cause sparks, explosion, overheating, orfire. Check and be sure the area is safe before doingany welding.

1. Protect yourself and others from flying sparksand hot metal.

2. Do not weld where flying sparks can strikeflammable 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 materialsfrom welding can easily go through smallcracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguishernearby.

6. Do not weld on closed containers such astanks, drums, or pipes, unless they areproperly prepared according to AWSF4.1 (seesafety Standards).

7. Connect work cable to the work as close tothe welding area as practical to preventwelding current traveling long, possiblyunknown paths and causing electric shockand fire hazards.

8. Wear oil-free protective garments such asleather gloves, heavy shirt, cuffless trousers,high shoes, and a cap.

G. Moving Parts

Moving parts, such as fans, rotors, and belts can cutfingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guardsclosed and securely in place.

2. Have only qualified people remove guards orcovers for maintenance and troubleshootingas necessary.

H. EMF Information

Considerations About Welding and the Effects ofLow Frequency Electric and Magnetic Fields

The following is a quotation from the GeneralConclusions Section of the U.S. Congress, Office ofTechnology Assessment, Biological Effects ofPower 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 scientificfindings based on experiments at the cellular leveland from studies with animals and people whichclearly establish that low frequency magnetic fieldscan interact with, and produce changes in, biologicalsystems. While most of this work is of very highquality, the results are complex. Current scientificunderstanding does not yet allow us to interpret theevidence in a single coherent framework. Even morefrustrating, it does not yet allow us to draw definiteconclusions abut questions of possible risk or tooffer clear science-based advice on strategies tominimize or avoid potential risks."

To reduce magnetic fields in the work place, use thefollowing procedures:

1. Keep cables close together by twisting ortaping them.

2. Arrange cables to one side and away from theoperator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as faraway as practical.

5. Connect work clamp to workpiece as close tothe weld as possible.

About Pacemakers:

The above procedures are among those alsonormally recommended for pacemaker wearers.Consult your doctor for complete information.


-4-

I. Principal Safety Standards

Reference as applicable

Safety in Welding and Cutting, ANSI StandardZ49.1, from American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

Safety and Health Standards, OSHA 29 CFR 1910,from Superintendent of Documents, U.S.Government Printing Office, Washington, D.C.20402

National Electric Code, NFPA Standard 70 fromNational Fire Protection Association, BatterymarchPark, Quincy, MA 02269

Recommended Safe Practices for the Preparation forWelding and Cutting of Containers That Have HeldHazardous Substances, American Welding SocietyStandard AWS F4.1, from American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

Safe Handling of Compressed Gases in Cylinders,CGA Pamphlet P-1, from Compressed GasAssociation, 1235 Jefferson Davis Highway, Suite501, Arlington, VA 22202

Code for Safety in Welding and Cutting, CSAStandard W117.2, from Canadian StandardsAssociation, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3

Sales Practices for Occupation and Educational Eyeand Face Protection, ANSI Standard Z87.1, fromAmerican National Standards Institute, 1430Broadway, New York, NY 10018

Cutting and Welding Processes, NFPA Standard51B, from National Fire Protection Association,Batterymarch Park, Quincy, MA 02269


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Section II

Introduction

Congratulations on your purchase of the JetlineLongitudinal Seam Welder. Its quality workmanshipshould bring many years of dependable service andconsistent high quality seam welds.

The Jetline seam welder is a standard designmachine which uses the chill shunt principle oftooling to conduct heat away from the part andminimize burn-through, warping, or excessivedistortion.

Jetline seam welders are designed to clamp a partwith a butt-joint type seam. A motorized carriage onwhich a torch can be mounted to weld the seam isprovided. The seam welder can be designed tohandle a variety of shapes and sizes. Seam welderscan accommodate part lengths from 3 inches to 40feet (76 mm to 12 m), dependent on the modelordered.

A welding torch can be mounted to the side beamcarriage by means of an optional torch holder andbracket. This allows the torch and carriage totraverse the entire length of the part whileperforming the weld. Prior to welding, the part ispositioned on the mandrel insert, clamped, and isthen welded in a stationary position.

The clamping of the part ensures that the joint isaligned down the centerline of the machine. With thepart on center and the torch mounted above the weldjoint, in many applications the welding of a butt-joint becomes a simple operation without thenecessity of tack welding prior to welding.

Jetline longitudinal seam welders are comprised ofseveral integral assemblies: a base/mainstay,mandrel, tabletop, track, carriage, and a controlpanel. These assemblies combined create an efficientwelding unit. The base is made of tubular steel andserves as the main support for the system. Themainstay houses all of the plumbing and electricalclamping control boxes. Attached to the mainstay isa mandrel on which is mounted an insert; this can bewater cooled as an option. The tabletop is mountedto the top of the mainstay and is where the holddown clamping fingers are mounted.

Mounted directly on the tabletop are two or threetrack supports, depending on the welding length ofthe tabletop. These track supports hold up the maintrack assembly which extends the entire length ofthe tabletop. Riding on the track assembly is amotorized carriage. The control panel that controlsthe carriage speed and weld time, is mounted to thecarriage face thus making the Jetline longitudinalseam welder a well integrated system.


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-7-

Section III

Initial Inspection

Upon receipt of the equipment, examine theshipping crate for freight damage. If the crateappears to have suffered major damage, the unitshould be examined carefully for possible damageand/or possible misalignment in the track andmandrel.

Although Jetline has packaged your equipment well,long and/or extremely rough shipping can have anadverse effect on the equipment. As a result, pleasespend a few extra minutes to insure that theassembly pieces are in good order.

The crate in which the seam welder has arrived willhave to be dismantled. Be careful to dismantle theequipment safely. Damage to the unit and personalinjury can occur during unpacking, therefore followall safety precautions.

Your seam welder was thoroughly tested andverified it met specifications before shipping. Afterreceipt, visual inspection of all adjustment pointsshould be made. See Figure 1.

If a cable carrier assembly was purchased as anoption, the carrier may have been removed from thetrack and packed separately. Verify that it too hasarrived in good condition before proceeding with itsinstallation.

