OM-LW-03-2013
OPERATION MANUAL
for External
Longitudinal Seam
Welders
March 2013
Effective with Serial Number 990547
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618
Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: sales@jetline.com
Longitudinal Seam Welders - Models LWI, LWP, LWS, LWX
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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.
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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.
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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.............................................................................................................18
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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..........................................................................................................................................39
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Longitudinal Seam Welders - Models LWP, LWS, LWX
Section I
Safety Precautions
4.Properly install and ground this equipment
according to the operation manual and
national, state and local codes.
WARNING
A.
Arc Welding
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.
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.
6.When making input connections, attach
proper grounding conductor first - doublecheck connections.
Frequently inspect input power cord for
7.
damage or bare wiring. Replace cord immediately if damaged - bare wiring can kill.
8.
Have all installation, operation, maintenance and
repair work performed only by qualified people.
B.
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.
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.
10.Do not touch electrode if you are in contact
with the work, ground, or another electrode
from a different machine.
1.
14.Clamp work cable with good metal-tometal contact to workpiece or worktable
as near the weld as practical.
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.
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
1910.147 (see Safety Standards).
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Longitudinal Seam Welders - Models LWP, LWS, LWX
C.
4.Read the Material Safety Data Sheets
(MSDS) and the manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
Arc Rays
Arc rays can burn eyes and skin; noise can
damage hearing; flying slag or sparks can injure
eyes.
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.
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.
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.
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.
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.
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.
E.Cylinders
5.Wear protective clothing made from
durable, flame-resistant material (wool
and leather) and foot protection where
necessary.
D.
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.
Fumes and Gases
Fumes and gases can be hazardous to your
health.
1.Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag,
open flames, sparks, and arcs.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
2.Install cylinders in an upright position by
securing to a stationary support or cylinder rack to prevent falling or tipping.
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.Keep cylinders away from any welding
or other electrical circuits.
4.Never weld on a pressurized cylinder
- explosion will result.
3.If ventilation is poor, use an approved
air-supplied respirator.
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Longitudinal Seam Welders - Models LWP, LWS, LWX
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.Do not weld on closed containers such
as tanks, drums, or pipes, unless they are
properly prepared according to AWSF4.1
(see safety Standards).
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.
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.Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in
Safety Standards.
8.Wear oil-free protective garments such
as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
G.
F.Welding
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
Welding can cause fire or explosion.
Moving Parts
1.Keep all doors, panels, covers, and guards
closed and securely in place.
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.
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
1.Protect yourself and others from flying
sparks and hot metal.
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):
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.
“.... 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
5.Watch for fire, and keep a fire extinguisher nearby.
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Longitudinal Seam Welders - Models LWP, LWS, LWX
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.”
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 33126
To reduce magnetic fields in the work place, use
the following procedures:
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202
1.Keep cables close together by twisting or
taping them.
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
2.Arrange cables to one side and away from
the operator.
3.Do not coil or drape cables around the
body.
Sales Practices for Occupation and Educational
Eye and Face Protection, ANSI Standard Z87.1,
from American National Standards Institute,
1430 Broadway, New York, NY 10018
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.
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
About Pacemakers:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
I.
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. §248224
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 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 from
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
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Longitudinal Seam Welders - Models LWP, LWS, LWX
Section II
Introduction
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.
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 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.
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.
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.
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.
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Longitudinal Seam Welders - Models LWP, LWS, LWX
Track
Support
Carriage
Track
Pressure
Gauge
Mandrel
Tape Switch
Ground
Lug
Latch
Base
Mainstay
Plug
Figure 1
Longitudinal Seam Welder
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Longitudinal Seam Welders - Models LWP, LWS, LWX
Section III
Initial Inspection
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.
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.
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.
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.
After this initial inspection is completed, installation of the longitudinal seam welder can begin.
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.
System is strapped down prior to crating.
Lattice crate packing
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Longitudinal Seam Welders - Models LWP, LWS, LWX
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Longitudinal Seam Welders - Models LWP, LWS, LWX
Section IV
Specifications
A.
For seam welders over 16 ft (4.8 m) long:
Input Requirements
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.)
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.
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.
Carriage Speed Ranges
For seam welders up to 16 ft (4.8 m) long:
SWCA-4A: 4 to 170 IPM (102 to 4,318 mm/min)
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-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
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
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Longitudinal Seam Welders - Models LWP, LWS, LWX
“C”
“D”
“E”
“F”
Approx.
