Professional Documents
Culture Documents
RANSOME
LIFT SYSTEM
Self Locking gear reducer and ¾ hp
variable speed motor raises and
lowers the saddle using a triple RC-
60 (12 Ton capacity) roller chain.
RANSOME SADDLE
SAFETY LOCK COLUMN SUPPORTS
Main column is supported by top
Automatically locks the head mount
roller assembly, two adjustable
and saddle assembly to the main
wheels that grip the back of the
support column in the event of
plate and by two wheels at the
chain failure.
bottom of the column.
CHOICE OF FIXTURE
MOUNTS.
LIFT SYSTEM
Self Locking gear reducer and ¾ hp
variable speed motor raises and
lowers the saddle using a triple RC-
60 (12 Ton capacity) roller chain.
RANSOME SADDLE
SAFETY LOCK COLUMN SUPPORTS
Main column is supported by top
Automatically locks the head mount
roller assembly, two adjustable
and saddle assembly to the main
wheels that grip the back of the
support column in the event of
plate and by two wheels at the
chain failure.
bottom of the column.
The “VUP” was mainly developed for the construction of Field Storage Tanks, other
models using the same proven technology are available for ship-building, blast furnace
repair, structure supports and in-plant fabrication. The VUP welding process was
developed by Lincoln Electric and uses their Innershield “NR-431 and NR-432” wires.
Wire description:
NR-431 is an Innershield, self-shielded, flux cored wire designed specifically for the single
pass vertical-up process.
Mechanical Properties- Yield Strength, 76,000 PSI; Tensile Strength, 92,000 PSI;
Elongation, 28%; Charpy V-Notch ft-lbs @-20° F, 33.
NR-432 is an Innershield, self-shielded, flux cored wire designed specifically for the single
pass vertical-up process for structural steels, including columbium-bearing steels and where
excellent impact properties are desired.
Mechanical Properties- Yield Strength, 70,000 PSI; Tensile Strength, 90,000 PSI;
Elongation, 29%; Charpy V-Notch ft-lbs @-20° F, 50.
Plate size range for Storage Tank Model VUP
Thickness: 3/8” to 2”
Plate heights of up to 10 feet
Process:
Moving Rear Copper Shoe
Fixed Rear Backing Bar
Joint Design:
Square Butt
Single Beveled
EQUIPMENT
All that is required to begin welding is to hang the unit on the tank, add the correct NR-
431 or NR-432 Wire and provide electrical power and air.
Optional components
Powered lateral travel-powered to move from joint to joint
Oscillator –required for all plates 1-1/4 or thicker.
Information required to provide a quotation
VUP (Vertical Up Single Pass) Welding System
Project information
• Location of project ______________________________________
• Equipment required date __________________________________
• Project completion date __________________________________
• Size of project __________________________________________
Tank Size
• Diameter (provide below)
• Course Height (provide below)
• Number of Courses (provide below)
• Plate thickness for each course (provide below)
• Joint design (square butt or single bevel) (provide below)
Equipment
• Electrical power (provide below)
• Rear Shoe or Backing Bar (provide below)
• Oscillator (required for 1-1/4 plate or larger) (provide below)
• Lateral travel (powered or manual) (provide below)
Welding Wire
• Will NR-431 or NR-432 wire meet construction codes for tank project?
Number of Tanks
Diameter of Tank
Height of Tank
Plate Height
Number of Courses
Joint Design Square Butt Beveled
Plate Thickness-list for each course
SPECIFICATIONS
OPERATION
The Ransome Model VUPNA-3ST Machine is designed to weld 5/16” to 2” thick, 6 to 10
ft. high vertical joints erected storage tanks at speeds considerably faster than any other
means. The Lincoln Innershield (NR-431 or 432) process is employed.
The machine consists of a vertical column supported by a carriage that rides the top of the
tank ring. Lincoln Welding Equipment is attached to a saddle, which in turn travels up the
column during welding. Seam guidance and vertical travel speed are automatically
controlled during welding. The machine is manually propelled to a succeeding joint after
completion of each weld. A power skid, usually located in the center of the storage tank,
contains the welding power supply and other service equipment.
The shoes then moves up faster than the weld puddle. This increases the electrode stickout
and causes a reduction in current, which signals the travel to switch to a speed slower than
weld progression rate. The cycle repeats as necessary to maintain constant wire stickout and
automatically maintains the arc in fixed relation to the copper shoe even with variations in
joint gap. A flow regulator and switch in the water system regulates the flow and protects
the shoes against no or low water flow.
COLUMN SUPPORTS
The main column is supported at the top by two wheels riding on the top edge of the plates
to be welded, by two adjustable wheels which grip the back of the plates at the top, and by
two wheels at the bottom of the column. The assembly can be pushed or pulled along the
tank shell plate to the next vertical joint. A friction lock is provided to clamp the column to
the plate in the desired location. An electro magnet is furnished at the bottom of the column
to stabilize the location of the column in relation to the plate.
OPERATOR'S CONTROLS
The operator's control consists of the following:
Welding Controls - Current, voltage, wire speed, start weld, stop weld, manual cross seam
adjustment, manual in-out adjustment of electrode. Air Cylinder Switch. (Cylinder may
operate from compressed air or CO2.)
Lift Controls - Up and down switch, low speed and high-speed potentiometers, rapid - set
speed selector. Operator's control is fastened to the saddle of the vertical travel mechanism.
An auxiliary pendant is located at base of column.
Power Skid - The fabricator must supply a source of power of at least 100 amp. capacity for
operation of the VUP machine. A fused disconnect switch to receive the power service is
mounted on the skid with a Lincoln DC-1000 power supply, Water Recirculator, and
plumbing service box is provided and mounted.
The machine is provided with 10 feet of double 4/0 ground cable which is generally fastened
to the tank floor. A 200 ft. long cable assembly consisting of double 4/0 welding cable,
multi-conductor control cable, water hose and air hose conveys all the services from the
power skid to the tank mounted welding machine. All of the cable and hoses have quick
disconnect joints at the machine proper to facilitate separation of the two basis units for
transportation. The skid is provided with a canvas cover that may be opened for ventilation
when the machine is operating. The fabricator must supply a source of air or bottled
nitrogen of 100 to 200 PSI to the skid for operating the pneumatic copper shoe mechanism.
INPUT POWER
Unit is wired for 230-380-460V-3Ph-50-60Hz,
Power requirements - 45 KVA.
OPTIONS:
Powered Oscillator to weld with oscillation on plate thickness from (1-3/8" to 2")
Powered Lateral Travel for power positioning from joint to joint.