The carriage assembly is normally shipped mountedon the track and requires only the removal of thetemporary mounting bracket. If the seam welder hasan optional riser (for larger diameters than standard)the carriage was removed before the seam welderwas shipped. If this is the case, the carriage will bemounted on the crate deck next to the seam welder.Verify there is no apparent damage to it or to theequipment mounted to it.

After this initial inspection is completed,installation of the longitudinal seam welder canbegin.


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Figure 1

Longitudinal Seam Welder


-9-

Section IV

Specifications

* ModelNumber

“A”WeldingLength

inch mm

“B”**Min. Dia.

Partinch mm

“C”***Max. Dia.

Part inch mm

“D”Overall Length

inch mm

“E”Overall Width

inch mm

“F”Overall Height

inch mm

Approx. Shipping Weight

Lb Kg

LW_-24 24 609 2 5/8 67 32 800 691/2 1,765 391/2 1,003 69 1,753 2,300 1,040

LW_-36 36 914 3 ½ 89 32 800 811/2 2,070 391/2 1,003 69 1,753 2,600 1,180

LW_-48 48 1,219 4 1/4 108 32 800 933/8 2,372 391/2 1.003 69 1,753 4,000 1,810

LW_-60 60 1,524 5 1/4 133 32 800 1053/8 2,677 391/2 1,003 69 1,753 4,700 2,130

LW_-72 72 1,829 6 152 32 800 1173/8 2,981 391/2 1,003 69 1,753 5,300 2,400

LW_-84 84 2,134 6 7/8 175 32 800 1293/8 3,286 391/2 1,003 69 1,753 5,900 2,680

LW_-96 96 2,438 7 1/4 184 32 800 1413/8 3,591 391/2 1,003 69 1,753 6,400 2,900

LW_-120 120 3,048 9 ½ 241 32 800 176 4,470 411/2 1,054 76 1,930 12,000 5,440

LW_-144 144 3,658 121/4 311 32 800 200 5,080 411/2 1,054 76 1,930 13,000 5,890

LW_-168 168 4,267 151/4 387 32 800 224 5,689 411/2 1,054 76 1,930 14,000 6,330

LW_-192 192 4,877 181/2 464 32 800 248 6,299 411/2 1,054 76 1,930 15,000 6,780

LW_-216 216 5,486 211/4 539 32 800 272 6,909 411/2 1,054 76 1,930 16,000 7,240

LW_-240 240 6,096 241/4 616 32 800 296 7,518 411/2 1,054 76 1,930 17,000 7,690

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 newmandrel.*** Can be increased to any convenient height by usingoptional riser block.

LWS Standard Seam Welder

Application: 0.020" to 3/8" (0.5 to 10 mm) - allweldable metals

Travel Accuracy: ±0.015" (0.4 mm) per 10 ft (3 m)Carriage Drive: Rack and Pinion

LWP Precision Seam Welder

Application: 0.005" to 3/8" (0.1 to 10 mm) - allweldable metals

Travel Accuracy: ±0.005" (0.1 mm) per 10 ft (3 m)Carriage Drive: Rack and Pinion

LWX Ultra-Precision Seam Welder

Application: For critical applications0.005" to 3/8" (0.1 to 10 mm) - allweldable metals

Travel Accuracy: ±0.005" (0.1 mm) per 10 ft (3 m)Carriage Drive: Linear Drive


-10-

Figure 2Dimensions - Longitudinal Seam Welder


-11-

A. Carriage Speed Range

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-3Carriage 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 1000lb (450 kg) capacity with the center of gravity out12" (305 mm) from the face of the carriage. Theyare designed for use with a TKMV style V-waytrack for structural integrity. (See the SWC-6Carriage 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 lineardrive provides smooth, backlash free carriagemovement.

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)

OptionalSWCA-4D: 0.22 to 106 IPM (5 to 2,700 mm/min)

Optional

B. 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 (74.4kg/cm) of clamping force on the part. See the airregulator settings chart in this section to set thecorrect clamping pressure for the material thicknessbeing welded.


-12-

C. Chill Bar Selection

TIG-DCSP TIG-AC TIG-DCSP

GROUP I* GROUP II** GROUP III

Thickness

Base Metal:SteelStainlessAluminumMagnesiumCopper* Copper Insert

Base Metal:AluminumMagnesium

** Steel or StainlessInsert

Base Metal:TitaniumMolybdenumZircalloyTantalumRene 41HastelloyInconelHaynes 25

.005 - .012 Fusion Filler

.040W .010D-

--

.040W .125D


.063W .010D-

--

.125W .100D


.093W .010D

.125W .020D.093W .010D.093W .015D

.187W .100D.033 - .040 Fusion Filler

.125W .020D

.187W .025D.125W .015D.125W .020D


.125W .020D

.187W .025D.156W .015D.156W .020D


.187W .020D

.250W .040D.187W .015D.187W .020D


.187W .020D

.250W .040D.250W .020D.250W .025D .250W .100D


.250W .020D

.312W .040D.312W .020D.312W .030D


.312W .020D

.375W .050D.375W .030D.375W .040D .312W .100D


--

.375W .030D

.438W .040D

Note: Group III inserts are all copper gas back-up. Part number reflects the groove width & depth in inches(.040W .010D is .040" wide & .010" deep).


-13-

Chill Bar Selection - MIG and Submerged Arc

GROUP I* GROUP II**

Thickness

Base Metal:SteelStainlessAluminumMagnesiumCopper

* Copper Chill Bar


** Steel or Stainless Chill Bar

.005 - .012 MIGSUB-ARC

--

--


--

--


.125W .040D-

.125W .040D-


.187W .050D-

.125W .040D-


.187W .050D

.125W .035D.187W .050D

-


.250W .050D

.140W .040D.250W .050D

-


.250W .050D

.187W .050D.250W .050D

-


.312W .060D

.375W .055D.312W .060D

-


.375W .060D

.470W .060D.375W .060D

-


.437 W. 080D.630W .065D

.437W .080D-

Note: Part number reflects the groove width & depth in inches (.040W .010D is .040" wide & .010" deep).


