ARONSON TECHINAL MANUAL
KOIKE ARONSON, INC.635 W. Main St., Arcade NY, 14009-0307 (585) 492 2400 Fax (585) 457 3517
AUTOMATED GIRTH WELDER(I and II)
WELDING POSITIONER
INSTRUCTION MANUAL MI1533ASubject to Change without Notice
January 2014Rev D
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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.........................................................................10
SECTION 2.1 General Description ....................................................................10SECTION 2.2 Machine Frame ...........................................................................10SECTION 2.3 Welding Process and Equipment ................................................10SECTION 2.4 Welding Power Supply ................................................................10SECTION 2.5 Platform Removal........................................................................11SECTION 2.6 Changing Directions....................................................................11SECTION 2.7 Operator Control Description.......................................................11SECTION 2.8 Preheat Torch .............................................................................11SECTION 2.9 Welding Controls.........................................................................12SECTION 2.10 Welding Process .........................................................................12SECTION 2.11 Troubleshooting ..........................................................................12SECTION 2.12 Modification for Odd Size Plates .................................................12
Flux Warning...............................................................................13
SECTION 3 INSTALLATION..........................................................................14
SECTION 3.1 Installation Safety Precaution......................................................14SECTION 3.2 Handling and Storage .................................................................14SECTION 3.3 Unpacking and Cleaning .............................................................14SECTION 3.4 Installation...................................................................................15
SECTION 4 MAINTENANCE..........................................................................17
SECTION 4.1 Lubrication Instructions ...............................................................19
TABLES
TABLE 4.1 Spare Parts Listing......................................................................20TABLE 4.1 Preventative Maintenance Schedule...........................................16TABLE 4.2 Trouble Shooting.........................................................................18
FIGURES
FIGURE 2.1 Physical Locations ......................................................................13FIGURE 3.1 Separator Tank and Hoses .........................................................15FIGURE 4.1 Belt Adjustment ...........................................................................17
APPENDIX
APPENDIX A AGW II ....................................................................................... A1
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SECTION 1SAFETY PRECAUTIONS
USER RESPONSIBILITY – Seller makes no representations or warrantiesregarding the adequacy of the structure on which the AGW-I/AGW-II is to bemounted. It is Buyer’s sole responsibility to determine whether the supportstructure is of sufficient strength and structural integrity to adequately hold theproduct and operating personnel. Buyer’s failure to make such a determinationmay result in a failure of the system, property damage or serious personal injury.
This equipment will perform in conformity with the description thereof in thismanual and accompanying labels and/or inserts when installed, operated,maintained and repaired in accordance with the instructions provided. Thisequipment must be checked periodically. Defective equipment should not beused. Parts that are broken, missing, plainly worn, distorted or contaminatedshould be replaced immediately. Should repair or replacement becomenecessary, KOIKE ARONSON recommends that a request for service be made tothe KOIKE ARONSON Authorized Distributor from whom purchased or directly tothe KOIKE ARONSON Service Department.
This equipment or any of its parts should not be altered without prior writtenapproval of KOIKE ARONSON. The user of this equipment shall have soleresponsibility for any malfunction, which results from improper use, faultymaintenance, damage, improper repair or alteration by anyone other than KOIKEARONSON 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 userin operating 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 anapplicable danger 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 proveto be dangerous. Follow the precautions inthis General Safety Section, as well asthose throughout this manual, for yourpersonal safety and the safety of people inthe area that may be affected. Failure toobserve these safety practices may causeserious injury or death.
1. Install and operate this machine only ina well-ventilated area.
2. Connect and maintain electricalgrounds to the equipment according tolocal codes and the National ElectricalCode.
3. Shut OFF, LOCK OUT and TAG OUTpower whenever leaving the machineunattended or before servicing.
4. Keep this equipment clean and in goodoperating condition.
5. Parts that are broken, worn, distorted ormissing must be replaced immediately.
6. Always, keep hands and tools away frommoving or rotating part of the machine.
7. 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 understandthe manufacturers’ instructions and your employer's safety practices. Use enoughventilation/exhaust at the flame/arc, or both, to keep fumes and gases from yourbreathing zone, and the general area. Keep your head out of the fumes.