* Payment Terms: Confirmed Irrevocable Letter of Credit on a U.S. Bank payable in full at
sight upon presentation of shipping documents. All banking charges are for the account of
the buyer.
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APPLICATIONS FEATURES
Vertical up butt welds - single pass Single bevel joints
3/8” thru 4” thick plate Square edge joints
Tank construction Moving copper shoe travels along seam
Shipbuilding Moving or fixed copper backup
Fixed steel or ceramic backup
Welds of virtually any length
Single pass - low distortion
- no interpass cleaning or grinding
MOVABLE DAM
The Movable Dam Verti-Shield process was developed to vertically weld 3/8” to 4”
thick steel, 4 ft. and longer in one pass.
The Movable Dam process consists of feeding an electrode through a contact nozzle
positioned just above a movable copper dam. When the weld puddle reaches a
specific point, the nozzle and dam must move vertically up the plate. Therefore, a
fixture is required to move the contact nozzle, copper dam, and wire feeder, but may
also be designed to carry the wire reel and the operator. The joint must remain open
on at least one side to allow the fixture to move. The contact nozzle is not
consumed.
Index
Safety Precautions ....................................... .............................................................4
Electrode Operating Data ............................. .............................................................6
Special Notes .......................................... .............................................................6
Set-Up Procedures ....................................... .............................................................7
Welder ..................................................... .............................................................7
Joint Preparation and Design .................. .............................................................7
Electrode Oscillation................................ .............................................................7
Starting .................................................... .............................................................8
Sumps ..................................................... .............................................................8
Risers ...................................................... .............................................................9
Grounding................................................ .............................................................9
Moving Copper Shoes ............................. .............................................................9
Stationary Copper Dams ......................... ...........................................................10
Steel Backups.......................................... ...........................................................10
Ceramic Backups .................................... ...........................................................10
Welding Procedure with Ceramic ............Backups..............................................11
Tip Height ................................................ ...........................................................11
Electrical Stickout .................................... ...........................................................11
Drag Angle............................................... ...........................................................12
Electrode Location................................... ...........................................................12
Current Setting Adjustments.................... ...........................................................13
Travel Speed ........................................... ...........................................................13
General Welding Procedures
Preheat.................................................... ...........................................................14
Starting Procedure................................... ...........................................................14
Restarting ................................................ ...........................................................15
Starting Without Sump............................. ...........................................................15
Finish Procedure ..................................... ...........................................................16
General Welding Problems
Distortion ................................................. ...........................................................16
Weld Bead Condition............................... ...........................................................16
Cracking and Porosity ............................. ...........................................................16
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Suggested Procedures ...................................................................................... 17-20
For 1/16” Electrodes Using Copper Dams ........................................................ 17
For 3/32” Electrodes Using Copper Dams ........................................................ 18
For .120” Electrodes Using Copper Dams ........................................................ 20
For .120” Electrodes With Oscillated Electrode................................................. 21
Equipment .............................................................................................................. 22
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ARC WELDING SAFETY PRECAUTIONS
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND
BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER
EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION.
Protect yourself from possible dangerous electrical b. Do not weld in locations near chlorinated
shock: hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and
a. The electrode and work (or ground) circuits are rays of the arc can react with solvent vapors to
electrically “hot” when the welder is on. Never form phosgene, a highly toxic gas, and other
permit contact between “hot” parts of the circuits irritating products.
and bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. c. Shielding gases used for arc welding can
displace air and cause injury or death. Always
b. Always insulate yourself from the work and use enough ventilation, especially in confined
ground by using dry insulation. When welding in areas, to insure breathing air is safe.
damp locations, on metal floors, gratings or
scaffolds, and when in positions such as sitting or d. Read and understand the manufacturer’s
lying, make certain the insulation is large enough instructions for this equipment and the
to cover your full area of physical contact with consumables to be used, including the material
work and ground. safety data sheet (MSDS) and follow your
employer’s safety practices.
c. Always be sure the work cable makes a good
electrical connection with the metal being e. Also see item 9b.
welded. The connection should be as close as
possible to the area being welded. 4. ARC RAYS can injure eyes and burn skin.
d. Ground the work or metal to be welded to a good a. Use a shield with the proper filter and cover
electrical ground. plates to protect your eyes from sparks and the
rays of the arc when welding or observing open
e. Maintain the electrode holder, work clamp, arc welding. Headshield and filter lens should
welding cable and welding machine in good, safe conform to ANSI Z87.I. standards.
operating condition.
b. Use suitable clothing made from durable, flame-
f. Never, dip the electrode in water for cooling. resistant material to protect your skin and that of
your helpers from the arc rays.
g. Never, simultaneously touch electrically “hot”
parts of electrode holders connected to two c. Protect other nearby personnel with suitable
welders because voltage between the two can be nonflammable screening and/or warn them not
the total of the open circuit voltage of both to watch the arc nor expose themselves to the
welders. arc rays or to hot spatter or metal.
h. If using the welder as a power source for 5. FIRE OR EXPLOSION can cause death or
mechanized welding, the above precautions also property damage.
apply for the automatic electrode, electrode reel,
welding head, nozzle or semiautomatic welding a. Remove fire hazards well away from the area. If
gun. this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember
i. When working above floor level, protect yourself that welding sparks and hot materials from
from a fall should you get a shock. welding can easily go through small cracks and
openings to adjacent areas. Have a fire
j. Also see Items 6c and 8. extinguisher readily available.
3. FUMES AND GASES can be dangerous to your b. Where compressed gases are to be used at the
health. job site, special precautions should be used to
prevent hazardous situations. Refer to “Safety
a. Welding may produce fumes and gases in Welding and Cutting” (ANSI Standard Z49.1)
hazardous to health. Avoid breathing these and the operating information for the equipment
fumes and gases. When welding, keep your head being used.
out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases c. When not welding, make certain no part of the
away from the breathing zone. electrode circuit is touching the work or ground.
Accidental contact can cause overheating and
create a fire hazard.
4
d. Do not heat, cut or weld tanks, drums or f. Valve protection caps should always be in place
containers until the proper steps have been taken and hand tight except when the cylinder is in
to insure that such procedures will not cause use or connected for use.
flammable or toxic vapors from substances
inside. They can cause an explosion even though g. Read and follow the instructions on compressed
they have been “cleaned”. For information gas cylinders, associated equipment, and CGA
purchase “Recommended Safe Practices for the publication P-1“ Precautions for Safe Handling
Preparation for Welding and Cutting of of Compressed Gases in Cylinders” available
Containers and Piping That Have Held from the Compressed Gas Association, 1235
Hazardous Substances”, AWS F4.1-80 from the Jefferson Davis Highway, Arlington, VA22202.