-14-

D. Distance Between Finger Tips

GROUP I GROUP II

Thickness

Base Metal:SteelStainlessAluminumMagnesiumCopper

Distance


Distance

.005 - .012 (0.1-0.3 mm) .063 (1.6 mm) --

.013 - .024 (0.3-0.6 mm) .100 (2.5 mm) --

.025 - .032 (0.6-0.8 mm) .125 (3.2 mm) .312 (8 mm)

.033 - .040 (0.8-1.0 mm) .187 (4.8 mm) .375 (10 mm)

.041 - .050 (1.0-1.3 mm) .250 (6 mm) .500 (12.7 mm)

.051 - .080 (1.3-2.0 mm) .375 (10 mm) .625 (16 mm)

.081 - .125 (2.0-3.2 mm) .438 (11 mm) .750 (19 mm)

.126 - .250 (3.2-6.3 mm) .500 (12.7 mm) .875 (22 mm)

.251 - .375 (6.3-10 mm) .565 (14 mm) 1.0 (25 mm)

E. Air Regulator Settings

MATERIAL THICKNESS REGULATOR SETTINGS

.005 - .012 (0.1 - 0.3 mm) 10 PSI (4.5 kg/sq mm)

.013 - .024 (0.3 - 0.6 mm) 15 PSI (6.8 kg/sq mm)

.025 - .032 (0.6 - 0.8 mm) 20 PSI (9 kg/sq mm)

.033 - .050 (0.8 - 1.3 mm) 25 PSI (11 kg/sq mm)

.051 - .080 (1.3 - 2.0 mm) 37 PSI (17 kg/sq mm)

.081 - .125 (2.0 - 3.2 mm) 50 PSI (22.7 kg/sq mm)

.126 - .250 (3.2 - 6.3 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 andlay flat, less hold-down pressure is required. Always use least amount necessary.


-15-

Section V

Mechanical Installation

Uncrate the machine, remove the skid and set theequipment at the desired location. Orientate theseamer according to your desired factory floorlayout. The seam welder need not be secured to thefloor. However, if the seamer is integrated with aconveyor system, we recommend anchoring theseamer to the floor by use of anchor bolts/red heads.

If the carriage has been removed for shipment, usethe following procedure: At each end of the track aretwo mechanical stops. These stops serve as a safetydevice to prevent the carriage from falling off theend of the track. When placing the carriage onto thetrack, one of the stops must be removed. Werecommend using a crane or fork lift truck to hoistthe carriage up to the track (see Figure 1). Whenlifting the carriage, you will find a ½-13 tapped holeon top of the carriage. This hole, along with an eyebolt (not supplied), can be used for lifting thecarriage. Another alternative for lifting the carriageis by using the gusset holes on both sides of thecarriage. (Refer to Figure 3.) Using these holes willstabilize the carriage when installing it onto thetrack. Please refer to Figure 3 to verify it is correctlyaligned. Once the carriage is mounted on the track,replace the mechanical stop on the end of the trackto its original position.

WARNING

When moving the seam welder by fork lift truck,do not put the forks under the mandrel. Alwaysmove the seam welder by placing the forks underthe base or through the base structural tubesfrom the mainstay end of the machine.

The longitudinal seam welder is equipped with acable channel which protects welding gas lines andcontrol cables from the rack and gears.

The air supply to the seam welder is ready to beconnected. In order for the seam welder to operateproperly, the shop air supply should be set at 80 PSI(5.6 kg/sq cm) minimum. The air supply must beconnected before the filter assembly.

WARNING

DO NOT BY-PASS THE FILTER. By-passingthe filter assembly when connecting the airsupply will allow moisture to enter into thesolenoid valves causing the valves to fail.


-16-

Figure 3

Carriage Assembly


-17-

Section VI

Electrical Installation

The electrical input requirements for the seamwelder are 110-120 VAC, 1 phase, 50/60 Hz. If theseam welder must operate on 220-240 VAC, 1phase, 50/60 Hz, a step-down transformer will beincorporated in the wiring circuit to achieve thisrequirement.

The standard seam welder is supplied with a model9627 Microprocessor Carriage Control. The controlis normally mounted on the front of the carriage.Refer to the separate 9627 manual supplied.

Other controls and equipment may have beenpurchased and installed on the seam welder.Therefore individual manuals will be supplied forthem. Please refer to the appropriate manuals forproper installation guidelines regarding thisequipment.


-18-


-19-

Section VII

Theory of Operation

A. Mechanical Operation

The seam welder is comprised of several mainassemblies. Each assembly is integrated to form acomplete system. The system consists of the follow-ing components: base/mainstay, mandrel, tabletop,track, carriage and control panel. Jetline seamwelders use the chill shunt principle of tooling toconduct heat away from the part. This processminimizes burn through, warping and excessivedistortion when performing butt-joint welding.

The edges of the part are clamped on the topcenterline of the mandrel and insert. (The inserts aremade of copper, stainless steel or steel, dependantupon the material type being welded.) The part isclamped against the insert by two banks ofaluminum clamping fingers, each bank fitted withcopper tips (see Figure 4). This clamping conceptallows the seam to be welded but restricts the heatfrom passing through the part. The heat is absorbedby the fingers and the mandrel. The seam weldermaintains sufficient force to hold parts with a wallthickness up to 0.375" (10 mm). However,dependant upon the welding process used, edgepreparation may be required and, on thickermaterials, multi-pass welds may be required as well.

The LWS, LWP and LWX seam welders aredesigned to perform butt-joint welds by arc weldingon all conventional metals. Some of the arc weldingprocesses include Gas Tungsten Arc Welding(GTAW), Gas Metal Arc Welding (GMAW),Shielded Metal Arc Welding (SMAW), SubmergedArc Welding (SAW) and Plasma Arc Welding(PAW). Materials that can be welded includestainless steel, weldable aluminum, magnesiumalloys, zirconium, molybdenum, titanium, mild steeland low carbon steels. Some of these metals requirea preparatory process in order to be weldedsuccessfully.

Part configurations which the seam welder canhandle are cylinders, cones, truncated cones, openended boxes, double bowl sinks, flat plates andsheets.

B. Base Section

The base is made from a rigid tube steel structurewhich provides stability and safety during operation.The base is equipped with mounting holes to ensurestability of the equipment on uneven surfaces.

