OPERATION MANUAL for Longitudinal Seam 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: sales@jetline.com

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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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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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Table of Contents
Section I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1A. C. D. E. F. G. H. I. Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1Arc Rays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2Fumes and Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -2Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -4-

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

Section III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -7-

Section IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -9A. B. C. D. E. Carriage Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -11Chill Bar Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -12Distance Between Finger Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -14Air Regulator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -14-

Section V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -15Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -15-

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

Longitudinal Seam Welders - LWS, LWP, LWX Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -17-

Section VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19A. B. C. D. E. F. G. Mechanical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19Mainstay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -19Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -21Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -21Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -22Carriage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -22-

Section VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25Start-up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25A. B. Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -25-

Section IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -27Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -27A. B. Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -27GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -29-

Section X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -33Mechanical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -33A. B. C. D. E. F. Adjustment & Replacement of the Clamping Fingers . . . . . . . . . . . . . . . . . . . . . . . . . -33Replacement of the Clamping Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -34Replacement of the Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -34Adjustment of the Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -36Adjustment of the Track to the Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -36Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -37-

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

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Longitudinal Seam Welders - LWS, LWP, LWX Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -39-

Section XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -47Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -47-

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Section I

Safety Precautions

4.

WARNING
A. Arc Welding

Properly install and ground this equipment according to the operation manual and national, state and local codes. 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. When making input connections, attach proper grounding conductor first - doublecheck connections. Frequently inspect input power cord for damage or bare wiring. Replace cord immediately if damaged - bare wiring can kill. Turn off all equipment when not in use. If earth grounding of the workpiece is required, ground it directly with a separate cable - do not use work clamp or work cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

5.

Arc Welding can be hazardous. Protect yourself and others from possible serious injury or death. Keep children away. Pacemaker wearers keep away until consulting your doctor. In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed at the end of this section. Read and follow all Safety Standards. Have all installation, operation, maintenance and repair work performed only by qualified people.

6.

7.

8. 9.

B.

Electric Shock

10.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. When using mechanized wire feed, the wire, wire reel, drive roll housing and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. 1. 2. 3. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and appropriate body protection. Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

11.

12. 13. 14.

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C.

Arc Rays
7.

Arc rays can burn eyes and skin; noise can damage hearing; flying slag or sparks can injure eyes. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Noise from some processes can damage hearing. Chipping, grinding and weld cooling throw off pieces of metal or slag. 1. 2. Use approved ear plugs or ear muffs if noise level is high. Use a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection where necessary.

cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. 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 air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

E.

Cylinders

Cylinders can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. 1. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses and fittings designed for the specific application; maintain them and associated parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

3. 4.

5.

2.

D.

Fumes and Gases

3. 4. 5.

Fumes and gases can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 1. 2. 3. 4. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved airsupplied respirator. Read the Material Safety Data Sheets (MSDS) and the manufacturer's instruction for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch person nearby. 6. 7.

8.

5.

6.

Do not weld in locations near degreasing,

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F.

Welding

H.

EMF Information

Welding can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. 1. 2. 3. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWSF4.1 (see safety Standards). 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. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

Considerations About Welding and the Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989): ".... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions abut questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks." To reduce magnetic fields in the work place, use the following procedures: 1. 2. 3. 4. 5. Keep cables close together by twisting or taping them. Arrange cables to one side and away from the operator. Do not coil or drape cables around the body. Keep welding power source and cables as far away as practical. Connect work clamp to workpiece as close to the weld as possible.

4.

5. 6.

7.

8.

About Pacemakers: The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

G.

Moving Parts

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. 1. 2. Keep all doors, panels, covers, and guards closed and securely in place. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

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I.

Principal Safety Standards

Reference as applicable Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 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 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 Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 Sales Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018 Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