American Welding Society (see address below).
8. For Electrically Powered Equipment.
e. Vent hollow castings or containers before
heating, cutting or welding. They may explode. a. Turn off input power using the disconnect switch
at the fuse box before working on the
f. Also see items 6c and 9c. equipment.
c. Be sure the work cable is connected to the work c. Do not add the fuel near an open flame, welding
as close to the welding area as practical. Work arc or when the engine is running. Stop the
cables connected to the building framework or engine and, if possible, allow it to cool when
other locations some distance from the welding refueling to prevent spilled fuel from vaporizing
area increase the possibility of the welding on contact with hot engine parts and igniting. Do
current passing through lifting chains, crane not spill fuel when filling tank. If fuel is spilled,
cables or other alternate circuits. This can create wipe it up and do not start engine until fumes
fire hazards or overheat lifting chains or cables have been eliminated.
until they fail.
d. In some cases it may be necessary to remove
7. For Gas-Shielded Arc Welding. safety guards to perform required maintenance.
Remove guards only when necessary and
a. Use only compressed gas cylinders containing replace them when the maintenance requiring
the correct shielding gas for the process used their removal is complete. Always use the
and properly operating regulators designed for greatest care when working near moving parts.
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and e. Do not put your hands near the engine fan. Do
maintained in good condition. not attempt to override the governor or idler by
pushing on the throttle control rods while the
b. Always keep cylinders in an upright position engine is running.
securely chained to an undercarriage or fixed
support. f. To prevent accidentally starting gasoline
engines while turning the engine or welding
c. Cylinders should be located: generator during maintenance work, disconnect
-Away from areas where they may be struck or the spark plug wires, distributor cap or magneto
subjected to physical damage. wire as appropriate.
-A safe distance from arc welding or cutting
operations and any other source of heat, sparks, g. To avoid scalding, do not remove the radiator
or flame. pressure cap when the engine is hot.
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June 18, 1998
Special Notes
Any change in parent material, joint design, copper dam dimensions, rate of water flow, wire
feed speed, voltage, etc. will probably alter the mechanical properties. For this reason, the
welding procedures must be followed. The procedures have been written to control dilution
and quench rates. Slower cooling lowers the yield and tensile strength while improving the
impact properties. Slow cooling is accomplished by increasing voltage (2 volts).
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June 18, 1998
Plate fixtures must be adequate to hold plates securely and to prevent changes in joint
and joint volume. This could affect weld quality, mechanical properties and operation
of equipment.
These procedures represent tested starting points for setting up individual field
applications. Variations other than those used to set the procedures, such as plate
chemistry, plate surface condition (oil, scale), plate thickness, joint fit-up and
equipment, may produce results different than those expected. Some adjustments to
the procedure may be necessary to compensate for the unique individual conditions.
Test all procedures duplicating actual field conditions. Some joints may require special
dam designs. For these applications or other questions, consult the Welding and
Cutting Technology Center at The Lincoln Electric Company in Cleveland, Ohio at
(216) 481-8100.
SET-UP PROCEDURES
Welder
For optimum bead wetting, the welder should be set in the Constant Voltage
Innershield (CVI) mode. Both NR-431 and NR-432 are welded DC(+), (electrode
positive).
The joints welded with this process are normally square-edge or beveled butt welds.
Plates should be free from grease, oil, excessive scale, etc. Sizeable nicks and dents
in the edges being welded can be tolerated provided fold-overs and laminations did
not occur. The plates should be fit-up so that the dams prevent slag spillage between
the dams and plates.
Electrode Oscillation
On 1-1/4 thru 4” plate, the electrode oscillates between the locations shown and along
the centerline of the gap. The oscillation locations, dwell times, and travel times are
given in the Procedures sheets (Page 20).
The electrode should dwell at each location for the dwell time given in the procedure
table. The electrode should travel between the locations with the oscillation travel time
given in the table.
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June 18, 1998
Starting
In order to minimize start porosity and obtain good wetting, use of a start circuit and
procedure is recommended. This circuit provides for a reduced wire feed speed and
reduced voltage for a given number of seconds. The starting time is decreased as the
plate thickness decreases. This reduces the possibility of the weld paddle spilling over
the top of the shoe(s) on thinner plates due to the reduced joint volume being filled
quicker.
Sumps
Starting sumps permit striking the arc below the actual joint so any starting porosity
can be easily removed. The sump must be long enough to allow time for the switch
from starting to welding procedures and for the arc and travel to stabilize before the
puddle rises into the joint being welded. The sump is cut off after welding.
If a copper sump is used, it should be large enough so that it does not become fused
to the weld. It should also have a tapered hole or be split for easy removal. A small
piece of steel should be placed in the bottom of a copper sump to avoid arcing the
copper. A small piece of fiberglass tape may be placed on the sump below the gap to
prevent weld spilling upon initiating the weld.
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Risers
Risers (or run-off tabs) are recommended because the solidification of the large
puddle at the end of the weld creates a shrinkage crater that has a tendency to trap
slag or gas. Typical risers are shown in the previous figure. Weld should continue into
the riser until weld puddle is approximately 1” to 2” above the top of the work.
Ground leads should be connected to the top of each plate. Connect the ground leads
securely approximately 1 foot away from the seam. If arc blow problems exist, adjust
grounding to reduce the problem.
Copper shoes are grooved to provide proper bead contour on front of weld. Shoes
have a V cut out at the top to permit excess slag to drain out. The weld puddle should
be just below the apex of the V. Enough water flow must be used to prevent
overheating of the shoe and vapor lock of the water flow (approximately 1-1/2 - 2
gal/mm). Water flow must not be interrupted while welding. lf the water lines vibrate
while welding, it means that water flow is insufficient and some of the water in the
copper shoe is boiling. The formation of steam results in high pressures in the water
lines. If a water line fails due to steam formation, it could cause injury to nearby
personnel. Do not use the same water supply for the copper shoe and the backup
dams. The travel mechanism should be adjusted to give the smoothest travel possible.
Large jerks indicate travel speed set too high or slight arcing to the copper shoe. If
slag builds up on the shoe (or nozzle), it may be knocked off with a piece of wood or
other non-conductive material.
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June 18, 1998
Dams are grooved to provide proper bead contour on back of weld. All copper dams
and shoes are water-cooled and must be made of electrical grade (99.9% pure)
copper, such as alloy #110. Dams may be used in stacked sections to make welds
longer than one dam length. If total weld length is more than 24 inches, use stacked
sections 18-24” long for the back dam. Longer back dams are difficult to line up, and
precise line-up is very important to back bead shape and root fusion.