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8. Read and understand further detailedsafety precautions throughout thismanual.
1.2 GENERAL SAFETY, ARCWELDING
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. Inaddition to the information in this manual, besure to consult flux and electrodemanufactures Material Safety Data Sheets(MSDSs) for specific technical data andprecautionary measures concerning theirmaterial. Arc Welding is a high intensitysource of visible light emission as well asultraviolet and infrared radiation. It cancause severe eye damage, penetratelightweight clothing, reflect from light-coloredsurfaces, and burn the skin and eyes. Skinburns resemble acute sunburn. Burns fromgas-shielded arcs are more severe andpainful.
Follow the precautions in this GeneralSafety Section and read the weldingequipment instruction manual for additionaland more detailed safety precautions.
WARNING
Failure to follow these safety andoperating instructions may result inpersonal injury
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1. Electric current flowing through anyconductor causes localized Electricaland Magnetic Fields (EMF). Weldingcurrent creates EMF fields aroundwelding cables and welding powersupplies.
EMF fields may interfere with somepacemakers, and welders having apacemaker should consult theirphysician before welding.
Exposure to EMF fields in welding mayhave other health effects that are not yetknown.
All welders should use the followingprocedures in order to minimizeexposure to EMF fields from the weldingcircuit:
a. Route the electrode and work cablestogether. Secure them with tapewhen possible.
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, thework cable should also be on yourright side.
d. Connect the work cable to the workpiece as close as possible to the areabeing welded.
e. Do Not work next to the weldingpower source.
2. Connect and maintain electricalgrounds to the equipment according tolocal codes and the National ElectricalCode.
3. After installation and regularlythereafter, check that all electricalconnections are tight.
4. Shut OFF, LOCK OUT and TAG OUTpower whenever leaving machineunattended or before servicing.
5. Inspect the primary power cordfrequently for damage or cracking of thejacket cover. Bare wiring can kill. Donot use the system with a damagedpower cord. If a power cord is damaged,replace it immediately.
6. Coil excess cords and place them out ofthe way to prevent damage and toeliminate a tripping hazard.
7. Machine guards should never beremoved unless the power connectionshave been disconnected and locked out.Always replace 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 replacedimmediately.
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11. Always, keep hands and tools awayfrom moving or rotating parts of themachine.
12. Always stand clear of the machine'stravel area.
13. All work pieces and tooling to be usedon this equipment must be securelyfastened in place. The fasteningrequirements should be determined byand obtained from the user’sengineering department.
14. The electrode and work (or ground)circuits are electrically “ENERGIZED”when the welder is ON. Do not touchthese “ENERGIZED” parts with yourbare skin or wet clothing. Wear glovesthat are dry, and free from defects toinsulate your hands.
15. Insulate yourself from the work pieceand ground using dry insulation. Makecertain the insulation is large enough tocover your full area of physical contactwith the work piece and ground.
16. Maintain the electrode holders, workclamp, welding cable, and powersupply in good, safe operatingcondition. Replace damaged or frayedleads.
Do Not touch other people with the holderor electrode.
17.Do Not use a welding current in excessof rated lead capacity. The lead willoverheat.
18.Never, operate the welder unless thepower supply unit covers are in place.Exposed power supply connectionspresent a severe electrical hazard.
19.Before removing the cover of a welderor plasma power supply formaintenance use approved lockoutprocedures, disconnect the main power
at the source, shut off switch or unplugthe power supply. To avoid exposure tosevere electrical hazard, wait five (5)minutes after disconnecting the mainpower to allow capacitor discharge tooccur. Test for zero (0) voltage.
20.Exposed “ENERGIZED” conductors orother bare metal in the welding circuit, orin ungrounded, electrically“ENERGIZED” equipment can fatallyshock a person whose body becomes aconductor. DO NOT STAND, SIT, LIE,LEAN ON OR TOUCH a wet surfacewhen welding, without suitableprotection.
