ARONSON TECHNICAL MANUAL

KOIKE ARONSON, INC.635 W. Main St., Arcade NY, 14009-0307 (585) 492 2400 Fax (585) 457 3517

VERTICAL UPWELDER

INSTRUCTION MANUAL MI1546ASubject to Change without Notice

January 2014Rev C

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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS .............................................................1

SECTION 1.1 General Safety ..............................................................................4SECTION 1.2 General Safety, Arc Welding.........................................................5

SECTION 2 INTRODUCTION...........................................................................9

SECTION 2.1 Scope ...........................................................................................9SECTION 2.2 Applications...................................................................................9SECTION 2.3 General Description.......................................................................9SECTION 2.4 Equipment Included ......................................................................9SECTION 2.5 Equipment Description ..................................................................9

SECTION 3 INSTALLATION ..........................................................................13

SECTION 3.1 Installation Safety Precautions ....................................................13SECTION 3.2 Handling And Storage .................................................................13SECTION 3.3 Unpacking And Cleaning.............................................................13SECTION 3.4 Installation...................................................................................13SECTION 3.5 System Requirements .................................................................13SECTION 3.6 Consumable Description .............................................................14

SECTION 4 OPERATION...............................................................................17

SECTION 4.1 Operational Safety.......................................................................17SECTION 4.2 Switch Descriptions Enclosure 1 .................................................17SECTION 4.3 Switch Descriptions Enclosure 2 .................................................17SECTION 4.4 Optional Components..................................................................18SECTION 4.5 Start Procedure ...........................................................................20SECTION 4.6 End Seam Procedure..................................................................20

SECTION 5 MAINTENANCE ..........................................................................21

SECTION 5.1 safety precautions .......................................................................21SECTION 5.2 general information .....................................................................21SECTION 5.3 preventive maintenance schedule ...............................................21

SECTION 6 REPLACEMENT PARTS ............................................................23

SECTION 7 WELD PROCEDURE..................................................................32

SECTION 7.1 Arc Welding Safety Procedure ....................................................32SECTION 7.2 Plate Holding...............................................................................37SECTION 7.3 Set-Up Procedures......................................................................37

SECTION 7.4 General Welding Procedures ......................................................43SECTION 7.5 General Welding Problems .........................................................44SECTION 7.6 Suggested Procedures................................................................46SECTION 7.7 Start Problems Troubleshooting Guide .......................................51SECTION 7.8 Weld Problems Troubleshooting Guide.......................................53SECTION 7.9 Crater Problems Troubleshooting Guide .....................................56SECTION 7.10 Dam/Shoe Problems Troubleshooting Guide ..............................57SECTION 7.11 Miscellaneous Problems Troubleshooting Guide ........................59

TABLES

TABLE 6.9 Spare Parts List...........................................................................31TABLE 7.1 Electrode Operation Data............................................................36TABLE 7.2 Recommended Minimum Preheat Temperature..........................43TABLE 7.3 1/16 Electrode Procedure............................................................46TABLE 7.4 3/32 Electrode Procedure............................................................47TABLE 7.5 .120 Electrode Procedure............................................................49TABLE 7.6 Equipment ...................................................................................50TABLE 7.7 Weld Seam Specs ......................................................................60

FIGURES

FIGURE 3.0 Strong Back.................................................................................14FIGURE 3.1 Fixed Copper Back Up Bar..........................................................14FIGURE 3.2 Wedge.........................................................................................14FIGURE 3.3 Typical Consumables ..................................................................15FIGURE 4.1 Enclosure 1 ................................................................................19FIGURE 4.2 Enclosure 2 .................................................................................19FIGURE 4.3 Lincoln NA-3 Controller ...............................................................20FIGURE 6.1 VUP .........................................................................................23FIGURE 6.2 Head Mount Assembly ................................................................24FIGURE 6.3 Head Mount Assembly w/Reel ....................................................25FIGURE 6.4 Mast Hanger Weldment ..............................................................26FIGURE 6.5 Magnet & Wheel Support Weldment...........................................27FIGURE 6.6 Roller Plate Carriage Assembly ..................................................28FIGURE 6.7 Pillow Block Bearing Assembly ..................................................29FIGURE 6.8 Elevation Chain Drive..................................................................30FIGURE 7.1 Sump Application ........................................................................38FIGURE 7.2 Ceramic Retainer ........................................................................39FIGURE 7.3 Draft Angle ..................................................................................40FIGURE 7.4 Electrode Location ......................................................................40FIGURE 7.5 Speed Control Description ..........................................................42FIGURE 7.6 Starting Gouge ............................................................................44

APPENDIXES

APPENDIX A INNERSHIELD NR-431 & NR-432 ............................................ A-1

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SECTION 1SAFETY PRECAUTIONS

USER RESPONSIBILITY – Seller makes no representations or warranties regardingthe adequacy of the structure on which the VUP is to be mounted. It is Buyer’s soleresponsibility to determine whether the support structure is of sufficient strengthand structural integrity to adequately hold the product and operating personnel.Buyer’s failure to make such a determination may result in a failure of the system,property damage or serious personal injury.

This equipment will perform in conformity with the description thereof in this manualand accompanying labels and/or inserts when installed, operated, maintained andrepaired in accordance with the instructions provided. This equipment must bechecked periodically. Defective equipment should not be used. Parts that are broken,missing, plainly worn, distorted or contaminated should be replaced immediately.Should repair or replacement become necessary, KOIKE ARONSON recommendsthat a request for service be made to the KOIKE ARONSON Authorized Distributorfrom whom purchased or directly to the KOIKE ARONSON Service Department.

This equipment or any of its parts should not be altered without prior written approval of KOIKEARONSON. The user of this equipment shall have sole responsibility for any malfunction, whichresults from improper use, faulty maintenance, damage, improper repair or alteration by anyone otherthan KOIKE ARONSON or a facility, designated by KOIKE ARONSON, INC.

NOTES, CAUTIONS & WARNINGS

Throughout this manual, notes, cautions, and warnings are used to describesituations that require additional information. The following formats are used foreach:

Notes: A note offers additional information, such as an operating tip, that aids the user inoperating the equipment.

A warning describes a situation that presents a physical danger to the operator, andoffers advice to avoid or rectify the situation. Each type of warning displays an applicabledanger symbol, such as fire, explosion, electrical shock and so on.

WARNING

Caution: A caution describes a situation that may cause damage to the machine andoffers advice to avoid or rectify the situation.

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KOIKE ARONSONSYMBOL LIBRARY

SYMBOL MEANING

GENERAL INFORMATION

ELECTRICAL SHOCK CAN KILL

POISON/TOXIC

FLAMMABLE/COMBUSTIBLE

EXPLOSION HAZARD

DO NOT WATCH THE ARC

OPEN GEARING

GROUND THIS EQUIPMENT

COMPRESSED GAS

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SYMBOL MEANING

EYE PROTECTION REQUIRED

USE AN APPROVED RESPIRATOR

WEAR APPROVED EAR PROTECTION

INSULATED GLOVES REQUIRED

INSULATED FOOTWARE REQUIRED

NO OPEN FLAME

HOT SURFACE DO NOT TOUCH

DO NOT REMOVE GUARDS

WEAR PROPER EYE PROTECTION WHEN PLASMA CUTTING

WEAR PROTECTIVE CLOTHING

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Before using this equipment and its options each person operating, maintaining orsupervising the use of this equipment must read the following safety instructions.

1.1 GENERAL SAFETY

Operation of this machine involves variousmoving and rotating parts that could prove tobe dangerous. Follow the precautions in thisGeneral Safety Section, as well as thosethroughout this manual, for your personalsafety and the safety of people in the areathat may be affected. Failure to observethese safety practices may cause seriousinjury or death.

1. Install and operate this machine only in awell-ventilated area.

2. Connect and maintain electrical groundsto the equipment according to localcodes and the National Electrical Code.

3. Always stand clear of the machine’sswing radius.

4. Shut OFF, LOCK OUT and TAG OUTpower whenever leaving the machineunattended or before servicing.

5. Keep this equipment clean and in goodoperating condition.

6. Parts that are broken, worn, distorted ormissing must be replaced immediately.

7. Always, keep hands and tools away frommoving or rotating part of the machine.

8. The work piece and tooling used on thisequipment must be securely fastened inplace. The fastening requirements aredetermined by and obtained from theuser’s engineering department.

WARNING

Protect yourself and others. Read and understand these instructions. FUMES ANDGASES can be dangerous to your health. HEAT RAYS (INFRARED & ULTRAVIOLET)from flame, arc or hot metal can injure eyes. Read and understand the manufacturers’instructions and your employer's safety practices. Use enough ventilation/exhaust at theflame/arc, or both, to keep fumes and gases from your breathing zone, and the generalarea. Keep your head out of the fumes.

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9. Read the drive system manual suppliedfor additional safety and operationguidelines before operating thisequipment.

10. Read the drive system instruction manualsupplied for additional safety andoperating guidelines before operating thisequipment.

11. Unbalanced loading may cause the loadto move unexpectedly, when clamping orlocking devices are removed.

12. Read and understand further detailedsafety precautions throughout thismanual.

1.2 GENERAL SAFETY, ARC WELDING

Operation of this machine involves variousmoving and rotating parts that could prove tobe dangerous. Follow the precautions in thisGeneral Safety Section, as well as thosethroughout this manual, for your personalsafety and the safety of people in the areathat may be affected.

Different arc welding processes, electrodealloys, and fluxes can produce differentfumes, gases, and radiation levels. In additionto the information in this manual, be sure toconsult flux and electrode manufacturesMaterial Safety Data Sheets (MSDSs) forspecific technical data and precautionarymeasures concerning their material. ArcWelding is a high intensity source of visiblelight emission as well as ultraviolet andinfrared radiation. It can cause severe eyedamage, penetrate lightweight clothing,

reflect from light-colored surfaces, and burnthe skin and eyes. Skin burns resemble acutesunburn. Burns from gas-shielded arcs aremore severe and painful.

Follow the precautions in this General SafetySection and read the welding equipmentinstruction manual for additional and moredetailed safety precautions.

1. Electric current flowing through anyconductor causes localized Electrical andMagnetic Fields (EMF). Welding currentcreates EMF fields around welding cablesand welding power supplies.

EMF fields may interfere with somepacemakers, and welders having apacemaker should consult their physicianbefore welding.

Exposure to EMF fields in welding mayhave other health effects that are not yetknown.

All welders should use the followingprocedures in order to minimize exposureto EMF fields from the welding circuit:

a. Route the electrode and work cablestogether. Secure them with tape whenpossible.

b. Never, coil the electrode lead aroundyour body.

c. Do Not place your body between theelectrode and work cables. If theelectrode is on your right side, the workcable should also be on your right side.

d. Connect the work cable to the workpiece as close as possible to the areabeing welded.

WARNING

Failure to follow these safety and operatinginstructions may result in personal injury

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e. Do Not work next to the welding powersource.

2. Connect and maintain electrical groundsto the equipment according to localcodes and the National Electrical Code.

3. After installation and regularly thereafter,check that all electrical connections aretight.

4. Shut OFF, LOCK OUT and TAG OUTpower whenever leaving machineunattended or before servicing.

5. Inspect the primary power cord frequentlyfor damage or cracking of the jacketcover. Bare wiring can kill. Do not usethe system with a damaged power cord. Ifa power cord is damaged, replace itimmediately.