Ship Weight
“A”
“B”
*Model
Number
Welding
Length in/mm
**Min. Dia
Part
in/mm
LW-24
24/609
2.63/67
32/800
70/1765
40/1003
69/1753
2300/1040
LW-36
36/914
3.5/89
32/800
82/2070
40/1003
69/1753
2600/1180
LW-48
48/1219
4.25/108
32/800
94/2372
40/1003
69/1753
4000/1810
LW-60
60/1524
5.25/133
32/800
106/2677
40/1003
69/1753
4700/2130
LW-72
72/1829
6/152
32/800
118/2981
40/1003
69/1753
5300/2400
LW-84
84/2134
6.87/175
32/800
130/3286
40/1003
69/1753
5900/2680
LW-96
96/2438
7.25/184
32/800
142/3591
40/1003
69/1753
6400/2900
LW-120
120/3048
9.5/241
32/800
176/4470
42/1054
76/1930
12000/5440
LW-144
144/3658
12.25/311
32/800
200/5080
42/1054
76/1930
13000/5890
LW-168
168/4267
15.25/387
32/800
224/5689
42/1054
76/1930
14000/6330
LW-192
192/4877
18.5/464
32/800
248/6300
42/1054
76/1930
15000/6780
LW-216
216/5486
21.25/539
32/800
272/6910
42/1054
76/1930
16000/7240
LW-240
240/6096
24.25/616
32/800
296/7518
42/1054
76/1930
17000/7690
***Min. Dia.
Overall length Overall Width Overall height
Part
in/mm
in/mm
in/mm
in/mm
Lb/Kg
LWP Precision Seam Welder
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.
Application: 0.005” to 3/8” (0.1 to 10 mm) - all
weldable metals
Travel Accuracy: 0.005” (0.1 mm)
per 10 ft (3 m)
Carriage Drive: Rack and Pinion
LWX Ultra-Precision Seam Welder
LWS Standard Seam Welder
Application: For critical applications
0.005” to 3/8” (0.1 to 10 mm) - all weldable
metals
Travel Accuracy: 0.005” (0.1 mm)
per 10 ft (3 m)
Carriage Drive: Linear Drive
Application: 0.020” to 3/8” (0.5 to 10 mm) – all
weldable metals
Travel Accuracy: 0.015” (0.4 mm)
per 10 ft (3 m)
Carriage Drive: Rack and Pinion
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Longitudinal Seam Welders - Models LWP, LWS, LWX
Figure 2
Dimensions - Longitudinal Seam Welder
- 11 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
D.
Chill Bar Selection - GTAW
Thickness
.005-.012
.013-.020
.021-.032
.033-.040
.041-.050
.051-.062
.063-.072
.073-.125
.126-.250
.251-.375
Fusion
Filler
Fusion
Filler
Fusion
Filler
Fusion
Filler
Fusion
Filler
Fusion
Filler
Fusion
Filler
Fusion
Filler
Fusion
Filler
Fusion
Filler
TIG-DCSP
GROUP I*
Base Metal:
Steel
Stainless
Aluminum
Magnesium
Copper
TIG-AC
GROUP II**
Base Metal:
Aluminum
Magnesium
*Copper Insert
.040W .010D
.063W .010D
.093W .010D
.125W .020D
.125W .020D
.187W .025D
.125W .020D
.187W .025D
.187W .020D
.250W .040D
.187W .020D
.250W .040D
.250W .040D
.312W .040D
.312W .020D
.375W .050D
-
** Steel or Stainless Insert
.093W .010D
.093W .015D
.125W .015D
.125W .020D
.156W .015D
.156W .020D
.187W .015D
.187W .020D
.250W .020D
.250W .025D
.312W .020D
.312W .030D
.375W .030D
.375W .040D
.375W .030D
.438W .040D
- 12 -
TIG-DCSP
GROUP III
Base Metal:
Titanium
Molybdenum
Zircalloy
Tantalum
Rene 41
Hastelloy
Inconel
Haynes 25
.040W .125D
.125W .100D
.187W .100D
.250W .100D
.312W .100D
Longitudinal Seam Welders - Models LWP, LWS, LWX
E.