21.To protect against shock wear dryinsulating gloves and body protection.Keep body and clothing dry. Never workin damp areas without adequateinsulation against electrical shock. Stayon a dry insulating platform or a rubbermat when dampness or sweat cannot beavoided. Sweat, seawater, or moisturebetween the body and an electrically“ENERGIZED” part reduces the body’selectrical resistance, and could permitdangerous and possibly fatal currents toflow through the body.
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22. Wear long sleeve clothing (particularlyfor gas-shielded arc) gloves, hardhatand safety shoes. Do not wear cufftrousers. When necessary, useadditional protective clothing such asleather/flame retardant jacket orsleeves, flameproof apron and flameresistant leggings. Avoid wearing outergarments containing untreated cotton.For bare skin protection, wear darksubstantial clothing. Button collar toprotect chest and neck and buttonpockets to prevent entry of sparks. Allareas of the body must be covered bydark substantial clothing (preferablyflame retardant) to protect against arcburn, sparks and flying hot metal.
23. Wear dark safety glasses or goggleswith side shields and a welding helmetfitted with a double lens. Use a clearlens outside and a filtered number 12 ordenser (AWS Standard) inside. Placethe helmet over your face beforestriking an arc.
24. Replace cracked, pitted, splattered, orbroken glasses, goggles or helmet.Prevent radiation from passing throughcausing burns. Dark safety glasses orgoggles with side shields MUST beworn under the helmet to give someprotection should the helmet not belowered over the face before an arc isstruck. Looking at an arc momentarilywith unprotected eyes (particularly ahigh intensity gas-shielded arc) cancause a retinal burn that may leave apermanent dark area in the field ofvision.
25.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 mannerthat reduces the reflection andtransmission of ultraviolet light. Forproduction welding, a separate room orenclosed bay is best. In open areas,surround the operation with low-reflective, non-combustible screens orpanels. Allow free air circulation,particularly at floor level. Before startingto weld, make sure screens, panels, orbay doors are closed.
26.Make fire extinguishers available in thewelding area
27.Fire and explosion are caused bycombustible materials being ignited bythe welding arc, flying sparks, hot weldslag, electrical short circuits, and misuseof compressed gases. Sparks andmolten metal can travel a considerabledistance.
28.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 thatwelding sparks and hot materials caneasily go through small cracks andopenings to adjacent areas.
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31. 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 35feet (10 m) that may exposecombustibles to sparks.
d. If there are combustibles adjacent towalls, ceilings, roofs, or metalpartitions that can be ignited byradiant or conducted heat.
After the work is done, check that the area isfree of sparks, glowing embers, and flames.
32.Do Not electrically overload the arcwelding equipment over its rated capacity.It may overheat cables and cause a fire.
33.Loose cable connections may overheat orflash and cause a fire.
34.Severe discomfort, illness or death mayresult from fumes, vapors, heat, or oxygenenrichment or depletion produced duringwelding operations. Prevent them withadequate ventilation. Never ventilate withoxygen.
35.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 GENERAL DESCRIPTION
The Automated Girth Welder is an automaticself-propelled welding machine used for theconstruction of field storage tanks having sixto ten feet (1.8-3.05M) high plate courses.The unit is supported by the shell plates tobe welded. The machine has its own weldinghead, control, flux support belt apparatus,and flux recovery unit so that 3-o’clock weldscan be made to the shell. The standardwelding process supplied is the LincolnElectric Company’s submerged arc system,using a Lincoln NA-3 solid-state control.
2.2 MACHINE FRAME
The machine is constructed of structuralsteel and tubular steel members. The tubularlegs of the frame telescope and aremanually adjustable by removing pins andraising or lowering the platform. Thus, themachine can weld shell plate ranging fromsix to ten feet (1.8-3.05M).
The master frame contains two serratedhardened steel flanged drive wheels, whichare manually adjusted to ride tank diametersdown to approximately fifteen feet (4.5M).The distance between wheel flanges is 1-3/4inches (44.5mm). One of the wheels isdriven by a positive-drive gear train (nosecondary chain reduction). The gear trainconsists of a one-half horsepowerelectronically controlled motor that drives adouble reduction gear unit. The machinespeed range is four to one hundred and fiveinches per minute (.10-2.67M/min).