Dams should be wedged or clamped tightly against the plates to prevent leakage of
the molten slag on the weld puddle. Dams must be replaced or repaired if they
become damaged enough so that they no longer fit properly against the plate.
When more than two dam sections are employed, each section must be water-cooled.
Enough water flow must be used to prevent overheating of dam and vapor lock of the
water flow (approximately 1 - 1-1/2 gals/mm in each side of each section). Exit water
should be warm to the touch (not hot). Water-cooling passages are located at the top
of the dams. The copper dams should extend a few inches beyond the top of the weld
to reduce heat buildup and help produce sound craters. Water flow should be left on
for several minutes after the weld is completed to cool the dams. Water flow must not
be interrupted while welding. If the water lines vibrate while welding, it means that
water flow is insufficient and some of the water in the copper dams is boiling. The
formation of steam results in high pressures in the water lines. If a water line fails due
to steam formation, it could cause injury to nearby personnel.
If the humidity is high, do not leave the water flow on when not welding or moisture will
condense on the outside of the dams.
Steel Backups
When a stationary steel backup is used, all rust, scale, oil, or other foreign material
should be ground off the mating faces. Otherwise, porosity will occur along the plate
edges where the steel backup is positioned. Steel backups should be mild steel or the
same material as the steel being welded.
Ceramic Backups
1/16” electrode may be used with certain ceramic backing material. The ceramic
should be high melting point type.
A metal retainer is recommended to hold the ceramic tight against the base plate. The
retainer should be clamped or welded to the base plate. It will act as a heat sink and
prevent melted ceramic, slag and molten weld metal from flowing away from the weld.
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Ceramic material is not as good a heat sink as copper. If the standard copper backup
welding procedures are used, the welds may be overheated and over welded when
using ceramic backups.
If welds appear to be overheated and over welded, reduce the wire feed speed and
arc voltage equal to the procedure recommended for the next thinner plate. For
example, 3/8” plate may be welded at 275 in/mm W.F.S. and 31 to 32 volts with
ceramic backups.
Tip Height
Tip height above the top of the copper cutout should be 7/8” to 1-3/4”. The puddle
height must be 1/4” below the top of the copper cutout. This will allow excess slag, if
any, to drain out. There may be some draining on heavier plate; little or none on
thinner plate.
While welding, do not allow the puddle to rise up too high in the shoe (stick-out too
short) or molten weld metal will run out. This will stop the vertical travel and interrupt
the weld. Do not let the puddle go too far down in the shoe (stick-out too long) or the
resulting weld will be “cold” and have poorly wet edges.
Electrical Stickout
Electrical stick-out of the electrode beyond the contact tip determines current and the
welding characteristics of the electrode. Incorrect stick-out can cause porosity, low
impact strength and improper location of the electrode during welding. Improper
electrode location can result in poorly wet bead edges and arcing to the copper shoe
or dam. Set the stick-out before bringing the electrode into the joint. Do not change the
stick-out when making other adjustments.
When welding with the extension guide (.120” diameter electrode), the electrical stick-
out is 1” longer than the visible stick-out.
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Drag angle
Drag angle determines direction of arc force and affects heat flow. A large drag
angle will direct more heat to the back, possibly causing missed edges on the
front. A large drag angle also causes relatively larger changes in electrode
location with variations in stick-out. Copper backup dams or front shoes may be
arced if this angle is improperly set. Drag angle is measured from the vertical to
the line of the electrode as it exists from the tip (or from the extension guide) as
shown below. Drag angle should be 6°-10°, depending on application.
Electrode Iocation
Electrode location is measured from the front face of the plate to the near side of
the electrode end after establishing correct stickout. Location must be set
carefully and monitored during welding. If location is too close to front, the
electrode may arc to the copper shoe and/or the back bead face may be poorly
wet. If location is too far back, the front bead face may be poorly wet and/or the
electrode may arc to the back dam. Set the electrode location according to the
recommended procedures on Pages 17-20 and defined in the diagrams below:
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June 18, 1998
The electrode location changes as the nozzle contact tip wears. Replace the
contact tip when it becomes worn or the end is fused or deformed.
Electrode location can also change due to wire straightness and flip. Wire
straightens and guides should be used to reduce this problem.
Current setting adjustments on the current meter relay are made only to control
stick-out and puddle height. Puddle height is defined as the distance between the
molten slag puddle and the copper cutout on the shoe. If the puddle height is too
great (stick-out too long), increase the current setting on meter relay. If the puddle
height is too low (stick-out too short), decrease the current setting. A 25-amp
change in current setting on .120” wire will change stick-out and puddle level by
1/4” to 1/2”. Stickout and puddle level must be held closely to maintain proper
electrode location and slag control.
Travel Speed
The operator has no direct control over weld travel speed. The electrode
diameter, wire feed speed, and joint volume will determine the actual weld travel
speed. The movement of the fixture is automatically controlled.
For a given electrode diameter, wire feed speed and electrical stick-out, there is a
resultant welding current. A change in any of these variables will cause a change
in the welding current. Since the electrode diameter and wire feed speed are
constant, only the electrical stick-out can change and influence the welding
current. This change in current is the basis for controlling the travel of the fixture.
As the stick-out gets longer, the current decreases; as the stick-out gets shorter,
the current increases. The change in current is the important factor and not the
actual current that may vary from setup to setup.
All Verti-Shield fixture manufacturers use this change in current to control the
fixture travel. The Ransome fixture uses a set point ammeter, the needle indicator
sets the point at which the travel starts and stops. This is not a travel speed
control but determines the level of the weld puddle in relation to the moving shoe.
A rule of thumb is “the higher the set point, the higher the puddle - the lower the
set point, the lower the puddle”.
Once the wire feed speed and stick-out are set, the ammeter set point controls
the position of the puddle in the moving shoe. The travel speed of the fixture,
when activated by the ammeter, is set by a different speed control. This speed
control sets the speed that the fixture moves when the control signals it to move.
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On equipment with on and off travel control, carriage travel speed should be set at
125% to 150% of arc travel speed. The arc travel speed range is determined by
the joint gap for a given wire feed speed.
Preheat
Starting Procedure
After starting time has elapsed, the weld procedure stick-out should be maintained.
Starting Porosity: Some starting porosity may occur. To improve starting and reduce
porosity, preheat starts and/or add 880M flux.
Use approximately 1-1/4 teaspoons of 880M flux for each inch of plate thickness.
The 880M flux is poured into the gap when starting the arc. Half of the
recommended amount of flux may be added before striking the arc as long as the
electrode is in contact with the striking surface. Add the remaining flux gradually so
as not to quench the arc. Add the flux with a non-metallic instrument to avoid arcing.