The base houses the electrical toe-touch clampingswitches. These switches run the entire length of thebase. When facing the front of the seam welder, theswitch closest to the operator controls the front bankof clamping fingers. The switch next in line controlsthe rear bank of clamping fingers. The third switchcontrols the rear clamping fingers only. To activateone of the switches, merely touch the switch withyour toe. This will either clamp or unclamp a bankof clamping fingers.

C. Mainstay

The primary purpose for the mainstay is to supportthe tabletop. On the standard seam welder, themainstay is high enough to accommodate an approx-imate 32" (800 mm) diameter. As an option the risercan be made taller for diameters greater than 32"(800 mm).

The mainstay also houses the control box (FCP-10B) for the toe-touch switches, the pneumaticvalves, water lines if applicable, and electricalsolenoids which operate the pressure hoseassemblies.

The air hose connection, filter, ground lug andelectrical box are located on the back side of themainstay. If a need for 460 volts is required, a stepdown transformer will be mounted on the mainstayas well.


-20-

Figure 4

Tabletop Half Section


-21-

D. Mandrel

The mandrel is mounted to the mainstay and istypically round, but can be designed to meet thedemands of the application. The mandrel mustsupport the part’s weight, along with supporting theclamping forces exerted by the clamping fingers. Inmost cases, the mandrel is designed to be supportedat the mainstay and at the latch end.

The mandrel is designed to support a back-up insertand may have optional water cooling capability.Depending on the thickness of the material to bewelded and the welding process, the insert will havea specific groove dimension (width and depth)machined into it. When several different thicknessesof materials are to be welded on the same seamwelder, additional inserts may be required to obtaina quality weld. The inserts may also be designed toprovide gas back-up to the part. This option providesbacking gas to the penetration side (bottom) of theweld. Backing gas is required for welding refractorymetals and is recommended for stainless steelmaterials. When welding aluminum, a stainless steelinsert is recommended, dependant upon the weldingprocess used.

In high production environments, and/or when weld-ing with high current, an optional water-cooledmandrel is required. The water-cooled mandrelprovides cooling of the insert using a separate watercirculator. This helps to maintain a consistenttemperature and weld throughout the production run.

E. Tabletop

The tabletop houses the two banks of clampingfingers, and supports the side beam track andcarriage.

One of the most outstanding features of the tabletopdesign is the ability to view the weld in progress viathe naked eye (with weld shield) or with a videocamera.

The two banks of clamping fingers are set andmounted within the tabletop. The tabletop sectionwill differ in size and weight as the welding lengthof the seam welder increases. The tabletop isdesigned to withstand the clamping forces generatedby the clamping fingers.

On both sides of the tabletop are adjusting screwsused to adjust the finger spacing (see Figure 4).There are several screws that are used to adjust thelocation of the fingers relative to the insert groove.These screws should be adjusted symmetrically tothe groove to provide an even chilling effect.

The finger spacing as a standard depends largely onthe material thickness being welded. See Section IVfor Jetline’s recommendation. As a safety note, afterthe adjustments have been completed, there shouldnot be a gap greater than 1/8" (3.2 mm) betweenfingertip and part when the bank of fingers is in itsunclamped state. This adjustment is made tominimize a pinch point condition between thefingers 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 eachfinger is a copper or optional stainless steel finger tipscrewed to the aluminum finger body. These tips arereversible and should be changed if damaged orworn. When welding aluminum, stainless steelfinger tips are recommended, dependant upon thewelding process used.

The latch assembly is mounted on the opposite endof the mainstay. The latch must be closed during theclamping of the fingers, thus securing andsupporting the mandrel. If the clamping forces areexerted on the mandrel without the latch support,there is a potential for mandrel damage. As a result,we have installed a safety switch which preventsclamping without the latch being closed.

WARNING

This safety switch should not be by-passed.


-22-

F. Track

Two or three track supports, depending on thewelding length of the seam welder, are mounted tothe tabletop. The side beam track is bolted securelyand mounted to these track supports. There are nosupports in the welding area of the seam welder. Thetrack is positioned in such a way that it is suspendedover the welding area. See Figure 5.

Typically a TKSA style track is adequate to spandistances under 192" (4875 mm) of weld length. Forlonger distances, the TKMV medium duty track isused. These Jetline tracks ensure a tracking accuracyof the carriage along the track of ±0.015" (0.4 mm)in both planes.

G. Carriage Control

The carriage is driven by the 9627 MicroprocessorControl which is designed for automatic sequencingof carriage travel and power supply starting andstopping. The control is equipped with a two linedisplay which guides the operator through setup anddisplays travel speed during the weld procedure. Theseparate 9627 manual contains complete operatinginstructions.


-23-

Figure 5

Track Support Assembly


-24-


-25-

Section VIII

Start-up and Operation

A. Initial Setup

1. Edge Preparation

It is important that the part edges are preparedso that when they are brought together in theseamer any resulting joint gap is less that 10%of the part’s thickness. Ideally, when using theGTAW or PAW process, the edges are as tighttogether as possible at the beginning of theweld to minimize burn through.

2. Finger Pressure

The finger pressure should be set based onmaterial thickness and the actual application.The Specifications section of this manual givessome recommended pressures for differentmaterial thicknesses.

3. Back-up Insert

Your back-up insert is designed specifically forcertain material types and material thicknessranges. The backup inserts can weld a varietyof material types and material thickness spans.Welding a wide range of material types andthicknesses will require additional inserts. TheSpecifications section of this manual givesrecommendations for back-up inserts. Theseinserts are readily available from JetlineEngineering.

The back-up insert, sitting inside the mandrel,should be parallel to the track. Refer to SectionX.

4. Distance Between Fingers

The distance between the front and rear banksof fingers is adjustable. Only adjust whenfingers are in the up position. It is best to adjusteach screw an equal distance and then to closethe fingers to inspect the finger distance fromthe insert groove. One full turn of each screwwill move the fingers 1/16" (1.6 mm). Eachbank of fingers should be an equal distancefrom the centerline of the back-up insert.

The closer that the fingers are to the groove ofthe back-up insert, the more chilling effect theywill cause in your welding operation. Thefurther the fingers are apart, the less chillingeffect is provided. Fingers that are adjustedclose to the groove can increase the control ofwelding heat input, while wider spaced fingerscan tend to give increased travel speeds. There-fore, it is important to set the finger distancebased on your specific part.