Small diameter wheels at the lower end ofthe tubular legs simplify loading andunloading the machine from the machinefrom the tank. Canvas curtains offer arc andoperator protection on windy days or duringinclement weather.
2.3 WELDING PROCESS AND EQUIPMENT
The standard welding equipment supplied isthe Lincoln NA-3 solid state control andwelding head fitted with nozzle, wire feedrolls, wire straightener, and 50Lb (22.7KG)wire reels for feeding up to 1/8 inch diameterwire (3.2mm diameter).
The welding nozzle is mounted on a manualcross slide system, which allows the operatorcomplete control of wire placement and jointfollow. Welding condition, wire and flux arethose recommended by the Lincoln ElectricCompany for this process. The welding headassembly includes a submerged arc flux beltmechanism.
2.4 WELDING POWER SUPPLY
The welding power is supplied by a LincolnDC-600Amp. power supply. Standard inputpower is 460/3/60 and line powerrequirement is 40KVA for the power supply.Other voltages and frequencies are available.The voltage is stepped down in the powersource to 115VAC, which is required forwelding controls.
Lincoln NA-3 welding equipment is mountedin the machine, and is under the control ofthe operator. A seperate electronic control isused to drive the machine around the tank.The control is located on the master side ofthe welding machine and includes allnecessary controls (such as the speedcontrol potentiometer, direction switch, rapidtravel pushbutton, as well as the emergencycut-off switch).
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This unit also includes a 100lb (45KG) fluxrecovery vacuum unit for each side. The flux(which falls from the flux belt into a fluxhopper mounted on the platform) is re-circulated to a primary tank mounted on theroof of the AGW by a vacuum unit mountedon the platform.
2.5 PLATFORM REMOVAL
If the platform needs to be removed, firstdisconnect the flux hose from the vacuumunit or remove the vacuum unit all together.Use a crane or other lifting device to hold theplatform during removal operation. Removethe bottom leg pins and the bottom bolts inthe square tubing of the frame and lower theplatform until it is off.
2.6 CHANGING DIRECTIONS
If the machine is going to weld in thedirection opposite of what it was set up for,move the flux pan and flux hose to the otherend of the flux belt. Also, move the flux hoseand the flux hopper to the welding nozzle tothe other side so the flux will fall in front ofthe arc.
2.7 OPERATOR CONTROL DESCRIPTION
The master side control houses theelectronic travel drive and associated controlrelays. A brief description of the controls theoperator has access to and what they dofollows.
1. Emergency Stop Pushbutton- Stopsall electrical functions includingwelding and travel.
2. Flux Recovery Switch- Each fluxrecovery unit has its own On/Offswitch located on the vacuum unit.
3. Speed Potentiometer- Adjusts thewelding speed of the machine. Somemachines include a direct readingtachometer while on others it isnecessary for the user to prepare aspeed calibration chart.
4. Forward/Reverse and Set/RapidSwitches- Placing the switch in theforward position causes the machineto move in the normal weldingdirection. The opposite is true for thereverse position. In either case, thecarriage will move at a speed set onthe speed potentiometer.Simultaneous operation of theSet/Rapid switch into the rapid positioncauses the machine to move atmaximum speed. Regardless of theposition of either of the switches, themachine will always move in thewelding direction at the speedpotentiometer setting when welding isfirst started. For automatic travel, thetravel switch on the NA-3 must be inthe travel position. To operatemanually, the switch must be in thehand position.
5. Light switch on front of control panel tocontrol panel to control outlets labled(Lights). Lights have cords and plugsthat have run mounted lights to outletbox.
2.8 PREHEAT TORCH
A preheat torch is supplied. Whenpreheating the plate to be welded, followall oxy-fuel safety precautions. Ensurethe tip and fuel gas used are compatible.
