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What is Electrogas Welding?

(EGW)

Welding process where a


moving shoe dam contains
a molten pool of electrode.
Flux cored wire protects the
weld from contamination
by the gas produced as the *
electrode melts.
The heat from the arc will
also melt a portion of the
work piece and combine the
plate and electrode sections.
Only used on vertical
square butt joint
applications. Most
commonly used by tank and
ship building companies. * Not used for the Koike Aronson Ransome VUP.
KOIKE ARONSON INC, / RANSOME

VERTICAL-UP WELDER
(VUP)
Standard Version

VUP
Electrogas w/NR-431 Flux
Cored Electrode Wire
VUP Specifications

Automatic, self propelled, Uses a Lincoln NA-3S control,


hanging unit, which uses the wire feeder, and DC-1000.
Electrogas Welding (EGW)
process for vertical seams. Welding head can be adjusted on
Extends for 6, 8, and 10 all axes.
plates. Water re-circulation system that
Fits on unlimited tank is directly fed into the welding
diameters. shoes.
Manual or powered lateral
travel (169 ipm.) for moving Air system which clamps the
from joint to joint. front and rear shoe assemblies to
Can ride on plates up to 2 the plates.
thick. Oscillation of nozzle for 1 to
Welding speed is 20 times 2 plates.
faster that conventional stick
welding. Magnet located on the bottom of
Can weld plates from 3/8 the machine secures it to the
thick to 2 thick. work piece.
VUP
Vertical Travel Motor
Lateral Drive Motor

Lifting Bail
Height Adjustment Lateral Drive Assembly

Vertical Column
NA-3S Control Box
Travel Carriage

Front and Rear Shoe Assemblies


Secondary Travel Control Box

Lateral Wheels
Magnet
VUP Head Arrangement

Width Adjustment

Rear Shoe Assembly Pneumatic


Actuator

Wire Straightener

Guide Roller Guide Roller Pneumatic Actuator

Vertical Adjustment

Inch In/Out Adjustment

Water Cooled Shoes

Horizontal Adjustment
VUP Head Arrangement

Air Control Valve

Rear Shoe Assembly Pivot


Wire Feeder Motor

Wire Tensioner

Nozzle
Oscillator Motor

Shoe Pivot Points

Safety Catch Points


Front Slide Assembly
Constant Voltage (CV) Output

A welding arc is not stable, voltage (V) and current (A) are continuously changing. A power
supply will monitor and make changes for a stable arc condition. Constant voltage means
that voltage will be maintained at fairly consistent levels. While the current is not monitored
and may vary.

Voltage controls the length of the welding arc, and Fig. A


resulting width and volume of the arc cone. As
voltage increases, the arc length gets longer and arc
cone broader, while as it decreases, the arc length
gets shorter and arc cone narrower. Fig. A

Current controls your melt off rate and will maintain


your voltage set point by varying the wire feed speed
(WFS).
Lincoln DC-1000 Power Supply

Standard Input Power

Input Power:

Output Range: CV 16VDC/150A -


46VDC/1,300A
Duty Cycle: 44V/1,000A 100%
Welding control is directly wired into a
terminal strip located within the power
source.
Can either keep stationary on the ground
or put into a tow behind power cart.
DC-1000 Switchology

2 3 4 5 6 7

1. Voltmeter- Indicates welding voltage only while 6. Weld Terminals/Remote- Set to the down
welding. position so that output of voltage and current
2. Ammeter- Indicates current only while welding. are controlled by the NA-3.
3. Meter Polarity- Controls the polarity of the 7. On/Off- Set to the up position to energize the
voltmeter and ammeter depending which studs machines input contactor.
the electrode cable is connected to (positive or
negative). Will be set to positive.
4. Output Control- Not used, set to the lowest
setting.
5. Welding Mode Switch- Set to the center position
for CV Innershield (flux core).
Power Skid

Welding Power Source


Fused Main Disconnect
Transformer
Power Junction Box
Water and Air Enclosure
Water Circulator Junction Box
Water Cooling System

Water Circulator Junction Box

DC-1000 Water
Cooling
System
Power Skid
120 VAC Routed From
460 Volts to Transformer (Travels to
Transformer Transformer
Secondary Travel Enclosure
Connection
Before Being Routed Back)

Fused Main Disconnect Water Circulator Junction Box Power Junction Box

Motor Starter
(Acts as a
fuse.)