Chill Bar Selection - GMAW
Base Metal:
Steel
Stainless
Aluminum
Magnesium
Copper
Thickness
.005-.012
.013-.020
.021-.032
.033-.040
.041-.050
.051-.062
.063-.072
.073-.125
.126-.250
.251-.375
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
MIG
SUB-ARC
GROUP I*
*Copper Chill Bar
.125W .040D
.187W .050D
.187W .050D
.125W .035D
.250W .050D
.140W .040D
.250W .050D
.187W .050D
.312W .060D
.375W .055D
.375W .060D
.470W .060D
.437W .080D
.630W .065D
- 13 -
GROUP II**
Base Metal:
Aluminum
Magnesium
** Steel or Stainless Insert
.125W .040D
.125W .040D
.187W .050D
.250W .050D
.250W .050D
.312W .060D
.375W .060D
.437W .080D
-
Longitudinal Seam Welders - Models LWP, LWS, LWX
F.
Distance Between Fingertips
Base Metal:
Steel
Stainless
Aluminum
Magnesium
Copper
Thickness
.005-.012" (0.1-0.3 mm)
.013-.024" (0.3-0.6 mm)
.025-.032" (0.6-0.8 mm)
.033-.040" (0.8-1.0 mm)
.041-.050" (1.0-1.3 mm)
.051-.080" (1.3-2.0 mm)
.081-.125" (2.0-3.2 mm)
.126-.250" (3.2-6.3 mm)
.251-.375" (6.3-10 mm)
G.
GROUP I*
Distance
.063" (1.6 mm)
.100" (2.5 mm)
.125" (3.2 mm)
.187" (4.8 mm)
.250" (6 mm)
.375" (10 mm)
.438" (11 mm)
.500" (12.7 mm)
.565" (14 mm)
GROUP II**
Base Metal:
Aluminum
Magnesium
Distance
.312" (8 mm)
.375" (10 mm)
.500" (12.7 mm)
.625" (16 mm)
.750" (19 mm)
.875" (22 mm)
1.0" (25 mm)
Air Regulator Settings
Material Thickness
.005-.012" (0.1-0.3 mm)
.013-.024" (0.3-0.6 mm)
.025-.032" (0.6-0.8 mm)
.033-.050" (0.8-1.3 mm)
.051-.080" (1.3-2.0 mm)
.081-.125" (3.2-6.3 mm)
.126-.250" (3.2-6.3 mm)
Regulator Settings
10 PSI (4.5 kg/sq mm)
15 PSI (6.8 kg/sq mm)
20 PSI (9 kg/sq mm)
25 PSI (11 kg/sq mm)
37 PSI (17 kg/sq mm)
50 PSI (22.7 kg/sq 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.
- 14 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Section V
Installation
• Air or electric impact drill if concrete anchoring bolts needed.
A.System Operating
Conditions
• Digital VOM electrical meter.
Temperature range: 0 to 40C
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.
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
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.
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.
One of four mounting holes for use with overhead crane. Two are located on each end of the
tabletop.
• 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.
- 15 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Remove this shipping bracket from the carriage
and discard. Look for tag as shown below.
CAUTION
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.
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.
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.
• 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.
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.
• 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.
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.
• Once the carriage is mounted on the track,
replace the mechanical stop on the end of
the track to its original position.
- 16 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Figure 3
Carriage Assembly
- 17 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
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.
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.
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.
Perform trial welds on scrap material to test
functioning of system.
C.
Electrical Installation
The electrical input requirements for the seam
welder are 110-120 VAC, 1 phase, 50/60 Hz. If
the seam welder must operate on 220-240 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.
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.
- 18 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Section VI
Theory of Operation
A.
(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.
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.
Part configurations which the seam welder can
handle are cylinders, cones, truncated cones,
open ended boxes, double bowl sinks, flat plates
and sheets.
B.
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
0.375” (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.
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.
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.
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 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
The mainstay also houses the control box (FCP10B) for the toe-touch switches, the pneumatic
- 19 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
valves, water lines if applicable, and electrical
solenoids which operate the pressure hose assemblies.
E.Tabletop
The tabletop houses the two banks of clamping
fingers, and supports the side beam track and
carriage.
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.
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.
D.Mandrel
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.
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.
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 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.
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.
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.
- 20 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Figure 4
Tabletop Half Section
- 21 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
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
0.015” (0.4 mm) in both planes.
- 22 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Figure 5
Track Support Assembly
- 23 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
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
- 24 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Section VII
Start-up and Operation
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.
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.
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.
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.
The chart in the Specifications section gives
initial recommendations for finger spacing.
Back-up Insert
B.Operation
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.
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.)
The back-up insert, sitting inside the mandrel, should be parallel to the track. Refer
to the maintenance section of this manual.
4.
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).
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
- 25 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
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.
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.
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.
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.
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.