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2.9 WELDING CONTROLS
Lincoln NA-3 welding equipment is normallysupplied with the Automated Girth Welder.This equipment can be operated either in the‘constant voltage’ mode, or in the ‘variablevoltage’ mode. To change from one toanother requires the following:
1. Correct ‘CV-V V’ switch position inside theLincoln control.
2. Selection of the proper Lincoln controlnameplate. Two are provided fastened tothe control. When in the ‘CV’ mode, thenameplate should read NA-3N. When inthe ‘V V’ mode, the nameplate shouldread NA-3S.
Compatible welding power supplies includethe Lincoln DC600, CV-VV, and rectifierunits suitable for inner shield, flux coredwire, and small diameter single wire welding.
The control is set for standing type starts.That is, when the weld start pushbutton isdepressed, the wire slowly feeds to thework, the arc strikes and weld travel begins.Scratch type starts are achieved by placingthe ‘set/rapid’ switch in the ‘set’ position andholding the travel switch in the ‘forward’position, this will start travel in the weldingdirection. Depress the weld start switch andafter the arc is established, release thetravel switch.
2.10 WELDING PROCESS
Automated Girth Welder is normallyequipped for single wire submerged arcprocess.
2.11 TROUBLESHOOTING
If any difficulty is experienced with thefeeding or control of the welding wire, theproblem may be associated with the Lincolnwelding control or the power supply. Check
all fuses on the power supply, the Lincolncontrol, and the electrical control. The‘emergency stop’ pushbutton must beenergized, the Lincoln control power switchmust be ‘on’ and the polarity switches on thepower supplies must be in either the‘negative’ or ‘positive’ polarity position.
If the above does not resolve the problem,the simplest and fastest way to diagnose isby substitution of components. Therecommended spare parts list suggests a setof spare P.C. boards to minimize downtimeand delays. Included in this manual is a chartto assist troubleshooting the Lincoln controlby observation of the L.E.D.’s (light emittingdiodes) on the P.C. boards during variousoperations of the control.The Automated Girth Welder utilizes anelectronic drive for machine travel around thetank. It is strongly recommended a drivepanel board be included as a spare.Replacement in the field is relatively simpleand will minimize machine down time.
The remaining electrical circuitry isstraightforward and can usually be tracedthrough by a local electrician using theelectrical schematic diagram included in thismanual.
Contact Koike Aronson Inc. if all the abovemeasures fail to resolve the problem.
2.12 MODIFICATION FOR ODD SIZEPLATES
Adjustments can be made to the AGW forodd size plates. For example, a five foot six-inch tall plate, loosen the U-bolts at the endsteel support and adjust up until it is inposition for welding the five foot six-inch tallplate and tight the U-bolts.
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Figure 2.1 Physical locations
WARNINGDo not fill flux separator tank to full. Flux granules should not be vacuumedinto the main vacuum unit. (If granules are in this unit, the separator tank is orwas too full.) To replenish flux into the system periodically, add flux into theflux hopper during operation.
Vacuum LinePrimary Separator Tank
Vacuum Unit
Flux Pick-UpHose
Flux Hopper
Flux Supply Hose
Flux Drop Hose
Flux Level
NA-3N Control
Flux Pick-up Tool
Operator Control
Light
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SECTION 3INSTALLATION
3.1 INSTALLATION SAFETY PRECAUTION
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 size of electricalcable.
Use normal precautions when loading oroperating heavy equipment. Follow theprocedures in your company safety manual.
3.2 HANDLING AND STORAGE
When the shipment arrives at your location,accompany the driver in counting all thecartons indicated on the driver's waybill.
Inspect each piece for signs of mishandling orapparent damage. If discrepancies exist orany evidence of damage exists, note itBOLDLY across the face of the waybillBEFORE YOU SIGN IT. Sign the waybill onlyafter this inspection. If you note discrepancieson the delivery ticket, DO NOT open thecartons.
Call the trucker's local office and ask that aclaims investigator be sent as soon aspossible to verify the status of the shipment.Also, call your Koike Aronson, Ransomerepresentative. 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 receivers’responsibility. Please follow these instructionscarefully; Koike Aronson, Ransome and yourdistributor will support you fully in the unlikelyevent that a freight claim is necessary.
Handle the packing cartons carefully, rightside up as marked. Store cartons in a drylocation until ready to install.