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Restarting
3. Be sure weld metal is clean and free of porosity or deep shrink cavity. If so,
arc gouge and grind the affected area. Reference “Starting without sump”
section of this Guideline.
6. A small ball of steel wool may be placed on top of weld to aid in starting the
arc.
7. Reset copper shoe - make sure shoe fits tight against plate (may need to
grind face of weld).
Sometimes the weld must be started without a starting sump. For example, the start
of vertical welds in tank erection is on the top of the previous course. Where such
starts or restarts are made on good plate, some repairs in the starting area are
sometimes necessary, particularly on the heavier plate thickness. The size and
accessibility of these repair areas can be controlled by preheating to about 400°F
min. One method of preparing the plate for a fast, preheated start using an arc
gouged start area is shown below. For plates requiring oscillation, it is best to simply
remove the slag from the crater and preheat to 600°F to 700°F.
15
NP-MD
June 18, 1998
3. Make weld.
Finish Procedure
Just before pressing the “Off” button, “cap” the weld by adding enough 880M flux to
completely cover the weld. This flux addition will help reduce shrinkage cavity and
crater porosity. This procedure should be done when the crater is in the run-off tab
area.
Distortion
If the joint tends to close during welding, the weld quality will be affected. On
beveled joints, the back bead may be lost. The plates must be held rigidly or allow a
1/8” greater gap at the top of the plates regardless of seam length.
Higher wire feed speeds and voltage are used on thicker plates or wider face
openings to get good wet-in on the faces. Square bead edges can result from a
“cold arc”. Increasing wire feed speed and arc volts will usually correct this
condition. The current meter relay should be increased to maintain proper stick-out.
Remember to check for a narrow gap that will make the puddle colder or mis-
location of the electrode due to improper tracking, improper electrical stick-out
(check meter relay setting), or improper setup location.
On oscillated welds, bad back beads can occur if the electrode moves too close to
the front of the joint and arcs off the sidewalls. Too short a dwell or too slow an
oscillation will cause square edges. Misalignment of the shoes on the joint will cause
under-wash on one edge with or without oscillation.
The most critical problems with automatic vertical up welding are cracking and
porosity.
16
NP-MD
June 18, 1998
Since the Moving Dam Process is an open arc process, the electrical stickout,
current, voltage and depth of the weld puddle below the top of the copper shoe(s)
control porosity. Decreased current for the same voltage, increased voltage for the
same current, or decreased stick-out for the same current and voltage will all
increase the tendency for porosity.
The starting circuit parameters are very important since poor starts can result in
completely porous welds for a considerable length of the joint.
The most important parameter that controls’ cracking is the wire feed speed.
Decreasing the wire feed speed by 15% and the voltage by 2-3 volts makes a
significant decrease in cracking tendency. Increasing the gap is sometimes
beneficial in decreasing cracking but may cause incomplete sidewall fusion.
Increasing the voltage will decrease cracking but must be done with caution since
the porosity tendency will increase. As with other processes, decreasing the quench
rate decreases the cracking tendency. With this process, lower wire feed rates
(lower current), for the same ESO actually result in slower quench rates due to
slower travel speeds. Oscillation is also very effective in decreasing cracking.
Welding on very cold days may produce cracking unless preheating is used.
SUGGESTED PROCEDURES
17
NP-MD
June 18, 1998
18
NP-MD
June 18, 1998
19
NP-MD
June 18, 1998
20
NP-MD
June 18, 1998
For 120” Electrodes Using Copper Dams on 1-1/4 4” Plate With Oscillated Electrode
-
Because design, fabrication, erection and welding variables affect the results
obtained in applying this type of information, the serviceability of a product or
structure is the responsibility of the builder/user.
21
NP-MD
June 18, 1998
Note: Higher wire feed speeds than those shown in the tables can sometimes be
used. Higher wire feed speeds produce faster weld travel speeds but demand
more care in running the welds and greater operator skill. Higher wire feed
speeds require correspondingly higher voltage and current settings to maintain
the correct puddle height and arc characteristics.
EQUIPMENT
Additional equipment necessary includes a water supply with hoses, clamps, etc.
and smoke removal equipment.
22
NP-MD
June 18, 1998
TROUBLESHOOTING GUIDE
STARTING PROBLEMS
Because design, fabrication, erection and welding variables affect the results obtained
in applying this type of information, the serviceability of a product or structure is the
responsibility of the builder/user.
23
NP-MD
June 18, 1998
TROUBLESHOOTING GUIDE
WELD PROBLEMS
Because design, fabrication, erection and welding variables affect the results obtained
in applying this type of information, the serviceability of a product or structure is the
responsibility of the builder/user.
24
NP-MD
June 18, 1998
TROUBLESHOOTING GUIDE
WELD PROBLEMS (continued)
Problem CAUSE CORRECTION
1. Narrow gap causing too fast 1. Increase gap.
travel speed.
Because design, fabrication, erection and welding variables affect the results obtained
in applying this type of information, the serviceability of a product or structure is the
responsibility of the builder/user.
25
NP-MD
June 18, 1998
TROUBLESHOOTING GUIDE
WELD PROBLEMS (continued)
COLD LOOKING 6. Travel speed too fast due to 6. Lower carriage travel speed.
FRONT - carriage travel speed set too Use wider gap.
IRREGULAR OR high or narrow gap.
MISSED EDGES - 7. Incorrect power source. 7. Use correct power source.
POORLY WET
EDGES (continued)
1. Shoe not tracking properly - 1. Center gap in groove.
joint gap off center with
respect to groove in copper.
2. Too much heat - arc too close 2. Move arc away from front.
to front or setting too hot Reduce heat. Reduce face
UNDERWASHED causing bead width to extend opening.
EDGES beyond copper groove. Face
opening too large.
TROUBLESHOOTING GUIDE
CRATER PROBLEMS
Because design, fabrication, erection and welding variables affect the results obtained
in applying this type of information, the serviceability of a product or structure is the
responsibility of the builder/user.
26
NP-MD
June 18, 1998
DAM/SHOE PROBLEMS
ARCING FRONT 3. Puddle riding too high - metal 3. Adjust parameters so that
SHOE spilling over top of shoe. puddle rides approximately
1/4” below cut out on shoe.
4. Too little electrode angle 4. Use correct electrode angle.
(electrode too much straight
up and down).
1. Electrode location too close 1. Move location away from dam
to dam or shoe. or shoe.
2 Excessive slag drainage (on 2. See corrections for excessive
thin plate). slag drainage.
3. Dams or shoe overheating. 3. Use water-cooled dams or
shoe; increase water flow.