Outside Power Input 460 VAC to DC-1000 460 VAC Off the 460 VAC To Water 460 VAC from water 120 VAC Off
Back of DC-1000 Circulator circulation junction box. Transformer
Fuse Box/Power Disconnect Power Contactor In- Power to the Water
Line With Water Flow Switch
Circulator
Power Skid
= Cool = Hot

Water and Air Enclosure


Air Pressure
Control/Coalescing
Filters

Gallons Per
Minute
Flow Meter

Air In: From Flow Switch Wired


customer provided into Water Circulator
source. Junction Box
Water Cooling System

Water Flow Sight


Glass

Input: 460V/3/60A
25 Gallon Reservoir
Water In
Water Out
10 Gallons Per Minute
High Efficiency Radiator
Stainless Steel w/Copper
Tubing
Water Cooling System

Use only distilled


water per
manufacturers
suggestion.
Hot Water
Out

Cool Water
In
Pneumatic Air System

Branches to Four Way Valve


and Actuators

Air In

Rear Shoe
Actuator

Guide Wheel
Actuator

Four Way Valve


w/ Vents
Front Shoe
Slide Actuator
Lincoln NA-3S Control
Constant Voltage (CV)

Input Power: 115 VAC/1/50-60 Hz


Routed from the power supply.
Set-up for constant voltage.
Extends the power supply controls so
that the operator can make amp/voltage
adjustments and start/stop as needed.

Inner Control Panel:

Adjusts OCV from a power source to control


weld starting characteristics. Set this dial to
the same setting as your voltage control when
Sets starting current and
using a DC-600.
voltage for an adjustable
time.
Sets the speed of electrode feeding when not welding.

Allows the electrode to keep burning and retract so it doesnt stay connected to the
cooling weld bead.
NA-3S Switchology

9
1. Ammeter- Indicates current
only while welding. 1
2. Current Control- Adjusts
wire feed speed to control 8
welding current. 2
3. Voltage Control- Adjusts
arc voltage. 3
4. Voltmeter- Indicates 7
welding voltage only while
welding.
4
5. Start- Pushbutton begins
welding process.
6. Stop- Pushbutton stops
welding process.
7. Inch Up and Inch Down-
5 6
Press to move electrode in
or out of nozzle. Speed set 8. Travel- Set to Off for no travel; Set to On for travel
by the Inch Speed without welding; Set to Auto for welding.
control on inner panel. 9. Power- Turns wire feeder input power on and off.
NA-3S Head

Tensioning the Electrode:

1. There is a hex head bolt that runs through the tensioner


arm of the wire feeder.
2. There is a U-shaped piece of metal that runs through
the bolt. It has two lines pressed into it. If you cant
see the lines then the piece of metal is backwards.
3. One of the lines is for 1/8" wire to 7/32" wire and the
other line is for 3/32" and smaller wire. Used with .035 to 7/32 in.
4. Adjust the bolt until the line you need matches up with solid electrode wires.
the black tensioner arm.
5. You want the electrode wire to have the lines from the
serrated wheels pressed into it. But you also dont
want it to be misshapen. Its cross sectional shape
should still be maintained.
Main Control Enclosure
Switchology
1. Oscillator Speed- Controls the speed of the in and out
movement of the oscillator motor.
2. Oscillator On/Off- Controls power to the oscillator
motor.
3. Oscillator Pots- Determine the oscillation pause
duration at the front or rear position.
4. Magnet On/Off- Controls power to the magnet.
5. Water On- Push in to turn on. It will then light up
green. The welder will not run if it doesnt sense
water at the flow switch on the skid.
6. Carriage High- Allows a speed to be set for the high
end of the current sense.
7. Carriage Low- Allows a speed to be set for the low
end of the current sense.
8. Test Up High and Test Up Low- Allows the operator
to test preset speeds.
9. Carriage Up/Off/Down- Raises and lowers the
carriage at a determined factory set speed in the drive.
10. Power On- Applies power to the electronics in the
main enclosure.
11. Lateral Travel- Moves the VUP clockwise or counter
clockwise around the tank.
12. E-Stop- Removes power to the main electronics in the
main enclosure.
Main Control Enclosure
250 Ohm 25 Watt Resistor
Wired Between Oscillator Time
Delays

Water Flow Shut Down Oscillator Forward Time Delay


Relay
Oscillator Forward Relay
Oscillator Reverse Relay
Oscillator Reverse Time Delay
Eight Minute
Water Run
Delay
10 Ohm 25 Watt Resistor Wired
Between Oscillator Speed
Control Drive and Fwd/Rev
Relays
High Travel Speed Test Battery: Forces
the current pointer above the high set
point on the Amp meter. 5 Amp Fuse: Wired between the
oscillator speed adjustment drive
and oscillator On/Off switch.
Secondary Travel Control
Enclosure