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Section II

Introduction
Congratulations on your purchase of the Jetline Longitudinal Seam Welder. Its quality workmanship should bring many years of dependable service and consistent high quality seam welds. The Jetline seam welder is a standard design machine which uses the chill shunt principle of tooling to conduct heat away from the part and minimize burn-through, warping, or excessive distortion. Jetline seam welders are designed to clamp a part with a butt-joint type seam. A motorized carriage on which a torch can be mounted to weld the seam is provided. 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. A welding torch can be mounted to the side beam carriage by means of an optional torch holder and bracket. This allows the torch and carriage to traverse the entire length of the part while performing the weld. Prior to welding, the part is positioned on the mandrel insert, clamped, and is then welded in a stationary position. 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 buttjoint becomes a simple operation without the necessity of tack welding prior to welding. Jetline longitudinal seam welders are comprised of several integral assemblies: a base/mainstay, mandrel, tabletop, track, carriage, and a control panel. 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 and is where the hold down clamping fingers are mounted. Mounted directly on the tabletop are two or three track supports, depending on the welding length of the tabletop. These track supports hold up the main track assembly which extends the entire length of the tabletop. Riding on the track assembly is a motorized carriage. The control panel that controls the carriage speed and weld time, is mounted to the carriage face thus making the Jetline longitudinal seam welder a well integrated system.

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Section III

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

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Figure 1 Longitudinal Seam Welder

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Section IV

Specifications
* Model Number LW_-24 LW_-36 LW_-48 LW_-60 LW_-72 LW_-84 LW_-96
LW_-120 LW_-144 LW_-168 LW_-192 LW_-216 LW_-240

A Welding Length inch mm 24 36 48 60 72 84 96 120 144 168 192 216 240 609 914 1,219 1,524 1,829 2,134 2,438 3,048 3,658 4,267 4,877 5,486 6,096

B **Min. Dia. Part inch mm 2 5/8 3 4 1/4 5 1/4 6 6 7/8 7 1/4 9 121/4 151/4 181/2 211/4 241/4 67 89 108 133 152 175 184 241 311 387 464 539 616

C ***Max. Dia. Part inch mm 32 32 32 32 32 32 32 32 32 32 32 32 32 800 800 800 800 800 800 800 800 800 800 800 800 800

D Overall Length inch 691/2 811/2 933/8 mm 1,765 2,070 2,372 2,677 2,981 3,286 3,591 4,470 5,080 5,689 6,299 6,909 7,518

E Overall Width inch 391/2 391/2 391/2 391/2 391/2 391/2 391/2 411/2 411/2 411/2 411/2 411/2 411/2 mm 1,003 1,003 1.003 1,003 1,003 1,003 1,003 1,054 1,054 1,054 1,054 1,054 1,054

F Overall Height Approx. Shipping Weight Kg inch mm Lb 69 69 69 69 69 69 69 76 76 76 76 76 76 1,753 1,753 1,753 1,753 1,753 1,753 1,753 1,930 1,930 1,930 1,930 1,930 1,930 2,300 2,600 4,000 4,700 5,300 5,900 6,400 12,000 13,000 14,000 15,000 16,000 17,000 1,040 1,180 1,810 2,130 2,400 2,680 2,900 5,440 5,890 6,330 6,780 7,240 7,690

1053/8
1173/8 1293/8 1413/8 176 200 224 248 272 296

Letters A through F in table above refer to Figure 2. * Prefix taken from model as noted below. ** Can be modified at any time by purchasing new mandrel. *** Can be increased to any convenient height by using optional riser block. LWS Standard Seam Welder Application: 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

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 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

LWP Precision Seam Welder

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Longitudinal Seam Welders - LWS, LWP, LWX

Figure 2 Dimensions - Longitudinal Seam Welder

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Longitudinal Seam Welders - LWS, LWP, LWX

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-3 Carriage Manual for more details.) SWCA-3A: 3 to 135 IPM (75 to 3,450 mm/min) SWCA-3B: 1.2 to 60 IPM (30 to 1,500 mm/min) SWCA-3D: 0.2 to 188 IPM (5 to 4,775 mm/min) Optional For seam welders over 16 ft (4.8 m) long: The SWC-6 medium duty carriage is rated for 1000 lb (450 kg) capacity with the center of gravity out 12" (305 mm) from the face of the carriage. They are designed for use with a TKMV style V-way track for structural integrity. (See the SWC-6 Carriage Manual for more details.) SWC-6A: SWC-6B: SWC-6C: SWC-6D: 4 to 165 IPM (102 to 4,191 mm/min) 3 to 108 IPM (76 to 2,743 mm/min) 2 to 67 IPM (51 to 1,702 mm/min) 1 to 45 IPM (25 to 1,143 mm/min)

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 (74.4 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.

