OM-LW-INSTALL-02-2013
February 2013
Read this manual carefully before installing,
Commissioning, or operating this product.
Miller Welding Automation, 281 E. Lies Rd., Carol Stream, Il 60188
Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web site: www.jetline.com • E-mail: sales@jetline.com
Installation Manual
for Longitudinal
Seam Welders
IMPORTANT
The installation, operation and maintenance guidelines set out in this manual will enable you to maintain the
equipment in peak condition and achieve maximum efficiency with your welding operation. Please read
these instructions carefully to become aware of every advantage.
Only experienced personnel familiar with the operation and safe practice of welding
equipment should install and/or use this equipment
.
Use general industry good practices to move, lift, and install this equipment.
Experienced, professional riggers should be employed for the installation process.
•
Forklift or overhead crane with 7000 lb (3175 kg) lifting capacity
•
Two lifting straps rated at 4000 lb (1800 kg) each
•
Hand tools - hammer, screw driver, hex keys, wrenches
•
Air or electric impact drill
• Four 10 mm diameter by 76 mm length concrete anchor bolts
NOTICE
CAUTION
TOOLS REQUIRED
INSTALLATION INSTRUCTIONS FOR LWS LONGITUDINAL SEAM WELDERS
Initial Inspection
Upon receipt of the equipment, examine the shipping crate for freight damage. If the crate appears to have suffered
major damage, contact the shipping company. Once the unit is unpacked carefully examine the contents for
possible damage or possible misalignment in the track and mandrel.
Check that all the items, packages, or individual boxes have been received.
Although Miller Welding Automation packages your equipment with great care, long or extremely rough shipping can
adversely affect the equipment. As a result, please spend a few extra minutes to insure that the assembly pieces are
in good order.
The crate in which the seam welder has arrived will have to be dismantled. Be careful to dismantle the equipment
safely. Damage to the unit and personal injury can occur during unpacking, therefore follow all safety precautions.
Your seam welder was thoroughly tested and verified it met specifications before shipping. After receipt, visual
inspection of all adjustment points should be made. See Figure 1.
If a cable carrier assembly was purchased as an option, the carrier may have been removed from the track and
packed separately. Verify that it has arrived in good condition before proceeding with its installation.
The carriage assembly is normally shipped mounted on the track and requires only the removal of the temporary
mounting bracket. If the seam welder has an optional riser (for larger diameters than standard) the carriage may have
been removed before the seam welder was shipped. If this is the case, the carriage will be mounted on the crate deck
next to the seam welder. Verify there is no apparent damage to it or to the equipment mounted to it.
After this initial inspection is completed, installation of the longitudinal seam welder can begin.
Installation Guide
System Operating Conditions:
This system is designed for use in an industrial building.
Operating Conditions
Temperature range: 0 to 40C
Humidity: 5 to 95% RH non condensation
Altitude: Up to 1000 meters
Mounting: Secured to reinforced concrete floor
Electrical Input: 400VAC, 3 phase, 50 Hz nominal for export and 460 VAC, 3 phase 60 Hz domestic USA
Single Phase, 220VAC, 50 Hz for export and 120VAC, 60 Hz domestic USA
Compressed Air: Clean, dry air at 80 PSI (5.6 kg/sq cm)
Welding Gas: Bottled or bulk supply at 100 PSI (7 kg/sq cm) minimum pressure
Transportation, Storage: -20 C Degrees to 60 C Degrees
Vibration, Shock: 1G rms 5 to 500 Hz
TOOLS REQUIRED
1)
Typically a forklift or overhead crane with at least 7000 pounds (3175Kg) capacity. For larger systems greater
capacity lifting is required.
2)
Two lifting straps rated for 4000 pounds (1800Kg). For larger systems greater capacity lifting is required.
3)
General Hand tools - claw hammer, screw driver(s), hex keys or allen wrenches, set of box end wrenches,
and adjustable wrench.
4)
Air or electric impact drill if concrete anchoring bolts needed.
5)
Digital VOM electrical meter.
Installation personnel: Should be trained and experienced and locally qualified in moving heavy loads, setting up
electric/mechanical systems. Familiar with local procedures and standards is necessary. A licensed electrician should
be involved in making primary connections.
Domestic Lattice Crate Packing of System showing external as received and after removal
1.
Remove the seam welder along with other equipment from shipping crate.
2.
Use a fork lift or an overhead crane to set fixture onto concrete floor. Do not lift by track. Special bolt
attachments are required for lifting via a swing and crane.