Because design, fabrication, erection and welding variables affect the results
obtained in applying this type of information, the serviceability of a product or
structure is the responsibility of the builder/user.
27
NP-MD
June 18, 1998
TROUBLESHOOTING GUIDE
MISCELLANEOUS PROBLEMS
Because design, fabrication, erection and welding variables affect the results
obtained in applying this type of information, the serviceability of a product or
structure is the responsibility of the builder/user.
28
IDEALARC ® DC-1000
The DC-1000 is a multiprocess DC arc • Mode switch used to select the • Recessed front panel protects
welding power source for semiauto- desired output characteristics for operating controls.
matic and automatic welding the process being used.
• Terminal strip and output studs for
applications. It produces outstanding
• Line voltage compensation for remote connections and cable.
arc characteristics on both constant
maintaining weld consistency, even
voltage and constant current • 500 amp output connections
with line voltage changes of ±10%.
processes. This provides great weld- provide enhanced arc characteris-
ing versatility in a single power source. • Low profile case allows installation tics for submerged arc and MIG
of the DC-1000 under a workbench welding procedures.
The DC-1000 is designed for and for stacking up to 2 machines
• Fuse protected 115V wire feeder
submerged arc welding, and FCAW to conserve floor space.
auxiliary power with 1000 volt-amp
processes within the capacity of the
• Removable side panels for easy capacity.
machine, plus the capability of air
access to internal parts.
carbon arc gouging up to 5/8” (16mm) • Power start/stop push button (NVR)
diameter carbons. It produces • Fan cooled with electronic and switches with pilot light.
outstanding welding performance with thermostatic protection from current
• 3 year warranty on parts and labor.
a single range full output control overload and excessive temperatures.
potentiometer. • Manufactured under a quality
• Windings and rectifiers protected
system certified to ISO 9002
against moisture and corrosive
The precise output of the DC-1000 requirements.
environments.
enhances productivity and quality
control when used with Lincoln LN-7,
LN-8 and LN-9 semiautomatic wire
feeders, NA-3, NA-5, and NA-5R
automatic wire feeders, and the LT-56
and LT-7 tractors.
ADVANTAGE
LINCOLN
• Solid state circuitry provides extra
long life for repetitive welding
applications. R
VOLTS
Idealarc DC-1000 1000A / 44V / 100% 1000A / 50V / 100% 16-46 821 lbs 30.7* x 22.5 x 39.0 in.
(372 kg) (781 x 572 x 991mm)
AMPS *includes lift
150-1300 bail
(1)
NEMA Class I Rated Output.
(2)
Based on a 10 minute period.
ORDERING
INFORMATION
OPTIONS
AVAILABLE
Remote Output Control Paralleling Kit 115V/42V Transformer Kit
For remote adjustment of output. Permits paralleling of two DC-1000’s Provides a way to use the LN-10 or
Consists of a control box with 28 ft. for welding currents of up to 2000 DH-10 wire feeder on a DC-1000 that
(8.5m) of four conductor cable for ter- amps, 100% duty cycle. has a 115V AC available on the
minal strip connection. Order K775. Order S20428. terminal strip. Order K1520-1.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of
the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
DISTRIBUTED BY:
THE
LINCOLN ELECTRIC
COMPANY
Local Sales and Service through Global
Subsidiaries and Distributors
Cleveland, Ohio 44117-1199 U.S.A .
TEL (216) 481-8100
FAX (216) 486-1751
WEB SITE: www.lincolnelectric.com
CC/CV Welders
E5.50 6/00
KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400
This machine is designed to make gapped square butt and single "V" vertical welds in steel
plates ranging from 3/8 to 4 inches thick. It utilizes the proven Lincoln Innershield process
with Special NR-431 or NR-432 wire developed for vertical welding. Constructed of
aluminum, the welding unit is easily transported and set up by one operator. Typical
welding applications include: bridge girder flanges and webs, building column splices, and a
myriad of other in-plant fabrications requiring welds up to about 6 feet long. Longer welds
are possible with extra length track.
Carriage Assembly
The welding unit consists of a 7 ft. long track that is fastened to the weldment, parallel to the
weld joint, my means of the clamps provided; weld studs, or other suitable means. The
track receives a powered carriage on which are mounted a special welding nozzle and a
nozzle oscillator for use when welding plate 1-1/4" and thicker. Means are provided for
maintaining a front water-cooled copper dam in contact with and in alignment to the weld
seam.
Running adjustments of the electrode nozzle in-out and cross seam is standard. Vertical
nozzle height and initial angular adjustment are preset fixed settings as required by the
process. The articulated shoe mounting provides cross seam and vertical angular tracking
while maintaining vertical alignment. A fixed copper bar running the full length of the weld
is required and is held in contact with the weldment by means of strong backs and wedges.
The backing bar is not supplied with the equipment but is of simple design and readily
fabricated by the user to the design shown in the Lincoln welding procedure.
The welding system consists of a Lincoln LN-9 solid-state control and wire feeder with 50
lb. wire reel in a dust resistant enclosure. These units are mounted on a four-wheel
undercarriage for mobility throughout the shop. Welding wire is fed to the nozzle assembly
on the welding unit through a 15 ft. long conduit suitable for either 3/32 or .120-inch
diameter wire. Ammeter, voltmeter, and wire speed meters are included to present and
monitor the welding parameters. During welding, the copper dam is automatically
maintained in fixed relation to the weld puddle by controlling carriage travel as a function of
change in electrode extension. A flow regulator and switch in the water-cooling circuit
protects the copper shoe against no or low water flow. A water recirculator cooler is
available as an option.
Welding Equipment
A Lincoln DC-600 Power Source provides welding power. Twenty-five feet control cables
run from the Power Source to the Control Unit along with 25 feet of ground cables. Also
provided are 15 feet of control cable, wire conduit and water hoses running from the Control
Unit to the Welding Carriage. The cable assembly going to the Welding Carriage is tie
wrapped together.
Wire Feeder
A Lincoln LN-9 Wire Feeder is provided with feed and pressure rolls, along with inlet-outlet
guides for either 3/32 or .120 inch diameter wire and a cored wire, wire straightener.
Nozzle Assembly
For welding plate 3/4 to 4 inch thick, the .120-inch diameter wire size is recommended. For
plate from 5/8 inch thick and under, 3/32-inch wire is used. One nozzle assembly for
welding with .120-inch diameter wire is supplied. A nozzle assembly for 3/32-inch wire is
optional.