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.
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.
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.
- 26 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Section VIII
Trouble Shooting
A.Fixture
Problem
Cause and Correction
1.Misalignment of torch to the weld joint
(insert groove centerline).
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.
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
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.
- 27 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Problem
Cause and Correction
3.Travel speed readout with optional tach
generator fluctuates.
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.
4.
a.
Clamping fingers will not clamp.
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.
6.Cannot establish tight, even butt-up of
final sheared parts.
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.
5.
Can hear air leaking in the vertical riser.
- 28 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
A.
GTAW Process
Problem
Cause and Correction
1.Cannot initiate an arc when using GTAW
welding equipment.
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.
2.If an arc still will not establish, check the
following steps.
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.
- 29 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Problem
Cause and Correction
3.Electrode sticks to part when using GTAW
welding equipment.
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.
4.Arc voltage raises or lowers during the
weld cycle when using GTAW welding
equipment.
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).
5.White smoke appears during GTAW welding process.
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.
- 30 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Problem
Cause and Correction
6.Black smoke appears during GTAW weld
cycle.
a.The electrode is contaminated from use
or has been ground on a contaminated
grinding wheel. Replace or re-grind the
electrode.
b.The torch head is overheating. The coolant
line (if so equipped) “to” and “from” the
torch may have insufficient water flow.
d.
7.Butted parts rise when welding light gauge
material.
Gas is not flowing.
a.Adjust the clamping pressure to eliminate
any deformation of the butt joint once the
parts are butted and clamped.
b.Fingertip distance is too far apart (see
chart, Section IV).
c.Welding amperage setting may be too
high and the carriage speed too slow. Adjust amperage first, then carriage speed if
needed.
8.
a.Check the welding parameters for material
being welded.
Incomplete penetration.
b.If the parameter is not listed, try the following steps:
- Increase the amperage on the power supply.
- Once penetration is attained, adjust the
carriage speed at the carriage control to
assure uniformity of the weld bead. Rule
of thumb is never try to over-penetrate. If
over-penetration occurs, increase the carriage speed or decrease the amperage.
- Check the insert selection chart (Section
IV) to be sure that the insert is manufactured from the correct material and that
the groove in the insert is the correct width
and depth for the thickness of material to
be welded.
- 31 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
- 32 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Section IX
Mechanical Maintenance
Once a month, check all the hoses and fittings
for leaks or deterioration. A leaking hose can
cause loss of clamping pressure and result in
poor quality work. Blow out water from the air
filter on the side of the mainstay by opening the
drain valve at the bottom of the filter while the
shop air is connected. See Figure 1.
CAUTION
Do not inter-exchange the front fingers with
the rear fingers, as they are of a different
design.
When all the fingers are removed, the clamping
hose will hang loose from the tabletop; this is
normal.
Re-machine or replace, if necessary, the copper
finger tips or continuous strips when they become marred by dents or excessive impression
marks. Both the finger tips and the continuous
strips are reversible for extended life.
To replace the fingers, start at the mainstay and
work toward the latch end of the seam welder.
Fasten a “C” clamp onto the nesting bar to keep
the finger adjusting bar from rolling out of the
nesting bar when the fingers are removed. See
Figure 4.
A.Adjustment & Replacement
of the Clamping Fingers
Both left and right banks of fingers can be adjusted in or out by means of screws located on
each side of the tabletop. Each screw applies
pressure to the finger adjusting bar which applies proportional pressure against the finger
bank assembly.
Install the aluminum only end of the finger into
the nesting bar. Guide the finger adjusting screw
through the clearance hole in the finger and pull
the screw back until it seats into the countersink.
Tighten the screw until the finger contacts the
lip of the tabletop. Continue to install the fingers
in the above manner until all are in place. The
screw in the last finger can be guided through
the finger with a screwdriver. Tighten all the
fingers proportionately so that they all return
against the tabletop lip when the air is exhausted
from the hoses.
Each finger bank must be adjusted parallel to
the insert groove. The distance from the groove
to the finger tips must be the same on each side.
Always start adjustment with the screws located
at the center of the machine. Turn the screws a
maximum of one revolution at a time, working
towards both ends. Repeat until proper setting
is reached.
The aluminum fingers are three inches wide and
have replaceable, reversible copper finger tips.
(As an option, they are available made from 300
series stainless steel.) The copper finger tips, in
addition to clamping the part against the backup insert, also act as a heat sink to absorb heat
created by the welding process. If a fingertip is
subject to nicks or gouges at the point it contacts
the part, it can affect its ability to act as a heat
sink and should be dressed or replaced.