The chart in the Specifications section givesinitial recommendations for finger spacing.

B. Operation

NOTE

The latch should be completely closed beforebeginning to weld.

1. Begin with both sets of fingers in theunclamped (up) position. (Seamers that utilizeany automatic loading or centering may needto be cycled in order to start at the beginning ofa cycle.)

2. The centering devices should be pushed downand toggled over. Check to make sure that theblade is located over the center of the back-upinsert. The back side of the centering deviceblades should be located on the centerline ofthe back-up insert. (Or very slightly to thefront of center).

If the seamer is equipped with more than twocentering devices, use only two, preferablyspaced as far apart as possible for yourparticular part.


-26-

3. The part should be loaded into the rear ofthe seamer first. Push the edge of the part upagainst the centering device blades. Once youare sure that the part is located properly,depress the rear finger toe touch strip. This willcause the rear pressure hose to fill, clampingthe rear bank of fingers and securing the part inthe seamer.

Try to space the part in the seamer so that theends of the part are at least half covered by afinger at each end. If the end is being coveredby less than half of a finger, then the fingercould tilt and result in insufficient chill. If thereis difficulty with burn through at the beginningor end of the part, this could be the cause. Tosolve the problem simply move the part so thatthe finger coverage is correct or insert a smalltab underneath the troublesome finger so thefinger bridges evenly between the end of yourpart and the small tab.

4. Now retract the centering devices.

5. Load the front side (edge) of the part and buttit up against the edge of the part that is alreadyclamped by the rear finger bank. Be sure thatthe ends are even.

6. Depress the front fingers’ toe touch strip andclamp the front fingers on the part. The frontfingers should always be closed last becausethese are the “push-in” fingers. These fingerspush in slightly as clamping pressure isapplied, ensuring a good fit at the joint.

7. Now that the part is loaded, you can prepare toweld.

8. If limit switches are used to determine the startand stop points of the weld, it is best to set upon a practice part. Move the carriage and torchat the desired starting point, then slide the“home” limit switch cam until it contacts the“home” limit switch. Now test this startingpoint by jogging the carriage forward (12 ormore inches if possible) and then returning thecarriage to the “home” position. This willindicate the true starting point.

To set the end of weld limit switch, use asimilar process. First manually set the contactlocation, then test it by reversing travel, thenmoving the carriage to the end of weld.

9. Welding

Each and every welding application requires itsown unique set of welding parameters. Wirespeeds, voltages, travel speeds, gas types, flowrates, back-up bar size, type, finger spacing,clamping pressures, material type, materialthickness and joint preparation are some of themany variables that need to be adjusted inorder to provide the most robust weldingprocedure for a particular application.

Weld development is the sole responsibility of theowner of the equipment and not the responsibility ofJetline Engineering.

10. Once the seam has been welded successfully,release both sets of fingers, open the latch ifneeded and carefully remove the part.


-27-

Section IX

Trouble Shooting

A. Fixture

Problem Cause and Correction

1. Misalignment of torch to the weld joint (insertgroove centerline).

a. The track and carriage not aligned parallel toinsert groove; readjust as per Section X.

b. Alignment devices not adjusted to centerline ofinsert. Clamp a straight edge or a length ofmaterial over centerline of insert groove andadjust the alignment devices by loosening thelocking nut on the Allen adjusting screw at thetop of the telescoping arm. Adjust the Allenscrew so that the device blades contact thestraight edge and tighten the lock nut.

c. The part is not against the two alignmentdevice blades when the part is clamped by thefingers. Unclamp, align and clamp.

d. Gibbs loose on the weld head cross seam slide;adjust as needed.

e. If an arc length control (AVC) is incorporatedon the fixture, check the ways and wheels inthe drive (actuator) for play and adjust.

2. Carriage will not travel. a. The main items to check are:

- Input power to carriage control

- Control fuse

- Check the drive motor brushes, brush springsand caps.

- Be sure the clutch is engaged.

- Fiber gear in gear head motor may bestripped.

b. Refer to the supplied carriage control manualfor wiring information.


-28-

Problem

3. Travel speed readout with optional tach-generator fluctuates.

Cause and Correction

a. Check the belt that connects the carriage drivemotor shaft to the tach generator. Replace thebelt if worn or loose.

b. Check for binding between the carriage wheelsand the rails on the track. Readjust the wheelsif required, see supplied carriage manual.

c. Refer to supplied control manual for wiringinformation

4. Clamping fingers will not clamp. a. Check air supply to fixture.

b. Check clamping pressure air regulator forproper 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 toe-touchpanel.

f. Shop line pressure is too low to actuate thepilot actuated air solenoid valve.

5. Can hear air leaking in the vertical riser. Open hinge door and check:

a. White poly flow tubing for leaks.

b. Internal air hoses for leaks.

c. Clamping hoses for leaks.

6. Cannot establish tight, even butt-up of finalsheared piece parts.

a. When worn or misaligned, the shear knives canproduce a concave cut, convex cut or sheardrag (burr). Once the cut-off shear blades arereadjusted, sharpened or replaced, thestraightness of the part should be checkedagainst a straight edge.


-29-

B. GTAW Process

Problem

1. Cannot initiate an arc when using GTAWwelding equipment.


a. Remove the torch cap which retains the colletand electrode. If the weld tip of the electrode isblue or contaminated, sharpen it or replacewith a new sharpened electrode. If the bore ofthe collet is worn or does not provide a tightgrip of the electrode when installed in thetorch, replace collet with a new one.

b. A blue finish to the surface of the tungstenimplies oxygen contamination. This can becaused by too short of a post flow time, a loosegas fitting, a contaminated gas supply, airturbulence at the weld zone, too small a shieldcup on the torch, or too low of a flow rate ofgas.

c. Check shield gas pressure (PSI) at the regulatorand flow (CFH) at the flowmeter. The PSIshould not be less than 50 and the CFH shouldcoincide with established welding parameters.

d. Make sure the “high frequency” control at thepower supply is switched to the proper modeof “start” for D.C.S.P. welding or continuousfor A.C.H.F. welding.