The machine is complete; ready for welding up to 6 foot long welds. Additional track in 6 ft.
increments is available for making longer welds. However, when making welds higher than
10 ft. from the floor, means must be provided by the user to raise the tractor unit above the
floor because of the limited length of cable and wire conduit between the control unit and
welding unit. Machine is wired for 460 volt, 3 phase, 60 hertz operation.
Furnish and install water cooler recirculating system. Recommended for service where
clean water is at a premium or not available and is required where available water pressure
is below 80 P.S.I. Two 25 ft. long hoses are supplied with the water recirculator.
Service Skid
Basically a steel channel base on which is mounted the power supply and water recirculator
The base has lifting lugs for a single pick when moving around the shop.
Average weld procedure called for a welding travel speed of around 30 IPM, 400 Amps,
28-30 Volts and a wire feed speed of 90 IPM. Single torch deposition rate is
approximately 11 lbs/hr.
The AGW system is available as a single sided (AGW-I) or double-sided unit (AGW-II).
The single sided unit, AGW-I, is the most commonly used unit due to a lighter weight
allowing it to operator on lighter plates. The AGW also requires only one operator and
will not be restricted due to slave side operations.
The double-sided unit, AGW-II, allows for welding on both sides of the plate at once. On
thicker plates (1/2 inch or thicker), this will provide a higher deposition rate.
On the AGW-II, two operators are required, one will have the main travel controls and
the slave operator will just have the welding controls for the slave side. A communication
system is provided to talk to one another.
The AGW systems will operator on standard plate sizes of 6’, 8’ and 10’. Pin adjustments
will set the unit up for the 6, 8 and 10 ft. plate sizes. For in between sizes, the equipment
mounting brackets will need to be adjusted.
Special units have been designed for larger height plates up to 13 ft. and thickness up to
2-1/2 inches. Units have also been provided to work on double walled tanks.
The Koike Aronson, Inc. / Ransome AGW Systems are provided complete, all that is
required is the hang unit on tank, add wire, flux and an operator and begin welding.
Options:
SPECIFICATIONS
GENERAL
The Ransome Girth Welder is an automatic self-propelled welding machine used for the
construction of field storage tanks having 6', 8’ and 10' (1.8, 2.4 and 3.04 M) high plate
courses. The unit is basically an "A" frame that straddles and is supported by the shell plates
to be welded. Each side of the machine has its own welding head, control, flux support belt
apparatus and flux recovery unit so that 3 O’clock welds can be made simultaneously from
both sides of the shell. The standard welding process supplied is the Lincoln Electric
Company's submerged arc system, using a Lincoln NA-3S solid state control. The system is
also designed for Lincoln Twinarc process, and Innershield process; where the client
approves such procedures.
MACHINE FRAME
"A" frame constructed of structural steel and tubular steel members. One side, referred to as
the master, is an entity and can be used by itself for one side welding. The second side
(slave) is pivotally fastened to the top of the master frame and is used when welding two
sides. The tubular legs of the frame telescope and are manually adjusted by removing pins
and lowering the platform. This machine can weld shell plate ranging from 6’,8’ and 10 Ft.
high (1.8,2.4 and 3.04 M.) The customer can drill additional holes for positions within the
above range. You can also make find adjustments of +/- 3 inches of the coarse adjustments.
The master frame contains two serrated hardened steel flanged drive wheels which are
manually adjusted to ride tank diameters down to a minimum of 30 ft. (9M.) Distance
between wheel flanges is 1-7/8 inches (47.6 mm) so tank plate can be as thick as 1-3/4"
(44.5 mm.) One of the wheels is driven by a positive drive gear train (no secondary chain
reduction.) The gear train consists of a 3/4 HP T.E.N.V. electronically controlled shunt
motor that drives a double reduction gear reducer. Machine speed range is 4 to 105 IPM.
(.10 - 2.67 M/Min.)
Both the master and slave side frame have a hand railed operator's platform with seat. A
ladder provides a means for operator movement from one side of the machine to the other
and for access to the primary separator tank. Small diameter wheels at the lower end of the
tubular legs simplify loading and unloading the machine on the tank. Canvas curtains offer
arc and operator protection on windy days or during inclement weather.
Average welding speed is approximately 30 inches per minute with a deposition rate of
11# per hour for each side.
* Payment Terms: Confirmed Irrevocable Letter of Credit on an U.S. Bank payable in full
at sight upon presentation of shipping documents. All banking charges are for the account
of the buyer.
DC-600
170G
INFORMATION 230/460/3/60
230/460/3/60
108/54
108/54
K1288-17
K1288-18
220/380/440/3/50/60 117/68/58.5 K1365-23
380/500/3/50/60 67.8/51.5 K1365-24
OPTIONS
AVAILABLE
Multi-Process Switch Remote Control Cable Adapter TIG Module
Recommended when using the Y connection adapter for connecting Supplies high frequency for superior
DC-600 for both semi-auto welding K857 Remote Voltage Control (6 pin starting, contactor control, remote
and stick/air carbon arc welding. plug connection) and wire feeder control capability and a gas valve for
Order K804-1. input cable (14 pin plug connection) DC TIG welding. Order K930-2.
to DC-600 14 pin receptacle.
Order K864.
Water Valve
For use with TIG Module. Shuts off
water flow when the arc is extin-
Remote Output Control Undercarriage guished when using Magnum® water-
For remote adjustment of output. A mounting frame and three wheels cooled TIG torches. Order K844-1.
Consists of a control box with 28 ft. for hand moving. Order K817P. Control Cable Extension
(8.5m) of four conductor cable for ter-
Undercarriage Allows the TIG Module to be operated
minal strip connection. Order K775.
Platform undercarriage with mount- at up to 22.5 -45 ft. (6.9-13.7m) from
Remote Output Control ings for two gas cylinders at rear of DC-600. Connects between the 2 ft.
Provides 25 ft. or 100 ft. (7.6m or welder. Order K842. (0.6m) control cable and the TIG
30m) of remote output control (6 pin Module.
plug connection). Requires K864 Paralleling Kit 22.5 ft. Order K937-22.5
Remote Control Cable Adapter. Permits paralleling of two DC-600’s 45 ft. Order K937-45.
For 25 ft. (7.6m), Order K857 for welding currents of up to 1200
amps, 100% duty cycle. The “mas- Docking Kit
For 100 ft. (30m), Order K857-1.
ter” DC-600 controls both paralleled Provides a means to “dock” the TIG
machines. Order K1611-1. Module on top of a flat-roofed power
source, or any other flat surface mea-
suring at least 10 x 15 in. (254 x
381mm). It includes a latch and provi-
sions for a user-supplied padlock to
lock the TIG Module in place.
Order K939-1.