To remove a finger assembly, first loosen the
slotted flat head screw from the bottom side of
the finger. Once the screw is loose in the countersink, move it towards the front of the finger and
pass the head of the screw through the clearance
hole. The finger can now be removed from the
fixture. Avoid removing the screw completely
from the spring and nut assembly.
- 33 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
from the tee by pushing the tube locking collet
and remove the tube from the collet. Remove
the larger pneumatic hose from the air solenoid
valves. (See Figure 6.) Pull the pressure hose
out of the tabletop from the mainstay, making
sure the fish tape is pulled through the tabletop.
If there is an orange spatter shield around the
hose, pull it out with the hose.
To remove a fingertip from the finger body,
remove the two Allen head screws which hold
it to the finger. These screws are located on the
bottom of the finger tip. Place the fingertip in a
vice and, using a flat file, draw the file over the
clamping surface of the finger tip. The maximum
which can be filed off the tip is 0.05” (1.3 mm).
The tip is reversible and, if the tip cannot be
dressed, replace the tip using the opposing side.
When both sides are beyond dressing, replace
the tip.
Cut a new pressure hose the same length as the
old. Pre-drill the three holes in the end of the new
hose for the hose clamp. Re-install the round
plug using two new H40 worm drive clamps.
Use No. 2 Permatex as a sealant for both ends
of the hose when assembling.
B.Replacement of the
Clamping Hoses
The clamping movement of the fingers is caused
by inflating the pressure hose located between
the tabletop and the upper surface of the fingers.
Over a period of time, the hose may become
damaged from extreme heat, weld spatter or
deterioration of the rubber in the hose. Should
this happen, the hose cannot be repaired but
must be replaced.
Pull the fish tape and the new hose through the
tabletop from the latch end of the machine. If
there is a spatter shield to be installed, it must be
pulled through with the hose. The seam of the
spatter shield must be either on the top or bottom
surface of the hose. The clamping fingers may
have to be loosened when installing hose with
a spatter shield.
To replace the hose, use the following procedure:
Reconnect the high pressure tube and pneumatic
hoses. Be sure to allow the Permatex to set up
before connecting to the shop air. Pressurize the
hoses and check for air leaks. Replace the finger
adjusting channels and, using the set screws,
adjust the channels for proper clearance and
spacing.
Disconnect the 115 volts AC and air supply to
the seam welder. Remove the finger adjusting
channels which are located at the latch end of
the machine. The channels are located between
the left and right first finger assemblies and the
front plate. Once the finger adjusting channel
is removed, the end of the pneumatic hose and
hose clamps will be exposed. The three hose
clamp bolts serve two purposes. They clamp the
ends of the hoses together and attach the ends
of the hoses to the tabletop. Remove the three
bolts from each clamp and remove the clamps
from the hoses. Tie an electrician’s fish tape to
this end of one of the hoses.
C.
Replacement of the Mandrel
To ease installation of a mandrel in a Jetline
Longitudinal Seam Welder, it is recommended
that a Jetline Mandrel Cart be used. Installing
the mandrel can also be done using a suitable
lifting device such as a fork lift truck.
Before doing the installation, a number of actions must be done first.
At the opposite end of the machine, open the
hinged door at the rear of the mainstay. On the
interior of the door is mounted the FCP-10B foot
control panel. The hoses and controls for the
clamping system are located inside the mainstay.
Remove the small white vinyl high pressure tube
On one end of the mandrel there is the mounting
plate which has four tapped holes and a number
of slots. In the four tapped holes there are four
square head bolts, used as “jacking screws”.
- 34 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Figure 6
Pneumatic System
- 35 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Welded on the front of mainstay, are two vertical
bars and one horizontal bar. One vertical bar and
the horizontal bar have adjusting screws. These
screws must be backed off to allow clearance for
the mandrel plate to fit between them. Ensure
that the nuts and washers have been removed
from the mandrel anchor bars which protrude
through the front face of the mainstay. Raise the
latch assembly.
mandrel from the side and using a scale measure
the gap at the mainstay end and the latch end.
Both measurements should be equal.
Next, adjust the insert groove parallel with the
centerline of the tabletop. Viewing from above
the tabletop, first measure and determine the
centerline distance between the formed tabletop
edges. Starting at the mainstay end of the mandrel, use the two screws in the vertical bar that is
welded to the front of the mainstay to move the
mandrel until the insert groove is on centerline
of the formed tabletop. Then use a combination
of the four square head “jacking screws” to move
the latch end of the insert groove to centerline
as well as maintain parallelism to the finger tips.