6. Coil excess cords and place them out ofthe way to prevent damage and toeliminate a tripping hazard.

7. Machine guards should never be removedunless the power connections have beendisconnected and locked out. Alwaysreplace machine guards beforeconnecting the power.

8. Keep Equipment clean and in goodoperating condition.

9. Keep combustibles away from the workarea or protect them from sparks.

10.Any parts, which are broken, worn,distorted or missing must be replaced

immediately.

11.Always, keep hands and tools away frommoving or rotating parts of the machine.

12.Always stand clear of the machine's travelarea.

13.All work pieces and tooling to be used onthis equipment must be securely fastenedin place. The fastening requirementsshould be determined by and obtainedfrom the user’s engineering department.

14.The electrode and work (or ground) circuitsare electrically “ENERGIZED” when thewelder is ON. Do not touch these“ENERGIZED” parts with your bare skinor wet clothing. Wear gloves that are dry,and free from defects to insulate yourhands.

15. Insulate yourself from the work piece andground using dry insulation. Make certainthe insulation is large enough to coveryour full area of physical contact with thework piece and ground.

16.Always be sure the work cable makesgood connection with the ground block onthe positioner.

17.Maintain the electrode holders, workclamp, welding cable, and power supplyin good, safe operating condition. Replacedamaged or frayed leads.

18.Use only fully insulated electrode holders.Keep them in good condition. Tightenscrews so that the handle and otherinsulated parts stay in place. Never dipthe electrode or electrode holder in waterto cool it, or lay it down on ground or workpiece surface. Do Not touch holdersconnected to two different power suppliesat the same time because voltagebetween the two can be the total of theopen circuit voltage of both welders.

.

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19.Do Not touch other people with the holderor electrode

20. Do Not use a welding current in excessof rated lead capacity. The lead willoverheat.

21.Never, operate the welder unless thepower supply unit covers are in place.Exposed power supply connectionspresent a severe electrical hazard.

22.Before removing the cover of a welder orplasma power supply for maintenance useapproved lockout procedures, disconnectthe main power at the source, shut offswitch or unplug the power supply. Toavoid exposure to severe electricalhazard, wait five (5) minutes afterdisconnecting the main power to allowcapacitor discharge to occur. Test for zero(0) voltage.

23.Exposed “ENERGIZED” conductors orother bare metal in the welding circuit, orin ungrounded, electrically “ENERGIZED”equipment can fatally shock a personwhose body becomes a conductor. DONOT STAND, SIT, LIE, LEAN ON ORTOUCH a wet surface when welding,without suitable protection.

24.To protect against shock wear dryinsulating gloves and body protection.Keep body and clothing dry. Never work indamp areas without adequate insulationagainst electrical shock. Stay on a dryinsulating platform or a rubber mat whendampness or sweat cannot be avoided.Sweat, seawater, or moisture between thebody and an electrically “ENERGIZED”part reduces the body’s electricalresistance, and could permit dangerousand possibly fatal currents to flow throughthe body.

25.Wear long sleeve clothing (particularly forgas-shielded arc) gloves, hardhat andsafety shoes. Do not wear cuff trousers.When necessary, use additionalprotective clothing such as leather/flameretardant jacket or sleeves, flameproofapron and flame resistant leggings. Avoidwearing outer garments containinguntreated cotton. For bare skin protection,wear dark substantial clothing. Buttoncollar to protect chest and neck andbutton pockets to prevent entry of sparks.All areas of the body must be covered bydark substantial clothing (preferably flameretardant) to protect against arc burn,sparks and flying hot metal.

26.Wear dark safety glasses or goggles withside shields and a welding helmet fittedwith a double lens. Use a clear lensoutside and a filtered number 12 ordenser (AWS Standard) inside. Place thehelmet over your face before striking anarc.

27.Replace cracked, pitted, splattered, orbroken glasses, goggles or helmet.Prevent radiation from passing throughcausing burns. Dark safety glasses orgoggles with side shields MUST be wornunder the helmet to give some protectionshould the helmet not be lowered over theface before an arc is struck. Looking at anarc momentarily with unprotected eyes(particularly a high intensity gas-shieldedarc) can cause a retinal burn that mayleave a permanent dark area in the fieldof vision.

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28.Warn others in the area not to directlylook at the arc unless they are wearingdark glasses, goggles, or a helmet.Prepare the welding area in a manner thatreduces the reflection and transmission ofultraviolet light. For production welding, aseparate room or enclosed bay is best. Inopen areas, surround the operation withlow-reflective, non-combustible screens orpanels. Allow free air circulation,particularly at floor level. Before starting toweld, make sure screens, panels, or baydoors are closed.

29.Make fire extinguishers available in thewelding area

30.Fire and explosion are caused bycombustible materials being ignited by thewelding arc, flying sparks, hot weld slag,electrical short circuits, and misuse ofcompressed gases. Sparks and moltenmetal can travel a considerable distance.

31.Remove combustible material from theimmediate welding area to a distance ofat least 35 feet (10 m). If combustiblescannot be moved, protect them withsuitable and snug-fitting fire-resistantcovers or shields. Remember that weldingsparks and hot materials can easily gothrough small cracks and openings toadjacent areas.

32.A Fire Watcher must be standing by withsuitable fire extinguishing equipmentduring and for some time after welding.

a. If there are appreciable combustibles(including building construction) within35 feet (10 m).

b. If there are appreciable combustiblesfurther than 35 feet (10 m) but can beignited by sparks.

c. If there are openings (concealed orvisible) in the floor or walls within 35 feet(10 m) that may expose combustibles tosparks.

d. If there are combustibles adjacent towalls, ceilings, roofs, or metal partitionsthat can be ignited by radiant orconducted heat.

After the work is done, check that the area isfree of sparks, glowing embers, and flames.

33.Do Not electrically overload the arc weldingequipment over its rated capacity. It mayoverheat cables and cause a fire.

34.Loose cable connections may overheat orflash and cause a fire.

35.Severe discomfort, illness or death mayresult from fumes, vapors, heat, or oxygenenrichment or depletion produced duringwelding operations. Prevent them withadequate ventilation. Never ventilate withoxygen.

36.Lead, cadmium, zinc, mercury, andberyllium-bearing and similar materialswhen welded may produce harmfulconcentrations of toxic fumes. Adequatelocal exhaust ventilation must be used, oreach person in the area as well as theoperator must wear an air-suppliedrespirator. For beryllium, both must used.

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SECTION 2INTRODUCTION

2.1 SCOPE

This manual provides general installation,operation and service information for theVERTICAL UP tank welding system. Thismanual includes an illustrated parts listingand recommended spare parts listing to aidin ordering parts.

2.2 APPLICATIONS

-Vertical up butt welds(single pass)with 3/8” thru 4” thick plate-Tank construction-Shipbuilding

2.3 GENERAL DESCRIPTION

The Koike Aronson/Ransome Model VUPMachine is designed to weld 5/16” to 2” thick,6 to 10 ft. high vertical joints erected storagetanks at speeds considerably faster than anyother means. The Lincoln Innershield (NR-431or 432) process is employed.

The machine consists of a vertical columnsupported by a carriage that rides the top ofthe tank ring. Lincoln Welding Equipment isattached to a saddle, which in turn travels upthe column during welding. Seam guidanceand vertical travel speed are automaticallycontrolled during welding. The machine ismanually propelled to a succeeding joint aftercompletion of each weld. A power skid,usually located in the center of the storagetank, contains the welding power supply andother service equipment.

2.4 EQUIPMENT INCLUDED:

VUP will consist of:Vertical Support Column with Lifting BaleFront and Rear Sliding ShoeLateral Travel Attachment to manuallymove from joint to jointMain Control PanelLincoln modified NA-3 ControlLincoln NA-3 Wire FeederLincoln DC-1000 Power SourceLincoln K-176 NozzleLincoln Wire Reel and SupportMounting SlidesPower Source SkidWater Re-circulatorInput Power Disconnect200 Feet of Control Cables and hoses20 feet of ground cablesWired for 220/380/440V - 3PH - 50/60HZTropicalized ControlsTool Kit

Optional components of the VUP include aPowered lateral travel to move from joint tojoint, and Oscillator (required for all plates1-1/4 or thicker).

2.5 EQUIPMENT DESCRIPTION

Main Column And Lift System

This system includes a Lincoln NA-3NInnershield head mount assembly, including a50-pound wire reel, is fastened to a saddlewhich in turn is supported by a main columnassembly. The lift system, located at the topof the column, employs a self-locking gearreducer and 3/4 HP variable speed motor withdynamic brake. The lift drive raises and

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lowers the saddle along the column by meansof a triple RC-60 (25,000 lb. capacity) rollerchain at infinitely variable speeds from 1 to 40IPM.The VUP machine employs the same liftsystem as employed on standard Manipulatorand features our proven saddle safety lock,which locks the head mount and saddleassembly to the column in the event of chainfailure.

The lift motor control is electrically integratedwith the welding control to provide thecontinuous and automatic speed changesnecessary to maintain a constant coppershoe-to-weld puddle relationship duringwelding. This is achieved by having thewelding head assembly alternately travelvertically at a speed slightly lower than andslightly higher than the weld puddle rise rate.At weld start, carriage travel is zero. As thepuddle rises in the shoe it reduces theelectrode stickout; the welding currentincreases and trips a relay which starts the uptravel. The welding puddle is maintainedbetween the front and rear slide shoeassemblies.

The shoes then moves up faster than the weldpuddle. This increases the electrode stickoutand causes a reduction in current, whichsignals the travel to switch to a speed slowerthan weld progression rate. The cycle repeatsas necessary to maintain constant wirestickout and automatically maintains the arc infixed relation to the copper shoe even withvariations in joint gap. A flow regulator andswitch in the water system regulates the flowand protects the shoes against no or lowwater flow.

Head Mount Assembly

The NA-3 welding head is mounted on a freemoving slide, which allows lateral movementof the head assembly and automatic seamguidance. This assembly is also controlled byan air operated bracket which supports anarticulating copper shoe, and cross-slide withthe NA-3 head and special nozzle assembly.With this arrangement the copper shoes and

weld nozzle can be easily positioned andmaintained with respect to the joint. A swivelmount provides easy alignment for inside oroutside application and torch relationship tojoint.

Column Supports

The main column is supported at the top bytwo wheels riding on the top edge of the platesto be welded, by two adjustable wheels whichgrip the back of the plates at the top, and bytwo wheels at the bottom of the column. Theassembly can be pushed or pulled along thetank shell plate to the next vertical joint. Afriction lock is provided to clamp the column tothe plate in the desired location. An electromagnet is furnished at the bottom of thecolumn to stabilize the location of the columnin relation to the plate.

Welding Controls

Current, voltage, wire speed, start weld, stopweld, manual cross seam adjustment, manualin-out adjustment of electrode. Air CylinderSwitch. (Cylinder may operate fromcompressed air or CO2.)

Lift Controls

Up and down switch, low speed and high-speed potentiometers, rapid - set speedselector. Operator's control is fastened to thesaddle of the vertical travel mechanism. Anauxiliary pendant is located at base of column.

Power Skid

The fabricator must supply a source of powerof at least 100 amp. capacity for operation ofthe VUP machine. A fused disconnectswitch to receive the power service ismounted on the skid with a Lincoln DC-1000power supply, Water Re-circulator, andplumbing service box is provided andmounted.