2. If an arc still will not establish, check thefollowing steps.

a. - Shut off power to the power supply.

- Check contact point gap setting. Refer topower supply manual.

- If contact points are pitted or worn, replace.

b. Increase the high frequency intensitypotentiometer on the power source.

c. Amperage setting at the power supply may betoo low to initiate an arc. Raise the amperagesetting.

d. Material to be welded may contain coated orscaled surface. Remove coating or scale byusing a fine emery cloth.

3. Electrode sticks to workpiece when usingGTAW welding equipment.

a. This condition usually occurs at the start of theweld cycle.

- Shut the welder off and stop carriage fromtraversing.

- Raise the torch head to free the electrode.


-30-

Problem Cause and Correction

- If that fails, unscrew the tube assembly of thetorch head and pull the tube, collet and electr-ode out.

- As a last resort, make sure that the weld modeis in the “off” position, then cut the tungstenelectrode with wire cutters.

4. Arc voltage raises or lowers during the weldcycle when using GTAW welding equipment.

a. Make sure the electrode is sharp (clean) andthe torch collet grips the electrode tightly.

b. Check the insert and travel carriage forparallelism. If a variation exists, adjust thetrack and/or mandrel.

c. Make sure all drive gearing, roundways andcam followers are clean.

d. If an arc length control (AVC) is used with thefixture, check to see if it is correcting forvariations in the arc length (check troubleshooting section in the ALC manual).

5. White smoke appears during GTAW weldingprocess.

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/orcracking. A loosely fitted or defective nozzlepermits aspiration. Check for too small anozzle orifice for size of tungsten.

6. Black smoke appears during GTAW weldcycle.

a. The electrode is contaminated from use or hasbeen ground on a contaminated grindingwheel. Replace or re-grind the electrode.

b. The torch head is overheating. The coolant line(if so equipped) “to” and “from” the torch mayhave insufficient water flow.

c. Gas is not flowing.

7. Butted parts rise when welding light gaugematerial.

a. Adjust the clamping pressure to eliminate anydeformation of the butt joint once the parts arebutted and clamped.

b. Finger tip distance is too far apart (see chart,Section IV).


-31-

Problem

8. Incomplete penetration.


c. Welding amperage setting may be too high andthe carriage speed too slow. Adjust amperagefirst, then carriage speed if needed.

a. Check the welding parameters for materialbeing welded.

b. If the parameter is not listed, try the followingsteps:

- Increase the amperage on the power supply.

- Once penetration is attained, adjust thecarriage speed at the carriage control to assureuniformity of the weld bead. Rule of thumb isnever try to over-penetrate. If over-penetrationoccurs, increase the carriage speed or decreasethe amperage.

- Check the insert selection chart (Section IV)to be sure that the insert is manufactured fromthe correct material and that the groove in theinsert is the correct width and depth for thethickness of material to be welded.


-32-


-33-

Section X

Mechanical Maintenance

Once a month, check all the hoses and fittings forleaks or deterioration. A leaking hose can cause lossof clamping pressure and result in poor qualitywork. Blow out water from the air filter on the sideof the mainstay by opening the drain valve at thebottom of the filter while the shop air is connected.See Figure 1.

Re-machine or replace, if necessary, the copperfinger tips or continuous strips when they becomemarred by dents or excessive impression marks.Both the finger tips and the continuous strips arereversible for extended life.

A. Adjustment & Replacementof the Clamping Fingers

Both left and right banks of fingers can be adjustedin or out by means of screws located on each side ofthe tabletop. Each screw applies pressure to thefinger adjusting bar which applies proportionalpressure against the finger bank assembly.

Each finger bank must be adjusted parallel to theinsert groove. The distance from the groove to thefinger tips must be the same on each side. Alwaysstart adjustment with the screws located at the centerof the machine. Turn the screws a maximum of onerevolution at a time, working towards both ends.Repeat until proper setting is reached.

To remove a finger assembly, first loosen the slottedflat head screw from the bottom side of the finger.Once the screw is loose in the countersink, move ittowards the front of the finger and pass the head ofthe screw through the clearance hole. The finger cannow be removed from the fixture. Avoid removingthe screw completely from the spring and nutassembly.

CAUTION

Do not inter-exchange the front fingers with therear fingers, as they are of a different design.

When all the fingers are removed, the clamping hosewill hang loose from the tabletop; this is normal.

To replace the fingers, start at the mainstay andwork toward the latch end of the seamer. Fasten a“C” clamp onto the nesting bar to keep the fingeradjusting bar from rolling out of the nesting barwhen the fingers are removed. See Figure 4.

Install the aluminum only end of the finger into thenesting bar. Guide the finger adjusting screwthrough the clearance hole in the finger and pull thescrew back until it seats into the countersink.Tighten the screw until the finger contacts the lip ofthe tabletop. Continue to install the fingers in theabove manner until all are in place. The screw in thelast finger can be guided through the finger with ascrewdriver. Tighten all the fingers proportionatelyso that they all return against the tabletop lip whenthe air is exhausted from the hoses.

The aluminum fingers are three inches wide andhave replaceable, reversible copper finger tips. (Asan option, they are available made from 300 seriesstainless steel.) The copper finger tips, in addition toclamping the part against the back-up insert, also actas a heat sink to absorb heat created by the weldingprocess. If a finger tip is subject to nicks or gougesat the point it contacts the part, it can affect itsability to act as a heat sink and should be dressed orreplaced.


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To remove a finger tip from the finger body, removethe two Allen head screws which hold it to thefinger. These screws are located on the bottom of thefinger tip. Place the finger tip in a vice and, using aflat file, draw the file over the clamping surface ofthe finger tip. The maximum which can be filed offthe tip is 0.05" (1.3 mm). The tip is reversible and,if the tip cannot be dressed, replace the tip using theopposing side. When both sides are beyond dressing,replace the tip.

B. Replacement of theClamping Hoses

The clamping movement of the fingers is caused byinflating the pressure hose located between thetabletop and the upper surface of the fingers. Over aperiod of time, the hose may become damaged fromextreme heat, weld spatter or deterioration of therubber in the hose. Should this happen, the hosecannot be repaired but must be replaced.