Using either the mandrel cart or fork lift truck,
move the mandrel mounting plate close to the
ends of the anchor bar screws that protrude
through the mainstay. Align the slots in the mandrel mounting plate with the anchor bar screws
and push the mandrel over them and up to the
mainstay front face.
The seam welder is designed to accommodate
different material thicknesses and the actual
vertical position of the mandrel is governed by
this. For the machine to work efficiently, the
gap between the fingers and insert should be the
material thickness plus 1/16” (3 mm).
Replace the washers and nuts onto the anchor
bar screws. Lightly tighten them to hold the
mandrel against the mainstay face so that the
mandrel plate lies between the two vertical bars
and above the horizontal bar. The cart, or similar
device, can now be removed.
D.
After these adjustments have been made, the
mandrel anchor nuts can now be tightened.
After tightening the nuts, check and readjust as
required.
Adjustment of the Mandrel
Once the mandrel has been fitted to the seam
welder, it then has to be adjusted to be positioned
correctly relative to the fingers and tabletop assembly. The adjustment procedure is made easier
by having the insert installed in its machined
groove in the top of the mandrel.
E.Adjustment of the Track to
the Insert
Once the back-up mandrel and insert have been
adjusted to the tabletop, the track will require
adjustment relative to the insert groove and
face. The vertical distance between the insert
face and the welding torch (mounted on the
travel carriage) should vary no more than 0.08”
(2 mm) at full clamping pressure. The tracking
accuracy (track to insert groove) should be . 015”
(0.4 mm) per 10 ft (3 m) of track length for the
standard machine. For the precision machines
(LWP, LWX), tracking accuracy (track to insert
groove) should be .005” (0.13 mm) per 10 ft (3
m) of track length.
With the mandrel anchor bar nuts slightly loose,
the first adjustment is to make the mandrel and
insert parallel with the underside of the clamping fingers. Based upon welding a 1/8” material
thickness (or less) as an example for adjusting
the machine, first, use the horizontal bar with
1” screw to coarse adjust the mandrel vertically.
Using a scale, adjust the mandrel up until there is
an approximate 3/16” space between the finger
tips and the highest point of the insert. Use the
square head “jacking screws” in the mandrel
plate to pitch the mandrel until its full length is
parallel with the clamping finger tips. View the
- 36 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
To check the vertical height accuracy, move
the carriage to the end of its travel, towards the
mainstay end of the machine. Actuate and clamp
both finger banks at 40 PSI against the backup
insert. Mount a machinist’s dial indicator to the
travel carriage and align the stem against the
face of the back-up insert. Set the indicator dial
at zero, and then manually move the carriage
towards the latch of the machine. Correct adjustment of the track is obtained when the indicator
also reads zero at the latch end of the machine.
If the indicator does not read zero, vertical track
adjustment is required. Note that it is typical for
the mandrel to deflect approximately 0.040”
(1 mm) between each end due to the clamping
pressure exerted.
G.
F.
On the mounting bracket above the vertical adjusting lever are four 3/4” bolts. For adjustment,
loosen the four bolts noting that the bracket is
slotted in the horizontal direction. At the rear of
the bracket is a single 3/4” adjustment screw.
When the adjustment screw is rotated clockwise,
the track will move away from the insert centerline. Rotating counter clockwise will move
the track towards the insert centerline. Once the
track is adjusted parallel to the machined edge
of the insert, tighten the four 3/4” bolts.
Horizontal Adjustment
Using the ground torch electrode or the welding wire as a pointer, adjust either so that it just
clears the upper surface of the insert. Adjust the
pointer horizontally so that it is right over the
tangent point where the edge of the machined
groove meets the flat surface on the insert. The
machined edge of the groove will be used as
the reference point for the electrode or wire to
track the insert groove. Starting at the mainstay
end of the machine, manually traverse the carriage along the track and stop at the latch end
of the machine. Observe if the track requires
adjustment and if so, which direction the pointer
must move in relation to the machined edge of
the insert.
Vertical Track Adjustment
If vertical adjustment of the track is required,
only make adjustment at the latch end of the
machine. Loosen the four 3/4” track mounting
bolts that are located at the backside of the track.
The track mounting bracket is slotted allowing
vertical adjustment using the lever arm mounted
on its side.