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The machine is provided with 25 feet ofdouble 4/0 ground cable which is generallyfastened to the tank floor. A 200 ft. long cableassembly consisting of double 4/0 weldingcable, multi-conductor control cable, waterhose and air hose conveys all the servicesfrom the power skid to the tank mountedwelding machine. All of the cable and hoseshave quick disconnect joints at the machineproper to facilitate separation of the two basisunits for transportation. The skid is providedwith a canvas cover that may be opened forventilation when the machine is operating.The fabricator must supply a source of air orbottled nitrogen of 100 to 200 PSI to the skidfor operating the pneumatic copper shoemechanism.

Welding Head And Controls

Lincoln NA-3N head and NA-3 control withtwo special K-176 nozzles for welding with3/32 and .120 diameter NR-431 Innershieldwire. Two sets of copper shoes are suppliedfor welding with either diameter wire.

Top Roller Assembly

This assembly holds the column to the tankand may be adjusted in 12" increments toallow welding of plates 6’, 8’ to 10' in height.

Back Slide Shoe Attachment

This attachment is required for the standardsquare butt joint process. The attachment isremovable for a “V” groove joint preparation,which uses a front moveable dam (slidingshoe), and fixed copper back up bar. Thefixed copper back-up bars are of simpledesign and can be readily fabricated by user.

Water Re-Circulating System

Cooling water for the copper welding shoe isstored in a water re-circulator unit located onthe skid by the power source.

Water flows from the re-circulator to theservice box where it passes through a flowswitch. The water exits the box and flowsthrough a hose to the copper shoe and out ofthe box to the return side of the water re-circulator.

The water flow regulator is a fixed orifice,non-adjustable device that maintains amaximum water flow through the coppershoes of .75 gallons per minute. The flow isregulated to prevent over-chilling of the weldpuddle.

When using only the front shoe the water andair hoses are connected as shown in the airand water system drawings included in thismanual. From the shoe the water flows backto the service box and through the flowswitch. This switch is set to actuate above aflow of ¾ to 1 gallon per minute. Its functionis to prevent starting a weld and to stop aweld in progress if for any reason the coolingwater flow should drop ¾-1 gallon perminute. If a weld cannot be started, checkfirst for a pinched or ruptured water hose.The flow switch is factory set and notadjustable.

A forced air water re-circulator is providedwith 200’ of hose to accommodate for largesize tanks.

Input Power

Unit is wired for 230-380-460V-3Ph-50-60Hz,Power requirements: 45 KVA.

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SECTION 3INSTALLATION

3.1 INSTALLATION SAFETYPRECAUTIONS

WARNING

Voltages used with this machine can beinjurious to personnel if improperly used. Allequipment must be installed and maintainedin accordance with local requirements andthe National Electrical Code.

Connect and maintain suitable electricalgrounds to the supply ground wire. Do notconnect ground to electrical conduit or topipes carrying gases or flammable liquids.Use only the recommended sizes of electricalcable.

Use normal precautions when loading oroperating heavy equipment. Follow theprocedures in your Company Safety Manual.

3.2 HANDLING AND STORAGE

Off-load the positioner either with a crane,hooking to the lifting eyes provided. Upondelivery, inspect machine packing, and ifdamage is found, file a claim with the carrierimmediately. Call the trucker's local officeand ask that a claims investigator be sent assoon as possible to verify the status of theshipment. Also, call your Koike Aronsonrepresentative. Try to arrange the meeting sothat the claims investigator and therepresentative will be present when thedamage/shortage is verified. The trucker willsupply you with the necessary claims forms ifrequired. Freight claims are the receiver'sresponsibility. Please follow theseinstructions carefully. Koike Aronson andyour distributor will support you fully in theunlikely event that a freight claim isnecessary.

Handle the packing case carefully, right sideup as marked. Store indoors in a dry locationuntil ready to install in the work site.

3.3 UNPACKING AND CLEANING

The equipment has been packed to preventdamage in transit. Unpack carefully toprevent accidental damage by uncratingtools. After uncrating, examine theequipment for signs of damage, particularlyto control knobs, switches and electricalcomponents. Report any damageimmediately to Koike Aronson and the freightcarrier in writing.

REMOVE PRESERVATION COATING fromall unpainted surfaces as components areneeded for installation with WD-40, LPS-1 ormineral spirits.

CAUTION: Follow safe handling practicesand use information recommended onMaterial Safety Data Sheets (M.S.D.S.) forthese products.

3.4 INSTALLATION

All that is required to begin welding is tohang the unit on the tank, add the correctNR-431 or NR-432 Wire, provide electricalpower, air and to fill the cooling waterreservoir.

When job is completed, remove machineform tank and Store indoors in a dry locationuntil ready to install on the next work site.

3.5 SYSTEM REQUIREMENTS

Incoming power: Large enough to supply theproper voltage and current required for thewelder and accessories purchased. Notespecifications

Gases: Required for the type of welderpurchased.

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Cooling water: Cooling water is required forthe type of weld process to cool the coppershoe.

A power skid assembly, normally located inthe center of the storage tank contains thewelder power supply, water recirculationsystem and other service equipment.

Strong backs (Customer supplied)

Wedges (Customer supplied) Reference

Copper shoe supplied for the diameter(s) ofwire used.

Back sliding shoe

Re-circulating system

Optional fixed copper back-up bars aresimple in design and usually fabricated bythe user. The basic process is suitable forsquare butt joint preparation using front andback moveable dams.

3.6 CONSUMABLE DESCRIPTION

The following descriptions explain thepurpose of customer-supplied consumables.Strong backs and the fixed bars will very indimension due to plate thickness.

STRONG BACK

Strong backs should be manufactured out ofmild steel or the same material to be welded.They will be free of rust, scale, oil, or otherforeign material. The face should be groundto prevent porosity along the edges.Strong backs are required to straddle theweld seam from the opposite side requiringthe weld.

FIXED COPPER BACK-UP BAR

The back-up bar must be tight and secureagainst the plates to prevent leakage of themolten slag on the weld puddle. A wedge(s)between the plate and strong back will giveenough support.

The back-up bar must be replaced orrepaired if they become damaged enough sothat they no longer fit properly against theplate.

WEDGE

Wedges are used to hold in place the back-up bar tight against the plate. A combinationof two may be required for the propertension.

FIGURE 3.2Wedge

FIGURE 3.0Typical Strong Back

9in. 5in.

1in.5in.

5in.

4in.

FIGURE 3.1Fixed Copper Back-Up Bar

471/2 in.

1in.

3/4in.

8in.

1in.7/8in.

11/2in.

1/8in.

1/8in.

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FIGURE 3.2Wedge

PlatePlate

Wedge

Strong back

Back-up bar

FIGURE 3.3Typical Consumables

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WARNING

Power is still on the control circuits.

SECTION 4OPERATION

4.1 OPERATIONAL SAFETY

Voltages used with this machine can beinjurious to personnel if improperly used. Allequipment must be installed and maintainedin accordance with local requirements andthe National Electrical Code.

Use normal precautions when loading oroperating this equipment. Follow procedures inyour company’s safety manual.

4.2 SWITCH DESCRIPTIONSENCLOSURE 1

4.2.1 AUX UPThe carriage will move in the up direction at thespeed set by the carriage HI speedpotentiometer.

4.2.2 RAPIDPressing the FAST and AUX UP or AUXDOWN together will move the carriage in theselected direction at the speed set by S4 in thedrive amplifier.

4.2.3 AUX DOWNThe carriage will move in the down direction atthe speed set by the carriage HI speedpotentiometer.

4.2.4 E-STOPMain power for the drive system is disabled.The 120VAC logic for the NA3 or the NA5control is galvanically isolated. No control fromthe welder is operational.

4.2.5 MAGNET ON/OFFThis applies/releases the magnet that holdsthe VUP in place for welding operation.

4.2.6 OPTIONAL LATERAL TRAVELThis switch is located on both enclosure oneand two. This toggle allows the operator tomove the VUP either clockwise or counter-clockwise on a given work piece.

4.3 SWITCH DESCRIPTIONSENCLOSURE 2

3.3.1 CARRIAGE HI SPEEDThis setting is set higher than therecommended welding speed. Note the settingis typically 150% higher than the desired weldspeed.

4.3.2 CARRIAGE LO SPEEDThe carriage LO speed setting is set at a speedslower than the actual weld speed to create theweld puddle. The carriage will move at thissetting until the amperage goes above theorange needle set point on the current meter.When the black amperage needle moves to theright of the orange set point, the carriage willmove at the HI speed setting. The current setpoint will vary depending on the gap width, wiresize and thickness of the plate.

The setting is typically 50% of the desired weldspeed.

4.3.3 TEST UP HI SPEEDThe carriage will move in the up direction at theLO speed setting until the black amperageneedle moves to the right of the orange setpoint, at this time the carriage will traverse atthe HI speed setting.A test is also made to the current meter utilizinga 1.5VDC battery. The current meter shoulddeflect to the maximum amperage setting. Notethe battery is not required for normaloperations.

WARNING

18

4.3.4 TEST UP LO SPEEDThe carriage will move in the up direction at thelow traverse speed setting.

4.3.5 WATER ONIlluminates green when the cooling water flowswitch is satisfied. When the light is off, welderSTART is disabled.

4.3.6 POWER ONIlluminates white when power is on and all E-STOP conditions are satisfied.

4.3.7 CARRIAGE UP-OFF-DOWNA three-position selector switch overrides thespeed potentiometer settings. The carriage willmove in the selected direction at maximumtraverse speed.

4.3.8 E-STOPMain power for the drive system is disabled.The 120VAC logic for the NA3 control isgalvanically isolated. No control from thewelder is operational.

4.3.9 MAGNET ON/OFFThis applies/releases the magnet that holdsthe VUP in place for welding operation.

4.4 OPTIONAL COMPONENTS

4.4.1 LATERAL TRAVELThis switch is located on both enclosure oneand two. This toggle allows the operator tomove the VUP either clockwise or counter-clock wise on a given work piece.

4.4.2 OSCILLATOR ON/OFFThis toggle turns the oscillation of the Lincolnnozzle on or off.

4.4.3 OSCILLATOR POTSThese pots determine the oscillation pauseduration

4.4.4 OSCILLATOR SPEEDPOTENTIOMETER

This potentiometer regulates the speed ofoscillation while welding.

WARNING

Power is still applied to the controlenclosure. The main disconnect must bein the off position when servicing themachine.

19

Figure 4.1 ENCLOSURE 1

Figure 4.2 ENCLOSURE 2

Auxdown

Magneton/off

Auxup Rapid E-stop

Lateral Travel

OscillatorSpeed

OscillatorOn/off

Water On

CarriageHi

Test UpHi

CarriageUp/off/Down

LateralTravel

Test UpLowCarriage

Low

E-stopPower On

OscillatorPots

Magnet0n / Off

20

Figure 4.3 Lincoln NA-3 Controller

4.5 START PROCEDURE

Before starting procedure ensure that theseam to be welded is properly setup andprepped according to Section 7.3 Set-UpProcedures.