1. Magnet On/Off- Controls power to the


magnet.
2. Auxiliary Up/ Auxiliary Down- Allows
the head assembly carriage to be raised
or lowered.
3. Rapid- Used in conjunction with #2
allows for the highest up/down travel
speed.
4. E-Stop- Removes power from the main
and secondary travel enclosure.
5. Lateral Travel- Moves the VUP
clockwise or counter clockwise around
the tank.
Secondary Travel Control
Enclosure

Solid State Drive Controls Lateral KBPB Drive Controls Vertical Travel
Travel

Rectifier Turns DC to AC For Magnet


Power
Electra Gear Reducer

Single piece housing has eliminated the need for


gaskets and sealants. All covers are sealed with O-
Rings, reducing the risk of leaks.
25-30% more torque capacity than previous designs.
Preventative Maintenance
Attention!
Spending a little time and money on the
maintenance of your machine will prevent
downtime and cut costs.

Blow out any build up of dust in electrical enclosures with low pressure air. Ensure that
any power source is removed from the machine when doing this. Metal dust can cause
arcing and may cause loss of life or damage your equipment.
Replace electrical enclosure seals when they become worn. Standing water in enclosures
is a shock risk and will damage/corrode wiring and components.
Do not store the VUP outside when not in use. Your machine will treat you as good as
you treat it.
Regularly grease the zirc fittings on the guide wheel assemblies.
Replace any wires or cables that have bare metal exposed to prevent shorts and shock
hazards.
Replace the contact tip if the weld seems to be deteriorating and your contact tip is worn.
Joint Design and Preparation
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

Joints welded with this process are


square or beveled design.
Plates should be clean and free from
grease, oil, and scale.
Joint alignment is critical for preventing
slag leakage between shoes and plates.
Use of a straight edge across the joint
during fit-up should be used to assure
Proper Alignment
plate to plate alignment.

Needs Alignment
Joint Design and Preparation
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

Run Off Tabs


Sufficient Strong Backs are required to
hold correct gap spacing between plates.
The joint should be 1/8 wider at the top to
compensate for shrinkage and distortion
during the weld. They should be securely
welded, not just tack welds.

Run off tabs are recommended for


finishing the weld.
Strong Backs
Ground current should travel towards the
top of the plate, attach grounds
approximately 12 from each side of the
joint. Ground Points
Joint Design and Preparation
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

An arc starting consumable is Repair Required


recommended for beginning a
weld. It will stabilize the arc,
reducing repair required
Pre-heating is always
recommended to reduce Arc Starting
starting cracks and porosity. Consumable
(Example: 880M
Manual repair is required at flux, Wad of Steel
Wool)
the starting and ending points
of the weld joint. 3/8 1-1/8 - 2
Plate 1
Thickness 9mm 13 25mm 32 50mm
Recommended Minimum Start Area 200 F 300 F 350 F
Preheat Temp. 93 C 150 C 175 C
Welding Electrode

The VUP Single Pass welding process can only be performed on carbon
steel and with the use of a Inner-Shield Lincoln NR-431 Wire. It is a self
shielded, flux-cored wire designed specially for single pass, vertical-
up welding.

AWS: EG72T-1 per A5.26


Size: 3/32 & .120 (2.4 & 3mm) Only Yield Strength psi (MPa): 76,000 (524)

ABS: Grade 3YA Tensile Strength psi (MPa): 92,000 (620)

Lloyds: 3Y Elongation %: 28

DNV: IIIY Charpy V-Notch


ft-lbs (Joules) -20F (-29C): 33 (46)
Packaging: 50 Lbs. Coil
Welding Set-up
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

Electrode Length:
Stick out of the electrode beyond the
contact tip determines current and the
welding characteristics of the electrode.
Incorrect stick out can cause porosity,
low impact strength, and improper
location of the electrode during welding.
Improper electrode location can result in
poor bead edges and arcing to the copper
shoe. Set the stick out before bringing
the electrode into the joint. Do not
change the stick out when making other
adjustments. Visible stick out from the tip is typically
1-1/2.
Welding Set-up
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

Tip Height:
Tip height above the top of the copper
cutout should be 7/8 to 1. The puddle
height must be 1/4 below the top of the
copper cutout. This will allow excess
slag to drain out. There may be some
draining on heavier plate and little to
none on thinner plate.
Welding Set-up
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