For LWX Ultra Precision seam welders: The SWC-4 linear drive carriage is rated for 300 lb (136 kg) capacity with the center of gravity out 12" (305 mm) from the face of the carriage. The linear drive provides smooth, backlash free carriage movement. SWCA-4A: 4 to 170 IPM (102 to 4,318 mm/min) SWCA-4B: 2 to 85 IPM (51 to 2,160 mm/min) SWCA-4C: 0.32 to 160 IPM (8 to 4,060 mm/min) Optional SWCA-4D: 0.22 to 106 IPM (5 to 2,700 mm/min) Optional

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Longitudinal Seam Welders - LWS, LWP, LWX

C. Chill Bar Selection

TIG-DCSP GROUP I* Base Metal: Steel Stainless Aluminum Magnesium Copper * Copper Insert 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 .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 .020D .312W .040D .312W .020D .375W .050D -

TIG-AC GROUP II** Base Metal: Aluminum Magnesium ** Steel or Stainless Insert

TIG-DCSP GROUP III Base Metal: Titanium Molybdenum Zircalloy Tantalum Rene 41 Hastelloy Inconel Haynes 25 .040W .125D .125W .100D

.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

.187W .100D

.250W .100D

.312W .100D

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).

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Longitudinal Seam Welders - LWS, LWP, LWX

Chill Bar Selection - MIG and Submerged Arc

GROUP I* 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 * 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 .437 W. 080D .630W .065D Base Metal: Aluminum Magnesium GROUP II**

** Steel or Stainless Chill Bar .125W .040D .125W .040D .187W .050D .250W .050D .250W .050D .312W .060D .375W .060D .437W .080D -

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

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Longitudinal Seam Welders - LWS, LWP, LWX

D. Distance Between Finger Tips

GROUP I 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) 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)

E. 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 (2.0 - 3.2 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 least amount necessary.

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Longitudinal Seam Welders - LWS, LWP, LWX

Section V

Mechanical Installation
Uncrate the machine, remove the skid and set the equipment at the desired location. Orientate the seamer according to your desired factory floor layout. The seam welder need not be secured to the floor. However, if the seamer is integrated with a conveyor system, we recommend anchoring the seamer to the floor by use of anchor bolts/red heads. 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. When placing the carriage onto the track, one of the stops must be removed. 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 -13 tapped hole on top of the carriage. This hole, along with an eye bolt (not supplied), can be used for lifting the carriage. Another alternative for lifting the carriage is by using the gusset holes on both sides of the carriage. (Refer to Figure 3.) Using these holes will stabilize the carriage when installing it onto the track. Please refer to Figure 3 to verify it is correctly aligned. Once the carriage is mounted on the track, replace the mechanical stop on the end of the track to its original position.

WARNING
When moving the seam welder by fork lift truck, do not put the forks under the mandrel. Always move the seam welder by placing the forks under the base or through the base structural tubes from the mainstay end of the machine. The longitudinal seam welder is equipped with a cable channel which protects welding gas lines and control cables from the rack and gears. 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.

WARNING
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.

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Longitudinal Seam Welders - LWS, LWP, LWX

Figure 3 Carriage Assembly

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Longitudinal Seam Welders - LWS, LWP, LWX

Section VI

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 will 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. Therefore individual manuals will be supplied for them. Please refer to the appropriate manuals for proper installation guidelines regarding this equipment.

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Longitudinal Seam Welders - LWS, LWP, LWX

Section VII

Theory of Operation
A. Mechanical Operation
The seam welder is comprised of several main assemblies. Each assembly is integrated to form a complete system. The system consists of the following components: base/mainstay, mandrel, tabletop, track, carriage and control panel. Jetline seam welders use the chill shunt principle of tooling to conduct heat away from the part. This process minimizes burn through, warping and excessive distortion when performing butt-joint welding. The edges of the part are clamped on the top centerline of the mandrel and insert. (The inserts are made of copper, stainless steel or steel, dependant 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, dependant upon the welding process used, edge preparation may be required and, on thicker materials, multi-pass welds may be required as well. The LWS, LWP and LWX seam welders are designed to perform butt-joint welds by arc welding on all conventional metals. Some of the arc welding processes include Gas Tungsten Arc Welding (GTAW), Gas Metal Arc Welding (GMAW), Shielded Metal Arc Welding (SMAW), Submerged Arc Welding (SAW) and Plasma Arc Welding (PAW). Materials that can be welded include stainless steel, weldable aluminum, magnesium alloys, zirconium, molybdenum, titanium, mild steel and low carbon steels. Some of these metals require a preparatory process in order to be welded successfully. Part configurations which the seam welder can handle are cylinders, cones, truncated cones, open ended boxes, double bowl sinks, flat plates and sheets.