1. Turn main disconnect “ON” (locatedon main power skid)

2. Turn power to welder “ON” (located onmain power skid)

3. Turn on Lincoln NA-3 welder control.

4. Move VUP into position for weldingmanually or with powered lateraltravel option.

5. Attach magnet to plate to steady theVUP during weld procedure.

6. Move carriage to the bottom of theseam.

7. Turn on water flow by pressing the‘Water On’ button. ‘Water On’ button

will illuminate when water flow isdetected on the power skid.

8. Once ‘Water On’ button is illuminatedmachine is fully operational; allfunctions on both enclosure one andtwo will function.

9. Use pneumatic actuator to pressshoes into weld position on givenplate.

10.Set weld procedures for given platetype and wire type according toSection 7, Weld Procedures

11.Press start on Lincoln NA-3 weldcontroller.

12. Re-adjust weld procedure to ensurequality weld.

4.6 SEAM END PROCEDURE

1. Once arc has been broken movecarriage up approx. 1/2”

2. Using NA-3 controller remove wirefrom weld puddle with the inch upfunction

3. Allow time for the weld and shoes toproperly cool.

VOLTS

IPM

Auto/on/off

InchUp

InchDown

StopStart

VOLTS

AMPS

21

SECTION 5MAINTENANCE

5.1 SAFETY PRECAUTIONS

1. Shut OFF main power switch and LOCKOUT and TAG OUT electrical power beforeattempting work on electrical circuits. Do nottouch electrically ENERGIZED parts or thosewith residual voltage, (such as capacitors)until they have been grounded and theirelectrical charge dissipated. Check for zeroenergy.

2. Keep power cables dry, free of oil andgrease, and protected from damage by hotmetal and sparks. Do Not use any powercable with worn or damaged insulation.Repair or replace any damaged cableimmediately.

3. Equipment that is not functioning properlyshould NOT be used until all repairs havebeen completed and the equipment has beentested to ascertain that it is in properoperating condition.

4. Inspection and maintenance of equipmentas indicated in this manual should beundertaken by a competent person having atleast general experience in the maintenanceof equipment of this nature.

5. Except inspection and maintenance listedin this manual, it is recommended that allother servicing be done by factory personnelfrom Koike Aronson, Inc.

5.2 GENERAL INFORMATION

This manual provides standard preventivemaintenance procedures required foraccurate and proper operation of thepositioner. Follow these procedures tomaintain machine operation at peakefficiency and to maximize the useful life ofthe machine. The machine has beenassembled, adjusted and factory testedbefore shipment. Factory settings, other thanthose listed in the

WARNING:

Shut OFF main power switch and LOCKOUT and TAG OUT electrical power be-fore attempting work on electrical circuits.Do not touch electrically ENERGIZEDparts or those with residual voltage, (suchas capacitors) until they have beengrounded and their electrical chargedissipated. Check for zero energy.

installation section of this manual, should notbe changed. If machine performance isunsatisfactory, contact a Koike Aronson, Inc.authorized service representative for advice.

Keep the machine clean, in good conditionand free of oil, grease and othercombustibles. If replacement parts arerequired, it is recommended that they bepurchased from Koike Aronson, Inc. throughan authorized distributor.

1. Gearboxes have been lubricated for life.Unless a cupful or more of the oil has leakedout, LEAVE IT ALONE. Bleeding andseeping are normal just wipe it clean.

5.3 PREVENTIVE MAINTENANCESCHEDULE

Although this machine does not require agreat deal of maintenance, the followingprocedures should be performed routinelybased on the operation hours. Thefollowing maintenance guidelines are solelythe responsibility of the operator (customer)and are not covered under machine warrantyeither by the Distributor or by KOIKEARONSON.

PREVENTIVE MAINTENANCE means themaintaining of equipment in sound conditionand is a way to avoid breakdowns andaccidents and the consequent expense ofrepairs and interruption in production flow.

22

1. EACH EIGHT (8) HOURS

a. All machine guards should be in theirproper positions. If a machine guard ismissing, the machine should bedisconnected from the power source andlocked and tagged out until the guard isreplaced.

Warning

Removal of guards exposes movingcomponents Turn OFF, LOCK OUT andTAG OUT electrical power beforeproceeding with repairs or service Failure tofollow these instructions could result inpersonal injury.

b. Check for any signs of oil leaks.

c. Inspect the exterior of the machine forphysical damage.

d. Listen for any abnormal noises while eachdrive is operated.

e. Push buttons and cables should be secureand in good working condition.

f. The work area should be examined forobstructions.

g. Power and control cables must be free ofcuts and abrasions, and secure.

h. Ensure that shoes nozzle and guide are inproper working order.

i. Check water circulation system for leaks.

j. Check for proper chain tension in elevationchain.

2. EVERY FORTY (40) HOURS

c. Work area should be examined forobstructions.

d. Power and control cables must be free ofcuts and abrasions, and secure.

e. Check for physical damage to thepositioner.

h. Panel Enclosure - check for physicaldamage, mechanical operation of allcomponents, electrical operation of allcomponents, and security of all wireconnections.

i. Check driveline chain and elevation chainfor stretch, wear and lubrication. Replace orlubricate if necessary. (See Figure 5.1 or 5.2)

j. Check bearings such as flange block andpillow blocks for security and mechanicaloperation.

k. Check latch body for correct operation.

3. EACH TWO HUNDRED (200) HOURS

a. Gently grease all accessible mountedbearings.The factory recommends Plastilube EP1.5.

e. Check pulleys and sprockets for wear,alignment and security. (See Figure 5.1 or5.2)

f. Check shafts for damage: Bent, missing,damaged or loose keys, etc.

g. Check that motors are secure, and that themechanical operation and alignment iscorrect.

WARNING:

Remove all parts and fixtures before anydriveline service work is going to be done.Failure to so may cause property damageand/or personal injury.

23

SECTION 6REPLACEMENT PARTS

To assure minimum down time it is recommended that spare parts listed in table 6.9 be kepton hand at all times. To assure proper operation, it is recommended that only genuine KOIKEARONSON parts and products be used with this equipment.

To order replacement parts:

a. Provide Sales Order (SO#), serial number and model of equipment from the Serial Taglocated on the junction box near the top of the machine.

b. Provide part number, description and quantity of part.c. Indicate any special shipping instructions.

Figure 6.1 VUP (Vertical Up Single Pass)

24

Figure 6.2 Head Mount Assembly (VUP)

Wheel Guide74127

Rear Shoe8271113A

Front Shoe9373277B

Slide Assembly (3x)3270004

.071HP, DC Motor3910101

Flux-Core Wire Straightener3270121

Wire-Feed Drive Roller3270035

Head Wire Drive Motor9500746

Compression Spring3420032

Lincoln Nozzle3270000

Tube Fitting948378405

25

Figure 6.3 Head Mount Assembly (VUP)With Reel

Swivel9948196744

Four-Way Valve3330028

Male Straight Adapter9948378406

Tube Package9500763

Male Tube Fitting9948378407

Tube9500774

Air Cylinder3320016

Air Cylinder3320089

Wire Reel Assembly3270207

Male Steel TubeFitting9948378404

Flow Control Valve33300029

26

Figure 6.4 Mast Hanger Weldment (VUP) Driven(MOTOR REMOVED)

*Not Shown:

Sprocket9935062800

Gear Reducer2730471

Heavy DutyFlange Bearing2390235

12 Tooth Sprocket9935062801

Cast Iron Wheel with Spanner3400047

Drive Wheel75517

Axle and BearingSpacer Saw Package9500768

Lateral drive ½ HP brake motor3610227

27

Figure 6.5 Magnet and Wheel Support Weldment

Clamp Toggle9990100

Lift Magnet3900085

Cast Iron Wheel with Spanner (2x)3400047

Cotter pin (4x)4040004

28

Figure 6.6 Roller Plate Carriage Assembly

Latch Body9500759

Latch Body CompressionSpring3420004

Cam-roller Bearing2410093

Cam-roller Bearing2410094

Cam-roller Bearing2410092

29

Figure 6.7 Pillow Block Bearing Assembly

Pillow Block Bearing2390198

30

Figure 6.8 Elevation Chain Drive(Motor Removed)

*Not Shown:

Reducer Gearbox2730474

Chain Tensioner32013B

Bushing2790026

14 Tooth Sprocket2580353

Bearing Flange2390040Sprocket Spacer

12327031

12 Tooth Sprocket2580139

¾ Hp elevation drive motor9983-0137-00

31

TABLE 6.9 SPARE PARTS LIST

PART NUMBER DESCRIPTION

1138550900 SOLENOID VALVE, SUPPLY AIR/WATER, 2-WAY,1/2"NPT,NC

3270000 LINCOLN NOZZLE, K176.120

3270001 NOZZLE, CONTACT, K-176, 3/32

3270002 TIP, T-14157, .120

3270003 TIPS, T-14157, 3/32

3270035 ROLL, DRIVE, WIRE FEED, 3/32-7/32, LINCOLN #S12514

3270323 AMMETER, M7980-2, NA3

3270676 PUMP REPAIR KIT P4016 (DYNA-FLUX)

3500037 FRL W/GAUGE, WILKERSON C16-02-G00

3900171 METER, CROMTON SERIES 239 P/N CR239302ANDNLXX-FK

8271113A SHOE, REAR, COPPER (3/8"-5/8" PLATE) 3/32" WIRE

8271113B SHOE, REAR, COPPER (3/4" PLATE & THICKER).120 WIRE

9373277A FRONT SHOE, COPPER, 1 X 4 X 5-3/4 (3/8-5/8 PLATES)

9373277B FRONT SHOE, COPPER, 1 X 4 X 5-3/4 (3/4 + PLATES)

9500774 TUBE, 304SS, 5/16 OD X .035 W X 8 LG

9938725124 FUSE 600V TIME DELAY REJECTION TYPE BUSS FNQ-R-10

9938803102 LIM SW TELE#ZCKJ404,Y13 2NO 2NC NEUT POS ARM INCLD

9938807100 POT,5K 10TURN 2W CLAROS#73JB5K

9938808500 KNOB DIAL 10 TURN DUO-DIAL RB

9948852800 RELAY,120VAC 4PDT IDEC# RY4S-U

9948853100 RELAY,120VAC 2PDT IDEC RY2S-U

9981008800 FUSE 12A, SLO-BLO, 326 SERIES LITTLE FUSE # 326012

9983013600 DRIVE, VARIABLE SPEED 115VAC KB # KBPB-125

9989004300 BATTERY (TYPE-D) 1.5 VOLT ALKALINE PREFERRED

32

SECTION 7SUGGESTED WELD PROCEDURE

AWS Classifications NR-431 EG72T-1 per AWS A5.26-91

NR-432 EG82T-G per AWS A5.26-91

Agency Approval NR-431 ABS Grade 3YA

Lloyd’s Register Grade 3-3Y

Det Norske Veritas Grade llIy

NR-432 ABS Grade 3YA

7.1 ARC WELDING SAFETY PRECAUTIONS

1. HAVE ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR WORKperformed only by qualified people.

2. ELECTRIC SHOCK can kill. Protect

yourself from possible dangerous electrical

shock:

a. The electrode and work (or ground)

circuits are electrically “hot” when the

welder is on. Never permit contact

between “energized” parts of the

circuits and bare skin or wet clothing.

Wear dry, hole-free gloves to insulate

hands.

b. Always insulate yourself from the work

and ground by using dry insulation.