3.3 UNPACKING AND CLEANING
The equipment has been packaged to preventdamage in transit. Unpack carefully to preventaccidental damage by uncrating tools. Afteruncrating, examine the equipment for signs ofdamage, particularly to control knobs,switches and electrical components. Reportany damage to the freight carrier and KoikeAronson, Ransome immediately.
Remove preservation coating from allunpainted surfaces, as components areneeded for installation, with WD-40®, LPS-1®
or mineral spirits.
WARNING
Voltages used with this machine canbe injurious to personnel if improperlyused. All equipment must be installedand maintained in accordance withlocal requirements and the NationalElectric Code.
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3.4 INSTALLATION
Proper installation and set-up is CRITICAL toensure proper operation of the AGW andwelding equipment.
3.4.1 STEPS FOR INSTALLATION
a. Remove the machine from the crate. Alifting device capable of lifting 4000pounds is required. Place a crane hookto the lifting eye and carefully uprightthe machine.
b. The Automated Girth Welder is shippedwith the “A” frame legs in their six-footposition and must be lengthened to theeight to ten foot positions depending onthe size of the plate being welded.
c. Set the separator tank on the roof andconnect flux hoses. Figure 3.1. Set thevacuum unit on the floor and tighten thefour bolts to hold it in place.
d. Adjust the machine for the correct tanksizes; first hook a crane to the lifting eyeon the roof. Remove the top leg pins onboth sides of the welder, the bolts in theladder, and the top bolts in the squaretubing of the frame. Also, loosen thebolts in the top U-bolts. Raise the craneuntil the required boltholes line up thenreplace the pins and bolts that wereintended to protect the flux beltmechanism during the hangingoperation.
e. Hang the machine on the tank using thecrane.
f. Retract the wheels back in and let theflux belt have intimate contact with thetank plate.
g. Each side of the welder has its owncanvas curtains. These curtains arepermanently fastened to the weatherhood at the top of the machine. Bolt thesides of the canvas curtains togetherthrough the canvas grommets and foldthe excess canvas up when weldingwith six to eight foot wide plates.
h. The flux hose lengths may need to beadjusted for the plate size to be welded.The system is set for eight-foot platewhen shipped. Connect the flux hoseline to the vacuum unit. Extra flux hoseis supplied and must be added to theinstalled hose when setting the machinefor ten-foot plate. When using six-footplate, replace the flux hose from thebottom of the primary separator tank tothe flux hopper with a shorter piece.See Figure 2.1.
WARNINGEnsure the tank is properly securedbefore placing the AGW on the rim.
Figure 3.1 Separator tank and hoses
Separator Tank
Hoses
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i. The weld nozzle assembly may beraised or lowered with respect to theweld seam by raising or lowering thechannel on which they are mounted.The flux belt is inclined from thehorizontal approximately fifteendegrees; similarly, the welding nozzle isalso inclined fifteen degrees and hasrunning adjustments to change theangle. It also has slides to allow three-axis positioning of the nozzle.
j. The welding power source is intendedto be located on the floor in the centerof the storage tank. All of the cables arerun from the power source to the cablehanger at the top of the machine. Allcable connections are made at thispoint and the hanger clamp fastened ina way that the connections themselvesdo not feel the strain of the cableweight.
k. Locate the skid assembly near thecenter of the tank. The skid assemblycontains main power distributiondisconnect, distribution transformer, andthe welder power supply.
l. Connect primary power of the propervoltage and frequency to the powersource. If rectifier type DC powersupplies are used, the power phasing isunimportant. If motor generators areused, phase the input power so themotor generators rotate in the properdirection as indicated by the ‘rotationdirection’ arrow on the case.
m.Adjust the angle of the travel wheels toconform to the diameter of the storagetank. The machine is now ready tooperate.
WARNINGEnsure proper voltage and fusing beforeapplying main power. Ensure thetransformer is correctly wired for theapplied voltage. Reference drawing0874-0000-00 page 1.
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SECTION 4MAINTENANCE
Figure 1 shows a properly adjusted belt. The belt is snug and both roll centerlines are parallel.