Optional Riser
One of Four Mounting Holes for
use with overhead crane lift
Located on both sides and ends of
tabletop
DO NOT LIFT FIXTURE BY TRACK OR MANDREL!
Proper method shown for using base forks for seamers 60 inches or less.
Make sure properly rated forks are inserted over half way into base as shown.
3.
The fixture is free-standing and can be placed on floor without anchoring to concrete. The seam welder
base should be secured to concrete floor if (a) the seamer is integrated with a conveyor system or (b) a
riser is being used to weld larger diameter shells. In these two cases the seamer base must be secured
to reinforced concrete floor by use of anchor bolts/red heads.
4. After the fixture has been removed and placed in its location in your factory, it can be anchored to the
floor using 10 mm concrete anchors.
5.
The welding head and carriage are fitted to the side beam track and require the removal of one shipping
bracket. The shipping bracket is bolted to the carriage and the track, keeping the carriage from moving
during shipment. The bracket is located on top portion of track and carriage and held in place with two
bolts.
Remove this shipping bracket from the carriage and discard. Look for tag as shown below.
6.
If the carriage has been removed for shipment, use the following procedure: At each end of the track are
two mechanical stops. These stops serve as a safety device to prevent the carriage from falling off the
end of the track. When placing the carriage onto the track, one of the stops must be removed. We
recommend using a crane or fork lift truck to hoist the carriage up to the track. When lifting the carriage,
you will find a ½-13 tapped hole on top of the carriage. This hole, along with an eye bolt (not supplied),
can be used for lifting the carriage. Another alternative for lifting the carriage is by using the gusset holes
on both sides of the carriage. Using these holes will stabilize the carriage when installing it onto the track.
Verify it is correctly aligned. Once the carriage is mounted on the track, replace the mechanical stop on
the end of the track to its original position.
7.
The wire feeder is often removed for shipping purposes and put in separate box. The wire feeder should
be installed onto the mounting brackets located on the carriage.
8.
Make the weld power, electrical, shield gas, air and water connections to the seam welder system. A
cable channel, which protects welding gas lines and control cables from the rack and gears, is provided.
The cables are located at the end of the cable carrier and are marked as to purpose.
The air supply to the seam welder is ready to be connected. In order for the seam welder to operate
properly, the shop air supply should be set at 80 PSI (5.6 kg/sq cm) minimum. The air supply must be
connected before the filter assembly.
WARNING
DO NOT BY-PASS THE FILTER. By-passing the filter assembly when connecting the air supply will
allow moisture to enter into the solenoid valves causing the valves to fail.
9.
Electrical power connections to the welding power source should be made in compliance with code
requirements by a qualified electrician.
Back side of mainstay showing various supply connection points.
10.
Dry run the carriage without welding to be sure the carriage moves back and forth.
11.
During shipment, bolts and hardware can be shaken loose. Please check all fasteners to be
certain they are tight before operating the system.
12.
Read and consult welding power source manuals to insure proper set up, polarity, and that torch
consumables are selected and installed properly.
13.
Perform trial welds on scrap material to test functioning of system.
Electrical Installation - Consult Control Schematic
The standard seam welder is supplied with a model 9700T Microprocessor Carriage Control. The control is
normally mounted on the front of the carriage. Refer to the separate 9700T manual supplied.
Other controls and equipment may have been purchased and installed on the seam welder. Individual manuals are
supplied for them. Please refer to the appropriate manuals for proper installation guidelines regarding the individual
pieces of equipment.
Input Requirements:
Electrical (Standard): 115 Volts, Single Phase, 50/60 Hz.
Electrical (Optional for export): 230 Volts, Single Phase, 50/60 Hz. A step-down transformer is used to achieve this
requirement.
Compressed Air: 80 PSI (5.6 kg / sq cm.)
Air pressure will generate up to 5,000 lb/ft (74.4 kg/cm) of clamping force on the part. See the air regulator settings
chart in this section to set the correct clamping pressure for the material thickness being welded.
Shield Gas: Bottled or bulk supply at 100PSI (7 kg/sq cm) minimum pressure. Shield gas type depends on weld
process and material being welded.
Typical views of controls, track, and carriage with controls
GTAW 9900 Based Carriage Layout
PAW-9600 Based Carriage Layout
GTAW 9600 Based Carriage Layout
GMAW 9600 Based Carriage Layout
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Miller JETLINE LW SEAM WELDER INSTALLATION Owner's manual
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