When welding in damp locations, on

metal floors, gratings or scaffolds, and

when in positions such as sitting or

lying, make certain the insulation is

large enough to cover your full area of

physical contact with work and ground.

c. Always be sure the work cable makes a

good electrical connection with the

metal being welded. The connection

should be as close as possible to the

area being welded.

d. Ground the work or metal to be welded

to a good electrical ground.

e. Maintain the electrode holder, work

clamp, welding cable and welding

machine in good, safe operating

condition.

f. Never dip the electrode in water for

cooling.

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.READ AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THEOPERATING MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED ASWELL AS THE FOLLOWING GENERAL INFORMATION.

33

g. Never simultaneously touch electrically “hot”

parts of electrode holders connected to two

welders because voltage between the two

can be the total of the open circuit voltage of

both welders.

h. If using the welder as a power source for

mechanized welding, the above precautions

also apply for the automatic electrode,

electrode reel, welding head, nozzle or

semiautomatic welding gun.

i. When working above floor level, protect

yourself from a fall should you get a shock.

j. Also see Items 6c and 8.

3. FUMES AND GASES can be dangerous to

your health.

a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases. When welding, keep your

head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing

zone.

When welding on galvanized, lead or cadmium

plated steel and other metals which product

toxic fumes, even greater care must be taken.

b. Do not weld in locations near chlorinated

hydrocarbon vapors coming from

degreasing, cleaning or spraying

operations. The heat and rays of the arc can

react with solvent vapors to form phosgene,

a highly toxic gas, and other irritating

products.

c. Shielding gases used for arc welding can

displace air and cause injury or death.

Always use enough ventilation, especially in

confined areas, to insure breathing air is

safe.

d. Read and understand the manufacturer’s

instructions for this equipment and the

consumables to be used, including the

material safety data sheet (MSDS) and

follow your employer’s safety practices.

e. Also see item 9b.

4. ARC RAYS can injure eyes and burn skin.

a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when welding orobserving open arc welding. Headshieldand filter lens should conform to ANSI Z87.I.standards.

b. Use suitable clothing made from durable,flame-resistant material to protect your skinand that of your helpers from the arc rays.

c. Protect other nearby personnel with suitablenonflammable screening and/or warn themnot to watch the arc nor expose themselvesto the arc rays or to hot spatter or metal.

5. FIRE OR EXPLOSION can cause death orproperty damage.

a. Remove fire hazards well away from thearea. If this is not possible, cover them toprevent the welding sparks from starting afire. Remember that welding sparks and hotmaterials from welding can easily gothrough small cracks and openings toadjacent areas. Have a fire extinguisherreadily available.

b. Where compressed gases are to be used atthe job site, special precautions should beused to prevent hazardous situations. Referto “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operatinginformation for the equipment being used.

c. When not welding, make certain no part ofthe electrode circuit is touching the work orground. Accidental contact can causeoverheating and create a fire hazard.

d. Do not heat, cut or weld tanks, drums orcontainers until the proper steps have beentaken to insure that such procedures will not

34

cause flammable or toxic vapors fromsubstances inside. They can cause anexplosion even though they have been“cleaned”. For information purchase“Recommended Safe Practices for thePreparation for Welding and Cutting ofContainers and Piping That Have HeldHazardous Substances”, AWS F4.1-80 fromthe American Welding Society (see addressbelow).

e. Vent hollow castings or containers before

heating, cutting or welding. They may

explode.

f. Also see items 6c and 9c.

6. For Welding in General.

a. Droplets of molten slag and metal are

thrown or fall from the welding arc. Protect

yourself with oil free protective garments

such as leather gloves, heavy shirt, cuff less

trousers, high shoes and a cap over your

hair. Wear ear plugs when welding out of

position or in confined places. Always wear

safety glasses when in a welding area. Use

glasses with side shields when near slag

chipping operations.

b. Keep all equipment safety guards, covers

and devices in position and in good repair.

Keep hands, hair, clothing and tools away

from V-belts, gears, fans and all other

moving parts when starting, operating or

repairing equipment.

c. Be sure the work cable is connected to the

work as close to the welding area as

practical. Work cables connected to the

building framework or other locations some

distance from the welding area increase the

possibility of the welding current passing

through lifting chains, crane cables or other

alternate circuits. This can create fire

hazards or overheat lifting chains or cables

until they fail.

7. For Gas-Shielded Arc Welding.

a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc.

should be suitable for the application and

maintained in good condition.

b. Always keep cylinders in an upright position

securely chained to an undercarriage or

fixed support.

c. Cylinders should be located:

-Away from areas where they may be struck

or subjected to physical damage.

-A safe distance from arc welding or cutting

operations and any other source of heat,

sparks, or flame.

d. Never allow the electrode, electrode holder,

or any other electrically “hot” parts to touch

a cylinder.

e. Keep your head and face away from the

cylinder valve outlet when opening the

cylinder valve.

f. Valve protection caps should always be in

place and handtight except when the

cylinder is in use or connected for use.

g. Read and follow the instructions on

compressed gas cylinders, associated

equipment, and CGA publication P-1“

Precautions for Safe Handling of

Compressed Gases in Cylinders” available

from the Compressed Gas Association,

1235 Jefferson Davis Highway, Arlington,

VA22202.

8. For Electrically Powered Equipment.

a. Turn off input power using the disconnect

switch at the fuse box before working on the

equipment.

35

b. Make the electrical installation in

accordance with the National Electrical

Code, all local codes and the

manufacturer’s recommendations.

c. Properly ground the equipment in accordance

with the National Electrical Code and the

manufacturer’s recommendations.

9. For Engine Powered Equipment.

a. Turn the engine off before troubleshooting

and maintenance work unless the

maintenance work requires it to be running.

b. Operate the internal combustion engines in

open, well-ventilated areas or’ vent the

engine exhaust fumes outdoors.

c. Do not add the fuel near an open flame,

welding arc or when the engine is running.

Stop the engine and, if possible, allow it to

cool when refueling to prevent spilled fuel

from vaporizing on contact with hot engine

parts and igniting. Do not spill fuel when

filling tank. If fuel is spilled, wipe it up and

do not start engine until fumes have been

eliminated.

d. In some cases it may be necessary to

remove safety guards to perform required

maintenance. Remove guards only when

necessary and replace them when the

maintenance requiring their removal is

complete. Always use the greatest care

when working near moving parts.

e. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

f. To prevent accidentally starting gasoline

engines while turning the engine or welding

generator during maintenance work,

disconnect the spark plug wires, distributor

cap or magneto wire as appropriate.

g. To avoid scalding, do not remove the

radiator pressure cap when the engine

is hot.

For more detailed information it is stronglyrecommended that you purchase a copy of“Safety in Welding & Cutting - ANSIStandard Z49.1” from the AmericanWelding Society, P. 0. Box 351040 Miami,Florida 33135.

36

TABLE 7.1 ELECTRODE OPERATING DATA

NR-431(DC+)

Wire Feed Speed(in/min)

Approx.Current

(amps), DC+

ArcVoltage(volts)

DepositionRate

(lbs/hr)

1/16”1” ESO . 71 lbs. per1000” of electrode

300350400450

260—270275—285285—295300—310

32—3435—3737—3939—41

11.313.014.716.4

3/32”1—1/2” ESO1.58 lbs. per

1000” off electrode

250300350400450

390—430435—465480—520530—570570—610

33—3535—3736—3838—4039—41

20.024.328.633.037.4

.120”2—1/2” ESO2.4 lbs. per

1000” of electrode

200300400500

500—540595—635695—735790—830

37—3941—4344—4648—50

23.336.048.861.8

NR-431(DC+)

Wire Feed Speed(in/min)

Approx.Current

(amps), DC+

ArcVoltage(volts)

DepositionRate

(lbs/hr)

1/16”1” ESO

.74lbs. Per1000” of electrode

300350400450

260—270285—295305—315330—350

32—3435—3737—3939—41

11.713.214.616.1

3/32”1—1/2” ~

1.71lbs. per1000” of electrode

250300350400450

430—470475—515520—560560—600610—650

33—3535—3736—3838—4039—41

23.728.032.336.641.0

.120”2—1/2” ESO2.52 lbs. per

1000” off electrode

200300400500

520—560615—655715—755810—850

37—3941—4344—4648—50

26.040.053.868.0

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).

37

7.2 PLATE HOLDING

Plate fixtures must be adequate to hold platessecurely and to prevent changes in joint and jointvolume. This could affect weld quality,mechanical properties and operation ofequipment.

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

fitup 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.

7.3 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.

Fairly sizeable nicks and dents in the edges

being welded can be tolerated provided foldovers

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

center line 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.

Starting

In order to minimize start porosity and obtaingood wetting, use of a start circuit and procedureis recommended. This circuit provides for areduced wire feed speed and reduced voltage fora given number of seconds. The starting time isdecreased as the plate thickness decreases. Thisreduces the possibility of the weld paddle spillingover the top of the shoe(s) on thinner plates dueto the reduced joint volume being filled quicker.

Sumps

Starting sumps permit striking the arc below theactual joint so any starting porosity can be easilyremoved. The sump must be long enough toallow time for the switch from starting to weldingprocedures and for the arc and travel to stabilizebefore the puddle rises into the joint beingwelded. The sump is cut off after welding.

The sump plate thickness and gap configurationmust be the same as the plates being welded.Attach the sump to the plates as shown. Be surethe top of the sump where it fits against thebottom of the plates is clean and dry. Usecontinuous seal welds and grind them flushwhere the dams fit. Insufficient seal weld strengthor thickness of material under the sump canresult in weld metal leakage which may preventthe travel from starting.

The depth of the sump should be 2” minimum.The use of 880M flux will help produce goodstarts with shallower sumps. A steel sump is cutoff after the weld is completed.

If a copper sump is used, it should be largeenough so that it does not become fused to theweld. It should also have a tapered hole or besplit for easy removal. A small piece of steelshould be placed in the bottom of a copper sumpto avoid arcing the copper. A small piece offiberglass tape may be placed on the sump belowthe gap to prevent weld spilling upon initiating the

38

weld.

Risers

Risers (or run-off tabs) are recommendedbecause the solidification of the large puddle atthe end of the weld creates a shrinkage craterwhich has a tendency to trap slag or gas. Typicalrisers are shown in the previous figure. Weldshould continue into the riser until weld puddle isapproximately 1” to 2” above the top of the work.

Grounding (Weld Toward Ground)

Ground leads should be connected to the top ofeach plate. Connect the ground leads securelyapproximately 1 foot away from the seam. If arcblow problems exist, adjust grounding to reducethe problem.

Moving Copper Shoes

Whenever a moving shoe is employed, it must be

water-cooled. The size of the copper shoe anddegree of water-cooling are very importantfactors since they have a strong effect on thequench rate of the weld puddle. Quench ratecontrols bead appearance, wetting, porosity,cracking and mechanical properties of the weldbead. The location of the water passage in thecopper shoe relative to the groove in the shoe,size of the passage, and length of the total flowpattern are also very important. For thesereasons, it is very important to use copper shoesthat meet the specifications given in theprocedure sheets. In addition, the water flowshould be controlled as prescribed. The groovedimensions are very important in the copper shoesince they control bead contour, reinforcement,and proper tie-in on the corners. A narrow groovewill cause poor tie-in. A wide groove will causesquare edges on the weld bead. Always try tomaintain perfect alignment of the shoe(s).Obviously, any projections on the face of theplates should be removed or the copper shoe(s)may be pushed away from the plate surface andthe weld puddle will spill out. The top chamfermust be maintained as specified for properelectrode clearance. Water should not be turnedon until welding starts or moisture will condenseon the shoes and joint in warm, humid weather.