To replace the hose, use the following procedure:

Disconnect the 115 volts AC and air supply to theseam welder. Remove the finger adjusting channelswhich are located at the latch end of the machine.The channels are located between the left and rightfirst finger assemblies and the front plate. Once thefinger adjusting channel is removed, the end of thepneumatic hose and hose clamps will be exposed.The three hose clamp bolts serve two purposes. Theyclamp the ends of the hoses together and attach theends of the hoses to the tabletop. Remove the threebolts from each clamp and remove the clamps fromthe hoses. Tie an electrician’s fish tape to this end ofone of the hoses.

At the opposite end of the machine, open the hingeddoor at the rear of the mainstay. On the interior ofthe door is mounted the FCP-10B foot control panel.The hoses and controls for the clamping system arelocated inside the mainstay. Remove the small whitevinyl high pressure tube from the tee by pushing thetube locking collet and remove the tube from thecollet. Remove the larger pneumatic hose from theair solenoid valves. (See Figure 6.) Pull the pressurehose out of the tabletop from the mainstay, makingsure the fish tape is pulled through the tabletop. Ifthere is an orange spatter shield around the hose,pull it out with the hose.

Cut a new pressure hose the same length as the old.Pre-drill the three holes in the end of the new hosefor the hose clamp. Re-install the round plug usingtwo new H40 worm drive clamps. Use No. 2Permatex as a sealant for both ends of the hose whenassembling.

Pull the fish tape and the new hose through thetabletop from the latch end of the machine. If thereis a spatter shield to be installed, it must be pulledthrough with the hose. The seam of the spatter shieldmust be either on the top or bottom surface of thehose. The clamping fingers may have to be loosenedwhen installing hose with a spatter shield.

Reconnect the high pressure tube and pneumatichoses. Be sure to allow the Permatex to set up beforeconnecting to the shop air. Pressurize the hoses andcheck for air leaks. Replace the finger adjustingchannels and, using the set screws, adjust thechannels for proper clearance and spacing.

C. Replacement of the Mandrel

To ease installation of a mandrel in a JetlineLongitudinal Seam Welder, it is recommended thata Jetline Mandrel Cart be used. Installing themandrel can also be done using a suitable liftingdevice such as a fork lift truck.

Before doing the installation, a number of actionsmust be done first.

On one end of the mandrel there is the mountingplate which has four tapped holes and a number ofslots. In the four tapped holes there are four squarehead bolts, used as “jacking screws”. Welded on thefront of mainstay, are two vertical bars and onehorizontal bar. One vertical bar and the horizontalbar have adjusting screws. These screws must bebacked off to allow clearance for the mandrel plateto fit between them. Ensure that the nuts andwashers have been removed from the mandrelanchor bars which protrude through the front face ofthe mainstay. Raise the latch assembly.


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Figure 6

Pneumatic System


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Using either the mandrel cart or fork lift truck, movethe mandrel mounting plate close to the ends of theanchor bar screws that protrude through themainstay. Align the slots in the mandrel mountingplate with the anchor bar screws and push themandrel over them and up to the mainstay front face.

Replace the washers and nuts onto the anchor barscrews. Lightly tighten them to hold the mandrelagainst the mainstay face so that the mandrel platelies between the two vertical bars and above thehorizontal bar. The cart, or similar device, can nowbe removed.

D. Adjustment of the Mandrel

Once the mandrel has been fitted to the seam welder,it then has to be adjusted to be positioned correctlyrelative to the fingers and tabletop assembly. Theadjustment procedure is made easier by having theinsert installed in its machined groove in the top ofthe mandrel.

With the mandrel anchor bar nuts slightly loose, thefirst adjustment is to make the mandrel and insertparallel with the underside of the clamping fingers.Based upon welding a 1/8" material thickness (orless) as an example for adjusting the machine, first,use the horizontal bar with 1" screw to coarse adjustthe mandrel vertically. Using a scale, adjust themandrel up until there is an approximate 3/16" spacebetween the finger tips and the highest point of theinsert. Use the square head “jacking screws” in themandrel plate to pitch the mandrel until its fulllength is parallel with the clamping finger tips. Viewthe mandrel from the side and using a scale measurethe gap at the mainstay end and the latch end. Bothmeasurements should be equal.

Next, adjust the insert groove parallel with thecenterline of the tabletop. Viewing from above thetabletop, first measure and determine the centerlinedistance between the formed tabletop edges. Startingat the mainstay end of the mandrel, use the twoscrews in the vertical bar that is welded to the frontof the mainstay to move the mandrel until the insertgroove is on centerline of the formed tabletop. Thenuse a combination of the four square head “jackingscrews” to move the latch end of the insert groove tocenterline as well as maintain parallelism to thefinger tips.

The seam welder is designed to accommodatedifferent material thicknesses and the actual vertical

position of the mandrel is governed by this. For themachine to work efficiently, the gap between thefingers and insert should be the material thicknessplus 1/16" (3 mm).

After these adjustments have been made, themandrel anchor nuts can now be tightened. Aftertightening the nuts, check and readjust as required.

E. Adjustment of the Track tothe Insert

Once the back-up mandrel and insert have beenadjusted to the tabletop, the track will requireadjustment relative to the insert groove and face.The vertical distance between the insert face and thewelding torch (mounted on the travel carriage)should vary no more than 0.08" (2 mm) at fullclamping pressure. The tracking accuracy (track toinsert groove) should be ±.015" (0.4 mm) per 10 ft(3 m) of track length for the standard machine. Forthe precision machines (LWP, LWX), trackingaccuracy (track to insert groove) should be ±.005"(0.13 mm) per 10 ft (3 m) of track length.

To check the vertical height accuracy, move thecarriage to the end of its travel, towards the mainstayend of the machine. Actuate and clamp both fingerbanks at 40 PSI against the backup insert. Mount amachinist’s dial indicator to the travel carriage andalign the stem against the face of the back-up insert.Set the indicator dial at zero, and then manuallymove the carriage towards the latch of the machine.Correct adjustment of the track is obtained when theindicator also reads zero at the latch end of themachine. If the indicator does not read zero, verticaltrack adjustment is required. Note that it is typicalfor the mandrel to deflect approximately 0.040" (1mm) between each end due to the clamping pressureexerted.