Figure 2 shows an improperly adjusted belt. The belt tension is to tight causing the rollers to skewbending both rollers and causing the belt to roll off.
Figure 4.1
Figure 4.2
Belt Roller
Adjustment Bolt
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FOR O REVRAPID
TRAVERSE
0 50
IPM
Operator Control
9980009700Pushbutton Operator99980008900Contact Block (N.C.)9980008700Contact Block (N.O.)
9980009400Switch 3-positionmaintained9980008500Contact Block (N.O.)
9980033000Potentiometer
998020200Meter (0-50IPM)
96084Belt Roller
32517Flux Belt
33215Flux Belt Insulator
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4.1 Lubrication instructions:
b. CAUTION: Each gear unit must be filled separately to the proper level. On double reductionunits, generally the secondary gear unit is filled to the high oil level.
Drain and re-fill to the proper level every 1000 hours. Be sure to use only AGMArated worm lubes.
Typical Replacement type oil: Mobil SHC 634 ambient operating temperature 0°to135°F with an AGMA rating of 7EP. When other operating temperatures areencountered, contact Koike Aronson Inc. for proper lube specifications.
b. Belt roller bearings are permanently sealed and no lubrication is required.
Double WormReducer
Primary GearUnit
Secondary GearUnit
Oil Fill Level (high level)
Oil Fill Level Centerline
WARNINGDo not use lubes than contain sulfur and or chlorine that arecorrosive to bronze gears. Some extreme pressure lubes containmaterials that are toxic. Be sure to read all warnings and MSDSreports.
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RECOMMENDED SPARE PARTS LIST
PART NUMBER DESCRIPTIONWhere Used on
MachineQuantity usedper machine
Recommendedspares permachine
3270323 Ammeter NA-3 2 1
3270286 Control Board NA-3 2 1
3270287 Logic Board NA-3 2 1
3930009 Speed Potentiometer NA-3 1 1
3270332 Relay NA-3 2 1
9983012700 Variable DC Drive AGW Electrical 1 1
9980033000 5K 1-Turn Potentiometer AGW Electrical 1 1
9981008800 Fuse Slo-Blo 12Amp AGW Electrical 2 2
9948853100 Relay AGW Electrical 1 1
9980020200 IPM Meter AGW Electrical 1 1
9938725125 FNQ 12Amp Fuse AGW Electrical 1 1
9938725127 FNQ 20Amp Fuse AGW Electrical 1 1
2330100 Flux Belt Assy. Bearing AGW Mechanical 8 2
2390226 Travel Wheel Bearing AGW Mechanical 4 2
76084 Belt Roller AGW Mechanical 1 1
32517 Flux Belt AGW Mechanical 2 6
33215 Flux Belt Insulator AGW Mechanical 2 2
32700821 Contact Nozzle Assy. K-231-3/32”Single WireWelding Only
2 1
3270047 Nozzle Extension (1-1/2”)Single WireWelding Only
2 2
32701311 Contact Tip S-10125-3/32”Single WireWelding Only
2 12
3270706 Dust Filter Flux Recovery 1 2
3270713 Motor Flux Recovery 1 1
3270332 Pilot Relay DC600 1 1
3270359 Reed Switch DC600 1 1
Table 4.1 Spare Parts Listing
A-1
APPENDIX A
AGW II
GENERAL DESCRIPTION
The Automated Girth Welder II consists of a master-slave configuration. Themaster AGW is configured as an AGW I with drive controls and a welding head.The slave is configured as an AGW I without the drive controls. The slave ispivotally fastened to the top of the master frame and is used when two sidewelding. A ladder is provided as a means for operator movement from one sideof the machine to the other and for access to the primary separator tank.
The AGW II requires two welder power supplies. Each unit has a flux recoveryunit and controls (ON/OFF).
Figure A1 Typical Setup for AGWII
Pivot Hinge Connection
Skid
DC600 DC600
Main Power
MasterSlave
KOIKE ARONSON, INC.635 W. Main St., Arcade NY, 14009-0307 (585) 492 2400, Fax (585) 457 3517visit us at www.koike.com
ATM MI1533A