Copper shoes are grooved to provide properbead contour on front of weld. Shoes have a Vcut out at the top to permit excess slag to drainout. The weld puddle should be just below theapex of the V. Enough water flow must be usedto prevent overheating of the shoe and vapor lockof the water flow (approximately 1-1/2 - 2gal/mm). Water flow must not be interruptedwhile welding. lf the water lines vibrate whilewelding, it means that water flow is insufficientand some of the water in the copper shoe isboiling. The formation of steam results in highpressures in the water lines. If a water line failsdue to steam formation, it could cause injury tonearby personnel. Do not use the same watersupply for the copper shoe and the backup dams.The travel mechanism should be adjusted to givethe smoothest travel possible. Large jerksindicate travel speed set too high or slight arcingto the copper shoe. If slag builds up on the shoe(or nozzle), it may be knocked off with a piece ofwood or other non-conductive material.

Figure 7.1 Sump application

39

Stationary Copper Dams

Dams are grooved to provide proper beadcontour on back of weld. All copper dams andshoes are water-cooled and must be made ofelectrical grade (99.9% pure) copper, such asalloy #110. Dams may be used in stackedsections to make welds longer than one damlength. If total weld length is more than 24 inches,use stacked sections 18-24” long for the backdam. Longer back dams are difficult to line up,and precise line-up is very important to backbead shape and root fusion.

Dams should be wedged or clamped tightlyagainst the plates to prevent leakage of themolten slag on the weld puddle. Dams must bereplaced or repaired if they become damagedenough so that they no longer fit properly againstthe plate.

When more than two dam sections areemployed, each section must be water-cooled.Enough water flow must be used to preventoverheating of dam and vapor lock of the waterflow (approximately 1 - 1-1/2 gals/mm in eachside of each section). Exit water should be warmto the touch (not hot). Water-cooling passagesare located at the top of the dams. The copperdams should extend a few inches beyond the topof the weld to reduce heat buildup and helpproduce sound craters. Water flow should be lefton for several minutes after the weld iscompleted to cool the dams. Water flow must notbe interrupted while welding. If the water linesvibrate while welding, it means that water flow isinsufficient and some of the water in the copperdams is boiling. The formation of steam results inhigh pressures in the water lines. If a water linefails due to steam formation, it could cause injuryto nearby personnel.

If the humidity is high, do not leave the water flowon when not welding or moisture will condenseon the outside of the dams.

Steel Backups

When a stationary steel backup is used, all rust,scale, oil, or other foreign material should beground off the mating faces. Otherwise, porositywill occur along the plate edges where the steelbackup is positioned. Steel backups should bemild 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.

Welding Procedure with Ceramic Backups

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.

Figure 7.2

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 (stickout too short) or molten

weld metal will run out. This will stop the vertical

40

travel and interrupt the weld. Do not let the

puddle go too far down in the shoe (stickout too

long) or the resulting weld will be “cold” and have

poorly wet edges.

Electrical Stickout

Electrical stickout of the electrode beyond the

contact tip determines current and the welding

characteristics of the electrode. Incorrect stickout

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 stickout before bringing the

electrode into the joint. Do not change the

stickout when making other adjustments.

When welding with the extension guide (.120”

diameter electrode), the electrical stickout is 1”

longer than the visible stickout.

Drag angle

Drag angle determines direction of arc force andaffects heat flow. A large drag angle will directmore heat to the back, possibly causing missededges on the front. A large drag angle alsocauses relatively larger changes in electrodelocation with variations in stickout. Copperbackup dams or front shoes may be arced if thisangle is improperly set. Drag angle is measuredfrom the vertical to the line of the electrode as itexists from the tip (or from the extension guide)as shown below. Drag angle should be 6°-10°,depending on application.

Figure 7.3 Drag Angle

Electrode Iocation

Electrode location is measured from the frontface of the plate to the near side of the electrodeend after establishing correct stickout. Location

must be set carefully and monitored duringwelding. If location is too close to front, theelectrode may arc to the copper shoe and/or theback bead face may be poorly wet. If location istoo far back, the front bead face may be poorlywet and/or the electrode may arc to the backdam. Set the electrode location according to therecommended procedures on Pages 44-46 anddefined in the diagrams below: The electrodelocation changes as the nozzle contact tip wears.Replace the contact tip when it becomes worn orthe end is fused or deformed.Electrode locationcan also change due to wire straightness and flip.Wire straightens and guides should be used toreduce this problem.

Figure 7.4 Electrode Location

Current Setting Adjustments

Current setting adjustments on the current meter

relay are made only to control stickout 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 (stickout too long), increase the current

setting on meter relay. If the puddle height is too

low (stickout too short), decrease the current

setting. A 25 amp change in current setting on

.120” wire will change stickout 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.

41

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 stickout, 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

stickout can change and influence the welding

current. This change in current is the basis for

controlling the travel of the fixture. As the stickout

gets longer, the current decreases; as the

stickout gets shorter, the current increases. The

change in current is the important factor and not

the actual current which 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 stickout 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.

On equipment with on and off travel control,carriage travel speed should be set at 125% to150% of arc travel speed. The arc travel speedrange is determined by the joint gap for a givenwire feed speed.

42

1in.

2in.

Copper Shoe

Condition 1

Approximately 3- incheswire stick out with weldpuddle about 1-inchbelow the top of thecopper shoe. The shoetravels up at the speedset on the low speedpotentiometer.

2in.

2in.

Orange Set PointerAdjustment

If the weld puddle rises toless than 1-inch below thetop of the copper shoe,wire stick out decreasesless than 3-inches,current thereforeincreases above theorange pointer settingand the shoe travels up atspeed set on high-speedpotentiometer untilcondition 1 prevails.

If the weld puddle dropsto more than 1inch belowthe top of the coppershoe, wire stick outincreases to more than3-inches, currenttherefore decreasesbelow the orange pointersetting and shoe travelsup at speed set on thelow speed potentiometeruntil condition 1 prevails.

Orange SetPointer

CurrentPointer

Condition 3

Condition 2

Figure 7.5 Travel Speed Conditions

43

7.4 GENERAL WELDING PROCEDURES

Preheat

Preheating is recommended, particularly at thestart area. Preheating minimizes any tendency forstarting cracks and starting porosity, and willimprove the edge wetting of the weld bead at thestart of the weld.

The following minimum preheat temperatures arerecommended as starting points. Higher or lowertemperatures may be used as required by jobconditions and/or prevailing codes. If crackingoccurs at the start, higher preheat temperaturemay be required. Cracking, if it occurs, will beinternal. Test welds of length equal to the jobshould be welded and tested along their entirelength for internal cracking. Higher or lowerpreheat temperatures may be used as requiredby job conditions and/or prevailing codes.

After starting time has elapsed, the weldprocedure stickout 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 fluxfor each inch of plate thickness.

The 880M flux is poured into the gap whenstarting the arc. Half of the recommendedamount of flux may be added before striking thearc as long as the

electrode is in contact with the striking surface.Add the remaining flux gradually so as not toquench the arc. Add the flux with a non-metallicinstrument to avoid arcing

TABLE 7.2 Recommended Minimum Preheat Temperatures

3/8”Plate Thickness

1/2 — 1”Plate Thickness

1—2”Plate Thickness

3—4”Plate Thickness

START AREA 2000

F 2500

F 3000

F 3500

F

Starting Procedure

Wire Diameter (in) 3/32 .120

Wire Feed Speed (in/mm) 150 250Voltage (volts) 29 37Electrical Stickout (in) 1—1/2 2—1/2 to 3

Visible Stickout (in) 1—1/2 1-1/2 to 2

After starting time has elapsed, the weldprocedure stickout 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 fluxfor each inch of plate thickness.

The 880M flux is poured into the gap whenstarting the arc. Half of the recommendedamount of flux may be added before striking thearc as long as the electrode is in contact with thestriking surface. Add the remaining flux graduallyso as not to quench the arc. Add the flux with anon-metallic instrument to avoid arcing.

44

Restarting

If a weld is interrupted beforecompletion:

1. Move carriage up.

2. Remove all slag from crater.

3. Be sure weld metal is clean and free

of porosity or deep shrink cavity. If so,

arc gouge and grind affected area.

Reference “Starting without sump”

section of this Guideline.

4. Cut electrode and reset proper

stickout.

5. Preheat start area to 400° F min.

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).

8. Follow 5.1 START PROCEDURE

page 20.

Starting Without Sump

Sometimes the weld must be startedwithout a starting sump. For example, thestart of vertical welds in tank erection is onthe top of the previous course. Wheresuch starts or restarts are made on goodplate, some repairs in the starting area aresometimes necessary, particularly on theheavier plate thicknesses. The size andaccessibility of these repair areas can becontrolled by preheating to about 400°Fmin. One method of preparing the platefor a fast, preheated start using an arcgouged start area is shown below. Forplates requiring oscillation, it is best tosimply remove the slag from the crater

and preheat to 600 to 700°F.

1. Arc gouge starting sump.

2. Preheat starting area 400°F.

3. Make weld.

4. Repair should be in starting area onfront side.

Figure 7.6 Starting Gouge

Finish Procedure

Just before pressing the “Off” button,“cap” the weld by adding enough 880Mflux to completely cover the weld. This fluxaddition will help reduce shrinkage cavityand crater porosity. This procedure shouldbe done when the crater is in the run-offtab area.

7.5 GENERAL WELDING PROBLEMS

Distortion

If the joint tends to close during welding,the weld quality will be affected. Onbeveled joints, the back bead may be lost.The plates must be held rigidly or allow a1/8” greater gap at the top of the platesregardless of seam length.

Weld Bead Condition

Higher wire feed speeds and voltage areused on thicker plates or wider faceopenings to get good wet-in on the faces.Square bead edges can result from a

45

“cold arc”. Increasing wire feed speed andarc volts will usually correct this condition.The current meter relay should beincreased to maintain proper stickout.Remember to check for a narrow gapwhich will make the puddle colder ormislocation of the electrode due toimproper tracking, improper electricalstickout (check meter relay setting), orimproper setup location.

On oscillated welds, bad back beads canoccur if the electrode moves too close tothe front of the joint and arcs off thesidewalls. Too short a dwell or too slow anoscillation will cause square edges.Misalignment of the shoes on the joint willcause underwash on one edge with orwithout oscillation.

Cracking and Porosity

The most critical problems withautomatic vertical up welding arecracking and porosity.

Since the Moving Dam Process is anopen arc process, the electrical stickout,current, voltage and depth of the weldpuddle below the top of the coppershoe(s) control porosity. Decreasedcurrent for the same voltage, increasedvoltage for the same current or decreased

stickout for the same current and voltagewill all increase the tendency for porosity.

The starting circuit parameters are veryimportant since poor starts can result incompletely porous welds for aconsiderable length of the joint.