Using an Allen wrench, turn the vertical adjusting bolt counter-clockwise to lower the track
(clockwise to raise). The amount of adjustment
is determined by watching the dial indicator
mounted on the carriage, trying to “match”
the zero reading from the mainstay end of the
machine. After the track is adjusted, tighten the
four 3/4” bolts on the track bracket.
- 37 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
H.
Preventive Maintenance
1.
Daily Mechanical
4.
Bi-annual Mechanical
a.Check oil level on SWC-6 series carriage
gear box (see SWC-6 operators manual).
a.Inspect roundway or v-way rails of the track, clean and coat with WD-40 or
equal.
5.
Quarterly Electrical
a.
Check all welding and exposed cables.
b.Inspect finger tips for excess weld spatter. Remove by wire brushing.
b.
Check carriage motor brushes.
6.
Bi-annual Electrical
c.Inspect inserts for oxides and foreign matter. Clear with wire brush, MEK or Acetone.
a.Check welding power source for dust
and dirt.
d.Drain the air filter at the rear of the
mainstay by turning the valve at the bottom of the bowl.
2.
Weekly Mechanical
a.Inspect track and mandrel alignment for
accuracy.
b.Check v-way wheels on SWC-6 series carriage for proper adjustment (see
SWC-6 operation manual).
3.
Monthly Mechanical
a.Check all bolts and components of the alignment devices to be sure that they
are tight.
b.Check coolant level in torch water recirculator.
c.Check all hoses, gas, water, and air for
leaks and deterioration.
- 38 -
b.Check all pushbutton emergency switches.
Longitudinal Seam Welders - Models LWP, LWS, LWX
Section X
Parts List
The following parts lists are included in this
manual, their page numbers are:
The following pages provide a detailed parts
list of the 9627 control. They are arranged so
that the parts list on the left hand page is for the
assembly illustrated on the adjacent right hand
page.
Replacement Parts..........................................41
Longitudinal Seam Welder....................... 42/43
Item numbers shown in the parts list refer to
those items referenced by the balloon in the
drawing. Each parts list shows the main assembly as item 1, all the quantities shown are
the quantities used to make the main assembly.
Retractable Centering Device.................. 44/45
Foot Control Panel................................... 46/47
Two columns are included in the list to show
the spare parts which it is recommended should
be stocked by the user. The two levels can be
defined as follows:
Level 1
These are the spares recommended for US domestic users whose use of the product does not
exceed 2000 hours per year.
Level 2
These are the spares recommended for International users of the product or for US domestic
users who will use the product in excess of 2000
hours per year.
- 39 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
- 40 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
COMMON SEAM WELDER REPLACEMENT PARTS
Part No. Description
094
O-ring for IGBU Inserts
102A
Tapeswitch Control strip
103A
Tapeswitch Terminal Connection
26E01039
Solenoid Valve Coil
3134
Solenoid Valve
3134RK
Solenoid Valve Repair Kit
CR-22
Cam Follower, Roundway Carriage
FCP-10B
Toe-touch Panel
FCP-10B-3
Toe-touch Panel Circuit Board
FS-200
Finger Return Spring
FS-201
Finger Screw
FS-202
Finger Nut
HCS1
Pressure Hose, 1½” (38 mm) internal diameter - for Bench style seamers
HCS3
Pressure Hose, 2½” (63 mm) internal diameter
HF103
Finger Assembly - LH (up to s/n 990616), aluminum body, copper finger tip
HF104
Finger Assembly - RH (up to s/n 990616), aluminum body, copper finger tip
HF105Finger Assembly - LH (beginning with s/n 990678), aluminum body, copper
finger tip
HF106Finger Assembly - RH (beginning with s/n 990678), aluminum body, copper
finger tip
HF201
Finger Tip
PH200
Pressure Hose Fitting (round), per hose
PH201/202
Hose Clamp Assembly (flat), per hose
V02625 AA07
Motor, carriage
- 41 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
- 42 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
LONGITUDINAL SEAM WELDER
Recommended
ItemPartLevelLevel
No.No.
Description
Qty
I
II
1
2
3
4
5
6
7
8
9 CBS
10
11
12
13
14
15
SWCB-3
16
9627
Track.........................................................................1
Track Arm.................................................................2
Pressure Gauge..........................................................1
Tabletop.....................................................................1
Mainstay....................................................................1
Base...........................................................................1
Electrical Cord, 116 VAC.........................................1
Switch, Finger Actuation..........................................3
Mandrel.....................................................................1
Latch Assembly.........................................................1
Mounting Plate Nuts.................................................4
Mandrel Plate Adjustment Screws............................4
Finger Adjustment Screws........................as required
Air Filter....................................................................1
Carriage Assembly, standard.....................................1
Control Panel Assembly, standard............................1
- 43 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
- 44 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
RETRACTABLE CENTERING DEVICE
CLW-110A
Recommended
ItemPartLevelLevel
No.No.