1. Vertical Track Adjustment

If vertical adjustment of the track is required,only make adjustment at the latch end of themachine. Loosen the four 3/4" track mountingbolts that are located at the backside of thetrack. The track mounting bracket is slottedallowing vertical adjustment using the leverarm mounted on its side.

Using an Allen wrench, turn the verticaladjusting bolt counter-clockwise to lower thetrack (clockwise to raise). The amount of


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adjustment is determined by watching the dialindicator mounted on the carriage, trying to“match” the zero reading from the mainstayend of the machine. After the track is adjusted,tighten the four 3/4" bolts on the track bracket.

2. Horizontal Adjustment

Using the ground torch electrode or thewelding wire as a pointer, adjust either so thatit just clears the upper surface of the insert.Adjust the pointer horizontally so that it isright over the tangent point where the edge ofthe machined groove meets the flat surface onthe insert. The machined edge of the groovewill be used as the reference point for theelectrode or wire to track the insert groove.Starting at the mainstay end of the machine,manually traverse the carriage along the trackand stop at the latch end of the machine.Observe if the track requires adjustment and ifso, which direction the pointer must move inrelation to the machined edge of the insert.

On the mounting bracket above the verticaladjusting lever are four 3/4" bolts. Foradjustment, loosen the four bolts noting thatthe bracket is slotted in the horizontaldirection. At the rear of the bracket is a single3/4" adjustment screw. When the adjustmentscrew is rotated clockwise, the track will moveaway from the insert centerline. Rotatingcounter clockwise will move the track towardsthe insert centerline. Once the track is adjustedparallel to the machined edge of the insert,tighten the four 3/4" bolts.

F. Preventive Maintenance

1. Daily Mechanical

a. Inspect roundway or v-way rails of thetrack, clean and coat with WD-40 or equal.

b. Inspect finger tips for excess weld spatter.Remove by wire brushing.

c. Inspect inserts for oxides and foreignmatter. Clear with wire brush, MEK orAcetone.

d. Drain the air filter at the rear of themainstay by turning the valve at the bottomof the bowl.

2. Weekly Mechanical

a. Inspect track and mandrel alignment foraccuracy.

b. Check v-way wheels on SWC-6 seriescarriage for proper adjustment (see SWC-6operation manual).

3. Monthly Mechanical

a. Check all bolts and components of thealignment devices to be sure that they aretight.

b. Check coolant level in torch waterrecirculator.

c. Check all hoses, gas, water, and air forleaks and deterioration.

3. Bi-annual Mechanical

a. Check oil level on SWC-6 series carriagegear box (see SWC-6 operators manual).

4. Quarterly Electrical

a. Check all welding and exposed cables.

b. Check carriage motor brushes.

5. Bi-annual Electrical

a. Check welding power source for dust anddirt.

b. Check all pushbutton emergency switches.


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Section XI

Parts List

The following pages provide a detailed parts list ofall the elements of the longitudinal seam welder.They are arranged so the parts list on the left handpage corresponds to the assembly illustrated on theright hand page. Item numbers shown in the partslist refer to those numbers contained in the balloonin the drawing. The quantities shown are the numberof items used in that particular assembly.

Two columns are included in the list to show thespare parts which are recommended to be stocked bythe user. The two levels can be defined as follows:

Level 1 These are the spares recommended for USdomestic users whose use of the productdoes not exceed 2000 hours per year.

Level 2 These are the spares recommended forinternational use of the product or for USdomestic users who will use the product inexcess of 2000 hours per year.

The following parts lists are included in this manual.Their appropriate page numbers are listed:

Longitudinal Seam Welder . . . . . . . . . . . . . 40/41

Foot Control Panel . . . . . . . . . . . . . . . . . . . . 42/43

Retractable Centering Device . . . . . . . . . . . . 44/45


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Longitudinal Seam Welder

LW-

Recommended Spares Item Part Level LevelNo. No. Description Qty I II

1 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Track Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mainstay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical Cord, 115 VAC . . . . . . . . . . . . . . . . . . . . 18 Switch, Finger Actuation . . . . . . . . . . . . . . . . . . . . . 39 CBS Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Mounting Plate Nuts . . . . . . . . . . . . . . . . . . . . . . . . 412 Mandrel Plate Adjustment Screws . . . . . . . . . . . . . . 413 Finger Adjustment Screws . . . . . . . . . . . . . . . . . . A/R14 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 SWCA-3 Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 116 9627 Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . 1


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Foot Control Panel

FCP-10B


2 A10N84 Nema 1 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FCP-10B-3 Foot Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 RY2LS-120A 120 VAC Latch Relay . . . . . . . . . . . . . . . . . . . . . . . 2 1 15 RY2S-U-24A 24 VAC DPDT Relay . . . . . . . . . . . . . . . . . . . . . . . . 2 1 16 RY2S-U-120A 120 VAC DPDT Relay . . . . . . . . . . . . . . . . . . . . . . . 2 1 17 J74 202A Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SY4S-51F1 LR1, LR2, Spring Hold . . . . . . . . . . . . . . . . . . . . . . 19 SY2S-02F1 CR1,2,3,4 / CR2, Spring Hold . . . . . . . . . . . . . . . . . 6

10 28F027 Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 GGC-3 Fuse, 3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1


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Retractable Centering Device

CLW-110A


2 CL-200 End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CL-201 Pivot Stop, regular and thin . . . . . . . . . . . . . . . . . 1 ea4 CL-202 Pivot Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CL-203 Spacer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CL-204 Guide Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CL-205A Extension Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3/8-16x3/4 Button Head Screw . . . . . . . . . . . . . . . . . . . . . . . . . 19 3/8-16x1 Socket Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 3/8-16x2 Hex Head Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . 211 3/8-16,5-10LB Ball Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 3/8-16,2-4LB Ball Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 3/8-16 Hex Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 3/8x3/4 Socket Head Shoulder Screw . . . . . . . . . . . . . . . . . . 115 3/16x1/2 Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 5/16x3/4 Brass Socket Set Screw . . . . . . . . . . . . . . . . . . . . . . 2


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Section XII

Electrical Drawings


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External Seam Welders Manual

Documents

Transcript of External Seam Welders Manual