DC-600 ORDER FORM
DC-600 K1288-17
DC-600 w/ Multi Process Switch K1288-18
Stick Welding
Accessory Kit - cables, clamps, helmet, 400 Amp K704
Undercarriage
for hand moving K817P
for moving with two gas cylinders K842
All-Terrain Undercarriage K1737-1
Factory Undercarriage K1770-1
Roll Cage K1788-1
Gas Cylinder Holder (not compatible with Roll Cage) K1745-1
TOTAL:
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results obtained in applying this type of fabrication methods and service requirements.
CV Welders
E5.40 7/01
˚ ˚
˚ ˚
X
Flux Dam
Wire
Feed AC W eld
W eld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
X (225) 80 18 - 5/8 NR203M 5/64 --- 14
All (725) 130 29 + 3/4 L61 2 5/64 860 30
COMMENTS
Land is approximately 1/8-inch.
Root-gap is approximately 1/8-inch.
Flux on the backside for the first automatic pass will control any burn –thru
1
Wire
Feed AC Weld
Weld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
st
1 400 90 28 + 1 L-60 3/32 780 18
Others 450 110 28 + 1 L60 3/32 780 18
COMMENTS
Electrode 10˚ to floor, 90˚ drag angle.
45˚ minimum cut angle 1/6-inch land maximum.
Six (6) passes each side.
2
Wire
Feed AC Weld
W eld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type W ires Size Type (IPM)
5/16 400 90 28 + 1 L-60 3/32 780 18
3/8 400 90 28 + 1 L-60 3/32 780 18
1ST Pass 350 70 28 + 1 L-60 3/32 780 18
1” All Others 450 110 28 + 1 L-60 3/32 780 18
COMMENTS
Electrode 10˚ to floor.
Five (5) passes are required on the 1-inch plate. 7/8-inch plate may require only four (4).
W FS shown for one wire.
3
Wire
Feed AC Weld
Weld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 400 26 + 1-1/8 L-61 1/8 780 26
2 600 32 + 1-1/8 L-61 1/8 780 32
COMMENTS
Flux shelf distance from weld is important.
4
Butts are square-edged and tight. Flux
dams are 1/2-inch below seam. Dam is
movable belt on production runs.
Wire
Feed AC Weld
Weld Amp Speed (+) Stickout Wire No. of Wire Flux Speed
No. s (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 400 26 + 1-1/8 L-61 1/8 780 26
2 600 32 + 1-1/8 L-61 1/8 780 32
COMMENTS
Flux shelf distance from weld is important.
5
45˚
1/16
20˚
W ire
Feed AC Weld
W eld Speed (+) Stickout W ire No. of W ire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 725 29 + 7/8 L-61 2 5/64 860 30
2 725 29 + 7/8 L-61 2 5/64 860 30
3 725 29 + 7/8 L-61 2 5/64 860 30
4 725 29 + 7/8 L-61 2 5/64 860 30
5 725 29 + 7/8 L-61 2 5/64 860 30
COMMENTS
A. Stringer made with 3/32 NR20.
B. Wires in line – if any skew trail wire should be lower.
C. Aiming point of lead wire should be lower than expected.
-- metal seems to have more than normal tendency to climb and wash up.
D. Welds were made away from ground.
E. No back-gouging was done.
F. First automatic pass cleaned easily on both sides.
G. Same angle was used on all five passes each side.
6
LEADING TRAILING 1-1/2 Inch Gap 0-1/32
3/32 L-61 or L-60 3/32 L-61 or L-60 or 760 50 IPM
400Amp 27v 400Amp 27v
(+) (+)
7
Wire
Feed AC Weld
W eld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1-5 700 130 29 + 7/8 L-61 2 5/64 860 30
COMMENTS
“X” stick pass with 1/8 E7018
Note: Electrode placement for the first sub-arc pass. It was located at the very bottom edge of
stick pass and plate. Location was the same on the second side.
8
1 2 Electrode angles range between
1
0 and10˚ from horizontal.
Wire
Feed AC Weld
Weld Speed Stickout
(+) Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (Inches)
(-) Type Wires Size Type (IPM)
1-Flush 650 28 + 1/2 L-50 2 1/16 780 91
1/4 &
2-Fillet 750 28 + 1/2 L-50 2 1/16 780 91
3/8 1-Flush 800 29 + 1/2 L-50 2 1/16 780 70
2-Fillet 850 29 + 1/2 L-50 2 1/16 780 70
3/8 & 1-Flush 850 29 + 1/2 L-50 2 1/16 780 68
1/2 2-Fillet 900 29 + 1/2 L-50 2 1/16 780 68
COMMENTS
1/2 & 5/8 *only
80% penetration Spacing between electrodes and lower plate must be 1/32”.
*Above procedures are for CP type power source moreover only 80% penetration will result with a ropey
bead.
Variable voltage consisting of (2) R3M 650 paralleled was also tried on the 1/2” and 5/8” joint. The
following results were obtained while using 3/16” – 1/4” angle bevel on the1/2” plate (refer to drawing
#2).
1 – Flush 1025 30 + 60in/min 1/2” L-50 2 5/64”
2 – Fillet 1025 30 + 68in/min 1/2” L-50 2 5/64”
Only 80% penetration resulted.
9
75% Penetration
Wire
Feed AC Weld
W eld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 700 28 + 3/4 L-50 2 1/16 780 50
2 500 30 + 3/4 L-50 2 1/16 780 50
3 700 28 + 3/4 L-50 2 1/16 780 50
4 500 30 + 3/4 L-50 2 1/16 780 50
COMMENTS
Any gap with 700amps will burn through.
10
Wire
Feed AC Weld
Weld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type W ires Size Type (IPM)
1 600 28 + 3/4 L-50 2 1/16 780 50
2 600 28 + 3/4 L-50 2 1/16 780 50
3 600 28 + 3/4 L-50 2 1/16 780 50
4 600 28 + 3/4 L-50 2 1/16 780 50
COMMENTS
Passes 1 and 3 slag must be chipped off.
11
Direction of travel
Wire
Feed AC Weld
Weld Speed (+) Stickout Wire No. of Wire Flux Speed
No. Amps (IPM) Volts (-) (Inches) Type Wires Size Type (IPM)
1 700 28 + 3/4 L-50 2 1/16 780 50
2 750 28 + 3/4 L-50 2 1/16 780 50
COMMENTS
1 leads 2 by 7 inches
Ground start
Electrodes in line
12
KOIKE ARONSON, INC. / RANSOME COMPANY
Houston Sales Center
1285 North Post Oak
Suite 150
Houston, TX 77055
713-682-9645 Fax 713-957-4852
Main Office Arcade, NY 585-492-2400