Electrode Angle:
The electrode angle determines the
direction of the arc and affects heat
flow. The angle of the electrode on the
VUP should be as close to 90 degrees as
possible. Arcing on the copper shoes
could happen if the angle is less than 90
degrees.
Welding Set-up
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

Electrode Location:
Electrode location is measured from the
front face of the plate to the near side of
the electrode end after establishing
correct electrode length. If location is
too close to front, the electrode may arc
to the copper shoe. If location is too far
back, the electrode may arc to the back
dam. The electrode location changes as
the nozzle contact tip wears.
Condition 1

Approximately 1-1/2
inches wire stick out with
weld puddle about 1/4-
2in. inch below the top of the
notch in copper shoe.
The shoe travels up at
1in. the speed set on the low
speed potentiometer.

Condition 2 If the weld puddle rises to


Automatic Weld Travel Speed: less than 1/4-inch below
the top of the copper Orange Set Current
The operator has no direct control over shoe, wire stick out Pointer Pointer
decreases less than 1-
weld travel speed. The electrode 2in. 1/2-inches, current
diameter, wire feed speed, and joint therefore increases
above the orange pointer
volume will determine the actual weld setting and the shoe
travel speed. The movement of the fixture travels up at speed set
on high-speed Orange Set Pointer
is automatically controlled. potentiometer until Adjustment
As the electrode length gets longer, the condition 1 prevails.
current decreases; as the electrode length
gets shorter, the current increases. Condition 3
If the weld puddle drops
The VUP uses a set point ammeter, the to more than 1/4-inch
below the top of the
needle indicator sets the point at which the copper shoe, wire stick
travel starts and stops. This is not a travel 2in. out increases to more
than 1-1/2-inch, current
speed control but determines the level of therefore decreases
the weld puddle in relation to the moving below the orange pointer
setting and shoe travels
shoe. A rule of thumb is; the higher the up at speed set on the
set point, the higher the puddle, and the low speed potentiometer
until condition 1 prevails.
lower the set point, the lower the puddle.
Welding Set-up
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

Basic Set-up:
1) Position VUP carriage over the joint and lower to the bottom of the seam.
2) Lock the electromagnet and adjust the head assembly until everything is lined up.
3) Set the electrode stick-out.
4) Set the nozzle height from the shoe.
5) Check the electrode angle.
6) Lower head to the bottom of weld joint.
7) Align the nozzle in center of weld joint.
8) Locate tip of the wire approximately off joint sump.
9) Set welding parameters for the process.
10) Begin the weld and adjust the parameters if needed to maintain the puddle height.

Listen to the Weld!


This process should have a Globular transfer type sound. (unstable, or erratic arc)
A smooth hissing type sound, similar to a MIG process is the first sign of a poor weld, look at puddle immediately and adjust accordingly.
Welding Set-up
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

3/32 Wire
Plate Thickness (in) (T) 3/8 1/2 5/8 3/4
Joint Angle (degrees) 60 90 90 90
Gap (in) (+ 1/8-0) (G) 3/8 1/4 1/4 1/4
Front Moving Shoe (in) 1x3x4-1/16 1x3x4-1/16 1x3x4-1/16 1x3x5-3/32

Wire Feed Speed (in/mm) 300 300 350 400

Current (Amps) (Approx.) NR-431 260-270 260-270 275-285 285-295


Voltage (volts) 32-33 32-34 34-35 35-37
Electrical Stickout (in) ( 1/8) 1 1 1 1
Visible Stickout (in) 1 1 1 1
Electrode Drag Angle (degrees) 8 8 8 8
Electrode Location from Front (in) (F) 3/16 1/4 1/4 3/8
Puddle Height (in) 1/4 1/4 1/4 1/4
Start Procedure Time (Sec) 1 1 1 2
Travel Speed (in/mm - approx.) 2.3 2.3 2.3 2.1
Deposition Rates (lbs/hr) NR-431 11.3 11.3 13.0 14.7
Welding Set-up
All Set-up and Welding Procedures discussed are rough starting references.
All Joints and procedures must be qualified by the end user or tank
manufacturer.

.120 Wire

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) 1x3x5-3/32 1x3x5-3/32 1x3x5-3/32 1x3x5-3/32
Wire Feed Speed (in/mm) 300 340 380 380
Current (Amps) (Approx.) 435-465 470-510 510-550 510-550
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) 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) 24.3 27.8 31.2 31.2

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