The most important parameter thatcontrols cracking is the wire feed speed.Decreasing the wire feed speed by 15%and the voltage by 2-3 volts makes asignificant decrease in cracking tendency.Increasing the gap is sometimesbeneficial in decreasing cracking but maycause incomplete side wall fusion.Increasing the voltage will decreasecracking but must be done with cautionsince the porosity tendency will increase.As with other processes, decreasing thequench rate decreases the crackingtendency. With this process, lower wirefeed rates (lower current), for the sameESO actually result in slower quench ratesdue to slower travel speeds. Oscillation isalso very effective in decreasing cracking.Welding on very cold days may producecracking unless preheating is used.

46

7.6 SUGGESTED PROCEDURES

TABLE 7.3 1/16” Electrodes Using Copper Dams(For Reference Only)

Plate Thickness (in) (T) 3/8 1/2 5/8 3/4Joint Angle (degrees) 60 60 40 40Gap (in) (+ 1/8”-0”) (G) 3/8 1/4 1/4 1/4Front Moving Shoe (in) 1x3x4-

1/161x3x4-1/16~

1x3x4-1/16

1x3x5-3/32

Stationary Copper Dam (see below) A A or B B BWire Feed Speed (in/mm) 300 300 350 400

Current (Amps) (Approx.) NR-431NR-432 260-270

260-270260-270260-270

275-285285-295

285-295305-315

Voltage (volts) 32-33 32-34 34-35 35-37Electrical Stickout (in) (± 1/8”) 1 1 1 1Visible Stickout (in) 1 1 1 1Electrode Drag Angle (degrees) 8 8 8 8Electrode Location from Front (in)(F)

3/16 1/4 1/4 3/8

Puddle Height (in) 1/4 1/4 1/4 1/4Start Procedure Time (Sec) 1 1 1 2Travel Speed (in/mm - approx.) 2.3 2.3 2.3 2.1Deposition Rates (lbs/hr) NR-431NR-432

11.311.7

11.311.7

13.013.2

14.714.6

47

TABLE 7.4 3/32” Electrodes Using Copper Dams

Plate Thickness (in) (T) 1/2 5/8 3/4 1

Joint Angle (degrees) 90 90 90 90

Gap (in) C+ 1/8”-O”) 1/2 5/8 3/4 3/4

Front Moving Shoe (in) 1x3x5-3/321x3x5-3/32 1x3x5-3/32 1x3x5-3/32

Stationary Copper Dam K562-1 K562-1 K562-1 K562-1

Wire Feed Speed (in/mm) 300 340 380 380

Current (Amps) (Approx.) NR-431NR-432

435-465475-515

470-510510-550

510-550545-585

510-550545-585

Voltage (volts) 35-37 36-38 37-39 37-39

Electrical Stickout (in) C± 1/8”) 1-1/2 1-1/2 1-1/2 1-1/2

Visible Stickout (in) 1-1/2 1-1/2 1-1/2 1-1/2

Electrode Drag Angle (degrees) - 8-10 8-10 8-10 8-10

Electrode Location from Front (in) (F) 1/8 3/16 1/4 5/16-3/8

Puddle Height (in) 1/4 1/4 1/4 1/4

Start Procedure Time (Sec) 2 3 4 6

Travel Speed (in/min - approx.) 6.0 3.2 2.7 2.2

Deposition Rates (lbs/hr) NR-431MR-432

24.328.0

27.831.4

31.235.0

31.235.0

48

49

TABLE 7.5 .120” Electrodes Using Copper Dams

Plate Thickness (in) (T) 3/4 1

Joint Angle (degrees) 90 90

Gap (in) 3/4-7/8 3/4-7/8

Front Moving Shoe (in) 1x4x6-.120

1x4x6-.120

Stationary Copper Dam K412 K412

Wire Feed Speed (in/min) 350 350

Current (Amps) (Approx.) NR-431 NR-432

645-685665-705

645-685665-705

Voltage (volts) 40-42 40-42

Electrical Stickout (in) (± 1/8”) 2-112 - 3 2-1/2 - 3

Visible Stickout (in) 1-1/2 - 2 1-1/2 - 2

Electrode Drag Angle (degrees) 8-10 8-10

Electrode Location from Front (in) (F) 1/4 5/16

Puddle Height (in) 1/4 1/4

Start Procedure Time (Sec) 2 5

Travel Speed (in/mm - approx.) 4.1 3.4

Deposition Rates (lbs/hr) NR-431 NR-432

45.050.0

45.050.0

Note: Higher wire feed speeds than those shown in the tables can sometimes be used. Higher wire feedspeeds produce faster weld travel speeds but demand more care in running the welds and greater operatorskill. Higher wire feed speeds require correspondingly higher voltage and current settings to maintain thecorrect puddle height and arc characteristics.

50

TABLE 7.6 EQUIPMENT

Wire Diameter 1/16” 3/32” .120”

Power Source DC—400, DC—600DC—600, DC—

1000 DC-1000

Wire Feeder ** ** **

Gun and Cable Assembly K126 K115—3/32 K115—. 120

Nozzle K126 Std. K242—3/32* K242—.120*

Contact Tip T15050—1/16” T14157—3/32” T13351

Wire Guide -- -- M12753

Lock Nut -- -- T13753

Vertical—Up WeldingCarriage

** ** **

Copper Dam K561—1 K562—1 K412

Copper Shoe1”x3”x4”—1/16 or 1”x3”x5”—

3/321”x3”x5”—3/32

1”x4”x8”—.120

Not standard Lincoln Part numbers.

* Koike Aronson Inc. / Ransome is the recommended supplier of Movable Dam welding equipment. Forspecific information, contact Koike Aronson Inc. or Ransome in Houston, Texas, or the local LincolnElectric Technical Representative.

Additional equipment nessary includes a water supply with hoses, clamps, etc. and smoke removal

equipment

51

7.7 STARTING PROBLEMSTROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

POROSITY

1. Dirt, oil, water, rust in joint.

2. Cold plates.

3. High starting voltage.

4. Short starting stickout.

5. Excessive slag drainage.

6. Incorrect start procedure or start time.

7. Not enough arc protection.

8. Incorrect power source.

1. Remove contaminants.

2. Preheat.

3. Lower start voltage.

4. Increase stickout.

5. Use 880M flux at start.Improve fit up.

6. Use correct startprocedure and time.

7. Add 880M flux.

8. Use correct powersource.

CRACKING

1. Poor weld-ability steel.

2. Cold plates.

3. Wire feed speed too high.

4. High restraint.

1. Use better steel.

2. Preheat.

3. Lower wire feed speed.

4. Preheat and use lowerwire feed speed.

52

LACK OF FUSIONAT START OF

WELD

1. Cold plates.

2. Too much flux added (quenching arc).

3. Flux added too fast (quenching arc).

4. Electrode located too far away from oneplate. 5. Gap too tight at start - plates notcut square. 6. Start time too long.

1. Increase preheat.

2. Use less flux.

3. Add flux more slowly.

4. Correct electrodelocation.

5. Use correct gap.

6. Use shorter start time.

Because design, fabrication, erection and welding variables affect the results obtained inapplying this type of information, the serviceability of a product or structure is the responsibilityof the builder/user.

53

7.8 WELD PROBLEMSTROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

POROSITY IN WELD

1. Excessive slag drainage.

2. Voltage too high.

3. Bad start carried up through weld.

4. Stickout too short.

5. Low wire feed speed for voltage.

6. Dirty, rusty, oily, or wet plates.

7. Arc blow.

8. Gap too small causing too fast travelspeed.

9. Poor fit between shoe and plates orbackup and plates allowing slag cover orweld puddle to leak out side.

1O.lncorrect power source.

1. See corrections forexcessive slagdrainage.

2. Lower voltage.

3. Use 880M flux at startand recommendedstarting procedure.

4. Decrease currentsetting to increasestickout. Check fixturing.

5. Raise wire feedspeed.

6. Removecontaminants.

7. Change groundlocation.

8. Use correct gap orimprove fixturing toprevent gap fromchanging.

9. Improve fit up and/orclamping devices.

1O.Use correct powersource (such as DC-600or DC- 1000).

CRACKING

1. Poor weld-ability steel.

2. Cold plates.

3. Wire feed speed too high.

4. High restraint.

5. Copper pick up due to arcing ormelting dam.

1. Use better steel.

2. Preheat.

3. Lower wire feedspeed.

4. Preheat and uselower wire feed speed.

5. See corrections forarcing or melting copperdam.

54

LACK OF FUSIONALONG LENGTH OFWELD

1. Narrow gap causing too fast travelspeed.

2. Edges of groove in copper dam tooclose to edge of gap.

3. Groove in dam too small.

4. High wire feed speed causing too fasttravel speed.5. Voltage too low.

6. Electrode located too far away fromedge.

7. Gap much too wide causing electrodeto be too far from edges.

8. Too little slag drainage.

9. Copper shoe not tracking along seamproperly.

1. Increase gap.

2. Line up dam properly.

3. Use correctly grooveddam.

4. Lower wire feedspeed.

5. Raise voltage.

6. Correct electrodelocation.

7. Reduce gap.

8. See corrections for“choked sounding arc”.

9. Line up fixture soshoe tracks properly.

SQUARE EDGES -WIDE BEAD, LUMPYBEAD

1. Shoe not staying tight against plate -riding out and allowing puddle to flowbeyond groove in copper. Or bad hi-low.

1. Check mounting ofshoe and fixture. Shoeshould be able toremain in contact withplates. Reduce hi-low.

COLD LOOKINGFRONTIRREGULAR ORMISSED EDGES -POORLY WETEDGES

1. Electrode location too far back.

2. Excessive slag drainage.

3. Too much electrode angle.

4. Stickout too long - puddle running toolow.

5. Wire feed speed too low or too high.

6. Travel speed too fast due to carriagetravel speed set too high or narrow gap.

7. Incorrect power source.

1. Move location towardfront.

2. See corrections forexcessive slagdrainage.

3. Decrease electrodeangle.

4. Adjust nozzle, shoe,and current sensingmechanism to givecorrect stickout andpuddle height.

5. Use correct wire feed(see procedure).

6. Lower carriage travelspeed. Use wider gap.

7. Use correct powersource.

55

UNDER-WASHED

EDGES

1. Shoe not tracking properly -joint gap offcenter with respect to groove in copper.

2. Too much heat - arc too close to front orsetting too hot causing bead width toextend beyond copper groove. Faceopening too large.

3. Voltage too high.

4. Groove in shoe or dam to narrow.

1. Center gap in groove.

2. Move arc away fromfront. Reduce heat.Reduce face opening.

3. Decrease voltage.

4. Increase groove width.

Because design, fabrication, erection and welding variables affect the results obtained inapplying this type of information, the serviceability of a product or structure is the responsibility ofthe builder/user.

56

7.9 CRATER PROBLEMSTROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

BAD CRATER

1.Large crater shrink or porosity.

2.Excessive slag drainage

3.Excessive heat buildup.

4.Stoping weld at very top of plate and damswhich do not extend beyond plate

1.Cap with 880M flux toprotect molten puddle.

2.See corrections forexcessive slag drainage.

3. Reduce wire feedspeed feed and voltageat top of weld.

4. Use risers and damswhich extend beyond topof plates. Cap with 880Mflux.

Because design, fabrication, erection and welding variables affect the results obtained inapplying this type of information, the serviceability of a product or structure is the responsibilityof the builder/user.