Description
Qty
I
II
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CL-200
CL-201
CL-202
CL-203
CL-204
CL-205A
3/8-16x3/4
3/8-16x1
3/8-16x2
3/8-16,5-10LB
3/8-16,2-4LB
3/8-16
3/8x3/4
3/16x1/2
5/16x3/4
End Piece..................................................................1
Pivot Stop, regular and thin................................. 1 ea
Pivot Block...............................................................1
Spacer Plate...............................................................1
Guide Block..............................................................1
Extension Arm..........................................................1
Button Head Screw...................................................1
Socket Set Screw.......................................................1
Hex Head Cap Screw................................................2
Ball Plunger..............................................................1
Ball Plunger..............................................................1
Hex Jam Nut.............................................................1
Socket Head Shoulder Screw....................................1
Roll Pin.....................................................................2
Brass Socket Set Screw.............................................2
- 45 -
- 46 GND
2CR
1CR
LR1
LR2
T1
ENCLOSURE / PANEL
LAYOUT
CR2
CR1
CR4
CR3
F1
F2
engineering
®
etline
Longitudinal Seam Welders - Models LWP, LWS, LWX
Longitudinal Seam Welders - Models LWP, LWS, LWX
FOOT CONTROL PANEL
FCP-10B
Recommended
ItemPartLevelLevel
No.No.
Description
Qty
I
II
1
2
3
4
5
6
7
8
9
10
11
12
13
14
A-10N84
A10N8P
FCP-10B-3
RY2LS-120A
RY2S-U-120A
RY2S-U-24A
GGC-3
AGC 1/4
27F794
SY4S-02F1
SY2S-02F1
27F234
RY2S-U-120A
SY2S-02F1
Enclosure...................................................................1
Panel..........................................................................1
Toe-touch Board........................................................11
120 VAC Latch Relay, LR1, LR2.............................211
24 VAC DPDT Relay, CR2, CR4..............................211
120 VAC DPDT Relay, CR1, CR3............................211
Fuse, 3A....................................................................111
Fuse 1/4A..................................................................111
Fuse Holder...............................................................2
Spring, Holding, LR1, LR2......................................1
Spring, Holding, CR1,2,3,4/CR2..............................6
Terminal Block..........................................................1
Relay, DPDT, 120VAC, 1CR, 2CR...........................211
Spring, Holding, 1CR, 2CR......................................2
- 47 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
- 48 -
Longitudinal Seam Welders - Models LWP, LWS, LWX
Section XI
Electrical Drawings
Each longitudinal seam welder made by Jetline
has an electrical control schematic. These drawings are identified by job number and are part of
the document package shipped with your system.
- 49 -
PANEL
- 50 KB
FC-5A
F
D
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NOTES:
D
B
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FOOT
CONTROL
PLUG
I
FOOT
CONTROL
PLUG
MOTOR CONTROL
EQUIVALENT CIRCUIT
FOOT
FC-5A
FOOT CONTROL
PEDAL
(OPTIONAL)
(STANDARD)
FOOT CONTROL
PEDAL
FULL RANGE
PROPORTIONAL RANGE
Longitudinal Seam Welders - Models LWP, LWS, LWX
- 51 H
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P1
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A
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MATING SIDE SHOWN
REQUIRED FOR OPERATION W/O FOOT CONTROL
MATING SIDE SHOWN
REMOTE SHORTING PLUG P2
FC-5A
FOOT CONTROL
PEDAL
WITH PROPORTIONAL RANGE
SPEED CONTROL
FOOT CONTROL CIRCUIT
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Longitudinal Seam Welders - Models LWP, LWS, LWX
- 52 H
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P1
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MATING SIDE SHOWN
REQUIRED FOR OPERATION W/O FOOT CONTROL
MATING SIDE SHOWN
REMOTE SHORTING PLUG P2
FC-5A
FOOT CONTROL
PEDAL
WITH FULL RANGE
SPEED CONTROL
FOOT CONTROL CIRCUIT
engineering
®
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Longitudinal Seam Welders - Models LWP, LWS, LWX