B. Base Section
The base is made from a rigid tube steel structure which provides stability and safety during operation. The base is equipped with mounting holes to ensure stability of the equipment on uneven surfaces. The base houses the electrical toe-touch clamping switches. These switches run the entire length of the base. When facing the front of the seam welder, the switch closest to the operator controls the front bank of clamping fingers. The switch next in line controls the rear bank of clamping fingers. The third switch controls the rear clamping fingers only. To activate one of the switches, merely touch the switch with your toe. This will either clamp or unclamp a bank of clamping fingers.

C. Mainstay
The primary purpose for the mainstay is to support the tabletop. On the standard seam welder, the mainstay is high enough to accommodate an approximate 32" (800 mm) diameter. As an option the riser can be made taller for diameters greater than 32" (800 mm). The mainstay also houses the control box (FCP10B) for the toe-touch switches, the pneumatic valves, water lines if applicable, and electrical solenoids which operate the pressure hose assemblies. The air hose connection, filter, ground lug and electrical box are located on the back side of the mainstay. If a need for 460 volts is required, a step down transformer will be mounted on the mainstay as well.

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Longitudinal Seam Welders - LWS, LWP, LWX

Figure 4 Tabletop Half Section

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Longitudinal Seam Welders - LWS, LWP, LWX

D. Mandrel
The mandrel is mounted to the mainstay and is typically round, but can be designed to meet the demands of the application. The mandrel must support the parts weight, along with supporting the clamping forces exerted by the clamping fingers. In most cases, the mandrel is designed to be supported at the mainstay and at the latch end. The mandrel is designed to support a back-up insert and may have optional water cooling capability. Depending on the thickness of the material to be welded and the welding process, the insert will have a specific groove dimension (width and depth) machined into it. When several different thicknesses of materials are to be welded on the same seam welder, additional inserts may be required to obtain a quality weld. The inserts may also be designed to provide gas back-up to the part. This option provides backing gas to the penetration side (bottom) of the weld. Backing gas is required for welding refractory metals and is recommended for stainless steel materials. When welding aluminum, a stainless steel insert is recommended, dependant upon the welding process used. In high production environments, and/or when welding with high current, an optional water-cooled 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.

The two banks of clamping fingers are set and mounted within the tabletop. The tabletop section will differ in size and weight as the welding length of the seam welder increases. The tabletop is designed to withstand the clamping forces generated by the clamping fingers. On both sides of the tabletop are adjusting screws used to adjust the finger spacing (see Figure 4). There are several screws that are used to adjust the location of the fingers relative to the insert groove. These screws should be adjusted symmetrically to the groove to provide an even chilling effect. The finger spacing as a standard depends largely on the material thickness being welded. See Section IV for Jetlines 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 finger tip screwed to the aluminum finger body. These tips are reversible and should be changed if damaged or worn. When welding aluminum, stainless steel finger tips are recommended, dependant upon the welding process used. 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.

E. Tabletop
The tabletop houses the two banks of clamping fingers, and supports the side beam track and carriage. One of the most outstanding features of the tabletop design is the ability to view the weld in progress via the naked eye (with weld shield) or with a video camera.

WARNING
This safety switch should not be by-passed.

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Longitudinal Seam Welders - LWS, LWP, LWX

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.

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.

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Longitudinal Seam Welders - LWS, LWP, LWX

Figure 5 Track Support Assembly

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Longitudinal Seam Welders - LWS, LWP, LWX

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Longitudinal Seam Welders - LWS, LWP, LWX

Section VIII

Start-up and Operation

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

B. Operation

NOTE

2.

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Longitudinal Seam Welders - LWS, LWP, LWX 3. The part should be loaded into the rear of the seamer 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 seamer. Try to space the part in the seamer 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. 5. Now retract the centering devices. 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. 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. Now that the part is loaded, you can prepare to weld. If limit switches are used to determine the start and stop points of the weld, it is best to set up on a practice part. Move the carriage and torch at the desired starting point, then slide the home limit switch cam until it contacts the home limit switch. Now test this starting point by jogging the carriage forward (12 or more inches if possible) and then returning the carriage to the home position. This will indicate the true starting point. To set the end of weld limit switch, use a similar process. First manually set the contact location, then test it by reversing travel, then moving the carriage to the end of weld. 9. Welding Each and every welding application requires its own unique set of welding parameters. Wire speeds, voltages, travel speeds, gas types, flow rates, back-up bar size, type, finger spacing, clamping pressures, material type, material thickness and joint preparation are some of the many variables that need to be adjusted in order to provide the most robust welding procedure for a particular application. Weld development is the sole responsibility of the owner of the equipment and not the responsibility of Jetline Engineering. 10. Once the seam has been welded successfully, release both sets of fingers, open the latch if needed and carefully remove the part.