57

7.10 DAM/SHOE PROBLEMSTROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

METAL SPILLAGEAT START OF

WELD

1. No glass tape plugs in copper dam orshoe grooves at start.

1. Use glass tape plugs.

SHOE STOPSTRAVELING ANDWELD PUDDLE

SPILLS OVER VEE

1. Puddle too high (stickout too short).

2. Electrode location too close to front -arcs shoe and fuses it to weld.

3. Irregularities, spatter on surface interferewith shoe travel.

1. Decrease currentsetting to lengthenstickout and lowerpuddle.

2. Move location awayfrom shoe.

3. Remove irregularities.

ARCING FRONTSHOE

1. Arc too close to shoe.

2. Wire feed speed or voltage too high.

3. Puddle riding too high - metal spilling overtop of shoe.

4. Too little electrode angle (electrode toomuch straight up and down).

1. Move arc away fromshoe.

2. Use correctprocedure.

3. Adjust parameters sothat puddle ridesapproximately 1/4” belowcut out on shoe.

4. Use correct electrodeangle.

58

ARCING ORMELTING COPPERDAM; COPPERDAMSOVERHEATING,TURNING RED

1. Electrode location too close to dam orshoe.2. Excessive slag drainage (on thin plate).

3. Dams or shoe overheating.No water-cooling.Vapor lock due to not enough water flow.

Ends of dams do not extend beyond end ofweld. Dams too small in cross section.

4. Voltage too high.

5. Arc blow due to improper grounding.6. Wrong composition of copper dams.

7. Dwell time too long.

8. Too much electrode angle.

1. Move location awayfrom dam or shoe.

2. See corrections forexcessive slag drainage.

3. Use water-cooleddams or shoe; increasewater flow.

Use longer dams.

Use larger dams.

4. Reduce voltage.

5. Ground at top of eachplate or change ground.

6. Use 99.9% purecopper such as alloy #110.

7. Reduce dwell time.

8. Adjust nozzle so thatelectrode is straighter upand down.

Because design, fabrication, erection and welding variables affect the results obtained inapplying this type of information, the serviceability of a product or structure is the responsibilityof the builder/user.

59

7.11 TROUBLESHOOTING GUIDEMISCELLANEOUS PROBLEMS

PROBLEM CAUSE CORRECTION

SMOOTH

SOUNDING ARC

1. Voltage too high.

2. Low wire feed speed for voltage.

3. Excessive slag drainage.

4. Stickout too short.

1. Lower voltage.

2. Raise wire feed speed.

3. See corrections forexcessive slag drainage.

4. Decrease currentsetting to increasestickout. Check fixturing.

CHOKED

SOUNDING ARC -

NOT ENOUGH

SLAG DRAINAGE.

1. Voltage too low.

2. Wire feed speed too high.

3. Puddle too low in shoe.

1. Raise voltage.

2. Lower wire feedspeed.

3. Increase currentsetting to shorten stickoutand raisepuddle height.

EXCESSIVE SLAG

DRAINING

1. Loose fit between dam and plates.

2. Puddle too high in shoe.

3. Irregular surface doesn’t allow shoe tostay tight against plate.

1. Tighter fit betweendam and plates.

2. Decrease currentsetting to lengthenstickout and raise puddle.

3. Remove irregularities.

EXCESSIVESMOKE

1. Welding in confined area. 1. Use smoke removalequipment.

60

Table 7.7 Seam Specs.

VERTICAL SEAMS - 66M (216.48Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea

Volume ofJoint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts Weight

1 NR431-.120 32 0.75 0.941 92.61 29.12 21 611.552 NR431-.120 28 0.75 0.824 81.04 25.48 21 535.13 NR431-.120 28 0.75 0.824 81.04 25.48 21 535.14 NR431-.120 22 0.75 0.647 63.67 20.02 21 420.445 NR431-.120 18 0.75 0.529 52.09 16.38 21 343.996 NR431-3/32 14 0.56 0.309 30.39 9.56 21 200.667 NR431-3/32 10 0.5 0.196 19.29 6.07 21 127.418 NR431-3/32 10 0.5 0.196 19.29 6.07 21 127.41

DIMENSION OF PLATES 2.5 X10M TOTAL POUNDS REQUIRED PER TANK 2901.66

VERTICAL SEAMS - 92M (301.76Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea

Volume ofJoint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts Weight

1 NR431-.120 42 0.75 1.235 121.55 38.22 29 1108.432 NR431-.120 41 0.75 1.206 118.66 37.31 29 11082.043 NR431-.120 33 0.75 0.971 95.51 30.03 29 870.914 NR431-.120 33 0.75 0.971 95.51 30.03 29 870.915 NR431-.120 24 0.75 0.706 69.46 21.84 29 633.396 NR431-3/32 18 0.75 0.529 52.09 16.38 29 475.047 NR431-3/32 12 0.5 0.235 23.15 7.28 29 211.138 NR431-3/32 10 0.5 0.196 19.29 6.07 29 175.94DIMENSION OF PLATES 2.5 X

10M TOTAL POUNDS REQUIRED PER TANK 5427.78

VERTICAL SEAMS - 51M (167.28Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea Volume of Joint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts Weight

1 NR431-.120 30 0.75 0.882 86.82 27.3 17 464.122 NR431-.120 26 0.75 0.765 75.25 23.66 17 402.243 NR431-.120 22 0.75 0.647 63.67 20.02 17 340.354 NR431-.120 20 0.75 0.588 57.88 18.2 17 309.415 NR431-3/32 16 0.625 0.392 38.59 12.13 17 206.286 NR431-3/32 12 0.56 0.265 26.05 8.19 17 139.247 MANUAL 8 0.5 0.157 15.44 4.85 17 82.518 MANUAL 8 0.5 0.157 15.44 4.85 17 82.51

DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 2026.66

61

VERTICAL SEAMS - 57M (186.96Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea

Volume ofJoint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts Weight

1 NR431-.120 34 0.75 1 98.4 30.94 18 556.942 NR431-.120 30 0.75 0.882 86.82 27.3 18 491.423 NR431-.120 25 0.75 0.735 72.35 22.75 18 409.524 NR431-.120 18 0.75 0.529 52.09 16.38 18 294.855 NR431-.120 14 0.75 0.412 40.52 12.74 18 229.336 NR431-3/32 10 0.56 0.221 21.71 6.83 18 122.867 MANUAL 8 0.5 0.157 15.44 4.85 18 87.368 MANUAL 8 0.5 0.157 15.44 4.85 18 87.36

DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 2279.65

VERTICAL SEAMS - 30M (98.4.4Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea Volume of Joint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts

Weight

1 NR431-.120 22 0.75 0.647 63.67 20.02 10 200.212 NR431-3/32 16 0.625 0.392 38.59 12.13 10 121.343 NR431-3/32 14 0.625 0.343 33.76 10.62 10 106.174 NR431-3/32 12 0.625 0.294 28.94 9.1 10 915 NR431-3/32 11 0.5 0.216 21.22 6.67 10 66.746 NR431-3/32 10 0.5 0.196 19.29 6.07 10 60.677 MANUAL 7 0.5 0.137 13.51 4.25 10 42.478 MANUAL 7 0.5 0.137 13.51 4.25 10 42.47

DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 731.06

VERTICAL SEAMS - 36M (118.08.4Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea Volume of Joint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts

Weight

1 NR431-.120 22 0.75 0.647 63.67 20.02 12 240.252 NR431-.120 20 0.75 0.588 57.88 18.2 12 218.413 NR431-3/32 16 0.625 0.392 38.59 12.13 12 145.614 NR431-3/32 14 0.625 0.343 33.76 10.62 12 127.415 NR431-3/32 11 0.5 0.216 21.22 6.67 12 80.086 NR431-3/32 10 0.5 0.196 19.29 6.07 12 72.87 MANUAL 8 0.5 0.157 15.44 4.85 12 58.248 MANUAL 7 0.5 0.137 13.51 4.25 12 50.96DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 993.76

62

VERTICAL SEAMS - 48M (157.44.4Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea Volume of Joint Lbs. Number Total

Consumable Size mm Gap inches2 Cubic inches Required of Verts Weight1 NR431-.120 28 0.75 0.824 81.04 25.48 16 407.72 NR431-.120 24 0.75 0.706 69.46 21.84 16 349.463 NR431-.120 22 0.75 0.647 63.67 20.02 16 320.334 NR431-3/32 18 0.75 0.529 52.09 16.38 16 262.095 NR431-3/32 14 0.56 0.309 30.39 9.56 16 152.896 NR431-3/32 11 0.56 0.243 23.88 7.51 16 120.137 NR431-3/32 10 0.5 0.196 19.29 6.07 16 97.078 MANUAL 8 0.5 0.157 15.44 4.85 16 77.66DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 1787.32

VERTICAL SEAMS - 17.5M (57.4Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea Volume of Joint Lbs. Number Total

ConsumableSizemm Gap inches2 33.76 Required of Verts

Weight

1 NR431-3/32 14 0.625 0.343 28.94 10.62 6 63.72 NR431-3/32 12 0.625 0.294 24.12 9.1 6 54.63 NR431-3/32 10 0.625 0.245 24.12 7.58 6 45.54 NR431-3/32 10 0.625 0.245 15.44 7.58 6 45.55 MANUAL 8 0.5 0.157 13.51 4.85 6 29.126 MANUAL 7 0.5 0.137 13.51 4.25 6 25.487 MANUAL 7 0.5 0.137 13.51 4.25 6 25.488 MANUAL 7 0.5 0.137 13.51 4.25 6 25.48

DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 314.87

VERTICAL SEAMS - 20M (65.6Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea Volume of Joint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts

Weight

1 NR431-3/32 12 0.625 0.294 28.94 9.1 7 63.72 NR431-3/32 10 0.625 0.245 24.12 7.58 7 53.093 NR431-3/32 10 0.625 0.245 24.12 7.58 7 53.094 MANUAL 8 0.5 0.157 15.44 4.85 7 33.975 MANUAL 7 0.5 0.137 13.51 4.25 7 29.736 MANUAL 7 0.5 0.137 13.51 4.25 7 29.737 MANUAL 7 0.5 0.137 13.51 4.25 7 29.738 MANUAL 7 0.5 0.137 13.51 4.25 7 29.73

DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 322.76

63

VERTICAL SEAMS - 22.5M (73.8Ft) - METER DIAMETER TANKWel

d Wire Plate JointJointArea Volume of Joint Lbs. Number Total

ConsumableSizemm Gap inches2 Cubic inches Required of Verts

Weight

1 NR431-3/32 12 0.625 0.294 28.94 9.1 8 72.82 NR431-3/32 11 0.625 0.27 26.53 8.34 8 66.743 NR431-3/32 10 0.625 0.245 24.12 7.58 8 60.674 MANUAL 8 0.5 0.157 15.44 4.85 8 38.835 MANUAL 8 0.5 0.157 15.44 4.85 8 38.836 MANUAL 8 0.5 0.157 15.44 4.85 8 38.837 MANUAL 7 0.5 0.137 13.51 4.25 8 33.978 MANUAL 7 0.5 0.137 13.51 4.25 8 33.97

DIMENSION OF PLATES 2.5 X 10M TOTAL POUNDS REQUIRED PER TANK 384.64

A- 1

Appendix A

A- 2

A- 3

A- 4