6.

7. 8.

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Longitudinal Seam Welders - LWS, LWP, LWX

Section IX

Trouble Shooting
A. Fixture
Problem 1. Misalignment of torch to the weld joint (insert groove centerline). a. b. Cause and Correction The track and carriage not aligned parallel to insert groove; readjust as per Section X. 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. The part is not against the two alignment device blades when the part is clamped by the fingers. Unclamp, align and clamp. Gibbs loose on the weld head cross seam slide; adjust as needed. If an arc length control (AVC) is incorporated on the fixture, check the ways and wheels in the drive (actuator) for play and adjust. 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 information.

c.

d. e.

2.

Carriage will not travel.

a.

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Longitudinal Seam Welders - LWS, LWP, LWX Problem 3. Travel speed readout with optional tachgenerator fluctuates. a. Cause and Correction Check the belt that connects the carriage drive motor shaft to the tach generator. Replace the belt if worn or loose. Check for binding between the carriage wheels and the rails on the track. Readjust the wheels if required, see supplied carriage manual. Refer to supplied control manual for wiring information Check air supply to fixture. Check clamping pressure air regulator for proper pressure (see Section IV). Check fuse in the FCP-10B toe-touch panel. Check toe-touch strip for short. If shorted, replace with new. Check relays and transformer and toe-touch panel. Shop line pressure is too low to actuate the pilot actuated air solenoid valve.

b.

c. 4. Clamping fingers will not clamp. a. b. c. d. e. f. 5. Can hear air leaking in the vertical riser.

Open hinge door and check: a. b. c. White poly flow tubing for leaks. Internal air hoses for leaks. Clamping hoses for leaks. 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.

6.

Cannot establish tight, even butt-up of final sheared piece parts.

a.

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Longitudinal Seam Welders - LWS, LWP, LWX

B. GTAW Process
Problem 1. Cannot initiate an arc when using GTAW welding equipment. a. Cause and Correction 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. 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. 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. 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. - Shut off power to the power supply. - Check contact point gap setting. Refer to power supply manual. - If contact points are pitted or worn, replace. b. c. Increase the high frequency intensity potentiometer on the power source. Amperage setting at the power supply may be too low to initiate an arc. Raise the amperage setting. Material to be welded may contain coated or scaled surface. Remove coating or scale by using a fine emery cloth. 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.

b.

c.

d.

2.

If an arc still will not establish, check the following steps.

a.

d.

3.

Electrode sticks to workpiece when using GTAW welding equipment.

a.

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Longitudinal Seam Welders - LWS, LWP, LWX Problem Cause and Correction - 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. b. Make sure the electrode is sharp (clean) and the torch collet grips the electrode tightly. Check the insert and travel carriage for parallelism. If a variation exists, adjust the track and/or mandrel. Make sure all drive gearing, roundways and cam followers are clean. 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). Check the shield gas bottle for pressure. Check the shield gas flow at the flowmeter. Check the electrode stick-out. Maximum stickout is 1/4" (6.35 mm) with standard collets, " (12.7 mm) with gas lens collet bodies. 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. The electrode is contaminated from use or has been ground on a contaminated grinding wheel. Replace or re-grind the electrode. The torch head is overheating. The coolant line (if so equipped) to and from the torch may have insufficient water flow. Gas is not flowing. Adjust the clamping pressure to eliminate any deformation of the butt joint once the parts are butted and clamped. Finger tip distance is too far apart (see chart, Section IV).

c. d.

5.

White smoke appears during GTAW welding process.

a. b. c.

d.

6.

Black smoke appears during GTAW weld cycle.

a.

b.

c. 7. Butted parts rise when welding light gauge material. a.

b.

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Longitudinal Seam Welders - LWS, LWP, LWX Problem c. Cause and Correction Welding amperage setting may be too high and the carriage speed too slow. Adjust amperage first, then carriage speed if needed. Check the welding parameters for material being welded. 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.

8.

Incomplete penetration.

a. b.

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Longitudinal Seam Welders - LWS, LWP, LWX

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Longitudinal Seam Welders - LWS, LWP, LWX

Section X

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. 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.

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. To replace the fingers, start at the mainstay and work toward the latch end of the seamer. 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. 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. 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 back-up insert, also act as a heat sink to absorb heat created by the welding process. If a finger tip 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.

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. 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. 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.

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Longitudinal Seam Welders - LWS, LWP, LWX To remove a finger tip 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 finger tip 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. 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. 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.

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. To replace the hose, use the following procedure: 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 electricians fish tape to this end of one of the hoses. 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 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.

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. 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. 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.

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Longitudinal Seam Welders - LWS, LWP, LWX

Figure 6 Pneumatic System

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Longitudinal Seam Welders - LWS, LWP, LWX 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. 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. 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). After these adjustments have been made, the mandrel anchor nuts can now be tightened. After tightening the nuts, check and readjust as required.

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. 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 machinists 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. 1. 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

D. 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. 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 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. The seam welder is designed to accommodate different material thicknesses and the actual vertical

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Longitudinal Seam Welders - LWS, LWP, LWX 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. 2. 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. 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.

F. Preventive Maintenance
1. Daily Mechanical a. Inspect roundway or v-way rails of the track, 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 foreign matter. Clear with wire brush, MEK or Acetone. 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. 3. Bi-annual Mechanical a. Check oil level on SWC-6 series carriage gear 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 and dirt. b. Check all pushbutton emergency switches.

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Longitudinal Seam Welders - LWS, LWP, LWX

Section XI

Parts List
The following pages provide a detailed parts list of all the elements of the longitudinal seam welder. They are arranged so the parts list on the left hand page corresponds to the assembly illustrated on the right hand page. Item numbers shown in the parts list refer to those numbers contained in the balloon in the drawing. The quantities shown are the number of items used in that particular assembly. Two columns are included in the list to show the spare parts which are recommended to 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 use of the product or for US domestic users who will use the product in excess 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 Welders - LWS, LWP, LWX

Longitudinal Seam Welder LWItem No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part No. Recommended Spares Level Level I II

Description

Qty

CBS

SWCA-3 9627

Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Track Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Mainstay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electrical Cord, 115 VAC . . . . . . . . . . . . . . . . . . . . 1 Switch, Finger Actuation . . . . . . . . . . . . . . . . . . . . . 3 Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Mounting Plate Nuts . . . . . . . . . . . . . . . . . . . . . . . . 4 Mandrel Plate Adjustment Screws . . . . . . . . . . . . . . 4 Finger Adjustment Screws . . . . . . . . . . . . . . . . . . A/R Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . . 1

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Longitudinal Seam Welders - LWS, LWP, LWX

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Longitudinal Seam Welders - LWS, LWP, LWX

Foot Control Panel FCP-10B Item No. 2 3 4 5 6 7 8 9 10 11 Part No. A10N84 FCP-10B-3 RY2LS-120A RY2S-U-24A RY2S-U-120A J74 SY4S-51F1 SY2S-02F1 28F027 GGC-3 Recommended Spares Level Level I II

Description

Qty 1 1 2 2 2 1 1 6 1 1

Nema 1 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . Foot Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC Latch Relay . . . . . . . . . . . . . . . . . . . . . . . 24 VAC DPDT Relay . . . . . . . . . . . . . . . . . . . . . . . . 120 VAC DPDT Relay . . . . . . . . . . . . . . . . . . . . . . . 202A Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LR1, LR2, Spring Hold . . . . . . . . . . . . . . . . . . . . . . CR1,2,3,4 / CR2, Spring Hold . . . . . . . . . . . . . . . . . Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse, 3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1

1 1 1

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Longitudinal Seam Welders - LWS, LWP, LWX

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Longitudinal Seam Welders - LWS, LWP, LWX

Retractable Centering Device CLW-110A Item No. 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part No. 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 Recommended Spares Level Level I II

Description

Qty

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

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Longitudinal Seam Welders - LWS, LWP, LWX

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Longitudinal Seam Welders - LWS, LWP, LWX

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Longitudinal Seam Welders - LWS, LWP, LWX

Section XII

Electrical Drawings

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Longitudinal Seam Welders - LWS, LWP, LWX

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